769D Off-Highway Truck

Time proven iron and modern technology combine to provide a highly productive, durable, reliable off-highway truck, focused on our customers greatest need...lowest cost-per-ton.

Power Train Engine

The eight cylinder, turbocharged and airtoair aftercooled HEUI engine is built for power, reliability and economy with reduced sound levels and low emissions.

Cat 3408E Diesel Engine

The fourstroke design uses long power strokes for more complete fuel combustion and optimum efficiency. Large displacement and a low speed rating can help extend engine life. This engine meets U.S. Environmental Protection Agency Tier II emissions regulations and Stage II UE Emissions Directive 9768EC.

Torque Rise

The 27 percent torque rise provides high lugging force during acceleration on grade or in high rimpull conditions. The torque rise effectively matches the transmission shift points to provide maximum efficiency and faster cycle times.

Engine

1 Turbocharger 2 Electronic Control Module ECM 3 Valve Rotators 4 StelliteFaced Valves 5 SteelBacked, CopperBonded Bearings 6 Oil Cooler 7 Forged Crankshaft 8 AdjustmentFree Fuel Injection Pump 9 Hydraulic Electronic Unit Injectors 10 Forged Steel Pistons 11 FullLength, WaterCooled Cylinder Liners

Engine Features

Contributing to the 3408E power and reliability are ulli High pressure injectionlili Full electronic control, one piece forged steel pistons with three rings cooled by oil spray lili Copperbonded crankshaft bearings lili Hardened crankshaft journalslili Drytype radial seal air cleaners with primary and secondary elements and precleanerlili Directelectric, 24volt starting system with 50amp alternator and four 172amphour, low maintenance, high output, 12volt batteriesliul

Hydraulic Electronic Unit Injector HEUI

The HEUI is a proven highpressure, direct injection fuel system. This system electronically monitors operator and machine inputs to optimize engine performance. HEUI is unique in its ability to independently control injection pressure over the entire engine operating range. This allows complete control over injection timing, duration, performance and efficiency. Rate shaping technology modifies the heat release characteristics of the combustion process for significant decreases in sound and emission levels. Exhaust smoke is significantly reduced through precise, electronic control of fueling limits and injection timing of the HEUI.

Electronic Control Module ECM

The ECM monitors key functions and logs critical indicators. The Electronic Technician can access this diagnostic information for easier maintenance and repair.

Advanced Modular Cooling System 40AMOCS41

Is a Caterpillar exclusive technology which improves serviceability and reduces downtime. It utilizes an exclusive two pass cooling system and increased cooling surface area to provide significantly more cooling capacity than conventional systems.

System Operation

The two pass system circulates coolant from the sectioned bottom tank up through one side of the cooling element and down through the other side returning it to the bottom tank.

AMOCS Design

The cooling elements are individual core modules, with brass tube construction within each core, that are connected to a sectioned bottom tank. There is no top tank to remove. Each core module can be replaced individually without removing the entire radiator, saving considerable cost and repair time. And with nine steel fins per inch, fin bending resistance is improved.

Power Train Transmission

The Cat sevenspeed, power shift transmission gets the job done smoothly and quickly.

Transmission

The Cat sevenspeed, power shift transmission, matched with the directinjection 3408E diesel engine provides constant power over a wide range of operating speeds.

Transmission Features

Include ulli Seven speeds forward, one reverselili Torque converter driven reverse lili First gear has both torque converter drive and direct drivelili Second through seventh gears are direct drivelili Singlelever shift control provides automatic shifting in all gears up to the one selected by the control leverlili Each shift is individually modulated for maximum smoothnesslili Separate hydraulic circuit with coolerlili Electronic control has builtin diagnostics and fault code memory, event memory and programmable featureslili Control throttle shiftinglili Economy shift modeliul

1 Lockup Torque Converter

Combines the maximum rimpull and cushioned shifting of torque converter drive with the efficiency and performance of direct drive. ulli Engages at approximately 6.9 kmh 4.3 mph, delivering more power to the wheels.lili Lockup clutch quickly releases and reengages during shifts, maintaining power windup, improving transmission life and increasing operator comfort.liul

2 Planetary Power Shift Transmission

Utilizes a modulating pressure valve to regulate clutch pressure rise and fall to ease clutch engagement. This reduces shock loads on power train components. Features include ulli Large diameter clutches and robust planetary gears and bearings.lili Patented rotating clutch pressure seals minimize drag losses and improve reliability.lili 35 percent gear splits between all gears match Cat engine design for optimum use of engine power with minimized shifting and torque converter use.liul

3 Final Drive

Final drive and differential torque multiplication of 13.151 further reduces stress on the drive train.

4 Sump

Transmission and torque converter share a common sump. The combined sump offers an easily accessible fill tube and sight gauges.

Axles

Full floating axles are shotpeened to relieve internal stresses and increase durability. Rolled splines also provide increased service life.

Wheels and Rims

Cast rear wheels and Cat centermount rims are mounted using studs and nuts to minimize maintenance and maximize durability.

Transmission Chassis Controller TCC

TCC uses electronically transferred engine rpm data to execute shifts at preset points for optimum performance and efficiency. This integration allows ulli Programmable top gear limitlili Control throttle shiftinglili Directional shift managementlili Neutral coast inhibitorlili Economy shift modeliul

Integration

The Caterpillar power train integration provides increased component life and operator comfort.

EnginePower Train Integration

Combining the electronic Engine Control Module ECM with the Caterpillar Transmission Chassis Controller TCC allows critical power train components to work more intelligently.

Integration

1 Electronic Technician 2 Cat Data Link System 3 Engine Control Module 4 Engine 5 Transmission Chassis Control 6 Automatic Retarder Control, Traction Control System and Integrated Brake Controller 7 Caterpillar Electronic Monitoring System 8 Transmission 9 Oilcooled Brakes

Cat Data Link

The Cat Data Link electronically integrates the machines computer systems, which allows communications and provides the following benefits

Controlled Throttle Shifting

Engine rpm is regulated during a shift to reduce driveline stress for smoother shifts and longer component life.

Economy Shift Mode

Modifies engine maps, resulting in improved fuel consumption.

Directional Shift Management

Regulates engine speed during directional shifts to prevent damage caused by high speed directional changes.

Elevated Idle Neutral Coast Inhibitor

Helps prevent the transmission from shifting to neutral at speeds above 6.5 kmh 4 mph.

Bodyup Shift Inhibitor

Helps prevent the transmission from shifting above a preprogrammed gear without the body fully lowered.

Event Memory

Records machine management data that can be accessed using the Electronic Technician. Recorded information includes ulli Shift histogramslili Operatorinduced eventslili Lockup clutch counterlili Machine overspeedlili Transmission overspeedliul

Electronic Technician ET

The electronic engine and transmission controls provide exhaustive diagnostic capability for service technicians. The ability to store both active and intermittent indicators will simplify problem diagnosis and total repair time, resulting in improved mechanical availability and lower operating cost. ET accesses data stored in the engine and transmission controls via the Cat Data Link System. ET displays the status of all engine parameters including throttle position, timing and fuel flow. ET replaces 13 mechanical tools to perform functions like cylinder cutout checks, injector solenoid tests and timing calibration.

Caterpillar Electronic Monitoring System 40CEMS41

CEMS allows the operator to view requested information and utilizes a threecategory warning system to alert the operator to abnormal machine conditions.

Optional Attachments

Caterpillar offers optional attachments that integrate with the Cat Data Link System.

Automatic Retarder Control ARC

Works with other electronic components to automatically control retarding on grade, maintaining approximately 2,230 rpm.

Traction Control System 40TCS41

Improves performance in poor underfoot conditions by electronically monitoring and controlling wheel slippage.

Integrated Brake Controller IBC

Combines ARC and TCS, reducing the number of electonic components and electrical lines.

OilCooled, Rear Disc Brakes

Rear braking lets the operator concentrate on the haul road.

Brakes

1 ParkingSecondary Piston 2 ServiceRetarding Piston 3 Friction Discs 4 Steel Plates 5 Actuating Springs 6 Cooling Oil In 7 Cooling Oil Out

Multiple Disc Brakes

Caterpillar forced oilcooled, multiple disc brakes are continuously cooled for exceptional, faderesistant braking and retarding. The optional ARC and TCS utilize the oilcooled rear brakes to enhance truck performance and increase productivity.

Oil Cooled Disc Brakes

Are designed and built for reliable, adjustmentfree operation providing superior performance and service life in comparison to shoetype and drydisc systems.

Oil Film

An oil film prevents direct contact between the discs. Absorbing the braking forces by shearing oil and carrying heat away, this design extends brake life.

Secondary Braking

Spring applied, hydraulically released, oilcooled disc brakes are located on the rear axle. The front brakes will activate as part of the secondary system, even if switched out of service.

Parking Brakes

Spring applied, hydraulically released parking brakes use wet disc brakes in service system. A toggle switch activates the parking brakes.

Pistons

A Caterpillar patented, twopiston design combines the service, secondary and parking brakes, along with retarding functions. The primary piston hydraulically actuates both service and retarding functions. The secondary piston is springapplied and held in the disengaged position by hydraulic pressure. If hydraulic system pressure drops below a certain level, the springapplied secondary piston automatically applies the brakes.

Integrated Braking Control IBC

Electronically combines Automatic Retarding Control ARC and the Traction Control System 40TCS41 into one integrated control system.

Cat Retarding System

When retarding, the engine runs against compression on downhill hauls, resulting in no fuel burn. Retarding forces and heat are absorbed through the oil. The retarding system generates lower drive line stresses than drive line retarding systems.

Automatic Retarder Control Optional

The ARC electronically controls braking on grade to maintain approximately 2,230 engine rpm engine rpm is adjustable from 2,1602,300 rpm in increments of 10 rpm. ARC is deactivated when the operator applies the brakes or throttle.

Engine Overspeed Protection

With the accelerator depressed andor ARC turned off, ARC will automatically activate at 2,475 rpm to help avoid potentially destructive and often costly engine overspeeds.

ARC Benefits

Include ulli Increased operating efficiency with faster downhill speeds. By maintaining consistently higher engine speeds, average truck speed will be higher than a manually controlled truck.lili Excellent controllability and reduced operator effort. Automatic brake modulation provides a smoother ride over manual modulation, allowing the operator to focus more on truck operation down the haul road.lili Improved component life, optimized system cooling capability and reduced torque fluctuations result from ARCs precision.lili Faster troubleshooting and diagnosis with selfdiagnostic capability and the ability to communicate with ET through the Cat Data Link System.lili Operator awareness through electronic integration and CEMS, alerting the operator to overspeed conditions and critical machine functions.liul

Traction Control System 40Optional41

Monitors wheel slip so if it exceeds the set limit, the oilcooled disc brakes are automatically applied to slow the spinning wheel.

Operator Awareness

An ondash indicator shows the operator that TCS is engaged.

Differential Action

Utilizes normal differential action to provide superior maneuvering in poor underfoot conditions. Also reduces tire scuffing as compared to positive lock differentials used on other systems.

Torque

TCS divides torque equally to reduce stress created on final drives and axles when torque is transferred to one side.

System Backup

Should sensors fail, the normal differential action is still available to maintain control and steering.

Structures

The backbone of the Cat offhighway truck.

BoxSection Design

The 769D frame uses a box section design, incorporating 17 castings in high stress areas with deep penetrating and continuous wraparound welding. Mild steel, which provides flexibility, durability and resistance to impact loads even in cold climates is used throughout.

Castings

Castings have large radii with internal reinforcing ribs to dissipate stress. Castings move welds to lower stress areas and provide two to three times the strength of equivalent sized fabricated structures.

Frame Features

Include ulli Integral front bumperlili Front box beams for suspension cylinder and ROPS supportlili Boxsection rear crossmember for body and ROPS support with attachment points for maintenance platform and rear engine hood hinge supportlili Castings are used to provide additional strength in critical stress areaslili Mild steel plates 290 MPa 42,000 psi minimum yield strength and castings 241 MPa 35,000 psi minimum yield strength provide flexibility, durability and easy field maintenanceliul

Frame Serviceability

The boxsection frame allows simple access to power train components. This open design reduces overall removal and installation time, lowering repair costs. Transmission access is excellent under the raised and pinned body. Repairs can be made without preheating in ambient temperatures 16 C 60 F using readily available welding supplies.

Rollover Protection Structure ROPS

The ROPS attaches securely to four castings welded into the frame.

Suspension System

Designed to dissipate haul road and loading impacts for extended frame life. Four, independent, selfcontained, oil pneumatic, variablerebound, suspension cylinders absorb shocks. Rear cylinders allow axle oscillation and absorb the bending and twisting stresses. Front cylinders, mounted to the frame, serve as steering kingpins, providing excellent maneuverability and reduced maintenance. Caster and camber are preset.

Body Options

Caterpillar builds a variety of rugged, durable bodies to perform in the toughest applications.

Design

769D bodies are designed to handle a variety of material densities. Maximum payload is reached in three to five passes from a matched Cat loader in 1700 kgm3 2,900 lbyd3 material and higher.

Sidewall and Floor Junctions

Are joined by fivesided beams to resist impact loading and sustained hauling stresses.

BoxSection Beams

Offer increased durability in the floor, sidewalls, top rail, corner and cab canopy areas.

400 Brinell Steel

Wear surfaces provide excellent wear resistance and are easily welded without preheating procedures.

TwoStage Hoist Cylinders

Provide fast dump cycle times of 7.5 seconds for Raise and 8.3 seconds for Lower.

Standard Body

Comes exhaust heated with options including a fulltime muffler or exhaust diverter.

Custom Attachments

Including tail extensions, liner packages, sideboards and other custom designs are offered to help ensure rated payload.

1 DualSlope Body

Offers the lowest costperton option in most construction and mining applications.

DualSlope Body Performance

Efficient under most haul road conditions, but its strength comes from higher levels of production in sites with rough haul roads and steeper grades.

Body Floor Construction

Uses an eight degree V bottom for increased load retention, a low center of gravity and reduced shock loading. It also aids in centering the load.

An 18 Degree Ducktail and 9 Degree Forward Body Slope

Retains the load on grades up to 15 percent and higher. This design also helps maintain proper load distribution.

2 Flat Floor Construction and Mining Body

Offers excellent load retention on grades up to 12 percent and on smoother haul road conditions.

Body Floor Construction

Uses a 12 degree single slope, offering excellent wear characteristics and uniform dumping into hoppers, crushers and feeders.

Operator Station

Control ease and comfort maximize productivity.

769D Operator Station

Rated highly by operators. Everything needed for top performance is at the operators fingertips.

1 Wraparound Dash Panel

Offers an easy lineofsight arrangement, using LED backlit rocker switches.

2 Caterpillar Contour Series Air Suspension Seat

Standard and fully adjustable, including an adjustable righthand armrest.

3 TiltTelescoping Steering Wheel

With ergonomic grip improves comfort and control. Low effort steering system and ergonomically designed retarder lever reduces operator fatigue. Also includes an enhanced turn signal lever with high beam actuator and electric windshield wiper controls.

4 Transmission Console

Has LED backlit gear numbers and ergonomic shift knob.

5 Visibility

Exceptional allaround viewing area reduces fatigue and improves productivity.

6 Integral, SoundSuppressed ROPSFOPS Cab

Is resiliently mounted providing a quiet, protected work environment. The cab is radioready with speakers, wiring harness, antenna and mounting bracket.

7 Front Brake CutOut Switch

Increases front brake component life.

8 Large Storage Compartment

0.10 m3 3.5 ft3 of space is located under the trainers seat.

9 Trainers Seat

Includes back rest and retractable seat belt.

10 Caterpillar Electronic Monitoring System 40CEMS41

Provides critical data. The system features three separate displays ulli Fourgauge cluster with coolant temperature, oil temperature, brake air pressure, fuel levellili Tachometer, digital speedometeractual gear indicatorlili Message center moduleliul

11 Standard Heater and Optional Air Conditioner

Includes fourspeed fan and nine vents.

12 Foot Pedals

Ergonomically designed for increased operator comfort.

13 Electric Power Window

For simplified operation.

Electrohydraulic Hoist Lever

Is fingertip actuated and provides low impact bodydown snubbing.

Truck Production Management System 40TPMS41 Optional

Provides payload and cycle time data. ulli Cat developed technology utilizes strut pressure sensors and an onboard microprocessor to determine payload weight.lili Accurate under normal loading to within five percent over a normal operating shift.lili Delivers consistent accurate payloads and improves efficiency by minimizing overloading and underloading liul Onboard computer stores 1,400 cycles for further analysis of payload weight, cycle segment times, cycle segment distances and actual clock time and date of each cycle. External lights signal loading tool operator when payload is reached. Internal troubleshooting and fault recording for easier maintenance.

SystemsApplications

The 769D is designed for versatility.

Machine Configuration Options

Caterpillar offers a variety of machine configuration options to help meet customer needs.

Body Options

Include a full line of standard and custom designs based on specific customer preference, material density, loading tool and site conditions.

Tire Options

A full line of tire options, representing various manufacturers, is offered by Caterpillar to maximize performance and life for specific applications.

Attachments

Give the customer options to tailor trucks for specific application requirements, including ulli Truck Production Management Systemlili Automatic Retarder Controllili Traction Control Systemlili Custom product offeringslili Mufflerexhaust diverterliul

System Approach

The Caterpillar system approach means increased efficiencies through common design. Haul trucks, loaders, excavators, tractors, engines for generator sets and pumps all designed by Caterpillar use common components, parts and design. Commonality reduces customer parts stock, improves parts availability, reduces trainingmaintenance and improves diagnostics. This system approach adds up to lower costperton. Dealer support is available to address customer needs regardless of the component.

Caterpillar Product Analysis Team PAT

Combined with Caterpillar software programs can assist customers with detailed, application evaluation.

Loader Match

Designed to work as part of a system, the 769D is best matched to the following Caterpillar loaders ulli 980G four to five passmatchlili 988G three to four passmatchlili 5080 four to five passmatchlili 375ME four to five passmatchliul

ServiceabilityTotal Customer Support

Purchase of a Caterpillar machine includes a total commitment to customer support.

Cat QuickEvacTM System

Is an exclusive Caterpillar onboard engine oil evacuation and prelubrication system.

Automated Engine Oil Change

A new, state of the art onboard system evacuates engine sump in less than one minute and allows for purge of oil filters prior to removal, minimizing oil spills. It delivers new oil through primary filters for filtered protection and ensures new filters are correctly filled following routine oil change.

Contamination Control

Environmentally efficient, clean oil changes are ensured since engine sump is evacuated directly into PM trucks or waste containers with flush faced, quick disconnects for fast evacuation and fill. This eliminates handling of waste oil, minimizes chances of oil spillage and enhances Contamination Control efforts by ensuring complete filtration of new oil on engine refill.

Complete Engine Prelubrication

Provides engine oil pressure prior to engine cranking. Reduces engine dry start wear and risk of cold starts for increased protection of key engine components. Also provides expanded low temperature range for 15W40 motor oils.

Improved Serviceability and Machine Availability

Reduces time to complete engine service changing engine oil, oil filters, fuel filter, air cleaner by as much as 30 to 50 percent. Improves the ability to schedule engine services at prescribed hours, allows for servicing during normal working hours and integrates easily with PM trucks to further reduce total cycle time of engine service.

Maintenance Platform

Provides access to air tanks, brake master cylinder and makeup tank engine oil level air filters steering hydraulic tank and battery compartment.

Ground Level Battery Disconnect Switch

Facilitates safe, convenient servicing and maintenance.

OnBoard Diagnostics

With CEMS, provides the machine operator with a threecategory warning system and quick access to stored diagnostic data.

OffBoard Diagnostics

With ET, allows service technicians access to stored diagnostics data reducing downtime and lowering operating costs. ET stores engine parameter information such as timing, throttle position and fuel flow. Transmission data is available through ET via access to the Cat Data Link System.

Radial Seal Filters

Are easy to change, reducing air filter maintenance times.

Vertical, Spinon Oil Filters

Provide for simplified servicing.

Quick Coupler Pressure Taps

Located in all hydraulic systems to provide clear, quick pressure checks. SOSSM oil analysis points make oil sampling quick, clean and easy.

Sealed Electrical Connectors

Lockout dust and moisture. Colorcoded wiring is standard for the entire Cat product line.

Machine Management Service

Cat dealers help manage equipment investments with ulli Vehicle systems analysis to help match the right machine to the joblili Preventative maintenance programslili SOS oil analysis and technical analysis programslili Repair option analysislili Training for operators and mechanicslili TPMS data analysisliul

Parts Availability

The Caterpillar worldwide computer network locates parts instantly to minimize machine downtime.

Literature Support

Caterpillar manuals are easy to use and help provide the full value of an equipment investment.

Operating Specifications
Nominal Payload Class	40 tons
Top Speed - Loaded	48.3 mph
Body Capacity - Struck	22.24 yd3
Body Capacity - SAE 2:1	31.7 yd3
Maximum Capacity	36 tons
Engine
Engine Model	Cat® 3408E
Gross Power - SAE J1995	518 hp
Net Power - SAE J1349	487 hp
Net Power - Cat	486 hp
Flywheel Power	487 hp
Net Power - 80/1269/EEC	487 hp
Net Power - ISO 9249	487 hp
Torque Rise	27 %
Bore	5.4 in
Stroke	6 in
Displacement	1099 in3
Weights - Approximate
Target Gross Machine Operating Weight	157000 lb
Operating Weight - Empty	24471.28 lb
Capacity - Dual Slope - 100% fill factor
Struck	22.2 yd3
Heaped 2:1 (SAE)	31.7 yd3
Heaped 3:1	28.4 yd3
Heaped 1:1	31 yd3
Weight Distributions - Approximate
Front Axle - Empty	49.8 %
Front Axle - Loaded	33.3 %
Rear Axle - Empty	50.2 %
Rear Axle - Loaded	66.7 %
Transmission
Forward 1	7.8 mph
Forward 2	10.7 mph
Forward 3	14.5 mph
Forward 4	19.5 mph
Forward 5	26.4 mph
Forward 6	35.6 mph
Forward 7	48.3 mph
Reverse	10.3 mph
Brakes
Brake Surface - Front	216 in2
Brake Surface - Rear	8525 in2
Service Refill Capacities
Fuel Tank	140 gal
Cooling System	30 gal
Differentials and Final Drives	22 gal
Steering Tank	9 gal
Steering System (Includes Tank)	15 gal
Torque Converter / Brake / Hoist Hydraulic Tank	35 gal
Brake / Hoist System (Includes Tank)	73 gal
Torque Converter / Transmission System (Includes Sump)	19 gal
Body Hoists
Pump Flow - High Idle	110 gal/min
Relief Valve Setting - Raise	2500 psi
Relief Valve Setting - Lower	500 psi
Body Raise Time - High Idle	7.5 Seconds
Body Lower Time - Float	8.3 Seconds
Body Power Down - High Idle	8.3 Seconds
Suspension
Effective Cylinder Stroke - Front	9.2 in
Effective Cylinder Stroke - Rear	5.9 in
Rear Axle Oscillation	8.5 Degrees
Approximate Weights - Quarry Flat Floor
Chassis	50600 lb
Body	17200 lb
Standard liner	7200 lb
Front axle - empty	49.7 %
Front axle - loaded	33.3 %
Rear axle - empty	50.3 %
Rear axle - loaded	66.7 %
Approximate Weights - Dual Slope
Chassis	50600 lb
Body	16200 lb
Standard liner	7000 lb
Front axle - empty	49.8 %
Front axle - loaded	33.3 %
Rear axle - empty	50.2 %
Rear axle - loaded	66.7 %
Capacity - Quarry Flat Floor - 100% fill factor
Struck	21.6 yd3
Heaped 3:1	28.3 yd3
Heaped 2:1 (SAE)	31.7 yd3
Heaped 1:1	41.5 yd3
Dimensions
Height - Top of ROPS	12.11 ft
Overall Body Length	24.98 ft
Inside Body Length	17.31 ft
Overall Length	26.37 ft
Wheelbase	12.18 ft
Rear Axle to Tail	8.34 ft
Ground Clearance	2.06 ft
Dump Clearance	1.53 ft
Loading Height - Empty	10.31 ft
Inside Body Depth - Max	4.56 ft
Overall Height - Body Raised	25.29 ft
Operating Width	16.63 ft
Centerline Front Tire Width	10.18 ft
Engine Guard Clearance	2.06 ft
Overall Canopy Width	14.43 ft
Inside Body Width	12 ft
Front Canopy Height	12.97 ft
Rear Axle Clearance	2.02 ft
Centerline Rear Dual Tire Width	8.1 ft
Overall Tire Width	11.76 ft