SAMPLE COMPANY Page 1 of 6 SOP # 04-6 Revision: 0 Prepared by: _ Effective Date: Approved by: _ Title: OPERATION/SERVICE MANUALS Policy: Operation/service manuals will be prepared for products manufactured by the company and will be developed to ensure optimum comprehensibility by the operator with adequate content information to safely and effectively install, operate, maintain and service the product. Purpose: To provide guidelines for consistent preparation of operation/service manuals with sufficient and appropriate information. Scope: All operation/service manuals for products manufactured by the company. Procedures: 1.0 Preparation and Updating of Operation/Service Manuals 1.1 Manuals will be prepared and reviewed in joint by Engineering, Marketing and Customer Service. It will be the responsibility of the assigned Product Manager to drive and oversee development and maintenance of the manual. The Product Manager may also select to separate operation and service sections of the manual and prepare two separate manuals depending on volume and the intended user's needs, preferences or requirements. Upon completion of a draft of the manual, the Product Manager should complete an Operation/Service manual evaluation form and make corrections, additions, etc., to the manual as appropriate before finalization and printing. 1.2 Any required changes to the product manual must be done in accordance with Document Change Control procedures. OPERATION/SERVICE MANUALS Page 2 of 6 2.0 Content 2.1 Except as determined by the Product Manager, acceptable Operation/Service Manuals shall contain, but not be limited to the following: Cover or Title Page Table of Contents Safety Precautions Introduction Preparation for Use Principles of Operation Operating Instructions Maintenance and Servicing Instructions Preparation for Shipment and/or Storage Parts List Illustrations and Diagrams 2.2 Cover or Title Page: - The cover or title page will contain the company name, address and telephone numbers, product name and model number, the date the manual was issued and the revision level. 2.3 Table of Contents: - A manual with more than ten (ten) pages shall include a table of contents. It shall list all parts, chapters, sections, and paragraphs in the order of presentation and with the same title used in the text. It shall include a list of illustrations and a list of tables if the manual contains more than ten (10) illustrations or tables. 2.4 Safety Precautions: - The manual shall contain safety precautions where hazards, such as high voltage, may be present during installation, operation, or maintenance of the equipment. Health hazards, such as electrostatic discharge, radio frequency radiation, radioactive materials, the presence of poisonous fumes or explosive gases, and the depletion of oxygen from the air in a closed environment, shall be preceded by a warning or caution at the point in the procedure where the hazard is likely to be encountered. OPERATION/SERVICE MANUALS Page 3 of 6 2.5 Introduction: - The manual shall contain an introduction, or introductory material, containing the following: a. Purpose and functions. b. Capabilities. c. Performance characteristics. d. Description and features. e. Specifications, capacities and technical data (i.e., dimensions, weight, cube volume, center of gravity, etc.). f. Full page composite illustration calling out major assemblies with nomenclature. g. List of items furnished. h. List of additional items required for operation and maintenance, but not supplied with the equipment. i. Tools and test equipment. j. Power and utility requirements and information. k. Environmental information. l. Warranty information. m. Customer Service information on how to obtain assistance. 2.6 Preparation for Use and Installation Instructions: - The manual shall contain unpacking, assembly and set-up instructions. Inspection for in-shipment damage and instructions on how to handle damaged equipment shall be included. Special installation instructions shall include requirements for ventilation, clearances, plumbing and electrical connections, mountings, wiring runs, initial lubrication, and alignment as applicable. 2.7 Principles or Theory of Operation: - The manual shall contain principles of operation information at the technical level necessary for the intended user. 2.8 Operating Instructions: - Operating instructions shall include the following: a. Explanations with illustrations of the uses and functions of all controls and indicators (including settings and readings, if applicable). b. Initial adjustments and control settings. c. Start up operations. d. Normal operation. e. Shut down procedures. f. Operation or shut down under emergency, adverse or abnormal conditions. OPERATION/SERVICE MANUALS Page 4 of 6 2.9 Maintenance and Servicing Instructions: - The manual shall include preventative and corrective action to be taken with a trouble shooting guide to allow operator's or technicians to locate trouble and make repairs or adjustments to the equipment. Instructions shall include a list of test equipment, special tools, and materials needed for maintenance and service. This list shall include nomenclature, part/model number, application, range, and accuracy. Instructions or illustrations shall explain or show how test connections are made. Actions and normal indications shall be defined for each text. Periodic cleaning and lubrication information, covering types of cleaning agents or lubricants shall be included. Frequency of lubrication and intervals (monthly, quarterly, hours of operation, etc.) shall be presented. Lubrication points and required amounts shall be identified. When applicable, pictorial format for lubrication instructions shall be included to clearly illustrate location of each lubrication point. Cleaning and lubrication during repair, replacement or reassembly shall be included in the instructions covering those actions. Instructions for calibration of the test, measurement and diagnostic equipment needed to restore the equipment to serviceable accuracy (performance verification) shall be provided. Instructions, including scheduling, for inspection of equipment for damage and wear shall be provided with emphasis on allowable service limits such as wear, backlash, end play, balance and length and depth of scoring. Malfunctions that might occur during operation of the equipment shall be identified. Troubleshooting data, and fault isolation techniques shall include: a. The indication or symptoms of trouble. b. The instructions necessary, including test hookups, to determine the cause. c. The action or references to action to restore the equipment to operating conditions. Applicable information shall be in chart form, logic tree form, in tabular format with appropriate headings, or as a logic, block or schematic diagrams. Sequential instructions for disassembling, repairing, replacing and reassembling the equipment shall be provided. Test, adjustment and check-out data after reassembly shall be provided. Illustrations, including exploded views, shall be used as necessary to support each of these functions. OPERATION/SERVICE MANUALS Page 5 of 6 2.10 Preparation for Shipment and/or Storage: - Manuals shall contain instructions for preparation for shipment and/or storage when applicable and can include the following: a. Disassembly, removal and separate packaging of electrostatic sensitive discharge devices or fragile components. b. Use of reusable shipping cases, containers, dunnage or special cradles. c. Mounting and securing. d. Covering and preservation. e. Precautions and instructions for shipping and unloading. f. Temperature, ventilation and other environmental limitations. g. Drainage. 2.11 Parts List: - The manual shall include a parts list containing positive identification of parts for support of the equipment and shall include the actual manufacturing or vendor part numbers or generic description to enable users to obtain replacement parts. Clear and legible illustrations shall identify component parts and parts relationships. Part numbers and part names should be shown on the illustrations or separately listed. If separately listed, both the illustrations and the separate listing shall index, reference or key numbers which will cross- reference illustrated parts to listed parts. Parts in listings shall be grouped by assemblies, subassemblies, and modules with parts identified to the assembly from which they are components. 2.12 Illustrations and Diagrams: - Manuals shall contain illustrations (line drawings, photographs or halftones) for locating and identifying all components significant to operation and maintenance and to show configurations and parts relationship for removal and disassembly procedures. Photographs (prescreened) shall be detailed and sharp, free of heavy shadows, distorted objects, cluttered foregrounds or backgrounds and give good contrast from white, middle tones, and black. When applicable, the following diagrams shall be included in the manual; a. Simplified functional block. b. Locator. c. Piping. d. Plumbing. e. Hydraulic. f. Schematic. g. Electrical. h. Digital. i. Other, as necessary. OPERATION/SERVICE MANUALS Page 6 of 6 Symbols used on illustrations and diagrams shall be standard or common to the trade or commodity. Where nonstandard symbols are used, explanations shall be provided. 3.0 Style, Format and Production 3.1 Manuals will be appropriately arranged or sectionalized with all pages numbered and all illustrations, figures or tables sequentially titled and numbered. 3.2 Manuals will be produced in the following format: Paper Stock: 24 lb., 8 1/2" by 11." Cover: 80 lb. cover stock, 9" by 11 1/4." Binding: Spiral. Layout: Two columns, Margins - Left 1 1/4" Right Justified 3/4" Typestyle: Headings - 14 pt. Sub-Headings - 12 pt. Content - 10 pt.