Hitachi Loading Policy For Training January 2015

Hitachi Loading Policy

For Training

Guidelines for the Understanding and Application

of
Loading Criteria for Hitachi Rigid Frame Trucks

January 2015

Contents

1.0 Explanation
2.0 Definitions and Abbreviations
3.0 Conditions
4.0 Loading Chart
5.0 Established Weight Chart
6.0 Example Calculation

Rev. September 2009 to September 2010 (effective October 2010)

1. Added the EH4000ACII to the Established Weight Chart. ( 5.0 )

2. Hitachi Loading Policy For Customer “September 2009” is unaffected by this change

Rev. September 2010 to January 2013

1. Added the EH5000AC-3 to the Established Weight Chart .( 5.0 : only Training )

2. Notes of a use tire are added. ( 3.4 : Customer and Training )

Rev. January 2013 to June 2014

1. Added the EH1100-5 to the Established Weight Chart .( 5.0 : only Training )

2. Deleted the EH4000ACII(Tires:40.00R57(Opt.)) to the Established Weight Chart .( 5.0 : only Training )

Rev. June 2014 to January 2015

1. Added the EH3500ac-3 and EH4000AC-3 to the Established Weight Chart .( 5.0 : only Training )

1/6
 Hitachi Loading Policy For Training January 2015

1.0 Explanation

The primary purpose of the Hitachi Loading Policy is to restate the guidelines that minimize the risk
experienced by Hitachi rigid frame dump trucks and coal haulers (the “Trucks”) as a result of overloading. If
overloading is avoided, the Truck will operate within the certified design criteria of the brake and steering
systems. Trucks utilized within the intended design envelope will benefit by getting longer frame, power train,
tire and suspension component life.

The integrity of the Trucks is a function of several factors, including maintenance of the Truck and the haul
roads, and very importantly, the occurrences of overloading. Overloading of a Truck is the result of poor
matching of loading equipment and disregard for the intended use and Gross Machine Operating Weight
rating of the machine.

To promote appropriate use of the Trucks, Hitachi designs to a Target Gross Machine Operating Weight
(TGMOW) rating. The TGMOW rating is used as the baseline around which all design criteria are
established including component sizing, material strength, component overhaul intervals, and performance.
Exceeding the TGMOW above and beyond established parameters may have an exponential adverse effect
on the function and the life of components.

Varying material density, moisture content level, blasting patterns and procedures, loading equipment’s
bucket payload and volume capacities, as well as bucket fill factors, make it difficult to load hauling Trucks
with a specific operating weight consistently. Loading using the Nominal Payload value as a target, assists
the Trucks in keeping the loading operation running efficiently and smoothly while helping to recognize and
prevent overloading. Optimum Truck availability and performance of the Trucks will be the result of the
above practices.

This policy also functions as an educational tool, providing a simple explanation of terms, conditions and
consequences of overloading.

Definitions and calculations within this document are based on the use of Radial tires.

Hitachi reserves the right to determine liability for Warranty Agreements, Cost Caps, Service Contracts,
MARC programs and Availability Guarantees due to the detrimental effects of overloading.

2/6
 Hitachi Loading Policy For Training January 2015

2.0 Definitions and Abbreviations

2.1 Hitachi Established Weights

2.1.1 Maximum Gross Machine Operation Weight (MGMOW) -This is the weight which Hitachi has
specified as not to be exceeded. This weight is certified to meet standards for ISO & SAE steering and
brake system.

2.1.2 Target Gross Machine Operating Weight (TGMOW) - This is the gross operating machine weight
Hitachi has specified and recommended as the desirable gross machine operating weight which adhered to
result in optimum Truck availability and performance.
TGMOW is used in performance curves and calculations, and relevant to sales information on the Truck.

2.2 Calculated Weights

2.2.1 Net Machine Weight (NMW) - This is the actual empty operating weight of the machine including
the driver, all fluids at 100%, all optional and customer installed attachments, rims and tires.
The NMW in the brochure indicates the empty operating weight of a standard equipped machine (Std.
NMW).
Calculation: NMW = Std. NMW + the weight of all optional and customer installed attachments and
fluids

2.2.2 Nominal Payload (NP) – This is the payload around which the distribution of payloads should be
centered. The average or mean of all payloads should be equal to the Nominal Payload.
Calculation: Nominal Payload = Target GMOW – NMW

2.2.3 Maximum Allowable Payload (MAP) - This is the maximum payload allowed and equal to 120% of
Nominal Payload. It should never cause the Gross Machine Operating Weight to exceed the MGMOW
value.
Calculation: Nominal Payload x 120% = Maximum Allowable Payload

2.2.4 Options – Options include anything that is added to the Truck above and beyond what is installed as
standard by the Truck manufacturer. Options including, but not limited to; body liners, noise attenuation,
additional fuel reservoirs, trolley assist, etc., add to the NMW specification and therefore take away from the
Nominal Payload.
Calculation: See 2.2.1

3/6
 Hitachi Loading Policy For Training January 2015

2.3 General

2.3.1 Hitachi Load Weighing System – This is the Hitachi onboard payload weighing system. This
system displays payload weight to the Truck operator and records haul cycle data for production
management personnel.

3.0 Conditions

3.1 The loading of Trucks is not an exact science and in consideration of this fact. This policy allows
loading above Nominal Payload within limitations. A Truck shall be considered overloaded when the
following limits are exceeded.
A) No more than 10% of all loads can fall between 110% and up to 120% of Nominal Payload
B) A payload greater than 120% of Nominal Payload is not allowed

3.2 If a payload exceeding 120% of Nominal Payload occurs (3.1 B), the Truck full of the load must be
dumped within 160 meters of the loading machine, otherwise warranty shall become void.

3.3 To establish appropriate NMW of the Truck and to ensure Hitachi Load Weighing System will function
with accuracy, certified scales are recommended to be used to weigh newly delivered Trucks. The local
dealer and customer are responsible for the costs incurred to weigh Trucks. If the NMW has not been
measured within 60 days of Truck commissioning or 120 days of fleet commissioning (whichever occurs
earlier), Hitachi will determine a conservative value. In addition, any local modification of the Truck requires
re-calibration. It is a responsibility for the customer to maintain proper function of the Hitachi Load Weighing
System.

3.4 The established Target and Maximum Gross Machine Operating Weights for each truck model are the
limitations of the truck. The limitations of the tire fitted to the truck must be considered before loading the
truck. Please consult with the tire manufacturer to determine safe and effective use of each specific tire
make and model used.

3.5 Payload data must be recorded for every Truckload utilizing an approved and calibrated recording
device. The Hitachi Load Weighing System is an approved device. Other comparable measuring devices
must be approved by Hitachi. Agreement shall be established between the customer and local dealer to
allow Hitachi and/or its representatives full access to the Hitachi Load Weighing System and any other
approved payload measuring device. Utilization of the software for latest Hitachi Load Weighing System and
Hitachi analysis of haul cycle data can reveal opportunities that could improve production capability and/or
machine reliability.

4/6
 Hitachi Loading Policy For Training January 2015

3.6 The Policy will be in effect during the period of all Truck warranties, component warranties, cost cap
guarantees, availability guarantees, MARC programs and any other guarantees offered by Hitachi.

NOTE: The rated capacity of the tires should always be considered in any evaluation.

4.0 Loading Chart

: Productive & Durable – 90% of all loads

Nominal should fall into this range
Payload = Target GMOW – Net Machine Weight

Target Gross Machine Operating Weight

: No more than 10% of all loads should
exceed 110% of Nominal Payload

: No loads should be above 120% of Nominal

Payload
Number of Loads

% Nominal Payload

5.0 Established Weight Chart

kg
Model Tires TGMOW MGMOW
EH1100-3 24.00R35 (Std.) 104,541 116,601
EH1100-5 24.00R35 (Std.) 108,950 121,650
EH1700-3 27.00R49 (Std.) 163,300 182,340
EH3500ACII 37.00R57 (Std.) 309,000 342,600
EH3500AC-3 37.00R57 (Std.) 322,000 359,600
EH3500AC-3 40.00R57 (Opt.) 324,000 359,600
EH4000ACII 46/90R57 (Std.) 384,000 428,400
EH4000AC-3 46/90R57 (Std.) 384,000 428,200
EH5000ACII 53/80R63 (Std.) 500,000 557,000
EH5000AC-3 53/80R63 (Std.) 500,000 559,200

5/6
 Hitachi Loading Policy For Training January 2015

6.0 Example Calculation

The following calculation is provided as an example for estimating Net Machine Weight. For best production
efficiency and the accuracy of Hitachi Load Weighing System, the Truck should be weighed empty using
certified scales.

EH5000ACII
Net Machine Weight as commissioned
Base chassis, with all fluids at 100% 118,536 kg
+ Drive system option 0 kg
+ Rim x6 20,614 kg
+ Tire x6 25,800 kg
+ Body with mounting hardware, no liner 45,050 kg
+ Body Liner 11,457 kg
+ Body Extensions 0 kg
+ Trolley 0 kg
+ Options installed at OEM facility 89 kg
+ Options and attachments installed
by customer and dealer 772 kg
+ Options required regionally and
attachments that are not included above 0 kg
222,318 kg
Nominal Payload (NP)
Target Gross Machine Operating Weight 500,000 kg
- Net Machine Weight as commissioned 222,318 kg
277,682 kg
Maximum Allowable Payload (MAP)
Nominal Payload 277,682 kg
X 120% 120% kg
333,218 kg
Verify that MGMOW is not exceeded
Maximum Allowable Payload 333,218 kg
+ Net Machine Weight 222,318 kg
result must be ≤ 557,000 kg * 555,536 kg
*if the result exceeds MGMOW, the MAP
value must not be greater
than (MGMOW minus NMW)

6/6