Lockhard Alulift M User manual

Operator's Manual No. 1/2014 "Mobile Access Platform type Alulift M"

June 2014 Page 1

Operator's Manual

MOBILE ACCESS PLATFORM

TYPE Alulift M

(Original Manual)

Operator's Manual No. 1/2014 "Mobile Access Platform type Alulift M"

June 2014 Page 2

Table of Contents

1. GENERAL INFORMATION ............................................................................................................................. 5

1.1. Manufacturer ................................................................................................................................................... 5

1.2. Machinery Marking ....................................................................................................................................... 5

1.3. Definitions ........................................................................................................................................................ 5

1.4. Safety Symbols Used in this Manual ........................................................................................................ 5

1.5. National Requirements ................................................................................................................................ 6

1.6. Sample Declaration of Conformity ........................................................................................................... 7

2. TECHNICAL DATA ........................................................................................................................................... 8

2.1. Use of PRP type Alulift M for the Intended Purpose .......................................................................... 8

2.2. Failure to Use PRP type Alulift M for the Intended Purpose .......................................................... 8

3. DESCRIPTION OF THE PRP CONSTRUCTION AND OPERATION AND ADJUSTMENT OF

SAFETY COMPONENTS .................................................................................................................................. 9

3.2. List of Components Necessary for PRP type Alulift M Assembly ............................................... 11

4. DESCRIPTION OF THE DRIVE SYSTEM CONSTRUCTION, OPERATION AND ADJUSTMENT 12

4.1 Drive Unit ....................................................................................................................................................... 12

4.2 Service Brake ................................................................................................................................................ 12

4.3 Emergency Brake – Emergency Gripper ............................................................................................. 13

4.4 Control Pendant ........................................................................................................................................... 13

4.5 Audio Alarms. ............................................................................................................................................... 13

4.6 Wheel Brakes ................................................................................................................................................ 13

4.7 Safety System to Prevent Platform Overloading .............................................................................. 13

4.8 Drive Operating Time Meter ................................................................................................................... 14

4.9 Battery Charger ........................................................................................................................................... 14

5. ASSEMBLY AND DISASSEMBLY INSTRUCTIONS................................................................................ 14

5.1. Assembly ........................................................................................................................................................ 15

5.2. Conditions of Stability - Variants of Stabilizers ................................................................................ 21

5.3. PRP type Alulift M Anchoring Instruction .......................................................................................... 21

5.4. Disassembly .................................................................................................................................................. 22

5.5. Battery Disassembly .................................................................................................................................. 23

6. OPERATOR'S MANUAL ............................................................................................................................... 23

6.1. Control via Control Pendant .................................................................................................................... 24

6.2. Operator's Working Station ..................................................................................................................... 24

6.3. Operator's Qualifications .......................................................................................................................... 24

6.4. PRP Handling ................................................................................................................................................ 24

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June 2014 Page 3

6.5. Troubleshooting .......................................................................................................................................... 24

7. HAZARDS IDENTIFICATION AND RESIDUAL RISK INFORMATION ............................................ 25

8. SAFETY GUIDELINES. ................................................................................................................................. 26

8.1. Lighting ........................................................................................................................................................... 27

9. MAINTENANCE INSTRUCTIONS .............................................................................................................. 27

9.1. Maintenance Operator .............................................................................................................................. 27

9.2. Maintenance and Inspection Schedule ................................................................................................ 27

9.3. Pre-Assembly Reviews ............................................................................................................................. 28

9.4. Maintenance Reviews. ............................................................................................................................... 28

9.5. Ad hoc and Service Reviews. ................................................................................................................... 28

10. CRITERIA FOR COMPONENTS REPLACEMENT .................................................................................. 29

11. STORAGE AND TRANSPORT .................................................................................................................... 29

12. SAFETY SIGNS USED ON THE PRODUCT .............................................................................................. 30

13. GUARANTEE AND WARRANTY……………………................…………………………………………………….....32

14. APPENDIX No. 1…………………………....………………………………………………………………………...………..34

15. APPENDIX No. 2…………………………….......……………………………………………………………………………..35

Operator's Manual No. 1/2014 "Mobile Access Platform type Alulift M"

June 2014 Page 4

Foreword

We would like to inform you that Mobile Access Platform type Alulift M 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

Inspection Certificate of the type issued.

Lockhard Sp. z o.o. [Ltd] is the only manufacturer of the Mobile Access Platform (Polish: PRP) type

Alulift M with a mobile work platform.

The Operator's Manual is considered to be a fundamental part of the Mobile Access Platform type

Alulift M. It contains necessary information on the assembly, disassembly and operation of the

device as well as users' work safety and how to maintain its efficiency.

Full and legible user's manual must be available at all times. "Mobile Access Platform type Alulift M"

will be hereinafter abbreviated as "PRP".

In order to avoid unnecessary damage and risks, the operator's responsibility is to read,

understand and obey this Operator's Manual

In addition to the PRP's Operator's Manual, general legal provisions and regulations for 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 M on site.

LOCKHARD is not liable for any damage resulting from failure to

comply with this Manual.

Risk in this respect shall be borne by the user.

Operator's Manual No. 1/2014 "Mobile Access Platform type Alulift M"

June 2014 Page 5

1. GENERAL INFORMATION

1.1. Manufacturer

LOCKHARD Sp. z o.o.

Gorzyce Wielkie ul. Ostrowska 74a

63-410 Ostrów Wielkopolski

Tel. +48 627347129

e-mail: office@lockhard.eu

www.lockhard.eu

1.2. Machinery Marking

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 lower access position, 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 work at heights, entitled on the basis of

knowledge and practical experience and equipped with the necessary instructions for working

with the PRP.

Safe working load - the maximum weight carried by the work platform provided for in the

draft by the manufacturer. The safe working load comprises the weight of persons, tools and

materials.

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.

Lockhard Sp. z o.o.

Gorzyce Wielkie ul.Ostrowska 74a

63-410 Ostrów Wielkopolski

POLAND

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: 2014

Operator's Manual No. 1/2014 "Mobile Access Platform type Alulift M"

June 2014 Page 6

Danger

This symbol indicates an immediate threat to people'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 other things, if the action

marked in this way is performed incorrectly.

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 M" 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 PRP 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.

Operator's Manual No. 1/2014 "Mobile Access Platform type Alulift M"

June 2014 Page 7

1.6. Sample 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 M"

Serial number: XXX/20XX

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 under the harmonized standards:

PN-EN 1808+A1:2010

(EN 1808:1999+A1:2010)

item: 1, 2, 3.5, 3.6, 3.8, 3.9, 4,

5, 6, 7, 8.1, 8.3.1, 8.3.2, 8.3.5,

8.9.1, 9.1.2, 9.1.4, 9.1.8, 11.1 –

11.6, 12, 13, 14, Annex A,

Annex B

PN-EN 280:2013-11

(EN 280:2013)

item: 4, 5.5.5, 5.7, 5.8, 6, 7

PN-EN 12100:2012

(EN 12100:2012)

other standards:

PN-EN 1004:2005

(EN 1004:2004)

item: 1, 2, 3, 4, 7.1 – 7.5, 7.7,

7.8, 8.3, 8.3.2.1, 8.3.2.2, 8.4. 9,

10, 11, 12, 13, Annex A

PN-EN 12810-1:2010

(EN 12810-1:2003)

item: 6.2.3, 8.2, 8.3, 8.5.2

PN-EN 12811-1:2010

(EN 12810-1:2003)

item: 4.2.2, 6.2.7, 6.2.9.2

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 Examination

Certificate No. TEST/9/MD2014

The Product carries the mark:

2057

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

……………………………………………

……...

Operator's Manual No. 1/2014 "Mobile Access Platform type Alulift M"

June 2014 Page 8

2. TECHNICAL DATA

Safe working load

250 kg (2 persons, tools and materials)

Work platform dimensions

660x2400 mm

Maximum platform lifting

and lowering speed

10 m/min (at full battery power)

Maximum height

12 m

Maximum PRP weight

approx. 475 kg

Supplied voltage

24 VDC

Engine power

600 W

Maximum drive motor speed

3000 rpm.

Transmission ratio

1:100

Battery capacity

33 Ah

Battery voltage

2x12 V

Operating temperature

-15° C up to +40 ° C

Noise

does not exceed 70 dB

c) load exerted by PRP on its setting and on the structure design, according to:

PN- EN 12811 clause 8 c

2.1. Use of PRP type Alulift M for the Intended Purpose

"Mobile Access Platform type ALULIFT M" 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 M" consists of the work platform with controls, a load-bearing

structure and a wheel assembly.

"Mobile Access Platform type Alulift M" can be used indoors and outdoors.

2.2. Failure to Use PRP type Alulift M for the Intended Purpose

 It is prohibited to use the PRP as a crane.

 It is prohibited to use and move the PRPP 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 exposedto the

wind will decrease machine stability.

 It is prohibited to stand on the handrails, braces and stabilizers.

 It is prohibited to tie rods (not for anchors) between the PRP and another structure

(buildings, other scaffolding, etc.).

 It is prohibited to place 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 a PRP that is not properly maintained and inspected or is not in good

technical condition.

Operator's Manual No. 1/2014 "Mobile Access Platform type Alulift M"

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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 M" components

Each PRP component is marked with:

a) a symbol in order to identify the PRP system and its manufacturer.

b) a year of manufacture, with the last two digits being used.

Table 1

Item

No.

Component

marking

Component photo

Component

description

Weigh

t

[kg]

1.

PS/14

Platform with

drive system

55

2.

H264/14

Horizontal

handrail

6

3.

HO264/14

Handrail with

access gate

8,5

4.

TB264/14

Toe-boards

6,1

5.

H95/14

Side handrail

3.9

6.

FR95100/14

FG95100/14

Base frame (right

and left marked

with colours)

complete with

pin bolts.

Running profile

mounted on the

base frame

10.6

7.

DB264/14

Diagonal braces

2.85

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8.

HB264/14

Horizontal braces

2.70

9.

CC05/14

Control pendant

PKS-3/W05

0.5

10.

WHEEL125/14

Small wheel

61125 CB

1.2

11.

WHEEL200/14

Large wheel

61200 CB

5.3

12.

BAT33/14

Gel batteries

Bt-02-12

2x9,5

13.

CHA1131/14

Battery charger

BAT 1131

0.45

14.

STAB3000/14

Stabilizer

4.28

15.

RA15/14

Gear rack

16.

SPR20/14

Gear

17.

GRA25/14

Gripper

(emergency

brake)

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18.

BFK457/14

Service brake

BFK 457

19.

AN450/14

Anchor bolt

20.

LI10-60/14

Pin bolt

Safety guardrails are an integral part of the platform

Pin bolts are an integral part of the load-bearing structure

3.2. List of Components Necessary for PRP type Alulift M Assembly

Table 2

PRP height

2

m

3

m

4

m

5

m

6

m

7

m

8

m

9

m

10

m

11

m

12

m

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

Horizontal handrail

1

Handrail with access gate

1

Side handrail

2

Wooden toe-board

2

Stabilizer

-

4

Small wheel

4

Large wheel

4

Battery

2

Platform

1

Total weight in kg

192

218

262

292

315

342

368

395

420

448

475

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Fig. 1 Main PRP components

4. DESCRIPTION OF THE DRIVE SYSTEM CONSTRUCTION, OPERATION AND ADJUSTMENT

4.1 Drive Unit

The drive system in the PRP type Alulift M is an electric motor with 24 V, 600 W and 3000 rpm

speed. It is permanently attached to the CM063 type worm gear of 100 to 1 ratio. The worm

gear output rotational speed is 30 rpm. The drive system power is 114 Nm. A drive shaft fi 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

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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, and which does not

allow its further operation; in this case you should notify the manufacturer or an authorized

service point in order to have the grippers replaced. Note - the gripper can be right-side and left-

side.

4.4 Control Pendant

Mobile Access Platform type Alulift M 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

is to disconnect control in the other two buttons. This button has a built-in continuous control

system 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.

Photo: 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 movements

during operation or stopping.

4.7 Safety System to Prevent Platform Overloading

The PRP is equipped with safety devices to protect the drive from overloading due to

platform overloading or blocking during upward movement. The overload protector

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protects the drive motor during upward movement, and the redundant protector protects

the circuit current of the drive motor and brake.

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 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.

In order to connect the batteries to the charger, you should remove the batteries from the

battery chamber on the PRP platform.

5. ASSEMBLY AND DISASSEMBLY INSTRUCTIONS

Below is the description of the procedure for assembling and disassembling the "Mobile Access

Platform type Alulift M" 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 functioning, in particular the gear racks

and drive gears as well as the emergency gripping equipment.

For assembly, use only undamaged and original manufacturer's parts.

Before commencing the PRP type Alulift M assembly, check the surrounding area for safety, eg. 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

 15.0 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.

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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 1 Photo 2

First, you must install the required guardrails on the platform.

Photo 3 Photo 4

Connect side handrails to the horizontal handrail and build the handrail with access gate

Photo 5 Photo 6

Install toe-boards

Photo 7 Photo 8

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Remove the covers protecting the gears and the roller guides of the drive system

Photo 9 Photo 10

Install the battery in the battery bay under the platform and connect the power supply cables

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

Photo 13 Photo 14

Photo 15 Photo 16

Using the key unlock the emergency stop button on the control pendant. Before pressing the

control pendant buttons, make sure that it is held securely.

Operator's Manual No. 1/2014 "Mobile Access Platform type Alulift M"

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Photo 17 Photo 18

Press and hold the white button on the control pendant until the platform is lifted 2 - 10 cm

upwards

PRP Alulift M will work properly as long as the gears and the gear racks

simultaneously engage on both sides of the load-bearing structure!

Install two (shorter) horizontal braces connecting PRP base frames

Install diagonal braces connecting PRP base frames on the opposite side of the access gate.

Install one end of the brace on the lowest level of the first segment of the base frame. Install the

other end of the brace on the highest level of the opposite side of the first segment.

Photo 19 Photo 20

The brace hooks should be fitted in the designated places.

Correct position of fitting braces.

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Level the equipment using aligning bolts in the wheels and lock the wheels using a brake at each

of the four wheels and check the levelness of the platform using a bubble level.

Photo 21 Photo 22

Stage III further structure levels assembly

From the ground fit further matching frames of the PRP load-bearing structure. (please pay

attention to the colour marking scheme of the components - red and green)

Photo 23 Photo 24

View of the base frames and mobile platform marking.

Each time after connecting base frames of the structure, secure them by

pin bolts in order to prevent their unintended retracting.

Photo 25 Photo 26

Insert pin bolts in the holes in the pillars of the frame structure. Install diagonal braces

connecting PRP base frames.

Install one end of the brace on the lowest level of the base frame. Install the other end of the

brace on the highest level of the opposite side. The correct braces assembly is shown in the

photograph No. 26.

When building the next level, the following should be loaded on the platform:

 The red-marked base frame

 The green-marked base frame

 Two diagonal braces

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While the PRP platform is moving, it is important to remember that all of the

transported components must not protrude beyond the outline of the platform

railings.

Operation may start only if the platform handrails are properly locked to prevent accidental fall.

Move the platform to the most suitable place in order to be able to install the third segment.

Photo 27

Install further frames of the load-bearing structure by matching them according to the colour

marking scheme.

Photo 28 Photo 29

Install diagonal braces connecting PRP base frames. Install one end of the brace on the lowest

level of the third segment of the base frame. Install the other end of the brace on the highest

level of the opposite side of the third segment.

Photo 30

Before commencing the fourth level assembly, four stabilisers should be fitted by screwing them

with radial grips down to the base frame of the structure.

After fitting the stabilizers, check if the stabilizer bars rigidly adjoin the ground in order to make

sure that they are fitted correctly.

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When applying large force, the stabilizer should not move in lateral direction - rotation and

vertical.

Photo 31 Photo 32

Photo 33

Photo 34

After fitting the stabilizers, you can proceed to install the fifth and any further level, according to

the instructions of Stage III.

Subsequent phases of fitting

stabilizers

View of the assembled platform type ALULIFT M

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Lockhard Alulift M User manual

Lockhard Alulift M User manual

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