Description of Requirements (Modular Inflatable Trainng Wall System).pdf

Description of Requirement Modular Inflatable Wall Training System

April 2024

1. Requirement Overview: The 172d Security Forces Squadron (SFS), Jackson MS, has a need to procure a modular inflatable training wall system to meet the increasing small arms training demands of the Security Forces Career Field. Coupled with the completion of the new Small Arms Indoor Shooting Range at Thompson Field, an inflatable and modular shoothouse will grant us extreme versatility in the way we train on weapons, use of force, small team tactics, and individual tactics. It will permit us the ability to complete our quarterly small arms sustainment training and Shoot, Move, Communicate requirements on Thompson Field in a safer and more readily available environment.

2. Scope of Work: The vendor shall provide the minimum specifications and quantity needed to meet or exceed Security Forces Operational requirements as listed. See attachments and additional Specifications follow.

2.1. Inflatable Wall Training System Specifications:

2.1.1 The system shall replicate real works and be deployable anywhere relative to North American climates.

2.1.2. The system shall allow the replication of any built single story structure. These shall be deployable in a warehouse, indoor or outdoor shooting range, and field training environments.

2.1.3. The system shall be inflatable, modular, and reconfigurable. Additionally, all accessories to ensure system installation and takedown shall be included. This includes storage bags, containers, and instructions.

2.1.4. The system shall be capable of withstanding approved SIMUNITION training ammunition used with the Close Combat Mission Capability Kit (CCMCK). (SEE

ATTACHMENT 1 & 2).

2.1.5. The system shall be made of a material that will allow direct heat contact from small arms weapons configured with Close Combat Mission Capability Kit (CCMCK) without damage. (SEE ATTACHMENT 1 & 2)

2.1.6. The system shall be capable of simple transportation, such as transported within a standard truck bed or utility van.

2.1.7. The system shall be compactable for a storage capacity between 200 and 300 cubic feet.

2.1.8 The system shall employ a 5 year factory warranty.

2.2. Inflatable Wall Training System Components:

2.2.1. The Modular Inflatable Wall Training System should contain enough components to create at least a 1400 square feet training space and include the following components:

2.2.1.1. Two (02) low wall sections w/carry bags.

2.2.1.2. Six (06) half wall sections w/ carry bags.

2.2.1.3. Ten (10) full wall sections w/carry bags.

2.2.1.4. Nine (09) doorway sections w/carry bags.

2.2.1.5. Eight (08) window sections w/ carry bag.

2.2.1.6. Nine (09) rapid screen doors.

2.2.1.7. Eight (08) rapid screen windows.

2.2.1.8. Nine (09) swinging door inserts.

2.2.1.9. Two (02) field repair kits.

2.2.1.10. Two (02) professional man of rubber electric blowers.

2.2.1.11. Two (02) pressure gauges.

2.2.1.12. Seventy (70) steel anchor weights

2.2.1.13. Black brick or gray brick skin pattern

2.3 Inflatable Wall Training System. Attachments:

2.3.1 Attachment 1 – AFSFC_CCMCK_Training_CONOPS_1_Oct_10

2.3.2 Attachment 2 – TM_9-6920-3700-10 - CCMCK

Attachment 1 – AFSFC_CCMCK_Training_CONOPS_1_Feb_14

Attachment 2 – TM_9-6920-3700-10 - CCMCK

TM 9-6920-3700-10

TECHNICAL MANUAL

OPERATOR’S MANUAL FOR

CLOSE COMBAT MISSION CAPABILITY KIT (CCMCK)

TRAINING DEVICE, FIRE DYE MARKING AMMO: M16/M4

NSN 6920-01-564-9657

TRAINING DEVICE, FIRE DYE MARKING AMMO: M249

NSN 6920-01-564-9655

TRAINING DEVICE, FIRE DYE MARKING AMMO: M9

NSN 6920-01-564-9656

TRAINING DEVICE, FIRE DYE MARKING AMMO: M11

NSN 6920-01-564-9658

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

13 MARCH 2009

a

WARNINGS

The Officer in Charge (OIC) shall brief all personnel on the boundaries of the exercise area and will ensure all personnel within those boundaries meet minimum safety requirements for CCMCK Weapon Conversion System.

The OIC shall verify that all weapons used for Force-On-Force training are clear and unloaded, that the appropriate CCMCK Weapon Conversion System is properly installed, and that only CCMCK ammunition is allowed in the Safety and Training Area.

The Range Safety Officer (RSO) shall enforce the Rules of Engagement established and reviewed prior to the start of the training exercise.

To prevent serious injury, NO head shots will be taken by any participant.

Minimum engagement distance when using CCMCK ammunition in converted weapons is 5 meters (16.4 ft). Personnel injury may occur if shots are taken at less than 5 meters (16.4 ft).

No personnel will be allowed within a radius of 75 meters (246 ft) of the CCMCK Training Area when Force-On-Force training is being conducted without meeting the minimum safety requirements for CCMCK use. Serious injury could occur if a participant is struck by a CCMCK projectile in the eyes or on exposed skin.

NO weapons are to be fired outside of the Training Area.

Safety equipment must be worn at all times while inside the CCMCK Safety and Training Areas to prevent personnel injury from projectile impact. Ensure all exposed skin is covered.

b

Personnel using CCMCK marking ammunition are required to follow good personal hygiene practices (i.e., hand washing, cleaning of contaminated clothing and equipment), following exposure/contamination with marking compounds. Seek medical care in the event of acute eye contamination, skin irritation, or inges-tion of marking compound.

Personnel injury can occur if safety requirements are not met when using the CCMCK Weapon Conversion System with CCMCK ammunition during Force-On-Force training.

To prevent serious eye injury, the ONLY approved eye protection for use with CCMCK is the standard issued Sun, Wind and Dust Goggles (NSN 8465-01-328-8268) which must be worn until all training has ceased.

Failure to inspect and clean the chamber and bore before firing service ammunition can result in personnel injury or catastrophic damage to the weapon if a CCMCK marking projectile remains lodged in the bore.

To prevent personnel injury, DO NOT interchange service bolts between weapons. Take appropriate steps to ensure that the same service bolt is put back in the weapon from which it was removed.

Before performing any conversion procedures or troubleshooting procedures, ensure weapon is clear/ unloaded.

To prevent personnel injury, ensure M249 bolt is in FORWARD position before removing return rod and transfer mechanism assembly and spring.

Wear approved goggles and use care when removing recoil spring and spring guide. Due to the amount of compression, assembly will be released under spring tension and could cause injury to personnel or become damaged or lost.

Seek qualified medical care in the event of acute eye contamination, skin irritation, or ingestion of marking compound.

A

LIST OF EFFECTIVE PAGES

Date of issue for original pages is:

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 141, CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change No. No. No. No. No. No.

Original . . . . . . 0. . . . . . . . 13 March 2009

*Zero in this column indicates an original page

Front Cover a and b A and B i and ii 1-1 thru 1-18 2-1 thru 2-12 3-1 thru 3-14 4-1 thru 4-28 5-1 thru 5-20 6-1 thru 6-20

7-1 thru 7-16 8-1 and 8-2 A-1 and A-2 B-1 and B-2

B

THIS PAGE INTENTIONALLY LEFT BLANK

i

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY

No. 9-6920-3700-10 Washington, DC, 13 March 2009

Operator’s Maintenance Manual for

CLOSE COMBAT MISSION CAPABILITY KIT (CCMCK)

TRAINING DEVICE, FIRE DYE MARKING AMMO: M16/M4

NSN 6920-01-564-9657

TRAINING DEVICE, FIRE DYE MARKING AMMO: M249

NSN 6920-01-564-9655

TRAINING DEVICE, FIRE DYE MARKING AMMO: M9

NSN 6920-01-564-9656

TRAINING DEVICE, FIRE DYE MARKING AMMO: M11

NSN 6920-01-564-9658

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms) directly to Logistics Research and Engineering Directorate (AMSRD-AAR-EIL-LS), U.S.

Army RDECOM, Armament Research, Development and Engineering Center, Picatinny Arsenal, NJ 07806- 5000. You may also send in your recommended changes via electronic mail or by fax. Our e-mail address is PICAPubChanges@conus.army.mil. Our fax number is DSN 880-4633, Commercial (973) 724-4633. A reply will be furnished to you.

ii

Page CHAPTER 1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Section I General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Section II Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Section III Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

CHAPTER 2 OPERATOR INSTRUCTIONS FOR CCMCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Section I CCMCK Range Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Section II CCMCK Marking Ammunition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Section III Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Section IV Special Cleaning Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

CHAPTER 3 OPERATOR INSTRUCTIONS FOR M16A2/A3/A4 RIFLES AND

M4/M4A1 CARBINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

CHAPTER 4 OPERATOR INSTRUCTIONS FOR M249 SQUAD AUTOMATIC WEAPON (SAW) . . . 4-1

CHAPTER 5 OPERATOR INSTRUCTIONS FOR M9 PISTOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 CHAPTER 6 OPERATOR INSTRUCTIONS FOR M11 PISTOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 CHAPTER 7 CCMCK TROUBLESHOOTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Section I Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Section II Troubleshooting Procedures for M16A2/A3/A4 Rifles and M4/M4A1 Carbines . . . . . . . . 7-2 Section III Troubleshooting Procedures for M249 Squad Automatic Weapon (SAW) . . . . . . . . . . . . . 7-5 Section IV Troubleshooting Procedures for M9 Pistol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Section V Troubleshooting Procedures for M11 Pistol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

CHAPTER 8 CLEANING SAFETY EQUIPMENT AND PERSONAL HYGIENE . . . . . . . . . . . . . . . . . . 8-1 Section I Cleaning Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Section II Personal Hygiene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 APPENDIX B EXPENDABLE AND DURABLE ITEMS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

1-1

CHAPTER 1

INTRODUCTION

SECTION I GENERAL INFORMATION

1.1 SCOPE.

These instructions, for use by operator personnel, apply to the Close Combat Mission Capability Kit (CCMCK).

Type of Manual: Operator Maintenance.

Model Number(s) and Equipment Name(s): Training Device, Fire Dye Marking Ammo: M16/M4; Training Device, Fire Dye Marking Ammo: M249; Training Device, Fire Dye Marking Ammo: M9; Training Device, Fire Dye Mark-ing Ammo: M11.

Purpose of Equipment: The CCMCK Weapon Conversion System allows Force-On-Force close combat training by temporarily converting service weapons (M16A2/M16A3/M16A4 Rifles, M4/M4A1 Carbines, M249 Squad Auto-matic Weapons (SAW), and M9 and M11 Pistols) to fire low-velocity marking ammunition. CCMCK ammunition includes 5.56mm Bulk marking ammunition for the M16A2/M16A3/M16A4 Rifle and M4/M4A1 Carbine, 5.56mm Linked marking ammunition for the M249 SAW, and 9mm marking ammunition for the M9 and M11 Pistols. Marking ammunition, manufactured in red, blue, and yellow, is loaded into the magazine of the converted weapon in the same manner as service ammunition. Once loaded, the weapon cycles and functions the same as service ammunition and marks the target with minimal hazard to personnel wearing appropriate safety equipment. The system allows normal weapon employment cues such as aiming, firing, Force-On-Force training, and interactive live-fire scenario task and mission execution.

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1.2 FORMS, RECORDS AND REPORTS.

Department of the Army forms and procedures used for equipment maintenance will be those prescribed (as applica-ble) by DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual per AR 700-138, Army Logistics Readiness and Sustainability. Accidents involving injury to personnel or damage to material will be reported on DA Form 285 (U.S. Army Accident Report) in accordance with AR 385-10, The Army Safety Program.

Explosives and ammunition malfunctions will be reported in accordance with AR 75-1, Malfunctions Involving Ammunition and Explosives.

1.3 REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR).

If your CCMCK needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or performance. If you have Internet access the fastest way to report problems or suggestions is to go to https://aeps.ria.army.mil/aepspublic.cfm (scroll down and choose the “Submit Quality Deficiency Report” bar). The Internet form lets you choose to submit an Equipment Improvement Recommendation (EIR), a Product Quality Deficiency Report (PQDR) or a Warranty Claim Action (WCA). You may also submit your information using an SF Form 368 (Product Quality Deficiency Report).

You can send your SF Form 368 via e-mail, or facsimile using the addresses/facsimile numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. We will send you a reply.

1.4 CORROSION PREVENTION AND CONTROL (CPC).

Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items.

1-3

Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion dam-age in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking.

Plastic, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solva-tion (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light.

Damage from these processes will appear as cracking, softening, swelling, and/or breaking.

SF Form 368 (Product Quality Deficiency Report) should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

1.5 PREPARATION FOR STORAGE OR SHIPMENT.

All CCMCK Weapon Conversion Kits must be clean and serviceable prior to storage or shipment. Any unused CCMCK 5.56mm marking ammunition must be repacked with the tip up to prevent marking compound from coming out.

1.6 LIST OF ABBREVIATIONS/ACRONYMS.

Abbreviation/Acronym Definition ACU Army Combat Uniform CCMCK Close Combat Mission Capability Kit CLP Cleaner, Lubricant, and Preservative CPC Corrosion Prevention Control

1-4

1.7 SAFETY, CARE, AND HANDLING.

Use CCMCK only in accordance with instructions. Observe all warning and cautions in this manual.

Personnel using CCMCK marking ammunition are required to follow good personal hygiene practices (i.e., hand washing, cleaning of contaminated clothing and equipment), following exposure/contamination with marking com-pounds. Seek medical care in the event of acute eye contamination, skin irritation, or ingestion of marking compound.

To prevent serious eye injury, the ONLY approved eye protection for use with CCMCK is the standard issued Sun, Wind, and Dust Goggles (NSN 8465-01-328-8268) which must be worn until all training has ceased.

Load only authorized CCMCK marking ammunition in weapons that have been configured with the appropriate CCMCK Weapon Conversion Kit. Equipment damage is possible if marking ammunition is interchanged.

CCMCK conversion kits and safety equipment must be cleaned before turn-in IAW procedures outlined in this TM.

DA Department of the Army IAW In Accordance With OIC Officer In Charge RSO Range Safety Officer SAW Squad Automatic Weapon TAMMS The Army Maintenance Management System TM Technical Manual

Abbreviation/Acronym Definition

1-5

All CCMCK Weapon Conversion Kits have built-in safety features that will not allow service ammunition to be fired.

Converting the weapon to use CCMCK marking ammunition does not cause any undue effects or degradation of the normal service components, its overall longevity or the general function of the weapon.

SECTION II EQUIPMENT DESCRIPTION AND DATA

1.8 EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES.

The Close Combat Mission Capability Kit (CCMCK) temporarily converts service weapons (M16A2/M16A3/M16A4 Rifles, M4/M4A1 Carbines, M249 Squad Automatic Weapon (SAW), and M9 and M11 Pistols) to fire low velocity marking ammunition.

CCMCK marking ammunition is manufactured in three colors (red, blue, yellow) and three different ammunition types. They include: 5.56mm Bulk for M16A2/M16A3/M16A4 Rifles or M4/M4A1 Carbines; 5.56mm Linked for M249 SAW; 9mm for M9 and M11 Pistols. The marking compound material is either wax or detergent based, non-toxic, and inert.

The CCMCK Weapon Conversion System consists of four training kits, each containing one Weapon Conversion Kit and one CCMCK Face Mask. The system allows normal weapon employment cues such as aiming, firing, Force-On- Force training, and interactive live-fire scenario task and mission execution.

1-6

The CCMCK system allows Force-On-Force close combat training using ammunition that marks the target and pres-ents minimal hazard to personnel wearing appropriate safety equipment. Safety equipment includes the CCMCK face mask. Other required safety equipment is included in the Soldier and Organizational Clothing and Individual Equip-ment (OCIE) CTA 50-900 items and will include gloves, standard issued Sun, Wind, and Dust Goggles (NSN 8465- 01-328-8268), and groin protection. Single hearing protection is also required.

CCMCK Weapon Conversion Kits will not allow service ammunition to be fired when a service weapon is converted.

The safety feature is achieved with all 5.56mm weapons by moving the CCMCK firing pin by 3mm off center, in effect turning the method of firing into a rim-fire style of operation. This ensures that the CCMCK firing pin is suffi-ciently moved to prevent initiation of the standard 5.56mm ammunition primer. The safety feature used in the CCMCK 9mm conversion of the M9 and M11 Pistols is that the barrel is less than 9mm to ensure that a standard ser-vice round will not chamber.

ALL CCMCK bolts and barrels are identified by blue markings. CCMCK marking ammunition is loaded into the standard magazine for the host weapon, fed into the converted weapon and operated in accordance with the normal operating procedures for that weapon. Converting the weapon to use CCMCK ammunition does not cause any undue effects or degradation of the live weapon components or the weapon itself.

1-7

1.9 LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.

1.9.1 M16A2/M16A3/M16A4 Rifle and M4/M4A1 Carbine Weapon Conversion Kit.

The CCMCK Weapon Conversion Kit for M16A2/M16A3/M16A4 Rifles and M4/M4A1 Carbines contains a training bolt and carrier assembly that is identified by a blue marking.

1.9.2 M249 SAW Weapon Conversion Kit.

The CCMCK Weapon Conversion Kit for the M249 SAW contains a training bolt and slide assembly and an ejector blade assembly, each identified by a blue marking, and a blue feed tray adapter.

1-8

1.9.3 M9 Pistol Weapon Conversion Kit.

The CCMCK Weapon Conversion Kit for the M9 Pistol contains a blue “drop in” training barrel.

1.9.4 M11 Pistol Weapon Conversion Kit.

The CCMCK Weapon Conversion Kit for the M11 Pistol contains a blue “drop in” training barrel and a training feed ramp.

1-9

1.9.5 CCMCK Face Mask.

The CCMCK Face Mask is a black nylon mask that protects the lower face and neck area.

1-10

1.10 EQUIPMENT DATA.

CCMCK Training Kit for M16A2/M16A3/M16A4 Rifles and M4/M4A1Carbines:

Consisting of ......................................................................... One (1) CCMCK Weapon Conversion Kit and one

(1) CCMCK Face Mask NSN ...................................................................................... 6920-01-564-9657 Training Device Number (DVC) .......................................... 07-164

CCMCK Weapon Conversion Kit for M16A2/ M16A3/M16A4 Rifles and M4/M4A1Carbines:

Consisting of ...................................................................... Training bolt and carrier assembly with a blue mark-ing NSN.................................................................................... 1005-99-132-2616 Ammunition used ............................................................... 5.56mm Bulk marking ammunition in three colors

Cartridge, 5.56mm, Practice: M1042, Bulk, Blue .......... NSN 1305-01-536-5822; P/N 13008767-1 Cartridge, 5.56mm, Practice: M1042, Bulk, Red ........... NSN 1305-01-536-5827; P/N 13008767-2 Cartridge, 5.56mm, Practice: M1042, Bulk, Yellow....... NSN 1305-01-536-5829; P/N 13008767-3 Cartridge case.................................................................. Metallic telescopic case with Rimfire primer Projectile:

Material ........................................................................ Plastic, aluminum, and marking compound Color ............................................................................ Silver base with translucent cup Weight .......................................................................... 6.95 gr

1-11

Marking compound......................................................... Non-toxic, inert, wax-based compound in colors of red, blue, and yellow

Velocity:

M16.............................................................................. 499.50 ft/sec M4................................................................................ 473.21 ft/sec

Shelf life.......................................................................... 24 months from date of manufacture with proper storage

Recommended storage .................................................... Cool and dry environment (approx 70°F) Temperature Limits:

Firing:

Lower limit................................................................... +32°F (0°C) Upper limit ................................................................... +120°F (+49°C)

Storage:

Lower limit................................................................... -40°F (-40°C) Upper limit ................................................................... +145°F (+63°C)

Packing Data:

Packing............................................................................ 1800 cartridges per wirebound box; 30 cartridges per carton; 30 cartons per M2A1 container; two M2A1 containers per wirebound box

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Wirebound box for M2A1:

Dimensions .................................................................. 14.44 x 12.53 x 8.13 in.

Weight .......................................................................... 7.5 lb

Shipping and Storage Data:

UN number DOD hazard class/div/SCG ............................................ 1.4S DOT class........................................................................ C DOT designation ............................................................. SMALL ARMS AMMUNITION

DODAC:

Cartridge, 5.56mm, Practice: M1042, Bulk, Blue .......... 1305-AB09 Cartridge, 5.56mm, Practice: M1042, Bulk, Red ........... 1305-AB10 Cartridge, 5.56mm, Practice: M1042, Bulk, Yellow....... 1305-AB11

CCMCK Training Kit for M249 Squad Automatic Weapon

(SAW):

Consisting of ......................................................................... One (1) CCMCK Weapon Conversion Kit and one

(1) CCMCK Face Mask NSN ...................................................................................... 6920-01-564-9655 Training Device Number (DVC) .......................................... 07-165

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CCMCK Weapon Conversion Kit for M249 Squad Automatic Weapon (SAW):

Consisting of ...................................................................... Training bolt and slide assembly and ejector blade assembly, each with blue markings, and a blue feed tray adapter

NSN.................................................................................... 1005-99-848-0609 Ammunition used ............................................................... 5.56mm Linked marking ammunition in three colors

Cartridge, 5.56mm, Practice: M1071, Linked, Blue....... NSN 1305-01-537-1521; P/N 13008770-1 Cartridge, 5.56mm, Practice: M1071, Linked, Red........ NSN 1305-01-537-1522; P/N 13008770-2 Cartridge, 5.56mm, Practice: M1071, Linked, Yellow... NSN 1305-01-536-9289; P/N 13008770-3 Cartridge case.................................................................. Metallic telescopic case with Rimfire primer Projectile:

Material ........................................................................ Plastic, aluminum, and marking compound Color ............................................................................ Silver base with translucent cap Weight .......................................................................... 6.95 gr

Marking compound......................................................... Non-toxic, inert, wax-based compound in colors of red, blue, and yellow

Velocity ........................................................................... 467.63 ft/sec Shelf life.......................................................................... 24 months from date of manufacture with proper storage Recommended storage .................................................... Cool and dry environment (approx 70°F)

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Temperature Limits:

Firing:

Lower limit................................................................... +32°F (0°C) Upper limit ................................................................... +120°F (+49°C)

Storage:

Lower limit................................................................... -40°F (-40°C) Upper limit ................................................................... +145°F (+63°C)

Packing Data:

Packing............................................................................ 2400 cartridges per wirebound box; 100 cartridges per belt, M27; 1 belt per M249 container;

12 containers per PA108 box; 2 PA108 boxes per wirebound box

Wirebound box for PA108:

Dimensions .................................................................. 17.0 x 13.37 x 9.37 in.

Weight .......................................................................... 6.0 lb

Shipping and Storage Data:

UN identification number DOD hazard class/div/SCG ............................................ 1.4S DOT class........................................................................ C DOT designation ............................................................. SMALL ARMS AMMUNITION

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DODAC:

Cartridge, 5.56mm, Practice: M1071, Linked, Blue....... 1305-AB16 Cartridge, 5.56mm, Practice: M1071, Linked, Red........ 1305-AB17 Cartridge, 5.56mm, Practice: M1071, Linked, Yellow... 1305-AB15

CCMCK Training Kit for M9/M11 Pistol:

Consisting of ......................................................................... One (1) CCMCK Weapon Conversion Kit and one

(1) CCMCK Face Mask

NSN:

M9 ...................................................................................... 6920-01-564-9656 M11 .................................................................................... 6920-01-564-9658

Training Device Number (DVC):

M9 ...................................................................................... 07-162 M11 .................................................................................... 07-163 CCMCK Weapon Conversion Kit for M9/M11 Pistol:

Consisting of ...................................................................... Blue training barrel (M9);

Blue training barrel and training feed ramp (M11)

NSN:

M9 ................................................................................... 1005-20-003-2362 M11 ................................................................................. 1005-20-003-2361

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Ammunition used ............................................................... 9mm marking ammunition in three colors Cartridge, 9mm, Practice: M1041, Blue ......................... NSN 1305-01-536-7721; P/N 13008817-1 Cartridge, 9mm, Practice: M1041, Red .......................... NSN 1305-01-536-7722; P/N 13008817-2 Cartridge, 9mm, Practice: M1041, Yellow ..................... NSN 1305-01-536-7720; P/N 13008817-3

Cartridge case..................................................................... Brass with polymer sabot and polymer projectile filled with marking compound

Projectile:

Material ........................................................................... Polypropylene and marking compound Color ............................................................................... Marking compound (blue, red, or yellow) Weight ............................................................................. 7.25 gr Marking compound......................................................... Non-toxic, inert, water-soluble, detergent-based compound in colors of red, blue, and yellow Marking cartridges per magazine....................................... Maximum of 10 or less Velocity .............................................................................. 574.80 ft/sec (M9)

491.06 ft/sec (M11) Recommended storage ....................................................... Cool, dry environment (approx 70°F) Shelf life ............................................................................. 24 months from date of manufacture with proper storage Temperature Limits:

Firing:

Lower limit................................................................... +25°F (-32°C) Upper limit ................................................................... +120°F (+49°C)

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Storage:

Lower limit................................................................... -40°F (-40°C) Upper limit ................................................................... +145°F (+63°C)

Packing Data:

Packing............................................................................ 2000 cartridges per wirebound box; 50 cartridges per carton; 20 cartons per M2A1 can; two M2A1 cans per wirebound box

Wirebound for M2A1:

Dimensions .................................................................. 14.44 x 12.53 x 8.13 in.

Weight .......................................................................... 7.5 lb

Shipping and Storage Data:

UN number DOD hazard class/div/SCG ............................................ 1.4S DOT class........................................................................ C DOT designation ............................................................. SMALL ARMS AMMUNITION

DODAC:

Cartridge, 9mm, Practice: M1041, Blue ......................... 1305-AB13 Cartridge, 9mm, Practice: M1041, Red .......................... 1305-AB14 Cartridge, 9mm, Practice: M1041, Yellow ..................... 1305-AB12

CCMCK Face Mask:

NSN.................................................................................... 8415-99-359-9160

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SECTION III

THEORY OF OPERATION

For the M16A2/M16A3/M16A4 Rifle and M4/M4A1 Carbine, the service bolt assembly is replaced with CCMCK training bolt assembly to allow the firing of CCMCK marking ammunition. For the M249 Squad Automatic Weapon (SAW), the service bolt assembly and ejector blade assembly are replaced with CCMCK training bolt assembly and ejector blade assembly to allow the firing of CCMCK marking ammunition. The M249 kit also contains a training feed tray adapter. In the M9 and M11 Pistols, the service barrel is replaced with a training barrel assembly. The M11 also contains a feed ramp.

The 5.56mm CCMCK marking cartridge consists of a two-piece cartridge case (front section, back section), and an aluminum projectile. The cartridge case contains a rim fire primer with a plastic ball in the back section of the car-tridge and an additional primer in the front section. Upon functioning, the rear primer propels the plastic ball forward where it initiates the primer in the front section of the cartridge case. The rear primer also propels the back section rearward which cycles the operating group of the weapon. The functioning of the primer in the front section propels the projectile. The projectile consists of an aluminum projectile body, a metal applicator ball, and a plastic cover that contains the marking compound. Upon impact, the metal applicator ball pushes the marking compound out through the plastic cover marking the target.

The 9mm CCMCK marking cartridge consists of a two-piece cartridge case (front section, back section), a primer, a small quantity of propellant, and a plastic projectile. Upon functioning, the primer ignites the propellant which propels the plastic projectile from the weapon. The projectile is designed to “mushroom” upon impact, force the marking compound out of the projectile, and mark the target. Cycling of the weapon occurs because the back section of the car-tridge case telescopes to slide rearward allowing the weapon to function in a straight blow-back action.

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CHAPTER 2

OPERATOR INSTRUCTIONS FOR CCMCK

SECTION I CCMCK RANGE SAFETY

2.1 EXERCISE AREA.

WARNING

The Officer in Charge (OIC) shall brief all personnel on the boundaries of the exercise area and will ensure all personnel within those boundaries meet minimum safety requirements for CCMCK Weapon Conversion System.

The OIC shall verify that all weapons used for Force-On-Force training are clear and unloaded, that the appropriate CCMCK Weapon Conversion System is properly installed, and that only CCMCK ammunition is allowed in the Safety and Training Areas.

The Range Safety Officer (RSO) shall enforce the Rules of Engagement established and reviewed prior to the training exercise.

To prevent serious injury, NO head shots will be taken by any participant.

Minimum engagement distance when using CCMCK ammunition in converted weapons is 5 meters (16.4 ft). Personnel injury may occur if shots are taken at less than 5 meters (16.4 ft).

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WARNING

No personnel will be allowed within a radius of 75 meters (246 ft) of the CCMCK Training Area when Force-On-Force training is being conducted without meeting the minimum safety requirements for CCMCK use. Serious injury could occur if a participant is struck by a CCMCK projectile in the eyes or on exposed skin.

CCMCK SAFETY AND TRAINING AREAS

WARNING

NO weapons are to be fired outside of the Training Area.

While inside the Safety and Training Areas, all required CCMCK safety equipment must be worn at all times until training has ceased.

NOTE

The 75 meter radius outside the Training Area is designated as the Safety Area.

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2.2 RULES OF ENGAGEMENT.

The Range Safety Officer (RSO) shall enforce the Rules of Engagement established and reviewed prior to beginning training exercises when using CCMCK.

SECTION II CCMCK MARKING AMMUNITION

2.3 INSPECT CCMCK MARKING AMMUNITION.

WARNING

Personnel using CCMCK marking ammunition are required to follow good personal hygiene prac-tices (i.e., hand washing, cleaning of contaminated clothing and equipment), following exposure/con-tamination with marking compounds. Seek medical care in the event of acute eye contamination, skin irritation, or ingestion of marking compound.

CCMCK marking ammunition is manufactured in three colors: Red, Blue, and Yellow. CCMCK includes: 5.56mm Bulk marking ammunition for the M16A2/M16A3/M16A4 Rifle and M4/M4A1 Carbine; 5.56mm Linked marking ammunition for M249 Squad Automatic Weapon (SAW); and 9mm marking ammunition for the M9 and M11 Pistol.

The 5.56mm Bulk and 5.56mm Linked CCMCK marking ammunition are NOT interchangeable due to different rear primers.

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Personnel injury can occur if safety requirements are not met when using the CCMCK Weapon Con-version System with CCMCK ammunition during Force-On-Force training.

CAUTION

DO NOT use corroded ammunition, dented cartridges, damaged cartridges or projectiles (i.e., pushed in), or cartridges that have been jammed in a weapon.

a. Ensure ammunition is clean and dry.

b. Inspect CCMCK marking ammunition to assure that cartridge cases and projectiles are intact. DO NOT use cor-roded ammunition, dented cartridges, or damaged cartridges or projectiles. Turn in damaged ammunition to Range NCO.

c. Ensure projectiles are properly seated in the cartridge case prior to loading into weapon. Damaged projectiles can cause weapon jams/lodged projectiles.

d. Inspect magazine for serviceability. An unserviceable magazine can cause damaged projectiles.

2-5

SECTION III SAFETY EQUIPMENT

2.4 PROCEDURES FOR SAFETY EQUIPMENT.

This section covers the proper procedures for putting on the safety equipment required to perform training using the CCMCK Weapon Conversion System and CCMCK ammunition. Safety equipment must be worn at all times while inside the CCMCK Safety and Training Areas to prevent personnel injury from projectile impact. Required safety equipment when using CCMCK in Force-On-Force training consists of: Single hearing protection, CCMCK Face Mask, standard Combat Helmet or Advanced Combat Helmet, standard gloves, standard issued Sun, Wind and Dust Goggles, groin protection, and a single layer of clothing (Army Combat Uniform (ACU)) with sleeves rolled down.

WARNING

Personnel injury can occur if safety requirements are not met when using the CCMCK Weapon Con-version System with CCMCK ammunition during Force-On-Force training.

Minimum engagement distance when using CCMCK ammunition in converted weapons is 5 meters (16.4 ft). Personnel injury may occur if shots are taken at less than 5 meters (16.4 ft).

Safety equipment must be worn at all times while inside the CCMCK Safety and Training Areas to prevent personnel injury from projectile impact. Ensure all exposed skin is covered.

To prevent serious eye injury, the ONLY approved eye protection for use with CCMCK is the stan-dard issued Sun, Wind and Dust Goggles (NSN 8465-01-328-8268) which must be worn until all training has ceased.

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2.4.1 Hearing Protection.

Insert single hearing protection.

2.4.2 Groin Protection.

Protect groin area with athletic cup or use padding.

2.4.3 CCMCK Face Mask.

Put on face mask, secure around the back of the neck with hook and loop fastener, tuck neck protection inside ACU shirt collar, and button collar so that no skin is exposed.

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2.4.4 Helmet.

Put on Standard Combat Helmet or Advanced Combat Helmet and adjust chin strap.

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2.4.5 Gloves.

Put on standard gloves.

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2.4.6 Sun, Wind, and Dust Goggles.

NOTE

Use of anti-fogging compound is recommended to prevent fogging of lenses.

Adjust Sun, Wind, and Dust Goggles ensuring there are no exposed areas between helmet, face mask and goggles that would allow CCMCK projectiles to enter.

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2.4.7 Final Check.

Check to ensure all exposed skin is covered. Make adjustments as necessary.

2-11

SECTION IV SPECIAL CLEANING INSTRUCTIONS

WARNING

Failure to inspect and clean the chamber and bore before firing service ammunition can result in per-sonnel injury or catastrophic damage to the weapon if a CCMCK marking projectile remains lodged in the bore.

CAUTION

Before installing CCMCK Weapon Conversion Kit, weapon must be cleaned and lubricated with CLP IAW the appropriate weapon TM.

During CCMCK use, weapon must be cleaned in accordance with the following cleaning instructions after the firing of every Ammunition Basic Load for the particular weapon.

2.5 CLEANING INSTRUCTIONS FOR M16A2/M16A3/M16A4 RIFLE, M4/M4A1 CARBINE, M249

SQUAD AUTOMATIC WEAPON (SAW), M9 PISTOL OR M11 PISTOL.

a. Prior to and during CCMCK use:

(1) Inspect, clean, and lubricate weapon using CLP IAW appropriate weapon TM (TM 9-1005-319-10, TM 9- 1005-201-10, TM 9-1005-317-10, or TM 9-1005-325-10).

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(2) Weapon chamber and bore must be cleaned and wiped DRY to properly fire CCMCK ammunition.

(3) Inspect, clean, and lightly lubricate CCMCK components using CLP.

(4) For M16 Series Rifles, M4/M4A1 Carbine, and M249 SAW, face of CCMCK training bolt must be wiped

DRY.

b. After CCMCK use:

(1) ROD THE WEAPON BORE FOR POSSIBLE STUCK PROJECTILES.

(2) Inspect, clean, and lubricate weapon using CLP IAW appropriate weapon TM (TM 9-1005-319-10, TM 9-1005-201-10, TM 9-1005-317-10, or TM 9-1005-325-10), paying special attention to chamber and bore, ensuring all CCMCK marking compound is removed.

(3) Before turn-in of CCMCK Weapon Conversion Kit, thoroughly clean all components with CLP. Use a suit-able cloth to clean any dirt, debris, carbon deposits, or marking compound.

3-1

CHAPTER 3

OPERATOR INSTRUCTIONS FOR M16A2/A3/A4 RIFLES

AND M4/M4A1 CARBINES

WARNING

Before performing any conversion procedures, ensure weapon is clear/unloaded.

Minimum engagement distance when using CCMCK marking ammunition in converted weapons is 5 meters (16.4 ft). Personnel injury may occur if shots are taken at less than 5 meters (16.4 ft).

To prevent serious injury, NO head shots will be taken by any participant.

CAUTION

Although the design of the CCMCK Weapon Conversion System prevents the firing of service ammunition, loading of service ammunition into a converted weapon may cause weapon damage.

To prevent possible weapon damage from a CCMCK projectile becoming lodged in bore, ensure that any new weapon barrel has fired a minimum of 200 standard 5.56mm service rounds before convert-ing for the first time to use CCMCK marking ammunition.

3-2

3.1 REMOVE M16/M4 SERVICE BOLT.

a. Point weapon in a safe direction. Ensure weapon is clear/unloaded IAW TM 9-1005-319-10.

CAUTION

Only use hand pressure to push takedown pin far enough to disengage upper receiver from lower receiver. Excessive force may cause weapon damage.

b. Push takedown pin as far as it will go. Pivot upper receiver from lower receiver.

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To prevent personnel injury, DO NOT interchange service bolts between weapons. Take appropriate steps to ensure that the same service bolt is put back in the weapon from which it was removed.

c. Pull charging handle part way back and remove service bolt carrier from weapon. Set bolt carrier aside.

3-4

3.2 INSTALL CCMCK M16/M4 CONVERSION KIT.

CAUTION

Before installing CCMCK Weapon Conversion Kit, weapon must be cleaned and lubricated with

CLP.

Weapon chamber and bore, and face of CCMCK training bolt must be cleaned and wiped DRY to properly fire CCMCK ammunition.

NOTE

As a safety design feature, the ejection port cover of the service weapon will not close when the CCMCK bolt is installed.

a. Ensure weapon is clean and lubricated with CLP IAW TM 9-1005-319-10. Ensure chamber and bore are DRY.

b. Using CLP, lightly lubricate CCMCK bolt and carrier assembly surface. Ensure face of bolt is DRY.

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c. With upper and lower receivers pivoted away from each other, slide CCMCK bolt and carrier assembly into upper receiver.

d. Push charging handle and bolt and carrier assembly together into upper receiver until fully seated.

3-6

CAUTION

To prevent weapon damage, selector lever must be on SAFE before closing upper receiver.

e. Ensure selector lever is on SAFE. Close upper and lower receiver and, using hands only, push IN takedown pin as far as it will go.

f. Perform function check IAW TM 9-1005-319-10. The weapon is now converted to use CCMCK marking ammunition.

g. Go to Chapter 2, Section III, Safety Equipment, to put on mandatory safety equipment required for CCMCK training.

3-7

3.3 LOAD CCMCK M16/M4 MARKING AMMUNITION.

CAUTION

Equipment damage is possible if marking ammunition is interchanged. Load only authorized CCMCK marking ammunition in weapons that have been configured with the appropriate CCMCK Weapon Conversion Kit.

The 5.56mm Bulk marking ammunition for the M16A2/M16A3/M16A4 Rifle and the M4/M4A1 Carbine is NOT interchangeable with 5.56mm Linked ammunition for the M249 SAW.

a. Ammunition is NOT interchangeable. See table 3-1 for approved CCMCK marking ammunition.

Table 3-1. Approved Marking Ammunition for CCMCK Conversion Kit Used in M16A2/M16A3/M16A4 Rifle and M4/M4A1 Carbine.

MARKING AMMO TYPE NSN

CARTRIDGE, 5.56MM, PRACTICE: M1042, BULK, BLUE 1305-01-536-5822

CARTRIDGE, 5.56MM, PRACTICE: M1042, BULK, RED 1305-01-536-5827

CARTRIDGE, 5.56MM, PRACTICE: M1042, BULK, YELLOW 1305-01-536-5829

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Use extreme care when handling and loading CCMCK marking ammunition. Marking ammunition is more susceptible to damage than service ammunition. DO NOT exert pressure on projectile as dam-age may occur. Damaged projectiles can cause bullet-in-bore and jammed weapons.

DO NOT use corroded ammunition, dented cartridges, or damaged cartridges or projectiles (i.e., pushed in), or cartridges that have been jammed in a weapon.

Projectiles may break or become lodged in the bore or misfeeds may occur if CCMCK marking ammunition is not properly loaded into the magazine and firmly inserted into the weapon, or if pro-jectiles are skewed or loose at time of loading or handling.

To prevent weapon jams, after the firing of every Ammunition Basic Load (approximately 200 CCMCK marking cartridges for M16/M4), the weapon must be cleaned and lubricated IAW this TM.

Ensure all weapon magazines are serviceable before loading CCMCK ammunition. DO NOT use a damaged magazine. An unserviceable magazine can cause damaged CCMCK projectiles.

Any unused CCMCK 5.56mm marking ammunition must be repacked with the tip up to prevent any marking compound from coming out.

b. Carefully load M16A2/M16A3/M16A4 Rifle or M4/M4A1 Carbine with CCMCK marking ammunition IAW TM 9-1005-319-10. Ensure projectiles do not become dislodged or damaged.

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NOTE

Once the authorized CCMCK marking ammunition has been loaded into the magazine of a converted weapon it will cycle the weapon and function in the same manner as service ammunition.

The 5.56mm CCMCK marking ammunition may drop up to 12-inches from line-of-sight at 22 meters (approx 72 ft).

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3.4 REMOVE CCMCK M16/M4 CONVERSION KIT.

a. Point weapon in a safe direction. Clear/unload weapon IAW TM 9-1005-319-10.

CAUTION

Only use hand pressure to push takedown pin far enough to disengage upper receiver from lower receiver. Excessive force may cause weapon damage.

b. Push takedown pin as far as it will go. Pivot upper receiver from lower receiver.

c. Pull charging handle part way back and remove CCMCK bolt and carrier assembly. Set aside for cleaning.

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Failure to inspect and clean the chamber and bore before firing service ammunition can result in per-sonnel injury or catastrophic damage to the weapon if a CCMCK marking projectile remains lodged in the bore.

d. ROD THE BORE FOR POSSIBLE STUCK PROJECTILES.

e. Inspect, clean, and lubricate weapon IAW TM 9-1005-319-10, paying special attention to chamber and bore, ensuring all CCMCK marking compound is removed.

f. Before turn-in of CCMCK Weapon Conversion Kit, thoroughly clean all components with CLP. Use a suitable cloth to clean any dirt, debris, carbon deposits, or marking compound.

3-12

3.5 REINSTALL M16/M4 SERVICE BOLT.

WARNING

To prevent personnel injury, DO NOT interchange service bolts between weapons. Take appropriate steps to ensure that the same service bolt is put back in the weapon from which it was removed.

a. With upper and lower receivers pivoted away from each other and charging handle inserted part way, slide ser-vice bolt carrier assembly into upper receiver.

b. Push charging handle and bolt carrier assembly together into upper receiver until fully seated.

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To prevent weapon damage, selector lever must be on SAFE before closing upper receiver.

c. Ensure selector lever is on SAFE. Close upper and lower receiver and, using hands only, push IN takedown pin as far as it will go.

d. Perform function check IAW TM 9-1005-319-10. The weapon is now converted back to service use.

3-14

4-1

CHAPTER 4

OPERATOR INSTRUCTIONS FOR M249 SQUAD

AUTOMATIC WEAPON (SAW)

WARNING

Before performing any conversion procedures, ensure weapon is clear/unloaded.

Minimum engagement distance when using CCMCK marking ammunition in converted weapons is 5 meters (16.4 ft). Personnel injury may occur if shots are taken at less than 5 meters (16.4 ft).

To prevent serious injury, NO head shots will be taken by any participant.

CAUTION

Although the design of the CCMCK Weapon Conversion System prevents the firing of service ammunition, loading of service ammunition into a converted weapon may cause weapon damage.

To prevent possible weapon damage from a CCMCK projectile becoming lodged in bore, ensure that any new weapon barrel has fired a minimum of 200 standard live service rounds before converting for the first time to use CCMCK marking ammunition.

4-2

4.1 REMOVE M249 SERVICE BOLT AND EJECTOR BLADE.

a. Point weapon in a safe direction. Ensure weapon is clear/unloaded IAW TM 9-1005-201-10.

WARNING

To prevent personnel injury, DO NOT interchange service bolts between weapons. Take appropriate steps to ensure that the same service bolt is put back in the weapon from which it was removed.

To prevent personnel injury, ensure M249 bolt is in FORWARD position before removing return rod and transfer mechanism assembly and spring.

b. If bolt is…