10/10/20 Policy

April, 2002 Mining Truck Marketing, Decatur

Large Mining Truck - Truck Overload Policy

"10/10/20" (Revision #4)
Gross machine operating weights have been frequently misapplied on off-highway trucks in the
market place. For example, maximum, which means, “not to exceed”, has been inappropriately
used as the target. Regulatory and product support considerations have prompted some dealers
and customers to request quantification of “acceptable” payloads on Caterpillar’s Mining Trucks.
Technically, the correct answer is that any overload will adversely affect component life and
potentially affect steering & braking performance. If the overloading is severe enough, the truck
will be unsafe to operate. The following is intended to communicate guidelines of the 10/10/20
policy, the relationship between payload and performance, and the maximum operating weights
and the associated payload policy that Caterpillar is using in support of warranty considerations
and maintenance and repair contracts (MARC's) for Mining Trucks.

Caterpillar’s payload overload policy, referred to as the “10/10/20” policy, states that “The
mean (average) of the payload distribution shall not exceed the target payload and no more than
10% of payloads may exceed 1.1 times the truck target payload and no single payload shall ever
exceed 1.2 times the target payload.”

KEY ISSUES

1. Target payloads for various Caterpillar truck models, when equipped with different truck
body configurations are outlined in the Table 1 at the end of this document. Site conditions
may dictate that underloading is more economical than loading at the target payload.

2. Gross machine operating weights and associated payloads are continually being updated.
For the latest approved mining truck gross operating weights with the target and maximum
payload visit: https://mining.cat.com/products/trucks.html

3. Actions required to maintain brake certification to SAE & ISO standards and British
Columbia (B.C.) codes are addressed.

4. Component life is directly related to gross machine weight and associated payload.
Therefore, specific support commitments will be required from Caterpillar and it’s dealers
for given applications.

1 of 7
5. In this policy, target payload is the difference between gross machine operating weight and
empty operating weight. The mean (average) payload distribution shall not exceed the target
payload. Reducing empty operating weight provides for increased payload capacity, and an
increase in empty machine weight decreases payload capacity. Empty operating weight
includes bare chassis plus 4% for normal debris accumulation and full fuel.

6. This policy is applicable to current production models with the latest power train and
structural improvements and non-current products updated to the latest improvements. The
power train improvements required under the 10/10/20 overload policy are outlined at the
end of this document.

PAYLOAD DISTRIBUTION

Figure 1. provides a generic illustration of Caterpillar’s “10/10/20” payload policy. Target

payload is defined as 100%. The target should always be 100. Caterpillar's 10/10/20 policy
allows for no more than 10% of the loads to fall in the 110% to 120% range (yellow region). No
loads should ever exceed the trucks steering and braking certification. Exceeding the steering
and braking certification would make the truck unsafe to operate.

Figure 1. Payload Distribution

2 of 7
COMPONENT LIFE vs. PAYLOAD

Figure 2. demonstrates that the component life is decreased significantly when overloaded 10%
to 20%. The rate at which component life decreases as a result of overloading is greater than the
rate at which component life increases as a result of underloading.

Figure 2. Component Life vs. Payload

There are a few basic rules of thumb related to component life vs. payload. First, engine life is
directly related to fuel burn. If payload is increased, the truck gets heavier creating a higher duty
cycle resulting in greater fuel burn and shorter life. The torque converter and transmission life
are related to torque and again as payload is increased the truck gets heavier. More torque is
required to move a heavier truck resulting in shorter torque converter and transmission life. The
lower powertrain life is related to load and speed. A heavier truck puts more load on the lower
powertrain and again the results is a decrease in component life.

3 of 7
PLACEMENT OF PAYLOAD

Not only is component life impacted by the amount of payload, but it is also impacted by the
placement of the payload. A decrease in component life similar to that shown in Figure 2. will
occur from improper load placement.

Specifically, there are three types of improper load placement, load shifted towards the front,
load shifted towards the rear, and load shifted towards the side. All three types of improper load
placement negatively impact frame and body life. If the load is shifted towards the front, the
front brakes, bearings, front tires, steering, hydraulic hoist, body rest pads, and body canopy will
be negatively impacted. Figure 3. shows trucks with correct load placement and incorrect load
placement with the load shifted towards the front

Figure 3. Side View of Load Placement

4 of 7
If the load is shifted towards the rear, the final drive and rear tires will be negatively impacted.
Furthermore, the payload will become unstable and dribble off the back of the body. Figure 5.
shows trucks with correct load placement and incorrect load placement with the load shifted
towards the rear.

Figure 4. Side View of Load Placement

If the load is shifted towards the side, the final drive, bearings, hoist cylinders, and pivot bore
areas will be negatively impacted. Figure 6. shows trucks with correct load placement and
incorrect load placement with the load shifted towards the side.

Figure 5. Rear View of Load Placement

5 of 7
777D & 793C

Note that modification to brake service procedures is required to maintain certification on 777D
and 793C models. Specifically, the brakes must be rebuilt at 75% brake wear to ensure that the
parking brake will hold in grade per ISO, SAE, braking codes. A measurement instruction has
been issued in conjunction with this overload policy. This action enables the brakes to be
certified to SAE and ISO standards at up to 1.2 times target payload.

TIRES AND RIMS

It is recommended that users of this policy contact their tire supplier and rim supplier, if other
than Caterpillar, to discuss application, site conditions, haul roads, and allowable tire loads
before adopting this policy.

TARGET AND MAXIMUM PAYLOADS BY MODEL

The following table is for a representative vehicle configuration. All weights are dependent on
chassis configuration, fuel tank, body type, tires, and optional equipment selected.

Table 1. METRIC Target and Maximum Payloads by Model

CGM Approved Mining Truck Gross Operating Weights (April 2002)

WEIGHTS IN KILOGRAMS 797B 793C 793C 789C 785C
Flat Floor* Dual Slope* Flat Floor* Dual Slope* Dual Slope*
Gross Machine Operating Weight 623,690 383,739 383,739 317,515 249,476

Chassis Weight - includes 10% Fuel 157,167 82,619 82,619 66,178 55,976
Fuel Tank & Full Fuel (90% Addition) 8,445 5,135 5,135 3,661 1,994
Tire Size 59/80R63 40.00R57 40.00R57 37.00R57 33.00R51
Tire Weight 31,800 20,700 20,700 17,976 12,818
Rim Size 44" 29" 29" 29" 24"
Rim Weight 17,410 9,253 9,253 9,253 6,260
Sub Total 214,821 117,707 117,707 97,069 77,047

Debris/Carryback(4% of Sub-total) 8,593 4,708 4,708 3,883 3,082

Dual Slope Body (without liners) n/a 32,108 n/a 27,045 21,471
Dual Slope Full Liner n/a 11,076 n/a 9,453 7,641
Flat Floor Body (without liners) 47,264 n/a 35,906 n/a n/a
Flat Floor Full Liner 3,992 n/a 2,513 n/a n/a
MSD Body 41,731 29,484 29,484 24,948 20,412
Attachments 0 0 0 0 0

Empty Machine Weight (Std.) 274,670 165,599 160,835 137,450 109,241

Empty Machine Weight (MSD) 265,145 151,899 151,899 125,899 100,541
PAYLOADS IN METRIC TONS
Target Payload (Std.) 349 218 223 180 140
Target Payload (MSD) 359 232 232 192 149

Max Gross Payload (Std.) 10/10/20 Limit (not to exceed) 419 262 267 216 168

Max Gross Payload (MSD) 10/10/20 Limit (not to exceed) 430 278 278 230 179

Maximum Do-Not-Ever-Exceed GMW 696,264 431,457 431,457 356,342 279,957

6 of 7
Overload is a major factor in life shortfalls of planned component replacement goals. Haul road
conditions, machine maintenance, and operation techniques are also significant factors.

POWER TRAIN IMPROVEMENTS REQUIRED UNDER OVERLOAD POLICY

797A Mining Truck

• Depending upon the serial number and configuration, existing 797A’s have an overload
policy ranging from 10/10/11 to 10/10/20. Most customers with 797A’s have the option to
upgrade to 59/80R63 tires so long as other changes are made to the chassis. For information
about changes to 797A’s that impact payload and the overload policy contact a mining truck-
marketing representative in Decatur.

793 Mining Truck

• Larger wheel bearings – production 10/96
• 20mm wrapper on fabricated wheel – production 1/96
• RAX filtration – production 7/95 (cost to add already paid by Caterpillar)
• Differential ring gear shroud – production 7/95
• Wheel bearing preload adjustment – production 12/97

789 Mining Truck

• Cast wheel with larger wheel bearing – production 10/97
• Differential ring gear shroud – production 11/95

785 Mining Truck

• Cast wheel with larger wheel bearing – production 3/97
• Differential ring gear shroud – production 12/95
• Enlarged wheel bearing retainer holes – screens removed – production 3/98

Questions

Requests for additional information can be directed to the Caterpillar Mining Truck Marketing
Support Group in Decatur, IL. or Caterpillar Global Mining in Peoria, IL.

7 of 7