Up-Armored HMMWV CASEVAC Conversion Kit (UAH-CCK)

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Beatrice Morton
6 years ago
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1 M1114

2 Up-Armored HMMWV CASEVAC Conversion Kit (UAH-CCK) Operation Performance Measures Place CCK Into Operation

3 Task: Conditions & Standard (1) Given one UAH with CCK installed and stored. (2) Two trained crewmembers, working as a team, must reconfigure the UAH from standard mission profile configuration to be ready to receive an attendant and one litter casualty. (3) The two crewmembers must complete the conversion engaging all components and safety features correctly. (4) The complete conversion must take less than two minutes. NOTE: Crewmembers wearing full ITO prescribed PPE

4 Use of Gunners Position while in CASEVAC Mode SAFETY: Gunners Position is NOT usable, either seated or standing. Do Not Traverse turret, as doing so will cause damage to the CCK, the turret, and possibly the gunner.

5 Ready All four doors are closed The gun turret is oriented to the vehicles 12 o clock NOTE: The driver will be at their station at all times they do not assist with the conversion Crewmembers designated as: Soldier One will be positioned outside of the vehicle commanders door Soldier Two will be positioned outside of the driver side rear door

6 Soldier One Task Set One Open Commanders door Place seat belt harness to an location that is easy to reach (view 1). View 1 CAUTION: Lifting the near side of the seat higher than 2 while the opposite side is still engaged may result in failure of the conversion kit. Only lift the seat enough to clear the detent pin and the lower seat plate (view 2). View 2 NOTE: Unless otherwise specified, Soldier One and Soldier Two perform steps simultaneously

Soldier One Task Set One Convert Commanders seat into attendant seat.

Grasp, lift and remove Commanders seat (view 2) see caution above. Rotate seat the reverse position (view 3).

bottom plate aligning the locking pin with the pin hole (view 4).

Release the detent pen, locking the seat in place (view 5).

7 Soldier One Task Set One Convert Commanders seat into attendant seat. Pull the detent ring and lock the retaining pin in the out position (view 1). Grasp, lift and remove Commanders seat (view 2) see caution above. Rotate seat the reverse position (view 3). Guide the flat edge of the top plate into the receiving lip of the lower plate and firmly seat the top plate into the bottom plate aligning the locking pin with the pin hole (view 4). This may require pushing the seat towards the rear and center console simultaneously. Release the detent pen, locking the seat in place (view 5). Grasp the retractor and seat belt anchor and secure the seat belt (view 6). Install seat cushion p/n between new seatback and dashboard looping the attached elastic straps around the seatback. Close commanders door and moves to passengers side rear door View 1 View 2 View 3 View 4 View 5 View 6 NOTE: Unless otherwise specified, Soldier One and Soldier Two perform steps simultaneously

Soldier Two Task Set One Open the driver side

Remove litter support chain from storage bag

Connects hook into the lower connection bracket

Removes cable from bag and untangles and waits

Waits for Soldier One to complete task set two.

8 Soldier Two Task Set One Open the driver side rear door. Remove litter support chain from storage bag (view 1) and untangle as needed. Connects hook into the lower connection bracket (view 2 & 3). Release cable tensioner (view 4). Removes cable from bag and untangles and waits for Soldier one (view 5 & 6). Waits for Soldier One to complete task set two. View 1 View 3 View 5 View 2 View 4 View 6 NOTE: Unless otherwise specified, Soldier One and Soldier Two perform steps simultaneously

Soldier One Task Set Two Open the rear passenger side door

(Note - A cotter pin is shown in the views but a detent pin

kit.) Place the detent pin back in the door strap bracket,

Remove litter support chain from storage bag (view 3) and

Connects hooks into the lower connection bracket (view 4 &

9 Soldier One Task Set Two Open the rear passenger side door Remove the detent pin to release the door strap (view 1) (Note - A cotter pin is shown in the views but a detent pin or square retainer pin may alternately be provided with the kit.) Place the detent pin back in the door strap bracket, leaving the door strap free (view 2). Remove litter support chain from storage bag (view 3) and untangle as needed. Connects hooks into the lower connection bracket (view 4 & 5). Release the right side quick release on the gunners seat (view 6) and wait for Soldier Two. View 1 View 3 View 5 View 2 View 2 View 4 View 4 View View 6 6 NOTE: Unless otherwise specified, Soldier One and Soldier Two perform steps simultaneously

Soldier Two Task Set Two Release the quick release on

Waits for Soldier One to complete Task Set Three.

10 Soldier Two Task Set Two Release the quick release on the gunners seat (view 1). Store gunners seat on floor board (view 2). Hand litter assist cable to Soldier one (view 3). Waits for Soldier One to complete Task Set Three. View 1 View 2 NOTE: Unless otherwise specified, Soldier One and Soldier Two perform steps simultaneously View 3

Soldier One Task Set Three Attaches the litter

View 1 View 2 NOTE: Unless otherwise specified,

11 Soldier One Task Set Three Attaches the litter assist cable to anchor point (view 1 & 2). Positions trolley closest to rear passenger door (view 3) Stands by to assist of loading casualty View 1 View 2 NOTE: Unless otherwise specified, Soldier One and Soldier Two perform steps simultaneously View 3

loading the casualty View 1 View 2 NOTE: Unless otherwise

12 Soldier Two Task Set Three Tightens the cable by closing and locking the cable tensioner (view 1 & 2) Stands by to assist loading the casualty View 1 View 2 NOTE: Unless otherwise specified, Soldier One and Soldier Two perform steps simultaneously

13 Up-Armored HMMWV CASEVAC Conversion Kit (UAH-CCK) Operation Performance Measures Load and Unload a Litter Casualty

14 Task: Conditions & Standard (1) Given one UAH with CCK ready to receive one litter casualty, and one casualty that has had all life threatening wounds stabilized, and has been properly secured on a UAH modified litter (2) All Soldiers involved in the task are familiar and trained in this Battle Drill. Soldier designations: Attendant, Litter bearer one, litter bearer two, litter bearer three, and far side assist (Soldier Two from UAH-CCK Conversion). (3) The crew will ensure that the attendant and casualty are completely loaded and all safety mechanisms are engaged. (4) The entire loading sequence will be completed in less than two minutes. NOTE: Crewmembers wearing full ITO prescribed PPE

15 Ready The CCK is ready to receive a litter and both rear doors are open. The prepared casualty is located in defilade 10 meters from the UAH, with their feet oriented toward the platform NOTE: The driver will be at their station at all times they do not assist with the conversion Crewmembers designated as: Litter Bearer One will be positioned at the left shoulder of the casualty Litter Bearer Two will be positioned at the right shoulder of the casualty Litter Bearer Three / Attendant will be positioned at the right foot of the casualty Litter Bearer Four will be positioned at the left foot of the casualty Far Side Assistant will be positioned at the driver side rear door facing the center of the vehicle This is /should be the same Soldier that performed Soldier Two duties during configuration

Step One: Move Casualty and Load Attendant Litter bound casualty is

rear door of the UAH NOTE: The designated attendant should be located

person litter carry (view 2) Designated attendant moves from his

3), sits in the attendant seat, secures the litter trolley (view 4)

16 Step One: Move Casualty and Load Attendant Litter bound casualty is carried, feet first, by standard four man litter carry (view 1) to the rear door of the UAH NOTE: The designated attendant should be located at the casualty right foot Litter bearers rotate to a modified three person litter carry (view 2) Designated attendant moves from his position at the right foot of the casualty, enters the vehicle (view 3), sits in the attendant seat, secures the litter trolley (view 4) and prepares to receive the litter View View 3 View 2 3 View 4

17 Step Two: Load Litter using the Litter Assist Litter bearers One, Two, and Four feed the litter into the door taking instructions from the attendant Attendant secures forward trolley hook (view 1), then the aft trolley hook (view 2) to the handles of the litter and informs the bearers the litter is secure Litter bearers Two and Four step away allowing litter bearer One to guide the litter completely into the vehicle (view 3 through 6) View 1 View 3 View 2 View 4 View 5 View 6

Step Three (Part One): Secure the Casualty

secures it into the forward litter handle (view 1 &

litter handles from the trolley hook and secures it

two stands by for litter bearer one to complete

18 Step Three (Part One): Secure the Casualty Attendant takes control of the near litter pole and secures it into the forward litter handle (view 1 & 2) Simultaneously soldier two removes the forward litter handles from the trolley hook and secures it to the forward litter handle (view 3 & 4) Soldier two stands by for litter bearer one to complete securing the casualty head end of litter View 1 View 3 View 2 View 4

Step Three (Part Two): Secure the Casualty Litter bearer one secures

rear litter pole from trolley hook and secures in litter chain hook

that the foot end is secure and then closes the driver side rear door

lifting the litter off of the trolley hooks exceeds MANPRINT lifting

as a berth, and load the casualty on a spine board.

19 Step Three (Part Two): Secure the Casualty Litter bearer one secures rear litter pole into litter chain hook (view 1) Soldier two removes rear litter pole from trolley hook and secures in litter chain hook (view 2 & 3) Makes eye contact and signal to litter bearer one (view 4) that the foot end is secure and then closes the driver side rear door (view 5) View 1 View 2 View 3 View 4 Note: The Safety testing found that lifting the litter off of the trolley hooks exceeds MANPRINT lifting reqs. To mitigate this risk, you can install the litter into the vehicle as a berth, and load the casualty on a spine board. This has a secondary benefit of having the litter remain with the vehicle so that the kit can be used again. View 5

Step Four: Secure Attendant and Prepare to

Litter bearer one observes the attendant

20 Step Four: Secure Attendant and Prepare to Move Attendant fastens lap belt (view 1) Litter bearer one observes the attendant fasten lap belt (view 2) and exchange ready to roll signal (view 3) Litter bearer one closes the passenger side rear door (view 4) Attendant informs driver that they are prepared to move View 1 View 3 View 2 View 4

21 Up-Armored HMMWV CASEVAC Conversion Kit (UAH-CCK) Installation Instructions For M1114 with Fragmentation Armor Kit 5

22 Task Given one M1114 (Frag 5 armor package), one UAH CCK, Vehicle Operators, and Organizational Maintenance Support: tools and personnel. Install the UAH CCK in 90 minutes or less. When complete, the M1114 is prepared to perform its original tasked mission profile

23 Required Tools - 1/4" drive socket set - 1/4" drive universal joint socket set - 3/8" drive socket set w/standard and deep well sockets - Combination ratchet wrench set (recommended, not required) - Standard Box/Open wrench set - Hex key wrench set (Allen style head) - Screwdriver set (with large flat tip to use for prying) - Flashlight - 3/8"-16 Tap & T-handle (for removing dirt/sand out of existing threaded hole) - Spray Lubricant (WD-40) - Loctite Optional: Torque Wrench

24 UAH CCK (M1114) Components Upper Plate 1 of 4 Lower Plate with Seat Bracket attached.

pin is shown in the view but a cotter pin or square

25 UAH CCK (M1114) Components Forward Litter Supports and mounting hardware 2 of 4 Detent Pin (A detent pin is shown in the view but a cotter pin or square retainer pin may alternately be provided with the kit.)

26 UAH CCK (M1114) Components Driver Side Upper support with spacer, cable, trolley, and tensioner. 3 of 4 Passenger Side Upper Support with spacer.

27 UAH CCK (M1114) Components Rear Litter Supports and mounting hardware 4 of 4 Trolley Litter Chain

28 Ready Open all four doors. Remove all stored ammunition and personal equipment from the crew compartment. Orient the gun turret to the vehicle s front and remove the gunner s sling Apply Loctite 242 on all threaded nuts and bolts. Torque Wrench use ft-lbs on all nuts and bolts

29 Common Terms C Pillar B Pillar A Pillar

Remove the bolt on the B Pillar, not on the door itself.

30 Task One: Install Upper Supports Step 1: Remove the Commanders seat / battery box cover. Step 2: Remove door strap bolt and nut on passenger side rear door. Bolt and nut will be replaced by detent pin provided with kit. Remove the bolt on the B Pillar, not on the door itself. (View 1) If desired, driver side rear door strap may be temporarily removed for Kit installation retain all parts. View 1 Step 3: Remove B pillar upper blast plate. (View 2) Optional: The bolt removal in the next step can be done without removing the B pillar blast plate, although it is more difficult. View 2

31 Task One: Install Upper Supports Step 4: Remove two rear most bolts on the upper armor of the B pillar. Discard the two bolts; they will not be used with the installation kit. View 2 View 1 View 3

(View 1) NOTE: After removal of one bolt, if the other bolt is too tight, insert screwdriver inside

32 Task One: Install Upper Supports Step 5: Remove the two bolts on top of the C pillar. Discard the bolts, they will not be used with the installation kit. (View 1) NOTE: After removal of one bolt, if the other bolt is too tight, insert screwdriver inside of inner nut assembly and turn it counter clock wise to loose (View 2) View 1 Step 6: Repeat steps 2-5 on the driver side of the vehicle. View 2

Task One: Install Upper Supports Passenger Side Upper Support Step 7: Install one (new) 2 ½ inch

(If the bolt doesn t go through easily, tap gently). Use 2 91257A550 bolt for the other hole.

(View 2) Step 9: Slide passenger side assembly 60212 from front to rear over the top of the turret

(View 3) View 1 View 2 Step 10: Secure the rear most bolt with the spall nut.

Step 13: Repeat steps 7 12 with Driver Side Support 60207: ensuring that the handle is forward.

33 Task One: Install Upper Supports Passenger Side Upper Support Step 7: Install one (new) 2 ½ inch 92620A552 bolt with 3/8 spacer 92415A441 (on outside for easier installation) through the upper C Pillar (If the bolt doesn t go through easily, tap gently). Use A550 bolt for the other hole. (View 1) Step 8: Place spacer on the installed bolt on the inside of C pillar. (View 2) Step 9: Slide passenger side assembly from front to rear over the top of the turret support bar, and seat it on the bolt and spacer. (View 3) View 1 View 2 Step 10: Secure the rear most bolt with the spall nut. (View 4) Step 11: Secure front portion of passenger side support to the inner B Pillar with provided hardware 92620A589 5/16-18 x 1 ¾ bolts. Step 12: Install C Pillar forward bolt through the support and spacer and secure it to the spall nut. Step 13: Repeat steps 7 12 with Driver Side Support 60207: ensuring that the handle is forward. (View 5) Step 14: Install cable and trolley storage bag with provided zip ties (see view 5 for placement). Trial fit Cable by connecting to Passenger Side Assembly, adjusting Latch U-Bolt until Cable is taught. Release cable, attach litter chain to trolley and store in storage bag. (View 6) View 3 View 4 View 5 View 6

Task Two: Install Forward Litter Supports Step 1: Seat the forward

box, and center the vertical portion on the turret support bar and

(View 1 and 2) View 1 Step 2: Knot provided litter arm strap at the

34 Task Two: Install Forward Litter Supports Step 1: Seat the forward litter support on the top of the Passenger Side B Pillar box, and center the vertical portion on the turret support bar and secure in place with two modified clamps provided. (View 1 and 2) View 1 Step 2: Knot provided litter arm strap at the bottom of the litter support. (View 3) Repeat Steps 1 and 2 on Driver Side View 2 View 3

Task Three: Install Rear Litter Supports Step 1: remove the

(View 1) Step 2: Install upper chain bracket 20506-1 and

NOTE: Upper Chain bracket must face forward.

(View 3) View 2 Step 4: Install lower chain bracket 20505-1

35 Task Three: Install Rear Litter Supports Step 1: remove the nut and washer from roof shock mount. (View 1) Step 2: Install upper chain bracket and secure in place with original nut and washer. NOTE: Upper Chain bracket must face forward. (View 2) View 1 Step 3: Remove seatbelt anchor bolt. (View 3) View 2 Step 4: Install lower chain bracket and secure to seatbelt anchor using original bolt NOTE: Install lower chain bracket with round edge facing upward. (View 4) View 3 View 4

Task Three: Install Rear Litter Supports Step 5:

indicated bracket (View 2) with provided zip ties

36 Task Three: Install Rear Litter Supports Step 5: Install litter chain clamps on upper chain bracket, attach chain and close clamp. (View 1) Step 6: Install chain storage bag to indicated bracket (View 2) with provided zip ties and store chain. (View 3) View 1 Repeat Steps 1 6 on drivers side of vehicle. View 2 View 3

Task Four: Convert Commanders Seat to Attendant Seat Step 1: Remove the four nuts

(View 1) Step 2: Attach top plate 60214-1 to seat bottom. (View 2).

the case add additional washers to reduce the length of the stud, which ensures top

37 Task Four: Convert Commanders Seat to Attendant Seat Step 1: Remove the four nuts holding the seat bottom to the blast attenuation device. (View 1) Step 2: Attach top plate to seat bottom. (View 2). Use 5/16-18 locknuts and 5/16 flatwashers newer seats have longer studs, if this is the case add additional washers to reduce the length of the stud, which ensures top plate secures to seat and helps reduce stud interference with the lower plate. (View 3) View 1 View 2 View 3 Optional washers

Task Four: Convert Commanders Seat to Attendant Seat Step 2, con t: Remove 4

blast attenuation assembly and secure with original nuts and washers removed in

38 Task Four: Convert Commanders Seat to Attendant Seat Step 2, con t: Remove 4 bolts (2 each side) and replace seat back with new seat back / headrest, using original bolts. (View 1). Remove bolts Seatback Step 3: Mount bottom plate to battery cover and blast attenuation assembly and secure with original nuts and washers removed in Step 1 - maximum torque of 10 ft- lbs. (View 2) View 1 Step 4: Reinstall battery box cover in vehicle (leaving the seat outside) (View 3) View 2 View 3

Task Four: Convert Commanders Seat to Attendant Seat Step 5: Attach

5/16-18 x 1bolts, 5/16 washers and nut plates 20504-1.

39 Task Four: Convert Commanders Seat to Attendant Seat Step 5: Attach seat bracket to the vehicle cross member using provided 5/16-18 x 1bolts, 5/16 washers and nut plates Attach seat bracket to seat bottom plate using Nut Plate and Knobs (View 1) Step 6: Remove indicated bolt (View 2) and use same bolt to secure lap-belt. (View 3) Step 7: Attach retractor to the A pillar as indicated with bracket and provided hardware for (Seat belt Assy). (View 4) View 1 View 2 View 4 View 3

40 Task Four: Convert Commanders Seat to Attendant Seat CAUTION: Lifting the near side of the seat higher than 2 while the opposite side is still engaged may result in failure of the conversion kit. Only lift the seat enough to clear the detent pin and lower seat plate.

Task Four: Convert Commanders Seat to Attendant Seat Step 8: Reinstall commanders seat

(View 1) Guide the flat edge of the top plate into the receiving lip of the lower plate

41 Task Four: Convert Commanders Seat to Attendant Seat Step 8: Reinstall commanders seat by: Pull and lock the detent in the out position. (View 1) Guide the flat edge of the top plate into the receiving lip of the lower plate and firmly seat the top plate into the bottom plate aligning the locking pin with the pin hole. (View 2 and 3) This may require pushing the seat towards the rear and center console simultaneously. View 1 View 2 Release the detent pending locking the seat in place. (opposite action of View 1) View 3

42 Task Four: Convert Commanders Seat to Attendant Seat If there is difficulty engaging the pin, gently lift bottom seat plate with a screwdriver as shown in this picture to engage detent pin. The view below is of a M1151 HMMWV, but the process is the same.

Task Five: Secure Rear Door Limiting Straps Step One: If removed, re-install original

(View 1) Step Two: Secure passenger side rear door limiting strap with provided

(View 2) Install seat cushion 60221-1 between new seatback and dashboard looping the

43 Task Five: Secure Rear Door Limiting Straps Step One: If removed, re-install original bolt and nut in driver side rear door limiting strap. (View 1) Step Two: Secure passenger side rear door limiting strap with provided cotter, detent or square retainer pin. (View 2) Install seat cushion between new seatback and dashboard looping the attached elastic straps around the seatback. The seat is shown in the reverse position. Notice new seat has headrest attached for head safety. (View 3) View 1 View 3 View 2

44 M1114 CASEVAC Kit Install Hardware QTY, Line Item QTY Spares Order Qty REF. PART # DESCRIPTION NOTES K56 CABLE TIE STANDARD (BLACK) 14 LG A029 WASHER, SPRING LOCK 1/4 STEEL ZINC PLATED GRADE 8 Installation of Installation of Chain Bags Installation of A030 WASHER, SPRING LOCK 5/16 STEEL ZINC PLATED GRADE 8 Installation of Installation of (alternate) A550 CAP SCREW HEX 1/4-20 X 2" STEEL ZINC PLATED 1 Installation of (alternate) A584 SOCKET CAP SCREW FLAT 3/8-16 X 1"LG Installation of A441 1/2" OD x 1/4" ID x 3/8" LG SPACER Installation of Installation of Installation of A552 CAP SCREW HEX 1/4-20 X 2 1/2" STEEL ZINC PLATED 1 Installation of A583 CAP SCREW HEX 5/16-18 X 1" STEEL ZINC PLATED Installation of Installation of A589 CAP SCREW HEX 5/16-18 X 1 3/4" STEEL ZINC PLATED 2 Installation of A041 PIN QUICK RELEASE 1/4 DIA X 2 1/2" LG Installation in DOOR HINGE STRAP 2 LOCKNUT OVAL LOCK W/CONICAL TOP 1/4-20 Installation of A210 2 STEEL GRADE 8 ZINC PLATED Installation of Installation of LOCKNUT OVAL LOCK W/CONICAL TOP 5/16-18 Installation of A220 4 STEEL GRADE 8 ZINC PLATED Installation of Installation of A029 WASHER, FLAT 1/4 STEEL ZINC PLATED GRADE A030 WASHER, FLAT 5/16 STEEL ZINC PLATED Installation of Installation of Installation of Installation of Installation of Installation of Installation of Installation of Installation of / spares

INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS Accessory Application Publications No. AII 27996 ATTACHMENT KIT 2005 CIVIC HYBRID Issue Date AUG 2004 PARTS LIST Changer Attachment Kit: P/N 08B26-S5B-100 4 Washer-screws, 4 x