Lockhard Alulift Series User manual

Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
August 2015 Page 1
Operator's Manual
MOBILE ACCESS PLATFORM
TYPE Alulift
(Translation)

Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
August 2015 Page 2

Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
August 2015 Page 3
Table of Contents
1. GENERAL INFORMATION.............................................................................................................................6
1.1. Manufacturer...................................................................................................................................................6
1.2. Machinery Marking .......................................................................................................................................6
1.3. Definitions ........................................................................................................................................................7
1.4. Safety symbols used in this Manual.........................................................................................................7
1.5. National requirements.................................................................................................................................8
1.6. Declaration of Conformity..........................................................................................................................9
2. TECHNICAL DATA........................................................................................................................................ 10
2.1. Use of PRP type Alulift for its intended purpose.............................................................................. 10
2.2. Failure to use PRP type Alulift for the intended purpose............................................................. 10
3. DESCRIPTION OF THE PRP CONSTRUCTION AND OPERATION AND ADJUSTMENT OF
SAFETY COMPONENTS............................................................................................................................... 11
3.2. List of Components Necessary for PRP type Alulift Assembly .................................................... 14
4. DESCRIPTION OF THE DRIVE SYSTEM CONSTRUCTION, OPERATION AND ADJUSTMENT 16
4.1 Drive Unit....................................................................................................................................................... 16
4.2 Service brake ................................................................................................................................................ 16
4.3 Emergency Brake - Emergency Gripper.............................................................................................. 16
4.4 Control Pendant........................................................................................................................................... 16
4.5 Audio Alarms. ............................................................................................................................................... 17
4.6 Wheel Brakes................................................................................................................................................ 17
4.7 Safety system to prevent platform overloading............................................................................... 17
4.8 Drive operating time meter..................................................................................................................... 17
4.9 Battery charger............................................................................................................................................ 17
5. ASSEMBLY AND DISASSEMBLY INSTRUCTIONS................................................................................ 18
5.1. Assembly ........................................................................................................................................................ 19
5.2. Conditions of stability - variants of stabilizers................................................................................. 26
5.3. PRP type Alulift S anchoring instruction ........................................................................................... 28
5.4. Disassembly .................................................................................................................................................. 29
5.5. Battery Disassembly .................................................................................................................................. 30
6. OPERATOR'S MANUAL............................................................................................................................... 30
6.1. Control via control pendant..................................................................................................................... 31
6.2. Operator's working station...................................................................................................................... 31
6.3. Operator's qualifications.......................................................................................................................... 31
6.4. Handling PRP ................................................................................................................................................ 32
6.5. Troubleshooting .......................................................................................................................................... 32

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7. HAZARDS IDENTIFICATION AND RESIDUAL RISK INFORMATION............................................. 34
8. SAFETY GUIDELINES................................................................................................................................... 35
8.1. Lighting........................................................................................................................................................... 36
9. MAINTENANCE INSTRUCTIONS.............................................................................................................. 36
9.1. Maintenance Operator .............................................................................................................................. 36
9.2. Maintenance and Inspection Schedule................................................................................................ 36
9.3. Pre-assembly reviews............................................................................................................................... 37
9.4. Maintenance Reviews................................................................................................................................ 37
9.5. Ad hoc and Service Reviews. .................................................................................................................. 38
10. CRITERIA FOR COMPONENTS REPLACEMENT.................................................................................. 38
11. STORAGE AND TRANSPORT..................................................................................................................... 38
12. AN INFORMATION BOARD PLACED ON THE PRODUCT ................................................................. 39
13. Guarantee and warranty .......................................................................................................................... 40
14. APPENDIX No. 1………………………………………………………………….………………………….......…………..42
15. APPENDIX No. 2……………………………………………………………………………………………………..………..43

Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
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Foreword
We would like to inform you that the Mobile Access Platform type Alulift has passed a detailed EC
type examination carried out by the certification body JOAiCW TEST Sp. z o.o. [Ltd] .
The confirmation of the positive result of the inspection carried out by JOAiCW TEST Sp. z o.o. is the
Type Examination Certificate issued.
Lockhard Sp. z o.o. [Ltd] is the only manufacturer of the Mobile Access Platform (Polish: PRP) type
Alulift with a mobile work platform.
This Operator's Manual is considered to be a fundamental part of the Mobile Access Platform type
Alulift. It contains all the necessary information on the assembly, disassembly and operation of the
device as well as users' work safety and the information on how to maintain its efficiency.
A full and legible user's manual must be accessible at all times. "Mobile Access Platform type Alulift"
will be hereinafter abbreviated as "PRP".
In order to avoid unnecessary damage and risks, the operator's and the assembly worker's
responsibility is to read, understand and comply with this Operator's Manual.
In addition to this PRP Operator's Manual, general legal provisions and regulations concerning
accident prevention and environmental protection in force in the user's country shall apply.
You should refer to all the national and local rules for operating PRP type Alulift on site.
LOCKHARD is not liable for any damage resulting from failure to
comply with this Manual.
Any risk in this respect shall be borne by the user.

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1. GENERAL INFORMATION
1.1. Manufacturer
LOCKHARD Sp. z o.o.
Gorzyce Wielkie ul. Ostrowska 74a
63-410 Ostrów Wielkopolski
e-mail: [e-mail]
www.lockhard.eu
1.2. Machinery Marking
Alulift S
Alulift M
Alulift XL
Lockhard Sp. z o.o.
Gorzyce Wielkie ul.Ostrowska 74a
63-410 Ostrów Wielkopolski
POLSKA
Product:
Mobile Access Platform type Alulift S
Alulift Type: S
Weight: 48.3 kg –330 kg
Safe working load: 250 kg
Voltage: 24V DC
Platform dimensions:
660x1720mm
Engine power: 600 W
Lift height: 8 m
Serial number: xxx
Platform speed:10 m/min
Year of manufacture: 2015
Lockhard Sp. z o.o.
Gorzyce Wielkie ul.Ostrowska 74a
63-410 Ostrów Wielkopolski
POLSKA
Product:
Mobile Access Platform type Alulift M
Alulift Type: M
Weight: 55 kg –475 kg
Safe working load: 250 kg
Voltage: 24V DC
Platform dimensions: 660x2400mm
Engine power: 600 W
Lift height: 12 m
Serial number: xxx
Platform speed: 10 m/min
Year of manufacture: 2015
Lockhard Sp. z o.o.
Gorzyce Wielkie ul.Ostrowska 74a
63-410 Ostrów Wielkopolski
POLSKA
Product:
Mobile Access Platform type Alulift XL
Alulift Type: XL
Weight: 67 kg –524 kg
Safe working load: 250 kg
Voltage: 24V DC
Platform dimensions:
1100x2400mm
Engine power: 600 W
Lift height: 12 m
Serial number: xxx
Platform speed: 10 m/min
Year of manufacture: 2015

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1.3. Definitions
Mobile Access Platform (PRP) - is a mobile machine intended to move persons to working
positions on which they carry out work from the work platform, on the assumption that these
persons enter the platform and exit the platform in its one lower access position, and which
consists of the work platform with controls, a load-bearing structure, a wheel assembly.
Work platform - a part of the mobile platform, a platform with railings, which can be moved
under load to a desired working position, and from which you can perform installations, repairs,
inspections or similar works.
Operator - a designated person, suitably trained to operate devices of this type subject to laws
and regulations applicable in a particular country. In Poland an operator must have proper
qualifications awarded by the Office of Technical Inspection (an operator may also work as a
service technician).
Service technician is a person who has been sufficiently trained by the manufacturer of the
device type Alulift, namely Lockhard Sp. z o.o. Each periodic replacement of parts or ad hoc
repairs of the device may be carried out by the manufacturer's service technicians or service
units authorized by the manufacturer.
Safe working load - the maximum weight carried by the work platform provided for by the
manufacturer in the design/specifications of the device. The safe working load comprises the
weight of persons, tools and materials placed on the platform.
1.4. Safety symbols used in this Manual
In order to draw your attention to the areas in this Manual which contain important information or
indicate danger, the following symbols are used. Special attention should be paid to areas marked
with these symbols as you study the instructions for use.
Danger
This symbol indicates an immediate threat to person's life and health.
Failure to comply may result in a risk to life or a risk of serious injury and a
significant property damage.
Caution
It is a warning against possible damage to PRP or another item, if the action
marked in this way is performed incorrectly.

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1.5. National requirements
In addition to this Operator's Manual, attention should be given to the need to know and comply
with the generally applicable national and local laws and other binding regulations relating to work
safety and environmental protection in the country where the machine is used.
In the Republic of Poland "Mobile Access Platform type Alulift" serving as a device for the movement
of persons and loads is a device qualifying for handling equipment and is subject to technical
supervision. It is the user's responsibility to report the equipment to UDT [Polish Office of Technical
Inspection].
Legal basis:
Regulation of the Council of Ministers of 7 December 2012 on types of technical devices subject to
technical inspection (Official Journal of Laws 2012 No. 0, item 1468), issued pursuant to Article 5,
paragraph 2 of the Law on technical inspection.
Pursuant to the Regulation of the Minister of Economy, Labour and Social Policy of 29 October 2003
on the technical conditions of technical supervision relating to operating certain types of handling
equipment. Pursuant to art. 25.1 item, 6 after changing the location of handling equipment due to
its disassembly and reassembly, a device with single-phase power supply does not require interim
in-service testing.

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1.6. Declaration of Conformity
EC DECLARATION OF CONFORMITY
Manufacturer: LOCKHARD Sp. z o.o.
Gorzyce Wielkie ul. Ostrowska 74a
63-410 Ostrów Wielkopolski
Product: Mobile Access Platform type Alulift
Serial number: ……………………….
We declare under our sole responsibility that the product referred to above fulfils the essential
health and safety requirements of the Directive 2006/42/EC OF THE EUROPEAN PARLIAMENT AND
OF THE COUNCIL.
The EC type examination was carried out by the notified body JOAiCW Test Sp. z o. o., number
NB2057, 41-103 Siemianowice Śl. ul. Wyzwolenia 14, which issued the CE Type Examination
Certificate No. ………………………….
The Product carries the mark:
The technical documentation is stored at:
LOCKHARD Sp. z o.o.
Gorzyce Wielkie ul. Ostrowska 74a
63-410 Ostrów Wielkopolski
Gorzyce Wielkie, dated ……………
Technical Manager:
Łukasz Leonhard
……………………………………………
……...

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2. TECHNICAL DATA
ALULIFT S
ALULIFT M
ALULIFT XL
Safe working load
250 kg (2 persons,
tools and materials)
250 kg (2 persons,
tools and materials)
250 kg (2 persons,
tools and materials)
Work platform dimensions
660x1720 mm
1100x2400 mm
1100x2400 mm
Maximum platform lifting
and lowering speed
10 m/min (at full
battery power)
10 m/min (at full
battery power)
10 m/min (at full
battery power)
Maximum height
approx. 330 kg
approx. 475 kg
approx. 530 kg
Maximum PRP weight
8m- internal height
12 - external height
8 m –internal height
12 - external height
8 m –internal height
12 - external height
Supplied voltage
VDC 24
VDC 24
VDC 24
Engine power
600 W
600 W
600 W
Maximum drive motor speed
3000 rpm.
3000 rpm.
3000 rpm.
Transmission ratio
1:100
1:100
1:100
Battery capacity
33 Ah
33 Ah
33 Ah
Battery voltage
2x12 V
2x12 V
2x12 V
Operating temperature
-15° C up to +40 ° C
-15° C up to +40 ° C
-15° C up to +40 ° C
Noise
does not exceed 70dB
adjusted individually
does not exceed 70dB
adjusted individually
does not exceed 70dB
adjusted individually
2.1. Use of PRP type Alulift for its intended purpose
"Mobile Access Platform type Alulift" is a mobile machine intended to move persons to working
positions on which they carry out work from the work platform, on the assumption that these
persons enter the platform and exit the platform in its one lower access position. "Mobile Access
Platform type Alulift” consists of the work platform with controls, a load-bearing structure and a
wheel assembly. "Mobile Access Platform type Alulift " can be used indoors and outdoors.
2.2. Failure to use PRP type Alulift for the intended purpose
It is prohibited to use the PRP as a crane.
It is prohibited to apply a point load - the load must be equally distributed across the
platform. Applying a high load on a small area (a point load) may damage the platform.
It is prohibited to use and move the PRP when wind speed exceeds (12m/s - 6 on the
Beaufort scale).
It is prohibited to use the PRP during a storm.
It is prohibited to move the PRP using any motor vehicles such as a car, forklift truck, tractor,
etc.
It is prohibited to use lifting devices (hand or mechanical winches) on the PRP.
Do not increase (obscure) the side surface of the PRP. Increasing the area exposed
to the wind will decrease machine stability.
It is prohibited to stand on the handrails, braces and stabilizers.
It is prohibited to tie rods (excluding anchors) between the PRP and another structure
(buildings, another scaffolding, etc.).
It is prohibited to lean any objects against the PRP structure during assembly and operation.
Not more than 2 persons may stay on the PRP work platform.
It is prohibited to use the PRP that is not properly maintained and inspected or is not in
good technical condition.
It is prohibited to use the device without pin bolts securing structure frames.
It is prohibited to use this device in explosive atmospheres.

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3. DESCRIPTION OF THE PRP CONSTRUCTION AND OPERATION AND ADJUSTMENT OF
SAFETY COMPONENTS
List of the "Mobile Access Platform type Alulift" components
Each PRP component is marked with a catalogue number in order to identify the PRP system.
Table 1
Item
No.
Component
marking
Component photo
Component
description
Weight [kg]
S
M
XL
1.
PS
Work platform
with a drive
system
48,3
55
67
2.
H264
Horizontal
handrail
5
6
6
3.
HO 264
Handrail with
access gate
6,1
8.5
8.5
4.
TB264
Toe-boards
2,67
6.1
6.1
5.
H95
Side handrail
3.9
3.9
6,9

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6.
FR139100
FG139100
Base frame (right
and left marked
with colours)
supplied with pin
bolts.
Running profile
mounted on the
base frame
10.6
10.6
12,10
7.
DB264
Diagonal braces
2,27
2.85
2.7
8.
HB264
Horizontal braces
2.18
2.70
2.7
9.
CC05
Control pendant
PKS-3/W05
0.5
0.5
0.5
10.
WHEEL125
Small wheel
61125 CB
1.2
1.2
1.2
11.
WHEEL200
Large wheel
61200 CB
5.3
5.3
5.5
12.
BAT33
Gel batteries
Bt-02-12
2x9,5
2x9,5
2x10,5
13.
TE04-0227
Battery charger
TE04-0227
0.8
0.45
0.8
14.
STAB3000
Stabilizer
4.28
4.28
4.28

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15.
RA15
Gear rack
9,8
9,8
9,8
16.
SPR20
Gear
0,68
0,68
0,68
17.
GRA25
Gripper
(emergency
brake)
1,17
1,17
1,17
18.
BFK457
Service brake
BFK 457
19.
AN450
Anchor bolt
2
2
2
20.
LI10-60
Pin bolt
0,05
0,05
0,05
21.
OB
Weight - ballast
10
10
10
Safety guardrails are an integral part of the platform
Pin bolts are an integral part of the load-bearing structure

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3.2. List of Components Necessary for PRP type Alulift Assembly Table 2
Alulift S
PRP height
2m
3m
4m
5m
6m
7m
8m
Component name
Number of components (pcs)
Red structure frame
2
3
4
5
6
7
8
Green structure frame
2
3
4
5
6
7
8
Diagonal braces
4
6
8
10
12
14
16
Horizontal braces
2
2
2
2
2
2
2
Horizontal handrail
1
1
1
1
1
1
1
Handrail with access gate
1
1
1
1
1
1
1
Side handrail
2
2
2
2
2
2
2
Toe-board
3
3
3
3
3
3
3
Stabilizer
-
-
4
4
4
4
4
Small wheel
8
8
8
8
8
8
8
Large wheel
4
4
4
4
4
4
4
Battery
2
2
2
2
2
2
2
Platform
1
1
1
1
1
1
1
Total weight in kg
159
185
227
253
279
305
330
Alulift M
PRP height
2m
3m
4m
5m
6m
7m
8m
9m
10m
11m
12m
Component name
Number of components (pcs)
Red structure frame
2
3
4
5
6
7
8
9
10
11
12
Green structure frame
2
3
4
5
6
7
8
9
10
11
12
Diagonal braces
4
6
8
10
12
14
16
18
20
22
24
Horizontal braces
2
2
2
2
2
2
2
2
2
2
2
Horizontal handrail
1
1
1
1
1
1
1
1
1
1
1
Handrail with access gate
1
1
1
1
1
1
1
1
1
1
1
Side handrail
2
2
2
2
2
2
2
2
2
2
2
Toe-board
3
3
3
3
3
3
3
3
3
3
3
Stabilizer
-
-
4
4
4
4
4
4
4
4
4
Small wheel
4
4
4
4
4
4
4
4
4
4
4
Large wheel
4
4
4
4
4
4
4
4
4
4
4
Battery
2
2
2
2
2
2
2
2
2
2
2
Platform
1
1
1
1
1
1
1
1
1
1
1
Total weight in kg
192
218
262
292
315
342
368
395
420
448
475
Alulift XL
PRP height
2
m
3
m
4
m
5
m
6
m
7
m
8
m
9
m
10m
11m
12m
Component name
Number of components (pcs)
Red structure frame
2
3
4
5
6
7
8
9
10
11
12
Green structure frame
2
3
4
5
6
7
8
9
10
11
12
Diagonal braces
4
6
8
10
12
14
16
18
20
22
24
Horizontal braces
2
2
2
2
2
2
2
2
2
2
2
Horizontal handrail
1
1
1
1
1
1
1
1
1
1
1
Handrail with access gate
1
1
1
1
1
1
1
1
1
1
1
Side handrail
2
2
2
2
2
2
2
2
2
2
2
Toe-board
3
3
3
3
3
3
3
3
3
3
3
Stabilizer
-
-
4
4
4
4
4
4
4
4
4
Small wheel
4
4
4
4
4
4
4
4
4
4
4
Large wheel
4
4
4
4
4
4
4
4
4
4
4
Battery
2
2
2
2
2
2
2
2
2
2
2
Platform
1
1
1
1
1
1
1
1
1
1
1
Total weight in kg
211
240
287
316
346
376
405
435
464
495
524

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Drawing 1 Main PRP components

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4. DESCRIPTION OF THE DRIVE SYSTEM CONSTRUCTION, OPERATION AND ADJUSTMENT
4.1 Drive Unit
The drive system in the PRP type Alulift is an electric motor with 24 V, 600 W and 3000 rpm
speed. It is permanently attached to the CM063 type worm gear of 1 to 100 ratio. The worm
gear output rotational speed is 30 rpm. Actuating force is 114 Nm. A drive shaft φ 25 is
mounted on the worm gear, by which the device driving force is transferred to two extreme
ends of the shaft, where gears are mounted. The gears are splined to the gear rack located in the
vertical structure of the device. Upon starting the drive, the drive shaft is moved by the worm
gear. The rotary motion of the shaft makes the gear rotate, which enables vertical movement of
the platform.
4.2 Service brake
The service brake system is composed of:
The INTORQ BFK457-08 COMPAKT type brake of rated voltage 24V, rated power 25 watt
and nominal braking torque 12 Nm.
CM 050 transmission of 1 to 10 ratio
The service brake has nominal braking torque of 120 Nm, which is sufficient to brake and
maintain a work platform with safe working load of 250 kg. The service brake is an
electromagnetic brake which automatically starts the braking process at the time of control
circuit interruption - power supply loss.
The braking process is carried out using springs pressing the brake pads on the discs. Brake
release occurs at the time voltage is supplied to the solenoid coil.
4.3 Emergency Brake - Emergency Gripper
The emergency brake is made up of two independent grippers which make the platform stop if
the lowering speed exceeds 0.5 m/s. The emergency gripper is triggered by centrifugal switches
forming an integral part of the gripper.
If the gripper and the emergency brake are triggered on the platform, it is necessary to replace the
emergency brake system, which gets damaged during the platform stop (the emergency gripper is
a single-use device) which does not allow its further operation; in this case you should notify the
manufacturer or an authorized service point to have the grippers replaced.
Note - the gripper can be right-side and left-side.
4.4 Control Pendant
Mobile Access Platform type Alulift is able to move vertically up and down. In order to start the
drive which makes the platform move, the control pendant is used. There are three control buttons
on the control pendant. The emergency stop button is a master control button that is used to
disconnect control in the other two buttons. This button has a built-in control system of
continuous disconnection through key locking. The other two buttons located on the control
pendant are used to make the mobile platform move vertically UP and DOWN. These buttons are
marked by arrows and arranged by logical operation on the control pendant.

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Photo 1: Control pendant
4.5 Audio Alarms.
The advance signal - before starting the platform a 5-second audio alarm is triggered
indicating that the platform is going to be started.
The operation signal - emitted while the platform is moving, which warns of possible
trapping, drawing-in or crushing.
4.6 Wheel Brakes
Wheel brakes are mechanical devices preventing the PRP from uncontrolled movement
during operation or stopping.
4.7 Safety system to prevent platform overloading
The PRP is equipped with a safety devices to protect the drive from overloading due to
platform overloading or blocking during upward movement. The overload protector
protects the drive motor during upward movement, and the redundant protector protects
the circuit current of the drive motor and brake. In the event that the safety system is
activated to prevent platform overloading, move downward, reduce the platform load and
wait 90 sec. until the system makes it possible to move upward.
4.8 Drive operating time meter
The drive operating time meter is located under the platform. The drive operating time
meter records and indicates the number of the PRP drive operating hours. In order to ensure
proper meter functioning you should check its status from time to time (preferably it should
be checked before and after operation).
4.9 Battery charger
The PRP drive is supplied with a set of two batteries. A special device is provided for
charging the PRP drive gel batteries.
To connect the battery to the charger, connect the plug of the charger to the distribution
board A. See the photograph below.
To charge emergency system batteries (see item 6.5.2) connect the plug of the charger to
the distribution board B. See the photograph below.
Photo 2 Distribution boards
A- The main distribution board
B- Emergency lowering device
distribution board

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5. ASSEMBLY AND DISASSEMBLY INSTRUCTIONS
Below is the description of the procedure for assembling and disassembling the "Mobile Access
Platform type Alulift " produced by Lockhard Sp. z o.o.
Assembly, disassembly, operation and maintenance of the PRP may only be performed by properly
trained personnel, who must read and fully understand the following procedures and descriptions
before attempting to assemble or disassemble.
Two persons are required for assembly and disassembly. The area of the PRP assembly and
operation must be protected against unauthorized access by third parties.
Pre-assembly works
Before you begin the PRP assembly, check all the elements and components listed in
Table No. 2, which are necessary for its proper operation,
For assembly, use only undamaged and original manufacturer's parts.
Before commencing the PRP type Alulift assembly, check the surrounding area for safety, e.g. if there
are no electrical installations, ruins, rubble, excavations, mobile cranes, pedestrian traffic, any
vehicle or machine traffic, etc. in the area.
If there is a risk of coming into contact with overhead electrical power lines, these lines should be
shut off.
Electrical power lines which are in the distance of the level of free-swinging extreme cables from the
furthest possible outer edge of the transferred elements at the time of PRP operation, assembly and
disassembly do not require being shut off, with the said distance being not closer than:
2 m for a low voltage line of 400V
5 m for a line of up to 15 kV
10 m for a line of up to 30 kV
15 m for a line of over 30 kV
You should check the ground on which PRP will be installed. The ground must be horizontal and
hardened.

Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
August 2015 Page 19
5.1. Assembly
The structure of the PRP provides for quick assembly without the use of tools.
Stage I - platform assembly
The PRP platform should be placed on the destination assembly location.
Photo 3
First, you must install the required side guardrails on the platform.
Photo 4 Photo 5
Connect side handrails to the horizontal handrail and build the handrail with access gate
Photo 6 Photo 7
Install toe-boards

Operator's Manual No. 1/2015 "Alulift type Mobile Elevating Work Platform"
August 2015 Page 20
Photo 8
Remove the covers protecting the gears and the roller guides of the drive system
Photo 9 Photo 10
Stage II - Load-bearing structure assembly
Put the frames of the load-bearing structure with the roller guides on the appropriate sides of
the mobile platform, in accordance with the markings - colour-coded green and red,
Photo 11 Photo 12