Caterpillar® Product Information

Salesgram
December 2001

Cat® Introduces the

New E-Series Quarry
& Construction Trucks
773E & 775E

In the next generation of off-highway trucks, Caterpillar introduces the

new 773E and 775E Quarry and Construction Trucks. There are several
new features and product enhancements with the new E-Series Trucks.
Building on the strong tradition of the D-Series Trucks, Caterpillar
continues to set the standards of “What a Truck Should Be.”

Model Source General Arrangement S/N Prefix

773E Decatur 169-3773 BDA
775E Decatur 169-3775 BEC

For Dealer Sales Personnel

E-Series Overview Cat Off-Highway Trucks are the world leaders in the construction and
mining industry. Caterpillar entered the market in 1963. Since then, we
have sold more than 25,000 trucks in the 35 to 70 ton size class.

The introduction of the new E-Series Trucks continues to set a new

standard in the next generation of quarry and construction off-highway
trucks. In January 2002, Caterpillar will introduce the 773E and 775E
rigid frame trucks.

The new E-Series Trucks build on the Cat tradition for performance,
comfort, serviceability, and reliability. Major improvements include:

773E and 775E

• Increased gross machine weight and payload
• Increased horsepower
• Increased torque rise
• Emissions compliant — Tier 2 U.S. EPA and EU Stage II (773E)
— Tier 1 U.S. EPA (775E)
• Caterpillar exclusive QuickEvac™ System
• Target payload rating
• New dual-slope construction body (775E only)

Additional improvements introduced with the D-Series update in

1999 included:
• Steering system improvements
• Hoist system improvements
• Miscellaneous operator station improvements

The 773E and 775E are direct replacements for the 773D and 775D,
respectively. With these changes, these trucks have been developed to
satisfy the ever-increasing demands from the quarry and construction
industries. As such, these trucks deliver to customers more of what they
need and less of what they don’t.

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Brief Specifications

New E-Series
Model Flywheel Power Volume SAE 2:1 Gross Machine Weight Target Payload

773E 671 hp/501 kW 46.0 yd3/35.2 m3 219,000 lb/99 300 kg 60 tons/54.4 mt

775E 730 hp/544 kW 54.3 yd3/41.5 m3 239,000 lb/108 400 kg 70 tons/63.5 mt

Previous D-Series
Model Flywheel Power Volume SAE 2:1 Gross Machine Weight Maximum Payload

773D 650 hp/485 kW 46.0 yd3/35.2 m3 204,000 lb/92 500 kg 58.4 tons/52.9 mt

775D 693 hp/517 kW 54.3 yd3/41.5 m3 235,000 lb/106 600 kg 69.9 tons/63.4 mt

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Engine On the 773E and 775E, software changes were made to the 3412E
engine to improve hauling performance and emissions standards. The
3412E engine has increased horsepower and torque rise on the 773E
and 775E. These changes include:

773D 773E 775D 775E

Gross Power 509 kW 682 hp 530 kW 710 hp 541 kW 725 hp 567 kW 760 hp

Net Power 485 kW 650 hp 501 kW 671 hp 517 kW 693 hp 544 kW 730 hp

Torque Rise 19% 40% 19% 33%

Torque Rise

Torque, n•m

Speed, rpm
773E 773D
Torque, n•m

Speed, rpm
775E 775D

The 3412E HEUI® engine offers a higher torque rise for each truck.
With this increased torque rise, this rugged engine provides higher
lugging force during acceleration and requires less downshifting on
grade or in rough underfoot conditions. It also matches the transmission
shift point to provide maximum efficiency and faster cycle times. The
integrated HEUI is a high-pressure, direct fuel-injection system that
independently controls injection timing, duration, performance, and
efficiency.

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Target Payload New Payload Rating
Caterpillar® 773E and 775E Quarry and Construction Trucks are now
specified with a target payload rating. This method of rating payload
achieves an accurate and realistic measurement of the payload target
necessary to help achieve the lowest cost per ton. The target payload is
based on the designed and certified maximum gross machine weight.
Thus, the target payload should be achieved in order to obtain the
highest level of production without adversely affecting machine life
and, ultimately, cost per ton.

Why Target Payloads?

Specified maximum operating weights have been frequently misapplied
on off-highway trucks in the marketplace. For example, maximum,
meaning not to exceed, has been inappropriately used as the target,
resulting in the maximum operating weights being exceeded. When the
truck operating weight is exceeded, the certification of the brake and
steering systems is exceeded. Also, overload is the most significant
factor in the life shortfalls of planned component and tire replacement
goals. Haul road conditions, machine maintenance, and operation
techniques are also significant factors and need to be managed
accordingly.

160
Relative Component Life (%)

Baseline*
140
120 Target
100 Target + 10%
80
Target + 20%**
60
40
(Max GMW)
20
0
Payload

**Payload and component life experience at several reference mines.

**No single payload to exceed this weight. Exceeds steering and
brake certification.

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Target Payload Regulatory and product support considerations prompted requests for
quantification of “acceptable” overload on Caterpillar Off-Highway
Continued Trucks. Technically, any overload will adversely affect component life
and potentially decertify brakes and/or steering. In an effort to support
warranty considerations and maintenance and repair contracts
(MARCs), target payload ratings were developed in conjunction with
the Caterpillar 10/10/20 Overload Policy.

Overloading, or exceeding the maximum designed GMW, causes

operation beyond the safety of brake and steering certification levels. In
addition, it raises operating costs, due to unnecessary wear and tear,
which results in shorter component life in:

• Structures
• Tires
• Suspension
• Power Train

Increased fuel consumption is another negative result of overloading.

Underloading the truck obviously results in lost payload and a

subsequent increase in cost per ton.

Underload Overload

Cost per Ton

GMW at Target Payload

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10/10/20 Overload Policy What is 10/10/20 Overload Policy?
The Caterpillar payload overload policy, referred to as the 10/10/20
Overload Policy, states that no more than 10% of payloads may exceed
110% of the truck’s target payload, and no single payload shall ever
exceed 120% of the maximum target payload. The graph below
provides an illustration of the 10/10/20 Overload Policy.

Payload Distribution

Number of
Payloads

No more than 10% of

payloads may exceed 110%
of the truck target payload

Never to exceed 120%

Target Target Payload Target Payload

Payload +10% +20%

What’s Different?
The Caterpillar reputation for building durable, long-lasting haul trucks
started over 30 years ago. Over the years, Cat haul trucks have been
refined, using proven designs and technology. Today, the latest 3-
dimensional modeling and analysis tools are used to ensure Cat trucks
meet customer needs. With the change to managing payloads to a target
level and following 10/10/20 guidelines, the effective, allowable
payload has increased on all models. Instead of managing payloads to
something less than “maximum payload,” a target payload is specified
to assist in maximizing productivity and machine life.

Payload Distribution

Number of
Payloads

Max payload
Average to never exceed
Payload

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773E Target Payload An example of calculating the target payload for a 773E is shown
below. Note that the base empty operating weight for the updated trucks
includes bare chassis plus 4% for normal debris accumulation, full fuel,
and dual-slope body with liners:

773E with Dual-Slope, Lined Body Pounds U.S. Tons Kg

Empty Chassis Weight 66,500 30 200

Fuel Correction (90% of 185 gal x 7 lbs/gal) 1,170 530
Optional Attachments 0 0
Debris Allowance (4% of empty chassis weight) 2,660 1200

Total Chassis Weight — Empty 70,330 31 930

Body Weight 20,300 9210
Liners 8,600 3900
Other Body Attachments 0 0

Total Body Weight — Empty 28,900 13 110

Total Operating Weight — Empty 99,230 45 040
Total Operating Weight — Loaded 219,000 99 300

Target Payload 119,770 60 54 260

Target Payload +10% 131,750 66 59 690
Target Payload +20% 143,720 72 65 110

The following table illustrates the results of managing to target payloads

versus maximum payloads.

773D (Max) 773E (Target)

Gross Machine Weight 204,000 lbs 219,000 lbs

Base Empty Operating Weight

95,000 lbs 99,230 lbs
with Dual-Slope, Lined Body

Payload 58.4 tons (Max) 60 tons

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775E Target Payload An example of calculating the target payload for a 775E is shown
below. Note that the base empty operating weight for the updated trucks
includes bare chassis plus 4% for normal debris accumulation, full fuel,
and quarry flat floor body:

775E with Quarry Flat Floor Body Pounds U.S. Tons kg

Empty Chassis Weight 67,000 30 400

Fuel Correction (90% of 185 gal x 7 lbs/gal) 1,170 530
Optional Attachments 0 0
Debris Allowance (4% of empty chassis weight) 2,680 1210

Total Chassis Weight — Empty 70,850 32 140

Body Weight 28,810 13 070
Liners 0 0
Other Body Attachments 0 0

Total Body Weight — Empty 28,810 13 070

Total Operating Weight — Empty 99,660 45 210
Total Operating Weight — Loaded 239,000 108 400

Target Payload 139,340 70 63 190

Target Payload +10% 153,270 77 69 510
Target Payload +20% 167,200 84 75 830

The following table illustrates the results of managing to target payloads

versus maximum payloads.

775D (Max) 775E (Target)

Gross Machine Weight 235,000 lbs 239,000 lbs

Base Empty Operating Weight

95,300 lbs 99,660 lbs
with Quarry Body

Payload 70 tons (Max) 70 tons

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Cooling System In the continuing effort to improve overall truck performance and meet
emissions requirements, the following changes have been made to the
cooling system:

Air-to-Air Aftercooler (ATAAC)

The ATAAC system replaces the Jacket Water Aftercooler in the 773E
truck. This system packs cooler and denser air into the cylinders for
more complete combustion. It also offers better accessibility since the
ATAAC is located in front of the radiator versus the old jacket water
aftercooler, which was located on top of the engine.

Serviceability Cat QuickEvac™ System

QuickEvac is an exclusive Caterpillar on-board engine oil evacuation
and prelubrication system that reduces the time needed to complete an
engine service interval by 30 to 50 percent.

Automated Engine Oil Change

This new, state-of-the-art system evacuates engine sump in less than
two minutes and allows for partial purging of the oil filters prior to their
removal which minimizes oil spills. New oil is delivered through
primary filters, enhancing contamination control efforts while ensuring
that new filters are correctly filled following routine oil changes.
Typical engine service (engine oil, oil filter, fuel filter, and air filter) can
be completed in approximately 20 minutes.

Step 1:
Purge the oil filters by disconnecting the “line to oil filter” at the
QuickEvac bracket disconnect fitting. Connect a compressed air line to
the “line to oil filter” to apply compressed air to the oil filters. This
partially purges used oil from the filter prior to sump evacuation. The
air will push the oil through the filter’s normal path thus eliminating the
risk of reintroducing any debris trapped in the filter into the oil stream.
1. Oil filter purge

Step 2:
Connect the oil waste line hose from a PM truck or shop waste oil
container to the QuickEvac pump’s quick disconnect fitting on the
QuickEvac bracket. Switch on the QuickEvac pump with the remote
operator switch to evacuate the engine oil sump in less than two
minutes. By using the QuickEvac Service Tool (part #187-1458), the oil
can be evacuated into an open waste container if required.
2. Engine sump evacuation

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Serviceability Continued

Step 3:
Change the oil filters. Note that the chance of spillage is virtually
eliminated because the used oil filters were partially purged of oil. Do
not prefill the new oil filters with fresh oil prior to installation.

3. Oil filter change

Step 4:
Fill the engine sump and new filters with fresh oil by connecting a fresh
oil fill line to the “line to oil filter” on the 775E. Fill the system with the
proper amount of oil. Note that the new oil flows through the filters in
its normal path at less than normal engine oil operating pressure,
filtering the new oil while filling the entire system. After filling the
system to capacity, verify the oil level in the sump by checking the
dipstick. There is no need to start the engine since the entire system,
4. Filter and sump refill
including filters, has been filled. Adjust the new oil level if necessary.

Step 5:
Disconnect the fresh oil fill line from the “line to oil filter.” Reconnect
the “line to oil filter” to the oil filters at the QuickEvac bracket (quick
disconnect fitting). The engine is fully prelubricated and ready to start.

5. QuickEvac reconnect

For More Information:

Visit your Caterpillar extranet Web site and look for QuickEvac under:
NACD – Product Support Marketing – QuickEvac
CACo – Parts and Service Excellence – Parts and Service Marketing –
QuickEvac
APD – Parts and Service Marketing – Parts Marketing – QuickEvac
EAME – Product Support – Parts Products – QuickEvac

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Serviceability Continued Contamination Control
Environmentally efficient, clean oil changes are ensured since the
engine sump is evacuated directly into waste containers with flush
faced, quick disconnects for fast evacuation and fill. This eliminates the
handling of waste oil and minimizes the chances of oil spillage while
enhancing Contamination Control efforts by ensuring complete filtration
of new oil on engine refill. QuickEvac procedures also lower the oil
level below the filler neck in the filter prior to removal. This also
reduces the chance of oil spillage when removing the old filters. For
evacuation into open waste containers, use the QuickEvac Service Tool
(part #187-1458).

Complete Engine Prelubrication

With complete engine prelubrication, engine oil pressure prior to
engine cranking is provided. Engine dry start wear and risk of cold
starts are reduced for increased protection of key components.

Improved Serviceability and Machine Availability

Serviceability and machine availability are improved as time to
complete engine service (changing engine oil, oil filters, fuel filter,
air cleaner) is reduced by as much as 30 to 50 percent. This time
savings enhances the ability to meet scheduled engine services at
prescribed hours.

Truck Body The dual-slope truck body, now available on the 775E, offers the lowest
cost-per-ton hauling solution in most construction applications. It
handles a variety of material conditions and densities, and, due to its
increased strength over the flat-floor design, is particularly effective in
sites with rough haul roads and steeper grades. An 8° “V”-shaped
bottom improves load retention, maintains a low center of gravity, and
reduces shock loading.

The 400 Brinell steel body resists loading impact and sustained hauling
stresses with side wall and floor junctions joined by five-sided beams.
In addition, box-section beams boost the durability of the floor, side
Dual-Slope Truck Body
walls, top rail, and canopy areas.

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Emissions Along with the other improvements, the 773E meets Tier 2 emissions
requirements set forth by the United States Environmental Protection
Agency. This machine will also meet European Stage II Emissions
Directive 97/98/EC for its horsepower class. Likewise, the 775E
continues to meet U.S. EPA Tier I Emissions standards.

Application Match The following Pass Match chart presents some general guidelines based
on “average” material and operator.

Cat Loaders

988G 990 Series II 992G 5080 5110B 5130B

773E 5 pass 3-4 pass 6 pass 4 pass

775E 5-6 pass 4 pass 3 pass 3-4 pass 3 pass

Sales Support Literature Specalogs 773E AEHQ5456

775E AEHQ5457
Product Bulletins 773E TEJB8062
775E TEJB8064
Introduction Brochure YEDQ0258
Introduction Video YEVN0259
CD (769D, 771D, 773E, 775E) YERQ0254
Environmental Brochure YEDQ0263
Productivity Brochure YEDQ0264

The information contained herein is intended for circulation only to Caterpillar and dealer employees whose duties require knowledge of such reports and is intended for
their information and training. It may contain unverified analysis and facts observed by various Caterpillar or dealer employees. However, effort has been made to provide
reliable results regarding any information comparing Caterpillar built and competitive machines. Effort has been made to use the latest available spec sheet and other
material in the full understanding that these are subject to change without notice. Any reproduction of this release without the foregoing explanation is prohibited.
YEXQ0253
January 2002
www.Cat.com
©2002 Caterpillar
Printed in the U.S.A.

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