IC-OUM-09073_1.2_B3.pdf

IC-OUM-09073 Rev 1.2 10/31/2017

Operator User Manual for the CSS-E Kit

Operator User Manual for the CSS-E Vehicle Kit

Date: 31 October 2017

Prepared by: Taylor Lynard / Luis Rivera

CHANGE LOG

CHANGE / REVISION RECORD

Revision Page(s) Description of Change Made By Date Approved By

1.0 All Initial Release

1.2 All Update Format Luis Rivera

31OCT17 James

DePersis

Operator User Manual for the CSS-E Kit

Table of Contents

1. Introduction

1.1 General Information

1.1.1 Scope

1.1.2 Safety, Care, and Handling

1.1.3 List of Abbreviations/Acronyms

1.2 Equipment Description: Characteristics and Features

1.2.1 Functions of the CSS-E Kit Transit Case

1.2.2 Functions of the EDI Vehicle Mounting Hardware

a. Magnetic Mounting Hardware Mount for CSS-E that can be used to mount EDI to any ferrous metal surface. There are two ratchet straps that secure the EDI to the plate

b. Mounting Plate Rail Hardware

Used to mount the CSS-E Magnetic Mounting Plate to a rail

c. Mounting Plate Tie-down Straps

Ratchet straps that connect to the CSS-E Mounting Plate are used to secure the Mounting plate to a vehicle. Good for installations where no surface is available for the magnets of the CSS-E Mounting Plate to adhere

1.2.3 Functions of CSS-E External Antenna Hardware

1.2.4 Function of MILES 2000 ITS Kit Interface Cable

1.2.5 Functions of the CSS-E EDI Power Components

1.2.6 Functions of the CSS-E Wiring Harness

1.3 Principles of Operations

2. Operating Instructions

2.1 Description and Use of Operator’s Controls and Indicators

2.2 Operation under Usual Conditions

2.2.1 Preparation for Operation

2.2.2 Operation

2.2.3 Termination

2.2.4 Removal

2.2.5 Preparation for Storage

2.2.6 Preparation for Shipment

2.3 Operation under Unusual Conditions

2.3.1 Unusual Environment

3. Operator Maintenance Instructions

3.1 Troubleshooting

3.2 Maintenance Procedures

4. Special Tools/Installation Equipment

5. Appendix

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1. Introduction

1.1 General Information

1.1.1 Scope

The CSS-E Kit contains everything you need to mount the EDI on or in a vehicle. It also contains external ancillary antennas and power adapters to connect to military and civilian vehicles. This document contains set up and mounting instructions and sustainment and maintenance directions for the CSS-E Kit.

The CSS-E Kit is intended to give the user different EDI vehicle mounting options and the option of the use of an external power supply, GPS antenna and 915 MHz comms antenna. It is at the users’ discretion to decide which components of the CSS-E Kit they want to use.

1.1.2 Safety, Care, and Handling

The Installer must ensure that routing of cabling and placement of Instrumentation mounting assemblies and components don’t interfere with the safe, efficient operation of the vehicle or ancillary equipment.

Become familiar with WARNINGS, CAUTIONS, and NOTES associated with the operation of this Vehicle to ensure the safe execution of tasks in this guide.

ONLY PROPERLY TRAINED AND LICENSED PERSONNEL SHOULD OPERATE MILITARY EQUIPMENT.

ENSURE THE PARKING BRAKE IS SET AND WHEEL CHOCKS ARE IN PLACE BEFORE

WORKING ON OR AROUND ANY TACTICAL VEHICLE.

NEVER WALK BETWEEN VEHICLES WITH ENGINE(S) RUNNING.

1.1.3 List of Abbreviations/Acronyms

comms communications

CSS-E Combat Service Support Kit - EDI

CVKI Combat Vehicle Kill Indicator

CV-TESS Combat Vehicle Tactical Engagement Simulations System

DC Direct Current

EDI Enhanced Dismount Instrumentation

GPS Global Positioning System

HEMTT Heavy Expanded Mobility Tactical Truck

HMMWV High Mobility Multi Wheeled Vehicle

IR Infrared

ITS Independent Targeting System

KSI Kill Status Indicator

Mag Magnetic

MHz Mega Hertz

MILES Multiple Integrated LASER Engagement System

MTV Medium Tactical Vehicle

NATO North Atlantic Treaty Organization

PMCS Preventative Maintenance Checks and Services

WITS Wireless Independent Targeting System

Operator User Manual for the CSS-E Kit

1.2 Equipment Description: Characteristics and Features

1.2.1 Functions of the CSS-E Kit Transit Case

The CSS-E Kit consists of different components that attach the EDI to a variety of tactical and civilian vehicles. The CSS-E Kit also provides options for external antenna’s and power supply.

1.2.2 Functions of the EDI Vehicle Mounting Hardware

a. Magnetic Mounting Hardware Mount for CSS-E that can be used to mount EDI to any ferrous metal surface. There are two ratchet straps that secure the EDI to the plate.

b. Mounting Plate Rail Hardware Used to mount the CSS-E Magnetic Mounting Plate to a rail

c. Mounting Plate Tie-down Straps Ratchet straps that connect to the CSS-E Mounting Plate are used to secure the Mounting plate to a vehicle. Good for installations where no surface is available for the magnets of the CSS-E Mounting Plate to adhere.

Operator User Manual for the CSS-E Kit

1.2.3 Functions of CSS-E External Antenna Hardware

3-A. CVKI GPS Plate GPS antenna and mounting bracket for CVKI light and external 915 MHz antenna. Mounts to the Side Mirror Mounting Bracket for the HMMWV.

3-B. 915 MHZ antenna bracket with RF choke

Used when CSS-E is mounted inside a HMMWV to mount the 915 MHz External antenna, attaches to the

CVKI GPS Plate. The RF choke alters the 915 MHz frequency to be compatible with the EDI.

3-C. 915 MHz Antenna

Used as an External 915 MHz data communication antenna when hooked up to the CSS-E.

3-D. Side Mirror Mounting Bracket

Used to mount the CVKI GPS Plate on the side mirror bracket of a HMMWV.

1.2.4 Function of MILES 2000 ITS Kit Interface Cable

Connects the CSS-E to the MILES 2000 ITS Vehicle MILES enabling the MILES event data to transfer to the EDI.

1.2.5 Functions of the CSS-E EDI Power Components

5-A. CSS-E Power Regulator

This component adapts DC power from the vehicles battery into the battery slot on the EDI. It is used in conjunction with the CSS-E Wiring Harness and the Slave Power Pass Through for Military applications or the Cigarette Lighter Power Plug for civilian applications.

5-B. Slave Power Pass Through Connects to the DC Power source of a NATO Military Vehicle (Slave Receptacle) and connects to the CSS- E power cable on the CSS-E wiring Harness. The Pass-through function allows for the Slave Receptacle to still be utilized for other applications. The Slave Power Pass Through is used in conjunction with the CSS- E Wiring Harness and the CSS-E Power Regulator.

5-C. Cigarette Lighter Power Plug Connects the EDI to a DC source from a cigarette lighter outlet. Used with the CSS-E Wiring Harness power cable and the CSS-E Power Regulator. For civilian vehicle, external power applications.

Operator User Manual for the CSS-E Kit

1.2.6 Functions of the CSS-E Wiring Harness

Includes the cabling for power and external GPS and 915MHz antenna’s for the EDI.

1.3 Principles of Operations

The CSS-E Kit contains the equipment needed to mount the EDI to tactical and civilian vehicles and provide external ancillary power and antennas (GPS and 915 MHz). The EDI is an instrumentation component used to transmit information about an entity position and MILES events to the Base Station where it is encoded and represented on a 3D and 2D virtual map of the terrain in real time. The external power supply allows the user to power the EDI off of the vehicles power system. The external GPS and 915 MHz antennas enhance GPS and RF performance.

2. Operating Instructions

2.1 Description and Use of Operator’s Controls and Indicators The only control and indicator in the CSS-E Kit is on the Slave Power Pass through that has a power switch that illuminates when powered on. The CSS-E Kit serves as an extension of the EDI. The EDI has a power switch located on top of the EDI. There is a green power indicator light located right next to it. Located on the lower back panel there are three red indicator lights labeled CIT. These lights indicate if the EDI is in comms, initialized and tracking (see IC-OUM- 09071 EDI Operators Manual).

2.2 Operation under Usual Conditions

2.2.1 Preparation for Operation

Prior to installing the kit onto a vehicle, familiarization of the vehicle and the kit is needed. Installer should inventory the kit and ensure all components are present. Once the vehicle kit is inventoried and location placement for the components is noted, installation can begin.

Determine EDI Location

The EDI mounting location varies with vehicle type. The vehicle type and EDI location determines what components off the CSS-E kit that can be utilized. For a HMMWV, the most common installation, the EDI is mounted with the Magnetic Mounting Plate on the side of the rear interior passenger side wheel well and the external antennas are mounted to the mirror mount bracket. When the EDI is mounted inside a

Operator User Manual for the CSS-E Kit vehicle the external GPS and 915 MHz antenna must be used. Civilian vehicles and heavier, larger Military vehicles generally require the EDI to be mounted on the exterior roof area of the vehicle with the Magnetic mounting plate or the shoulder straps of the EDI carrier reinforced with large zip-ties. This application requires no external antennas see IC-OUM-09071 EDI Operators Manual.

2.2.2 Operation

To place the kit into operation, install the kit using the steps below.

1. Install the Side Mirror Mount (Military Vehicles with Mirror Arms)

For vehicles using external 915 MHz and GPS antennas mounted to the Side Mirror Mount. If you are installing the EDI Externally and are not using the external antennas and side mirror mount proceed to step 5(b).

i. Loosen threaded knobs (1) on J-bolts. See Figure 2.2.2.1.i.

ii. Position Bracket on Vehicle mirror frame as shown in Figure 2.2.2.1.ii.

iii. Adjust J-bolt positions as required and tighten.

Figure 2.2.2.1.i Figure 2.2.2.1.ii

2. Mount CVKI/COM Mounting Assembly

i. Lower mounting assembly onto mirror bracket

ii. Push down on mounting assembly to compress rubber bushings and align mounting holes.

iii. Insert mounting pins fully (Figure 2.2.2.2.iii).

iv. Screw the 915 MHz RF antenna to the 915 MHz Antenna Bracket with RF Choke

v. Mount the 915 MHz Antenna Bracket with RF Choke with antenna to the quick release bolt in center of the CVKI GPS Plate. Some CVKI GPS Plates have a wingnut instead of a quick release device.

NOTE

The square tubes on the bottom of CVKI/COM Mounting Assembly that lower onto the Mirror Bracket have rubber bushings inside to facilitate a firm fit and eliminate wobble and vibration. It is necessary to push down firmly to compress the bushing and insert the mounting pins.

Applying a small amount of lubricant such as “Break Free”, WD 40, or 3 in 1 Oil to the mounting pins will ease insertion into mounting holes.

Figure 2.2.2.2.iii

Operator User Manual for the CSS-E Kit

3. Install Slave Pass through Power Adapter

i. Remove Protective cover from Vehicle 24 VDC Power connector located under the right front seat (Figure 14).

ii. Ensure the lighted power switch on the Slave Pass through Adapter is in the “O”

OFF position (Figure 15).

iii. Install the Slave Pass through Power Adapter on the receptacle using a firm pushing and twisting motion until it is fully seated.

Figure 2.2.2.3.i Figure 2.2.2.3.ii

NOTE

The CSS-E Kit Slave Power Pass through Adapter’s “pass-through” feature allows the use of the vehicles Slave Receptacle as it would be used during normal operation. It also facilitates connecting other Slave powered equipment to the Slave Receptacle with the Slave Power Pass through Adapter in place.

4. Internal CSS-E Wiring Harness Routing:

After the EDI location has been determined. Route the CSS-E Wiring Harness Cables and connect to the EDI and the external components being utilized.

i. Form a loop in the primary cable routed out to the CVKI GPS Plate and feed the loop of excess cable into the channel in the door frame (Figure 2.2.2.4.i)

ii. Route cable behind heater housing and up along the left side of the right seat area attaching it to the console brace as shown in Figure 2.2.2.4.ii.

Figure 2.2.2.4.i Figure 2.2.2.4.ii

iii. Route Slave Power Pass through Adapter’s power cable connector along front of Right Front seat using latches for seat compartment to secure it as shown in Figure 2.2.2.4.iii.

Figure 2.2.2.4.iii

iv. Route CSS-E Wiring Harness to the EDI. Route the cable so that it is out of the way and is unlikely to get hung up on personnel and equipment.

Operator User Manual for the CSS-E Kit

v. Connect the GPS, 915 MHz comms cables to the EDI at their designated connectors on the side of the CSS-E.

vi. If using the Vehicle’s DC power source install the CSS-E Power Regulator into the EDI Battery slot and connect the Power cable.

Figures 2.2.2.4.vi

5(a). External Cable Routing & Connections

If you are utilizing the external 915 MHz and GPS antennas and the side mirror mounting bracket follow the steps below otherwise proceed to 5(b).

i. Wrap the cables around the legs of the CVKI GPS Plate by starting in front, and then counter clockwise back around to the front. Use a zip tie to secure the wiring harness to the CVKI GPS Plate and/or Mirror Mount Bracket. (Figure 2.2.2.5(a).i)

ii. Connect cables to the Com Antenna and GPS-1 antenna

Operator User Manual for the CSS-E Kit

Figure 2.2.2.5(a).i

5(b). External Cable Routing with External EDI Mount

Measures to protect the antenna cable connections will be needed when mounting an EDI on the exterior of a vehicle when not utilizing the external antennas from the CSS-E Kit. This applies to civilian vehicles, MTV’s, HEMMT’s and any other vehicle that has a SLAVE Receptacle or 12V DC cigarette lighter receptacle where external power to the EDI is desired. Excess cabling will need to be looped and fastened to the interior of the vehicle so that it will not be kinked, stepped on or have a chance of any cargo placed upon it.

i. Strap the EDI into the Mag Plate with Mag Plate ratchet straps and mount to vehicle. Mount EDI and Mag Plate to ferrous metal, preferably to the roof of the vehicle.

ii. Connect power cable of CSS-E Wiring Harness to CSS-E Battery Adapter. (See step 4. vi)

iii. Use electrical tape to fasten GPS and 915 MHz cable ends to power cable. Tape the cable connecters to protect them from dust and debris. (Figures 2.2.2.5(b).iii)

iv. Form a stress loop at the base of the Mag Mount. Use a tie wrap to secure the stress loop to the Mag Mount Velcro. Do not kink coax cables when forming stress loop. (Figure 2.2.2.5(b).iv)

Figures 2.2.2.5(b).iii Figure 2.2.2.5(b).iv

v. Route Cables through a window. And secure the cabling to the door or window frame. Ensure there is enough slack in the cable for when the door is opened and closed.

vi. Make a final inspection of the cable routing to ensure it doesn’t interfere with movement in and out of the vehicle or operation of the equipment.

vii. Neatly coil and anchor excess cable where it is protected from cargo and passengers.

CAUTION

Vehicles with electric windows must be modified to prevent damage to the cabling. Place a shim beside the cable at the top of the door frame to ensure the glass does not damage the cabling.

Use a small piece of wood or something for a shim and tape it to the top of the door.

6. Install MILES Interface Cable

The CSS-E Kit has an interface cable for MILES 2000 ITS. There are 2 other interface cables available for different MILES vehicle systems. The WITS Interface Cable is compatible with the WITS Kit TVS Kit and CV- TESS (see figure 2.2.2.6.1). The MILES XXI works with MILES XXI only (see figure 2.2.2.6.2.). These MILES interface cables are stored separately and can be used in conjunction with the CSS-E Kit and EDI.

Figure 2.2.2.6.1 WITS Interface Cable Figure 2.2.2.6.2 MILES XXI Interface Cable

i. Connect the IR port with the two little screws to the MILES ITS Kit at the MILES KSI Light. The IR port is located on the side of the light. Route the MILES Interface Cable through the top of the back hatch on a HMMWV. Make sure that when the back hatch closes it will not damage the cable. For other types of vehicles route cable to MILES IR port so that it is well secured and will not get damaged by moving parts, doors and hatches.

ii. Plug the other end of the MILES Interface Cable into the EDI at the connector that is marked MILES on the side of the EDI (Figure 2.2.26.ii).

iii. Coil up any excess interface cabling and secure it near or to the EDI so that it is out of the way of any moving parts and possibility of snagging on any gear and equipment.

Figures 2.2.2.6.ii

7. Place the System into Operation

i. Power the EDI on by depressing the power button located on top of the EDI and check the green power indicator light. (see IC-OUM-09071 EDI Operators Manual)

ii. Wait at least 30 seconds and then Check with the base station to ensure that the EDI has good 915 MHz data comms, GPS tracking and MILES interface. They will need the EDI serial number and net. (see IC-OUM-09071EDI Operators Manual)

iii. Ensure that the Base Station Operator has the correct vehicle nomenclature and color so that they can get the correct 3-D model entered.

8. Daily Inspection PMCS

The CSS-E Kit components need to be inspected daily preferably right before the start of training. If any problems exist refer to

i. Check all cable connections and tighten as needed.

ii. Check mounting components for damage and proper placement.

iii. Inspect cabling for damage and correct routing.

iv. Check EDI power indicator light (see IC-OUM-09071EDI Operators Manual)

v. Contact Base Station to confirm that the EDI is in comms, tracking and has a good MILES interface if applicable. See section 3 Operator Maintenance: Troubleshooting for help fixing any issues.

Operator User Manual for the CSS-E Kit

2.2.3 Termination

When the vehicle kit is no longer needed it should be removed.

2.2.4 Removal

To remove the CSS-E Vehicle Kit, complete Section 2.2.2 steps 1-7 in reverse order.

2.2.5 Preparation for Storage

The CSS-E Vehicle kit should be stored in environmentally controlled area. All components of the CSS-E Kit need to be cleaned and inspected for damage and placed back into the transit case. Damaged or missing equipment is noted tagged and reported.

2.2.6 Preparation for Shipment

If the transit cases are to be palletized follow stacking directions stenciled on cases or if there is no stacking directions then stack no more than 5 high and two wide on a standard 45’ x 48” pallet. The palletized CSS- E Kits are then banded and shrink wrapped.

2.3 Operation under Unusual Conditions

See Usual Conditions section. Operation of CSS-E Kit components are not effected by adverse weather.

Care should be taken during install at keep cable connectors clean and free of debris.

2.3.1 Unusual Environment

2.3.1.1 Lightning

If lightning is the local area when installing kit on the vehicle, care should be taken that antennas are not handled.

2.3.1.2 Strong Winds

Ensure equipment is secured correctly on the vehicle to prevent damage to either the vehicle or CSS-E kit components.

Operator User Manual for the CSS-E Kit

3. Operator Maintenance Instructions

3.1 Troubleshooting

Observation: There is no power to the EDI device.

Solutions: Verify the Slave Power Pass through is seated properly on the Slave Receptacle; Check that the switch on the NATO Plug Adapter is on; Check Vehicle power cable connectors are connected; inspect the CSS-E Wiring Harness for damage, replace if necessary and check EDI for power; verify the CSS-E Power Regulator is properly seated in the EDI battery slot; check that the vehicle has a good battery;

observe the EDI for a green power indicator light.

If there is still no power use known good spare CSS-E parts to identify and replace the non- operational part(s). Replace the Slave Power Pass through and check EDI for power; replace the CSS-E Power Regulator and check the EDI for power; Hook up but do not route a CSS-E Wiring Harness to the CSS-E Power Regulator and the Slave Power Pass through and check the EDI for Power. If the wiring harness fixes the problem replace and re-route the cabling. If the EDI still will not power on replace the EDI (see IC-OUM- 09071 EDI Operators Manual).

Observation: No 915 MHZ Communications

Solutions: Before performing any trouble shooting ensure that you are in an area where 915MHz communications with the Base Station are good and that the vehicle has a good battery. A bad battery can power the EDI power indicator light but not the 915MHz radio inside the EDI.

Cycle the EDI power button to reboot the EDI; Check both connections of the 915 MHz coax cable located at the 915 MHz Antenna Bracket with RF Choke and the EDI; ensure that the 915 MHz antenna is properly seated to the 915 MHz Antenna Bracket with RF Choke; inspect the CSS-E Wiring Harness for damage and replace if necessary; check with the Base Station for comms.

If there is still no comms use known good spare parts to identify and replace the non-operational part(s).

Hook up but do not mount a 915 MHz Antenna with 915 MHz Antenna Bracket with RF Choke to the CSSE- Wiring Harness, wait 30 seconds and check comms with base station; Hook up but do not route the RF coaxial cable on the CSS-E Wiring Harness to the 915 MHz Antenna Bracket with RF Choke and the EDI, wait 30 seconds and check comms with the Base Station;

a. If the EDI is still out of comms replace the EDI (see IC-OUM-09071 EDI Operators Manual).

Operator User Manual for the CSS-E Kit

3.2 Maintenance Procedures

Not Applicable

4. Special Tools/Installation Equipment Not Applicable

5. Appendix Not Applicable

1.3 Principles of Operations