DI-TMSS-82370

Training System Maintenance Manual (TSMM)

Specifies the format and content for the Training System Maintenance Manual (TSMM), covering testing, fault isolation, adjustment, assembly/disassembly, cleaning, calibration, lubrication, removal/installation, and repair procedures for Trainer Unique Equipment (TUE).

Approval DateJanuary 11, 2022

AMSC NumberN10289

Preparing ActivityAS

Project NumberTMSS-2022-002

OPR—

DTIC ApplicableNo

GIDEP ApplicableNo

LimitationNone

Applicable FormsNone

Approval Limitation—

Form Version—

DID Formatfree_text

963C CompliantYes

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

Supersedes

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DI-SESS-82371DI-TMSS-80527C

Description & Purpose

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Application & Interrelationship

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Use & Relationship

The Training System Maintenance Manual (TSMM) shall provide complete procedures for performing testing, fault isolation/troubleshooting, adjustment/alignment, assembly/disassembly, cleaning and corrosion control, calibration, lubrication, removal/installation, repair, and servicing for Trainer Unique Equipment (TUE) that would permit maintenance to be performed on-equipment and off-equipment in accordance with the Government's training system maintenance concept.

a. Maintenance task analysis (MTA) shall be the primary method of determining both scheduled and unscheduled maintenance tasks for the training system. The MTA is the identification of the steps, spares, and materials, tools, support equipment, and personnel that must be considered for a given repair task. MTAs cover both scheduled (preventive) and unscheduled (corrective) maintenance tasks and, when complete, identifies all physical resources required to support a training system in accordance with the Government's maintenance concept. MTA results will be analyzed during the program technical reviews. The MTA shall be in accordance with DI-SESS-82371.

b. Data rights and data rights marking requirements for the TSMM (excluding COTS manuals) shall comply with DFARS 252.227-7013.

c. Commercial off-the-shelf (COTS) service manuals that provide the on-equipment and off-equipment fault isolation, module repair and removal, installation, and alignment procedures shall be referenced in the TSMM and included as an attachment. COTS manual shall be in accordance with DI-TMSS-80527C.

d. This Data Item Description (DID) contains the format, content, and intended use information for the data deliverable resulting from the work task described in the solicitation.

e. It is not intended that all the requirements contained herein be applied to every program. Any data requirement contained in this DID is subject to deletion in tailoring by the acquiring activity.

Definitions:

a. Units/Assembly/Subassembly/part - As defined by ASME Y14.100-2017 Engineering Drawing Practices, Section 3:

1. Unit - An assembly or any combination of parts, subassemblies, and assemblies mounted together normally capable of independent operation in a variety of situations.

2. Assembly - A number of parts, or combination thereof, that are joined together to perform a specific function and subject to disassembly without degradation of any of the parts.

3. Subassembly - Two or more parts that form a portion of an assembly or a unit replaceable as a whole but having a part or parts that are individually replaceable.

4. Part - One item, or two or more items joined, that is not normally subject to disassembly without destruction or impairment of designed use.

b. Trainer-Unique Equipment (TUE). The following types of equipment are defined as TUE:

1. Trainer equipment which has not been classified by the Government as a Commercial Item, Government-Furnished Equipment (GFE), Non-developmental Item (NDI), or Contractor Acquired Operational Equipment (CAOE).

2. Commercial Item, NDI, GFE, or CAOE, that:

(i) Needs other than Minor Modifications or modifications which are not of a type customarily available in the commercial marketplace to meet the requirements of the contract, or:

(ii) Does not have sufficient existing product documentation for Government logistics support.

Preparation Instructions

1Reference DocumentsThe applicable issue of the documents cited herein, including the approval dates and dates of any applicable amendments, notices, and revisions, shall be as specified in the contract.

2FormatThe TSMM shall be in the contractor's format.

2.1The level of writing in the manualshall be to that of a Department of Labor Electronics Technician, Maintenance, I, II, and III (23181, 23182, and 23183).

3ContentThe TSMM shall contain the following content organized in the order below:

3.1Front mattershall contain a cover, record of changes and table of contents.

3.1.1The covershall include security classification or Controlled Unclassified Information (CUI) marking, document number, revision number, destruction notice, disclosure statement, export control warning statement, CUI designation indicator block, and authority notice. Front matter shall be in accordance with MIL-STD-38784B.

3.2Warnings, cautions, and notesshall be in accordance with MIL-STD-38784B.

3.3IntroductionThe Introduction shall explain that coverage in the manual is limited to TUE equipment or functions and that reference should be made to external available COTS, ACOE, or GFE service manuals for additional instruction, as applicable. The Introduction shall contain the following sections:

3.3.1Use of the manualThis section shall explain the use of the manual, including the major sections and organization of the manual, text formatting and hyperlinking conventions, reference designators, and drawing number assignments.

3.3.2Maintenance conceptThis section shall describe the maintenance concept for the training system.

3.3.3Safety summaryThis section shall provide a safety summary to include, at a minimum:

3.3.3.1Use of Emergency Power Off (EPO) switches and a depiction of EPO locations.

3.3.3.2Step-by-step instructions for safely removing a trainee or trainees from the training device in the event of a mishap.

3.3.3.3Lethal voltages.

3.3.3.4Hazardous materials warning summary, the symbols used to identify hazardous materials, and an explanation of each symbol.

3.3.3.5Fire and smoke detection/protection for the training system.

3.3.3.6Lift and carry limitations.

3.3.3.7Electrostatic Discharge Sensitive (ESDS) Components.

3.3.4Reference documentsThis section shall contain a list of referenced documents to include related COTS and contractor developed manuals by number and title that affect the operation and maintenance procedures of the training system.

3.3.5Acronyms, abbreviations, and definitionsThis section shall contain a list of non-standard acronyms, abbreviations, and definitions used throughout the manual.

3.3.6Technical Publication Discrepancy Reporting (TPDR)This section shall contain the instructions for submitting a technical publication discrepancy report.

3.4Training system overviewThis section shall provide an overview of the training system features, characteristics, capabilities, limitations, and units, assemblies, and subassemblies. The training system overview shall contain the following, as applicable:

3.4.1Scope of operation.

3.4.2A description of training system features:

3.4.3A list of capabilities and limitations.

3.4.4A table of leading particularsincluding physical characteristics of the training system (i.e., length, width, height, weight, cubic space of major assembly units) and electrical characteristics (i.e., total power factor, overall voltage, current, allowable deviation from the normal of the electrical characteristics.

3.4.5A description of the simulation equipmentin unit, assembly, and subassembly order to include depictions and locations of each.

3.4.6A description of the use of the following itemsas applicable, as aids in troubleshooting the training system such as diagnostic programs, daily operational readiness test, built-in test, fault logic diagrams, and assembly test procedures.

3.5Scheduled (preventive) maintenanceThis section shall contain all scheduled maintenance procedures organized by the following periodicity: daily (including pre and post operational, between missions/exercises); periodic, followed by the requirement periodicity; and special "on condition", followed by the requirement periodicity. The scheduled maintenance requirements shall be arranged in a logical sequence to provide a means of performing the requirements in the most rapid and accurate manner in order to ensure training system availability.

3.5.1Scheduled maintenance proceduresshall include, at a minimum, procedures required to examine, clean, and lubricate the training system equipment and shall contain the following:

3.5.1.1Time required to complete the procedure.

3.5.1.2Number of personnel required to complete the procedure.

3.5.1.3Safety Precautions.

3.5.1.4Tools, parts, materials, and test equipment required.

3.5.1.5Cleaning solventsSolvents shall be identified by Government specific numbers and National stock numbers.

3.5.1.6Instructions for properly maintainingall safety devices and interlocks, with warnings and cautions.

3.5.1.7Instructions for lubrication/cleaning/servicing; also types and quantities of lubricants to be applied.Lubricants shall be identified by Government specification numbers and National stock numbers.

3.5.1.8Procedures for obtaining access to subassemblies of subcomponents.

3.5.1.9Inspection procedures for parts that deterioratedue to cycles of usage, age, and/or other conditions.

3.5.1.10Illustrations to support the procedurelubrication points, and other relevant information.

3.5.2Scheduled performance checksshall contain step-by-step procedures necessary to verify that the equipment is operating within standards for all modes of operation and to detect malfunctions prior to failure. Performance checks shall contain the following:

3.5.2.1Safety Precautions.

3.5.2.2A list of tools and test equipmentidentified by type, manufacturer, and model number.

3.5.2.3The title of the performance checksto be completed.

3.5.2.4Preliminary setup data required to conductthe performance check.

3.5.2.5Detailed procedures for accomplishing the performance checkProcedures requiring lengthy and identical setup data may be presented in detail in one procedure and referenced in succeeding procedures.

3.5.2.6Values or conditions, with tolerancesindicative of normal operation.

3.5.2.7Reference to corrective maintenance proceduresto be used if the performance check is not within tolerances.

3.5.2.8Illustrations to support the performance check.

3.5.2.9No references to procedures located in other documents.

3.6Theory of OperationThis section shall contain a discussion of the theory of operation necessary to provide technicians with an understanding of the interrelationships of the functional system of the overall training system to include operating theory of the support systems integrated into the training system such as commercial computers, visual systems, motion systems, Government Furnished Equipment (GFE), etc. The following information shall be included in this section:

3.6.1A description of each systemits purpose, interconnections, and controls and indicators.

3.6.2A description of system interfaces.

3.6.3The theory of operation of the systemssubsystems, circuits, units, and assemblies, or subassemblies to include references to the associated functional block diagrams, logic diagrams, and simplified block and schematic diagrams.

3.6.4Detailed descriptions required by a maintenance technicianto provide the understanding necessary for fault isolation to the level of repair specified by the Government's training system maintenance concept.

3.6.5A description of the general functioningand interfaces of the operational and COTS equipment in the training system, with references to the operational or COTS service manuals for detailed theory of operation.

3.6.6Simplified block and schematic diagramsin order to assist the maintenance technician to understand the theory of operation for the training system.

3.6.7References to COTS service manuals as applicable.

3.7Unscheduled (corrective) maintenanceComplete procedures shall be provided for the following categories of unscheduled maintenance and in accordance with the Government's training system maintenance concept, as applicable:

3.7.1References to drawings for troubleshootingdisassembly/assembly, testing, repair/replacement, adjustment, as applicable.

3.7.2Troubleshooting procedures to guide a technicianin the logical sequence of isolating a fault to a unit, assembly, subassembly, module, or part in accordance with the Government's maintenance concept.

3.7.2.1Troubleshooting proceduresshall be table format and include the following: trouble, probable cause, troubleshooting task, and corrective action.

3.7.3Detailed procedural steps required to detacha unit, assembly, subassembly, or component for replacement, test, inspection, or repair with precautions to be observed, except when the methods or procedures are obvious.

3.7.4Instructions to inspect the disassembled equipmentfor damage or wear to include allowable service limits and tolerances, standards for determining when parts may safely be continued in service and when they should be replaced.

3.7.5Detailed testing procedures required for fault isolationto the lowest replaceable unit (LRU) for all repairable assemblies and subassemblies.

3.7.6Procedures for repair/replacement of a faulty piece partto include special cleaning or lubricating instructions.

3.7.7Procedures for any required adjustments/realignmentof the assembly following a repair action.

3.7.8Procedures for requalification testing of a repaired unitassembly, or subassembly.

3.7.9Corrective adjustment procedures and support informationnecessary to restore electrical and mechanical alignment of the simulation equipment, including all values and tolerances.

3.7.10Calibration requirements.

3.7.11Procedures for loading and configuring softwarefollowing a maintenance action.

3.7.12References to COTS service manuals, as applicable.

References

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