Caterpillar® Product Information

Salesgram
January 2002

To enable mine managers to reduce the cost-per-ton of material

MAX Payload and moved and increase the life of mining trucks; Caterpillar has
Speed Manager introduced the MAX Payload and Speed Manager System. This
system is a standard feature on VIMS equipped Caterpillar mining
trucks (785,789,793 and 797).

Utilizing the True Weight Production Management System and

the VIMS 2nd gear weighing feature to calculate truck payloads,
it is now possible to actively manage payloads to meet Caterpillar’s
10/10/20 payload policy. Managing a fleet with MAX Payload
and Speed Manager and the 10/10/20 policy helps lengthen the
life of truck frames, tires, rims and power train components, as
well as protect the operator.

Functional Description MAX Payload and Speed Manager compares the actual payload
weight on the machine to an overload setting. When VIMS has
determined that the machine is overloaded, transmission shift
range is limited and the engine speed is reduced at the limited
gear in order to slow the machine down. The payload weight is
monitored as the machine shifts to second gear.

MAX Payload and Speed Manager will activate when the weight
of the payload exceeds the set limit regardless of the location of
the truck. Speed limiting of the machine is activated when the
weight of the payload exceeds the set limit and will remain active
until the payload is dumped. Limiting of the machine speed and
the VIMS messages cease automatically after the payload has
been dumped and the machine is returned to normal operation.

The weight of the payload is calculated as the truck is shifted into

second gear (second gear weighing) and then used to determine if
limiting the speed of the machine is necessary.

For Dealer Sales Personnel

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 Once MAX Payload and Speed Manager has determined that the
truck is overload, the following actions are initiated:
• The shift range of the transmission is limited to second gear.
• High idle of the engine is limited to 1750 rpm.
• The set point for automatic retarding is reduced to 1750 rpm.

The settings listed above are not adjustable. For more detailed
information on truck operation and VIMS warnings, please see
Chart 1.

Conditions and the Corresponding Response of the Machine

Condition Response
The weight of the payload is within the specified No action is taken. The machine will continue
limit for the target payload. normal operation.
The weight of the payload is greater than the A machine overload event is recorded.
specified Target Payload Setting, but less than A machine overload event is broadcast via
the specified Payload Overload Limit. a radio telemetry system.
The VIMS displays messages to the operator.
These messages warn the operator that the
machine is overloaded and the messages instruct
the operator to proceed carefully.
Weight of the payload is greater than the An event for the machine overload limit
specified Payload Overload Limit Setting. is recorded.
An event for the machine overload limit is
broadcast via a radio telemetry system.
The VIMS displays warning messages to the
operator that the machine is overloaded.
A category II warning sounds if the operator
proceeds without correcting the overload condition.
The VIMS displays warning messages to the
operator that machine operation has been limited
and the VIMS instructs the operator to resolve
the overload condition.
The shift range of the transmission is limited to
second gear.
High idle of the engine is adjusted to 1750 RPM.
Automatic retarding RPM is reduced to 1750 RPM.
Chart 1

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The Project Manager for a site has decided with the customer that Example of the Operation
a 793C will normally haul loads of 240 tons and the loads should
never exceed a limit of 288 tons. In order to achieve these objectives
of the Maximum Payload
the Project Manager would set the parameters of MAX Payload Speed Manager
and Speed Manager to the values listed below:

Target Payload Setting – 240 tons

Payload Overload Limit Setting – 120% (288/240=120%)

With these settings MAX Payload and Speed Manager will

function as listed below:
• The loading lamps on the external payload display will target
240 tons.
• The overload warnings will occur above 264 tons.
• The engine speed will be limited to 1750 rpm in second gear
above 288 tons.
• The external payload display will show the current payload
weight.

Chart 2 shows a graphical representation of MAX Payload and

Speed Manager operational settings for the example listed above.

Chart 2

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Setup of MAX Payload and MAX Payload and Speed Manager requires the user to enter
information into the system. This information is used to define
Speed Manager the system behaviors listed below:
• Overload speed limiting
• Overload events
• Overload warnings

Target Payload Setting

The Target Payload Setting is used during payload operations
in order to control the operation of the external payload lamps.
The Target Payload Setting is adjustable from zero to the target
weight of the truck being setup. The target weight is the nominal
payload of the machine. This setting is stored in the onboard
memory of the VIMS ECM and is programmed via the keypad.

The service operation of Payload Configuration (PAYCONF) is

used to set this value. Please refer to Service Manual RENR2635
for instruction on entering this information into the system.

Payload Overload Limit

The Payload Overload Limit is the maximum payload weight
that is allowed before the VIMS will display warning messages
to the operator. VIMS will also limit the speed of the machine,
if the payload weight is too high. The Payload Overload Limit is
adjustable from 105 percent to 120 percent in increments of one
percent and may be disabled by setting the limit to zero. Although
this is an option, Caterpillar does not recommend disabling the
feature. The default setting is zero percent, so the system will
need to be “turned on” in order to gain the benefits of the feature.
The Payload Overload Limit is stored in the onboard memory of
the VIMS ECM. The service operation of Payload Configuration
(PAYCONF) is used to set this value. Please refer to Service
Manual RENR2635 for instruction on entering this information
into the system.

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 Benefits
Transmission shift and speed limiting under overloaded
operating conditions reduces the impact of overloading on
machine components, thereby decreasing cost to the customer.
While experiencing engine derate and transmission limiting, the
steering and braking systems will maintain full power, protecting
the truck, operator, and surrounding people and equipment.

This feature is standard on all new Caterpillar Mining Trucks Implementation

(785-797). See table below for machines shipped from the
factory with MAX Payload and Speed Manager equipped:
and Retrofit Plans

Model Effective Serial Number Effective Production Date

785C APX00172 and up May, 2000
785C HAA 5AZ00274 and up May, 2000
789C 2BW00303 and up May, 2000
793C ATY00210 and up July, 2000
797 5YW00236 and up September, 2000

All trucks with flashable ECM’s can be upgraded by installing

current software. See table below for machines shipped from
the factory with flashable ECM’s:

Model Effective Serial Number Effective Production Date

785C 1HW00085 and up January 15, 1999
785C APX00160 and up January 1, 2000
785C HAA 5AZ00085 and up April 6, 1998
789C 2BW00089 and up September 15, 1998
793C 4GZ00093 and up November 16, 1998
793C ATY00183 and up February 22, 2000
797 5YW00193 and up September 8, 1998

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 Machines that have been upgraded in the field must have the
following to be able to accept MAX Payload and Speed Manager
software:
• VIMS 68K with interface modules in cab, or VIMS ABL 10.0
without interface modules (both flashable)
• MAC-14 Chassis/Transmission ecm (flashable)
• MAC-14 Brake ecm (flashable)
• ADEM-II Engine ecm (flashable)

For the large population of non-current machine models,

implementation is strongly recommended in order to adhere
to and enforce the agreed-to overload policies. This should
be accomplished by flashing in new software. No support for
older trucks equipped with EPTC-I, ARC/TCS attachment,
MUI, ADEM-I or EMS is planned at this time. For more detailed
retrofit information, please review service magazine SEPD0582
or Service Manual RENR2635.

Questions Any questions can be directed to Mining Truck Marketing Support

in Decatur, IL by calling: (217) 475-4723 or (217) 475-5636.

The information contained herein is intended for circulation only to Caterpillar and dealer employees whose duties require knowledge of such reports and
is intended exclusively 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.

TELQ3749-01
January 2002
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© 2002 Caterpillar
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