MIL-DTL-9854D
REQUIREMENTS
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3.1 Preparation. The general manner of preparation of the basic structural repair manual and battle damage
data, when required, shall be in accordance with MIL-STD-38784. System Subsystem Sub-subsystem
Numbering (SSSN) shall be developed in accordance with MIL-STD-1808.
3.1.1 Marginal Copy. When structural repair manuals will be used in conjunction with Organizational
Maintenance Manuals (OMMS) prepared in accordance with of MIL-DTL-83495.
Electronic media: Display of SSSN shall be in accordance with MIL-STD-38784.
Print media: Structural repair manuals shall display the applicable SSSN in the lower-outer corner of
each page, using 18 point type, directly above the page number.
3.1.2 Nomenclature. When SSSNs are used, vehicle equipment nomenclatures excluding structural
components shall be followed by the applicable higher level reference designation in parenthesis. Manual
titles, chapter/section titles, and system/subsystem nomenclatures shall be followed by the applicable
SSSN in parenthesis.
3.2 Basic structural repair manual. The extent of coverage shall be as follows:
3.2.1 Content. The structural repair manual shall contain information required by maintenance personnel
for determining the extent of damage to the aircraft structure and instructions for its repair that are not
contained in general manuals for structural repair and other general repair manuals.
3.2.1.1 Covered repairs. When repairs covered in the general repair manuals are acceptable for the
applicable aircraft, it shall be so stated and referenced in the appropriate chapter/section of the manual.
If the information in the general repair manuals is unacceptable, the aircraft manual shall contain the
proper information as the aircraft manual will take precedence over the general manual. Electronic media
only: All references shall be linked to the data to which it applies.
3.2.1.2 New or peculiar structures. Repair instructions for new or peculiar structures, such as tapered skin,
sandwich materials, honeycomb assemblies, reinforced plastics, and composite materials shall be included in
the manual if they are not covered in the general repair manuals. Coverage of structural components of
pods and external tanks shall also be provided.
3.2.1.3 Detail. Repairs contained shall be simple and practical (considering accessibility, adjacent structures,
etc.). Wherever practical, repairs shall require only hand tools. The use of jigs, machine tools, etc., and
rivets requiring heat treatment before driving, shall be speciied when necessary.
3.2.1.4 Repairs involving extrusion. When a covered repair involves the use of an extrusion, an alternate
repair, utilizing sheet, bar, or tubing, instead of extrusion, shall also be shown, when practical.
3.2.1.5 New types or classes of material. When new types or classes of material are incorporated in the
original construction of the aircraft, an alternate repair, if practical, shall be included based on using
the more common materials generally available.
3.2.1.6 Removal and installation instructions. Removal and installation instructions shall be included
for all structure beyond organizational and intermediate level maintenance that is not included in
the organizational maintenance manual.
3.2.1.7 Corrosion control information. Corrosion control information shall be included when a separate
corrosion control manual is not being procured (see 6.2).
3.2.1.8 Special repair instructions. Instructions for one-time (ferry) light repairs, temporary repairs, critical
area repairs, and combat area repairs shall include information of light restrictions to be imposed (if
applicable) until such time as permanent repairs have been completed.
3.2.2 Damage. Classiication shall be as follows: negligible damage, repairable damage, crash damage, and
combat area damage.
3.2.2.1 Deining classes of damage. Each class of damage shall be clearly deined, with examples cited, for
each component of the major structural groups covered by the structural group repair sections in the
manual. The deinitions of each class of damage for a component shall appear in the section of
the manual covering the component.
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