Future Tower Iii, Sharjah: Operation & Maintenance Manual Building Maintenance Unit

FUTURE TOWER III, SHARJAH
Operation & Maintenance Manual

BUILDING MAINTENANCE UNIT
Kookaburra and Monorail System with sharing Two Man
Self-Powered Cradle
Document No.: EWC-4870-OMM-0001

Revision No.: 00
Manufacturer / Subcontractor:
CHANGE HISTORY
REV. DATE DESCRIPTION CREATED BY APPROVED BY
00 06-03-2019 FIRST ISSUE JFB JA
EWC-4870-OMM-0001-00 i
Contents
1. PRELIMS ............................................................................................................................ 1
2. SYSTEM DESCRIPTION .................................................................................................... 3
2.1. Kookaburra .............................................................................................................. 3
2.2. Monorail System ...................................................................................................... 6
2.3. Two Man Self-Powered Cradle ................................................................................ 8
3. PARTS IDENTIFICATION ..................................................................................................11
3.1. Kookaburra .............................................................................................................11
3.2. Monorail System .....................................................................................................13
3.3. Two Man Self-Powered Cradle Components ..........................................................14
3.3.1. Traction Hoist Components ..............................................................................16
4. CONTROLS .......................................................................................................................18
4.1. Kookaburra Controls...............................................................................................18
4.1.1. Roof Unit Control Box ......................................................................................18
4.1.2. Pendant Controller ...........................................................................................20
4.2. Monorail Trolley Control..........................................................................................21
4.3. Cradle Control ........................................................................................................22
5. PRE-OPERATIONAL PROCEDURES ...............................................................................24
5.1. Pre Operational Checks..........................................................................................26
5.1.1. Kookaburra Pre Operational Check ..................................................................26
5.1.2. Wire Ropes Pre-Operational Check .................................................................28
5.1.3. Cradle Pre-Operational Check .........................................................................29
6. OPERATIONAL PROCEDURES........................................................................................36
6.1. Kookaburra Operating Procedure ...........................................................................36
6.2. Cradle Restraining Procedure.................................................................................39
6.3. Cradle Rigging to Monorail System ........................................................................48
6.4. Monorail System Operating Procedure ...................................................................51
6.5. System Normal Running Checks ............................................................................54
7. SAFETY & EMERGENCY INFORMATION ........................................................................55
7.1. Emergency Information...........................................................................................55
7.1.1. U.A.E. Authority Emergency Contact Information ............................................55
7.1.2. COX GOYML Emergency Contact Personnel ..................................................55
7.2. Safety Hazards .......................................................................................................56
7.3. Precautions ............................................................................................................56
7.4. Use of Electrical Equipment ....................................................................................57
7.5. Use of Portable Equipment .....................................................................................57
7.6. Training of Personnel .............................................................................................57
EWC-4870-OMM-0001-00 ii
7.7. Personal Protective Equipment...............................................................................57
7.8. Fire Fighting Equipment..........................................................................................58
7.9. Protective / Safety Devices of the BMU ..................................................................58
7.10. Emergency Procedures ..........................................................................................59
7.10.1. Manual Descent Procedure ..............................................................................60
7.10.2. Procedure to Reset the Over Speed Safety Device ..........................................61
8. MAINTENANCE .................................................................................................................62
8.1. Preventive Maintenance Activities ..........................................................................63
8.2. Corrective Maintenance Activities ...........................................................................68
8.3. Inspections .............................................................................................................71
9. PARTS LISTING & SPARE ................................................................................................73
10. TROUBLESHOOTING .....................................................................................................74
11. DISPOSAL INSTRUCTION ..............................................................................................75
12. MANUFACTURER’S INFORMATION ..............................................................................76
13. ATTACHMENTS ..............................................................................................................76
• TESTING & COMMISSIONING CERTIFICATES
• WARRANTY CERTIFICATE
• AS BUILT DRAWINGS
• KOOKABURRA WIRING DIAGRAMS
• SELF-POWERED CRADLE WIRING DIAGRAM
EWC-4870-OMM-0001-00 iii
1. PRELIMS
This Operation and Maintenance (O&M) Manual will serve as a guide for the proper
utilization and maintenance of BMU Systems – Kookaburra and Monorail System with
sharing two man self-powered cradle supplied and installed by CoxGomyl M.E. at Future
Tower III, Sharjah.
This document will provide vital information essential for the facility management personnel
who will operate and maintain the system to achieve an orderly and efficient use of the
constructed features to meet project goals and objectives. The intent of the maintenance
instructions is to present preventative maintenance information consisting of systematic
inspections and subsequent corrective actions to ensure long term utilization of project
features. A timely preventative maintenance program reduces and prevents damage to
constructed features by early corrective action.
Layout and Guide to Contents
The O&M Manual provides the general standards of operation, maintenance and establishes
an initial frequency of management responsibilities to ensure satisfactory project
performance.
This document is divided into the following sections:
Section 1 – Prelims
Provides description for the use of the manual and its scope
Section 2 – System Description
It provides technical information on the BMU machine.
Section 3 – Equipment Schedules & Identifications
It is a list of equipment and its components as provided for the project.
Section 4 – Controls
Description of the BMU controls, the locations and the functions of the
switches and buttons.
EWC-4870-OMM-0001-00 Page 1 of 77
Section 5 – Pre-Operating Procedures
Are procedures to be completed before using the system to ensure safety

and efficiency of use.
Section 6 – Operating Procedures
A step by step procedure of the system including the setting, start up and
shutting down.
Section 7 – Safety & Emergency Information
Provides information for the safe use of the system and all the necessary
precautions.
Section 8 – Maintenance
Provides maintenance procedures for the BMU
Section 9 – Parts Listing & Spares
Provides a list of parts and its identification
Section 10 – Trouble Shooting
Diagnostic and troubleshooting procedures
Section 11- Disposal
Disposal instruction of the system
Section 12 – Manufacturers Information
Provides information on the system’s manufacturer
Section 13 – Attachments
This section contains relevant or supporting documents such as copies of

Testing & Commissioning Certificate, Warranty Certificates, As built
Drawings, Electrical Drawings & etc.
EWC-4870-OMM-0001-00 Page 2 of 77
2. SYSTEM DESCRIPTION
2.1. Kookaburra
EWC-4870-OMM-0001-00 Page 3 of 77
KOOKABURRA TECHNICAL DETAILS
General
BMU Model  Front Angle Guided K-Type BMU (Kookaburra)
Safe Working Load (SWL)  250 kg (2 persons + tools & materials)
Serial No.  4039
Jib Description
Jib Type  Fixed Length Single Shoulder Jib
Jib Max Reach  3300 mm (slew center to center of crossbar)
Slew of Jib / BMU  Electric Drive chain & sprocket
Cross Bar Slew  Manual using rope
Sub Frame Description
Sub frame Type  Front Angle Guide
Brake System  Self-lock worm gearbox on all drive wheels
Long travel drive motors  2 on front wheels
Travel Speed  11 meters per minute (nominal)
Wheel Type  Polyurethane (on concrete)
Suspended Platform Description (See item 2.1.1)
 Two Man Self Powered Cradle (shared with the monorail

Type
system)
Safe Working Load  250 (2 operators + tools)
Electrical Summary
Main Power Supply  380 V (III + PE)
Outlet type  16 A SOCKET (III phase + PE)
EWC-4870-OMM-0001-00 Page 4 of 77
Load  12 A
Control Voltage  12V AC
Controls
Roof Unit Control Box
Location  Mast section of the Kookaburra
Control for  Kookaburra (roof unit control only)
Control Button & Switches
▪ Main Key Switch ▪ Emergency Stop Button (mushroom head twist to reset)
▪ Traverse Switch ▪ “Ready” & “Fault” Indicator Lights
▪ Unit Slew Switch ▪
Pendant Controller
Location  End of Jib
Control for  Kookaburra (roof car only- switch key to remote)
Control Button & Switches
▪ Emergency Stop Button (mushroom head twist to reset)
▪ Traverse Buttons
▪ Unit Slew Buttons
EWC-4870-OMM-0001-00 Page 5 of 77
2.2. Monorail System
EWC-4870-OMM-0001-00 Page 6 of 77
MONORAIL TECHNICAL DETAILS
General
 Parapet Mounted Monorail System with Manual Push

BMU Model
Trolleys
Safe Working Load (SWL)  250 kg (2 persons + tools & materials)
Fixation Details
Type  Cast-in Anchors
Material  Stainless Steel Anchors
Monorail Bracket Description
Type  Side Mounted Monorail Bracket for EWC 138
Material  Hot Dip Galvanized and Painted
Monorail Track Description
Type  EWC-138
Material  Extruded Aluminium Allloy 6063 T6
Finish  Powder Coated to approved RAL Color
Monorail Trolley Description
Type  EWC-138 Manual Push Trolley
Working Load Limit  500kg each trolley
Units Supplied  2 units
Material  Hot Dip Galvanized Mild Steel Frame;

Stainless Steel Rollers & Screw brake
Control  Manual push;

Manual Screw brake
Suspended Platform Description (See item 2.3)
Type  Two Man Self-powered Cradle (shared with the Kookaburra)
Safe Working Load  250 (2 operators + tools)
EWC-4870-OMM-0001-00 Page 7 of 77
2.3. Two Man Self-Powered Cradle
Shared between the Kookaburra & monorail system.
SELF POWERED CRADLE TECHNICAL DATA

CRADLE DESCRIPTION
Cradle Type  Two Man Self Powered Cradle
Cradle Dimension  2m (L) x 0.7m (W) x 1.0m (H)
Cradle SWL  250 Kg (2 nos. Operator + Materials)
Design Standard  BS EN 1808
Units to be provided  1 unit (shared between systems)
EWC-4870-OMM-0001-00 Page 8 of 77
 Hot Dip Galvanized Mild Steel Frame / Aluminium hand
Construction
rails, walls and non-slip floor panels
Cradle Finish  Powder Coated to Approved non metallic RAL Color
Hoisting Speed  8.0 m/min
Wire Rope Nos.  2 suspension & 2 safety wire ropes
Wire Rope
 8.4 mm Galvanized
Specification
Wire Rope Collection  Motorized wire winder
Façade Protection  2 x Bump Rollers
SAFETY FEATURES
▪ Safety Harness attachment points 2 Nos.
▪ Bottom Trip Bar
▪ Top Limit & Ultimate Top Limit Switches
▪ Overload Sensor at each hoist (built-in)
▪ Over speed Safety device, Manual Activation Button &

Reset at each hoist (built-in)
▪ Slack rope safety device at each hoist (built-in)
▪ No Power Emergency descent (built-in)
▪ Wire Winder Safety Cover
CRADLE CONTROLS
Location  Control Panel inside the cradle
Control for  Cradle movement
Control Button &

▪ Key Switch
Switches
▪ Cradle Raise/Lower switch
EWC-4870-OMM-0001-00 Page 9 of 77
▪ Hoist Selector Switch
▪ Trip Bar Over ride
▪ FAULT & READY indicator lights
▪ Overspeed test button
HOIST DESCRIPTION
Hoist Type  Traction Hoist (Titan)
Hoist Rated Load  400 kg
No. of Hoist  2 Nos.
Braking system  Electro-mechanical service brake
 Over speed safety device with mechanical interlock
Hoist wires  2 No. Suspension Wire Rope ( 1 on each end)
 2 No. Safety Wire Rope (1 on each end)
Wire Rope Diameter  Ø 8.4mm
Wire Rope Minimum

 38 kN
Breaking Load
Climbing Speed  8.0m/min
Electric Motor  Three phase – 380V-50Hz
Built-In Safety
 Slack Rope Safety Device
Components
 Over speed Safety Device
 Overload Detection Device
ELECTRICAL SUMMARY
Main Power Supply  380 V, 3Ø 50 Hz AC Supply
Outlet type  32 Amps, 3P+N+E (male) Mobile Type
Load  5 kW
Control Voltage  12 V.A.C
EWC-4870-OMM-0001-00 Page 10 of 77
3. PARTS IDENTIFICATION
3.1. Kookaburra
01
02
03
03
06
05
13
04
07
14
09
08
18
10
15 12
17 13
16
NO. PART DESCRIPTION NO. PART DESCRIPTION

01 Crossbar 10 Slew Assembly
02 Cradle Wire rope attachment plate 11 Slew Limit Switch
03 Crossbar Slew Actuator 12 Subframe
04 Pendant Controller 13 Drive Wheel Assembly
05 Cradle power supply socket 14 Traverse limit switch
06 Jib 15 Idler Wheel Assembly
07 Strut 16 Cable Reeler with rotary limit switch
08 Insert 17 Front Angle Guide (FAG) Track
09 Counterweight 18 Control Panel
EWC-4870-OMM-0001-00 Page 11 of 77
S/N KOOKABURRA COMPONENTS FUNCTION / LOCATION
Cross Bar Installed at the jib end which supports the cradle wire
01
ropes.
Wire Rope Attachment slots Slots at the end of the cross bar where the cradle wire
02
ropes are to be attached via safety D-shackles
03 Crossbar Slew Actuator A linear actuator that turns the crossbar
Pendant Controller Suspended from the jib end which is used by the
04
operators in the cradle to operate the Kookaburra.
Cradle Power Supply Socket Pendant socket suspended at the jib end which supplies
05
power to cradle.
06 Jib Fixed Length arm that carries the cross bar
07 Strut Diagonal support of the jib
08 Insert The frame that supports the jib and the counterweight
Counterweight Provides stability for the kookaburra to prevent it from

09
overturning due to the suspended weight on the jib.
Slew Assembly Consisting of Sprocket, chain & a motor that rotates the
10
kookaburra from it insert.
11 Slew Limit Switch It limits the slewing movement of the kookaburra.

-
Subframe The main frame that supports the majority of
12
components of the kookaburra
Drive Wheel Assembly Positioned in the front of the machine which provides
13
the motorized traversing to the kookaburra.
Traverse Limit Switch Installed in the drive wheel that stops the machine
14
traversing once it reaches the end of the track.
Idler Wheel Assembly Free moving caster wheels positioned at the rear of the
15
machine.
A drum reel that automatically winds the cable via
16
spring mechanism which also tensions the cable
keeping the cable off the ground to prevent damage.
Spring Loaded Cable Reel Provided with a rotary limit switch that prevents the
cable to be pulled out or torn apart while the BMU is
moving by maintaining extra length of cable in the reel
drum.
Front Angle Guide Track Angle track secured to the running slab which guides
17
the traversing of the machine.
An enclosure at the insert portion of the kookaburra
18 Control Panel which contains the electrical circuitry and controls for
the kookaburra.
EWC-4870-OMM-0001-00 Page 12 of 77
3.2. Monorail System
01
02
04
03
No. Part Description
01 EWC-138 Monorail Track
02 Roller
03 Screw Brake
04 Wire Rope Attachment slots
EWC-4870-OMM-0001-00 Page 13 of 77
3.3. Two Man Self-Powered Cradle Components
01
03
02
04
09
15 05
08
10
11
06
07
13
14
12
No. Part Description No. Part Description No. Part Description

Galvanized Steel Wire ropes
01 06 Cradle Control Panel 11 Bottom Trip Bar
(Safety + Suspension
02 Striker Plate 07 Wire Winder w/ Safety Cover 12 Bottom Trip Bar Limit Switch
03 Full Up & Ultimate Full Up Limit 08 Mild Steel Frame 13 Cable Bin
04 Traction Hoist 09 Aluminium Side & Floor Panel 14 Caster Wheel
05 Safety Harness Attachment Bolt 10 Bump Roller 15 Step
EWC-4870-OMM-0001-00 Page 14 of 77
S/N Cradle Component Function/Location
8mmØ Galvanized Steel wire ropes that support the

01 cradle. A pair consists of a suspension rope & a safety
rope. The suspension wire passes directly thru the
Galvanized Steel Wire ropes traction hoist mechanism to raise and lower the cradle.
(Safety + Suspension)
The safety wire is where the safety device of the hoist will
be engaged in case of suspension rope breakage,
overspeed, slacking of rope.
An accessory installed at the upper portion of the wire
02 Striker Plate rope which will trigger the full up & ultimate full up limit
switches once the cradle reaches its top most position.
Safety devices that limit the upward movement of

03
the cradle once the full up position is reached. To
Full Up & Ultimate Full Up Limit be activated by the striker plate located at the upper
most part of the wire ropes.
Traction Hoist It is a motorized traction hoist that drives the cradle up

04 (see hoist component details) and down.
Two eyebolts found at the upper corners of the cradle

05 Safety Harness Attachment Bolt which serve as the anchoring points for the operators’
harnesses.
An enclosure inside the cradle which houses all electrical

06 circuitry and controls of the cradle.
Cradle Control Panel
The cradle control box is independent from the control of
the Roof Unit.
Located inside the cradle which winds & unwinds the

07 Wire Winder w/ Safety Cover wire ropes to a pair of drum. A clutch mechanism keeps
the wire in the drum in the correct tension.
It is the main steel frame of the cradle where the hoists

08 Mild Steel Frame and the rest cradle wall & floor panels frame are
mounted.
Aluminium Panels for the wall and floor of the cradle. The
09 Aluminium Side & Floor Panel
floor is a non slip chequered aluminium.
Soft rubber roller that protects the building façade should

10 Bump Roller
the cradle comes in contact.
It a bar mounted at the bottom of the cradle that detects

11 obstruction along the cradle descent path which then
Bottom Trip Bar
prevents the cradle from overturning by stopping the
down movement once the obstruction is detected
A safety switch that works with the trip bar to disable the
12 Bottom Trip Bar Limit Switch down movement of the cradle should the trip bar hits an
obstruction along its descent path.
13 Cable Bin It holds the power supply cable.
Wheel for transferring the cradle while it is still on the

14 Caster Wheel
ground
A slot in the front of the cradle which is used for getting in

15 Step
& out of the cradle.
EWC-4870-OMM-0001-00 Page 15 of 77
3.3.1. Traction Hoist Components
Motor Cover w/
Full Up & Ultimate Full Up Limit
Removable Plug
Switches
Manual Descent
Lever
Slack Rope Lever
Overspeed Safety Device,

Manual Activation Button &
Reset Knob Hand Wheel
EWC-4870-OMM-0001-00 Page 16 of 77
S/N Traction Hoist Component Function/Location
Safety devices that limit the upward movement of

Full up Limit & Ultimate Full up the cradle once the full up position is reached. To
1
limit switches be activated by the striker plate located at the
upper most part of the wire ropes.
Safety device that detects if the suspension wire

rope loses tension caused either by the rope
slacking or rope breakage.
2 Slack Rope Lever It will activate the automatic slack rope safety
device that will acts mechanically onto the safety
wire ropes to stop the downward movement of the
cradle.
It locks automatically onto the suspension wire

ropes when the suspension wire rope passes
3 Over speed Safety device
through the hoist (descent speed) at more than
15m/min.
Over speed Safety device It is use for the manual activation of the Over
4
Manual Activation Button speed Safety device.
Over speed Safety device It is use to reset the activated over speed safety
5
Reset Knob device.
It is a safety device that is factory set to stop the

6 Over Load Detection Device up direction of travel if the Safe Working Load is
exceeded by 25%.
Manual Descent Lever It is used for the manual descent of the cradle
7
(NO POWER DESCENT) during a power cut off.
8 Electric Motor It provides the power for the Traction hoist.
The plug must be removed when the hoist needs

Electric Motor Top Cover with
9 to be reset due to activation of the over speed
removable plug
safety device.
An accessory used for the resetting of the safety

10 Hand Wheel devices in case of power failure, to manually raise
the cradle in case over speed device is engaged.
Connected to the cradle control box that provides

11 Control & Power Cable
the power and control for the hoist
Overheating Protection for It is thermal contact serves as a safety device to

12
hoist cut power to the motors in case of overheating.
EWC-4870-OMM-0001-00 Page 17 of 77
4. CONTROLS
4.1. Kookaburra Controls

The kookaburra and the self-powered cradle are controlled independently.
The kookaburra has two control points, one is the main control box located in the insert of
the machine and the other is the pendant controller at the jib end which allows the
operators in the cradle to control the kookaburra.
The control point of the kookaburra is set thru the selector key switch on the main control
box. Set switch to “LOC” to select the main control box and “REM” for the pendant
controller.
4.1.1. Roof Unit Control Box
01 02
03 04 05
06 07
EWC-4870-OMM-0001-00 Page 18 of 77
Kookaburra In- Car
S/N Control Box Function
Button & Switches
− A Green light which indicates that the

01 “READY” Indicator Lights
system is ready & no fault exists.
− A red light that indicates that there is a

fault in the system or if emergency stop is
02
“FAULT” Indicator Lights activated or either of the limit switches is
activated (traverse, unit slew or cable reel
rotary limit switch)
− A return to center switch that controls the

03 CRADLE SLEW CW/CCW slewing of the crossbar which then relates
to the slewing of the cradle
− A return to center switch that controls that

04 TRAVEL L/R Switch
controls the travelling of the kookaburra
− A return to center switch that controls the

05 UNIT SLEW CW/CCW
slewing of the jib
− The key switch to turn ON/OFF the

equipment. It is also used to select the
06 LOC/OFF/REM Key Switch
control point either from “ LOC” local or
“REM” remote
− It disables all system movements and
controls. A mushroom type button that can
07 Emergency Stop Button
be reset by twisting it to the direction of
the arrows indicated on the button.
Note: Verify first the orientation of movement before fully operate the BMU. Make a
small movement to verify.
EWC-4870-OMM-0001-00 Page 19 of 77
4.1.2. Pendant Controller
Pendant Controller
S/N Function
Button & Switches
It controls the
01 Traverse Buttons traversing movement of
the machine
It controls the slewing

02 Unit Slew Buttons
of the Jib
It disables all system

movements and
controls. A mushroom
Emergency Stop type button that can be
03 Button reset by twisting it to
the direction of the
arrows indicated on the
button.
NOTE:
01
• Verify the function of each button before fully operate the
machine. Make small movement to verify.
• The selector key on the main control box must be set to

REM to active pendant controller.
02
03
EWC-4870-OMM-0001-00 Page 20 of 77
4.2. Monorail Trolley Control
The trolley traversing along the track is done manually by the operatives inside the
cradle. By grabbing onto the track or pushing against the face of the building, operatives
will be able to move the trolleys to the direction they desire to travel to. The screw brakes
on each trolley is used to lock the trolley position before the cradle lowering which will
prevent unwanted movement of the trolley while the cradle is in the middle of a drop.
EWC-4870-OMM-0001-00 Page 21 of 77
4.3. Cradle Control
The control for the cradle movement is made thru the control box inside the platform. It is
the only control point for the cradle and is independent from the control of the roof
machine.
NOTE:
When the cradle is used with the kookaburra the controls from the kookaburra control
panel & pendant controller is independent from the controls on the cradle control panel
HOIST SELECT
L/BOTH /R
CRADLE
UP/DOWN
FAULT
READY
BY-PASS
OVERSPEED EMERGENCY STOP

BRAKE TEST
POWER ON/OFF
NOTE: Arrangement of the buttons and switches may vary from actual,
check the label to verify each function of each button or switch.
EWC-4870-OMM-0001-00 Page 22 of 77
Cradle Control Box
S/N Function
Button & Switches
“READY” indicator
01 − It indicates that the system is ready & no fault exists.
light
− It indicates that there is a fault in the system or if

“FAULT” indicator emergency stop is activated or either of the limit switches
02 light is activated (Full Up & Ultimate Full Up & bottom trip bar
limit switch)
− It overrides the activation of the bottom trip bar should the

cradle needs to be lowered to the ground for parking. This
03 BY PASS Button button must only be used for the above function and not
when the cradle is in the middle of a drop and an
obstruction gets in its descent path.
POWER ON/OFF Key

05 − The main ON/OFF switch of the cradle
Switch
− It disables all cradle movement & controls. A mushroom

EMERGENCY STOP
06 type button that can be reset by twisting it to the direction
Button
of the arrows indicated on the button.
CRADLE UP/DOWN
07 − It controls the up & down movement of the cradle
Switch
HOIST L/BOTH /R − Switch to select which hoist will be operational. On a

08 Selector Switch normal cradle operation this switch must be set to “BOTH”.
EWC-4870-OMM-0001-00 Page 23 of 77
5. PRE-OPERATIONAL PROCEDURES
The following are the pre-operational procedures to be followed to ensure a smooth flow of
work using the BMU systems:
1. The building Manager or building in-charge must ensure the minimum no. of operatives
is present during BMU operation. Helpers are required for setting up, transporting and
storing the system.
System Operator-Cleaner Assistant (minimum)

Kookaburra with the self-
2 Nos. 1 Nos.
powered cradle
Monorail System with the
2 Nos. 1 Nos.
self-powered cradle
2. Only authorised and well trained operators must operate the BMU. Operators to present
their BMU Operator I.D. duly issued by COX GOMYL for verification by the Facility
Management in-charge of BMU.
3. Ensure that all personnel involve in this operation has their Proper PPE’s. NO works
should be done without the proper inspection of the P.P.E. A defective P.P.E. is more
dangerous than working without P.P.E. at all because it will give false belief that the
worker is safe. Suitable & independent fall arrest equipment (by others) is a must when
operating the system. The safety harness must have a shock-absorbing lanyard that
limits the applied load to 6kN.
HARD HAT WITH CHIN

STRAP
SAFETY SHOES
SAFETY HARNESS WITH SHOCK

ABSORBING LANYARD
(FOR THOSE WORKING AT HEIGHT)
EYE PROTECTION
REFLECTIVE VEST
OVERALL HAND GLOVES
EWC-4870-OMM-0001-00 Page 24 of 77
4. Do not operate the BMU in adverse weather conditions or wind speeds in excess of 40
Km/h as measured at any point on the building. Do not operate if thunderstorms are likely.
5. Precautions are to be taken at ground level and roof level to create safety zones around the
building maintenance unit working area. Put an exclusion zone complete with signs stating
that there is a work on going and unauthorized access on the area is not allowed.
6. Ensure that there are 2 available communication devices (mobile phone or radio) to have a
clear mode of communication between the people on the ground and those working in the
cradle.
7. The BMU components are stored or parked in their respective storage area (as per Building
Manager’s instructions). They should be returned after use in a manner that they will not be
damage during storage.
8. Obtain system key, and complete all appropriate sign-in forms with the Building Manager.
Advise the Building Manager, which drops that the operatives are about to do. Building
Manager must verify that all appropriate safety barriers are in place.
9. Prior to normal operation of the equipment carry out the daily testing and inspection as
outlined in the manual.
10. Do not overload the Cradle above its Load Capacity of 250 kg (operators + tools), or with
more persons than are permitted.
11. It is obligatory that cleaning equipment and tools used by the operators remain safely
attached to the Cradle or Personnel to avoid falling out of the Cradle.
12. No cradle should be left unattended in positions where it could be misused. Under no
circumstances should a cradle be left hanging down a building face unattended unless
adequate precautions are taken to secure it.
13. The approved means of access to and from the cradle by operatives must be obeyed and
under no circumstances should operatives enter or leave the cradle by unapproved
methods, unless in an emergency and when so directed by a responsible authority.
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5.1. Pre Operational Checks
5.1.1. Kookaburra Pre Operational Check
• Checking the General Condition
- Visually inspect the condition of the machine, check for any irregularity in their
appearance. (Discoloration and deformation can be a sign that the system was
subjected to a condition that can result to system damage)
- Check for accumulation of dirt or other foreign object that may damage or impaired the
proper movement of the system. Pay attention to the moving parts especially those that
are lubricated or greased.
- Inspect possible anomalies in small mechanical parts such as loose or missing bolts or
fasteners.
- Check for cracks and rust that may weaken the welding connections.
• Checking the power plug ,cable and cable reel
- Check the continuity of the cable, make sure it is not tangled and twisted that can cause
damage to the cable.
- Check for any cuts or uneven diameter of the cable that can be a sign that the cable is
damage.
- Carry out a visual check on the plug point element (free cable, plug & cable reel),
verifying its sound electrical and mechanical condition.
- Check the plug of the cable for cracks. Inspect the plug for bent, damaged or missing
prongs. Pay particular attention to the grounding prong, making sure that it isn't broken
or missing. A missing or broken grounding prong can cause electrical damage to the
device, or electrical shock.
- To check the rotary limit switch on the cable reel, pull the cable from the reel until the
reel is almost empty. Try to traverse the kookaburra, no movement can be made if the
rotary limit switch is activated. Return the cable to the reel then try to traverse the
machine, it should work as normal which indicates that the rotary limit switch is
functioning correctly.
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• Checking the functionality of Kookaburra Control Buttons and Switches
Upon ensuring that all the electrical components of the kookaburra have passed the
inspection, a pre-run should be done to check the functionality of each button and switch.
- Attached the power plug to the designated power outlet.
- Turn the Power Key Switch to the LOC position. The green light will illuminate indicating
that the system is ready for operation.
- Check if the emergency push button is working, press the button and the fault indicator
light will illuminate. When the emergency stop is activated, no function / movement can
be made to the kookaburra.
- Turn emergency button on the direction of the arrow to reset it.
- Test the slew & traverse switch.
- Check the service brake of the wheels by making a small movement, the machine
should stop immediately once the traverse switch is release indicating that the service
brake is functional.
• Checking / Testing the Limit Switches
- To check the traverse & slew limit switch, manually activate the limit switch.
- Try to manoeuvre the machine (slew / traverse); there should be no movement on

the machine if the limit switch for the said movement is activated.
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5.1.2. Wire Ropes Pre-Operational Check
Before operating the BMU, make a visual inspection and check any signs that the cable
needs to be replaced.
- More than ten wires are broken on a length of 30 x diameter of wire

- Kinking, crushing, bird caging or any other distortion on the wire rope structure.
- Excessive Corrosion
- Damage cause by heat
- Reduction of nominal diameter by 10%
Bird Caging
Kinking
Crushing
IMPORTANT:
When using the platform, continually inspect the steel wire ropes and supply cable for
any signs of damage.
• Check the thimble eye wearing and the swaging of the aluminum ferrule to the cable.
Thimble
eye
Aluminiu
m Ferule
Wire
Ropes
If the wires passed the checking, start the cradle pre operational check.
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5.1.3. Cradle Pre-Operational Check
• Checking the General Condition

- Check the external appearance of the cradle. Deformity can be a sign that the cradle
was subjected to a condition damaging to the equipment.
- Check for any missing parts such us bolts, nuts and pins.
- Check for any accumulation of dirt and other foreign object that can result to cradle
damage.
• Checking the Cradle Control Panel

- Inspect the control box exterior condition; check for any sign of corrosion and cracks.
- Inspect the cables for tightness and possible cracks or cuts.
- Check the movements of the buttons and switches.
- Open the control box and inspect each connection for any signs of damage (burned
fuse, contactors, circuit breakers, etc.). Check for any sign of water penetration.
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• Checking the Hoist
− Visually inspect the hoist and look for signs of oil leak, cracks, missing parts/bolts etc.
− Check oil level & condition. Oil level should not be below the marking on the center of the
gauge.
− Check that the hoist is securely bolted to the cradle’s main frame.
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• Checking the power plug and cable
- Check the continuity of the cable, make sure it is not tangled and twisted that can
cause damage to the cable.
- Check for any cuts or uneven diameter of the cable that can be a sign that the cable
is damage.
- Carry out a visual check on the plug point element (free cable, cable roller, or
electrical rail), verifying its sound electrical and mechanical condition.
- Check the plug of the cable for cracks. Inspect the plug for bent, damaged or missing
prongs. Pay particular attention to the grounding prong, making sure that it isn't
broken or missing. A missing or broken grounding prong can cause electrical
damage to the device, or electrical shock.
Prong
• Checking the functionality of Control Box Buttons and Switches
Upon ensuring that all the electrical components of the cradle have passed the
inspection, a pre-run should be done to check the functionality of each button and switch
of the cradle.
- Attached the power plug to the designated power outlet.
- Turn the Power Key Switch ON then green light will illuminate indicating that the
system is ready for operation. Should the red light illuminates refer to the trouble
shooting guide for steps or call for the technician to check the fault.
- Check if the emergency push button is working, press the button and the fault
indicator light will illuminate. There should be no movement possible when the
emergency stop button is activated.
- Reset the emergency button by twisting the knob to the clockwise direction. This will
normalize the cradle controls.
- Check the hoist select switch by selecting one of the hoist and operate it. Repeat the
same step to the other houst then set the switch to BOTH to operate the two hoist at
the same time.
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• Testing the TOP LIMIT SWITCH:
- Raised the cradle to a height that the bottom trip bar will not touch the ground.
- Push down the Top Limit Switch lever and check that the UP direction is disabled
while the platform can still be driven DOWN. This indicates that the Top Limit
Switch is functional. Follow the same to check the other hoist.
- To check the Ultimate Top Limit Switch, push down the Ultimate Top Limit Switch
and check if both the up & down movements are disabled. The fault indicator will
also illuminate if the ultimate full up is activated.
Top Limit
Switch
a.
Ultimate Top Limit

Switch
• Testing the Bottom Trip Bar and the By Pass Button
Check the functionality of the bottom trip bar by conducting a simulated movement of
the cradle. This check should only be done after the above initial checks have been
made as it will involve the raising of the cradle.
- Raised the cradle up to a height that the bottom trip bar will not touch the floor.
- Lower the cradle until the bottom trip bar is activated preventing the cradle to further go
down.
- Check if the DOWN direction is interrupted whilst the up direction still works, this means
that the bottom trip bar is working.
- Push the bypass push button and lower the cradle until the cradle is completely landed
on the floor.
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-
Suspended cradle Bottom

Trip Bar Un activated
Cradle on ground with

bottom trip bar by-pass
• Testing the Slack Rope Safety Device and “NO-POWER” descent
- Turn OFF the power key switch from the control panel.
- On one of the hoists, lift the “NO POWER” descent lever until the cradle tilts. This
indicates that the “NO POWER” manual descent of that particular hoist is working.
“NO POWER”
descent lever
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Slack Rope
- Continue until the cradle tilts for about 10-15 degrees and slack rope safety device will
be activated. The slack rope safety device is functional once the cradle stops from
tilting.
- Repeat the procedure on the other hoist
- Testing the slack rope safety device can also be done when the power is on. Select one
of the hoists and turn the down switch to operate it until the cradle tilts for about 10-15
degrees. At this point the cradle will stop from tilting indicating that the slack rope safety
device is working. Repeat the same to the other hoist.
• Testing the Over Speed Safety Device and the Over Speed Safety Device Manual
Activation.
The over speeding of the cradle will likely to happen during the manual descent having
the two hoists to descend simultaneously at a speed of 15 m/min or more. As a safety
feature of the cradle its traction hoists are designed not to exceed the overspeed when
descending; however it is a must to test the overspeed safety brakes of the traction
hoists and to do this the follow steps must be performed.
- Raised the cradle 1 – 2 meters to have an enough clearance above the floor to allow
the cradle to descend.
- After reaching the required height, press the brake test button found at the side of
the cradle control panel.
- Abruptly raised the levers of the traction hoist to their full actuated position to
descend the cradle on the required overspeed of 15m/min to trigger the overspeed
safety devices on the hoists.
- The safety devices on the hoists will automatically engage to the safety wire ropes
once the overspeed is reached. The safety devices are operational when the cradle
stops as a result of the devices engaging to the safety wire ropes.
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- Reset the safety devices by raising the cradle back to the initial position and turning
the reset knobs found on the side of the hoists to disengage the safety device.
Raising the cradle can be done either manually or by operating the hoists.
Working Position of the Position of the knob

Safety device Knob when the safety device
is activated
- The black button on the hoist is used to manually activate the safety device should
the device doesn’t automatically activates or if the cradle descends uncontrollably
without reaching the overspeed of 15m/min to activate the safety device.
Reset Knob
Manual Activation
Button
- By pressing the button the safety devices engages to the safety wire rope preventing
the passing of the wire rope to move the cradle down. To reset raise the cradle and
turn the reset knob back to its initial position as shown above.
• Absence of Anomalous Noises

− During the checking process, attention must be paid to any abnormal noise arising due to
the movements of the trolley & cradle.
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6. OPERATIONAL PROCEDURES
6.1. Kookaburra Operating Procedure
The following are standard procedures to operate the Kookaburra.
1. From the parking location of the kookaburra, the maintenance personnel will prepare the
machine and perform the pre operational check and inspection as detailed in this
manual. Operators should also inspect the area where the machine will be deployed to
ensure no obstruction can block the machine operation.
2. After ensuring that the machine is in good working condition via the pre-operation
check, it can now be moved to the first drop point.
3. Energized the BMU, and turn the main key switch of the roof unit control box to “REM”
or remote.
4. After selecting the control point to REM, two cleaner-operators will then access the
cradle. Access and egress from the cradle must only happen from the front and only
when the platform is landed on the floor
The correct manner in which to enter and exit the cradle is as described below.
o When the cradle is landed on the ground, approach the platform from the front.
The front is the side with the rollers attached.
o Attach the lanyard from the safety harness to the attachment slots on the
cradle. The attachment slots are located at the top corners.
o Then using the foot holes (step) in the platform walls climb over the front wall
and into the platform. Do not jump into the platform.
o To exit the platform the above procedure is reversed.
5. Turn ON the cradle main key switch and raise it to full up position. Once the cradle
reaches the full up position, the cleaner -operator needs to hold the pendant controller
to control the traversing of the roof unit.
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6. Using the pendant control, the kookaburra will be manoeuvred to the area where the
first drop will start. The operators must ensure that their safety harnesses are attached
to the attachment point in the cradle before making any movement on the machine.
7. The kookaburra will be positioned to the first dropping point. Bring the cradle outside the
roof and position it in parallel to the façade thru the unit slew and manual slewing of the
crossbar. Refer to attached cradle drop layout.
8. During the traversing of the BMU, take care of the power cable. Relocate the plug if the
length of the power cable is not sufficiently enough to reach the preferred location.
9. Once the kookaburra is in position, the cradle can now be lowered using the cradle
control. Operator should always keep a visual on the direction where the cradle is going
to avoid clash with the building façade.
10. The cradle is provided with restraint lanyards which are to be attached to the restraint
sockets on the facade when descending and to be detached when ascending. This is
very important step to keep the cradle safe from moving dangerously should an extreme
gust of wind hit the cradle during operation. Refer to cradle restraining procedure for
details.
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LEGEND:
- Standard Kookaburra
Cradle Drop
- Kookaburra Power
Supply point @ Roof
Level
- Water point @ Podium

Level
- Auxillary Power Supply

point @ Roof Level
KOOKABURRA OPERATION – CRADLE DROP

EWC-4870-OMM-0001-00 Page 38 of 77
11. The cleaning will start from the top most portion of the façade going down.
12. After finishing the first façade segment, the cradle needs to be raised back to the full up
position to reposition the kookaburra to the next adjacent segment. Repositioning will
require traversing, unit slewing and manual cross bar slewing of the machine.
13. Then resume the cleaning and carry on the process until all areas are covered and
cleaned.
14. After the cleaning is over, the Kookaburra needs to be moved back to the parking
location. Then remove all equipment and materials used for façade cleaning from the
cradle.
15. Once in the parking location, turn off the key switch and the power switch from the roof
unit & cradle control box then retrieve all the keys. Unplug the power cable and make
sure that the cable is properly winded in the cable reel.
16. Make a walk around inspection to see if the machine is in correct and right parking
position before leaving the area.
17. Inform the building management after the activity and fill out all necessary documents
for record.
6.2. Cradle Restraining Procedure
The cradle must be restrained when lowered in front of the façade to prevent the side
movement when a gust of wind hit the cradle. This procedure must be applied at all
times when the cradle is in use.
1. Located in the façade are the restraint sockets where the restraint lanyards will be
attached.
2. The restraint sockets are located in levels 23, 17 , 11 & 5. See attached sketches for
the socket locations.
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3. Lower the cradle to the first restraining level 22, take the restraint lanyard from the
cradle and attach one end to the cradle wire ropes and the other end to the restraint
socket.
4. Resume the cradle lowering until the next restraint level-12 is reached, attached
another pair of lanyard to the restraints. Repeat the process to the remaining
restraints at levels 7 & 3.
5. For the cradle to be positioned to the podium level at the monorail rigging / de-
rigging area which has an offset distance from the upper level façade to connect
another sets of wire ropes to the monorail trolleys, the cradle must be raised first to
full up position for the operators to manoeuvre the roof unit from its pendant
controller hanging to the jib end.
Monorail Rigging /
De-rigging area
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6. When raising the cradle, the installed restraint lanyards will be detached from the
cradle wire ropes while it will be kept hanging from the restraint sockets on the
façade.
7. The lanyard length will be adjusted longer which is necessary for the cradle to be
positioned to the podium level.
Restraint Socket
Initially installed lanyard
Additional Lanyard to
increase total length of lanyard
8. After raising the cradle, the operators to adjust the roof unit position for the cradle to
align with the podium façade line.
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9. Start lowering the cradle to the first restraint level, operatives will use a stick to reach
the restraint lanyards hanging from the façade and the free ends of the restraints will
be connected to the cradle wire ropes.
10. Resume the cradle lowering to the next restraint level and perform the same to
connect the restraint lanyards.
11. Continue the process until the cradle reaches the level of the podium where the
cradle operator will be able to reach the position of the monorail trolleys to attach the
wire ropes.
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6.3. Cradle Rigging to Monorail System
As the cradle is shared between the Kookaburra and the monorail system, a rigging
procedure is to be performed to transfer the cradle from the kookaburra to the monorail
and vice versa.
1. The monorail trolleys are parked to either of the two ends of the monorail track and
this is where the cradle rigging to the monorail will happen.
CRADLE RIGGING
/ DE-RIGGING LOCATION
2. An extra set of wire ropes is provided to connect the cradle to the monorail system
thru the use of the kookaburra. Place the extra wire ropes inside the cradle before the
rigging starts.
3. With the standard Kookaburra manoeuvring, position it directly above the rigging
location where the monorail trolleys are parked.
4. The power supply cable of the cradle must be transferred from the power outlet at the
jib end of the kookaburra to the power supply point at the podium level.
5. Turn off the cradle power and detach the power cable from the power outlet at the jib
and lower the cable to the podium level. Another worker in the podium will connect the
power cable to the power outlet.
6. Turn ON the cradle power and lower the cradle to the level of the monorail track
where the operators in the cradle will be able to reach the monorail trolleys.
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7. Connect the extra set of wire ropes to the trolleys and let them hang to reach the
ground level.
8. Land the cradle to the ground level and detached it from the kookaburra by de-reeving
the wire ropes from its traction hoists. The following are the steps to de-reeve the wire
ropes form the traction hoist.
- Ensure that the wire ropes hanging from the kookaburra that support the cradle have
no slacks whilst the cradle is landed to the ground. This will make the de-reeving of
the safety wire ropes easier as the slack rope safety device will be kept from
engaging to the wire rope.
- The de-reeving of wire ropes will start from the safety wire rope. It is the wire rope that
doesn’t pass the slack rope lever as shown.
SUSPENSION WIRE ROPE
SAFETY WIRE ROPE

SLACK ROPE LEVER
- Inside of the cradle, pull the safety wire from the wire winder drum and then pull it from
the top of the traction hoist until the wire winder drum comes to empty. Disconnect the
wire rope from the wire winder drum and continue pulling it until the remaining wire is
removed from the hoist. Repeat the steps to the safety wire rope of the other hoist.
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- After the safe ropes are de-reveed, turn the cradle power ON then press the by-pass
button while turning the down switch to automatically de-reeve the suspension wire
ropes from the traction hoists.
Suspension Wire rope
- Continue actuating the down switch until the wire winder drum comes to empty.
Disconnect the suspension wire rope from the wire winder drum then continue the de-
reeving until the remaining wire rope exits the hoist. Repeat the step to remove the
suspension wire rope from the other hoist.
9. The ropes hanging from the kookaburra will remain on the area until the cradle is
returned at the end of the monorail system use.
10. After de-reeving the wire ropes move the cradle directly below the monorail trolleys
where the other set of wire ropes are hanging from them.
11. Connect the cradle to the monorail trolley wire ropes by following the reeving
process.
- Start the reeving process on the suspension wire ropes of the two hoists. Feed the ends
of the suspension wire ropes to the slack rope levers up to the openings on the traction
hoists until the wire ropes stop.
- Turn ON the cradle power and actuate the up switch to start the automatic reeving of the
suspension wire ropes to the traction hoists until wire rope ends reach the wire winder
drums.
- Proceed to the reeving of the safety wire rope by pushing the slack rope lever of the
hoist and inserting the wire rope to the other slot on the hoist until the wire rope end
reaches the wire winder drum. Do the same step to the other hoist.
- Attach the safety & suspension wire ropes to the wire winder drums and start actuating
the up switch to wind the wire ropes top the drums equally.
- Continue until the slacks are removed. If the wire ropes are not equally winded in the
drums, select the hoist with the slacked wire ropes thru the hoist selector switch and
actuate the up switch to remove the slack.
12. After reeving the monorail trolley wire ropes to the hoists, the cradle is now connected to
the monorail.
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6.4. Monorail System Operating Procedure
1. After connecting the cradle and ensuring that the system is in good working condition
via the pre-operation check, it can now be moved to the first cradle drop location.
2. Two cleaner-operators will get inside the cradle. Access and egress to the cradle must
only happen from the front and only when the platform is landed to the floor.
The correct manner in which to enter and exit the cradle is as described below.
o When the cradle is landed to the floor, approach the platform from the front.
The front is the side with the rollers attached.
o Attach the lanyard of the operator’s safety harness to the attachment slot on the
cradle. The attachment slots are located at the top corners.
o Then using the foot holes (step) in the platform walls climb over the front wall
and into the platform. Do not jump into the platform.
o To exit the platform the above procedure is reversed.
3. Turn ON the cradle key switch and raise it to full up position. The cradle will
automatically stop once the full up position is reached.
4. When the cradle is at full up position, operators will be able to reach the monorail
trolleys to start the traversing.
5. Start by disengaging the screw brakes of the trolleys.
6. With the screw brakes loosen, operators need to hold onto the track or push against
the façade to move the trolleys and the cradle to their desired direction.
7. The third person positioned at the podium must transfer the power cable of the cradle
during the traversing.
8. Once the first cradle drop area is reach the trolley screw brakes will be reengaged.
9. Start the façade cleaning from the top until the lowest façade level is reached. After
finishing the first cradle drop, return the cradle to full up position to reposition the
system to the next area and resume the cleaning.
10. At the end of the façade cleaning, return the cradle to the rigging & derigging the area
to disconnect it from the monorail. Follow the de-rigging procedure in section 6.3.
Reconnect the cradle to the kookaburra by reeving the wire ropes hanging from it to
the cradle. Follow the rigging procedure in section 6.3.
11. With the cradle reconnected to the kookaburra, raise it to the level of the monorail
trolley to disconnect the wire ropes hanging from the monorail trolleys.
12. Keep the extra set of wire ropes inside the cradle.
13. Raise the cradle to full up position and transfer its power supply cable that is
connected to the power supply point in the podium level to the power outlet hanging
from the jib of the kookaburra.
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14. A third person positioned in the cradle needs to disconnect the cradle power cable.
The operators in the cradle will then pull the cable and connect it to the power outlet at
the jib of the kookaburra.
15. Manoeuvre the kookaburra with the cradle back to its parking location.
16. Once in the parking location, turn off the key switch and the power switch of the
kookaburra & the cradle then retrieve all the keys. Unplug the power cable and make
sure that the cable is properly winded in the cable reel.
17. Make a walk around inspection to see if the machine is in correct and right parking
position before leaving the area.
18. Inform the building management after the activity and fill out all necessary documents
for record.
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LEGEND:
- Monorail Track Layout
- Monorail Cradle Drop
- Monorail Trolley Parking

/ Cradle Rigging &
Derigging Area
- Monorail Power Supply

point @ Podium Level
- Water point @ Podium

Level
MONORAIL SYSTEM OPERATION – CRADLE DROP

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6.5. System Normal Running Checks
While using the BMU it is required to perform a check to see if the system is working
normally, perform the standard operation as follows.
• Kookaburra with the Self- Powered Cradle
- Traversing of the kookaburra along the track & activation of the traverse limit switches.
- Slewing of the Jib and crossbar
- Up and Down Cradle Movement using the Cradle Up & Down Switch
- Up limit switch activation by raising the cradle up to its maximum height
- Bottom Trip bar Activation & by-pass button by allowing the cradle to descent until the
trip bar touch the ground and pressing the by-pass button to override the bottom trip
bar
- Green Indicator Lights are illuminated in the Kookaburra control panel and cradle control
panel.
- Emergency Buttons on the kookaburra & cradle are operational.
NOTE: emergency stop buttons of the kookaburra and cradle are not linked therefore
they must be activated separately.
Monorail System with the Self- Powered Cradle
- Manual traversing of the trolleys along the track & engagement / disengagement of
trolley screw brakes
- Up and Down Cradle Movement using the Cradle Up & Down Switch
- Up limit switch activation by raising the cradle up to its maximum height
- Bottom Trip bar Activation & by-pass button by allowing the cradle to descent until the
trip bar touch the ground and pressing the by-pass button to override the bottom trip
bar
- Green Indicator Light is illuminated in the cradle control panel.
- Emergency Buttons of the cradle is operational.
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7. SAFETY & EMERGENCY INFORMATION
This manual contains important information relating to hazards associated with the safe
operation and maintenance of the BMU system.
7.1. Emergency Information
The provided information is very important for the facility management personnel and
operators of the BMU to be conversant.
7.1.1. U.A.E. Authority Emergency Contact Information
In case of accidents or other emergency situations in Sharjah Emirate, the number to dial
listed below.
When calling the emergency number, please remember to state your name, the nature of
the accident, address of the emergency and how serious the situation is. And remember to
provide them with the telephone number you are calling from. Remain calm and provide the
paramedics with clear information so they can supply the necessary help.
EMERGENCY NUMBERS
Ambulance: 06-998
Fire emergency: 06-997
Police: 06-999
7.1.2. COX GOYML Emergency Contact Personnel
The type of emergency that will be attended by COX GOMYL personnel are limited to those
BMU breakdowns related emergencies such as personnel get stock on a suspended cradle
due to BMU fault.
Other emergencies should be attended either by a specialised rescue service provider

commissioned by the owner or by the civil defence.
The provided list is the Cox Gomyl’s priority contact personnel in case of emergency or
breakdown.
Priority Name Designation Contact Number
Service &
1st Pathirana Arsana Harsana Maintenance +971 50 6511812
Technician
2nd Gary Clarke Technical Manager +971 50 3794169
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Important
The operation & maintenance team should not consider the following advice to be the sole
reference for safety purposes: they are represented merely as reminders of the most basic
of safety considerations.
• It is the responsibility of each individual to ensure that, via the application of plain
"common sense" and the mandatory safety regulations, each task is carried out safely.
• Always assume every circuit is 'live' until it has been checked with a voltmeter, or similar
approved means: check your instruments with a known 'live' source before using them
for testing.
• Never touch two sides of a circuit simultaneously, whether it is alive or dead.
• Do not use metal rules or measuring tapes when working on or near live equipment.
• Always use tools with hand grips adequately insulated against the voltage of the circuit
being worked on.
7.2. Safety Hazards
Equipment and the site environment present the following potential hazards to personnel
while using the Kookaburra machine:
• Electrical Supply Voltages
• Dust, extreme heat, strong winds
• Working at heights.
• Low headroom.
• Moving machinery.
• Hot metal surfaces.
7.3. Precautions
Facilities Maintenance personnel should take note of the following precautions:
1. Read and comply with the safety, quality and environmental control instructions
contained in the manual.
2. Ensure all personnel are aware of the site fire rules and regulations (including no
smoking), the locations of fire extinguishers and nearest emergency exit routes and first
aid procedures.
3. All maintenance personal must wear Personnel Protective Equipment (PPE).
EWC-4870-OMM-0001-00 Page 56 of 77
4. Maintain good housekeeping on the area.
5. Do not eat or drink while working. Do not take food or drink into the work environment.
6. Always wash your hands and face after working.
7. Always check equipment and materials for hazard warning labels.
8. All toxic/flammable substances (e.g., cleaning fluids) must be stored, handled, used and
disposed of in accordance with local safety instructions.
9. All spillages (e.g., water, cleaning fluids) and rubbish must be cleaned up immediately
and disposed of correctly.
10. Ensure that at all times the walkways and emergency exit routes are kept clear and are
free of obstructions and hazards.
7.4. Use of Electrical Equipment
Where equipment requiring removal and replacement has or requires an electrical power
source, ensure that only approved equipment is used and that safe working practices are
adopted.
7.5. Use of Portable Equipment
Where portable equipment is necessary, ensure that only approved equipment is used and
that safe working practices are adopted.
7.6. Training of Personnel
All personal allocated to maintenance and/or cleaning tasks must have successfully
completed suitable training on the specific equipment used in order to ensure safe and
effective working practices. In addition, personnel should be fully conversant with, and
adhere to, the requirements of local safety procedures.
7.7. Personal Protective Equipment
PPE is to be worn by all personnel engaged in maintenance/cleaning tasks; base level PPE
generally comprises:
• Overalls/boiler suit.
• Safety footwear.
• Protective helmet/hard hat, as applicable.
EWC-4870-OMM-0001-00 Page 57 of 77
• High visibility vest. (ORANGE/YELLOW).
• Protective gloves (as required, rigger-type to protect from cuts/abrasions, and Nitrile
lined type to protect from oils, liquids, etc.).
• Eye protection (goggles/safety spectacles).
• Safety harnesses (required where work is carried out over 2m high or over a void
greater than 2m in depth).
Additional PPE may be required for specialised tasks, such as:
• Waterproof clothing (wellington boots, trousers, jackets, etc.), as required by the

working conditions.
• Dust masks, as required by the working conditions.
• Ear defenders in noisy environments.
7.8. Fire Fighting Equipment
Facilities Maintenance Personnel, when they enter any area in which they are going to
work, they should first check the locations of all Fire Fighting equipment within and around
that area of work, and should also ensure that the available Fire Fighting equipment is
complete and in full working order.
7.9. Protective / Safety Devices of the BMU
The Kookaburra & cradle have safety devices designed to protect the system from any
damage that may jeopardise the safety of the user. The system has the following safety
devices
• LIMIT SWITCH FOR MOVEMENTS
All the movements are controlled by a stop limit switch.
• RUN LIMIT FOR MOVEMENTS
At the end of runway, all the movements have a second end stop operated either by
limit switches or by a mechanical stop.
• EMERGENCY STOPS
The BMU is equipped with several EMERGENCY buttons, which stop all of the
machine's movements.
• SAFETY DURING TRAVERSE
EWC-4870-OMM-0001-00 Page 58 of 77
The BMU is equipped with an acoustic warning device in the Roof-Car itself, which
sounds when it is moving from one place to another.
• SAFETY DEVICE AGAINST BREAKAGE OF ELECTRIC CABLE
The BMU is equipped with a limit switch control (within the cable reel) which stops the
traversing movement when the cable is fully unwound.
• SAFETY DURING SLEWING
The BMU is equipped with an acoustic warning device in the Roof-Car itself, which
sounds during the slewing movement.
• PROTECTION OF ELECTRICAL PARTS
All electrical parts (motors, transformers, etc.) are protected by means of thermal-
magnetic circuit breakers which will, in the event of a fault, cut the electric current of the
corresponding part.
• RESIDUAL CURRENT PROTECTION
The BMU is inactivated in the event of excessive residual current by means of

differential circuit breakers which will, in the event of a fault, cut the electric current of
the BMU.
7.10. Emergency Procedures
If an emergency situation occurs while operating the BMU, the operators in the cradle may
perform the following procedures the safely exit from the cradle.
1. Stop all system movements by activating the emergency stops from the roof unit control
box or pendant controller and from the cradle control panel. Take note that the
emergency stops on the kookaburra is not linked to that on the cradle so it is necessary
to activate both.
2. Assess the situation to know whether the cradle can be brought back to the roof or
ground thru normal maneuvering of the machine. There should be clear communication
between the people on the ground and the people on the cradle to know exactly the
situation.
3. If it is safe, reset the emergency stops to operate the machine.
4. Perform the standard BMU operation to bring the cradle back to the roof level or down to
the ground level where the operators can safely get out from the cradle.
5. Make a report about the incident and inform immediately the building maintenance
manager.
6. If the power is cut or the motorized maneuvering of the machine is not possible, the
manual cradle descent of the cradle must be performed.
EWC-4870-OMM-0001-00 Page 59 of 77
7.10.1. Manual Descent Procedure
The manual descent can be done in two ways, the simultaneous two hoists manual descent
and the one hoist manual descent:
• Simultaneous Two Hoist Manual Descent
This procedure will be performed by two cradle operators operating the two hoists
simultaneously.
- Turn off the key switch on the cradle control box.
- If possible, activate the emergency button from the pendant controller of the kookaburra.
- Locate the “NO POWER” descent levers on the two hoists
- Push the lever up to release the electro-magnetic brakes acting on the motors.
- Ensure that the releasing of brakes are done simultaneously and slowly to avoid the
tilting & over speeding of the cradle.
- If over speeding occurs, a reset procedure is required to continue the manual descent of
the cradle
- Continue the procedure until the cradle safely landed onto the ground.
• One Hoist Manual Cradle Descent
This procedure is applicable if only one of the two cradle operators can do the manual
descent procedure. Please consider the first method before proceeding to this method.
- Turn off the key switch on the cradle control box.
- If possible, activate the emergency button from the pendant controller of the kookaburra.
- Locate the “NO POWER” descent lever on each of the hoist and push the lever into the
up direction to release the electro-magnetic brake acting on the motor.
- The cradle will tilt until it reaches the limit of the cradle degree of tilt. Once the limit was
reached, the safety lock will be activated and it will prevent the down movement of the
hoist being manually lowered.
- After the hoist stop from moving, apply the same procedure onto the other hoist and
continue the process until the cradle landed onto the ground.
EWC-4870-OMM-0001-00 Page 60 of 77
7.10.2. Procedure to Reset the Over Speed Safety Device
If an over speed happens during the manual descent of the cradle, the over speed safety
device will automatically engaged that will stop the cradle from further lowering.The safety
device must be reset to continue the manual descend of the cradle.
1. Turn off the key switch and activate the emergency stop of the cradle. From one of the
hoist, removed the plug from top cover of its motor to expose the slot where the hand
wheel will be installed.
2. Insert the hand wheel to the slot on the top cover of electric motor. This will connect the
handwheel to the shaft of the motor.
3. After placing the hand wheel, make a counter clock wise turn while raising the “NO
POWER” descent lever at the same time. Grab the hand wheel firmly while opening the
brake to prevent it from turning in the opposite direction..
Counter Clockwise Turn
Counter Clockwise Turn
Pull Up
4. After making a turn release the “NO POWER” descent lever to reengage the brake of
the motor then repeat.
5. After a couple of turns, turn the over speed safety knob back to its original position.
6. This can also be done if power is available, just raise the hoist then turn the reset knob.
EWC-4870-OMM-0001-00 Page 61 of 77
8. MAINTENANCE
No persons deemed to be less than competent and suitably experienced should carry out
any maintenance activities on the items\equipment covered by this manual. All works are to
be carried out in accordance with the current general and local Health & Safety regulations.
The method of installation and support should be carefully noted when dismantling
units\equipment that is to be replaced so that replacing/re-installing may be expedited
efficiently and effectively, thereby maintaining the integrity of the initial installation.
The Supplier strongly recommends that ONLY a specialist contractor be permitted to affect
any maintenance repair or replacement tasks on the BMU system.
EWC-4870-OMM-0001-00 Page 62 of 77
8.1. Preventive Maintenance Activities
Preventive maintenance is defined as regular and systematic checking and replacement of

worn parts, materials, to prevent parts, system failures by ensuring that parts and materials
are in good working order.
Under normal use and service the items\equipment covered here are warranted to be free
from any defects in materials or workmanship within the specified term on completion of
installation and commissioning.
The preventive maintenance activities must be carried out four times a year during the
Defect liability Period and after the DLP period an Annual Maintenance Contract is to
be made with Facility Maintenance Contractor.
The preventive maintenance activities will comprise of the following:
• Crossbar
- Inspect structure for signs damage.
- Corrosion; clean, prepare and paint where necessary. Note any
- Areas retaining water and causing corrosion problems.
- Inspect welds for signs of distress or cracking.
- Check all connection bolts are secure.
• Jib
- Corrosion; clean, prepare and paint where necessary. Note any areas retaining water
and causing corrosion problems.
• Slew Assembly
- Inspect motor (brake operation, mounting bolts tight, ingress of water into motor/terminal
box, correct operation).
- Inspect sprocket & chain (grease levels, misalignment, excessive wear or markings on
teeth, side deflection, and correct operation).
• Counterweight
EWC-4870-OMM-0001-00 Page 63 of 77
• Machine Frame
• Sub frame
• Wheel Assembly
- Corrosion; clean, prepare and paint where necessary. Note any areas retaining water and
causing corrosion problems.
- Inspect motor (brake operation, mounting bolts tight, ingress of water into motor/terminal
box, correct operation).
- Inspect wheel blocks (bearings, excessive wear, tight fit of stainless steel pivot pin in wheel
housing, correct operation).
- Inspect guide rollers (wear, anchorage, safety ends).
• Electric installation: Check electric control panel, push buttons, thermal magnetic
protections, contactors, wiring, terminals and motor earth bands.
• General cleaning with special attention to areas for lubrication.
• Check condition of paint and repaint if needed.
• General lubrication of the machine.
• Check rail track or rail guide, anchorages and supports.
• Verify the correct operation of the machine.
During these works the operator will record the results obtained on the file and report regarding
this maintenance procedure, highlighting any anomaly which will need corrective or
improvement maintenance.
EWC-4870-OMM-0001-00 Page 64 of 77
8.2. Corrective Maintenance Activities
Corrective maintenance is defined as that which is required when a system/equipment/ item

has failed or worn out in order to bring it back to a working condition.
No corrective/remedial maintenance should be undertaken by persons deemed to be less

than competent and suitably experienced; to this end, all repairs should be referred to Coo
Gomyl Middle East.
Priority CG Personnel for Corrective Maintenance
Priority Name Designation Contact Number
Service &
st
1 Pathirana Arsana Harsana Maintenance +971 50 6511812
Technician
2nd Gary Clarke Technical Manager +971 50 3794169
EWC-4870-OMM-0001-00 Page 68 of 77
8.3. Inspections
General Inspections shall be carried out with sufficient frequency to ensure the BMU is kept
in a safe and satisfactory condition.
Inspections shall be as follows:
a) Pre-operational inspection (before start of any work using the system)
b) Routine maintenance inspection (as discussed under the Preventive Maintenance)
c) Annual inspections
d) Future Use
All such work shall be noted and recorded in this Manual.
Pre-operational Inspections
Before the BMU is used, and at the beginning of each work shift, it shall be given a visual
inspection and functional test which may be carried out by the operator who shall engage
assistance from a suitably competent person in specialist areas, such as electronics or
communications, as required. The inspection and test shall include, but not limited to, the
following:
a) Operating and emergency controls
b) Safety switches and interlocks
c) Structure
d) Wire ropes
e) Personal protective equipment.
Where pre-operational inspections reveal a malfunction or potential hazard, the BMU shall
not be put in-service and the problem shall be reported and recorded in this manual. The
related problems shall be rectified prior to using the BMU. (Refer to attached pre
operational checklist)
EWC-4870-OMM-0001-00 Page 71 of 77
9. PARTS LISTING & SPARE
No spares have been left behind on completion of the BMU installation.
In the event that replacement of any items may be required in the future, you should, in the first
instance, contact the supplier or call on the services of a specialist contractor.
The following us the list of the usually replace BMU parts
1. 5 pin male socket
2. Power Supply Cable
3. Bump Rollers
4. Castor Wheels
5. Bottom Trip Bar
6. Locking Pins
7. Limit Switches
EWC-4870-OMM-0001-00 Page 73 of 77
10. TROUBLESHOOTING
The following are the possible fault and the recommended troubleshooting procedure in using
the BMU System.
Fault Possible Cause Recommended Fix

Check to see if there is any
Irregular Power supply: leakage, and take preventive
BMU not working
• Leakage breaker disengaged measures
(all functions & lights)
• Phase lacking Check if the 3-phase power is
normal and reconnect
• Only down movement is

• Cradle full up has been tripped
Cradle will not raise allowed
• Cradle is overloaded
• Remove excess weight
• Raise the cradle to clear

the obstruction.
• Cradle trip bar has been triggered
Cradle will not lower • Raise the cradle until
• There is slack rope on the hoist
ropes become tight before
lowering again.
• Motor electromagnetic brake fails

Suspended platform
• The spacing between brake and
slides down in static • Contact Supplier for repair
armature is over too big
condition
• Sensitivity difference in the motor

brake
• Adjust the load of
Suspended platform • Difference in motor rotating speed
suspended platform (by
tilt and hoist rope pulling
authorized technician only)
• Uneven load in the suspended
platform
For other fault aside from the above given, contact the supplier / manufacturer for checks &
repairs.
EWC-4870-OMM-0001-00 Page 74 of 77
11. DISPOSAL INSTRUCTION
a. Refuse from façade cleaning activities must be removed from the cradle and
disposed according to the disposal procedure as mentioned on the packaging or
instruction of the material being disposed.
b. Refuse from the equipment during maintenance or once the equipment reaches its
end of service can be retrieve from the site and be recycled. As the system and its
parts are mostly made from steel, 90-95 percent of the system can be recycled and
be used to produce new steel products.
c. The recycling of the system should only be done by an authorized party that
specialized in recycling.
d. The system uses minimum amount of oil/grease that can cause pollution if
improperly disposed. Used oil and grease should be stored in an appropriate
container and be brought to a recovery facility for recycling; if recycling facility is not
available it should be disposed in an environmentally safe manner and in
accordance with governmental regulations.
EWC-4870-OMM-0001-00 Page 75 of 77
12. MANUFACTURER’S INFORMATION
13. ATTACHMENTS
• TESTING & COMMISSIONING CERTIFICATES

• WARRANTY CERTIFICATE
• AS BUILT DRAWINGS
• KOOKABURRA WIRING DIAGRAMS
• SELF-POWERED CRADLE WIRING DIAGRAM
EWC-4870-OMM-0001-00 Page 76 of 77
TESTING & COMMISSIONING
(TO FOLLOW)
EWC-4870-OMM-0001-00
WARRANTY CERTIFICATE
EWC-4870-OMM-0001-00
AS BUILT DRAWINGS
EWC-4870-OMM-0001-00

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KOOKABURRA WIRING DIAGRAMS
EWC-4870-OMM-0001-00
SELF-POWERED CRADLE WIRING
DIAGRAM
EWC-4870-OMM-0001-00

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FUTURE TOWER III, SHARJAH

Operation & Maintenance Manual

Document No.: EWC-4870-OMM-0001

Layout and Guide to Contents

This document is divided into the following sections:

Section 2 – System Description

It provides technical information on the BMU machine.

Section 3 – Equipment Schedules & Identifications

It is a list of equipment and its components as provided for the project.

Are procedures to be completed before using the system to ensure safety

Section 6 – Operating Procedures

Section 7 – Safety & Emergency Information

Provides maintenance procedures for the BMU

Section 9 – Parts Listing & Spares

Provides a list of parts and its identification

Section 10 – Trouble Shooting

Diagnostic and troubleshooting procedures

Section 11- Disposal

Disposal instruction of the system

Section 12 – Manufacturers Information

Provides information on the system’s manufacturer

This section contains relevant or supporting documents such as copies of

BMU Model  Front Angle Guided K-Type BMU (Kookaburra)

Safe Working Load (SWL)  250 kg (2 persons + tools & materials)

Serial No.  4039

Jib Type  Fixed Length Single Shoulder Jib

Jib Max Reach  3300 mm (slew center to center of crossbar)

Slew of Jib / BMU  Electric Drive chain & sprocket

Cross Bar Slew  Manual using rope

Sub Frame Description

Sub frame Type  Front Angle Guide

Brake System  Self-lock worm gearbox on all drive wheels

Long travel drive motors  2 on front wheels

Travel Speed  11 meters per minute (nominal)

Wheel Type  Polyurethane (on concrete)

Suspended Platform Description (See item 2.1.1)

 Two Man Self Powered Cradle (shared with the monorail

Safe Working Load  250 (2 operators + tools)

Main Power Supply  380 V (III + PE)

Outlet type  16 A SOCKET (III phase + PE)

Control Voltage  12V AC

Roof Unit Control Box

Location  Mast section of the Kookaburra

Control for  Kookaburra (roof unit control only)

Control Button & Switches

▪ Traverse Switch ▪ “Ready” & “Fault” Indicator Lights

▪ Unit Slew Switch ▪

Location  End of Jib

Control for  Kookaburra (roof car only- switch key to remote)

Control Button & Switches

▪ Emergency Stop Button (mushroom head twist to reset)

▪ Unit Slew Buttons

 Parapet Mounted Monorail System with Manual Push

Safe Working Load (SWL)  250 kg (2 persons + tools & materials)

Type  Cast-in Anchors

Material  Stainless Steel Anchors

Monorail Bracket Description

Type  Side Mounted Monorail Bracket for EWC 138

Material  Hot Dip Galvanized and Painted

Monorail Track Description

Material  Extruded Aluminium Allloy 6063 T6

Finish  Powder Coated to approved RAL Color

Monorail Trolley Description