P-19R_TMCR.doc

TECHNICAL MANUAL CONTRACT REQUIREMENT (TMCR)

Truck, Firefighting, Aircraft Crash and Structure Fire, A/S32P-19A Replacement

(P-19R)

September 2012

Prepared By

Program Manager, Medium & Heavy Tactical Vehicles

PEO Land Systems

United States Marine Corps

DISTRIBUTION STATEMENT D: Distribution Authorized to Department of Defense (DoD) and U.S. DoD contractors only to protect information in management reviews, records, or contract performance evaluations, or other advisory documents, evaluating programs of contractors, and to protect technical or operational data.

TECHNICAL MANUAL CONTRACT REQUIREMENT (TMCR)

Truck, Firefighting, Aircraft Crash and Structure Fire, A/S32P-19A Replacement

(P-19R)

SUBJECT:

CREW/OPERATOR, FIELD, AND SUSTAINMENT LEVEL INTERACTIVE ELECTRONIC TECHNICAL MANUAL (IETM) FOR THE P19 Replacement SCOPE: The requirements specified herein constitute technical manual tasks to be performed by the contractor and the resulting deliverables to the Government. This TMCR sets forth the work efforts required of the contractor to produce and deliver the IETMs and paper TMs required for the P-19R.

1.0 APPLICABLE DOCUMENTS

1.1 Government Documents. The following documents were used to establish the requirements of this TMCR to the extent covered herein and shall be used for the development of the P-19R IETMs. In the event of conflict between the requirements of this TMCR, and the documents referenced herein, the contractor shall notify the government and the requirements of this TMCR shall take precedence. These documents support both electronic delivery of the IETM and paper TMs generated from the IETMs.

MIL-STD-1840

Automated Interchange of Technical Information

MIL-STD-2073-1

Standard Practice for Military Packaging

MIL-STD-2361D

Production XML DTD

MIL-STD-40051-1

Department of Defense Standard Practice: Preparation of Digital Technical Information for Interactive Eletctronic Technical Manuals

MIL-STD 40051-2

Preprartion of Digital Technical Information for Page Based Technical Manuals.

MIL-PRF-28000B

Digital Representation for Communication of Product Data: IGES (Initial Graphics Exchange Specification) Application Subsets and IGES Application Protocols

MIL-PRF-28002C

Raster Graphics Representation in Binary Format

MIL-PRF-28002

Raster Graphics Representation in Binary Format, Requirements for

MIL-PRF-87268A

Manuals Interactive Electronic Technical: General Content, Style, Format and User-Interaction Requirements

MIL-PRF-87269A

Data Base, Revisable: Interactive Electronic Technical Manuals, For the Support of

MIL-HDBK-511

Interoperability of Interactive Electronic Technical Manuals (IETM)

MIL-HDBK-38790

Printing Production of Technical Manuals

MCO 5215.17_

The Marine Corps Technical Publication System

ASME Y14.38M

Abbreviations and Acronyms

2.0 REQUIREMENTS. United States Marine Corps P-19R Program Technical Publications will consist of:

TM XXXX, CREW/ OPERATOR LEVEL OPERATIONS AND MAINTENANCE INTERACTIVE ELECTRONIC TECHNICAL MANUAL (IETM) FOR P19A REPLACEMENT (P-19R) WITH COMPONENTS LIST

TM XXXX, FIELD LEVEL MAINTENANCE INTERACTIVE ELECTRONIC TECHNICAL MANUAL (IETM) FOR P19A REPLACEMENT (P-19R) WITH REPAIR PARTS AND SPECIAL TOOLS LISTS

TM XXXX, SUSTAINMENT LEVEL MAINTENANCE INTERACTIVE ELECTRONIC TECHNICAL MANUAL (IETM) FOR P19A REPLACEMENT (P-19R) WITH REPAIR PARTS AND SPECIAL TOOLS LISTS

2.1 Start of Work Meeting. The Contractor shall meet with the Government during the Start of Work meeting to discuss the IETM requirements and the schedule of IPRs and IETM deliverables.

2.2 Technical Manual Quality Assurance. The Contractor shall be responsible for the quality of the IETMs provided by vendors or subcontractors and for manuals to be developed In Accordance With (IAW) this TMCR.

2.3 Copyright. All technical manuals delivered shall be free of copyright restrictions for copying, printing and distribution by all U.S. Government activities. The contractor shall identify copyrighted material, if any, and shall obtain the written approval from the copyright owner. When the contractor uses a manual, which covers a vendor's component(s) or a portion thereof, and the vendor's manual contains copyrighted material, the contractor shall be responsible for obtaining a copyright release from the vendor and providing the copyright release to the Government. The Contractor shall provide a copyright release letter, with the delivery of each IETM submission, which provides the U.S. Government with the rights stated above.

2.4 IETMs. All three IETMs shall be produced separatly, and capable of interfacing the lower level IETMs as required through hyperlinking. Each CDRL deliverable will consist of the following:

a. CDRL T010 – IETM Validation Certificate

b. CDRL T012 – Crew/Operator, Field & Sustainment Level IETM Book Plan and Outline

c. CDRL T013 – Crew/Operator Level IETM

d. CDRL T011 – Field Level Maintenance IETM

e. CDRL T014 – Sustainment Level Mainteannce IETM

2.5 Paper Technical Manuals. All three IETMs shall be capable of being printed into a paper Technical Manual, formatted IAW MIL-STD 40051-2. Paper Crew/Operator TMs are to be included with the delivery of each P-19R as part of the vehicle Basic Issue Item (BII).

2.6 Printing of Manual. The contractor shall print the approved final manual in quantities sufficient to meet distribution requirements. Print manual on JCP-A60 (50 pounds per 500 sheets) white paper. Print the front and back covers on JCP-K20 (110 pounds per 500 sheets) buff index paper. The printed manual will be three (3) hole standard punched, round holes 1/4 inch in diameter and holes spaced 4 1/4 inches center to center, bound with fasteners, and shrink wrapped. See MIL-HDBK-38790 for guidance.

2.7 Detail Requirements

2.7.1 Technical Manuals Preparation Instructions. The IETMs shall be developed using the Contractor’s database. The manuscript/draft for the IETMs for review shall be the most current stage of development complete with front matter, text, tables and illustrations. Included shall be corrections resulting from any IPR, and validation and verification. Abbreviations used shall be IAW ASME Y14.38M.

2.7.2 Markup Language (XML). The Contractor shall XML tag the IETMs IAW MIL-STD-2361D for the P-19R utilizing non proprietary authoring software, which meets the requirements of MIL-PRF-87268A and be capable of conversion to a database to meet the requirements of MIL-PRF-87269A. The IETM shall be tagged to ensure that the user can locate instructions, figures, schematics or the parts lists required, electronically throughout the IETMs and print screen or a complete procedure. This technique will roll all information normally associated with the paper technical manuals, repair parts and related information into an IETM on CD-ROM(s). MIL-STD-1840 shall be used in the standardization of formats for exchange of digital information necessary for the development and logistic support of systems throughout their life cycle and formats for delivery of the maintenance manual in electronic media/CD-ROM(s). Raster graphic representation shall be IAW MIL-PRF-28002. The IETM shall be in compliance with the MIL-PRF-28000 series guiding IETM development and delivery.

2.7.3 IETM Formats. Current DoD equipment manual formats will be availabel upon request as samples of operator, maintenance, equipment troubleshooting, PMCS, lubrication instructions and appendices for use by the Contractor if desired.

2.7.4 Electronic Preparation. All IETMs prepared under provisions of this TMCR will be composed utilizing EMS-NextGen and in accordnance with MIL-STD-40051.2. They will also be reproducible into a printed format to meet MIL-STD 40051-2. All IETMs shall be produced in accordnacne with MIL-HDBK-511. From the point of view of an essential requirement and deliverable of this TMCR, such a program must produce/result in delivery of both hard copy paper technical manuals and an editable, XML tagged electronic file for each technical manual provided on CD-ROM. The medium utilized shall be clearly labeled with the equipment publications number along with the specific software name and version utilized in the IETM development.

2.7.5 Hyperlinking. All troubleshooting procedures written or developed for the IETM portions of this requirement shall be linked to related schematics and any other appropriate aid in isolating their fault and the user is automatically linked to the maintenance procedure used to correct the fault. This maintenance procedure shall link to its related Repair Parts and Special Tools List information and automated parts ordering processes. Once the maintainer has completed the maintenance action, the maintainer shall be able to link back to a verification procedure to make sure the completed maintenance action has successfully corrected the fault.

2.7.6 Cover and Title Page. The following distribution statement shall be printed on the front cover of the paper TMs, and the disks containing the IETMs. The statement shall be centered, one-half inch below the Marine Corps Seal in 6.5 point font on the paper TMs, and located on the label of each disk containing the IETMs.

THIS PUBLICATION IS REQUIRED FOR OFFICIAL USE OR FOR ADMINISTRATIVE OR OPERATIONAL PURPOSES. DISTRIBUTION IS LIMITED TO U.S. AGENCIES ONLY. OTHER REQUESTS FOR THIS DOCUMENT MUST BE REFERRED TO: PROGRAM MANAGER, MEDIUM AND HEAVY TACTICAL VEHICLES, PROGRAM EXECUTIVE OFFICER LAND SYSTEMS, MARINE CORPS SYSTEMS COMMAND, 2200 LESTER STRET, QUANTICO, VIRGINIA 22134-5010.

2.7.7 Destruction Notice. The following destruction statement shall be printed on the front cover of the paper TMs, and the disks containing the IETMs. The following destruction notice shall be printed two line spaces beneath the above distribution statement in 6.5 point font on the paper TMs and located on the label of each disk containing the IETMs.

DESTRUCTION NOTICE - FOR UNCLASSIFIED, LIMITED DOCUMENTS, DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENTS.

2.7.8 Use Statement. The following usage statement shall be printed on the front cover of the paper TMs, and the disks containing the IETMs. The statement FOR OFFICIAL USE ONLY shall appear in 14.4 point font, 0.125-inch below the bottom horizontal-rule line, centered on the paper TMs and located on the label of each disk containing the IETMs.

2.7.9 Publication Number. The publication shall be assigned a Technical Manual (TM) Number and PCN (Publication Control Number). The numbers shall be assigned by Program Manager Medium & Heavy Tactical Vehicles, Program Executive Officer Land Systems. The TM number shall be printed on the front cover of the paper TMs, and the disks containing the IETMs in accordnance with MCO 5215.17. The TM number shall be placed on the front cover and shall be on all pages of the paper TMs, and located on the label of each disk containing the IETMs. The number shall slso be placed on the opening screen of the IETM and also be accessible through an “ABOUT” menu item.

2.7.10 Publication Date. The publication date shall be the Copy Freeze date which is an engineering cut-off date established by the Government. Hardware changes shall not be incorporated into the publication after the Copy Freeze date without Government approval. The Publication Date shall be printed on the front cover of the paper TMs, and the disks containing the IETMs. The publication date shall be shown on the front cover only of the paper TMs (Refer to MIL-STD-38784(1) for correct placement), and located on the label of each disk containing the IETMs.

2.7.11 Photograph/Illustrations/Line Drawings. Line drawings shall be prepared in lieu of photographs for all IETMs.

2.7.11.1 Illustrations. Illustrations shall follow as close as possible to its first reference in the narrative text. Illustrations and associated text shall be on the same page, or facing pages when printed, whenever possible. Callouts on illustrations shall be IAW MIL-SD-40051.2. However, when an illustration is extensive and requires a foldout sheet, such as for a large schematic diagram, it shall be located at the end of the manual when printed. In-text and foldout artwork and graphic depictions shall be an integral part of the manual and shall be included throughout the text. The IETMs shall contain all art necessary to illustrate and/or clarify written explanations. The graphics shall be developed IAW MIL-PRF-87269. The graphics for the IETMs shall be derived from the engineer drawing data base.

2.7.11.2 Clarity. Line art, including schematics, wiring diagrams and block diagrams, shall be of sufficient darkness and sharpness of line to reproduce clearly at required reproduction size without additional treatment. Nomenclature, callouts, tabular material and symbols appearing on illustrations shall be upper case, with 10 point minimum reproduced size IAW MIL-SD-40051.2.

2.7.12 Reproducible Copy and Integrally Related Art. A manuscript having all corrections resulting from in-process reviews, validation and verification incorporated shall be provided. The material shall be prepared legibly and usably at the most economical cost, considering initial and follow-on costs, such as reproduction printing, handling, filing and storing and any combination thereof.

2.7.13 Front Matter. Front matter for the IETMs shall conform to the requirements of MIL-PRF-87268. Front matter shall consist of:

(1) Title Frame

(2) Notice of Changes

(3) Table of Contents (as applicable)

(4) List of Illustrations

(5) List of Tables

(6) Safety Summary

This information shall appear in a title screen and shall be accessed through a Contractor proposed design for the presentation and access of the materials contained in the IETMs.

2.7.14 IETM CD-ROM(s) for Review. The IETM CD-ROM(s) shall be complete with content to support the installation, operation, test and maintenance, to include repair parts listings. Included shall be corrections resulting from in-process reviews and testing (Government or Contractor), as applicable, validation and verification.

2.7.15 IETM Updates. Corrections resulting from reviews, technical evaluation, validation, verification and updating of the IETMs database as applicable, shall be incorporated into the IETMs. The Contractor shall propose a methodology for identifying the updated portions of the IETMs to ensure accuracy and configuration control.

2.7.16 IETM Book Plan and Outline. The Contractor shall prepare and submit an IETM book plan and outline for each IETM, which fully demonstrates the Contractor's understanding of the IETM requirements IAW CDRL T012. The technical publications listed in paragraph 2.0 must completely and accurately inform users of the P-19R, how to operate and maintain these systems, how to quickly and efficiently troubleshoot the equipment as well as provide complete parts support for both implementation of P-19R parts support approach for the near term and future sustainment years.

2.7.17 Functional organization

a. Graphics shall show relationships of components to an assembly and parts to a component.

b. Graphics shall be keyed in procedural/disassembly sequence.

c. Parts information shall be accessible from the reference designator. The illustrated parts breakdown (IPB) typically contained in IETMs shall be replaced by drawings and graphics to specific part(s) contained in the parts list. Component views or illustrations shall be linked to the parts list.

2.7.17.1 Theory Information. This module shall provide a detailed theory of operations for the P-19R to the subsystem level. Block diagrams, and schematic diagrams shall be used throughout. Information shall not be duplicated except for emphasis and clarity. All necessary information shall be provided to enable the technician to determine whether the component or circuit is functioning properly.

2.7.17.2 Preventive Maintenance Checks and Services (PMCS) Information. PMCS as required by this specification is defined as the scheduled cleaning, inspection, and adjustment of equipment. Either operator or maintenance personnel accomplish this as required including the replacement of consumable components. PMCS interval shall be determined by equipment manufacturer for government approval.

a. PMCS to be performed by operators and maintenance personnel shall be arranged in a logical sequence requiring minimum time and motion on the part of the person(s) performing the tasks. An illustration of the equipment/system or component upon which PMCS will be performed is required.

b. PMCS is usually presented in a table format and shall address the following minimum requirements:

1) Sequence Number. In this column, each PMCS task will be numbered in chronological order regardless of interval.

2) Interval/Maintenance Schedule. The appropriate interval (monthly, semiannually, annually, before, during, or after operation, or whatever is applicable) shall be part of the table. Only the interval columns required will be part of the table.

3) Item to be inspected. The items listed in this column shall be divided indicating the portion of the equipment of which they are a part. Under these groupings the item to be inspected shall be identified by as few words, usually the common name, as will clearly identify the item, e.g., bumper, gas can, mounting bracket and fuel pump.

4) Task Description. The Task Description gives a brief description of the procedures by which PMCS is to be performed. The Task Description follows the item to be inspected in the same column. Other illustrations may be integrated with the tables wherever practicable. This column shall contain all the information required to accomplish the checks and services, including appropriate tolerances, adjustment limits, and instrument and gauge readings.

2.7.17.3 Troubleshooting Information Module. This module shall provide information on how to troubleshoot the equipment/system IAW the maintenance concept for the P-19R. The technician needs to know the symptoms that caused the equipment/system to fail. A list of possible failure symptoms with the most common causes shall be provided. The most probable cause for each symptom shall be listed first. The list shall access the corrective action needed to return the faulty equipment/system to an operational readiness condition. Diagrams, schematics and graphics shall be provided to aid the maintenance technician in fault location and repair of the equipment/system.

a. Diagnostic Tests. Each step in the diagnostic test process shall be fully explained. Diagnostic test procedures may be combined with the troubleshooting diagrams. The Field and Sustainment Level Maintenance IETM shall be capable of utilizing current USMC diagnostics equipment to conduct intrusive diagnostics tests.

b. Fault Isolation. Fault isolation procedures may be combined with the troubleshooting diagrams. Fault isolation shall be linked to the associated corrective maintenance procedures, including automated parts ordering processes.

2.7.17.4 Parts Information. This module shall contain a listing of spares and repair parts required for the performance of maintenance on the P-19R. The repair parts module authorizes the requisitioning and issue of spares and repair parts as indicated by the Source and Maintenance Repair (SMR) codes. The repair parts module shall contain spares and repair parts authorized for use in performing the maintenance to include mandatory replacement parts. Parts shall be presented by functional groups in alphabetic sequence, with the parts in each group listed in figure and reference designator sequence. Bulk materials shall be listed in National Stock Number (NSN) sequence. Circled reference designators on equipment multi-media shall be used to indicate parts that must be replaced during reassembly.

The repair parts data shall consist of the following:

a. Figure Number. The number of the illustration in which the item is shown.

b. Figure Title. The title of the figure in depicting the item shown

c. Reference Designator. The number used to identify the item called out in the illustration. When a figure has more than one illustration, an item may appear on several illustrations.

d. Source, Maintenance, and Recoverability (SMR) Codes. The SMR codes indicate the manner of acquiring supporting items for maintenance, repair, or overhaul of end items.

e. National Stock Number (NSN). The NSN assigned to the item is used for requisitioning. NSNs and part numbers shall be cross-referenced to each illustration, figure and item number.

f. Contractor and Government Entity (CAGE). The CAGE is a 5-digit alpha-numeric code used to identify the manufacturer, distributor, or Government agency, etc.

g. Part Number. This is the primary number used by the manufacturer (corporation or Government activity) that controls the design and characteristics of the item by means of engineering drawings, specifications, standards, and inspection requirements to identify an item or range of items.

h. Description. This is the Federal item name and, if required, a minimum description to identify the item. Items that are included in kits and sets are listed below the name of the kit or set along with the quantity of each item in the kit or set indicated in the Quantity Incorporated in Unit column/field. When the part serial numbers differ for the same model, the effective serial number of that model shall be shown as the last line of the description.

i. Replace-Economically/Mandatory (ECO/MAN). The ECO column/field indicates items that are more economical to replace during rebuild than to expend the man-hours necessary to fully inspect those items. The MAN column/field indicates items that must be replaced any time they are loosened or removed. No "X" in either column/field indicates the item has special inspection procedures or that the item is further dissembled and components will be covered by a subsequent IPB frame.

j. Unit of Measure (U/M). This is the standard measure of the listed item used in performing the actual maintenance function. This measure is expressed by a two-letter abbreviation (e.g., ea, in, pr, etc.). When the unit of measure differs from unit of issue, the lowest unit of issue that will satisfy the required units of measure will be requisitioned.

k. Quantity Incorporated in Unit. This is the quantity of the item used in the breakout shown on the illustration figure, which is prepared for a functional group, sub-functional group, or an assembly. An "AR" appearing in this column/field in lieu of a quantity indicates that no specific quantity is applicable (e.g., shims, spacers, etc.).

2.7.17.5 Operation Information Module. This module shall include the following information packages on the operation of the P-19R and other Government or contractor identified information packages.

a. System Description and Data Package. Describe in detail the system to the component level. Illustrate the location of system components in detail i.e. frame, tank, pump motor, pumping system, filters, fuses, valves, sensors, tabulated data, etc.

b. Description and Use of Operator Controls and Indicators Package. Describe and illustrate the function and operator controls and indicators.

c. Operation of the P-19R Package. This package contains complete instructions on how to operate the system.

d. Components of the End Item (COEI), Basic Issue Items (BII), and Additional Authorized List (AAL) Items Package. This package lists all COEI, BII, and AAL Items complete with graphics and associated data to include NSN, Item description, Unit of issue, part Number CAGE code, Part Number, and Quantity required.

e. Expendable/Durable Supply List Package. List all expendable durable supplies need to operate this system. Data is normally displayed in table format. Required data elements are as follows:

1) Column (1) - Item Number. This number is assigned to the entry in the listing and is referenced in the narrative of the TM to identify material, (e.g., use cleaning compound Item 4 from Expendable /Durable Supply List).

2) Column (2) - Level. This column identifies the lowest level of maintenance that requires the listed item. (O-Operator, M-Maintainer).

3) Column (3) - National Stock Number. This is the NSN assigned to the item. The NSN is used to request or requisition an item.

4) Column (4) - Description. Provide Item Name, if required, a description of the item, last line for each item indicates the federal supply code for Manufacture in parentheses followed by part number.

5) Column (5) - Unit of Measure (U/M). Indicates the measure used in performing the actual maintenance function. This measure is expressed in two-character alphabetical abbreviation (e.g. ea, oz., lb., qt., gl.). If unit of measure differs from the unit of issue, requisition the lowest unit of issue that will meet your requirements.

f. Lubrication Instruction Package. Provide complete lubrication instructions to include graphics of lubrication points, type of lubrication, and interval of lubrication to operate this system.

2.7.17.6 Support Information Module. This module provides supporting information for the P-19R and includes the following information packages:

a. References. This information package consists of external technical information that provides supplemental support for the P-19R attachments.

b. Tools. This information package shall contain all information and procedures required for identification and use of common tools, special tools, and equipment.

1) Common tools and test equipment are authorized for field use in appropriate Department of Defense (DoD) documents. Maximum reference to these common tools and test equipment shall be made during the preparation of the maintenance portion of the manuals.

2) Special tools shall be illustrated with reference to the figure/paragraph for the task to be performed.

3) If tools or test jigs are to be fabricated, detailed instructions shall be provided appropriately for each level of maintenance. Supporting text shall consist of all instructional information needed by maintenance personnel to manufacture/fabricate the item. A list of materials needed for manufacture/fabrication of the items shall also be included on each illustration.

c. Transportation. This information package provides for the safe transportation of the P-19R via land, air and sea.

d. General Description & Data. This information package shall contain a listing of the performance characteristics for the complete system. This information may be presented in tabular format with the approval of the requiring activity.

1) Description data consists of a complete description of the equipment. The text shall begin with an overall description of the significant features.

2) Data such as number of channels, transmission ranges, distance ranges, frequency ranges, input requirements, output characteristics, power consumption, power output, incoming and outgoing signals, temperature ranges, physical characteristics, etc., shall be included.

e. Demolition. This information package consists of procedures to render the P-19R inoperative for use by the enemy.

3.0 TECHNICAL MANUALS

3.1. Crew/Operator Level IETM. The Crew/Operator Level IETM shall describe in detail the operation instructions necessary to operate the equipment per CDRL T013. The IETM shall be written in simple, practical English written to an eighth grade reading level. All terminology, symbols and abbreviations shall be readily understandable by operators. Use of abbreviations shall be held to a minimum and shall be defined the first time they appear in each chapter. All abbreviations shall be hypertext linked to a master glossary.

3.1.1. Description, Purpose and Organization of IETM.

3.1.1.1. TM XXXX. The IETM will not necessarily have the hierarchy represented by a chapter/section/paragraph arrangement. This portion of the IETM shall contain equipment, operation and maintenance instructions performed by the user or operator.

3.1.1.2. Content/Format. The IETM shall conform to the referenced documents, this TMCR and data derived from the Contractor. The IETM, at a minimum, shall contain but not be limited to, the following system information:

(7) Front Matter

(8) Equipment Description and Data

(9) Safety Precautions

(10) General Information

(11) Principles of Operation

(12) Operating Instructions

(13) Maintenance Instructions to include PMCS

(14) Troubleshooting Procedures

(15) Appendixes: Additional Authorized Listing (AAL) stowage, preparing for transport via all modes, index, and Components Of End Item (COEI), BII, Crew/Operator Lubrication Instructions.

3.2. Field Level Maintenance IETM. The Field Level Maintenance IETM shall describe in detail the maintenance tasks, support equipment and repair parts necessary to maintain or restore equipment/systems at field maintenance levels per CDRL T011. The IETM shall be written in simple, practical English written to an eighth grade reading level. All terminology, symbols and abbreviations shall be readily understandable by maintenance technicians. Use of abbreviations shall be held to a minimum and shall be defined the first time they appear in each chapter. All abbreviations shall be hypertext linked to a master glossary.

3.2.1. Description, Purpose and Organization of IETM

3.2.1.1. TM XXXX. The IETM will not necessarily have the hierarchy represented by a chapter/section/paragraph arrangement. Each maintenance task shall be presented in detail and in logical step-by-step procedures for the work to be accomplished. The IETM shall accurately provide the mechanic with all the information needed to keep the equipment operational.

3.2.1.2. Content/Format. The IETM shall conform to the referenced documents, this TMCR and data derived from the Contractor. The IETM, at a minimum, shall contain but not be limited to, the following system maintenance information:

(1) Front Matter

(2) General Information

(3) Equipment Description and Data

(4) Safety Precautions

(5) Principles of Operation

(6) TMDE and Support Equipment

(7) Preventive Maintenance Checks and Services (PMCS)

(8) Maintenance Procedures

(9) Troubleshooting Procedures

(10) Adjustment and Alignment Procedures

(11) Preparation for Shipment and Storage

(12) Expendable/Durable Supplies and Materials List

(13) Illustrated List of Locally Fabricated Items with Instructions (if applicable)

(14) Functional, Schematic and Wiring Diagrams

(15) Repair Parts and Special Tools List

(16) Lubrication Instructions

(17) Maintenance Allocation Chart

(18) Preparation for long-term storage

3.2.1.1. Diagnostic Strategy. The Contractor shall analyze the overall end item diagnostic strategy of the P19R as it relates to the maintenance concept, supply support system, and IETM development. The Contractor’s diagnostics strategy shall consider emerging mechanical diagnostics capabilities to the maximum extent practicable. It shall be presented at software and hardware design reviews and program reviews. The strategy shall be updated to reflect the P19R as the design matures. Strategy updates will be delivered to the Government as part of meeting minutes per CDRL P004.

3.2.1.2. Diagnostics Concept. Fault isolation shall be linked to the associated corrective maintenance procedures, including automated parts ordering processes, making full use of inter-application communications via Dynamic Link Libraries (DLLs) and Dynamic Data Exchange (DDE) and similar industry standards for intrusive diagnostics.

3.1. Sustainment Level Maintenance IETM.

3.3.1. Description, Purpose and Organization of IETM

3.3.1.1. TM XXXX. The intent of the Sustainment Level Maintenance IETM is to sustain equipment throughout its lifecycle by performing major repair, overhaul or complete rebuild of parts, subassemblies, assemblies or principal end items to include manufacturing parts and conducting required modifications, testing, calibrating and reclaiming per CDRL T014. Marine Corps multi commodity maintenance centers, other services depots, commercial industrial facilities, original equipment manufacturer or a combination thereof may perform sustainment level maintenance. Sustainment Level Maintenance also supports lower level maintenance by providing overflow maintenance services and performing on site maintenance services including technical assistance when required. The Sustainment Level Maintenance TM shall describe in detail the maintenance tasks, support equipment and repair parts necessary to maintain or restore equipment/systems at Sustainment Maintenance levels. The TM shall be written in simple, practical English written to an eighth grade reading level. All terminology, symbols and abbreviations shall be readily understandable by maintenance technicians. Use of abbreviations shall be held to a minimum and shall be defined the first time they appear in each chapter.

3.3.1.2. Technical Content/Format Manuals Organization. The IETM shall conform to the referenced documents, this TMCR and data derived from the Contractor. The IETM, at a minimum, shall contain but not be limited to, the following system maintenance information:

(1) Front Matter

(2) General Information

(3) Equipment Description and Data

(4) Safety Precautions

(5) Principles of Operation

(6) TMDE and Support Equipment

(7) Preventive Maintenance Checks and Services (PMCS)

(8) Maintenance Procedures

(9) Troubleshooting Procedures

(10) Adjustment and Alignment Procedures

(11) Preparation for Shipment and Storage

(12) Expendable/Durable Supplies and Materials List

(13) Illustrated List of Locally Fabricated Items with Instructions (if applicable)

(14) Functional, Schematic and Wiring Diagrams

(15) Repair Parts and Special Tools List

(16) Lubrication Instructions

3.3.1.1. Diagnostic Strategy. The Contractor shall analyze the overall end item diagnostic strategy of the P19R as it relates to the maintenance concept, supply support system, and IETM development. The Contractor’s diagnostics strategy shall consider emerging mechanical diagnostics capabilities to the maximum extent practicable. It shall be presented at software and hardware design reviews and program reviews. The strategy shall be updated to reflect the P19R as the design matures. Strategy updates will be delivered to the Government as part of meeting minutes per CDRL P004.

3.3.1.2. Diagnostics Concept. Fault isolation shall be linked to the associated corrective maintenance procedures, including automated parts ordering processes, making full use of inter-application communications via Dynamic Link Libraries (DLLs) and Dynamic Data Exchange (DDE) and similar industry standards for intrusive diagnostics.

4.0 VALIDATION/VERIFICATION

4.1 Validation. The Contractor shall validate that the IETMs meets the requirements of this TMCR. Validation is a contractor responsibility and shall be performed on all IETMs, changes, supplemental data, and revisions at the Contractors facility. The contractor shall ensure the quality of all IETMs prepared by subcontractors and vendors. The contractor shall notify the government 30 days prior to IETM validation. The Government reserves the right to observe the contractor’s validation, to participate in the contractor's validation, or to conduct a concurrent validation/verification. Validation will not be considered complete until the following conditions have been fulfilled:

a. Contractor’s engineering technical review has been completed.

b. Information reflects latest/current configuration of system/s and includes all approved engineering changes.

c. Procedural instructions are readily understandable by the intended user at the eigth grade reading level and adequate to perform all operations and maintenance functions.

d. Adequacy of data is checked to ensure that it supports the approved maintenance and support plan.

e. Hardware of the proper configuration is availabel for the validation effort.

f. All safety hazards identified in the Safety Assessment Report (SAR) shall be identified and mitigated within the text as Warnings or Cautions necessary to protect the personnel and equipment as appropriate.

4.1.1 Validation Performance. Operating and maintenance procedures, including checkout, Preventive Maintenance Checks and Services (PMCS), Lubrication Instructions, scheduled maintenance, removal and replacement instructions, diagnostics tests, and any associated checklists, shall be validated against the system by actual demonstration. Malfunctions shall be introduced into the system for purpose of validation of troubleshooting. The contractor is required to correct all discrepancies found during validation.

4.1.2 Support Equipment. Government-approved support equipment shall be used in the performance of validation. Simulation or substitution of support equipment must be approved by the Government. The Contractor is responsible for submitting requests for Government Furnished Equipment (GFE) to support the validation effort.

4.1.3 Validation Records. Records of all validations performed shall be maintained and be availabel for Government review. These records shall indicate the affected manual, system or component part number and/or serial number and the date validated.

4.1.4 Disposition of Validated Data. Corrections and comments resulting from validation shall be incorporated prior to the certification and acceptance of the IETM. Correction of discrepancies or changes in baseline/configuration shall be made prior to submittal for Government review and approval.

4.1.5 Validation Certification. The Contractor shall, concurrently with the final draft IETM, deliver a document of certification attesting to the adequacy and accuracy of the IETM and the satisfaction of the validation’s requirement for Government review and acceptance. The certificate(s) shall be signed by an authorized Contractor representative. A certificate shall be provided for each IETM validated per CDRL T010.

4.2 Verification. The Government will verify that the IETM are accurate and that it represents the actual hardware. The Government may choose to perform verification concurrently with the Contractor’s validation effort or at an alternate site. The Contractor shall provide technical/engineering support and facilities as required to aid the Government in the performance of the verification effort. The Contractor shall provide one paper/hardcopy set of technical manuals and an one IETM CD/ROM to each verification participant 60 days prior to the scheduled verification effort . The Contractor shall incorporate all Government comments from In Process Reviews (IPRs), technical accuracy reviews, and Government verification reviews into the final submission.

4.2.1 Verification – Contractor Supplied Materials.

The Contractor shall supply and or make availabel all materials required to perform Verification of selected Technical Manual procedures to include:

a. Special tools listed under “Special Tools”

b. Expendable items listed under “Material”

c. Replaceable items listed under “Reference Material”

These items shall be ready for use prior to commencement of any Government verification effort.

5.0 QUALITY ASSURANCE PROVISIONS

5.1 Quality Assurance Functions. All IETM elements and processes shall be evaluated at various stages of development/revision.

5.1.1 Control of Subcontractors. The Contractor shall be held responsible for the quality of TMs/IETMs prepared by subcontractors and vendors.

5.1.2 In-Process Review (IPR). IPRs will be required at stages of TM development by the Government to provide for coordinated monitoring of IETM preparation by the Contractor and the Government. The Contractor shall support all IPRs by providing copies of material to be reviewed, composing minutes of the IPR and ensuring attendance by the engineering, technical writing and program manager’s staff IAW CDRLs P003, P004 and P005. Material to be evaluated may include:

(1) Source data

(2) IETM and QA plans and outlines

(3) Presentation methods

(4) Modes of preparation

(5) TMCR compliance

(6) Draft or completed text and artwork

(7) Current XML tagged Files (IETM on CD-ROM)

5.1.1 Scheduling IPRs. IPRs may be held at the Contractor’s plant or a designated Government facility. The Contractor shall submit a proposed IPR schedule for review during the Start of Work meeting. IPRs may be held at various stages of TM development prior to preparation of final reproducible copy. The Contractor may request IPRs when assistance or clarification is desired. The Government may require and the Contractor may request additional IPRs.

5.1.2 Review Levels. At a minimum, IPRs will be held at the 40% and 80% of development of the paper manual and IETM, and again at completion. IPRs may be requested by the Government to provide for coordinated monitoring of TM preparation by the Contractor and the Government. The Contractor shall support IPRs and provide access to TM materials, intermediate products and final products. The Contractor shall provide one set of technical manuals and an IETM CD-ROM to each IPR participant.

5.1.3 IPR Records. The Contractor shall act as recorder and record decisions/discrepancies resulting from or associated with IPRs. Any discrepancies and/or deficiencies noted in the technical manual/IETM as the result of the IPR shall be corrected prior to follow-on IPR, certification or submission of manual to the Government for review and acceptance.

5.1.4 Disposition of IPR Findings. Discrepancies and/or deficiencies found as the result of the IPR shall be corrected prior to certification and acceptance of the TM.

5.2 Contractor Surveillance. The Contractor shall maintain the quality assurance program IAWthe Contractor’s Quality Assurance Plan. Contractor surveillance shall be performed on a continuing basis to ensure compliance with his quality program plans, this TMCR and the contract. The Contractor shall be held responsible for the quality of TMs prepared by subcontractors and vendors.

6.0 PACKAGING AND DELIVERY

6.1 Packaging

6.1.1 Package Marking. In addition to sender and addressee information, the exterior of each package shall bear the following:

(1) Publication number

(2) Contract Number

(3) Type of material enclosed

(4) Number of containers in the shipment

6.1.2 Packing List. A copy of the letter of transmittal or the packing list shall be placed inside the package. When a shipment consists of several packages, the letter of transmittal or packing list shall be enclosed in the first package and shall identify the material that was wrapped in each package.

6.1.3 Technical Manuals Shipped with Equipment (Overpack). Copies of the technical manual are to be overpacked with the equipment. The manuals shall be so placed that they are readily accessible prior to removing the equipment; they shall not be placed within the vapor-proof barrier material used to enclose the equipment. Technical manuals, which accompany equipment shipments, shall be packaged IAWMIL-STD-2073-1. The invoice, packing list or bill of lading shall indicate the publication number and quantity of the manuals and shall indicate which container includes the manual and its approximate location therein.

6.2 Delivery

6.2.1 Manuscript Copy for Review. Manuscript copies shall be wrapped separately and packaged flat in cartons. Final size illustrations shall be included in the manuscript. Foldouts shall be folded, as necessary, to fit the bound manuscript. Maximum thickness of bound matter shall be three inches, not including covers. If the number of foldouts is enough to cause a substantial difference in thickness of the manuscript, the binding edge spaces shall be added to equalize the two sides of the manuscript. The manuscript shall be bound with posts or inserted in three-ring binders. Elaborate containers shall not be used. Packaging must protect the manuscript so that it cannot shift within the container.

6.2.2 CD-ROM for Review. CD-ROM shall be wrapped to provide maximum protection during shipping. Each CD-ROM shall be delivered in a standard compact digital audio disc case and wrapping. The case is to be usable as storage for the disc once the plastic cover wrapping is removed. Multiple CD copies may be delivered in the same shipping container.

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