ROUTINE - Gear Report

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ROUTINEMWO effective date is 1 January 2001 and completion date is 31 December 2004.MWO 9-2320-280-20-6MODIFICATION WORK ORDERMODIFICATION OF 1-1/4 TON VEHICLESHEAVY VARIANT, ARMAMENT CARRIER, ANDEXPANDED CAPACITY VEHICLESM1097, M1097A1, M1025A2,M1097A2, M1113, AND M1114AIRLIFT BUMPER REINFORCEMENTHeadquarters, Department of the Army, Washington, D.C.1 January 2001REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTSYou can help improve this publication. If you find any mistakes or if you know of a wayto improve the procedures, please let us know. Submit your DA Form 2028-2(Recommended Changes to Equipment Technical Publications), through the Internet,on the Army Electronic Product Support (AEPS) website.The Internet address ishttp://aeps.ria.army.mil. If you need a password, scroll down and click on “ACCESSREQUEST FORM”. The DA Form 2028 is located in the ONLINE FORMSPROCESSING section of the AEPS. Fill out the form and click on SUBMIT. Using thisform on the AEPS will enable us to respond quicker to your comments and bettermanage the DA Form 2028 program. You may also mail, fax or E-mail your letter, DAForm 2028 or DA Form 2028-2 direct to: Commander, U.S. Army Tank-automotiveand Armaments Command, ATTN:AMSTA-LC-CIP-WT, Rock Island, IL 61299-7630.The email address is TACOM-TECH-PUBS@ria.army.mil. The fax number is DSN793-0726 or Commercial (309) 782-0726.APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED.

MWO 9-2320-280-20-61. PURPOSE.This modification provides a reinforcement for the bumper during towing operations. After the vehicle ismodified it will be “AUTHORIZED TO TOW TRAILERS WITH MAX GROSS WEIGHT OF 4,200 LB(1,907 KG)”.2. PRIORITY.This modification is classified as ROUTINE.3. END ITEM TO BE MODIFIED.NOTEApplication will be controlled/determined by PM, LTV basedon approved DCSOPS distribution plans/funding streamsfor HMT.a. Selected vehicles as identified by models below and serial numbers selected by the user.NOMENCLATURETruck, Utility, 1-1/4 ton, 4x4:Armament Carrier, ArmoredTruck, Utility, Heavy Variant1-1/4 ton 4x4:*Heavy Variant*Heavy Variant*Heavy VariantTruck, Utility, ExpandedCapacity 4x4:*Shelter CarrierUp-Armored CarrierNSNPART 1920719207M1113M1114*Not applicable to vehicles equipped with Pintle Extension Kit, or not applicable to vehicles withshelters extending past the rear bumper.b. Vehicle National Stock Number (NSN) will not change as a result of this MWO.4. MODULE(S) TO BE MODIFIED.Not applicable.5. PART(S) TO BE MODIFIED.Not applicable.6. APPLICATION.a. Time Compliance Schedule: The effective date of this MWO is 1 January 2001 and its completion dateis 31 December 2004.b. The lowest level of maintenance authorized to apply the MWO is Organizational maintenance.c. Work force and man-hour requirements for application of the MWO to a single unit, end item, orREQUIREMENTSWORK FORCE/SKILLS2MAN-HOURSOne Wheeled Vehicle Mechanic(MOS 63B) or equivalent0.8Total man-hours required for a singleapplication of this MWO0.8

MWO 9-2320-280-20-6system:7. TECHNICAL PUBLICATIONS AFFECTED/CHANGED AS A RESULT OF THIS MWO.Technical PublicationDateTM 9-2320-280-10TM 9-2320-280-20TM 9-2320-280-24PTM 9-2320-387-10TM 9-2320-387-24TM 9-2320-387-24P31 Jan 9631 Jan 9631 Jan 9631 Oct 9731 Nov 9731 Sep 988. MWO KITS, PARTS, AND THEIR DISPOSITION.a. The following kit is required to accomplish this modification. The security classification of this kit isunclassified. Shipping data is: weight 32 lbs; the kit measures 31.5 x 9 x 3 in.; its volume is 0.492 cu ft.NSNNOMENCLATURECAGECPART NO.5340-01-477-6588Airlift Bumper1920757K3554ReinforcementModification Kitb. Airlift Bumper Reinforcement Modification Kit component parts are listed below. The listing is usedto inventory the kit for -00-071-2077NOMENCLATURECAGECPART TURECAGECPART NO.QTY.Adhesive: Versilok6W728204A/RPlate, Instruction, MWOPlate, BumperReinforcementBracket, PintleFitting, LubeScrew, DrivePin, CotterNutNutScrewScrewScrewc. Bulk and Expendable Material.NSNd. Parts Disposition. All parts not reused during installation will be returned to stock for disposition inaccordance with AR 725-50.9. SPECIAL TOOLS; TOOL KITS; JIGS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE); AND FIXTURESREQUIRED.a. Hand tools necessary to apply MWO are contained in following tool kit:NOMENCLATURENSNCAGECSUPPLY CATALOG3

MWO 9-2320-280-20-6Tool Kit, General Mechanic’s5180-00-177-703350980SC 5180-95-N26b. Tools necessary to apply MWO are contained in following shop set:NOMENCLATURENSNCAGECSUPPLY CATALOGShop Equipment, AutomotiveMaintenance and Repair:Organizational Maintenance,Common No. 14910-00-754-065419204SC 4910-95-A7410. MODIFICATION PROCEDURE.a. Vehicle Preparation.(1) Park vehicle and apply parking brake lever. (Refer to TM 9-2320-280-10 or TM 9-2320-387-10.)(2) Remove towing pintle assembly. (Refer to TM 9-2320-280-20 or TM 9-2320-387-24.)(3) Remove four nuts, screws, cover assembly, and trailer connector from receptacle mountingbracket and rear bumper as shown in figure 1.(4) Remove two nuts, screws, and receptacle mounting bracket from rear bumper as shown infigure 1.(5) Remove four nuts, eight washers, and four screws from rear bumper and bumper mountingbrackets as shown in figure 2.b. Airlift Bumper Reinforcement Installation.(1) Install 12469169 bumper reinforcement plate on rear bumper and bumper mounting bracketswith four B1821BH050C350N screws, eight existing washers, and four M45913/4-8CG8Z nuts asshown in figure 3. Do not tighten nuts.(2) Install MS15001-4 lube fitting in 12469170 pintle bracket as shown in figure 4.(3) Install existing safety chain plate, support plate, spacer, and pintle bracket (12469170) onbumper reinforcement plate and rear bumper with four B1821BH050C300N screws, eightexisting washers, and four M45913/4-8CG8Z nuts as shown in figure 4. Do not tighten nuts.c. Vehicle Final Preparation.(1) Route trailer connector through existing receptacle mounting bracket and install receptaclemounting bracket on bumper reinforcement plate and rear bumper with two B1821BH025C150Nscrews and 271172 nuts as shown in figure 5. Do not tighten nuts.(2) Install existing cover assembly and trailer connector on receptacle mounting bracket, bumperreinforcement plate, and rear bumper with two B1821BH025C150N screws, two existing screws,and four 271172 nuts as shown in figure 5.(3) Install towing pintle on bumper reinforcement plate and rear bumper with existing washer andslotted nut as shown in figure 6. Loosen slotted nut slightly if towing pintle will not rotate easily.(4) Align hole in towing pintle and slotted nut and install MS24665-628 cotter pin through slottednut and towing pintle as shown in figure 6.(5) Tighten nuts installed in para. b, steps 1 and 3 to 90 lb-ft (122 N m) as shown in figures 3 and 4.(6) Tighten nuts installed in para. c, steps 1 and 2 to 10 lb-ft (14 N m) as shown in figure 5.4

MWO 9-2320-280-20-611. CALIBRATION REQUIREMENTS.Not applicable to this MWO.12. WEIGHT AND BALANCE DATA.Weight and balance are not significantly affected by this MWO.13. QUALITY ASSURANCE REQUIREMENTS.a. General. The following information is furnished to ensure the proper application of this MWO andprovide clarification in regard to the adequacy of installer’s inspection methods and procedures applicable toQuality Assurance (QA). Inspection shall be IAW TM 750-245-4, TM 9-2320-280-10, TM 9-2320-280-20, TM 92320-387-10, TM 9-2320-387-24, and MWO 9-2320-280-20-6.b. Installer Responsibilities. The installer is responsible for following instructions in MWO 9-2320-28020-6, TM 9-2320-280-10, TM 9-2320-280-20, TM 9-2320-387-10, and TM 9-2320-387-24. The installer willreport Airlift Bumper Reinforcement Modification Kits received that are damaged or missing componentparts so the kit supplier can be properly notified. Any discrepancies noted will be corrected before the vehicleleaves the installer’s work area. Requirements contained in this MWO shall be included in the installer’sinspection plan or quality assurance program. These requirements shall not be construed as eliminating theinstaller’s responsibility from complete compliance with provisions of the contract and submitting to theGovernment products that meet all requirements of the contract.c. Government Verification. All QA operations and installation changes and inspections performed bythe installer are subject to Government verification at unannounced and varying intervals. Verification willconsist of observations and inspections to confirm that practices, methods, and procedures of the installer’swritten inspection plan are being properly applied; and that Government product inspection to confirm thequality of product offered for Government acceptance does not deviate from prescribed acceptance standardsspecified in TM 9-2320-280-10, TM 9-2320-280-20, TM 9-2320-387-10, TM 9-2320-387-24, and TM 750-245-4.Deviations will be brought to the attention of the installer for correction.d. In-process Inspection. During normal assembly operations, paragraph 10, Modification Procedure,will be used to check the installer’s work. After installation is complete, the vehicle will be checked IAW thePMCS checklist for correct installation and to ensure there are no defects. Any defects noted will be correctedby the installer before the vehicle is placed in service. All vehicles modified during a production shift will bechecked to ensure product quality.14. RECORDING AND REPORTING OF THE MODIFICATION.a. Records and Reports. The organization responsible for MWO application will report applicationinformation as follows:(1)Reporting will be accomplished by electronic means. MWO application information can be inputdirectly into the Modification Management Information System (MMIS) over the internet. Ifinternet is not available, recording will be on a 3.5-inch disk, which will be mailed to the MMISadministrator. Entry into the MMIS system is password protected. New users can register online at http://208.242.67.250/mwo. Passwords are normally approved and issued within 48hours.(2)Submission will be comprised of the nine (9) data elements listed in the table below. Elements1,2,4,6,7,8 & 9 are given for this MWO (as shown). The person reporting the MWO data, willacquire the remaining elements (3 & 5), and input all nine into MMIS.DATA Elements1.2.3.4.5.Input DataMaterial Change Number (MCN)MWO NumberUnit Identification Code (UIC) @ Battalion LevelNSN of End ItemSerial Number5

MWO 9-2320-280-20-66.7.8.9.(3)USA Registration NumberDate of ApplicationHours required for Application.Software VersionFor off-line reporting, the 3.5-inch disk shall be mailed to the following address:CommanderTACOM-WarrenATTN: AMSTA-LC-CIPWMWarren, MI 48397-5000b. Marking Equipment.(1) After Airlift Bumper Reinforcement Modification Kit is installed, mark MWO under “9-2320-28020-6” in the MWO Applied block and date applied in Date block on 10930014 MWO instructionplate.NOTE Do not remove any existing MWO instruction platesaffixed to the reinforcement panel. Perform steps 2 and 3 for M1097, M1097A1, M1025A2,M1097A2, M1113, and step 4 for M1114.(2) Install MWO instruction plate 10930014 by drilling a 0.104-inch diameter hole (#37 drill bit)within designated area on left side body reinforcement panel and secure with MS21318-20 drivescrew as shown in figure 7.(3) After drive screw is installed, flatten or remove protruding excess drive screw material frominside of side body reinforcement panel.(4) Apply versilok adhesive 204 on back of MWO instruction plate 10930014 and install on left sidebody armor panel as shown in figure 8.15. MATERIAL CHANGE (MC) NUMBER.This MWO is authorized by (MC) number 1-00-06-0009.16. MODIFICATION IDENTIFICATION.a. When installed correctly, the Airlift Bumper Reinforcement Modification Kit will appear as shownin figure 9.b. After the Airlift Bumper Reinforcement Modification Kit is installed, the airlift bumper reinforcementshould be inspected for secure mounting. Any faults detected, or discrepancies noted, will be corrected beforethe vehicle is returned to normal service.c. After the vehicle is modified it will be “AUTHORIZED TO TOW TRAILERS WITH MAX GROSSWEIGHT OF 4,200 LB (1,907 KG)”.6

MWO 9-2320-280-20-6RECEPTACLEMOUNTINGBRACKET – REFREAR BUMPER – REF2 – SCREW – REF2 – NUT – REFCOVERASSEMBLY – REF4 – NUT – REF4 – SCREW – REFTRAILER CONNECTOR – REFFIGURE 1

MWO 9-2320-280-20-62 – BUMPER MOUNTINGBRACKET – REF4 – NUT – REF8 – WASHER – REF4 – SCREW – REFREAR BUMPER – REFRIGHT SIDE SHOWN, LEFT SIDE OPPOSITEFIGURE 2

MWO 9-2320-280-20-62 – BUMPER MOUNTINGBRACKET – REF4 – NUT –M45913/4-8CG8ZREAR BUMPER – REF8 – WASHER – REF4 – SCREW –B1821BH050C350NBUMPER REINFORCEMENTPLATE – 12469169FIGURE 3

MWO 9-2320-280-20-6REARBUMPER – REFBUMPERREINFORCEMENTPLATE – REF4 – SCREWB1821BH050C300N4 – NUT –M45913/4-8CG8Z8 – WASHER – REFSUPPORT PLATE – REFSPACER – REFSAFETY CHAIN PLATE – REFPINTLE BRACKET – 12469170LUBE FITTING – MS15001-4FIGURE 4

MWO 9-2320-280-20-6RECEPTACLE MOUNTING BRACKET – REF2 – SCREW – B1821BH025C150NTRAILER CONNECTOR – REFCOVERASSEMBLY – REF2 – SCREW –B1821BH025C150N2 – NUT – 2711722 – SCREW - REF4 – NUT – 271172REAR BUMPER – REFBUMPER REINFORCEMENTPLATE – REFFIGURE 5

MWO 9-2320-280-20-6REAR BUMPER - REFBUMPER REINFORCEMENTPLATE - REFTOWING PINTLE - REFWASHER - REFCOTTER PIN - MS24665-628SLOTTED NUT - REFFIGURE 6

MWO 9-2320-280-20-6NOTE: ALL DIMENSIONS ARE IN INCHESTO FRONT OF VEHICLE1.5BODY REINFORCEMENT PANEL – REFDRILL 0.104-INCH DIAMETER HOLE15.0LEFT SIDE BODY – REFDRIVE SCREW – MS21318-20MWO INSTRUCTION PLATE – 109300144.00DESIGNATED AREA – REFFIGURE 72.00

MWO 9-2320-280-20-6NOTE: ALL DIMENSIONS ARE IN INCHESARMOR PANEL – REF2.06.0APPLY VERSILOKADHESIVE 204 ON BACKMWO INSTRUCTION PLATE – 10930014LEFT SIDE BODY – REF4.00DESIGNATED AREA – REFTO FRONT OF VEHICLEFIGURE 82.00

MWO 9-2320-280-20-6AIRLIFT BUMPER REINFORCEMENT INSTALLEDFIGURE 9

MWO 9-2320-280-20-6By Order of the Secretary of the Army:ERIC K. SHINSEKIGeneral, United States ArmyChief of StaffOfficial:JOEL B. HUDSONAdministrative Assistant to theSecretary of the Army0024511Distribution:To be distributed in accordance with the initial distribution number (IDN) 381104, requirements forMWO 9-2320-280-20-6.

THE METRIC SYSTEM AND EQUIVALENTSLINEAR MEASURE1 Centimeter 10 Millimeters 0.01 Meters 0.3937 Inches1 Meter 100 Centimeters 1,000 Millimeters 39.37 Inches1 Kilometer 1,000 Meters 0.621 MilesSQUARE MEASURE1 Sq Centimeter 100 Sq Millimeters 0.155 Sq Inches1 Sq Meter 10,000 Sq Centimeters 10.76 Sq Feet1 Sq Kilometer 1,000,000 Sq Meters 0.386 Sq MilesCUBIC MEASURE1 Cu Centimeter 1,000 Cu Millimeters 0.06 Cu Inches1 Cu Meter 1,000,000 Cu Centimeters 35.31 Cu FeetLIQUID MEASURE1 Milliliter 0.001 Liters 0.0338 Fluid Ounces1 Liter 1,000 Milliliters 33.82 Fluid OuncesTEMPERATURE5/9 ( F -32) C212 Fahrenheit is equivalent to 100 Celsius90 Fahrenheit is equivalent to 32.2 Celsius32 Fahrenheit is equivalent to 0 Celsius9/5 C 32 FWEIGHTS1 Gram 0.001 Kilograms 1,000 Milligrams 0.035Ounces1 Kilogram 1,000 Grams 2.2 Lb1 Metric Ton 1,000 Kilograms 1 Megagram 1.1 ShortAPPROXIMATE CONVERSION FACTORSTO CHANGE . . . . . . . . . . . . . . . . . . .Inches . . . . . . . . . . . . . . . . . . . . . . . .Feet . . . . . . . . . . . . . . . . . . . . . . . . .Yards . . . . . . . . . . . . . . . . . . . . . . . .Miles . . . . . . . . . . . . . . . . . . . . . . . .Square Inches . . . . . . . . . . . . . . . . .Square Feet . . . . . . . . . . . . . . . . . . .Square Yards . . . . . . . . . . . . . . . . . .Square Miles . . . . . . . . . . . . . . . . . .Acres . . . . . . . . . . . . . . . . . . . . . . . .Cubic Feet . . . . . . . . . . . . . . . . . . . .Cubic Yards . . . . . . . . . . . . . . . . . . .Fluid Ounces . . . . . . . . . . . . . . . . . .Pints . . . . . . . . . . . . . . . . . . . . . . . . .Quarts . . . . . . . . . . . . . . . . . . . . . . .Gallons . . . . . . . . . . . . . . . . . . . . . . .Ounces . . . . . . . . . . . . . . . . . . . . . . .Pounds . . . . . . . . . . . . . . . . . . . . . . .Short Tons . . . . . . . . . . . . . . . . . . . .Pound-Feet . . . . . . . . . . . . . . . . . . . .Pounds Per Square Inch . . . . . . . . .Miles Per Gallon . . . . . . . . . . . . . . .Miles Per Hour . . . . . . . . . . . . . . . .TO . . . . . . . . . . . . . . . . . . . . . .Centimeters . . . . . . . . . . . . . . .Meters . . . . . . . . . . . . . . . . . . .Meters . . . . . . . . . . . . . . . . . . .Kilometers . . . . . . . . . . . . . . . .Square Centimeters . . . . . . . . .Square Meters . . . . . . . . . . . . .Square Meters . . . . . . . . . . . . .Square Kilometers . . . . . . . . . .Square Hectometers . . . . . . . . .Cubic Meters . . . . . . . . . . . . . .Cubic Meters . . . . . . . . . . . . . .Milliliters . . . . . . . . . . . . . . . . .Liters . . . . . . . . . . . . . . . . . . . .Liters . . . . . . . . . . . . . . . . . . . .Liters . . . . . . . . . . . . . . . . . . . .Grams . . . . . . . . . . . . . . . . . . . .Kilograms . . . . . . . . . . . . . . . . .Metric Tons . . . . . . . . . . . . . . .Newton-Meters . . . . . . . . . . . . .Kilopascals . . . . . . . . . . . . . . . .Kilometers Per Liter . . . . . . . .Kilometers Per Hour . . . . . . . .MULTIPLY .0.405.0.028.0.765. 29.573.0.473.0.946.3.785. 28.349.0.454.0.907.1.356.6.895.0.425.1.609TO CHANGE . . . . . . . . . . . . . . . .Centimeters . . . . . . . . . . . . . . . .Meters . . . . . . . . . . . . . . . . . . . .Meters . . . . . . . . . . . . . . . . . . . .Kilometers . . . . . . . . . . . . . . . . .Square Centimeters . . . . . . . . . .Square Meters . . . . . . . . . . . . . .Square Meters . . . . . . . . . . . . . .Square Kilometers . . . . . . . . . . .Square Hectometers . . . . . . . . . .Cubic Meters . . . . . . . . . . . . . . .Cubic Meters . . . . . . . . . . . . . . .Milliliters . . . . . . . . . . . . . . . . . .Liters . . . . . . . . . . . . . . . . . . . . .Liters . . . . . . . . . . . . . . . . . . . . .Liters . . . . . . . . . . . . . . . . . . . . .Grams . . . . . . . . . . . . . . . . . . . .Kilograms . . . . . . . . . . . . . . . . . .Metric Tons . . . . . . . . . . . . . . . .Newton-Meters . . . . . . . . . . . . .Kilopascals . . . . . . . . . . . . . . . . .Kilometers Per Liter . . . . . . . . .Kilometers Per Hour . . . . . . . . .TO . . . . . . . . . . . . . . . . . . . . . .Inches . . . . . . . . . . . . . . . . . . . .Feet . . . . . . . . . . . . . . . . . . . . .Yards . . . . . . . . . . . . . . . . . . . .Miles . . . . . . . . . . . . . . . . . . . . .Square Inches . . . . . . . . . . . . . .Square Feet . . . . . . . . . . . . . . .Square Yards . . . . . . . . . . . . . .Square Miles . . . . . . . . . . . . . .Acres . . . . . . . . . . . . . . . . . . . . .Cubic Feet . . . . . . . . . . . . . . . .Cubic Yards . . . . . . . . . . . . . . .Fluid Ounces . . . . . . . . . . . . . .Pints . . . . . . . . . . . . . . . . . . . . .Quarts . . . . . . . . . . . . . . . . . . .Gallons . . . . . . . . . . . . . . . . . . .Ounces . . . . . . . . . . . . . . . . . . .Pounds . . . . . . . . . . . . . . . . . . .Short Tons . . . . . . . . . . . . . . . .Pound-Feet . . . . . . . . . . . . . . . .Pounds Per Square Inch . . . . . .Miles Per Gallon . . . . . . . . . . .Miles Per Hour . . . . . . . . . . . . .MULTIPLY BY.0.394.3.280.1.094.0.621.0.155. 10.764.1.196.0.386.2.471. .102.0.738.0.145.2.354.0.621.

PIN: 078464-000

specified in TM 9-2320-280-10, TM 9-2320-280-20, TM 9-2320-387-10, TM 9-2320-387-24, and TM 750-245-4. Deviations will be brought to the attention of the installer for correction. d. In-process Inspection. During normal assembly operations, paragra

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