Professional Documents
Culture Documents
Guide
A Reference Guide to
Mining Machine Applications
This document is primarily intended for use by Basic Application Benchmarks and
Caterpillar and CAT dealer project managers as a ready Operating Techniques
reference for the assessment of machine application Loading Tools 2
Trucks 8
and haul road conditions on their project sites. It may
Wheel Dozers 14
also prove useful to other Caterpillar and CAT dealer Motor Graders 18
personnel in need of a concise reference tool. Track-type Tractors/Wheel Tractor Scrapers 22
Basic Haul Road Design and Maintenance
It contains practical benchmarking data that is Design 26
Maintenance 34
achievable with correct and well-managed machine
Management Ideas
application. It is also intended to provide guidance on Management Strategies 41
assessing haul road design and maintenance that Hauling System Application Zones 45
supports sound industry practices. Reference Information
Percentage Swell and Load Factors 49
Approximate Loose Weight of Materials 50
Typical Rolling Resistances 52
Approximate Coefficient of Traction Factors 53
Formulas and Rules of Thumb 54
Weights and Measures 56
Miscellaneous Technical Data 60
Machine Specifications
Track-type Tractors 63
Wheel Loaders 65
Wheel Dozers 67
Trucks 69
Motor Graders 73
Tractor Scraper 75
Underground Mining Equipment 77
Loading Tools
First pass must be a good pass Hydraulic Backhoes (ME**) • Maintain proper kick-out
Watch for... (operator has entire truck exchange adjustment
• Maintain tight work zone;
to get bucket full) ideally dig no more than 45 • Keep time in face below 0.2
Ensure truck is correctly “spotted” degrees either side of minute (12 seconds)
by loader (with first pass, or the center line (i.e., work over • Wheel turns only from face
horn) idlers and swing no more to truck
than 60 degrees to truck) • Never operate a bare edge
Hydraulic Front Shovels • Watch poorly blasted toe
• First two passes: • Maximize GET* tip contact Rope Shovels
Upper half of face and minimize bucket • 70 - 90 degree
• 3rd / 4th passes: contact (i.e., enter face maximum swing
Load out the center with tips at the correct
angle and curl bucket • Efficient support machine
• Final passes: through material). Use activity to keep floor clean
Clean up floor boom-up to minimize • Power cable maintenance
• Keep work area as tight bucket heel contact • Never operate a
as possible • Never operate a bare edge bare edge
• Avoid excessive prying or
corner loading; don’t swing
into pile Wheel Loaders
• Maximize GET* tip contact and • Enter pile straight-on, with
minimize bowl contact (i.e., floor of bucket parallel to
boom up and curl bowl through floor
material). • Keep frame straight
• Use “boom-up” to minimize when digging
bucket heel contact. • Lift bucket before crowding
• Never operate a bare edge • Fill bucket by the time lift
arms are horizontal
* GET - Ground • Minimize non-productive
Engaging Tools floor contact (cleanup)
** ME - Mass
Excavation
LOADING TOOLS
Basic Application Benchmarks and Operating Techniques 4
Favorable Site • Working a single face of the • Selective digging: can also efficiently mine
Conditions correct height multiple targets
• Stable/level floor • Tight load area with tight material
• Wide benches • Can work in poor floor conditions
(to facilitate truck maneuverability) • Angle tracks slightly to face
• Well-shot material • Define dig pattern,
L to R or R to L, and maintain pattern
Favorable Site • Correct bench height (worth 10-15% • Level, dry, smooth, firm floors
Conditions more production than too high) • Sufficient crossfall and drainage in high rainfall areas
• Truck below HEX to minimize tire damage
(worth 15-20% over same-level loading) • Well-fragmented materials that minimize crowding
• Tight load area, with tight material time, particularly in the toe-area of the cut
• Short swing — 60° (worth 5% over • Lower face profile
90° swing) • Multi-face loading
• Well-shot material
• Remove farthest pass during
truck exchange
• Maintain key-cut
For further information, consult H-series Motor Grader Application Guide AEGQ0945.
Track-Type Tractors/
Wheel Tractor Scrapers
621 – D8
631 – D9 / D10
651 – D10 / D11 CAT GLOBAL MINING
Grade General
Smooth and of constant grade to
minimize transmission shifts and
maintain higher average grade
speed. This also allows more
constant braking effort on returns.
Correct Incorrect
Corners Radius
Use maximum practical radius.
Keep constant and smooth as
possible.
Super-elevation
Employ if speeds exceed 15 km/h
(10 mph) per Performance
Handbook recommendations
(Tables section). Super-elevation
greater than 10% should be used
with caution due to the danger of
sideways slippage in wet
conditions.
Road Width 1 way Straights/Corners A
minimum 2 - 2.5 widths is
recommended.
2 way - In Straights A minimum of
3 - 3.5 truck widths.
One-way (Straights/Corners)
- In Corners A minimum of Two-way (In Straights)
3.5 - 4 truck widths. Two-way (In Corners)
Basic Haul Road Design and Maintenance 32
tire penetration
Basic Haul Road Design and Maintenance 34
Soft/Wet Areas
It is far more practical to fully
remove wet/soft spots in the
haul road completely and refill
than to continually try and
maintain.
Fix it once, fix it right!
Dust
Watering to remove the hazard
of dust also helps maintain
compaction (and strength) of
the road base. Use “checker
board” or “spot” intermittent
watering pattern on slopes to
reduce the risk of slippage
during braking.
“Spot” watering works well for
areas with limited water supply.
Basic Haul Road Design and Maintenance 36
Analysis Tools Fleet Production and Cost (FPC) Fleet Productivity Optimization Vital Information Management
(FPO) System (VIMS)
Use FPC to compare actual cycle Use FPO to assess machine Use VIMS to help manage
times with theoretical values: application severity: machine application:
• Are trucks achieving predicted • To identify locations/features • Datalogger data export to FPO
speed on grades? on the road for improvement to quantify haul road
• Are trucks cycling in predicted conditions
• To quantify the severity of the
cycle times? haul from strut pressure data • Better payload management
• Are truck wait times at the to optimize speed on grade
• To illustrate transmission shift
loader in the predicted range? frequency and gear on grade • Check event logs for high
brake temperatures, engine
• To identify brake/retarder
If theoretical values don’t match over-speeds, etc.
application (frequency and
actual times, investigate location) • Use RAC (Road Analysis
possible causes: Control) to alert an operator to
a damaging haul road
• Rough/slippery roads Note: Earlier version of FPO condition
causing operators to slow were known as (ASA)
• Higher rolling resistance Application Severity Analysis
than planned/expected
• Tight corners forcing
machine to slow
• Poor visibility due to dust
or obscured views
• Pinch points, STOP signs at
intersections, etc.
Basic Haul Road Design and Maintenance 38
Management Present machine application • Higher average OHT road Use Cat® Software Tools [FPC,
Strategies issues to mine management in a speeds through: EMF, DOZSIM, etc.] to:
language they understand; i.e., • Smoother Roads (including • Compare theoretical with
Productivity (lost or gained) loading and dump zones) actual:
and Cost per Ton. -use Vital Information • Grade speeds/Cycle times
Identify the potential to improve Management System
• Fuel consumption
productivity. (VIMS) • Total machine/fleet
- RAC
• Better bucket fill factors productivity
- FPO
through:
• Improved fragmentation -use TPMS (Truck Payload • Model the effects on total
• Correct bucket selection, Measurement System) productivity through changes
- FPO to:
GET selection and GET • Minimize rolling resistance
maintenance • Average road speeds
• Correct bench heights • Better haul road designs -higher on-grade speeds
• Correct loader orientation that: -reduced rolling resistance
-reduce switchbacks -reduced corner severity
to face -remove cross-overs with -removal of speed limits
STOP signs • Improved bucket fill factors
• Faster loader cycle times -allow constant and truck/loader match
through: speed/gear on grades • Reduced truck exchange
• Correct orientation to face • Better payload control to and waiting times
• Correct truck placement ensure highest possible gear • Reduced fuel consumption
• Improved material condition on grade • Improved component life
• Improved floor conditions -use VIMS/TPMS and
and machine/fleet
VIMS Supervisor
availability
• Improved tire life/reduced
tire costs
Management Ideas 44
Percentage swell and load factors of different materials* Approxiamate loose weight of materials*
% Swell Load Factor lbs/yd3 kg/m3
CINDERS 45 .69 BASALT 3,300 1960
CLAY BAUXITE, KAOLIN 2,400 1420
Dry 40 .72 CALICHE 2,100 1250
Wet 40 .72 CARNOTITE, URANIUM ORE 2,750 1630
CLAY & GRAVEL CINDERS 950 560
Dry 40 .72 CLAY
Wet 40 .72 Natural Bed 2,800 1600
COAL Dry 2,500 1480
Anthracite 35 .74 Wet 2,800 1660
Bituminous 35 .74 CLAY & GRAVEL
EARTH, LOAM Dry 2,400 1420
Dry 25 .80 Wet 2,600 1540
Wet 25 .80 COAL
GRAVEL Anthracite, Raw 2,000 1190
Dry 12 .89 Washed 1,850 1100
Wet 12 .89 Ash, Bituminous Coal 900-1,100 530-650
GYPSUM 74 .57 Bituminous, Raw 1,600 950
HARDPAN 50 .67 Washed 1,400 830
LIMESTONE 67 .60 DECOMPOSED ROCK
ROCK, WELL BLASTED 65 .60 75% Rock, 25% Earth 3,300 1960
SAND 50% Rock, 50% Earth 2,900 1720
Dry 12 .89 25% Rock, 75% Earth 2,650 1570
Wet 12 .89 EARTH
SANDSTONE 54 .65 Dry packed 2,550 1510
SHALE & SOFT ROCK 65 .60 Wet excavated 2,700 1600
SLAG, BANK 23 .81 Loam 2,100 1250
SLATE 65 .60 GRANITE
TRAP ROCK 65 .61 Broken or Crushed 2,800 1660
*Varies with moisture content, grain size, degree of compaction, etc. Tests must GRAVEL
be made to determine exact material characteristics. Pit Run 3,250 1930
Dry 2,550 1510
Dry 1/4” – 2” 2,850 1690
Wet 1/4” – 2” 3,400 2020
GYPSUM
Broken 3,050 1810
Crushed 2,700 1600
*Varies with moisture content, grain size, degree of compaction, etc. Tests must
be made to determine exact material characteristics.
Reference Information 50
Approximate loose weight of materials* Typical Rolling Resistances in lbs. per gross ton of weight*
lbs/yd3 kg/m3 A hard, smooth, stabilized, surfaced roadway without penetration
HEMATITE, IRON ORE, HIGH GRADE 4,000-5,400 1810-2450 under load, watered, maintained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
LIMESTONE
Broken or Crushed 2,600 1540
MAGNETITE, IRON ORE 4,700 2790 A firm, smooth, rolling roadway with dirt or light surfacing,
PYRITES, IRON ORE 4,350 2580 flexing slightly under load or undulating, maintained fairly regularly,
SAND watered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Dry, Loose 2,400 1420
Damp 2,850 1690 Snow
Wet 3,100 1840
SAND & CLAY Packed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Loose 2,700 1600 Loose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Compacted 4,050 2400
SAND & GRAVEL A dirt roadway, rutted, flexing under load, little if any maintenance, no
Dry 2,900 1720 water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Wet 3,400 2020
SANDSTONE 2,550 1510
SHALE 2100 1250 Rutted dirt roadway, soft under travel, no maintenance,
SLAG no stabilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Broken 2,950 1750
SNOW Loose sand or gravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
Dry 220 130
Wet 860 520
STONE, CRUSHED 2,700 1600 Soft, muddy, rutted roadway, no maintenance . . . . . . . . . . . .200 to 400
TACONITE 3,600-4,200 1630-1900
TOPSOIL 1,600 950 *Various tire sizes and inflation pressures will greatly reduce or increase
TAP ROCK estimating purposes when specific information on performance of particular
Broken 2,950 1750 equipment on given soil conditions is not available.
* Varies with moisture content, grain size, degree of compaction, etc.
Tests must be made to determine exact material characteristics.
Reference Information 52
Operating Weight 105,600 (47 900) 146,500 (66 451) 230,100 (104 600) 248,600 (113 000)
lb (kg) (Differential Steer)
Flywheel Power 410 (306) 580 (433) 850 (634) 850 (634)
hp (KW)
Blade Capacity
SU 17.7 (13.5) 24.2 (18.5) 35.5 (27.2)
U 21.4 (16.4) 28.7 (22) 45 (34.4)
CD 57 (43.6)
yd3 (m3)
Blade Width
SU 14'2" (4.31) 15'11" (4.86) 18'4" (5.60)
U 15'3" (4.65) 17'3" (5.26) 20'10" (6.35)
CD 22'0" (6.71)
ft/in (m)
(included end bits)
Track On Ground 11'5" (3.47) 12'9" (3.89) 14'7" (4.44) 14'7" (4.44)
ft/in (m)
General Dimensions
Height 13'1" (3.99) 14'2" (4.34) 15'0" (4.57) 15'0" (4.57)
ft/in (m)
(to top of canopy ROPS)
Overall Length 27'8" (8.48) 30'4" (9.26) 34'1" (10.68) 35'5" (10.50)
ft/in (m)
(U-Blade & Single Shank Ripper)
Miscellaneous 64
Full Turn Tip Load (lb) 243,760 203,968 152,014 112,764 108,664
(kg) 110 570 92 518 68 952 51 149 49 289
Miscellaneous 66
Blade Capacity
- Semi - U (yd3) 33.1 20.7 14.56
(m3) 25.4 15.9 11.13
- Coal (yd3) 58.2 40.2 29
(m3) 44.7 30.7 22.2
- Straight (yd3) 10.33
(m3) 7.9
Blade Width
- Semi - U (ft/in) 20' 9" 19' 4" 16' 11"
(mm) 6321 5846 5151
- Coal (ft/in) 23' 7" 17' 9" 18' 7"
(mm) 7200 5418 5677
- Straight (ft/in) 16' 8"
(mm) 5074
Top Speed
- Forward (mph) 13.6 14 24.1
(kph) 23.2 22.5 38.7
- Reverse (mph) 15 15.4 14.3
(kph) 24.2 24.8 23
Miscellaneous 68
Gross Machine
Operating Weight* (lb) 219,000 239,000 360,000
(kg) (99 300) (108 400) (163 293)
Capacity
Heaped (2:1) (SAE) (yd3) 46 53.9 73.6
(m3) (35.2) (41.2) (60.1)
Engine 3412E 3412E 3508B
Gross Power (hp) 710 760 1000
(kW) (530) (567) (746)
Tire Size 24.00R35 24.00R35 27.00R49
Top Speed (loaded) (mph) 41.1 41.1 39.9
(km/h) (65.8) (65.8) (60.4)
Underground Mining MODEL AD55 DE-1681 DNW1 & UP (*Based on 26.9m3 Body)
Equipment Description Metric Imperial
Engine Power (Gross) 485 kW 650 hp
Engine Model Caterpillar C18 DI TA AAAC
Weight (Empty) 47 467 kg 104,647 lb
Weight (Loaded) 102 000 kg 224,871 lb
Capacity (Body) 55 tonnes 60.6 tons
Heaped SAE 2:1 26.9 m 3
35.2 yd3
Turning Radius SAE 9171 mm 361.1 inch
Outer Clearance Radius 9885 mm 389.2 inch
Inner Turning Radius 5540 mm 218.1 inch
Height (Cab) 3000 mm 118.1 inch
Overall Length* 11 547 mm 454.6 inch
Loading Height* 3045 mm 119.9 inch
Width* 3346 mm 131.7 inch
Axle Oscillation ± 10.0°
Articulation Angle ± 42.5°
Speeds Forward
1st Speed Forward 8.1 km/h 5.1 mph
2nd Speed Forward 11.2 km/h 6.9 mph
3rd Speed Forward 15.1 km/h 9.4 mph
4th Speed Forward 20.3 km/h 12.6 mph
5th Speed Forward 27.6 km/h 17.1 mph
6th Speed Forward 37.2 km/h 23.1 mph
7th Speed Forward 50.4 km/h 31.3 mph
Speeds Reverse
1st Speed Reverse 7.9 km/h 4.9 mph
2nd Speed Reverse 10.7 km/h 6.6 mph
3rd Speed Reverse 0.0 km/h
4th Speed Reverse 0.0 km/h
Tires BRIDGESTONE 35 X 65 R33 MS VSNT E4
Unladen Front Axle Weight 31 300 kg 69,005 lb
Unladen Rear Axle Weights 16 167 kg 35,642 lb
Laden Front Axle Weight 48 202 kg 106,268 lb
Laden Rear Axle Weights 53 798 kg 118,603 lb
Weight Distribution Front Unladen 66%
Weight Distribution Rear Unladen 34%
Weight Distribution Front Laden 47%
Weight Distribution Rear Laden 53%
Miscellaneous 80