AIRPORT DOORS (QLD) PTY LTD

Phone : (07) 3803 6255 Fax: (07) 3803 6249

A .C. N. 074 521823 A .B.N . 12 074 521 823

Operation & Maintenance Manual

for

Steel Roller Shutter

Client / Managing Contractor : F K Gardner & Sons

Sub-Contractor /Manufacturer: Airport Doors (Qid) Pty Ltd Date of Installation (approximate): December 2006

Project Name: Project Address:

Quantum Business Park Lot 4 Gardner Court Toowoomba

Scope of Works: Supply & Install the following:

Door Number Door 1-12 Door 13-14

Door Type Steel Roller Shutter Steel Roller Shutter

Appox Operation Opening size height x width Mechanism 6000x4800 4000x3000 Electric Electric

Finish

Powder Coated Powder Coated

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AIRPORT DOORS (QLD) PTY LTD A.C.N. 074 521823 A.B.N. 12 074 521 823 Phone : (07) 3803 6255 Fax: (07) 3803 6249

1 . TABLE OF CONTENTS

1.

TABLE OF CONTENTS

2.

CONTACT DIRECTORY

3.

TECHNICAL DATA 3.1 Components Identified

3.2 Component Features

4. OPERATIONS PROCEDURES
4.1 General Electric Operation Overview 4.2 General Chain Operation Overview 4.3 Emergency Stop 4.4 Recommended Safety Actions to be taken by client 4.5 Emergency Contact 24 Hours

5. MAINTENANCE PROCEDURES 5.1 Maintenance Instructions 5.2 Repair and Spare Parts 5.3 Preventative Maintenance 5.4 Overhaul 5.5 Roller Shutter Service Checklist & Report

6. CERTIFICATES AND PERFORMANCE TEST RESULTS

7. WARRANTY POLICY

Operation & Maintenance Manual - SRS Electric-Chain Page 2

AIRPORT DOORS (QLD) PTY LTD A.C.N.

Phone: (07) 3803 6255 Fax: (07) 3803 6249

074 521823 A .B.N . 12 074 521 823

2. CONTACT DIRECTORY

Business Address

60 Platinum St, CRESTMEAD QLD 4132

Postal Address

PO Box 2100, CRESTMEAD QLD 4132

Contact Details

Ph: -during work hours Fax: -during work hours Ph: -after hours -

(07) 3803 6255 (07) 3803 6249 (07) 3803 6255

Email Address: salesgld@airportdoors.com Website: www.airportdoors.com

Important Personnel

Manama (07) 3803 6255 Email Address: salesgld@airportdoors.com Person: Graham Waites Service/Repairs (07) 3803 6255 Email Address: servicegld@airportdoors.com Person: Peter Hopkins Contract Administration (07) 3803 6255 Email Address: eburke@airportdoors.com Person: Elaine Burke

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AIRPORT DOORS (QLD) PTY LTD

Phone: (07) 3803 6255 Fax: (07) 3803 6249

A.C.N. 074 521823 A.B.N. 12 074 521 823

3. TECHNICAL DATA
Diagram 3 . 1 - Components Identifed

ROLLER SHUTTER
MOTOR OPERATION

ROLLER
2 CURTAIN

DRUM

P/N

1001
P/N 1002

3 4 5 6
7

SPROCKET 38 NYLON END CLIPS SHAFT OPERATING BRACKET MOTOR ASSY. CHAIN WHEEL
HAND CHAIN

P/N 1003 P/N 1004 P/N 1005 P/N 1006

P/N P/N P/N 1007

8
9

1008
1009

10

PLAIN END BRACKET TENTION BOLT TRANSMISSION CHAIN & CON LINK

P/N 1010 P/N 1011 P/N 1012

11
12

13 LOXIN BOLT (NOT SUPPLIED) 14 TENTION HOLE 15 16 17 TENTION BOLT HOLE GUIDE TRACK STOP GUIDE TRACK BOTTOM RAIL CHAIN LOCK GUIDE LUGS SPROCKET 14
oTYj

P/N 1013 P/N 1014

P/N P/N 1015 1016

18
19 20 22 PUSH BOTTON STATION 23 CHAIN GUIDE
24 WINLOCK (OPTIONAL) 25 LIMIT SWITCH BOX 26 CURTAIN SCREWS (NOT SHOWN) 27 TORSION SPRINGS (NOT SHOWN) 28 MOTOR PLATE P/N 1019 P/N 1020 P/N 1021 P/N 1022 P/N 1023 P/N 1024

P/N 1017 P/N 1018

21

17D1 DESCRIPTION f D'NG Na. CLIENT

REN9ON

DATE ^ht of SCALE Noted

AIRPORT DOORS -_-J

KHOA CHI D CttARiJE ^3 ocr APPR'D
D1MG. No D.

ROLLER SHUTTER

Rs-Cat4

Op

AIRPORT DOORS (QLD) PTY LTD

Phone: (07) 3803 6255 Fax: (07) 3803 6249

A .C. N. 074 521823 A .B.N . 12 074 521 823

3.2 Component Features (refer to Diagram 3.1 on previous page 4): 1. Roller Drum Door consists of spiral welded tube encasing helical torsion springs matched to suit door size and weight. Springs are manufactured from a super grade wire revolving around a steel axle. The roller drum has been designed and tested to give minimum deflection over the door span. On large doors or high cycle operations , a solid six inch pipe is used to minimise deflection. On extra large doors, a solid eight inch pipe may be used. 2. Curtain Interlocking slats are manufactured from galvanised steel sections using a slat gauge (thickness) of between 0 . 6mm, 0 . 8mm and 1 .0mm with approximate slat widths of 75mm and 100mm. The appropriate gauge will be determined based on the requirements for the door . Curtain slats are fitted with nylon end clips to stop lateral movement of the curtain and ensure smooth operation . Windlock clips can be incorporated into the curtain design of the door should it be a requirement. 3. Sprockets Drum) A minimum of 38 teeth sprocket and maximum of 57 teeth sprocket has been supplied . This roller drum sprocket as per drawing is connected to the drum. 4. Nylon End Clips See Number (2) for description 5. Shaft Steel axle to support centre collars and attachment for springs. 6. Operating Bracket Manufactured from mild steel plate having a minimum thickness of 6mm and maximum thickness of 10mm. These have been welded to suit door weight and size. The operating bracket allows for the installation of the motors on the specified side. It has flexibility in its installation in order to allow for restricted side rooms. 7. Door Operation la. Standard Electric Motor lb . Standard Push Button Station

Precision Grifco Products RC 374, 4kw 415v, (240V coils) 3 phase 415V Three Phase Standard Standard Three Phase Control

.75kw, l.Ohp, 415v STR

2. Chain Operator HDHWO Heavy duty, manual shutter hoist used for chain operated doors.

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AIRPORT DOORS (QLD) PTY LTD A.C.N. 074 521823 A.B.N. 12 074 521 823 Phone: (07) 3803 6255 Fax: (07) 3803 6249

3.2 Component Features( continued) 8. Chain Wheel This provides a backup mechanism for the door opening and closing should the electric's or backup generator fail. 9. Hand Chain The chain to which the person would pull on in order to open or close the doors in the case of electric ' s failing. As per the diagram, hand chain is supported by the chain wheel mechanism. 10. Plain End Bracket Manufactured from mild steel plate having a minimum thickness of 6mm and maximum thickness of 10mm. These have been welded to suit door weight and size. 11. Tension Bolt Tension bolt is installed through the tension bolt hole of the shaft in order to maintain the required tension on the springs . It is 12mm in thickness and is made of high tensile strength. 12. Transmission chain and conlink Drive chain that connects the motor sprocket to the drum sprocket which enables door operation. 13. Loxin Bolt (not supplied) 14. Tension Hole Tension bar is placed through the tension hole to generate the tension on the springs. 15. Tension Bolt Hole

The hole on the shaft through which the tension bolt remains. The tension bolt also penetrates through the bracket shaft support plate.
16. Guide Track Stop Not supplied as electric operation and hence limits set the distance 17. Guide Track Roll formed from steel to suit door design . Should the door specifications require windlocks , special heavy duty tracks to suit those conditions will be used. 18. Bottom Rail Manufactured from heavy duty steel which allows interlocking to the slats . It has flexibility in its design to allow for shootbolts/locking options. 19. Chain Lock

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AIRPORT DOORS (QLD) PTY LTD

Phone: (07) 3803 6255 Fax: (07) 3803 6249

A.C.N. 074 521823 A .s.N .12 074 521 823

To lock the chain in place so as not to move into the door opening. .:a 3.2 Component Features( continued) 20. Guide Lugs These are supplied loose and welded on site at equal intervals to lock the guides in place. 21. Sprocket 14 Drive sprocket allows the chain to connect between the motor and the drum. 22. Push Button Station / Key Switch To suit motor - see page 5 23. Chain Guide Allows the hand chain to guide below the chain wheel so as not to interfere with shutter operation. 24. Windlock Optional Windlocks can be allowed for in the design of roller shutters. 25. Limit Switch Box 26. Curtain Screws (not shown) 27. Torsion Springs (not shown but as per drum description which holds the springs) 28. Motor Plate This plate consists of holes to allow for the installation of the motor. The motor plate is also connected to the brackets. 29. Finish (As per scope of works on front cover page)

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AIRPORT DOORS (QLD) PTY LTD

Phone : (07) 3803 6255 Fax: (07) 3803 6249

A.C.N. 074 521823 A.B.N. 12 074 521 823

4.

OPERATIONS PRO CEDURES

4.1 General Electric Operation Overview TO OPEN DOOR: 1. Use the push button station. 2. Hold down the "RAISE" button. 3. When the door reaches the upper limit it will automatically stop. TO CLOSE DOOR: 1. Use the push button station. 2. Hold down the "LOWER" button. 3. When the door reaches the lower limit it will automatically stop. By releasing the RAISE and LOWER buttons, the door operation can be stopped at any position. The operation can be continued or reversed from the position by using the RAISE or LOWER buttons. 4.2 General Chain Operation Overview Standing on the inside of the door looking out, locate hand chain left hand or right hand side. Ensure the chain is released from chain guide and shoot bolts to bottom rail are retracted. Pull hand chain to raise or lower the door.

4.3 Emergency stop To stop door in case of emergency, simply release the push button being depressed. 4.4 Recommended Safety Actions to be Taken by the Client

Use the hand chain for manual operation when the motor has failed . Every door is supplied with manual operation in the event of power failure . CAUTION - Ensure that the power supply to the door has been turned off. Place the chain over the chain wheel and manually operate the door. When the power supply is restored, the power must not be connected to the door until the chain is disconnected . The door can then be operated electrically. For ease of operation an auto chain engage is available as an optional extra. 4.5 Emergency Contact 24hours AIRPORT DOORS QUEENSLAND PTY LTD 60 Platinum Drive, CRESTMEAD QLD 4132.

Tel: (07) 3803 6255 - (24 hours / 365 days) Fax: (07) 3803 6249
Emergency service is available 24hours/365 days per year. Simply calling our number that will be diverted to a service crew after hours can access this service. Charges for these services vary depending on the particular circumstances, however the service technician will be able to advise you at the time.

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AIRPORT DOORS (QLD) PTY LTD

Phone: (07) 3803 6255 Fax: (07) 3803 6249

A.C.N. 074 521823 A .B.N . 12 074 521 823

5. MAINTENANCE PROCEDURES
5.1 Maintenance Instructions i. Check that the guide tracks are not twisted that they may impair the operation of the door. ii. Lubricate the guides every three months with dry lubricant (graphite type). iii. Plastic end clips and cast iron Windlocks inside the door guide tracks should be visually inspected to check the fasteners are not working loose. iv. The tension of the motor drive chains should be examined along with the spring tension. V. The fixing bolts on the motor , gearbox and motor plate should be examined to check they are all secure. As well , the Grifco door drive unit has a fully enclosed gearbox with only the main door drive sprocket exposed. All wearing components are sealed and lubricated for life and no maintenance is required. Similarly, the drive chain requires little maintenance if the conditions are good . However, it is recommended that if the system is used to a maximum of 20 times per day , the chain should be oiled with multi purpose oil and should be checked for excessive wear every 6 to 9 months. If the use is less than 5 times per day, maintenance is recommended every 2 years. 5.2 Repair and Spare Parts To arrange any repairs or spare parts, please call 07-3803-6255 and ask to speak to the service department. Understanding the urgency of spare parts, your order will be prioritised by our production department and dispatched with the Transport Company of your choice. 5.3 Preventative Maintenance To prevent the maintenance, by inspecting and checking as the period required by the Maintenance Instructions above. 5.4 Overhaul If, for some reasons after many years of operation, there is a problem or fault in the drive unit, it may be necessary to overhaul the unit to check for damage /ware or re-lubricate components . This should be carried out, following the steps outlined below. . I . Remove from gearbox by unfastening the four bolts . Some force may be required to separate the shaft. 2. Unfasten the four bolts retaining the gearbox end plate, remove the end plate and gasket. 3. Remove limit assembly, as outlined earlier. 4. Remove limit box casing by unfastening bolts. 5. Once inspection and l or re-lubrication have been completed , the assembly procedure is the reverse of the above steps . When lubricating , use a suitable lubricant . Make sure all seals are lubricated when assembly. 6. By the way, all parts should be checked carefully , such as shaft, track, bracket, curtain etc... If any parts have been damaged or worn out after many operations, apply backwards the Installation Instructions &

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AIRPORT DOORS (QLD) PTY LTD

Phone : (07) 3803 6255 Fax: (07) 3803 6249

A.C.N . 074 521823 A .B.N . 12 074 521 823

Drawings to dismantling and replacing parts where needed.

5.5 Service & Repair Checklist

Door Type: Service Person:

Steel Roller Shutter

Door Number: Date: Pass Fail Remarks

Feature-Mechanical 1. Check general door appearance & condition.

2. Check and tighten tracks.

3. Check & adjust fixing bolts of brackets. 4. Check & adjust spring tension.

5. Check & adjust chain tension.

6. Lubricate all moving components.

7. Check & report on general operation. 8. Electrical. - check & test wiring - check & test switches - check & test limit switches

9. Defects list.

10. Additional works required.

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AIRPORT DOORS (QLD) PTY LTD

Phone : (07) 3803 6255 Fax: (07) 3803 6249

A.C.N. 074 521823 A .B.N . 12 074 521 823

6. CERTIFICATES & PERFORMANCE TEST RESULTS

6.1 System Inspections and Testing Upon award of some projects we are required to submit to the customer Inspection and Test Plans. The intention of our Inspection and Test plans are to adequately allow us to forecast the requirement and time that certain events will occur that require inspection or testing. The plan enables all parties who interface with our scope of work to be informed as to our schedule and method utilised for the particular project. The individual contracts set the framework of the plan. In all instances where inspection and testing is required we utilise laboratories registered with the National Association of Testing Authorities (NATA) which are certified for the appropriate tests.

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