Cat Product Information

Performance Report
November 2010

Komatsu 1500-7

Study Purpose The primary purpose of the study was to conduct a

performance analysis of the 993K HL which was new
to the site. Because of this study a secondary opportunity
to evaluate a Komatsu 1500-7 occurred. The focus of this
report will be on the Komatsu 1500-7 Off-Highway Truck.

Study Date July 7 and 8, 2010

Field Data By Pierre Godelaine – Caterpillar Global Mining

Randy Aneloski – Caterpillar Global Mining
Kent Clifton – Caterpillar Global Mining
Ronald Kuykendall – Caterpillar Customer Services Support
Jim Vesterdal – Caterpillar Customer Services Support
Jeff Taylor – Caterpillar Global Mining

For Dealer Sales Personnel

Location The study was completed at an Eastern U.S. Open Cut Coal Mine.
The site has a workforce of approximately 40 persons per shift.
These employees work a 24 hour day, 6 days a week schedule
with (3) 8 hour shifts. Operators have the option to skip lunch
and go home 0.5 hours early. Therefore, shift change in the pit
is based on the 7.5 hour shift.

Written By Jeff Taylor, Technical Marketing Specialist and Body Sales

Support for 785 and 789 Mining Trucks

Weather Conditions Temperatures ranged from 29° C to 37° C (85° F to 99° F)

with sunny and dry conditions.

Tested Units Komatsu 1500-7

Material The material is an overburden consisting of 50% decomposed

rock and 50% rock. These trucks were on a temporary job
removing mountain top soil/dirt. The material was very loose,
fine course and provided easy loading with high fill factors.
Density estimated at 1.72 Tonne/LCM (2,900 lb/LCY).

Section IV: Scale System The scale system used for this test was the Caterpillar Global
Mining set of Transcale AS300 weigh system. This was
operated by Senior Product Demonstrator/Instructor –
Ronald Kuykendall.

Calibration Date March 2010

Business Unit This study was completed by Caterpillar Global Mining

with assistance from Carter and Caterpillar Customer
Services Support.

2
The Komatsu 1500-7 is in the 150 ton Off-Highway Truck class. Key Findings
The scale truck measured an average fleet payload of 137.7 tonne
(151.8 ton). We assume this meets customer expectations when
considering the fleet is trucking high fill factor material using
standard 80 m3 (105 yd3), flat floor truck bodies with no
sideboards or tail extensions. The test found a 6% difference
between the on-board payload weight and the off-board
scale weights.

The wheel loader operator’s technique of using the last bucket

pass to center the load contributed to the high fill factors
and payloads.

During the course of the study one haul road profile was Executive Summary
studied. This study was composed of two test periods in which
data was recorded for the following parameters:
• Fuel Consumption
• Payload
• Cycle Times
For this study fuel consumption data has been reported
in L (gallon) of fuel burned per hour.

Machine Specifications
Engine Cat 785D Komatsu HD1500-7

Engine Model Cat® 3512C HD Komatsu SDA12V160

Rated Power kW (hp) 1082 (1,450) —
Gross Power – SAE J1995 kW (hp) 1082 (1,450) 1109 (1,487)
Net Power – SAE J1349 kW (hp) 1005 (1,348) 1048 (1,406)
Net Power kW (hp) 1005 (1,348) 1048 (1,406)
Net Power – Cat kW (hp) 1005 (1,348) —
Net Power – ISO 9249 kW (hp) 1005 (1,348) 1048 (1,406)
Net Power – 80/1269/EEC kW (hp) 1005 (1,348) —
Torque Rise % 23 —
Bore mm (in) 170 (6.7) 159 (6.26)
Stroke mm (in) 215 (8.4) 190 (7.48)
Displacement L (in3) 58.56 (3,573.6) 45 (2,746)

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 Weights – Approximate Cat 785D Komatsu HD1500-7

Gross Machine Operating Weight (GMW) kg (lb) 249 476 (550,000) 249 478 (550,004)
Body Weight Range kg (lb) 20 831-30 623 (45,924-67,512) —
Operating Chassis Weight Empty (EOMW) kg (lb) — 105 300 (232,144)

Operating Specifications Cat 785D Komatsu HD1500-7

Nominal Payload Capacity tonnes (tons) 136 (150) 144.1 (158.9)

3 3
Body Capacity (SAE 2:1) m (yd ) — 78 (102)
3 3
Heaped Capacity (SAE 2:1) m (yd ) — 78 (102)
Maximum Payload Capacity tonnes (tons) 136 (150) —
3 3
Maximum Capacity Struck (SAE) m (yd ) — 54 (71)
Top Speed – Loaded km/h (mph) 54.8 (34) 58 (36)
Steer Angle Degrees 36 41
Turning Diameter – Front m (ft) 29.8 (97.7) —
Raise Time Seconds — 15
Lower Time Seconds — 15
Turning Circle Clearance Diameter m (ft) — 12.2 (40)
Machine Clearance Turning Diameter m (ft) 33.2 (108.9) 24.38 (80)
Target Payload (Dual Slope) tonnes (tons) 133 (146) —
Maximum Target Payload tonnes (tons) 141 (155) —
Minimum Target Payload tonnes (tons) 131 (144) —

Final Drives Cat 785D Komatsu HD1500-7

Differential Ratio 2.10:1 2.647

Planetary Ratio 10.83:1 7.235
Total Reduction Ratio 22.75:1 19.151

Transmission Cat 785D Komatsu HD1500-7

Forward 1 km/h (mph) 12.1 (7.5) 10.9 (6.8)

Forward 2 km/h (mph) 16.3 (10.2) 14.6 (9.1)
Forward 3 km/h (mph) 22.2 (13.8) 19.6 (12.2)
Forward 4 km/h (mph) 29.9 (18.6) 24.5 (15.2)
Forward 5 km/h (mph) 40.6 (25.2) 32.7 (20.3)
Forward 6 km/h (mph) 54.8 (34) 44.3 (27.5)
Forward 7 km/h (mph) — 58.4 (36.3)
Reverse km/h (mph) 11 (6.8) —

4
Suspension Cat 785D Komatsu HD1500-7

Effective Cylinder Stroke – Front mm (in) 306.5 (12.1) 375 (14.76)

Effective Cylinder Stroke – Rear mm (in) 165 (6.5) 106 (4.17)
Rear Axle Oscillation — ±9.2 Degrees

Body Hoists Cat 785D Komatsu HD1500-7

Pump Flow – High Idle L/min (gal/min) 750 (198) —

Relief Valve Setting – Raise kPa (psi) 17 238 (2,500) 19 000 (2,750)
Body Raise Time – High Idle Seconds 15.2 15
Body Lower Time – High Idle Seconds 15.9 15
Body Lower Time – Float Seconds 16.2 —
Body Power Down – High Idle Seconds 15.9 —

Brakes Cat 785D Komatsu HD1500-7

Brake Surface – Front cm2 (in2) 61 270 (9,497) —

2 2
Brake Surface cm (in ) — 159 148 (24,668)
Brake Surface – Rear cm2 (in2) 89 729 (13,908) —
Standards SAE J1473 OCT90 Meets ISO 3450
ISO 3450-1985

Weight Distributions – Approximate Cat 785D Komatsu HD1500-7

Front Axle – Empty % 45 47

Rear Axle – Empty % 54 53
Front Axle – Loaded % 33.3 35
Rear Axle – Loaded % 67 65

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 Service Refill Capacities Cat 785D Komatsu HD1500-7

Fuel Tank L (gal) 1893 (500) 2120 (560)

Cooling System L (gal) 379 (100) —
Crankcase L (gal) 204 (54) 193 (51)
Differentials and Final Drives L (gal) 436 (115) —
Final Drives, Each L (gal) — 120 (31.75)
Differentials L (gal) — 297 (78)
Steering Tank L (gal) 90 (24) —
Steering System (Includes Tank) L (gal) 117 (31) —
Brake/Hoist Hydraulic Tank L (gal) 337 (89) —
Brake/Hoist System (Includes Tank) L (gal) 641 (169) —
Torque Converter/Transmission Sump L (gal) — 153 (40.5)
Torque Converter/Transmission System (Includes Sump) 248 (65.51) —
L (gal)

Tires Cat 785D Komatsu HD1500-7

Standard Tire 33.00-R51 (E3 & E4) —

ROPS Cat 785D Komatsu HD1500-7

ROPS Standards SAE J1040 APR88 Meets SAE J1040 APR88

ISO 3471:1994

Sound Cat 785D Komatsu HD1500-7

Sound Standards ANSI/SAE J1166 MAY90 —

SAE J88 APR95

Steering Cat 785D Komatsu HD1500-7

Steering Standards SAE J1511 OCT90 —

ISO 5010:1992

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Body – Dual Slope Cat 785D Komatsu HD1500-7

Body Weight kg (lb) 22 295 (49,150) —

3 3
Heaped SAE (2:1) m (yd ) 78 (102) —

Body – X Cat 785D Komatsu HD1500-7

Body Weight kg (lb) 25 160 (55,468) —

3 3
Heaped SAE (2:1) m (yd ) 85 (111) —

Fuel Consumption
Liters Liters
Fuel Used – Duration – Fuel – liters (gallons) – (gallons) –
Test Period kg (lb) minutes (gallons) Cycles Per Cycle Per Hour
1 87 (192) 125 103.7 (27.4) 8 13 (3.4) 49.9 (13.2)
2 42 (93) 52 50.3 (13.3) 4 12.6 (3.3) 57.9 (15.3)

Truck payload information was collected using Caterpillar Global Payload Measurement
Mining’s certified portable scale system, the Transcale AS300.
In order to ensure the accuracy of the scale system, the earthen
pads that the scales rest on were constructed to be level within
one tenth of a foot. These measurements were checked during
the construction of the pads as well as after the scales were set
using a tripod mounted laser and grade rod. The same method
and accuracy was applied to the ramps leading to the scale pads.

Throughout the duration of the study the scale pads and ramps
were checked to ensure they remained level. This was done
using both the laser and grade rod, and also by completing a
“Site Level Test.” During a Site Level Test a loaded haul truck
is weighed one axle at a time in the usual manner and then
re-weighed in the opposite direction. The weight is recorded
and must match within ±0.5%.

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Haul Road Profile Dump
Area

7 8

4 5 6
9
11
10

3
Scales
2
12
Enter
Load Area
1
Loading
Area

Description of the Study Segments

Length – Est. Rolling
Segment # Description meters (feet) Resistance Grade
1 Dump Area to Scale 143 (470) 3% –3.0%
2 Enter Scales 1% 0.0%
3 Exit Scales 22 (73) 1% 0.0%
Haul
4 1st Turn – Loaded 195 (640) 3% –1.0%
5 Top of Hill – Loaded 62 (203) 3% 1.5%
6 2nd Turn – Loaded 124 (406) 3% –5.0%
7 Enter Dump Area – Loaded 213 (700) 3% –12.0%
Return Trip
8 Exit Dump Area – Unloaded 213 (700) 3% 12.0%
9 2nd Turn – Unloaded 124 (406) 3% 5.0%
10 Top of Hill – Unloaded 62 (203) 3% –1.5%
11 1st Turn – Unloaded 195 (640) 3% 1.0%
12 Enter Dump Area – Unloaded 166 (543) 3% 3.0%

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Haul Cycle data – Collected cycle time data on 13 cycles Cycle Times
(see details below).

2nd Top of 1st Enter

Haul Enter Exit 1st Top of 2nd Dump Dump Corner – Hill – Corner – Load
Cycle Scale Scale Corner Hill Corner Enter Exit Return Return Return Area
1 3.86 5.24 5.90 5.95 6.42 7.14 8.70 9.25 9.61 9.80 10.69
2 3.54 5.04 5.64 5.79 6.25 6.80 8.29 8.93 9.39 9.56 10.46
3 3.60 4.91 5.55 5.72 6.10 6.84 8.30 8.92 9.34 9.53 10.56
4 4.53 5.79 6.54 6.70 7.09 7.79 9.29 9.49 10.39 10.56 11.49
5 3.70 5.02 5.68 5.88 6.26 6.99 8.74 9.42 9.80 9.99 10.81
6 3.44 4.73 5.32 5.54 5.88 6.53 7.86 8.59 8.98 9.20 10.21
7 3.50 5.35 5.91 6.10 6.50 7.15 8.56 9.26 9.71 9.91 10.95
8 3.60 5.15 5.77 5.95 6.37 7.06 8.61 9.33 9.81 9.99 10.99
9 skipped skipped 3.90 4.11 4.71 5.30 6.75 7.38 7.80 7.97 8.87
10 3.50 5.80 6.38 6.53 6.89 7.51 8.81 9.40 9.96 10.10 11.02
11 3.27 4.82 5.48 5.66 6.07 6.76 8.28 8.90 9.36 9.53 10.34
12 3.66 4.85 5.68 5.98 6.64 7.32 8.85 9.43 9.85 10.05 10.99
13 3.72 5.24 5.92 6.2 6.62 7.31 9.36 9.78 9.91 10.02 10.69

3.67 5.16 5.67 5.85 6.29 6.96 8.49 9.08 9.53 9.71 10.62 Average

* Study began at 11:13 A.M. and ended at 3:16 P.M.

Average dump and maneuver time was one minute and

32 seconds.

The average cycle time (while using the scales) was 10 minutes
and 62 seconds. Reference cycle #9 provided a higher cycle time
when the scale was bypassed because this allowed operator to
achieve a higher speed from the loading area to the 1st corner.

Generally, on cycles that the scales were used, the operator

maintained speeds from 18 to 22. Specifically, ~ 22 mph @
1st corner down to 18 mph retard set speed to the dump.

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Test Results
Unit Front Rear Rated Rated Actual Net TPMS
No. Loads Axle Distribution Axle Distribution GMW Payload GMW Empty Gross TPMS Weight % Diff. Volume
tonnes tonnes kg tonnes kg tonnes tonnes tonnes tonnes m³
(tons) (tons) (lb) (tons) (lb) (tons) (tons) (tons) (tons) (yd³)
5004 12 89.1 34.27% 171.0 65.73% 249 476 136 260 128 119.4 260.1 148.7 140.8 5.49% 82
(98.3) (188.5) (550,000) (150) (573,483) (131.6) (286.7) (164) (155.2) (107)
5005 12 89.1 35.10% 164.8 64.90% 249 476 136 253 944 118.0 253.9 147.9 135.9 8.56% 79
(98.2) (181.7) (550,000) (150) (559,850) (130.1) (279.9) (163) (149.9) (103)
5006 12 88.2 34.98% 164.0 65.02% 249 476 136 252 152 117.8 252.2 149.7 134.4 11.07% 78
(97.2) (180.8) (550,000) (150) (555,900) (129.8) (278.0) (165) (148.2) (102)
5007 13 88.9 34.58% 168.1 65.42% 249 476 136 256 950 117.3 256.9 138.8 139.6 –0.61% 81
(97.9) (185.3) (550,000) (150) (566,477) (129.3) (283.2) (153) (153.9) (106)

Combined 88.8 34.73% 167 65.27% 255 793 118.0 255.8 146 137.7 5.99% 80
Averages (97.9) (184) (563,928) (130.1) (282) (161) (151.8) (105)

On Unit #5007 we collected thirteen onboard truck weight

samples. Ten samples were taken at the scale. Overall, average
onboard weight at the scale was 147.8 tonnes (163 tons).
Two samples were taken on the haul road. The second sample
was 1% less than when taken at the scale. Observational
Note: The Komatsu 1500-7 has a small informational display
and the machine must be stopped in order to read this screen.
Total Material
Unit Hauled Fuel Used Average Fuel Average Fuel
tonnes (tons) L (gal) (tonnes/L) (tons/gal)
5007 1680 (1,851.9) 154 (40.7) 10.9 45.5

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– Truck bunching at the loader. Comments
– High payload variation.
– 6 – 7 pass.
– 993K pushed last past to the center of the body.
– Overloads.

HD1500-7 Operator Comments

– Operator has been at site for years and driven all the trucks.
Operator likes the new Komatsu 1500-7.
– Specifically, the operator likes the “bigger cab and seat.”
“Cab feels bigger than Cat 789C.” Komatsu exterior cab
measures 1.5 m W × 1.9 m L × 1.6 m H (62 in W × 75 in L
× 64 in H) (at midpoint of cab). Suspect that Komatsu is
~102 mm (~ 4 in) taller and longer inside than the Cat cab
(otherwise operator hits his head on the ceiling and his
knees are in the dash). Operator suggests the key to leg room
is maximum seat adjust ability.
– The Cat 789C seat bottoms out and makes it feel like he
is falling out of the seat. (Note operator is ~450+ pounds)
and the 789C seat has not been upgraded with the additional
spring and negative slope pad. The operator likes Komatsu
seat adjust ability – low/high lumbar, fore and aft adjustments
batwing adjustments.
– Komatsu has a tighter turn radius (their literature states
3 meter [10 feet] diameter better). However, a negative to this
tighter turn radius is short tire life due to scuffing.
– Operator likes the “ARCS” retarder system because he can
set a speed and it displays digitally on the dash. With this
retarder system Komatsu trainers told them to set and not
to use the service brakes.
– Digital load counter on this truck has never worked so
operator installed a manual counter (counter on other
trucks work).
– Canopy coverage and walkway height over the RH platform
is good – “easy access and good clearance.”
– Operator dislikes the operator side mirrors. They are good
for visibility but poor for backing up due to distortion.
– Operator likes the powered passenger windows.
– Operator dislikes the cab because it does not have a manual
air pressure gauge (e.g. brake pressure).

11
 – Using a hand held sound device, the Cab sound recordings
were ~80 to 84 dBa with windows closed. ~91 dBa uphill with
full engine load and with the windows closed. ~91 dBa on a
small decline, full throttle with window open. Operator did
think that Komatsu’s was a bit louder than the Cat cab.
– When operator selects the auto transmission or drive, they
have the ability to select a 1st gear or 2nd gear auto start.
They were trained to use the 1st gear only.
– Operator is trained to use the manual retarder and NOT
to use manual brake pedal (ever) because use of the manual
brake pedal does not open valves which cool the system.
Using the manual brake pedal during normal operation may
lead to brake system overheat. Manual brake “foot” pedal is
only for use around the shop during maintenance (e.g. very
small distances).
Operator does not like the fact that these standard bodies do
not have tail extensions. Operator explains that without tail
extensions – the dump body tail gets into the berms during
the dump cycle.

General Comments:
Observation – On July 7 A.M. 2 to 3 trucks usually waiting on
the loader. Yet loader is still trying to optimize 6/7 pass
payloads. Onboard payload information would indicate the
trucks were overloaded.

Our scale study cycle time focused on the Komatsu 1500-7 fleet of
four trucks. The 1500-7 fleets have Yokahoma Y-523 E-4 tires.

Jeff Taylor, Technical Marketing Specialist and Body Sales

Support for 785 and 789 Mining Trucks rode in one of these
units throughout the day on July 7 capturing data, reviewing
features, assessing machine performance and talking with the
operator. This truck had 938 service meter hours.

Secondary purpose of this study was to improve overall

knowledge of the Komatsu 1500-7. Additional performance
information can be found in TEJB9511, “785D vs. 1500-7
Competitive Bulletin.”

12
Komatsu 1500-7 Truck Feature Observations:
The integrated diagonal stairway on Cat 785D Off-Highway
trucks provide much better access and egress. The 1500-7 machine
does have specific lighting to illuminate the access/egress steps.
And the 1500-7 does have rear working lights at front fenders.

In addition, to a parking brake switch the 1500-7 has rear wheel

brake switch. The operator said they were trained to use this
switch while the truck was being loaded and the parking switch
was used for parking. I did observe that the operator was
extremely busy clicking the appropriate switches while we were
weighing the trucks. On one occasion, when actively talking,
the operator mistakenly clicked the wrong switches.

These machines were equipped with heated body exhaust with

no exhaust diverters. The truck body canopies did not extend
out past the front handrails. And the body canopy protection
was on the driver’s side only.

Komatsu’s payload indicator had multiple lights. Functionality

example: on the 3rd pass a green light flashes, on the 4th pass
the green light stays on and a yellow light flashes. For the 5th pass
the green light and yellow lights stay on and red light flashes.
On the 6th pass the red light is on.

Observation – during the dump operation, the hoist cylinders

were noticeably loud and moved the truck during each of
the 3 phases (on both the hoist up and hoist down cycles).
Operator said – now that you mention it…one time sample
recorded 24 seconds for the body hoist up and 22 seconds for
the body hoist down.

13
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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
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TEXR0522
November 2010
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