RFP_Attch_14_MIL-DTL-83495D_Capability Task Ref.pdf

NOT MEASUREMENT

SENSITIVE

MIL-DTL-83495D(USAF)

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SUPERSEDING

MIL-DTL-83495D(USAF)

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DETAILED SPECIFICATION

MANUALS, TECHNICAL - ON-EQUIPMENT

MAINTENANCE MANUAL SET

Comments, suggestions, or questions on this document should be addressed to AFLCMC/GBS Technical Data Section, 4170 Hebble Creek Road, Bldg. 280, Door 15, Area A, Wright-Patterson AFB, OH 45433-5653 or emailed to SGMLsupport@us.af.mil. Since contact information can change, you may want to verify the currency of this address infor-mation using the ASSIST Online database at https://assist.dla.mil.

AMSC 10381 AREA TMSS

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This specification is approved for use by the Department of the Air Force and is available for use by all Departments and Agencies of the Department of Defense.

1 SCOPE

1.1 Scope. This specification covers the requirements for the preparation of the On-equipment Maintenance Manual Set (OMMS) for USAF equipment. Use of Standardized System Subsystem Sub-Subsystem Numbering (SSSN) assignment in accordance with MIL-STD-1808 provides maximum cross referencing and reducing the research time required to locate needed data. Appendices A through G provide information for utilization of markup language tools for the digital preparation of OMMS to be delivered to the Government (see A.3.4).

1.2 Types of manuals. The following manual types are covered by this specification:

General Equipment Manual (see 3.2) General System Manual (see 3.3) Job Guide Manual (see 3.4) Fault Reporting Manual (see 3.5) Fault Isolation Manual (see 3.5) Wiring Data Manual (see 3.6) Schematic Diagrams Manual (see 3.7)

1.3 Illustrations in this specification. The illustrations appearing in this specification are used only as examples.

If there is any conflict between the text and illustrations of this document, the text applies.

2 APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-1808 - System Subsystem Sub-subsystem Numbering MIL-STD-38784 - General Style and Format Requirements for Technical Manuals

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-863 - Wiring Data and System Schematic Diagrams, Preparation of MIL-HDBK-275 - Guide for Selection of Lubricants, Fluids, and Compounds for Use in Flight Vehicles and Components

(Copies of these documents are available online at https://quicksearch.dla.mil.)

2.2.2 Other Government documents, drawings and publications. The following other government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues are those cited in the solicitation.

PUBLICATIONS

AIR FORCE TECHNICAL MANUALS

TO 1-1-17 - Storage of Aircraft and Missile Systems

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(Copies of this document required by users with “.mil” government web address access are available online at https://www.my.af.mil/etims/ETIMS/index.jsp. Copies of documents required by contractors in connection with specific procurement functions should be obtained from the acquiring activity or as directed by the contracting officer.)

2.3 Deleted.

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3 REQUIREMENTS

3.1 General requirements.

3.1.1 Preparation requirements. The general manner of preparation and format for all manuals shall be in accordance with the requirements of MIL-STD-38784, except as modified herein.

3.1.2 Technical Manual (TM) paper and PDF functionality/formatting requirements. The acquiring activity shall select the applicable outputting requirements, PDF output (see 6.4.16) or paper output (see 6.4.15), for the development of all manuals specified herein.

3.1.3 Nomenclature requirements. System/subsystem nomenclatures are assigned in accordance with MIL-STD- 1808. (For guidance on higher level designation see MIL-HDBK-863.) Nomenclature shall agree with the drawing title and shall be forward reading. Chapter/Section titles shall correspond with chapter/section requirements specified herein. Nomenclature shall be used consistently throughout a chapter for text and illustrations. Nomenclature appearing on decals, engraved legends, nameplates, or other markings shall be repeated verbatim on the first occurrence. All attaching hardware items involved in a task shall be specifically mentioned.

3.1.3.1 Short form use of common names. After first use, nomenclature shall be shortened as required, if there is no other name with which it can be confused. Simple identifying nomenclature shall be provided for attaching parts in both pictorial callouts and text, if appropriate.

3.1.3.2 Terminology. Only terminology that conveys the purpose, function, or nature of an item relevant to the task shall be used. Modifiers shall be used when one or more items of the same object nomenclature are acted upon in the same task. For example, a procedure to rig a spoiler center wing input quadrant includes an illustration of the unit. The presence of the illustration showing the location of the unit enables the writing of a simple task step, e.g., “Insert rig-pin.” If more than one rig-pin exists, a proper modifier shall be added, e.g., “Insert lower rig-pin.”

3.1.4 Diagrams. MIL-HDBK-863 may be referred to for development of equipment wiring data and schematic diagrams.

Paper output: Parallel lines on wiring data and schematic diagrams shall in no case be less than 0.10 inches apart and no less than 0.06 inches high when reduced to printed size.

3.1.5 Foldout pages. Paper output: Foldout pages shall be in accordance with MIL-STD-38784, unless otherwise specified herein. SSSN, figure number, and figure title for foldout pages shall be placed so they are visible when the printed page is folded.

3.1.6 Marginal data SSSN placement. The SSSN shall appear directly above the page number and shall be 18-point type. The SSSN shall not be placed at the bottom of front matter pages.

3.1.7 Numbering. Chapters, sections, paragraphs, figures, and tables shall be numbered in accordance with MIL-STD-38784, except as specified herein. The SSSN shall form a part of the paragraph heading when the heading introduces an item having an SSSN assigned, e.g., “1-17 Null Amplifier (03-17-04).”

3.1.7.1 Use of SSSN. The SSSN shall be used as described in the following paragraphs and MIL-STD-1808.

When used for electronic data, the SSSN shall be used in task oriented view packages.

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3.1.7.1.1 Use of “System” number. The system number is used to denote a chapter in General Equipment (GE), Fault Reporting (FR), and Fault Isolation (FI) manuals. In General System (GS) manuals, the system number is used to denote a manual (if separate manuals) or a chapter (if combined manuals). For Job Guide (JG) manuals, the system number designates the manual chapter as specified herein (see 3.4.3). Systems which are reserved or not used shall not be included in the manuals (see 3.2.3.2).

3.1.7.1.2 Use of “Subsystem” number. The subsystem number is used to denote a section in the GE, FR, and FI manuals. In GS manuals, the subsystem number is used as a reference only. For JG manuals, the system number designates a chapter within the manual(s) for that system. The contents of the chapter or section and the system separations are assigned by MIL-STD-1808. The application of the subsystem designator as shown herein must be confined to discussion of the total subsystem; e.g., material contained in 34-50 would necessarily be confined to general discussion of the total Dependent Position Determining subsystem and requires the addition of zeros in the third element (34-50-00).

3.1.7.1.3 Use of “Sub-subsystem” number. The sub-subsystem number is assigned by the manufacturer.

Subsystems which contain very complex sub-subsystems may require further chapter breakout. This will be indicated by the fourth digit, such as 34-51-00. In this case, -51 would be a sub-subsystem of the Dependent Position Determining subsystem of the Navigation System. A sub-subsystem shall not be identified in the second element unless a fourth designator, different from zero (0), is assigned.

3.1.7.1.4 Task/component number numbering. This number is assigned by the manufacturer to a specific task or component. This number shall be assigned in consecutive order within the manual or view package in which it is used. For example, the fifth component covered in a JG would be XX-XX-05-XXX.

3.1.7.1.4.1 Task/component number development for FR and FI manuals. The subject number assignment shall reference the SSSN in the terminal steps of the fault tree contained in the FR and FI manuals.

For example: If an FR or FI page contains fault tree segments applicable to a specific item of a sub-subsystem of the Dependent Position Determining subsystem, the page would reflect 34-51-00; if a page contains segments of the fault tree applicable to more than one subject (general) breakdown of the Dependent Position Determining subsystem, the page would reflect 34-50-00; if the page contains segments of the fault tree applicable to multiple subsystems within the Navigation system, the page would reflect 34-00-00.

PDF output: The SSSN shall be reflected in the lower right corner of the FR and FI manuals. The number shall reflect the first three elements, to the lowest element possible, as allowed by the composition of the segment of the fault tree displayed on that page.

Paper output: The SSSN shall be reflected in the lower outer corner of the FR and FI manuals. The number shall reflect the first three elements, to the lowest element possible, as allowed by the composition of the segment of the fault tree displayed on that page.

3.1.7.1.4.2 Subject number development for other than JG, FR and FI manuals. When used in view packages or other manuals, the task/component number is assigned in sequence of the system. This number is developed in a similar manner for manuals other than the JG, FR, and FI manuals.

3.1.7.1.5 Function number. The function number (fourth element) shall be assigned as specified herein.

3.1.7.1.5.1 Function number requirements for JG manuals. The assignment of the function number shall follow the task/component number in the JG manual and shall be assigned as specified herein. For example, a system operational checkout will be identified as “XX-XX-XX-001.”

3.1.7.1.5.2 Typical functions. The following functions shall be used for development of the function numbers and may be expanded/changed to suit equipment requirements if approved by the acquiring activity (see 3.4.3.2.1):

001 - Operational Checkout 008 - Cleaning

002 - Access 009 - Lubrication

003 - Remove 010 - Servicing

004 - Install 011 - Jacking

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005 - Repair 012 - Alignment and Adjustment

006 - Rigging 013 - Calibrate

007 - Inspect

3.1.8 Applicability codes. Applicability codes shall be listed in tables as part of the introduction. Equipment differences (equipment type-model-series and serial number) shall be annotated using flagnotes indicating the applicability code.

3.1.9 Classified material. If classified information is essential, it shall be in accordance with MIL-STD-38784.

3.1.10 References. References shall be in accordance with MIL-STD-38784 with the following exception:

When using a SSSN reference to another manual in the OMMS, the SSSN shall be prefixed with the abbreviation for that manual type, e.g., reference to a SSSN in a General System (GS) manual would be shown as “GS XX-

XX-XX.”

3.2 General Equipment (GE) manual. One GE manual shall be prepared for the equipment. The GE manual shall be written for standalone use. Detailed description and theory of operation shall not be included.

Paper output: When GE manual exceeds 800 pages (400 sheets) separate volumes shall be prepared. See appendix A for resources available for digital preparation of the GE manual.

3.2.1 Scope. The GE manual shall provide general information about the equipment. Specifically, it shall provide:

a. An overview and detailed explanation of the OMMS.

b. A functional description of the SSSN system.

c. A listing of all equipment Time Compliance Technical Orders (TCTOs).

d. An overall equipment description (effectivity [application] by model and serial number), general arrangement, principal dimensions, pictorial diagrams e.g., access, danger areas, equipment location, cable routing, station diagrams, etc.

e. A summary description of all equipment systems, supported by diagrams.

f. Non-JG information applicable to more than one system.

g. Non-JG guide formatted information and instructions that are generally applicable to all systems.

h. General information on the interface between systems and integration of two or more systems.

3.2.2 Page size. The GE manuals shall be prepared in 8½ x 11 inch page size.

3.2.3 Arrangement. This specification refers to “systems” as chapters, e.g., System 5 in MIL-STD-1808 is Chapter 5 herein. The basic contents of the GE manual and its arrangement shall be as shown below.

The following list is updated to reflect alignment of MIL-DTL-83495 with MIL-STD-1808.

a. Front Matter (see 3.2.3.1)

b. Chapter 1 - Reserved (see 3.2.3.2.1)

c. Chapter 2 - Reserved (see 3.2.3.2.1)

d. Chapter 3 - Reserved (see 3.2.3.2.1)

e. Chapter 4 - Reserved (see 3.2.3.2.1)

f. Chapter 5 - General Equipment Description (see 3.2.3.2.2)

g. Chapter 6 - Dimensions and Areas (see 3.2.3.2.3)

h. Chapter 7 - Lifting, Jacking, and Shoring (see 3.2.3.2.4)

i. Chapter 8 - Leveling and Weighing (For Reference Only) (see 3.2.3.2.5)

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j. Chapter 9 - Towing and Taxiing (see 3.2.3.2.4)

k. Chapter 10 - Parking and Mooring (see 3.2.3.2.4)

l. Chapter 11 - Placards and Markings (see 3.2.3.2.3)

m. Chapter 12 - Servicing (see 3.2.3.2.4)

n. Chapter 13 - Time Limits, Inspections (see 3.2.3.2.5)

o. Chapter 14 - Corrosion (see 3.2.3.2.6)

p. Chapter 15 - Non-Destructive Inspections (see 3.2.3.2.7)

q. Chapter 16 - Siting Installation (GROUND EQUIPMENT ONLY) (see 3.2.3.2.8)

r. Chapter 17 - Preparation for Use and Shipment (GROUND EQUIPMENT ONLY) (see 3.2.3.2.9)

s. Chapter 18 - Weapons Instrumentation (see 3.2.3.2.10)

t. Chapter 19 - Training Equipment (see 3.2.3.2.11)

u. Chapter 20 - Equipment Storage (see 3.2.3.2.12)

3.2.3.1 Front matter. Front matter shall be prepared in accordance with MIL-STD-38784 and applicable requirements specified herein (see 3.1).

3.2.3.1.1 Introduction. The Introduction shall identify the equipment applicability by government or manufacturers type designation and provide a brief explanation of the manual’s purpose, scope, and arrangement, including any relevant information that will increase the usability of the manual. An explanation of “shall,” “will,” “should,” and “may” as defined in MIL-STD-38784 shall be provided. An overview and detailed explanation of OMMS use, TO numbering and assignment of higher level designations as they relate to a functional system, definition of a functional system, and a detailed explanation and intended use of each type of manual shall be provided. Illustrations shall be used to assist in explanations, as required (see MIL-HDBK-863 for explanation of higher level designations).

3.2.3.2 Chapters. Chapters shall be constructed in accordance with MIL-STD-1808 numbering. The TOC lists unused chapters as “Not Used.” Unused chapter numbers and titles shall not be included in the manual or referenced in the text.

Note: Special support equipment shall be covered under the system/chapter for the equipment it supports.

3.2.3.2.1 Chapters 1, 2, 3, and 4 reserved. These chapters are reserved for additional requirements as specified by the acquiring activity (see 6.2.d).

3.2.3.2.2 Chapter 5 - General Equipment Description. This chapter shall provide a general description of the equipment and installed systems, as well as applicable safety and protective devices. The general arrangement, principal dimensions, station diagrams (if required), pictorial diagrams (e.g., walkways, access, danger areas, equipment location, cable routing), and any capabilities or limitations peculiar to the equipment (e.g., ambient operating temperatures, relative humidity, operating and non-operating barometric pressures, wind loading, ice loading, fatigue life calculations) shall be provided. First level equipment block diagrams, with supporting illustrations, shall be used to aid understanding. Associated JG manuals shall not be prepared.

3.2.3.2.3 Chapters 6 and 11. Chapter 6 - Dimensions and Areas, Chapter 11 - Placards and Markings. These chapters shall provide the information required by MIL-STD-1808. Associated JG manuals shall not be prepared.

3.2.3.2.4 Chapters 7, 9, 10, and 12. Chapter 7 - Lifting Jacking and Shoring, Chapter 9 - Towing and Taxiing, Chapter - 10 Parking and Mooring, and Chapter 12 - Servicing. These chapters shall provide the information required by MIL-STD-1808 and shall have associated JG manuals prepared.

3.2.3.2.5 Chapters 8 and 13. Chapter 8 - Leveling and Weighing, and Chapter 13 - Time Limits, Inspections, and Maintenance Checks. The subsystem information covering time limits for inspections and maintenance checks (both scheduled and unscheduled). This system is used for reference only (see equipment -6 manual and workcards for actual inspections and time limits).

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3.2.3.2.6 Chapter 14 - Corrosion. This chapter covers the overall system peculiar information to determine the extent of corrosion damage. Includes instructions for treatment or removal of corrosion, corrosion repair and prevention procedures, identification of corrosion prone areas, corrosion inspections, and specific damage limits.

Excludes pressurization sealing requirements.

3.2.3.2.7 Chapter 15 - Non-Destructive Inspection. This chapter shall list instructions on how to detect flaws, measure geometric characteristics, determine material structure or composition and how to characterize physical, electrical or thermal properties without causing changes in the part or impairing future usefulness.

3.2.3.2.8 Chapter 16 - Siting Installation. When specified by the acquiring activity (see 6.2.e), this chapter shall provide installation data, in the form of text, illustrations, tables, and charts for equipment (e.g., ground communications equipment (CE)) and shall be divided into the following sections:

a. Section I - Installation Logistics. (see 3.2.3.2.8.1)

b. Section II - Installation Procedures. (see 3.2.3.2.8.2)

3.2.3.2.8.1 Section I - Installation Logistics. This section shall contain information relative to unloading, unpacking, housing, and storage of equipment prior to and during installation.

3.2.3.2.8.1.1 Unloading and unpacking. Unloading instructions shall include tie-down cable removal, strapping or blocking, and equipment securing procedures with illustrations. All precautions to be observed when removing equipment from shipping devices shall be provided. If necessary, procedures to remove the equipment and accessory packaging shall be stated. Storage and accountability of reusable equipment, covers, protectors, cases, special containers, etc., shall be included.

3.2.3.2.8.1.2 Required equipment list. Crated and uncrated dimensions and weights of equipment and parts shall be indicated. Where applicable, the purpose and a brief description of each major group, e.g., antenna group, shall be provided. A table shall list all the supplied assemblies, components, units, cables, etc., by official nomenclature (if such exists) and common names. The listing shall include mounting hardware, gaskets, shims, air duct hoods, fittings, cabinet hardware, etc. A list of equipment required, but not supplied by the contractor, shall be included. Equipment required for service or installation of the equipment shall be identified by the manufacturer, including Government Furnished Property (GFP).

3.2.3.2.8.1.3 Material handling equipment. Equipment required to transport, handle, and aid in the installation shall be identified.

3.2.3.2.8.1.4 Cables. A table listing of interconnecting power and remote control cable assemblies, shall be prepared, as required. Instructions shall include the fabrication of cable assemblies not supplied, critical cable lengths, and technical characteristics.

3.2.3.2.8.2 Section II - Installation Procedures. This section shall contain installation requirements to ensure operational performance. Man-hours and manpower requirements shall be listed for all phases of the installation, if variables exist. Installation procedures and sequencing shall be sufficient for field installation.

3.2.3.2.8.2.1 Installation requirements. Information required to support the equipment installation, e.g., antenna towers and radomes, including a table showing guying tension in pounds, sag, vibration limits at various ambient temperatures, etc., shall be provided.

3.2.3.2.8.2.2 Installation sequence. Step-by-step procedures required to accomplish assembly, installation, and interconnection of equipment parts shall be stated. Illustrations shall be included, as required. Procedures shall be divided into applicable headings, e.g., power generating equipment, antenna and waveguide (or antenna cables) systems, transmitters, receivers.

3.2.3.2.9 Chapter 17 - Preparation for Use and Shipment. When specified by the acquiring activity (see 6.2.f), this chapter shall provide preparation instructions for use and shipment. Illustrations, tables, and charts, as required, shall be provided. The chapter shall be divided into the following sections:

a. Section I - Preparation for Use. (see 3.2.3.2.9.1)

b. Section II - Preparation for Shipment. (see 3.2.3.2.9.2)

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3.2.3.2.9.1 Section I - Preparation for Use. Tune-up, testing, and adjustment instructions required to make the equipment operational shall be provided. Required illustrations shall be included. Instructions located elsewhere shall be referenced. This section shall include:

a. Test descriptions needed to demonstrate all functional requirements.

b. Procedures to determine performance levels and to record test data.

c. A sequence list of all tests, including flight and electronic countermeasure testing.

d. Test criteria such as, performance specification, test interface (cables, plugs, attenuators, etc.), test equipment, use of test data sheets, oscilloscope patterns, pen charts, computer readouts, test configuration diagrams etc.

3.2.3.2.9.2 Section II - Preparation for Shipment. This section shall describe and illustrate procedures to prepare the equipment for shipment, and include:

a. Methods and conditions of shipment.

b. Special disassembly or dismantling instructions to prepare the equipment for shipment, or a condition or procedure requiring special attention.

c. Instructions for reuse of shipping cases or containers. A tabular listing, by part number, shall be included for reusable containers and shipping covers.

d. Removal instructions for special tubes, plug-in units, etc., before shipping, including removal of equipment or parts from mountings. Instructions for building packing crates shall not be included.

3.2.3.2.10 Chapter 18 - Weapons Instrumentation. This chapter shall provide the necessary coverage for airborne weapons used for test, data acquisition and flight termination. It shall encompass all necessary information to accommodate weapon payload and telemetry testing. This chapter shall be used for aircraft in lieu of a “-101” TO. When specified by the acquiring activity (see 6.2.g), associated JG Manuals shall be prepared.

3.2.3.2.11 Chapter 19 - Training Equipment. Specialized training equipment shall be included in this chapter.

When specified by the acquiring activity (see 6.2.h), associated JG manuals shall be prepared.

3.2.3.2.12 Chapter 20 - Equipment Storage. The section I introduction of this chapter shall explain the purpose of the chapter, shall reference TO 1-1-17 as a source of additional general information, and shall include relevant information needed to use the manual. If the information in TO 1-1-17 is not sufficient, the equipment storage chapter shall contain the information needed to supplement TO 1-1-17. Unless otherwise specified by the acquiring activity (see 6.2.i), associated JG manuals shall be prepared. This chapter shall include instructions to process equipment for:

a. Temporary storage.

b. Extended storage (over 90 days).

c. Inspections and treatments during storage.

d. Removal from storage.

e. Procedures for moving or flying a system to an overhaul/maintenance facility.

3.2.3.2.12.1 Required storage equipment. Designs or part numbers with sources for material or equipment needed to process the system shall be given. This shall include stands needed to store components in or near a system. A tabular format of special tools and test equipment shall be prepared and listed according to 3.3.5.3.2.1.

3.2.3.2.12.2 Equipment storage arrangement.

a. Section I - Introduction.

1. Purpose.

2. Types of Storage.

3. General Instructions.

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4. Special Tools and Test Equipment.

b. Section II - Temporary Storage. (see 3.2.3.2.12.2.1)

1. Preparation and Securing.

2. Inspection and Treatment During Storage.

3. Removal.

c. Section III - Extended Storage (see 3.2.3.2.12.2.2)

1. Preparation and Securing.

2. Inspection and Treatment During Storage.

3. Removal.

4. Moving or Flying System to Another Location.

3.2.3.2.12.2.1 Section II - Temporary Storage. The section on temporary storage shall include the location of protective covers and tie-down points. Any other procedures necessary to protect the system during temporary storage shall be given.

3.2.3.2.12.2.2 Section III - Extended Storage. This section shall contain diagrams of the equipment exterior and instructions which give the following:

a. Openings that must be sealed from rain and dust.

b. Location of vent tubes or drain holes.

c. Location of acrylic windows which need protection from sunlight.

d. Tie-down points and cable strength.

e. General location of unpainted metal surfaces which need protection.

f. Location of fuselage drain plugs on amphibious aircraft shall be shown or referenced.

g. The type of preservative or protection required.

3.3 General System (GS) manual. Normally, separate GS manuals shall be prepared for each system. Combined GS manuals shall be prepared, depending upon systems complexity, as specified by the acquiring activity (see 6.2.j). Coverage of a specific subsystem shall not be divided between two GS manuals. See appendix B for resources available for digital preparation of the GS manual.

Paper output: Multiple manuals shall be prepared when the system coverage exceeds 800 pages (400 sheets).

3.3.1 Scope. The GS manual shall provide detailed system, subsystem, and sub-subsystem descriptions, theory of operation, software interface, emergency operation, tolerances, special procedures, and maintenance support information not suitable for JG manuals. It shall reflect purpose, type, main features, and supporting data for the system being covered. If the equipment is an integral part of a functional end item, it shall explain how the equipment functions within the end item.

3.3.1.1 Classified material. When a classified supplemental GS manual is prepared, the scope of the manual shall be expanded to include classified information not normally pertinent to a GS manual, e.g., testing, fault isolation, etc. Classified information provided shall pertain only to the system(s) of the basic manual.

3.3.2 Numbering. Chapters, paragraphs, figures, and tables shall be numbered in accordance with MIL-STD- 38784, except the SSSN shall form a part of the paragraph heading. Each manual shall be divided into chapters as defined in GS arrangement, (see 3.3.5). All pages shall be numbered in accordance with MIL-STD-38784.

3.3.3 Size. The GS manuals shall be prepared in the standard 8½ x 11 inch size.

3.3.4 Systems covered. The system(s) covered shall be identified by Government assigned titles. SSSN shall be in accordance with MIL-STD-1808.

3.3.5 General systems arrangement. The GS manuals shall be arranged in the following manner:

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a. Front Matter. (see 3.3.5.2)

b. Chapter 1 - Theory of Operation. (see 3.3.5.3.1)

c. Chapter 2 - Special Tools, Test Equipment, and Consumables. (see 3.3.5.3.2)

d. Chapter 3 - System Peculiar Maintenance. (see 3.3.5.3.3)

3.3.5.1 Combined GS manual. Each chapter shall have three sections, as follows.

a. Front Matter. (see 3.3.5.2)

b. Chapter 1 - (System 23).

1. Section I - Theory of Operation. (see 3.3.5.3.1)

2. Section II - Special Tools, Test Equipment, and Consumables. (see 3.3.5.3.2)

3. Section III - System Peculiar Maintenance. (see 3.3.5.3.3)

c. Chapter 2 - (System 24).

1. Section I - Theory of Operation. (see 3.3.5.3.1)

2. Section II - Special Tools, Test Equipment, and Consumables. (see 3.3.5.3.2)

3. Section III - System Peculiar Maintenance. (see 3.3.5.3.3)

In combined manuals, Chapter 1, Chapter 2, etc., shall be used to include each system, e.g., Chapter 1 - (System 23), Chapter 2 - (System 24), etc. (The systems covered and the method of how chapters and sections are set up shall be explained in the introduction of each manual.)

3.3.5.2 Front matter. Front matter shall be prepared in accordance with MIL-STD-38784 and applicable requirements specified herein (see 3.1).

3.3.5.2.1 Introduction. The introduction shall provide an explanation of the manual’s scope and arrangement, including any relevant information, e.g., Computer Program Identification Number (CPIN) list by number and title in table format.

3.3.5.3 Chapters.

3.3.5.3.1 Chapter 1 - Theory of Operation. Chapter 1 shall provide system/subsystem overall functional description and general information, as required. Theory of operation shall be based on the functional flows within the system to a level compatible with level one schematics (see MIL-HDBK-863 for examples). Level one, two, and three schematics shall be used, as necessary, to support the system description. Illustrations showing the appropriate locations of all Line Replaceable Units (LRU) shall be provided. Appropriate references to the diagrams shall be included.

3.3.5.3.2 Chapter 2 - Special Tools, Test Equipment, and Consumables. This chapter shall list and illustrate the special tools, test equipment, and consumables required for all system functional tasks. Standard tools and test equipment shall not be illustrated. Such items shall be selected from the list of tools and test equipment approved by the Government by means of Support Equipment (SE) listings, provisioning processes, engineering changes, procurement documents, etc. Standard tools, such as screwdrivers and pliers, shall not be listed. Standard test equipment, such as voltmeters and oscilloscopes, shall be listed. When a contractor cannot obtain an approved list, the contractor’s recommended special tools and test equipment shall be shown and promptly updated to conform to the official Government list.

3.3.5.3.2.1 Special Tools and Test Equipment List. When specified by the acquiring activity (see 6.2.k), illustrations of peculiar equipment shall follow the table listing special tools and support equipment.

The table shall be formatted as follows:

SPECIAL TOOLS AND TEST EQUIPMENT

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Item Nomenclature Part Number/

Type Designation CAGE Code Figure and

Index Number

a. Item - Consecutive numbers shall be used for individual items.

b. Nomenclature - Nomenclature shall be in accordance with the requirements of MIL-STD-38784.

c. Part Number/Type Designation - Special tools and test equipment shall be listed in alphanumeric sequence by part number/type designation. If alternate or suitable substitutes may not be used, footnotes to the table shall so state.

d. CAGE Code - The Commercial and Government Entity (CAGE) code or manufacturer’s name and address if no CAGE Code is assigned.

e. Figure and Index Number - The figure and index number shall be shown.

3.3.5.3.2.2 List of Consumable Materials. Consumable materials and expendable items shall be listed. All chemicals shall be grouped separately at the beginning of the list.

The list shall be in tabular format, in alphabetical order by nomenclature, as follows:

LIST OF CONSUMABLE MATERIALS

Item Nomenclature Specification/PN CAGE Code Use Reference

a. Item - Consecutive numbers shall be used for individual items.

b. Nomenclature - Nomenclature shall be in accordance with the engineering drawing title block and

MIL-STD-38784.

c. Specification/PN - The military, Government, commercial specification number or part number shall be shown.

d. CAGE Code - The CAGE Code or manufacturer’s name and address shall be used if a CAGE Code has not been assigned.

e. Use - The purpose and primary use of each item shall be included.

f. Reference - Reference where each item will be used.

3.3.5.3.3 Chapter 3 - System Peculiar Maintenance. This chapter shall contain system peculiar maintenance that does not lend itself to JG format, e.g., structural crack limitations.

3.4 Job Guide (JG) manual. JG manuals shall provide complete detailed procedures for on-equipment maintenance. These procedures shall be organized into a series of publications with a separate manual, or manuals, for each major system. Separate manuals may be prepared for a subsystem(s) when necessary due to equipment complexity. SSSN breakouts shall be in accordance with MIL-STD-1808. See appendix C for resources available for digital preparation of the JG manual.

3.4.1 Scope. The JG manual shall provide detailed start-to-finish, step-by-step, maintenance instructions. Each procedure shall be arranged in logical sequence. Instructions shall be fully illustrated to support the text.

Instructions shall cover removal, installation, alignment (electrical and mechanical), adjustment, calibration, operational checkout, and other maintenance procedures as applicable, including operation of special equipment.

3.4.2 General requirements.

3.4.2.1 Style of writing. The material shall be factual, specific, concise, and clearly worded. Use of common names shall conform to the requirements of 3.1.3.1. Emphasis shall be placed on steps to be followed.

3.4.2.1.1 Syntax. Normal sentence structure (subject, verb, object) shall be used for narrative text. Task steps shall be written in the second person imperative (see 3.4.2.1.1.a). Modifiers, if required, shall be used to define equipment location and method or direction of manipulation. When a special tool is called out as a part of a step, the word “using” and the tool name shall precede the statement (see 3.4.2.1.1.b). The third person indicative mood or second person imperative mood, whichever is more effective, shall be used for description and

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w/AMENDMENT 2 discussion statements such as warnings, cautions, and notes. Task step numbers shall be keyed to the illustration (see 3.4.2.2) to minimize the need for complex sentence structure and modifiers (adjectives and adverbs).

Examples:

a. “1. Set switch to ON.”

(The switch and location are identified as callout “1” on the accompanying illustration.)

b. “3. Using snap-ring pliers, remove retainer clip.”

(The special tool identifier is added.)

3.4.2.2 Format. Function and task titles shall not be underlined.

Paper output: Text information in 5 x 8 inch manuals shall be presented on the left-hand page and the related illustration on the right-hand page. Text information for standard size 8½ x 11 inch manuals shall be presented in double column format with textual information located at the top half of the page and the related illustration on the bottom.

PDF output: Text information in 5 x 8 inch manuals shall be presented with text on one page and illustration on the next. Text information for standard size 8½ x 11 inch manuals shall be presented at the top half of the page and the related illustration on the bottom.

3.4.2.3 Numbering. Chapters shall be numbered within a JG manual(s) covering a specific subsystem and shall be sub-subsystem oriented. Functions shall be consecutively numbered within a chapter. Tasks shall be consecutively numbered within functions, e.g., the fourth task, in the second function, in chapter three, would be 3-2-4. Each numerical identifier shall be separated by a dash. Steps shall be consecutively numbered within a task, e.g., task 6-11-10 might have eight steps numbered 1 through 8.

3.4.2.4 Size. JG manuals shall be prepared in 5 x 8 inch pocket size. When specified by the acquiring activity (see 6.2.l), JG manual shall instead be prepared in 8½ x 11 inch standard size.

Paper output: Pocket size JG manuals shall be limited to 400 pages (200 sheets). Standard size JG manuals shall be limited to 800 pages (400 sheets). If the proposed JG manual exceeds these page limitations, it shall be divided at lowest level nearest the complete function. Tasks shall not be divided unless absolutely necessary. The contractor’s recommended breakout shall be approved by the acquiring activity on a case by case basis.

3.4.2.5 Nomenclature. Consistency shall be maintained between the first usage of nomenclature in the text of each task and illustration call outs on the first reference of an equipment item (see 3.1.3.1). When specified by the acquiring activity (see 6.2.m), the Higher Level Designator (HLD) shall follow the first usage nomenclature.

3.4.2.6 Tolerances. Information on how the equipment must respond, either in numerical or qualitative terms shall be provided. Clearances, flow rates, pressures, nonstandard and critical torque values, voltage, frequency, amperage, resistance, or other measures shall be provided, with applicable tolerances. Measurements shall be given in the units of the tool(s) or equipment required. If general instructions for installation of standard hardware must be given, it shall provide complete instructions in the task step, e.g., “Install panel screws and tighten so that screw heads are flush with the panel and the panel is flush with surrounding surfaces.” Use of general instructions within JG tasks shall be held to an absolute minimum.

3.4.2.7 Foldouts. Foldout pages shall follow the general requirements of MIL-STD-38784 except for the following given in these paragraphs. Foldouts shall only be used for tables and illustrations as approved by the acquiring activity (see 6.2.n). Tables or illustrations may be rotated 90 degrees counterclockwise to preclude the use of foldouts. When used, foldout pages shall be interspersed throughout the manual.

Paper output: Turn-pages (text on back) shall not be used.

3.4.2.7.1 Blank aprons. Paper output: Foldouts used in JG manuals shall not have blank aprons if they support a single page task and shall be located opposite the task instruction. Foldouts supporting multi-page tasks shall have blank aprons and shall be located on the right-hand page following the last text page supported. Use of foldouts to support a single page task shall be approved by the acquiring activity (see 6.2.o).

3.4.2.8 Cross-reference. The JG manual(s) shall contain a minimum of cross-references to other than those procedures or tasks within the same section or subsystem. Cross-referencing within the section or subsystem may be made when the reference applies to a complete task.

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3.4.3 Arrangement. The basic contents of the JG manual and its arrangement shall be as follows:

a. Front Matter (see 3.4.3.1).

b. Chapter - 1 General Instructions (system peculiar) (see 3.4.3.2).

c. Chapter - 2 and subsequent Chapters (system maintenance instructions) (see 3.4.3.2).

3.4.3.1 Front matter. JG manuals front matter shall be prepared in accordance with MIL-STD-38784 and applicable requirements specified herein (see 3.1), except no List of Illustrations (LOI) or List of Tables (LOT) is required.

3.4.3.1.1 Table of Contents. The TOC shall list each Line Replaceable Unit (LRU) or item covered, each function and task for the listed LRU or item, and shall cross-reference the applicable SSSN (if a function consists of only one task, only the function shall be listed). Each manual of a multi-manual set shall contain a cross-reference listing of the functions in all other manuals in that series. Tasks shall be listed only in the JG manual in which they exist (see figure 1).

3.4.3.1.2 Introduction. In multi-manual JGs, only the first manual shall contain the introduction. Notes explaining the applicability of a system shall be used, e.g., “This is applicable to F-16C aircraft.” When required, the following note pertaining to CPIN shall be added to the introduction of the JG manual: “NOTE: Refer to the applicable CPIN compendium to verify the latest version/revision of any Computer Program Configuration Item (CPCI) required to perform operational checkouts, automatic testing features, etc.”

3.4.3.1.3 Safety summary. In multi-manual JGs, only the first manual shall contain the safety summary.

Paper output: In 5 x 8 inch JGs, the safety summary shall be the last primary paragraph in the introduction.

3.4.3.2 Chapters. Chapter 1 shall provide system peculiar information, e.g., specific torque wrench usage, lockwire procedures, “O” ring seal installation, and leakage rates. Subsequent chapters shall contain information applicable to specific subsystems or parts of the system. Chapter numbering shall continue through the entire system JG, e.g., XX-JG-00-1 has chapter 1, XX-JG-10-1 has chapter 2, etc.

3.4.3.2.1 Functions. A maintenance function consists of input conditions, a task or series of tasks, and supporting illustrations. Maintenance functions to be used are determined by the acquiring activity (see 6.2.p).

Tasks shall be related in nature to the function, e.g., “all tasks supporting the installation of an engine shall relate to and support the installation process and use the same input conditions.” Functions shall not be combined unless supported by the same input conditions. An example of a combined function might be “remove and install amplifier.” Combined functions shall not include any subtasks. When typical maintenance functions are used, the tasks within shall be arranged in the following sequence.

a. Operational checkout - Location data for all end-items affected by the check and the primary equipment required for complete testing of the system shall be included. Normal indications (shown as “dot” results) shall be provided as well as appropriate fault codes, when applicable, e.g., “•MASTER CAUTION light goes out. (33-10-XJ)”

b. Access - All operations necessary to gain access to an item or to remove equipment blocking accessibility to that item shall be provided. Access panels, screws, and fasteners of different sizes within the same panel shall be identified.

c. Remove - All hardware items to be removed shall be specified by name. Instructions shall be included for matching, marking, or labeling for reinstallation of any part which could be installed incorrectly, including: cables, hoses, or lines which are disconnected during removal; special hardware items (nonstandard fasteners, brackets, or fittings slightly different from others in the same assembly).

Characteristics (longer, thicker, plastic, etc.) shall also appear as a callout on the illustration.

Instructions shall be included to retain items for reinstallation and to record the position of items removed, such as the number of shims at each attaching point.

d. Repair - Instructions shall cover repair or replacement of items, e.g., hoses, desiccants, special connectors, clamps, etc.

e. Install - All hardware items to be installed shall be specified by applicable nomenclature (see 3.4.2.5).

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Instructions shall refer to any items retained during removal and to the item’s position before removal.

No steps shall be included to install an item that must be removed in an immediately performed, subsequent function, task, or follow-on procedure.

f. Rigging - Procedures and illustrations for rigging shall be provided, e.g., flight controls, engine throttles etc.

g. Inspection - Methods, equipment, and instructions for complete inspection shall be provided.

Allowable service limits and adequate standards for determining appropriate maintenance action shall be stated. Required testing of assemblies or subassemblies shall be included. Inspections covered by manuals such as non-destructive inspections, corrosion control, structural repair, etc., shall not be included.

h. Cleaning - Special cleaning requirements shall be described, including the nomenclature and specifications of cleaning agents.

i. Lubrication - Type, amount, method of application, and the specification of the lubricant shall be stated. Lubrication points shall be illustrated and identified. Only the lubrication required as a result of the maintenance performed shall be included (see MIL-HDBK-275 for guidance as applicable).

j. Servicing - Procedures shall be provided to check, replenish or remove fuel, oil, hydraulic fluid, other fluids, oxygen, tire pressure, and all items involved in completely servicing/deservicing equipment, except scheduled equipment lubrication. Tank and reservoir capacities, and specifications and grades shall be shown.

k. Jacking - Procedures shall include diagrams showing the location of jack points, jack types, and specific methods to be used. Instructions shall be included for hoisting the equipment, e.g., missile stages, trailers, antennae, etc. Use of slings and procedures for maintaining correct balance of hoisted items shall be provided, including location of leveling legs, reference points, and access points.

l. Alignment and Adjustment - Procedures shall be provided for alignment and adjustment following the replacement of parts or assemblies, or as required to ensure the part or equipment meets operational performance standards.

m. Calibration - Procedures shall be provided to accomplish recurring on-equipment accuracy checks or adjustments.

3.4.3.2.1.1 Input conditions. The input conditions (see figure 2) shall provide all the necessary information needed prior to performing the function. Unused headings shall be listed as “none” or “not applicable,” as appropriate. Optional headings shall not be listed if not used. The following items shall be included in the input conditions, in the order described.

3.4.3.2.1.1.1 Applicability. Applicability codes (see 3.1.8) shall be provided. If the instructions apply to all equipment, the word “All” shall be used. Statements which explain applicability for individual items of equipment shall use either serial number range, block designation, or similar identification. Such terms as “on later equipment” and “on early serial numbers” shall not be used.

3.4.3.2.1.1.2 Required conditions. When required conditions must be obtained by performing other organizational maintenance instructions, these instructions shall be indicated as prerequisite to the task, e.g., “Aircraft safe for maintenance (JG 10-30-01).”

3.4.3.2.1.1.3 Personnel recommended. The minimum number of personnel required to effectively perform the maintenance shall be provided. Location and duties for multi-person requirements shall be identified at the beginning of the function. When a team is required, members of the team shall be identified at the beginning of the procedure. For example:

Personnel Recommended: Four

Technician A: Supervise operations.

Technician B: Connect and disconnect equipment.

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Technician C: Operate equipment.

Technician D: Inspector

3.4.3.2.1.1.3.1 Multi-person requirements. Multi-person requirements shall be included as identified in the supportability analysis. Assistants shall be identified when required (see 6.4.19). The responsible technician shall be associated with the applicable action or observation. Steps shall be presented in the sequence to be performed.

A notation shall precede each step indicating which member of the team will perform the step. For example:

(A) Position

(B) Insert

(B and C) Raise and install

(D) Inspect clearance

(A) Turn power switch to

3.4.3.2.1.1.4 Support equipment. The Government approved support equipment (test equipment, special tools, and ground handling equipment) shall be identified. Common types of tools normally found in the technician’s tool kit shall not be listed. Common types of test equipment, such as voltmeters, signal generators, etc., shall be listed.