ISO 9928-2:2015 Gantry Crane Operation Manual Standard Explained
ISO 9928-2:2015 "Cranes — Operation Manual — Part 2: Overhead and Gantry Cranes" specifies the requirements for preparing operation manuals for overhead and gantry cranes. It defines the manual's content framework, format requirements, update management, and usage requirements.
Manual Content Framework
The operation manual shall include the following sections: a preface covering the application scope and version; safety instructions with hazard warnings and prohibited actions; technical specifications with parameter tables; transportation and installation plans with step-by-step procedures; operating instructions detailing control devices and operation sequences; inspection and maintenance covering daily inspection, monthly inspection, lubrication, and wear parts; fault elimination with symptoms, causes, and remedies; and appendices with circuit diagrams and spare parts information. Chapters are numbered using Arabic numerals with a hierarchical grading system. Safety warnings are classified into three levels — Danger (red background with white text), Warning (yellow background with black text), and Caution (blue background with white text). Operating procedures are presented as numbered sequences in the imperative mood.
Format Requirements for Manual Preparation
Pages shall be perfect-bound or loose-leaf. Use SimSun font for Chinese text and Arial for English text, with a minimum font size of 9pt and 1.5 line spacing. All tables and figures must be numbered sequentially. Each page shall display the page number and total page count. The cover shall include the manufacturer's name, model series, manual title, version number, and date. Terminology must comply with ISO 4306 Cranes - Vocabulary. The PDF electronic version shall be identical to the printed version and available for download from the manufacturer's website. The inside front cover shall contain a quick reference table for emergency operation, with the title in red text on a white background, operating steps in black text on a white background, and cautionary notes in yellow text on a black background, with a minimum text height of 4mm.
| Section | Main Content | Format |
|---|---|---|
| safety instructions | Hazard Warning/Prohibition | Tri-color Warning Box |
| technical specifications | Parameter Table/Structural Diagram | Table+Schematic Diagram |
| Transportation and Installation | Procedure/Step/Safety | Step Numbering |
| operating instructions | Control/Step/Emergency | Illustration+Text |
| inspection and maintenance | daily inspection/monthly inspection/Lubrication | Periodic Table |
| fault elimination | Symptom/Cause/Remedy | Cross-reference Table |
Emergency Operation Quick Reference Table
Quick reference card on the inside cover — Brake failure (emergency stop, manual release valve for controlled lowering), controller malfunction (emergency stop, cut main power supply, manual operation), suspended load out of control (emergency stop, alarm, one-way lowering, evacuate), limit switch failure (emergency stop, manual limit switch inspection), fire or electric shock (emergency stop, cut power supply, fire extinguisher). Red background with white text for the title, white background with black text for the steps, yellow background with black text for the cautions.
| emergency situation | Step | Caution |
|---|---|---|
| Brake Failure | emergency stopmanual release Slow Lowering | speed≤50%Rated |
| Controller Malfunction | emergency stop Disconnect Power Supply Manual | Verify Power Supply Disconnect |
| suspended load Runaway | emergency stop Sound Alarm Lowering Evacuate | Keep Clear of Swing Radius |
| Limit Switch Fault | emergency stop Manuallimit switch Inspect | Clear Before Resuming Operation |
| Fire/Electrical Leakage | emergency stop Cut Off Power Supply Extinguish | Do Not Use Water on Electrical Fires |
FAQ
Q: What sections are included in the manual?
A: The manual covers the following sections: preface, safety instructions, technical specifications, transport and installation, operating instructions, inspection and maintenance, fault elimination, and appendices. Sections are numbered with Arabic numerals. Warnings are classified into three levels: Danger, Warning, and Caution.
Q: What are the formatting requirements?
A: Body text must be at least A4≥9 pt. Tables must be numbered, and figures must include captions. A quick reference table is placed on the inside of the front cover. Terminology follows ISO 4306 Cranes - Vocabulary. The manual is provided as an electronic version in PDF format.
Q: How are safety warnings formatted?
A: Danger warnings use white text on a red background, Warning uses black text on a yellow background, and Caution uses white text on a blue background. All safety signs comply with ISO 7010 Safety signs standard.
Q: How are manual updates handled?
A: A new edition is issued within 90 days of any equipment modification, and users are given 30 days to replace outdated copies. Version numbers are synchronized across all documentation. Manuals are prepared bilingually in Chinese and English by Kelude.
