SS i aatlYn, ig oS 2011000971Z : “Mf oXS “halt CNAS L0138 No.: GGJ2.2012.MY04.02.170 ROPS&FOPS for crawler dozer Test Report Product Designation: 97 Name of Manufacturer: Zoomlion Heavy Industry Science and Technology Co., Ltd Type of Test: Performance Test 5 agohe Military THMEchnology AcademyAttention . Without the stamp on this report, it would be invalid . Without any signature of manager, verifier or approver, the report would be invalid. No copying without Lab. Permission. The copy of this report must be stamped again, otherwise it would be invalid. |. The report would be invalid if itis altered. .. The inspection results are responsible for the sample only, generally Test lab: ‘The Proving Ground for Construction Machinery & Military Refitting Trucks of Machinery Science and ‘Technology Academy Address: No.55, Dongwai Street, Yanging, Beijing, China Postcode: 102100 Tel 86-10-69141870 Complaint Tel.:86-10-69145748 Fax: 86 -10-69141870 ‘Name of Manufacturer: “Weinan branch, Zoomlion Heavy Industry Science and Technology Co.,Ltd. Address: West Section No.86, Chaoyang Street, High-tech Development Zone, Weinan, Shanxi (714000) Tels 86-913-2288909 Fax: 86-913-2288101 Legal representative: Zhan Chunxin L gy Entrusted unit: Zoomlion Heavy Industry Science and Technolog¥Co., Ltd. ‘Address: Zoomlion Science Park, Yinpen South Road 361, Changsha, Hunan (410013) j Tel.: 86-731-88923897 t Fax: 86-731-88807517 Legal representative: Zhan ChunxinContent ‘AL Sample appearance. A2 Specification of sample. A3 List of main identification ... ‘Annex B Test standards. ‘Annex C Test condition. ‘Cl Ambient temperature ae performance test.... D2 Location of DLV... D3 Machine ox ead esti‘The Proving Ground for Constuction Machin & Miliary Reiting No: GGJ2.2012.MY04,02.170 “Trucks of Machinery Scene and Technology Acaemy Test Report Page Lot 19 Product a Date of a Desteniaiod ROPS&FOPS for Crawler dozer ee 2012.06 Sample Type 97 ROPS&FOPS Nouber Name of _ | Weinan branch, Zoomlion Heavy Industry = Manufacturer_| Science and Technology Co., Ltd. DAR | Pet formance’ Test Entrustment “| Zoomlion Heavy Industry Science and |. oryaq | 2008.10.18~ Company _| Technology Co., Lid. es 2008.10.15 Testing Items Ability to resist the impact test of FOPS ; Lateral force resistance and energy absorption test of ROPS ; aries ISO Standards & Vertical load-carrying capacity Test of ; EN Standards ROPS According To | (See Annex ) Longitudinal force resistance Test of | ROPS. Test Conclusion 1. Energy imparted to the test object without causing penetration of any part of the FOPS structure into the DLV nor penetration of the FOPS by the test object 11600J. The ability to resist the impact of FOPS meets the requirement of level Il impact protection of ISO 3449:2005, 2. When the maximum lateral load force is 496.7KN and maximum lateral load energy is 78908.13, no portion of ROPS enters the DLV at any time during the lateral loading phases of the test. The Lateral force resistance and absorbed energy performance of ROPS meets the requirement of ISO 3471-2008, 3. When the vertical load force is 828.4KN, no portion of ROPS enters the DLV at any time during the vertical loading phases of the test. The vertical load-carrying capacity of ROPS meets the requirement of ISO 3471:2008, 4. When the longitudinal load force is 318.2KN, no portion of ROPS enters the DLV at any time during the longitudinal loading phases of the test. The longitudinal load-carrying capacity of ROPS meets the requirement of ISO 3471:2008, 5. The performance of bolts and nuts for ROPS&FOPS and bedplate is in accordance with ISO 898-1 and ISO 898-2. In conclusion, the minimum performance requiremeints uf ISO 3449:2005 and ISO 3471:2008 are met respectively in thi R crawler dozer with a maximum recommended mi Date of Issued: Note 1) Test From: Entrusted (5) Test results: See Annex D (2) Testsample: See Annex (6) Tester: See Annex E (3) Teststandards: SeeAnnexB (7) Testpictures: See Annex F (4) Test condition: See Annex C rove Ferg, wit As i AReThe Proving Ground or Constson Maher & Miliary Rfiting No: GGI2.2012. MY04.02.170 “Truss of Machina Scinne ad Tecnology Aca Test Report Page 2 0f 19 AnnexA Test sample ‘At Sample Appearance Bi a Picture A1-1 Sample Appearance Picture A1-2 Sample Appearance“The Proving Gund or Cosson Machina & Mitr Refine ‘No.: GG2.2012MY04.02.170 “Thc of Maher Seine Tabla Acad “Test Report Page 3 of 19 A2 Specification of sample 97 type Roll-over Protective Structures and Falling-object Protective Structures for crawler dozer is designed and built by Weinan branch, Zoomlion Heavy Industry Science and Technology Co., Ltd. by itself Before test, the ROPS&FOPS is atached to the machine frame as it would be on an operating machine. The representative specimen is secured to the bedplate so that the members connecting the assembly and bedplate experience minimal deflection during testing. The sample is, in a good state before test. ‘A3 List of main identification a crawler dozer ‘manufacturer inan branch, Zoomlion Heavy Industry Science and Technology Co. Ltd. machine [ Model Number 2320-3, 7220-3. ZD160-3. Serial number — Maximum recommended 42228 Machine frame part number ___| 2012076# Weinan branch, Zoomlion Heavy Industry eee Science and Technology C rors | Model 7 Serial number 20120834 OPS part number 20120834 ‘Weinan branch, Zoomlion Heavy Industry ete Science and Technology Co., Ltd. Fors | Model 7 aan 20T205F ROPS part number 20120834‘No: GGI2 2012 MYO4.02.170 Page 4 of 19 Annex B Test standards Earth-moving machinery — Falling-object protective structures — Laboratory tests and performance requirements 1803471:2008 _Earth-moving machinery — Roll-over protective structures — 1$0 3164;1995 _Earth-moving machinery — Laboratory evaluations of protective ISO 148-1:2006 Metallic materials — Charpy pendulum impact test (V-notch) — Part 1: Test method ISO 898-1:1999 “Mechanical properties of fasteners made of carbon steel and alloy steel —part I:bolts,screws and studs 180 898-2:1992 Mechanical properties of fasteners —part 2:nuts with specified ‘proof load values—Coarse thread| TheProving Ground for Consteton Machinery & Miltary Refiting No.: GG32.2012.MY04.02.170 “Tks of Machinery Scince and Tedhnology Acaeny Test Report Page $ of 19 Annex C_ Test condition C1 Ambient temperature during performance test ‘Test date _| Weather | Temperature, ‘C | Wind speed, m/s_| Wind direction 2012.06.27 | _ sunny 21~25 0 windless 2012.06.28 _| sunny 20~27 os South wind 2012.06.29 _| sunny | 21~28 10. South wind C2 Main measurement Next Measurement No| 1S : ‘Type Seria No | Accuracy | calibration 1 | Force Sensor BI sins o1 2012.11.29 Draw-wire 2 | Displacement | PT8S10-0025-121-1110 | L1706878A || —— | 2013.04.03 Sensor ‘Operator protective ae 3 es RTF1000-116 1% Charpy pendulum 4 | impact testing, 38-3005 2645 1 | 2013.04.20 ‘machine C3 Test site No. Test items “Test site 1 Ability to resist the impact test of FOPS ; ‘The Proving Ground for Construction 2 Lateral loading test of ROPS Machingy & Miltary Refiting A 3 ‘Trucks of Machinery Science and 3. | Vertical load-carrying capacity test of ROPS ag any 4 Longitudinal loading test of ROPS.‘The Proving Grund er Conran Machinery & Miliary Reiting ‘No: GGI2.2012.MV04,02.170 ‘Tiassa Scien and Acaley ‘Test Report Page 6 of 19 Annex D_ Test results D1 Check results of sample before test For the check results of sample before test, see table D1. Table DL (Check items ‘Cheek results type crawler dozer ‘manufacturer ‘Weinan branch, Zoomlion Heavy Industry Science and Technology Co., Ltd. Machine [Model Number 2D320-3,_ZD220-3._ ZD160-3. ‘Serial number = ‘Maximum recommended mass» kg | 42228 Machine frame part number 20120764 ‘manufacturer ‘Weinan branch, Zoomlion Heavy Industry Science and Technology Co., Ld Ropserors | Mode! 97 ‘Serial number. puiaviow ROPS part number 20120457 D2 Description of Deflection-limiting Volume (DLV) ‘That volume, related to the operator, which serves to set limits and deflections permissible when performing laboratory evaluation of operator protective guards. An approximation of a large, seated, male operator wearing normal clothing and a protective helmet according to ISO 3164:1995,See figure D1. The location of DLV in the ROPS&FOPS, see figure D2&D3. Figure DI _Deflection-limiting Volume|The Proving Grund er Consus Machinery & Mii Refiing No: GGI2.2012MY04, Tass Test Figure D2 The location of DLV Figure D3 The location of DLV D3 Machine or test bed condition ‘The ROPS&FOPS is attached to the machine frame as it would be on an operating machine, The ‘machine frame and mounted ROPS&FOPS test specimen represent the structural configuration of ‘an operating installation, including those portions of the frame that can absorb energy in a ‘machine roll-over. | The representative specimen is secured to the bedplate so that the members connecting the assembly and bedplate experience minimal deflection during testing. The representative specimen thas not received any support from the bedplate, other than that due to the intial attachment. The fixture arrangement does not inhibit possible machine frame deformation in the ROPS&FOPS“The Proving Gund Corstucton Machinery & Military Refiting No: 632.2012. MY06.02.170 “Trucks of Machin Scie and Technolgy Academy ‘Test Report Page 8 of 19 ‘mounting areas. The intent is that the energy be absorbed by the representative specimen and not by the fixture arrangement. The load distribution device can prevent local penetration of the ROPS. ‘members atthe load application point during loading phases of the test. D4 FOPS impact Test ‘According to ISO 3449:200S, the protective properties of the FOPS for crawler dozer is estimated by the ability of the cab or protective structure to resist impact. Level II impact protection is applicable to impact strength for protection from heavy falling objects (e.g. tees, rocks) for machines involved in site clearing, overhead demolition or forestry. In tis test, the manufacturer's maximum recommended mass of crawler dozer is 42228 kg. The DLY shall not be penetrated by ‘any part of the protective structure under the first or subsequent impacts of the test object at the ‘energy levels of 11600 J. The test object shall not penetrate through the FOPS. ‘The actual mass of drop test object is 326 kg and so we determine the drop height ratio necessary to obtain the required energy is 3.63 m. In this drop test, Place the test object on top of the FOPS, with the small end downwards for level II, at the impact location, The impact location shall touch, ‘or be within the vertical projection of, the uppermost plane area of the DLV. The first contact between the object and the FOPS is made by the small end of the drop test object. The drop test object is released so that it falls without restraint onto the FOPS and entirely within the determinate circle Figure D4 The impact location of FOPS before drop test Before drop test, the distance between the top end of the DLV and enclosure ceiling in transverse plane is 391 mm. After drop test, for the deflection of FOPS, see Figure DS. The distance between the top end of the DLV and enclosure ceiling in transverse plane is 385 mm. The Maximum remained deflection of top guard is 6 mm. The test object does't penetrate through the FOPS. The DLV is not penetrated by any part of FOPS.The Proving Ground for Consusion Machinery & Misr Refiting ‘No: GGI2.2012MY04.02.170 “Trusso Machinery See and Tecnology Academy Test Report Page 9 of 19 Figure DS The deflection of FOPS after drop test D6 Lateral loading Test According to ISO 3471:2008, the specific lateral force and lateral energy requirements of the ROPS for crawler dozer (The maximum recommended mass is 42228 kg) shall be met or exceeded in the testing of a single representative specimen. No part of the ROPS shall enter the DLV at any time during the lateral loading phases of the test. According to the formula 13000(—™)'** for the determination of lateral energy required and 70000 the formula 70000¢-<7)' for the determination of lateral force required, the lateral energy is 78694.4 and the lateral force is 394292.6N at least. Before loading test, the minimum distance between the DLV and the part of ROPS is 503mm. For the location of loading, see the Figure D6. The load force and energy is applied on the ROPS via the load distribution device by lateral loading cylinder. The load application point is on the same plane with the upper lateral cross-member. The initial direction of the loading is horizontal and perpendicular to a vertical plane through the machine longitudinal centerline. As loading continues, representative specimen deformations can cause the direction of loading to change. This is permissible. The force and energy requirements, under lateral loading need not be attainable simultaneously. One may be significantly exceeded before the other is attained. If the force is attained before the energy, the force may decrease but shall again attain the required level when the lateral energy requirement is met or exceeded. The loading is to continue until the specific force and energy levels have been reachedThe Proving Ground or Gaston Machina & Miliary Refiting Truds of Machinery Simee and Technology Aca Test Report Figure D6 The location of lateral loading test of ROPS No: GGI2.2012. MY04.02.170 Page 10 of 19 For the test data and curve of force-deflection during the lateral loading test, see table D2 and figure D7 and D8, ‘Table D2 _ the test data of the lateral loading test Load force, kN of 497s 2428] 607] 758] 947 Deflection, mm 0 3 10 14 19 24 28 33 Load energy, J of _i27|_s22{_ i287 2ei9[ siza| so7i| 1206.1 Loadforce, IN| 114] 1346] 1564] 1804] 2003] 2251 | 248.7] 270.7 Deflection, mm 37 41 46 50 34 39 a 7 Load energy, 3| 1667.1| 22114] 2876| 35652| 43922[ 5335.1 | 62553 73893 Load force, KN] 2933[ 3145] 3344] 350.7] 363| 3707[ 3773833, Deflection, mm 7 5 81 87 2 95 99] 105 Load energy, 1 | 8589.4 | 9777.8 | 11167.5 | 126092 | 4058.8 | 151594 | 166548 | 199359 Load force, EN] 3894| 3944] 4003| 4054] 4113] 4182] 4274[ 435.2 Deflection, mm| _1i| _1i6[ u9| _iz2| 12632] 39 | tae Load energy, | 21254.1 | 23213.5 | 24405.5 | 256140 | 27247.4 | 29735.9 | 326954 | 34851.7 Loadforce, KN| 4429 a49a| 4523| 4543 4564| 457.7| 4603] 4634 Deflection, mm| 150| 156[ 162[ t66| 173179 tea | 187 Load energy, J | 374859 | 40162.6 | 42867.7 | 4680.9 | 47868.3 | 506106 | 51987.6 | 54296.9 Load force, EN] 4664 4705] 4741| 4793] 4835] 4853] 4873 489.6 Deflection, mm| _191| _196| 202| 206] 2] 2i4[ 2i7[ 220 Load energy, J | 561565 | 58498.7 | 613325 | 632393 | 656463 | 67099.5 | 685584 | 70512.2 Loadforee, KN| 4923] 4942[ 4956[ 4967[ ——| ——-| ——[ — Deflection, mm| __225| _229| 234| 23a| ——| —-| ——| —— Load energy, 3 | 72476.0 | 74449. | 769235 | 7as081 [| ——| | —‘The Proving Ground for Consouton Machinery & Miliary Refiing “Trucs Scie ‘Test Figure D8 Energy-force curve of lateral loading test From the above table and curves, we know the maximum lateral load force is 496.7KN and ‘maximum lateral load energy is 78908.1J. After test, the distance between the part of ROPS and ‘the lateral nearest part of DLV is 413mm. No part of ROPS enters the DLV and the ROPS does not break away from the machine frame.The Pring Ground fer Consbuson Machinery & Mitr Refiting 2.2012 MY04.02.170 “Trucks of Machinay Seca and Te Page 12 of 19 Figure D9 The lateral loading test Figure D10 The lateral loading test D6 Vertical loading test According to ISO 3471:2008, the specific vertical force requirements of the ROPS for crawler dozer (The maximum recommended mass is 42228 kg) shall be met or exceeded in the testing of a single representative specimen. No part of the ROPS shall enter the DLV at any time during the vertical loading phases of the tes. ‘According to the formula 19.61M (M is the maximum recommended mass) for the determination of vertical force required, the vertical force is 828091N at least. Before loading test, the minimum vertical distance between the DLV and the part of ROPS is 155mm, After completion of the lateral loading, a vertical load is applied to the top of the ROPS. The centre of the vertical load is applied in the same vertical plane, perpendicular to the longitudinal‘The Proving Grand ir Cosbuson Machina & Mitr Refiting No.: GGI2.2012.M¥04.02.170 “Tiuks of Machin Sine and Tanai Aealemy Test Report Page 13 of 19 ‘centreline of the ROPS structure, asthe lateral load of defined on the structure before deformation. For the location of loading, see the Figure D1. The load force is applied on the ROPS via the load distribution device by vertical loading cylinder. The loading is to continue until the specific force has been reached, Figure DIl__ The loading location before vertical loading test For the test data and curve of force-deflection during the vertical loading test, see table D3 and figure D12. Table D3 vertical loading test data Load ead oe KN 12 Load [esters 38 29.8 Load force, i Gn Load =e 1723 [Haat ree. aX [a7 } OG] 3574Trove Grund fa Cenason Machinery & Miia Rfiting No: 66322012. MY04.02.170 TrudsofMachinay Scinceand Tako Acalemy Test Report Page 14 0f 19 force,kN uo SS eece-t i800 }r00 |__| eal |e00 - ‘soo - lau 300 3500 4000 4500 5000 x08 PROPS during vertical loading test From the table and figure, Vertical loading force is 828.4KN which have exceeded vertical force require Toading test, the mit portion of ROPS and the part of DEV INo part of the ROPS enters the DLV during the loading phase of the test. See fi Figure D12 mum distance between t Figure D13 the vertical loading test of ROPS D7 Longitudinal loading Test According to ISO 347122008, the speeifi longitudinal force requirements of the ROPS for crawler dozer (The maximum reeommended mass is 42228 kg) shall be met or exceeded in the testing of a{he Pony Croera tir Const Machinery & Military Refiting No: GGI2,2012.Mv04.02.170 Tihs of Machina inne and Technology Acide Test Report Page 15 of 19 single representative specimen. No part of the ROPS shall enter the DLV at any time during the longitudinal loading phases of the test. ‘cording to the formula e000 My MMT He maximum recommended mass) for the determination of longitudinal foree requited, the longitudinal force is 315434 N at least. Before loading test, the minimum longitudinal distance between the DLV and the part of ROPS is. 409mm. After completion of the vertical loading, a fongitudinal Yoad shall be applied to the ROPS. The longitudinal load is applied to the Upper structural members of the ROPS along the longitudinal centreline of the ROPS. For the location of loading, see the Figure DIA, The load force is applied on the ROPS via the load distribution device by longitudinal loading eylinder: The Toading is to continue until the specific force has been reached Figure Dif the loading location of longitudinal test For the test data and eurve of foree-defleetion during the longitudinal loading test, see table D4 and figure DIS, Table D4 the longitudinal loading test data of ROPS Load force, KN | OSmjmsmepeto? | 159 | 212 | 27.5 Deflection, mm o 4 7 9 12 14 Load forces KN 50.9 58.7 66.8 75.3 2. 1014 | 110.3 Deflection, mm, 2alieeae2? | 30 35 7 [40 Load force, KN Tigo ereiars | 147.2 | 157.0 | 167.0 | 177.5 | 188.8 Deflection, mm a2 | 4 | 47 | Al 54 36 | 38 Load force, kN) 200@uluamamnfeaaza | 233.1 | 244.3 | 255.3 | 2654 | 282.8 Deflection, mm oa | @ | 6 | 67 Load forces KN | 295 | 308 | 3034 | 3045 Deflection, mm. 7% | a | «2 | %“TheProvng Ground for Consbuson Machinery & Mii Refiting No: GGI2.2012.MY04.02.170 “Tis of Mahinery Scene nd Tetnclgy Acakany Test Report Page 16 of 19 ar —— | tore force-deflection | 350 eB |00 20 200 30 100 | deflectionsmm Figure DIS Force-deflection curve of ROPS during longitudinal loading test From the table and figure, we know the maximum longitudinal loading force is 318.2 KN which have exceeded longitudinal force required. ‘The minimum longitudinal distance between the portion of the ROPS and the part of DLV is 343mm, No part of the ROPS enters the DLV. See figure D16. Figure D16 the longitudinal loading test of ROPS.“The Proving Grond for Conston Machinery & Mii Refiing No: GG32.2012MY4.02.170 ‘Truss of Machin Scene an Tecnology Academy TestReport Page 17 of 19 D8 Temperature and material The test was performed with the ROPS&FOPS for crawler dozer and machine frame members soakedto 23 0. The temperature is over -18°C.The Charpy V-notch impact strength requirements for the ROPS&FOPS for crawler dozer structural metallic members were tested on a specimen size 10 mm * 7.5 mm (required impact energy at least is 241 at-20°C) ‘The absorbed energy was: 31.620°C) ‘Nut property class: M27%3-10-2n,D. Bolt property class: _M27x3x201210,.9The Proving Geound for Cosson Machinery & Miliary Refiting No: GGI2.2012MY04.02.170 “Truck Machinry Science ane Technology Acar ‘Test Report Page 18 of 19 Annex E Tester and participants ‘The Proving Ground for Construction Machinery & Military Refitting Trucks of the Ministry of Machinery Industry: {i jun, Xu Wei, Wang Jiongyu, Hu Ze, Zheng lijao, ‘Weinan branch, Zoomtion Heavy Industry Science and Technology Co., Ltd.: Wang Kuan!‘The Proving Ground fr Corton Maher & Miliary Refi, No: GGI2.2012.MY04.02.170 Truk of Machina Seine ni Techno Academy Test Report Page 19 of 19 Annex F Test pictures Pic. F-I lateral loading test of ROPS. Pic. F-2 vertical loading test of ROPS