specalog for 769d off-highway truck, aehq5440-01

®®

EngineEngine Model Caterpillar 3408EGross Power 386 kW 518 hpFlywheel Power 363 kW 487 hp

WeightsGross Machine Weight 71 400 kg 157,000 lb

Operating SpecificationsSAE (2:1) Capacity 24.2 m3 31.7 yd3

Nominal Payload 36.4 tonnes 40.0 tons

769DOff-Highway Truck

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769D Off-Highway TruckEngineered for performance, designed for comfort and built to last.

Time proven iron and modern technologycombine to provide a highly productive,durable, reliable off-highway truck, focusedon our customers greatest need...lowestcost-per-ton.

Operator Station

Controls and gauges are positioned tomaximize productivity and comfort.The cab includes air suspension seatand advanced electronic monitoringsystem. Adjustable telescoping steeringcolumn, electric wipers, window andbody controls reduce operator effortand simplify control. pg. 14

Engine/Power Train Integration

The Caterpillar Data Link Systemelectronically combines engine,transmission, brake and operationalinformation to optimize overalltruck performance. The ElectronicTechnician (ET) accesses storeddiagnostic data, significantlyreducing downtime. pg. 8

Power Train - Transmission

The Cat® seven-speed, power shifttransmission, matched with the direct-injection 3408E diesel engine providesconstant power over a wide range ofoperating speeds. pg. 6

Power Train - Engine

The power train features the Caterpillar®

3408E Diesel engine and AdvancedModular Cooling System for efficientoperation. pg. 4

Body Options

The 769D offers a flat floor or dual-slopeoption to meet specific user applications.Both incorporate time-proven boxbeam and full-length stringer designfor extended life. A full offering ofattachments and customized options areavailable to meet specific needs. pg. 13

✔ New Feature

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Serviceability/Total Customer Support

Easy serviceability access, QuickEvacTM

system, on- and off-board diagnostics,machine management service, worldwideparts availability and literature supportrepresents the Caterpillar commitmentto customer support. pg. 16

✔

Systems/Applications

Numerous options and a systemapproach to match the 769D to themost appropriate loader meets customerneeds for various applications. pg. 18

Structures

Caterpillar truck frames are built forsevere applications. Mild steel providesflexibility, durability and resistance toimpact loads. Castings and forgings inhigh stress areas of the frame providegreat structural strength. pg. 12

Oil-Cooled, Rear Disc Brakes

Caterpillar oil-cooled, multiple discbrakes offer exceptional, fade-resistantbraking and retarding. pg. 10

Integrated Braking Control (IBC)

IBC integrates the optional AutomaticRetarder Control and Traction ControlSystem (TCS) into one system toenhance truck performance andproductivity and improve operatorconfidence. pg. 11

Cat 3408E Diesel Engine. The four-strokedesign uses long power strokes for morecomplete fuel combustion and optimumefficiency. Large displacement and a lowspeed rating can help extend engine life.This engine meets U.S. EnvironmentalProtection Agency Tier 2 emissionsregulations and Stage II EU EmissionsDirective 97/68/EC.

Torque Rise. The 27 percent torquerise provides high lugging force duringacceleration on grade or in high rimpullconditions. The torque rise effectivelymatches the transmission shift points toprovide maximum efficiency and fastercycle times.

Engine.

1) Turbocharger

2) Electronic Control Module (ECM)

3) Valve Rotators

4) Stellite-Faced Valves

5) Steel-Backed, Copper-BondedBearings

6) Oil Cooler

7) Forged Crankshaft

8) Adjustment-Free Fuel Injection Pump

9) Hydraulic Electronic Unit Injectors

10) Forged Steel Pistons

11) Full-Length, Water-CooledCylinder Liners

Engine Features. Contributing to the3408E power and reliability are:

• High pressure injection

• Full electronic control, one pieceforged steel pistons with three ringscooled by oil spray

• Copper-bonded crankshaft bearings

• Hardened crankshaft journals

• Dry-type radial seal air cleaners withprimary and secondary elements andprecleaner

• Direct-electric, 24-volt startingsystem with 50-amp alternator andfour 172-amp-hour, low maintenance,high output, 12-volt batteries

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Power Train - EngineThe eight cylinder, turbocharged and air-to-air aftercooled HEUI engine is built for power,reliability and economy with reduced sound levels and low emissions.

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Hydraulic Electronic Unit Injector (HEUI).The HEUI is a proven high-pressure,direct injection fuel system. This systemelectronically monitors operator andmachine inputs to optimize engineperformance. HEUI is unique in itsability to independently control injectionpressure over the entire engine operatingrange. This allows complete control overinjection timing, duration, performanceand efficiency. Rate shaping technologymodifies the heat release characteristicsof the combustion process for significantdecreases in sound and emission levels.Exhaust smoke is significantly reducedthrough precise, electronic control offueling limits and injection timing ofthe HEUI.

Electronic Control Module (ECM).The ECM monitors key functions andlogs critical indicators. The ElectronicTechnician can access this diagnosticinformation for easier maintenanceand repair.

Advanced Modular Cooling System(AMOCS). Is a Caterpillar exclusivetechnology which improves serviceabilityand reduces downtime. It utilizes anexclusive two pass cooling systemand increased cooling surface area toprovide significantly more coolingcapacity than conventional systems.

System Operation. The two pass systemcirculates coolant from the sectionedbottom tank up through one side of thecooling element and down through theother side returning it to the bottom tank.

AMOCS Design. The cooling elementsare individual core modules, with brasstube construction within each core, thatare connected to a sectioned bottomtank. There is no top tank to remove.Each core module can be replacedindividually (without removing theentire radiator), saving considerablecost and repair time. And with ninesteel fins per inch, fin bendingresistance is improved.

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Transmission. The Cat seven-speed,power shift transmission, matched withthe direct-injection 3408E diesel engineprovides constant power over a widerange of operating speeds.

Transmission Features. Include:

• Seven speeds forward, one reverse

• Torque converter driven reverse

• First gear has both torque converterdrive and direct drive

• Second through seventh gears aredirect drive

• Single-lever shift control providesautomatic shifting in all gears up tothe one selected by the control lever

• Each shift is individually modulatedfor maximum smoothness

• Separate hydraulic circuit with cooler

• Electronic control has built-indiagnostics and fault code memory,event memory and programmablefeatures

• Control throttle shifting

• Economy shift mode

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Power Train - TransmissionThe Cat seven-speed, power shift transmission gets the job done smoothly and quickly.

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1) Lock-up Torque Converter. Combinesthe maximum rimpull and cushionedshifting of torque converter drivewith the efficiency and performanceof direct drive.

• Engages at approximately 6.9 km/h(4.3 mph), delivering more powerto the wheels.

• Lock-up clutch quickly releases andre-engages during shifts, maintainingpower wind-up, improving transmissionlife and increasing operator comfort.

2) Planetary Power Shift Transmission.Utilizes a modulating pressure valve toregulate clutch pressure rise and fall toease clutch engagement. This reducesshock loads on power train components.Features include:

• Large diameter clutches and robustplanetary gears and bearings.

• Patented rotating clutch pressure sealsminimize drag losses and improvereliability.

• 35 percent gear splits between allgears match Cat engine design foroptimum use of engine power withminimized shifting and torqueconverter use.

3) Final Drive. Final drive and differentialtorque multiplication of 13.15:1 furtherreduces stress on the drive train.

4) Sump. Transmission and torqueconverter share a common sump.The combined sump offers an easilyaccessible fill tube and sight gauges.

Axles. Full floating axles are shot-peenedto relieve internal stresses and increasedurability. Rolled splines also provideincreased service life.

Wheels and Rims. Cast rear wheelsand Cat center-mount rims are mountedusing studs and nuts to minimizemaintenance and maximize durability.

Transmission Chassis Controller (TCC).TCC uses electronically transferredengine rpm data to execute shifts atpreset points for optimum performanceand efficiency. This integration allows:

• Programmable top gear limit

• Control throttle shifting

• Directional shift management

• Neutral coast inhibitor

• Economy shift mode

Integration. The Caterpillar powertrain integration provides increasedcomponent life and operator comfort.

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Integration.

1) Electronic Technician

2) Cat Data Link System

3) Engine Control Module

4) Engine

5) Transmission Chassis Control

6) Automatic Retarder Control, TractionControl System and Integrated BrakeController

7) Caterpillar Electronic MonitoringSystem

8) Transmission

9) Oil-cooled Brakes

Cat Data Link. The Cat Data Linkelectronically integrates the machine’scomputer systems, which allowscommunications and provides thefollowing benefits:

• Controlled Throttle Shifting. Enginerpm is regulated during a shift toreduce driveline stress for smoothershifts and longer component life.

• Economy Shift Mode. Modifiesengine maps, resulting in improvedfuel consumption.

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Engine/Power Train IntegrationCombining the electronic Engine Control Module (ECM) with the Caterpillar Transmission ChassisController (TCC) allows critical power train components to work more intelligently.

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• Directional Shift Management.Regulates engine speed duringdirectional shifts to prevent damagecaused by high speed directionalchanges.

Elevated Idle Neutral Coast Inhibitor.Helps prevent the transmission fromshifting to neutral at speeds above6.5 km/h (4 mph).

Body-up Shift Inhibitor. Helps preventthe transmission from shifting above apre-programmed gear without the bodyfully lowered.

Event Memory. Records machinemanagement data that can be accessedusing the Electronic Technician.Recorded information includes:

• Shift histograms

• Operator-induced events

• Lock-up clutch counter

• Machine overspeed

• Transmission overspeed

Electronic Technician (ET). The electronicengine and transmission controls provideexhaustive diagnostic capability forservice technicians. The ability to storeboth active and intermittent indicatorswill simplify problem diagnosis andtotal repair time, resulting in improvedmechanical availability and loweroperating cost.

ET accesses data stored in the engineand transmission controls via theCat Data Link System.

ET displays the status of all engineparameters including throttle position,timing and fuel flow.

ET replaces 13 mechanical tools toperform functions like cylinder cutoutchecks, injector solenoid tests andtiming calibration.

Caterpillar Electronic MonitoringSystem (CEMS). CEMS allows theoperator to view requested informationand utilizes a three-category warningsystem to alert the operator to abnormalmachine conditions.

Optional Attachments. Caterpillar offersoptional attachments that integrate withthe Cat Data Link System.

• Automatic Retarder Control (ARC).Works with other electroniccomponents to automatically controlretarding on grade, maintainingapproximately 2,230 rpm.

• Traction Control System (TCS).Improves performance in poorunderfoot conditions by electronicallymonitoring and controlling wheelslippage.

• Integrated Brake Controller (IBC).Combines ARC and TCS, reducingthe number of electronic componentsand electrical lines.

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Brakes.

1) Parking/Secondary Piston

2) Service/Retarding Piston

3) Friction Discs

4) Steel Plates

5) Actuating Springs

6) Cooling Oil In

7) Cooling Oil Out

Multiple Disc Brakes. Caterpillar forcedoil-cooled, multiple disc brakes arecontinuously cooled for exceptional,fade-resistant braking and retarding.The optional ARC and TCS utilize theoil-cooled rear brakes to enhance truckperformance and increase productivity.

Oil Cooled Disc Brakes. Are designedand built for reliable, adjustment-freeoperation providing superior performanceand service life in comparison to shoe-type and dry-disc systems.

Oil Film. An oil film prevents directcontact between the discs. Absorbingthe braking forces by shearing oil andcarrying heat away, this design extendsbrake life.

Secondary Braking. Spring applied,hydraulically released, oil-cooled discbrakes are located on the rear axle.The front brakes will activate as partof the secondary system, even ifswitched out of service.

Parking Brakes. Spring applied,hydraulically released parking brakesuse wet disc brakes in service system.A toggle switch activates theparking brakes.

Pistons. A Caterpillar patented, two-piston design combines the service,secondary and parking brakes, alongwith retarding functions.

The primary piston hydraulically actuatesboth service and retarding functions.The secondary piston is spring-appliedand held in the disengaged position byhydraulic pressure. If hydraulic systempressure drops below a certain level,the spring-applied secondary pistonautomatically applies the brakes.

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Oil-Cooled, Rear Disc BrakesRear braking lets the operator concentrate on the haul road.

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Cat Retarding System. When retarding,the engine runs against compression ondownhill hauls, resulting in no fuel burn.

Retarding forces and heat are absorbedthrough the oil. The retarding systemgenerates lower drive line stresses thandrive line retarding systems.

Automatic Retarder Control (Optional).The ARC electronically controls brakingon grade to maintain approximately2,230 engine rpm (engine rpm isadjustable from 2,160-2,300 rpmin increments of 10 rpm). ARC isdeactivated when the operator appliesthe brakes or throttle.

Engine Overspeed Protection. With theaccelerator depressed and/or ARCturned off, ARC will automaticallyactivate at 2,475 rpm to help avoidpotentially destructive and often costlyengine overspeeds.

ARC Benefits. Include:

• Increased operating efficiency withfaster downhill speeds. By maintainingconsistently higher engine speeds,average truck speed will be higherthan a manually controlled truck.

• Excellent controllability and reducedoperator effort. Automatic brakemodulation provides a smoother rideover manual modulation, allowingthe operator to focus more on truckoperation down the haul road.

• Improved component life, optimizedsystem cooling capability and reducedtorque fluctuations result from ARC’sprecision.

• Faster troubleshooting and diagnosiswith self-diagnostic capability andthe ability to communicate with ETthrough the Cat Data Link System.

• Operator awareness through electronicintegration and CEMS, alerting theoperator to overspeed conditions andcritical machine functions.

Traction Control System (Optional).Monitors wheel slip so if it exceedsthe set limit, the oil-cooled disc brakesare automatically applied to slow thespinning wheel.

Operator Awareness. An on-dashindicator shows the operator that TCSis engaged.

Differential Action. Utilizes normaldifferential action to provide superiormaneuvering in poor underfootconditions. Also reduces tire scuffing ascompared to positive lock differentialsused on other systems.

Torque. TCS divides torque equallyto reduce stress created on final drivesand axles when torque is transferredto one side.

System Back-up. Should sensors fail,the normal differential action is stillavailable to maintain control and steering.

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ARC Operating Efficiency Advantages

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10Time (Seconds)

20 30 40 50 60

Automatic Retarder Control(Maintains Engine rpm between 2160-2300)

Manual Retarder Control(Wide Variation in Engine rpm)

* Optimum Engine rpm

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Integrated Braking Control (IBC)Electronically combines Automatic Retarding Control (ARC) and the Traction ControlSystem (TCS) into one integrated control system.

Box-Section Design. The 769D frameuses a box section design, incorporating17 castings in high stress areas withdeep penetrating and continuous wrap-around welding. Mild steel, whichprovides flexibility, durability andresistance to impact loads even incold climates is used throughout.

Castings. Castings have large radii withinternal reinforcing ribs to dissipatestress. Castings move welds to lowerstress areas and provide two to threetimes the strength of equivalent sizedfabricated structures.

Frame Features. Include:

• Integral front bumper

• Front box beams for suspensioncylinder and ROPS support

• Box-section rear crossmember for bodyand ROPS support with attachmentpoints for maintenance platform andrear engine hood hinge support

• Castings are used to provide additionalstrength in critical stress areas

• Mild steel plates (290 MPa [42,000 psi]minimum yield strength) and castings(241 MPa [35,000 psi] minimum yieldstrength) provide flexibility, durabilityand easy field maintenance

Frame Serviceability. The box-sectionframe allows simple access to powertrain components. This open designreduces overall removal and installationtime, lowering repair costs. Transmissionaccess is excellent under the raised andpinned body. Repairs can be madewithout preheating in ambienttemperatures 16° C (60° F) usingreadily available welding supplies.

Rollover Protection Structure (ROPS).The ROPS attaches securely to fourcastings welded into the frame.

Suspension System. Designed todissipate haul road and loading impactsfor extended frame life.

Four, independent, self-contained, oilpneumatic, variable-rebound, suspensioncylinders absorb shocks. Rear cylindersallow axle oscillation and absorb thebending and twisting stresses. Frontcylinders, mounted to the frame,serve as steering kingpins, providingexcellent maneuverability and reducedmaintenance. Caster and camberare preset.

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StructuresThe backbone of the Cat off-highway truck.

Design. 769D bodies are designed tohandle a variety of material densities.Maximum payload is reached in threeto five passes from a matched Catloader in 1700 kg/m3 (2,900 lb/yd3)material and higher.

Sidewall and Floor Junctions. Are joinedby five-sided beams to resist impactloading and sustained hauling stresses.

Box-Section Beams. Offer increaseddurability in the floor, sidewalls, toprail, corner and cab canopy areas.

400 Brinell Steel. Wear surfaces provideexcellent wear resistance and are easilywelded without preheating procedures.

Two-Stage Hoist Cylinders. Providefast dump cycle times of 7.5 secondsfor Raise and 8.3 seconds for Lower.

Standard Body. Comes exhaust heatedwith options including a full-timemuffler or exhaust diverter.

Custom Attachments. Including tailextensions, liner packages, sideboardsand other custom designs are offeredto help ensure rated payload.

1) Dual-Slope Body. Offers the lowestcost-per-ton option in most constructionand mining applications.

Dual-Slope Body Performance. Efficientunder most haul road conditions, but itsstrength comes from higher levels ofproduction in sites with rough haulroads and steeper grades.

Body Floor Construction. Uses an eightdegree “V” bottom for increased loadretention, a low center of gravity andreduced shock loading. It also aids incentering the load.

An 18 Degree Ducktail and 9 DegreeForward Body Slope. Retains the loadon grades up to 15 percent and higher.This design also helps maintain properload distribution.

2) Flat Floor Construction and MiningBody. Offers excellent load retention ongrades up to 12 percent and on smootherhaul road conditions.

Body Floor Construction. Uses a12 degree single slope, offeringexcellent wear characteristics anduniform dumping into hoppers,crushers and feeders.

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Body OptionsCaterpillar builds a variety of rugged, durable bodies to perform in the toughestapplications.

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Operator StationControl ease and comfort maximize productivity.

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769D Operator Station. Rated highlyby operators. Everything needed fortop performance is at the operator’sfingertips.

1) Wraparound Dash Panel. Offers aneasy line-of-sight arrangement, usingLED backlit rocker switches.

2) Caterpillar Contour Series AirSuspension Seat. Standard and fullyadjustable, including an adjustableright-hand armrest.

3) Tilt/Telescoping Steering Wheel.With ergonomic grip improves comfortand control. Low effort steering systemand ergonomically designed retarderlever reduces operator fatigue. Alsoincludes an enhanced turn signal leverwith high beam actuator and electricwindshield wiper controls.

4) Transmission Console. Has LEDbacklit gear numbers and ergonomicshift knob.

5) Visibility. Exceptional all-aroundviewing area reduces fatigue andimproves productivity.

6) Integral, Sound-SuppressedROPS/FOPS Cab. Is resiliently mountedproviding a quiet, protected workenvironment. The cab is radio-readywith speakers, wiring harness, antennaand mounting bracket.

7) Front Brake Cut-Out Switch.Increases front brake component life.

8) Large Storage Compartment. 0.10 m3

(3.5 ft3) of space is located under thetrainer’s seat.

9) Trainer’s Seat. Includes back rest andretractable seat belt.

10) Caterpillar Electronic MonitoringSystem (CEMS). Provides critical data.The system features three separatedisplays:

• Four-gauge cluster with coolanttemperature, oil temperature, brakeair pressure, fuel level

• Tachometer, digital speedometer/actual gear indicator

• Message center module

11) Standard Heater and Optional AirConditioner. Includes four-speed fanand nine vents.

12) Foot Pedals. Ergonomically designedfor increased operator comfort.

13) Electric Power Window.For simplified operation.

14) Electrohydraulic Hoist Lever.Is fingertip actuated and provideslow impact body-down snubbing.

15) Truck Production ManagementSystem (TPMS) (Optional). Providespayload and cycle time data.

• Cat developed technology utilizesstrut pressure sensors and an on-boardmicroprocessor to determine payloadweight.

• Accurate under normal loading towithin ± five percent over a normaloperating shift.

• Delivers consistent accurate payloadsand improves efficiency by minimizingoverloading and underloading

• - On-board computer stores 1,400 cyclesfor further analysis of payload weight,cycle segment times, cycle segmentdistances and actual clock time anddate of each cycle.

• - External lights signal loading tooloperator when payload is reached.

• - Internal troubleshooting and faultrecording for easier maintenance.

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Cat QuickEvacTM System. Is an exclusiveCaterpillar on-board engine oilevacuation and prelubrication system.

Automated Engine Oil Change. A new,state of the art, on-board system evacuatesengine sump in less than two minutesand allows for partial purge of oil filtersprior to removal, minimizing oil spills.New oil is delivered through primaryfilters, enhancing contamination controlefforts while ensuring that new filtersare correctly filled following routineoil change.

Contamination Control. Environmentallyefficient, clean oil changes are ensuredsince engine sump is evacuated directlyinto PM trucks or waste containers withflush faced, quick disconnects for fastevacuation and fill. This eliminateshandling of waste oil, minimizeschances of oil spillage and enhancescontamination control efforts byensuring complete filtration of newoil on engine refill.

Complete Engine Prelubrication.Provides engine oil pressure prior toengine cranking. Reduces engine drystart wear and risk of cold starts forincreased protection of key components.Also provides expanded low temperaturerange for 15W40 motor oils.

Improved Serviceability and MachineAvailability. Reduces time to completeengine service (changing engine oil, oilfilters, fuel filter, air cleaner) by as muchas 30 to 50 percent. Improves the abilityto better schedule engine services atprescribed hours, and integrates easilywith PM trucks to further reduce totalcycle time of engine service.

Maintenance Platform. Provides accessto air tanks, brake master cylinder andmake-up tank; engine oil level; airfilters; steering hydraulic tank; andbattery compartment.

Ground Level Battery DisconnectSwitch. Facilitates safe, convenientservicing and maintenance.

Serviceability/Total Customer SupportPurchase of a Caterpillar machine includes a total commitment to customer support.

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On-Board Diagnostics. With CEMS,provides the machine operator witha three-category warning system andquick access to stored diagnostic data.

Off-Board Diagnostics. With ET, allowsservice technicians access to storeddiagnostics data reducing downtimeand lowering operating costs. ET storesengine parameter information such astiming, throttle position and fuel flow.Transmission data is available through ETvia access to the Cat Data Link System.

Radial Seal Filters. Are easy to change,reducing air filter maintenance times.

Vertical, Spin-on Oil Filters. Provide forsimplified servicing.

Quick Coupler Pressure Taps. Locatedin all hydraulic systems provide clear,quick pressure checks. S·O·SSM oilanalysis points make oil samplingquick, clean and easy.

Sealed Electrical Connectors. Lockoutdust and moisture. Color-coded wiring isstandard for the entire Cat product line.

Machine Management Service.Cat Dealers help manage equipmentinvestments with:

• Vehicle systems analysis to helpmatch the right machine to the job

• Preventative maintenance programs

• S·O·S oil analysis and technicalanalysis programs

• Repair option analysis

• Training for operators and mechanics

• TPMS data analysis

Parts Availability. The Caterpillarworldwide computer network locatesparts instantly to minimize machinedowntime.

Literature Support. Caterpillar manualsare easy to use and help provide the fullvalue of an equipment investment.

Machine Configuration Options.Caterpillar offers a variety of machineconfiguration options to help meetcustomer needs.

Body Options. Include a full line ofstandard and custom designs based onspecific customer preference, materialdensity, loading tool and site conditions.

Tire Options. A full line of tire options,representing various manufacturers, isoffered by Caterpillar to maximizeperformance and life for specificapplications.

Attachments. Give the customer optionsto tailor trucks for specific applicationrequirements, including:

• Truck Production Management System

• Automatic Retarder Control

• Traction Control System

• Custom product offerings

• Muffler/exhaust diverter

System Approach. The Caterpillarsystem approach means increasedefficiencies through common design.Haul trucks, loaders, excavators,tractors, engines for generator sets andpumps - all designed by Caterpillar -use common components, parts anddesign. Commonality reduces customerparts stock, improves parts availability,reduces training/maintenance andimproves diagnostics. This systemapproach adds up to lower cost-per-ton.Dealer support is available to addresscustomer needs regardless of thecomponent.

Caterpillar Product Analysis Team(PAT). Combined with Caterpillarsoftware programs can assist customerswith detailed, application evaluation.

Loader Match. Designed to work as partof a system, the 769D is best matched tothe following Caterpillar loaders:

• 980G - four to five pass/match

• 988G - three to four pass/match

• 5080 - four to five pass/match

• 375ME - four to five pass/match

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Systems/ApplicationsThe 769D is designed for versatility.

19769D Off-Highway Truck specifications

Brakes

Brake surface - front 1395 cm2 216 in2

Brake surface - rear 54 999 cm2 8,525 in2

Differential ratio 2.74:1Planetary ratio 4.80:1Total reduction ratio 13.15:1• Brakes meet the SAE J/ISO 3450:1998, ISO 3450:1996

standards up to 71 400 kg (157,000 lb) gross operating weight.

Service Refill Capacities

Fuel Tank 530 L 140 galCooling System 113.5 L 30 galCrankcase 45 L 12 galDifferentials and final drives 83 L 22 galSteering tank 34 L 9 galSteering system (includes tank) 56 L 15 galBrake/hoist hydraulic tank 155 L 35 galBrake/hoist system 277 L 73 gal(includes tank)Torque converter/ 53 L 14 galtransmission sumpTorque converter/transmission 72 L 19 galsystem (includes sump)

Body Hoists

Pump flow - high idle 417 L/min 110 gal/minRelief valve setting - raise 17 225 kPa 2,500 psiRelief valve setting - lower 3445 kPa 500 psiBody raise time @ high idle 7.5 SecondsBody lower time float 8.3 SecondsBody power down @ high idle 8.3 Seconds• Twin, two-stage, hydraulic cylinders mounted inside the

main frame, double acting in second stage.

• Power raise in both stages and power down in secondstage.

Suspension

Effective cylinder stroke - front 234 mm 9.2 inEffective cylinder stroke - rear 149 mm 5.9 inRear axle oscillation ±8.5°

Engine

Engine Model Cat 3408EGross Power 386 kW 518 hpFlywheel Power 363 kW 487 hpDIN 70020 505 PSMax. Torque 2194 N.m 1,618 lb ftTorque rise 27 %Bore 137 mm 5.4 inStroke 152 mm 6 inDisplacement 18 L 1,099 in3

• Gross power meets ISO 3046-02 standards.

• Flywheel power meets ISO 9249, SAE J1349 JUN 95 andEEC 80/1269 standards.

• These ratings apply at 2,000 rpm when tested under thespecified standard conditions for the specified standard.

• Power rating conditions based on standard air conditionsof 25° C (77° F) and 99 kPa (29.32 in Hg) dry barometer,using 35° C API gravity fuel having an LHV of 42 780 kJ/kg(18,390 Btu/lb) when used at 30° C (86° F) [reference a fueldensity of 838.9 g/L (7.001 lb/gal)].

• Net power advertised is the power available at the flywheelwhen the engine is equipped with fan, air cleaner, mufflerand alternator.

• No derating required up to 3050 m (10,000 ft) altitude.

• Meets U.S. Environmental Protection Agency Tier 2emissions regulations.

• Meets Stage II EU Emissions Directive 97/68/EC.

Transmission

Forward 1 12.6 kph 7.8 mphForward 2 17.2 kph 10.7 mphForward 3 23.3 kph 14.5 mphForward 4 31.4 kph 19.5 mphForward 5 42.5 kph 26.4 mphForward 6 57.3 kph 35.6 mphForward 7 77.7 kph 48.3 mphReverse 16.6 kph 10.3 mph• Maximum travel speeds (standard 18.00-R33).

ROPS

• ROPS Meets SAE J1040 MAY94and ISO 3741:1994

• Rollover Protective Structure (ROPS) is offered byCaterpillar as standard equipment.

• The operator sound pressure level is less than 74 dB(A)when measured according to the stationary test proceduresand the conditions specified in ISO 6394.

• The operator sound exposure Leq (equivalent soundpressure level) is less than 79 dB(A) when measuredaccording to the work cycle procedures specified inANSI/SAE J1166 MAY 90 for the cab offered by Caterpillarwhen properly installed and maintained and windowsclosed.

Tires

• Tires Standard: 18.00-R33 (E4)• Productive capabilities of the 769D are such that, under

certain job conditions, TKPH (TMPH) capabilities ofstandard or optional tires could be exceeded and,therefore, limit production.

• Caterpillar recommends the user evaluate all job conditionsand consult the tire manufacturer to make proper tireselection.

Sound

• Exterior Sound Meets ISO, ANSI/SAEstandards

• This machine, in standard configuration, when measuredand operated per the prescribed modes in ANSI/SAE J88APR95 has a 15 m sound pressure level of 84 dB(A) for themode that gives the highest level.

• When the optional attachment sound suppression packageis properly installed and maintained, this machine complieswith the European Directive for Equipment Used Outdoors -2000/14/EC.

Steering

• Steering Meets SAE J1511 FEB94and ISO 5010-1992

• Turning diameter per ISO 7457-1997 is 17.0 m (55 ft 9 in).

• Machine clearance diameter per ISO 7457-1997 (E) is 20.3 m(66 ft 7 in).

• Steering angle (left or right) is 39 degrees.

• Separate hydraulic system prevents cross contamination.

• Steering wheel effort is low and cycle times are reducedwith dynamic, load sensing, variable displacement piston-type steering pump.

Final Drives

Differential ratio 2.74:1Planetary ratio 4.80:1Total reduction ratio 13.15:1• Planetary, full-floating.

Approximate Weights - Flat Floor

Gross vehicle 71 400 kg 157,000 lbChassis 23 000 kg 50,600 lbBody 7800 kg 17,200 lbStandard liner 3300 kg 7,200 lbFront axle - empty 49.7 %Front axle - loaded 33.3 %Rear axle - empty 50.3 %Rear axle - loaded 66.7 %• Percentages represent weight distribution without liner

Approximate Weights - Dual-slope

Gross vehicle 71 400 kg 157,000 lbChassis 23 000 kg 50,600 lbBody 7300 kg 16,200 lbStandard liner 3200 kg 7,000 lbFront axle - empty 49.8 %Front axle - loaded 33.3 %Rear axle - empty 50.2 %Rear axle - loaded 66.7 %

Weights

Gross Machine Weight 71 400 kg 157,000 lb

Operating Specifications

SAE (2:1) Capacity 24.2 m3 31.7 yd3

Nominal Payload Capacity 36.4 tonnes 40.0 tons• Refer to the Caterpillar 10/10/20 Payload Policy.

20 769D Off-Highway Truck specifications


11 7615 mm 25 ft 0 in 7430 mm 24 ft 5 in12 1390 mm 4 ft 7 in 1454 mm 4 ft 9 in13 5430 mm 17 ft 10 in 5275 mm 17 ft 4 in14 7751 mm 25 ft 5 in 7709 mm 25 ft 4 in15 3188 mm 10 ft 6 in 3143 mm 10 ft 4 in16 465 mm 1 ft 6 in 525 mm 1 ft 9 in17 315 mm 1 ft 0 in 415 mm 1 ft 4 in18 2541 mm 8 ft 4 in 2380 mm 7 ft 10 in19 4072 mm 13 ft 4 in 4027 mm 13 ft 3 in10 3997 mm 13 ft 1 in 3952 mm 13 ft 0 in

Flat Floor Dual-slope

* Operating width to r.h. mirror

200 mm(8 in)

1

23690 mm

(12 ft 1 in)empty

3590 mm(11 ft 9 in)

loaded

8039 mm(26 ft 5 in)

3713 mm(12 ft 2 in)

empty

9°

60°

5

empty6

8

loaded7

43

empty

loaded

3632 mm(11 ft 11 in)

3658 mm(12 ft)

4398 mm(14 ft 5 in)

3665 mm(12 ft)

3102 mm(10 ft 2 in)

*5069 mm(16 ft 8 in)

4437 mm(14 ft 6 in)

627 mm(24 in)empty

615 mm(25 in)empty 3584 mm

(11 ft 9 in)

2470 mm(8 ft 1 in)

3615 mm(11 ft 10 in)

3910 mm(12 ft 10 in)

9

10

Capacity - Flat Floor - 100% fill factor

Struck 16.5 m3 21.6 yd3

Heaped 3:1 21.6 m3 28.3 yd3

Heaped 2:1 (SAE) 24.2 m3 31.7 yd3

Heaped 1:1 31.7 m3 41.5 yd3

Capacity - Dual-slope - 100% fill factor

Struck 17 m3 22.2 yd3

Heaped 3:1 21.7 m3 28.4 yd3

Heaped 2:1 (SAE) 24.2 m3 31.7 yd3

Heaped 1:1 23.7 m3 31 yd3

DimensionsAll dimensions are approximate.

The brake performance retarding curves shown in this sectionare for general guidance only. As each site has many uniqueenvironmental and operating conditions that will impactretarding performance, actual site performance could varyconsiderably from predicted performance. Users should usethe retarding speed (gear) recommendations from these tablesas a starting point for determining retarding performance andthen adjust retarding speeds to their site-specific conditions.In adjusting retarding performance to continuously changingenvironmental and site-specific conditions, users need toexercise care to maintain brake cooling and machinecontrollability at all times.

To determine brake retarding performance from retarding tables:

1. Determine the total distance of all downhill grades combinedfor a given haul profile. This total distance determines theappropriate retarding table (continuous or one of the gradedistance tables) applicable to your haul profile.

2. Read from the appropriate gross weight down to percentfavorable effective grade. (For these retarding charts,effective grade equals the maximum grade of all downhillhaul segments minus rolling resistance – do not use anaverage grade value.)

3. From the intersection of the gross weight and effective gradeline point, read horizontally to the appropriate gear curve.If the horizontal line intersects two gear curves, choose thefirst gear curve that the horizontal line intersects (readingfrom right to left) and read the retarding speed performanceimmediately below this point. If the intersection point fallson a vertical line between two gears, choose the lowest of thetwo gears to allow for higher engine rpm thus maximizingbrake cooling capability.

4. Adjust recommended retarding speeds to site specific(environmental and operational) conditions. If the brakesystem overheats or specific site conditions dictate (tightturns, short steep grades, manual braking, etc.), reduceground speed to allow the transmission to shift to the nextlower speed range.

Retarding Performance

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h

mph

kg x 1000

5th Gear

2nd Gear

6th Gear

4th Gear

3rd Gear

LE

EFF

ECTI

VE G

RAD

E (F

avor

able

)

Gross Weightlb x 1000

25%

5%

10%

15%20%

30%

SPEEDContinuous Grade Length

0 10 20 30 40 50 60 70 80 90

7th Gear

0 40 80 120 160 200

0 5 10 15 20 25 30 35 40 45 50

Empty Weight

Gross Machine Weight

71 400 kg (157,000 lb)



0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h

mph

kg x 1000

5th Gear

2nd Gear

6th Gear

4th Gear

3rd Gear

LE

E

FFEC

TIVE

GRA

DE

(Fav

orab

le)


25%

5%

10%

15%20%

30%

SPEEDGrade Length 450 m (1500 ft)

0 10 20 30 40 50 60 70 80 90

7th Gear

0 40 80 120 160 200

0 5 10 15 20 25 30 35 40 45 50

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h

mph

kg x 1000

5th Gear

2nd Gear

6th Gear

4th Gear

3rd Gear

LE

E

FFEC

TIVE

GRA

DE

(Fav

orab

le)


25%

5%

10%

15%20%

30%


0 10 20 30 40 50 60 70 80 90

7th Gear

0 40 80 120 160 200

0 5 10 15 20 25 30 35 40 45 50


Retarding Performance (continued)

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h

mph

kg x 1000

5th Gear

2nd Gear

6th Gear

4th Gear

3rd Gear

LE

E

FFEC

TIVE

GRA

DE

(Fav

orab

le)


25%

5%

10%

15%20%

30%


0 10 20 30 40 50 60 70 80 90

7th Gear

0 40 80 120 160 200

0 5 10 15 20 25 30 35 40 45 50

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h

mph

kg x 1000

5th Gear

2nd Gear

6th Gear

4th Gear

3rd Gear

LE

E

FFEC

TIVE

GRA

DE

(Fav

orab

le)


25%

5%

10%

15%

20%

30%


0 10 20 30 40 50 60 70 80 90

7th Gear

0 40 80 120 160 200

0 5 10 15 20 25 30 35 40 45 50


Gradeability/Speed/Rimpull

To determine gradeability performance,read from gross weight down to thepercent of total resistance. Totalresistance equals actual percent gradeplus one percent for each 10 kg/tonne(20 lb/ton) of rolling resistance. Fromthis weight-resistance point, readhorizontally to the curve with thehighest obtainable gear, then down tomaximum speed. Usable rimpull willdepend upon traction available andweight on drive wheels.

0 5 10 15 20 25 30 35 40 45 500

10

20

30

40

50

60

Rim

pu

ll

kg x1000

lb x1000

km/h

mph

kg x 1000

LE

Eff

ecti

ve G

rad

e (F

avo

rab

le)

Gross Weight

lb x 1000

25%

5%

10%

15%

20%

30%

Speed

0 20 40 60 80 100 120 140 160 180 200 220

Direct DriveDriveTorque Converter

0 10 20 30 40 50 60 70 80 90 100

0 10 20 30 40 50 60 70 80

0

4

8

12

16

20

24

28

1st Gear

1st Gear

2nd Gear

3rd Gear4th Gear

5th Gear6th Gear 7th Gear

Empty Weight

Gross Machine Weight

71 400 kg (157,000 lb)


Air horn, electricAir line dryerAlternator, 50-ampAuxiliary jump start receptacleBackup alarmBattery disconnect switch, ground levelBody mounting groupBrakes

Caliper disc (front)Oil disc (rear)ParkingSecondary

Brake (front) disconnect switchBrake heat exchangerBrake release motor for towingCab, ROPS

Caterpillar Contour Series air suspension seatCoat hookCup holderInsulated and sound-suppressedRadio-readyStorage compartmentSun visorTinted glass

Crankcase guardDiagnostic connection port, 24-voltDriveline guardElectrical system, 24-voltElectronic Monitoring SystemFilters, spin-onGauges

Actual Gear IndicatorAir pressureBrake oil temperatureCoolant temperatureFuelHour meter, electricOdometerSpeedometerTachometer

Heater/defroster 11 070 kCal (43,930 Btu)Hoist lever, fingertip-actuatedLighting system

Backup lightDome/courtesy lightHazard and directional signals, LEDHeadlights, halogen, with dimmerStop/tail lights, LED

Mirrors, right and leftPower port, 24-voltPrecleanerQuickEvacTM SystemReservoirs (separate)

Brake/hoistSteeringTransmission/torque converter

RetarderRock ejectorsSeat belts, retractableSeat, passengerService platform, bolt-onStarting, electricSteering, automatic supplemental, electricSteering wheel, padded, tilt, telescopicTires, 18.00-33, radialTow hooks, frontTow pin, rearTransmission, electronically controlled automatic power shift

with downshift/reverse shift inhibitor, neutralizer duringdumping, neutral start switch, engine overspeed protection,directional shift management, programmable top gear,body-up shift limiter, economy shift mode and controlthrottle shifting

Vandalism protection locksWindow, electric power (operator)Windshield wipers and washer, electric intermittent

Standard EquipmentStandard equipment may vary. Consult a Caterpillar Dealer for specifics.


kg lbAir conditioning 90 200

Automatic lube system 60 135

Automatic Retarder Control (ARC) 6 13

Clustered grease fittings 20 50

Engine coolant heater - 120-volt 3 7

Engine coolant heater - 240-volt 4 9

Engine ground level shut-off 80 180

Ether starting aid 5 10

Exhaust diverter/muffler 75 170

Fuel heater kit 5 12

Integrated brake control 56 123

Muffler 55 120

Sound suppression package 136 300(2000/14/EC compliant)

kg lbSpare rim (330 mm) 13" 360 800

Traction Control System (TCS) 50 110

Truck Bodies:

Dual slope body 7300 16,200

Body liner for dual-slope body [Liner thickness - 16 mm (.063") floor, 8 mm (.031") front and side walls] 3200 7,000

Flat floor body 7800 17,200

Body liner for flat floor body[Liner thickness - 16 mm (.063") floor,8 mm (.031") front and side walls] 3300 7,200

Truck Production ManagementSystem (TPMS) 45 100

Wheel chocks 25 50

Wiggins fast fuel change 2 5

Wiggins high speed oil change 1 2

Optional EquipmentWith approximate changes in operating weights. Optional equipment may vary.Consult a Caterpillar Dealer for specifics.

Flat Floor Dual-slopekg lb kg lb

Empty Chassis Weight 23 000 50,600 23 000 50,600

Fuel Correction (90% × 140 gal.) 400 882 400 882

Optional Attachments WeightDebris Allowance (4% of chassis) +920 +2024 +920 +2024

Chassis Weight 24 320 53,506 24 320 53,506

Body Weight 7800 17,200 7300 16,200

Body Attachments Weight +3300 +7200 +3200 +7000

Total Empty Operating Weight 35 420 77,906 34 820 76,706

Target Payload +35 980 +79,094 +36 580 +80 294

Gross Machine Operating Weight 71 400 157,000 71 400 157,000

*Note: Refer to Caterpillar's 10/10/20 Payload Policy for Quarry and Construction Trucks.

Weight/Payload Calculation*(Example)

R

For more complete information on Cat products, dealer services, and industry solutions, visit uson the web at www.CAT.com

© 2001 CaterpillarPrinted in U.S.A.

Materials and specifications are subject to change without notice.Featured machines in photos may include additional equipment.

See your Caterpillar dealer for available options.

AEHQ5440-01 (12-01)

Replaces AEHQ5440

769D Off-Highway Truck

specalog for 769d off-highway truck, aehq5440-01

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