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AD: ICOSTECH REPORT 70-4

FEBRUARY 1970

COST & TECHNICAL INFORMATION REPORT

M520, (GOER) 8 TON TRUCK SYSTEM

James Morvison

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COST' ANALYSIS DIVISIONCOMPTROLLER & DIRECTOR OF PROGRAMSU.S. ARMY TANK-AUTOMOTIVE COMMAND

SWARREN, MICHIGAN 48090 B ,•oT

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COSTECH RFPORT YO-4

M520 (GOER) 6 TON TRUCK SYSTE COST ANDTECHNICAL INFOR.]ATION REPORT

JAMES MORRISON

U. S. ARMY TANK-AUTOMOTIVE COMMAND

FEBRUARY 1)70

COST ANiALYSIS DIVISION

COMPTRLT.TER ;"4i) DIRECTOR OF PROGRAMSU. S. ARMY TANK-AUTOMOTIVE COMI 1 A8ND

WARREN, MICHIGAN 48COM

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TABLE OF CONTENTS

Abstract i

List of Figures and Tables ii

I Introduction 1

II System Description 2

III System History 7

IV Development Ccsts and Analysis 9

V Investment Costs and Analysis 13

VI Operating Costs i6

VII Financial Surmmary 18

VIII References 19

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ABSTRACT

This r.sLsummakrizes the system history and theAeveiepiw iii~testu-enL,, an perating, costs of the HJ-~ih

M~hi it.> (a0ER) vehicles. Development of these vehicles,ca.1i'M 4ziie (G~')uccurreu fromn ]jA'O to 1965. The M520,

10-T !c CatJ , Truck., anll,- 1:59 GOLR Tanker werety~~~-Ž (~2:; Sl~TD-A) i t May - o The XM'933ý, 10-Ton

- Wrckeris :scheduled 1>ýýr t.Ype clas 1' icatior" FY 1970,.

Tii(@ý. veiiicies are in the final phase AdvanceProduc,ý; r. £: nŽrv;this is presently being doneunde.-r th -dvianco Pr'duczjion E-n;i neeri ng Cc;ntzract priorr,ýŽa uh,"I12J procuremen~t of hseve~hicles in FY 1971.

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LIST OF TABLES AND FIGURES

Figures I Truck, Cargo, 8-Ton, 4x14, XY52OEI 4

II Technical Characteristics 5

Tables i Actual 14520 Development CostR&D Phase 10

II STEC PLOT: M520 (GOER FAMILY) 1i

III M520 (GOER) STEC Plot 12

IV M520 Investaent Non-RecurringCosts 15

V M520 Investment Recurring Costs 15

VI Operating Cost Factors (Estimated) 17

VII Financial Summary 18

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I. INTRODUCTION

The objective of this report is to present the develop-ment, investment and operating costs associated with the8-Ton Cargo Truck, M520 GOER family of vehicles.

Costs for this study are derived from prior RDT&E con-tracts, Technical Development Plans and the Program MasterPlan at Product Manager, W520 Office, USATACOM.

Hardware estimates are taken from the December 1969GOER Cost Study conducted at USATACOM.

The M520 vehicle is not in production and the operatingcosts utilized are from the REVAL WHEELS Cost Study. Thissource is used to provide operating cost estimates on theM520 vehicle.

A requirement exists to provide combat areas and support-ing units with wheeled vehicles of vastly improved groundmobility and logistical support for combat operations. Theobjective of this project is to provide wheeled vehicles witha degree of cross-country mobility for tactical and logisti-cal support elements commensurate with the future concept ofwidely dispersed operations.

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II. SYSTEm4 DESCRIPTION

The origin of the GOER concept dates back to mid-195 4 .In general, this concept involved a vehicle or family ofvehicles, which possessed all terrain all weather perform-ance possibili •ies.

From mid-1954 through late 1958 several "evolutions"took place. A 5- 'on Cargo Unit was built, tested and a15-Ton Vehicle was studied. Then, in 1959 a 16-Ton GOERfamily was brought into existence, followed by an 8-TonFamily in early 1960.

The concept 8-Ton Vehicle exemplified the followinginitial ideas: Large diameter, low pressure tires, positivearticulated steering, exoskeletal body frames, mechanicalsimplicity achieved through elimination of complex suspen-sion systems, vastly improved ratios of payload to - grossweight.

The M520 Vehicle is an 8-Ton payload rated four-by-fourall-welded steel cargo truck consisting of the prime mover(cab) and cargo trail unit. The vehicle is powered by a six-cylinder liquid cooled diesel engine, driving through apower shift transmission, transfer gears, limited-slip dif-ferentials and planetary final drives. The transmissionprovides six forward speeds and one reverse speed, =anuallyselected by the operator.

Front and rear wheels are engine driven thrcugbh limitedslip differentials. An oil disconnect clutch is provided fcrthe rear wheel drive. A positive powered, wagon-type steer-ing is used with the 8-Ton GOERS. With this type of steering,the front wheels do not turn in relation to the front axle.SteerinS is by means of two double acting hydraulic cylinders,with one end of each cylinder attached to the power unit andthe other to the hitch.

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The vehicle is designed for use over all types of roads,highways and cross-country terrain, it possesses a swimmingcapability, and is air transportable. The vehicle does notuse a suspension system and is dependent solely on largetires as a suspension.

During the testing of the first 8-Ton cargo prototypes,more evolutions took place. Two different transmissionswere tested and evaluated. Because of simplicity and rugged-ness, the Caterpillar built power shift transmission wasselected.

The Caterpillar D333 Engine became the power plant ofthe 8-Ton GOER Family.

Utilizing the same principles and power train as thefirst 8-Ton Cargo vehicles the 10-Ton GOER wreckers emergedin April 1963 followed by the 2500 Gallon GOER tankers inOctober 1963.

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FIGURE ITCARGO TRUCK, M520

14559 5FJE,, XM'13 WRECKER'Tf mHNTCAT CHARACTERISTICS

M520 M39 XMSr3

Clirb Weight 23,500 lbs 27,590 lbs 38,220 lbn

Dimensions

Overall Length 385 in 391.2 in hOl.3 inHeight 132 in 132 in 132 inRediieiable Height 97 in ?7 in 118 inWidth 108 in 108 in 108 inWi>-ee Base 235 in 235 in 235 inGrolnd Clearance at

Axles 23.3 in 23.3 in 23.3 inGround Clearance at

Midship 30.1 in 30.1 in 30.1 inAngle of Approach 35' 350 350Angle of Departure 410 330 3h°

Engine Transmission Transfer Case

D333 B Engine, Diesel Cqterpillar 6 speed Single Speed6 cy! 4n line Powershift with Integral with525 cu in Displ tPraue converter TransmissionFY213 (Gross BHP)

Perfoormance Characteristics

Max Speed 30.2 MPHFuel Capacity 110 GALFuel Consumrtion 2.13 MPG AVG

Suspension System - Large Tires act as the suspension.

Brakes - Mechanical, on Tran,•mission Case

StePring - L',draulic w/echanical follow-up.

Tires - 7.900 x 33 10 ply tubeless

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FIGURE, TI

TEC-TNICAL CHIARACTERTSTICS(contimied)

glcctrical Sirstem - 2hV 100 AMP

Body T,-re - Medium and High strength Steel.

Crew Space - 2

Fording Depth -

Buoyant at approximately 70 inches with full loadswiming speed 3 MPH.

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III. SYSTEIM HISTORY

In June 1960, Caterpillar Tractor Co., Peoria, Illinoiswas awarded Contract DA-ll-022-ORD-3491 to design, develop,and fabricate the 8-Ton GOER Vehicle. In August 1961, thefirst tw) 8-Ton GOER Units were shipped to Aberdeen ProvingGrounds for test evaluation. Six additional cargo unitswere subsequently built and successfully tested. A proto-type acceptance meeting was held in Peoria, Illinois in July1961.

After reviewing several Caterpillar proposals, USATACOMestablished the basic configuration using an all mechanicaldrive to the power unit wheels and a mechanical assist to therear wheels in the form of a clutch controlled drive shaftgoing Throjugh the articulatiozi hitch. The steering was limit-ed to 00 degrees both right and left.

In Autgust 1961, a decision was made to equip six cargovehicles with a hydraulically actuated planetary-gear trans-mission with torque converter; and two cargo units with aconventional truck type, constant mesh spin-gear transmrission.

The Caterpillar D333 basic engine was selected for usein all vehicles. Performance evaluation of the first twotest vehicles with different transmissions was begun atAberdeen Proving Grounds in August 1"461.

In June 1962, a meeting was held in Peoria to discussdes.•ign and component selection of the second confij_-;uratLýn,the 10-Ton Wrecker, which would become a paert of the i-TonGC2 FamiL-y. It was decided that the basic powe;- unit andPower train with the pianetry tcrque converter transmIssionoaf khe iniial ,-Ton Cargo version -ouia he "tilized in thei0-Ton Wrecker. A Review Point meetine, was held in ?ý'oria anithe Wrecktcr demonstrated in April 1963.

The design and conf~iguration of the third versicn .f the8-T.,n GOG, Family, the 2500-fgllon tanker was discussed ata meetig,, in Auu'st 1963.

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The cargo basic power unit and power train with planetary-torque converter transmission was also utilized in the 2500-gallon tanker. The bulk-fuel tank trailer and all dispensingequipment was designed to specification contained in RDPD 60-31E.The vehicle was built and demonstrated in October 1963 - eight8-Ton Cargo Units, two 10-Ton Wreckers, and two 2500-gallonTankers were built and underwent engineering and service tests.Test sites included extreme environmental conditions, rangingfrom Alaska to Panama.

In May 1963, Caterpillar was awarded a contract to build23 updated versions of the three models in the 8-Ton GOERFamily. These units were shipped to the Seventh Army in West

Germany for troop-test in April 19 64, to prove their reliability,durability and maintainability.

In May 1965, one of each model Cargo, Tanker and Wreckerwere returned from Germany to Caterpillar Tractor to be reworkedin order to incorporate the latest design changes and/or cor-rections prior to confirmatory testing at Fort Knox subsequentto type classification as STD-A.

In February 1966, USATACOM was directed to ship all thelatest hardware versions of the GOER Family to S.E.A. for ser-vice used by our troops in the theatre.

In March 1966, Caterpillar T-actor was awarded Contractfl\-20-113-AMC-09867, wherein the 'amily concepts were to beengineered into a competitive production package. The AdvanceProduction Engineering provided for conversion of the develop-ment drawings to military format and create the required techni-cal data, quality control provisions, and inspection aids toenable competitive procurement and mass production of the products.

This project required to fabricate ten pre-production proto-types; three each, M559 and M520 and four each, XM553. Therewere no major difficulties encountered in R&D prototypes whichhad to be resolved in the pre-production prototypes. The itemscovered by the project are: Truck Wrecker, l0-Ton,lsx4, XM553(Code "B"); Truck, Cargo, 8-Ton, 4x4, M52O (Code "A"); Truck,Tank, Fuel Servicing, 2500-gallon, 4x4, 14559 (Code "A").

IV. DEVELOPMFENT COSTS AND ANALYSIS

On 29 June 1960, a development contract DA-11-022-ORD-3491was awarded to Caterpillar Tractor Co., Peoria, Illinois in theamount of $363,000.

The contract was for services and property required forthe design, development, fabrication, and test support of oneprototype and seven pilot models of the Truck, Cargo Logistical,High Mobility, 8-Ton, 4x4, XM520E1.

The Engineering work was to be accomplished in ten phases,beginning with concept study and investigation to determinethe basic components and configuration and completed with Phase

X; the Modification and Drawing Revisions.

There were a total of 18 modifications to the basic cor

tract. The cost increases to the RDT&E contract were the re-sult of increasing the number of pilot vehicles built to twelve8-Ton GOER vehicles: eight 8-Ton Cargo Units (XM520), twolO-TonWreckers (XM553), and two 2500-gallon Tankers (XM559).

Other modifications were to include the design, develcp-ment and fabrication of arctic kits for application on the

XM520E1 and front mounted winch kit for application on theXM520El Vehicle.

All R&D-activities on the GOER Vehicles were completed inthe 2nd Quarter, FY 1965.

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TABL-' I

ACTUtNL M3520 jEVELOPMENT COST

DESC.UIP'IOi§J cum

FY C~ ~OKTOTAL TOTML

_ j". prent &363,000 363,000

71, , ;0 0 0 441,000

"351,000 9ý)2, 000

~G3111,000 1,103,000

*144,613 1,247,613

33,3310 1,2~30,923

'(OTAL R&D C.OSTS 1,2480,!?23 1,23SO,L-23

* zjj~~ rD itýi Sticctz fr::Om Ri)DT&Z, Pr.uJcct GOER ProjectNo. 1J)543'00uL402

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In October of 1962, the contractor was requested to submita proposal on the basis of a cost-plus-fixed-fee type contractto initiate Phase I (Troop Test) of the Advance Production En-gineering on the GOER program.

This contract was to run concurrent with the R&D contractas a coordinate phase of R&D effort with the Advance ProductionEngineering.

In May 1963, Contract DA-11-022-AmC-409(T) was awarded toCaterpillar Tractor Company in the amount of $2.7 million toproceed on Phase I of the Advance Production Engineering of theGOER Vehicles.

The basic contract-scope required the contractor to performengineering services as required for 13 each Cargo M520; 8 eachTanker M559; 2 each Truck Wrecker XM553; accessories (tools,manuals, spare parts, 23 Slave Cable Kits, 23 Power Unit WinchKits and modifications as directed by USATACOM).

There we: e a t- al of forty modifications to ContractDA-11-O22-AMC-4O9(T), with the largest cost increase to coverEngineering Test-Service Tests in Europe and S.E.A.

The abcve tests costs provided for technical representativesto USATACOM and USARJEU and S.E.A.; together with OME, more repairparts and changes in scope of work.

Troop tests for the 8-Ton GOER Vehicle Family were conductedin Europe from 15 May 1964 to 15 February 1965.

GOER type vehicles were mixed with stanard vehicles to pro-vide a basis for comparison. During June 1966 ten 8-Ton Cargo,six 2500-gallon Tanker and cne 10-Ton Wrecker were inspected andrepaired and shipped to South Vietnam to form a GOER provizionalcompany for tests in S.E.A. areas.

In Ma•y 1966, the M520, 8-Ton GOER Cargo Truck, and the )659,2500-gallon GOER Tanker were type classified as Standard (STD-A).

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C ritract DA-11-022-AMC-W4O(T) was ermiplezed ý.' i'eerI5 with a total value of $3.583 million.

In March 196b, a cost-plus-fixed-fee .ontract, DA-20-13-AMC-006)87(T) was consummated with Caterpillar Tractor Company to con-tinue Advance Production En~rineering on the GOER Vehicles.

Advance Production Engineering was to provide for conversionof the developmental drawings to military format and create re-quired technical data, i.e., quality control, provisions and in-spection aids to enable competitive procurement and mass pro-duction of the products essential for the fabrication o: pre-production pritotypes.

This project required the contrac-"r t; fabricate ten pre-production prototypes; three each, M520; three each. M559; and fý.ureach. XMQ153. There were no major difficultieS enc-untered in R&Dprototypes which had to be resolved in the pre-pro.ducticn prztotypes.

As of January 1970, a total of forty-seven modifications havebeen added to APE Contract aA-20-II3-AFC-09,67(T) which br=ught thetotal contract value to $6.o37 million. Most of the cost increaseswere t,) incorporate all design changes made to the ori;inal 23 GOERVehicles which were tested in USAREUR and made product improvementsto an additional ten pilot vehicles.

The APE contract on the GOEM program has not been completed andis to continue through the 4th Q~uarter of FY 1970.

In Arril I~o, a Product Improve.ent Project was initiated to

investigate other Engine/Transmission alternates for adaptation in

the GOER with the intent of reducing weight and to eliminate pro-an• .. arT .n.•ine. aý.d Transmission. which are currently being used inthe GOER Vehicles. The total investment in the prz-ect was $2.0'million shown in Table IV.

The GOER Vehicles are not in production, but an LGATACOM in-hrosehardware estimate was made for a protected procurement in FY70. TheGOEM hardware estimates assumed a multi-year procure-ment of 1300 ve-hicles consisting of 607 Cargo, 371 Tanker ard 122 Wrecker Vehicleswith production in yearly quantities of 100, 40O, LOO and 400. Theestimated manufacturint costs are shj:wn on Table V.

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VI. OPERATING COSTS

'able VI provides the operating costs estimates bycost categories and cost data references. These factorshave been derived from REVAL WHEELS cost studies.

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TABLE VI

OPERATING COST FACTORS (ESTIMATED)

POL $187/veh/yr

Maintenance Pcr-onncl 180/veh/yr

Depot Ovohac 12

Total Ena Itcm $17,540

Engine 2,200

Transmission 990

Crew3 - 2 men (E4) $2,164/veh/yr

Repair Parts 4 6.39% x hardware cost/veh/yr

4Repair Parts Transportation $ 73/veh/yr

Line Item Management 5 $453,241

Operating Factors

Estimate useful life of ea.unit 12 years

Average miles per year 4,000

COURCE:

AMC REVAL WHEELS Update, 13 May 1969 with maintenance personnelpay rate adjustment of $3.22/hr (DA Comptroller, Cost AnalysisData)

2 TACOM REVAL WHEELS Update, 13 February 1969.

3 FY70 Army Audit Agency pay rate of $5.41/yr for driver (200operating hrs per year - AMC REVAL WHEELS Update, 13 May 1969.

4 AMC REVAL 'WHEELS update, 10 March 1969.

155AMC REVAL WHEELS Update, 13 May 1969 with Federal pay raiseadjustment of 8.9%.

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VIII REF'E{NC ZIES

1. RDT&E Project No. O5'310006D4O2 (GOER ,rc!iC -Lz,).

2. Contract DA-11-O22-ORD-3h91 Development Ccontractwith Caterpillar Tractor Compary.

3. Project Management Master Plan (PM2P) for (GOFR)Trucks.

4. Technical Development Plan Trucks, :Iigh Mobility

(GOER) 4xh, January 1969.

5. USATACOM Project h4712 APE (GOER).

6. USATACOM Project h4232 (Alternate Engine Progrm).

7. Advance Production Engineering Contracts DA-1-C22-A1C-h09(T), DA-20-U3-A,•C-o9867(T).

8. "REVAL WHEELS" cost studies data - February, Marchand May 1969.

9. GOER Production Cost Analysis Report USATACC*,dated 12 December 1969.

10. "'Macrobehavior of Development Costs and Estimates(STEC PLOTS)" Unclassified, Major Horace Schow If.Technical Report 68-2, Systems and Cost AnalysisDivision, HQ, USAMC, September 1968, AD674653.

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