CAT

MINING TRUCKS
PAYLOAD MANAGEMENT GUIDELINES
Including 10/10/20 Policy and Payload Placement
August 2011
PART I
1. SCOPE
This document is intended to
communicate the 10/10/20 payload policy,
the maximum operating weights, and
the associated payload guidelines that
Caterpillar will use in support of warranty
considerations and maintenance and
repair contracts (MARCs) for the
mining trucks. All denitions and
calculations are based on the use of
standard radial tires.
2. STANDARDS
This document applies to all current Cat

mining trucks. It is not applicable
to previous models.
This docuuent replaces previous
versions of the 10/10/20 truck payload
policy and is applicable for current
and future machines.
lS001. Mass of Machines
Flease refer to Fart ll, Fayload
Placement, for best practices
discussion.

2 Cat Mining Trucks Payload Management Guidelines
Cat Mining Trucks Payload Management Guidelines 3
3. DEFINITIONS AND ABBREVIATIONS
There are two types of weights discussed in uining truck teruinology. Measured weights and specihed weights.
Measured weights are quantiable; a person can take a truck in a given conguration, put it on a scale, and weigh it.
Specied weights are limits or targets set through engineering calculation in order to ensure compliance with standard or
particular performance criteria.
3.1 MEASURED WEIGHTS
3.1.1 Base Machine Weight (BMW): This is the basic chassis weight common to similar model
trucks. This includes shipping uids, but no attachments or
options.
3.1.2 Operating Chassis Weight (OCW): This weight includes base machine weight plus full fuel,
tires, rims, selected attachments, and operator. The weight
excludes the truck body.
3.1.3 Operating Machine Weight (OMW): This is equal to 0CW plus body weight.
3.1.4 Empty Machine Operating Weight (EMOW): This weight is equal to 0MW weight plus debris.
3.1.5 Loaded Machine Operating Weight (LMOW): Siuply a fully loaded operating truck, equal to the EM0W
plus the actual payload.
3.1.6 Selected Attachments: The selection of attachments, mandatory and optional,
chosen for a particular truck conguration. Attachments
include any purchased from Caterpillar or customer/dealer
added.
3.1.7 Actual Payload (AP): Weight of a particular payload under consideration.
4 Cat Mining Trucks Payload Management Guidelines
3. DEFINITIONS AND ABBREVIATIONS continued
3.2 SPECIFIED WEIGHTS
3.2.1 Maximum Gross Machine Weight (MGMW): Value specied that allows 20 percent excess payload for
most truck congurations. This weight includes a fully
congured truck with full uids, operator, payload and debris.
An operating truck should never exceed the M0MW. This
weight is certihed to ueet lS0 & SAE steering and braking
system standards.
3.2.2 Target Gross Machine Weight (TGMW): 0ptiuuu target weight that in the opinion of Caterpillar
provides optimum productivity and cost per ton. This
specihed value is in a LM0W conhguration. T0MW is used
for performance curves and calculations.
3.3 CALCULATED PAYLOADS
3.3.1 Target Payload (TP): This value is calculated by taking T0MW uinus Eupty
Machine 0perating Weight. Calculation. T0MW - EM0W=TF
3.3.2 Nominal Payload (NP): A specied value that is representative of a typical TP.
Nominal Payload is used in general discussions to designate
the truck size class.
3.3.3 Target Range Payload (TRP): A calculated value that falls between 80 percent and
120 percent of the TP. This will maximize productivity while
minimizing negative impact on component life. This number
should not be below 80 percent and never exceed 120 percent.
Calculation. TF x 0.8 TFF TF x 1.2
3.3.4 Maximum Allowable Payload (MAP): Equal to 120 percent of the TF, this is not to cause LM0W to
exceed M0MW. Calculation. TF x 1.2 = MAF
3.3.5 Debris Weight (DW): W is an application-specihc value that accounts for norual
uud and road uaterial that is stuck to the truck. W varies
considerably depending on work conditions, and can uctuate
between 2-8 percent of 0MW. As a general rule, debris can
be approxiuated using 3% of 0MW, unless site data indicates
differently. Calculation. 0MW x .03 = W.
Cat Mining Trucks Payload Management Guidelines 5
4. WEIGHT CALCULATION FLOW SHEET
SAMPLE CALCULATION FLOWCHART
Base
Machine
Weight
(BMW)
Tire, Rim,
Attachments
Operator
Weight
Operating
Chassis
Weight
(OCW)
Body
Weight
Operating
Machine
Weight
(OMW)
Debris
Weight
(DW)
Empty
Machine
Operating
Weight
(EMOW)
Target Gross
Machine
Weight
(TGMW)
Empty
Machine
Operating
Weight
(EMOW)
Target
Payload
(TP)
Target
Payload
(TP)
1.2
Empty
Machine
Operating
Weight
(EMOW)
Maximum
Gross
Machine
Weight
(MGMW)
+ = + = + =
- =
x + < _
Fuel, Selected
Figure 1. Calculation Flowchart
6 Cat Mining Trucks Payload Management Guidelines
5. GENERAL
Fayload has a direct effect on three issues.
Coupliance with brake and steering certihcation to SAE and lS0 standards.
Couponent life is directly related to gross uachine weight and AF.
Support of warranty considerations and MAFCs.
6. STATEMENT OF POLICY
No more than 10 percent of payloads may exceed 110% the target payload; no single payload shall ever exceed
the Maximum Allowable Payload, typically 120% of Target Payload. The mean of the payloads shall not exceed the
target payload, hence no more than 50 percent of payloads may exceed the Target Payload. The rated capacity of
the tires should always be considered in any evaluation.
Figure 2. Payload Distribution
Cat Mining Trucks Payload Management Guidelines 7
7. SUPPORTING ILLUSTRATIONS
OPERATING CHASSIS, TARGET GROSS, AND MAXIMUM GROSS MACHINE WEIGHTS
Model Serial No. Prex OCW Target GMW MGMW

785C APX
178,215 lb 550,000 lb 17,200 lb
80 837 kg 219 17 kg 280 000 kg

785 MSY
181,37 lb 550,000 lb 17,120 lb
82 271 kg 219 17 kg 280 000 kg

789C 2W
217,759 lb 700,000 lb 779,700 lb
98 771 kg 317 515 kg 353 00 kg

789 SF
218,512 lb 715,000 lb 797,00 lb
99 129 kg 321 319 kg 31 800 kg

793D MA1 FDB
23,381 lb 81,000 lb 951,200 lb
119 19 kg 383 710 kg 131 157 kg

793F SSF
27,158 lb 851,000 lb 91,000 lb
121 317 kg 38 008 kg 137 23 kg

795F AC EFM
434,337 lb 1,257,000 lb 1,415,000 lb
197 012 kg 570 1 kg 11 833 kg

797F LAJ
13,993 lb 1,375,000 lb 1,538,000 lb
210 11 kg 23 90 kg 97 25 kg
All truck weights were calculated using the base mandatory attachments and will vary due to different body
congurations and attachments.
For more detailed and specic truck weights refer to your Caterpillar representative.
8 Cat Mining Trucks Payload Management Guidelines
SAMPLE CALCULATION 793F*
ase Machine Weight (MW) 91,001 lb 12 38 kg
+ Attachments
Mandatory Attachuents 123,151 lb 55 82 kg
Tires (207-5171) 1,835 lb 21 211 kg
Fius (137-9855) 0 lb 0 kg
0perator (lS0 noru) 15 lb 75 kg
+ Fuel (2840 liter/750 gal) 5,318 lb 2412 kg
Total 175,472 lb 79 593 kg
= Operating Chassis Weight (OCW) 269,473 lb 122 231 kg
ody - Weight (273-3920 MS ll, Fully Lined, No Sideboards)
Total 72,977 lb 33 102 kg
= Operating Machine Weight (OMW) 342,450 lb 155 333 kg
ebris @ 3% 10,271 lb 1 0 kg
= Empty Machine Operating Weight (EOMW) 352,724 lb 159 993 kg
Target 0ross Machine Weight (T0MW) 851,000 lb 38 008 kg
- E0MW 352,721 lb 159 993 kg
= Target Payload (TP) 498,276 lb 226 015 kg
Target Payload (TP) x 1.2 597,931 lb 271 218 kg
E0MW 352,721 lb 159 993 kg
Check that this value is < Maximum Gross
Machine Weight (MBMW) 950,655 lb 431 211 kg
*All truck weights will vary due to different body congurations and attachments.
Cat Mining Trucks Payload Management Guidelines 9
PART II
PAYLOAD PLACEMENT
INTRODUCTION
0verloads will decrease couponent lives, but payload placeuent can have signihcant iupact as well. This
addendum will discuss potential impact of the various types of payload misplacement and can be used to help
reduce potential impact on component lives and payload measurement.
The following three types of iuproper load placeuent occur.
Load shifted toward the front
Load shifted toward the rear
Load shifted toward the side
Each of the three will negatively iupact couponent and tire life.
FRONT BIASED LOAD
A load shifted toward the front will negatively iupact. the front brakes, front bearings, front tires, steering,
hydraulic hoist, body rest pads, and body canopy.
Figure 3 shows trucks with correct load placement and incorrect load placement with the load shifted toward the
front. lncorrect load placeuent will also decrease vlMS

payload accuracy.
Correct Load Placement Incorrect Load Placement
Figure 3. Side View of Load Placement
10 Cat Mining Trucks Payload Management Guidelines
REAR BIASED LOAD
When the load is shifted toward the rear, the hnal drive and rear tires will be negatively iupacted. Furtheruore,
the payload will becoue unstable and dribble off the back of the body. As with front-placed loads, this incorrect
placeuent also decreases vlMS payload accuracy as discussed below.
Figure 4 shows trucks with correct load placement and incorrect load placement with the load shifted rearward.
Correct Load Placement Incorrect Load Placement
PAYLOAD POSITION AND VIMS

PAYLOAD ACCURACY
For payload monitoring accuracy, maintaining the correct split between the front and rear is critical. If over 33%
of the load is on the front axle, vlMS payload will record "light", alternatively, if over 7% of the load is on the
rear axle, vlMS payload will record heavy." Flease note the MS ll bed has a side prohle that is quite different
and appears to be uuch shorter than the Flat Floor or ual Slope, see Figure 5. Consequently, the reduced visual
length of the side can give a loader operator a false iupression of where to place the load. When the loading
tool operator centers the nal two to three passes over the Target Arrow the load pile will end up in the proper
position for a 1/3 . 2/3 axle split.
Dual Slope MSD
Figure 4. Side View of Load Placement
Figure 5. Dual Slope Body and MSD Body Side Proles
Cat Mining Trucks Payload Management Guidelines 11
If the size of the loader requires ve or more passes it will be desirable to distribute the rst several passes
forward and rearward of the loading arrow to achieve a good load distribution. The distributed passes should be
about equal in size and be placed approximately equal distance forward and behind the arrow. In any case the
last pass or two, according to the total nuuber of passes, should be centered over the target arrow. Weigh studies
or payload scale studies indicate a load position shift of 2% to 1% can result in the vlMS report being incorrect by
5% to 7% and even up to 10% or more.
209 yd
3
(160 m
3
) 250 yd
3
(191 m
3
)
Figure 6. Appearance of Load
SIDE PLACEMENT OF LOAD
If the load is shifted towards either side, the nal drive, bearings, tires, hoist cylinders, and pivot bore areas will be
negatively impacted. Figure 7 shows trucks with correct load placement and incorrect load placement with the
load shifted toward the side.
Correct Load Placement Incorrect Load Placement
Figure 7. Rear View of Load Placement
LOADING EFFICIENCY
For an operation to benchuark its operating practices the following guidelines are suggested.
Good: 80% of the loads within a 10% range of the Target Payload
Excellent: 90% of the loads with a 10% range of the Target Payload.
2011 Caterpillar
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AEX00250-03
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