TE_J_DID_A009_Technical_Manuals.doc

A009, Technical Manuals Continued

OMB NO. 0704-0188

Public reporting burden for this collection of information is estimated to average 110 hours per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing this burden, to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 22202-4302, and to the Office of Management and Budget, Paperwork Reduction Project (0704-0188), Washington, DC 20503.

1. TITLE

A009, Technical Manuals

2. IDENTIFICATION NUMBER

3. DESCRIPTION/PURPOSE

To prescribe minimum requirements for contractor prepared maintenance, operator, and software user manuals.

4. APPROVAL DATE (YYMMDD)

120821

5. OFFICE OF PRIMARY RESPONSIBILITY (OPR)

USAOTC G4

6a. DTIC APPLICABLE

6b. GIDEP APPLICABLE

7. APPLICATION/INTERRELATIONSHIP

These requirements are applicable to in-house developed instrumentation and other acquired systems lacking adequate documentation to operate or maintain. The resulting documents are subject to Government approval before being accepted as a deliverable.

8. APPROVAL LIMITATION

9a. APPLICABLE FORMS

9b. AMSC NUMBER

10. PREPARATION INSTRUCTIONS

10.1 When the contractor develops instrumentation he shall provide manual(s) that meet the requirements of paragraphs 10.3 through 10.7 below. If the instrumentation is modified, the manual shall be updated to reflect the changes. Contractor format is acceptable.

10.2 The contractor shall use best judgment in determining applicability of each sub-element of the chapters and sections required by paragraphs 10.3 and 10.7 However, the manual shall provide the necessary operating instructions, alignment procedures, schematics, parts lists, etc. to enable safe operation and facilitate efficient repair.

10.3 A Maintenance Manual, Operator’s Manual, and/or Software User’s Guide shall be developed in accordance with the following items and topics.

a. Maintenance Manual.

(1) Purpose

(2) References

(3) Overview/Description

(4) Installation

(5) Theory of Operation

(6) Alignment and Calibration

(7) Maintenance

(8) Parts List/Bill of Materials

11. DISTRIBUTION STATEMENT

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

(7) Drawings

(8) Safety b.

Operator’s Manual

(1) Purpose/Description

(2) References

(3) Operation

(4) Equipment

(5) Set up

(6) Software

(a) Principles of Operation

(b) Pre-Operational Procedures

(c) Operations Procedures

(d) Operator Maintenance Checks

(e) Post-Operational Checks c.

Software User’s Guide

Scope

References

Operating instructions

Hardware/Software

10.4 Definition of Maintenance Manual Terms

a.

Principles of Operation

Table of contents, organized to section and page

List of illustrations, to include the figure number, exact title, and page number

An introduction stating the general purpose of the manual

Theory of operation

System description, specifications, and features

References to related documents

Procedures to operate, calibrate, maintain, and troubleshoot

Block diagram(s)

(9) An illustration(s) calling out major assemblies and subassemblies with their nomenclature

(10) Tables of technical, environmental, and physical characteristics

Installation

Information on unpacking, location of units, interconnections, and initial pre-operational adjustments

Details of cables, ground requirements, and cable fabrication

Illustration(s) of interconnections and front and rear panel and their respective functions

Theory of Operation

Functional block diagram

For mechanical features, a complete explanation using block diagrams

Circuit description

Top down structured proceeding from simplified descriptions and block diagrams of the entire system to detailed description and drawings in stepwise refinements d.

Alignment and Calibration

A description of each procedure required to align or calibrate the system

Complete description of instrumentation and set up procedures

A complete list, with pictures and drawings as required, of the measurements and the tolerance for these measurements e.

Maintenance

A schedule maintenance adjustments and procedures

A list of recommended test equipment

Physical and functional description

Lubrication data, cleaning data, materials to be used/avoided

Troubleshooting steps that permits a technician to locate problems, interpret warning messages, and to make repairs and adjustments quickly and accurately

For complex equipment or where procedure is not obvious, an outline of disassembly and re-assembly procedures

Test procedures

Complete adjustment and maintenance information for mechanical and electromechanical devices

Oscilloscope waveforms illustrated with peak voltage, duration, repetition rate, pulse shape, and control positions

A list of cable drawings (internal and external) including drawing number and description

(11) Maintenance procedures

(12) Identification of firmware and software f.

Parts List. The parts list shall have two sections. Section I shall list the components of the End Item and section II shall consist of a tabulation of description data on all electrical and mechanical parts. All parts lists shall be sufficiently described to implement re-order and replacement. The parts list shall contain at least the following information.

Section I

Line drawings of each component or assembly with noun nomenclature. This section shall provide the information needed to facilitate a complete inventory of the system, e.g., components, cables, brackets, mounting hardware, software, manuals, etc.

Vendor data

Repair level

Section II

Reference designation to a line drawing

Name and description (including firmware and software)

True manufacturer’s code (FSCM) and separately list referenced manufacturer’s codes and addresses

Federal Stock Number or true manufacturer’s part number

Quantity g.

Drawings (unless otherwise specified) shall be included in the manual.

Schematic diagrams of individual major assemblies, printed circuit boards (PCB), and where practical, of the complete system.

Logic diagrams

Interconnecting diagrams

Cabling diagrams

Wiring diagrams

Illustrations that identify and call out all circuit components on PBC’s

Schematic of all circuitry and chips to include a one-page schematic of the entire system

Mechanical drawings or part, assemblies, PCB’s, etc

PCB artwork

All drawings contained in the manual shall be legible and uncluttered

(11) A drawing tree, showing all drawings top down in a structured, stepwise refined method h.

Enumerate potential safety hazards and methods of handling, using and operating hazardous material and equipment

Safety operational procedures and emergency procedures 10.5 Definition of Operator’s Manual Terms

Operations. Principles of operation

Table of contents, organized to section and page

List of illustrations, to include the figure number, exact title, and page number

Clear, concise, non-technical explanation of the operation of the system or equipment

Installation procedures

System/equipment capabilities

Basic principles of operation

Operation. Pre-operational procedures

Step-by-step procedures for starting the equipment

Equipment and functional check-out procedures

Operator maintenance checks and procedures

Operation. Operating procedures

Step-by-step procedures for equipment operation

Tables and illustrations calling out all controls and indicators and their functions and operation

Tables showing errors/problems and operational procedures to correct

Post-operation checks and procedures

Step-by-step shutdown procedures d.

Operation. Operator maintenance checks

10.6 Definition of Software User’s Guide Terms

Description

Preparation of Inputs. A definition of the program inputs, other than those required to operate the program. These inputs constitute the basic data that are to be processed by the program. The definition shall include:

Title of inputs

Description of inputs

Purpose and use

Input media

Limitation/restrictions

(f) Format and content

(g) Sequencing

(h) Special instructions

(i) Relationship of inputs to outputs

Results of Operation. A definition of expected results after completion of program operation.

Description of results

Form in which results will appear

Output format and content

Instruction, on use of outputs

Limitations/restrictions

(f) Relationship of outputs to inputs

(g) Examples

Operating procedures. The step-by-step procedures required to:

Initiate the program

Maintain program operation

Terminate and restart the program

Operator Inputs. A complete description of all the control inputs and data formats for the program and the computer operating system, including the function of purpose shall be provided. All inputs, other than those described in paragraph 2a, required to operate the program shall be defined in a similar manner as follows:

Title of output

Input media

Limitations/restrictions

Format and content

Operator Outputs. A complete description of the output formats, other than those described in paragraph 2b, of the program. This shall include samples of each type of possible output format. This subparagraph shall include, but not be limited to the following.

Title of output

Output media

Output format

Output content (symbols, codes, etc.)

Method of Modification. This portion shall describe how the source language may be modified. Included shall be the source language computer’s reference to an appropriate programming manual, the host computer’s operational system’s identity, and description of the necessary controls for recompilation or re-assembly. Sufficient information shall be included to allow for the production of a new source program and a new object program.

Re-qualification. The original method of qualifying the program shall be described together with the necessary information to repeat this qualification. Also, a sample run shall be supplied for continued-checks on the program’s configuration. The necessary input and expected output shall be included for the sample run.

DD Form 1664, APR 89 Previous editions are obsolete