The weigh range is the segment of the lift during which data is collected to calculate a weight. The weigh range settings can be adjusted through Cat® Electronic Technician (Cat ET) or the display.
Following are the weigh range considerations:
- The weigh range bottom must be high enough to avoid digging while in the weigh range. (At least 20% higher than the end of dig)
- The bottom of the weigh range can be set from a minimum of 35% to a maximum of 65%
- The top of the weigh range should end at least 10% lower than the kickout
- The total size of the weigh range, bottom to top, must be at least 15%
- The default setting for the weigh range is from 50% to 65% of the lift
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| Illustration 1 | g06129082 |
(1) Truck Weight - Displays the total of the material loaded into the truck. The smaller number indicates the number of passes in the truck. Bucket weight will instantly transfer to the truck when scaled weight is calculated.
(2) Remaining Weight - Displays the remaining weight needed to achieve the target payload for the currently selected truck.
(3) Bucket Weight - Displays the weight of material currently in the bucket.
(4) Weigh Range Indicator - Displays when the linkage reaches the weight range.
(5) Bucket Zero - Zeros the current bucket weight.
(6) Estimated Weigh - Displays the estimated weight.
(7) Material ID - Displays the list of Material IDs.
(8) Truck ID - Displays the list of Truck IDs.
(9) Scale System Standby - Allows the user to activate and deactivate Standby.
(10) -1 Pass/Truck Clear - Removes the last pass on first press then clears the truck on second press.
Store Button - Press at the end of a truck to store the data to memory and update lifetime and trip payload totals.
Note: An icon will appear while the bucket is in the weigh range. The icon will show whenever the bucket is in the programmed weigh range not indicating that the system is weighing.
Scaled Weight
Scaled weight is the most accurate weight measurement. The weight is displayed within a green box (1) on the payload screen. The measurement occurs after lifting through the weigh range smoothly with the bucket in the fully racked position.
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| Illustration 2 | g06127839 |
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| Illustration 3 | g03750054 |
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Weigh range | |
Estimated Weight
A weight with no green box showing. Methods to obtain an estimated weight:
- Low lift weigh estimates weight anytime lift arms are above 30% of height and smooth lift command issued for 1-3 seconds
- While tipping the bucket when operating in one of the tip-off modes
- "Estimated Weigh" is pressed (at any lift height)
Note: A new estimated weight is not calculated within 2% of full lift height.
Low Lift Weigh
Low lift weigh is used when a scaled weight is not achievable. While issuing a slow and smooth lift command, the system monitors the calculated payload. Once the payload signal has stabilized, a weight will be shown if the linkage is above 30% of full lift travel. Since this weight is calculated while the linkage is moving, the weight is:
- More closely correlated to the calibration
- Not as accurate as a scaled weight, but more accurate than other estimated weights
When this application feature is active, the store button is used to store the current truck information to memory. Storing the truck information also resets the current truck weight, remaining weight, and pass count. The following information is stored:
- Truck ID
- Material ID
- Pass Count
- Truck Weight
- Time and Date of the Truck
- Weight of each pass
- Time and Date of each pass
The Auto-Store feature will automatically store data every 50 passes if the payload information is not stored or cleared. The stored passes will remain on the screen until a key cycle is performed, the store button is pressed, or the truck is cleared. The same information is stored as with a manual store button press. The stored passes will be removed from the display after the 50th pass.
The -1 button will remove the weight of the most recent pass from the truck and decrement the pass count by 1.
The Truck Clear button will be displayed if the -1 button has been pressed and the pass count remains greater than 0. If the Truck Clear button is pressed, the following occurs:
- All remaining weight will be removed from the truck
- The pass count will be reset to 0
- The data will not be stored to memory
Note: If an Auto Store has occurred on the current truck, the data already stored will remain in memory.
Tip-Off - A live, estimated weight shown on the screen while partially dumping a bucket.
The attributes of tip-off are:
- The live weight is most accurate at mid-lift height
- Eliminates the need to press the "-1" button after partially dumping the bucket
- Allows faster cycle time on final pass of truck loading
- Less accurate than the scaled weight
Note: For best accuracy, confirm tip-off weight with scaled weight by lifting the final payload through the weigh range.
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| Illustration 4 | g06127730 |
Machine Menu: Settings > Payload > Tip Off > Trigger
The tip-off trigger is selected in the Payload Settings menu and is indicated in the main payload screen.
Following are the three tip-off mode options:
Auto - Requires no operator input and immediately enters tip off when the bucket begins to dump.
Manual - Requires the operator to manually select the tip off button (2) when choosing to enter tip off.
Disabled - No tip-off mode is active.
The default is set to Disabled.
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| Illustration 5 | g06129589 |
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Manual Tip Off Button Turned Green | |
Machine Menu: Settings > Payload > Tip Off Mode
The tip-off mode is selected in the Payload Settings menu and is indicated in the main payload screen.
Following are the three tip-off mode options:
Stockpile Tip Off - Used for discarding excess material at the stock pile. The expectation is that the material remaining in the bucket is fully dumped into the truck.
Truck Tip Off - Used for tipping material directly into the truck, tipped off material is added to the truck weight.
Disabled - No tip-off mode is active.
Following is a list of tip-off modes:
The stockpile tip-off mode has the following attributes:
- When a weight is measured (Estimated or Scaled) that weight is added to the truck total and removed from the remaining truck weight.
- The system enters tip-off mode after a weight has been measured, and the bucket is tipped partially. "Zero" on the payload screen changes to "Tip Off Toggle" once Tip Off mode is active. A live estimated weight will be shown (no Green Box).
- As material is dumped out of the bucket, and the estimated bucket weight decreases, the truck weight decreases and the remaining truck weight increases.
- When the desired truck weight is achieved, rack back the bucket completely before dumping the bucket weight into the truck. The last racked weight is what will be committed to the truck when a full dump is detected, or the Store Button is pressed.
- If a full dump is missed, and the Store button is not pressed: The system assumes that the last pass was not a tip-off pass and commits the first measured weight when a new dig is detected.
- If the Store button is pressed while the bucket is not racked back: The last racked weight will be stored to the truck and the truck weight will be presented to the operator for a few seconds.
Stockpile Tip-Off Mode Operation
The stockpile tip-off mode operation is:
- End dig with bucket as low as practical and fully racked back.
- Slowly lift until an estimated weight appears.
- Slowly dump material back to stockpile until desired weight is reached.
- Achieve scaled weight by lifting through the weigh range while approaching truck.
- Dump scaled weight into the truck.
Note: To commit last bucket weight to the truck weight, either fully dump the bucket or press the Store button.
- Press the Store button to end the truck.
Useful when leftover material from the first truck can be immediately dumped into the next truck. Could result in higher fuel burn if unwanted material is carried and lifted through the cycle.
- End dig with bucket fully racked back.
- When approaching a truck, execute a scaled weight by lifting through weigh range.
- Slowly dump material into the truck until desired weight is reached.
- To achieve most accurate weight, lower and raise again to achieve scaled weight.
If scaled weight is not achievable, fully rack bucket to get a more accurate estimated weight.
- Press the Store button to end the truck.
The following factors will affect the payload accuracy during tip-off:
- Pausing before, during, or after tipping
- Amount and position of material in the bucket at the start of tipping
- Lift height when tipping
- Speed of dump command while tipping
Higher accuracy can be achieved from estimated tip-off weights by:
- Developing a consistent machine operation.
- Developing repeatable operator behavior: One operator may need to stop 0.2 tons short of target weight. Others may be able to stop at target weight.
Tip-Off Toggle Technique for Loading Trucks with More Than One Trailer
When loading trucks with more than one trailer, the tip-off toggle button can be used to get the correct amount in each trailer. The following procedure explains how to use tip-off toggle to load a truck with two trailers with a 10 ton loader.
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| Illustration 6 | g03749995 |
Procedure:
- First Pass:
- Load the bucket with 10 tons.
- Scale the weight.
- Fully dump the bucket into the first truck bed.
The first bed needs 2 tons more.
- Second Pass:
- Load the bucket with 10 tons.
- Scale the weight.
- Slowly start dumping into the first truck bed.
- Ensure that the system is in truck tip-off mode. If in stockpile tip-off mode, press the toggle button once while the bucket has partially dumped.
- Tip 2 tons into the first bed.
- Rack the bucket back.
The first bed is complete with 12 tons.
- Move to the second bed.
- Fully dump the remainder (8 tons) of the bucket into the second truck bed.
The second bed needs 7 tons more.
- Third Pass:
- Load the bucket with 10 tons.
- Obtain a low lift weigh estimated weight.
The system automatically switches back to stockpile tip-off mode.
- Use stockpile tip-off to get 7 tons in the bucket.
- Scale the weight.
- Fully dump the bucket into the second truck bed.
The second bed is complete with 15 tons.
Tip-Off Toggle Technique for Loading a Truck with Tarp Braces
When loading a truck with one or multiple tarp braces, the operator is required to dump partial passes into one trailer to spread the load throughout the truck. In this scenario, the tip-off toggle button can be used to disperse the load, accordingly. The following scenarios explain how to use tip-off toggle in different situations assuming a 9 ton loader.
Note: Many variants of this system can be used to successfully load a truck with multiple dumps to position the material evenly. For example, the operator could choose to set the Tip Off Default mode either to Truck or to Stockpile. The operator could also choose to disable the tip-off mode altogether, which may be the easiest.
Scenario 1: When Default Tip-Off Mode Is Set to "Stockpile Tip-Off"
This default setting is set by the operator by going to the main menu and going to: Machine/Settings/Payload/Tip-Off Mode ⇒ "Stockpile Tip-Off". Confirmation of this setting will be a white box outlining the Material ID Selection button on the Payload Menu.
This scenario is an example of a 972M with 9 tons in the bucket trying to load 24 tons into a truck.
- First Pass:
- Load the bucket with 9 tons.
- Scale the weight.
- Fully dump the bucket into the truck bed toward the front.
The truck now has 9 tons loaded in the bed.
- Second Pass:
- Load the bucket with 9 tons.
- Scale the weight.
- Fully dump the bucket into the truck bed toward the rear.
The truck now has 18 tons loaded in the bed.
- Third Pass:
- Load the bucket with 9 tons.
- Obtain a low lift weigh estimated weight.
The system automatically switches back to stockpile tip-off mode.
- Use stockpile tip-off to get approximately 6 tons in the bucket.
Now, press the -1 button. This action clears the split weight for the stockpile.
- Scale the weight.
- Partially dump the bucket into the truck bed toward the front.
- Once the bucket is partially dumped, press the toggle button to switch to truck tip-off mode. This action must be done so that the system does not think this material is being left at the stockpile.
- Tip 3 tons into this front portion of the truck bed.
- Rack the bucket back.
The front portion of the bed is complete with approximately 12 tons.
- Reposition the loader toward the rear of the truck.
- The truck should show approximately 24 tons loaded. The operator can press the store button. The CPM Scale resets to zero for the next truck and tip-off mode returns to the default setting.
Scenario 2: When Default Tip Off Mode Is Set to "Truck Tip-Off"
This default setting is set by the operator by going to the main menu and going to: Machine/Settings/Payload/Tip-Off Mode ⇒ "Truck Tip-Off". Confirmation of this setting will be a white box outlining the Truck ID Selection button on the Payload Menu.
Note: The following procedure assumes no tip-off to stockpile is performed. When that action is performed a Split Weight is created in the background.
This scenario is an example of a 972M with 9 tons in the bucket trying to load 24 tons into a truck.
- First Pass:
- Load the bucket with 9 tons.
- Scale the weight.
- Fully dump the bucket into the truck bed toward the front.
The truck now has 9 tons loaded in the bed.
- Second Pass:
- Load the bucket with 9 tons.
- Scale the weight.
- Fully dump the bucket into the truck bed toward the rear.
The truck now has 18 tons loaded in the bed.
- Third Pass:
- Load the bucket with 9 tons.
- Scale the weight.
- Partially dump the bucket into the truck bed toward the front.
- Rack back and reposition the loader toward the rear of the truck.
- Partially dump the bucket into the truck bed, until the target weight is obtained.
- The operator can choose to press store at this point to save that material to the truck.
If a more accurate weight is desired for storing, prior to pressing the store button, the operator could lower the bucket. Then raise up the bucket through the weigh range for a scaled weight. Now when stored, the hauling unit weight will be adjusted appropriately to the new scaled weight. The operator can press store to close out the truck with a more accurate cumulative truck weight.
- Return the remaining material in the bucket to the stockpile or save for the next truck.
To obtain a weight for the material remaining in the bucket, the operator can either press reweigh for an estimated weight. For a better estimated weight, slightly lift the bucket. For a scaled weight, lift the bucket through the weigh range.
Scenario 3: When Default Tip Off Mode Is Set to "Disable" (NOT recommended)
This default setting is set by the operator by going to the main menu and going to: Machine/Settings/Payload/Tip-Off Mode/Tip-Off Trigger⇒ "Disable". Confirmation of this setting will be no white box outlining either the Truck ID or Material ID Selection button on the Payload Menu.
This scenario is an example of a 972M with 9 tons in the bucket trying to load 24 tons into a truck.
- First Pass:
- Load the bucket with 9 tons.
- Scale the weight.
- Fully dump the bucket into the truck bed toward the front.
The truck now has 9 tons loaded in the bed.
- Second Pass:
- Load the bucket with 9 tons.
- Scale the weight.
- Fully dump the bucket into the truck bed toward the rear.
The truck now has 18 tons loaded in the bed, but needs 6 tons more, evenly dispersed.
- Third Pass:
- Load the bucket with approximately 6 tons.
- Scale the weight.
- If the weight is off, adjust the bucket load by either adding or subtracting material.
Note: With Tip Off enabled, once the operator passes a certain dump threshold the weight will become live. Then the operator can adjust the weight. With Tip Off disabled, once the operator passes a certain dump threshold (a bit lower than the one used for tip-off activation) the bucket weight will become *** and the pass will be added to the truck weight. To know how much was actually tipped off, the operator will need to generate a new weight, which will start a new pass. Before doing that, the operator must press the -1 button to negate the previous pass. This process is functionally the same as the reweighing used to work on Standalone and K-series PCS.
- Scale the weight.
- Readjust as necessary.
- Partially dump the bucket into the truck bed toward the front.
- Rack back and reposition the loader toward the rear of the truck.
- Dump the bucket into the truck bed.
- Press the store button to reset the system for the next truck to load.
The overload warning feature notifies the operator when a payload measurement exceeds 116.5% of the Loader Bucket Payload Target Weight configured in Cat ET . The feature can be enabled/disabled through Cat ET as well, and is disabled by default. If a low lift weigh or scaled weight shows as overloaded, and the machine has gone into reverse since digging, the operator will be notified via a pop-up. This fault is also sent off board into VisionLink® and logged on the machine. The system monitors for overload both in normal operating mode and in standby mode. (VisionLink is a trademark of Trimble Navigation Limited, registered in the United States and in other countries).