Attachment_0028__120M_MG_Final_Transportability_Report_(CAT).pdf

Transportability Report

For

US Army 120M Military Motor Grader

Prepared By:

Kellie Titus

Engineer Caterpillar Inc.

Defense & Federal Products

Date:

July 30, 2010

Line Item Number:

CLIN 0004AA

CDRL C020

Contract No:

W56HZV-08-D-0037

Caterpillar Inc. Transportability Report

Table of Contents

Section Title

1. Brief Description

1.1 Intended Use

1.2 Type of Equipment

1.3 Military Units

1.4 Theaters of Operation

1.5 Planned Quantity

2. Transportation Data

2.1 Hazardous Materials

2.2 Sectionalization and Reduction

2.3 Modeling and Simulation

2.4 Transportability Tests

2.5 Speed Requirements

2.6 Shipping Data Plate

2.7 Crew Size

2.8 Photographs

2.9 Dimensional and Weight Data Sets

2.10 Lifting and Tiedown Provisions

2.11 Projections

2.12 Additional Information

List of Figures

Figure Title

2-1 120M Motor Grader on 51-inch-high railcar inside AAR rail diagram 2-2 120M Motor Grader on 51.4-inch-high railcar inside GIC rail diagram 2-3 120M Motor Grader railcar cab and door storage 2-4 120M Motor Grader on M870 semi-trailer 2-5 120M Motor Grader inside C-130 aircraft 2-6 120M Motor Grader inside C-17 aircraft 2-7 120M Motor Grader inside C-5 aircraft 2-8 Shipping data 2-9 120M Motor Grader-Top Right 2-10 120M Motor Grader-Top Left 2-11 120M Motor Grader-Right Side 2-12 120M Motor Grader-Left Side 2-13 Grader dimensions 2-14 Grader lift and tiedown provision 2-15 Dimensions Defining the Location of the Lifting and Tie down Provisions 2-16 ROPS/FOPS cab multi-purpose provisions 2-17 Lift and tie down provision dimensions 2-18 Crest angle 2-19 Tire footprint locations and dimensions 2-20 Tracking width

List of Tables

Table Title

1-1 Planned quantities 2-1 Tools included with grader 2-2 Grader lift and tiedown provision information 2-3 ROPS/FOPS cab multi-purpose provision information 2-4 Lift and tiedown provision dimensions

1. Brief Description

1.1 Intended Use. The 120M Motor Grader is intended for coarse and fine grading, low and high bank sloping, flat and V-ditching, and scarifying materials through a forward motion involved with military construction of roads, bridges, and airfields.

1.2 Type of Equipment. The 120M Motor Graders are based on the Caterpillar 120H Motor Grader.

1.3 Military Units. The 120M Motor Graders are intended for active component, reserve component, and National Guard combat-light engineering units.

1.4 Theaters of Operation. The 120M Motor Graders provide tactical mobility for worldwide use.

1.5 Planned Quantity. The following table summarizes acquisition quantity by fiscal year for the 120M Motor Graders. The total number of machines planned is 607.

Fiscal Year Quantity 2008 37 2009 52 2010 50 2011 80 2012 80 2013 84 2014 84 2015 80 2016 30 2017 30

Table 1-1. Planned quantities

2. Transportation Data

2.1 Hazardous Materials.

2.1.1 Vehicle.

• Hazardous material class 9

• DOT proper shipping name Vehicle, flammable liquid powered

• Net explosive weight N/A

• Venting requirements None

• Grounding requirements None

2.1.2 Ether Starting Cylinder.

• Hazardous material class 3

• DOT proper shipping name Ethyl ether

• Net explosive weight 18 oz.

• Venting requirements None

• Grounding requirements None

2.2 Sectionalization and Reduction. The 120M Motor Grader is equipped with a split ROPS/FOPS cab so that the top portion of the cab can be removed to reduce height for transport. The exhaust stack can also be removed from the grader to reduce height. The height of the 120M Motor Graders before removal of the top portion of the ROPS/FOPS cab and exhaust stack is approximately 129 inches. The height of the graders without the top portion of the ROPS/FOPS cab and exhaust stack is approximately 102 inches to the top of the seat back. The top portion of the ROPS/FOPS cab and exhaust stack need to be removed during highway transport using the M870 series trailer and rail transport both outside of the Continental United States (OCONUS) and inside the Continental United States (CONUS) to meet the Gabarit International de Chargement (GIC) and Association of American Railroads (AAR) gauge diagrams. Removal and installation of the top portion of the ROPS/FOPS cab and exhaust stack can be accomplished in 30 minutes or less with two soldiers. The ROPS/FOPS top weighs roughly 800 lbs and is approximately 72 inches long, 44 inches high, and 55 inches wide. The ROPS/FOPS top has four MIL-STD-209K compliant multi-purpose provisions. The exhaust stacks measure 3.6 inches in diameter, 25 inches long, and weighs approximately 2.7 lbs. The blade lift cylinders must also be repositioned to reduce their height.

All tools needed to remove and install components can be seen in Table 2-1. A suitable lifting device is required to lift the top portion of the ROPS/FOPS off of the grader.

Qty Part # Description 1 6V-9113 Socket – 18mm, ½” drive 1 199-6154 Socket – 24mm, ½” drive 1 9U-6539 Socket – 36mm, ¾” drive 1 8H-8561 Adapter – ½” Female to ¾” Male 1 168-0383 ½” Breaker Bar 1 214-7322 8” Adjustable Wrench

Table 2-1. Tools needed for reduced height transport

2.3 Modeling and Simulation.

2.3.1 Rail. Figure 2-1 shows a computer model of the 120M Motor Grader on a 51-inch-high rail car inside the AAR rail diagram for single loads, without end overhang, on open-top cars. This simulation verified that removal of the ROPS/FOPS top and exhaust stack is not required for CONUS rail transport.

Figure 2-2 shows a computer model of the 120M Motor Grader on a 51.4-inch-high rail car inside the GIC rail diagram. The simulation verified that the top portion of the ROPS/FOPS cab and exhaust stack need to be removed to fit within the outline as shown in Figure 2-2. Figure 2-3 shows the cab removed and the left and right doors stored along each side of the cab. Cab removal assembly sets on the railcar and is secured using the four lift/tie down locations on cab roof. The blade lift cylinders must also be repositioned to reduce their height.

Figure 2-1. 120M Motor Grader on 51-inch-high railcar inside AAR rail diagram

Figure 2-2. 120M Motor Grader on 51.4 inch-high railcar inside GIC rail diagram

Figure 2-3. 120M Motor Grader railcar cab and door storage

2.3.2 Highway. Figure 2-3 shows a computer model of the 120M Motor Grader on an M870 semi-trailer. The simulation verified that the ROPS/FOPS top, and exhaust stack, need to be removed to meet general unrestricted CONUS highway transport. The blade does not have to be removed to meet width requirements. The top portion of the ROPS/FOPS cab and the exhaust stack has been removed from the model in Figure 2-3. The blade lift cylinders must also be repositioned to reduce their height.

Figure 2-3. 120M Motor Grader on M870 semi-trailer

2.3.3 Air. Figures 2-4, 2-5, and 2-6 show a computer model of the 120M Motor Grader inside a C-

130, C-17 and C-5 aircraft design envelope. The simulation verified that the C-130 requires the top portion of the ROPS/FOPS cab and exhaust stack need to be removed, the blade lift cylinders be repositioned to reduce their height, and the two rear tag links removed to reduce rear axle floor loading to allowable limits. The ROPS/FOPS does not need to be removed to fit within the C-17 and C-5 aircraft.

Figure 2-4. 120M Motor Grader inside C-130 aircraft

Figure 2-5. 120M Motor Grader inside C-17 aircraft

Figure 2-6. 120M Motor Grader inside C-5 aircraft

2.4 Transportability Tests. The physical dimension and weight of each grader (including CPK container) were tested for compliance with all transport mode requirements of 3.4. The tests described below are according to the Purchase Description ATPD-2358.

2.4.1 Rail Transport Test. The grader was tested in accordance with 4.3.6 prior to the rail impact test. The graders were tested for compliance with 3.4.1, the dimensions of the AAR and GIC diagrams, and were subjected to the rail impact test. The graders are capable of withstanding shock loads resulting from rail impact testing without failure, damage or permanent deformation. The test was conducted in accordance with MIL-STD-810 by mounting the test item on a rail car in its rail shipment configuration and then performing a series of at least four impacts. The first three impacts were at 6.4, 9.7, and 13 km/h (4, 6, and 8 mph), respectively, in the same direction. The fourth was conducted at 13 km/h (8 mph) in the reverse direction. All four impacts had a tolerance of +0.8, -0.0 km/h. After each impact, the graders were inspected for spillage of lubricants, fuel, water and structural damage.

Electrical shorts and normal operations and performance were checked and tested following the completion of the test.

2.4.2 Marine Transport Test. To determine conformance with 3.4.2, the grader was tested to determine conformance with the dimensions and weight limitation for transport on break-bulk, RORO and barge-carrying ships.

2.4.3 Highway Transport Test. The grader was evaluated for compliance with 3.4.3. and tested to verify compliance with transportation dimensional requirements when transported on M870 series trailers. The grader was tested for agreement with the dimensions and weight limits of the U.S. and NATO countries highway legal limits for transport on military trailers.

2.4.4 Air Transportability Test. The grader was inspected and calculations provided for meeting the aircrafts shipping configurations. If the inspection or calculations show possible interference, the grader, with soldier participation (if available), shall be loaded, tied down, and unloaded in a C-130 aircraft.

2.5 Speed Requirements. The 120M Motor Grader has a maximum travel speed of 27.7 mph forward and 23.5 mph reverse.

2.6 Shipping Data Plate. Figure 2-7 shows the shipping data for the 120M Motor Grader Shipping Data Plate. The actual plate has a black background with aluminum colored lettering.

Figure 2-7. Shipping data

2.7 Crew Size. One soldier is needed to operate the 120M Motor Grader. Two soldiers are required to prepare for modes of transport where height reduction is needed.

2.8 Photographs.

Figure 2-8. 120M Motor Grader-Top Right

Figure 2-9. 120M Motor Grader-Top Left

Figure 2-10. 120M Motor Grader-Right Side

Figure 2-11. 120M Motor Grader-Left Side

2.9 Dimensional and Weight Data Sets.

2.9.1 Weights.

Without Armor With Armor o Machine (In Operation) 37600 lb 43600 lb o Machine (In Transport) 36500 lb 37040 lb o ROPS/FOPS 1100 lb 7300 lb

2.9.2 Drawings.

Figure 2-12. Grader dimensions

2.10 Lifting and Tiedown Provisions. The lifting and tiedown provisions on the 120M Motor Grader were designed to meet MIL-STD-209K.

2.10.1 Number, Location, and Strength.

Figure 2-13. Grader lift and tiedown provisions

Location (relative to centerline of vehicle and front tandem)

Provision No. Longitudinal Vertical Lateral A - Lift 2 229 in 41 in ± 8 in B - Tie down 2 236 in 24 in ± 8 in C - Aircraft Tie down 2 54.5 in 17 in ± 5.6 in D - Aircraft Tie down 2 162 in 47 in ± 9 in E - Lift 2 102 in 13 in ± 33.7 in F - Tie down 2 98 in 14 in ± 18.3 in G - Aircraft Tie down 2 108 in 15.4 in ± 36 in

Table 2-2. Grader lift and tie down provision information

Figure 2-14. Dimensions Defining the Location of the Lifting Provisions

Figure 2-15. ROPS/FOPS cab multi-purpose provisions

Location (Relative to ROPS/FOPS Rear Lift

Eye Centerline of Cab)

Provision No. Longitudinal Vertical Lateral A – Lift 2 72.24 0 8 in A – Tiedown 2 72.24 0 8 in B – Lift 2 0 0 28 in B – Tiedown 2 0 0 28 in

Table 2-3. ROPS/FOPS cab multi-purpose provision information

2.10.2 Dimensions. The dimensions of the lift and tiedown provisions can be seen in Table 2-4 below. The table uses Figure 2-16 for reference.

A MAX B MAX CL MIN CS MIN D MIN E MIN HEIGHT

Inch 1.72" 1.72" 12" 5" 3.5" 3.9" <72"

Front Lift 1.18 1.50 14.96 ∞ 3.54 7.87 64.80 Front Tie down 1.57 1.50 ∞ ∞ 3.54 4.41 48.58

Aircraft Tie down (front) 1.18 0.98 ∞ ∞ 2.99 3.54 71.46 Aircraft Tie down (rear) 1.18 0.98 ∞ ∞ 2.99 3.54 30.51

Rear Lift 1.57 1.50 ∞ ∞ 3.54 6.61 37.72 Rear Tie down 1.57 1.50 ∞ ∞ 3.50 5.00 36.85

ROPS/FOPS Cab Multi-Purpose (non armor 0.50 1.00 ∞ ∞ 3.00 TBD 44.2

ROPS/FOPS Cab Multi-Purpose (non armor TBD TBD ∞ ∞ 3.00 TBD TBD

Table 2-4. Lift and tiedown provision dimensions

Figure 2-16. Lift and tiedown provision dimensions

2.11 Projections. The 120M Motor Grader have no significant projections.

2.12 Additional Information.

2.12.1 Weight Rating.

• Gross Vehicle Weight Rating (GVWR) o 37600 lbs (without armor) o 43600 lbs (with armor)

2.12.2 Tires.

• Number 6

• Size 14.00R24

• Load Rating 8050 lbs @ 54 psi

• Locations Left Front

Right Front Left Rear qty (2) Right Rear qty (2)

• Inflation Pressure o Front 35 psi o Rear 45 psi

2.12.3 Axle Loads.

FRONT AXLE WT (LB) MID AXLE WT (LB) REAR AXLE WT (LB) TOTAL WT (LB)

VEH, CAB, Full Armor 13820 15360 15160 44340 VEH, CAB, No Armor 12000 12800 12800 37600 VEH, CAB removed, Partial Armor 11544 12832 12664 37040 VEH, CAB removed, No Armor 11650 12425 12425 36500

2.12.4 Maximum Axle Load Rating.

• Front (Static) 16312 lbs

• Rear (Static) 28378 lbs

2.12.5 Suspension Type and Rating

• Front Suspension Type Oscillating ±32°

• Rear Suspension Type Tandem Up 15°, Down 25°

• Front Suspension Rating N/A

• Rear Suspension Rating N/A

2.12.6 Crest Angle.

• φ 15°

Figure 2-17. Crest angle

2.12.7 Tire Footprint Area per Tire (See FIG 2-18)

• Front o 132.5 in2 (Gross) o 58.3 in2 (Net)

• Rear o 132.5 in2 (Gross) o 58.3 in2 (Net)

• F1 and R1 o 11.1 in

• F2 and R4 o 13.6 in

• R2 o 59.5 in

• F3 and R3 o 84.1 in

• WB

o 206 in

Figure 2-18. Tire footprint locations and dimensions

2.12.8 Axle Tracking Width (see FIG 2-19)

• F1 – Outside Distance 100 in

• F2 – Inside Distance 85 in

• F3 – Front Tire Width 14.7 in

• R1 – Outside Distance 101 in

• R2 – Inside Distance 85 in

• R3 – Rear Tire Width 14.7 in

Figure 2-19. Axle tracking width

2.12.9 Vehicle Turning Diameter.

• Wall-to-Wall 51.5 ft (15.7 m)

• Curb-to-Curb 49 ft (15m)