0120723
Elevating Work Platform
Operator’s Safety and Maintenance Handbook
dual use machine: with and without stabilisers (auto brakes fitted)
At Pop-Up Products we welcome
any feedback and suggested
improvements for our products.
Please email us at
feedback@popupproducts.co.uk
You can also download a copy
of this handbook online at
www.popupproducts.co.uk
0120723
Section 1
DESCRIPTION
Introduction
Description
Intended use
Training
Modifications
Terminology
Section 2
SPECIFICATION
Technical data
Operating site
Noise and vibration
Limitations
Section 3
SAFETY RULES
Safety Rules
Section 4
OPERATING INSTRUCTIONS
Daily checks
Manoeuvring the platform
Engaging the brakes
Auto brakes
Stowing the stabilisers
Battery isolation switch
Entering and leaving the platform
Control pendant
Emergency stop
Emergency lowering
Emergency plunger valve
Battery charging
Section 5
MAINTENANCE
Safety during maintenance
Periodical maintenance and checks
Storage
Lubrication
Hydraulic oil
Electrical schematic
Hydraulic schematic
Troubleshooting
Section 6
TRANSPORT INSTRUCTIONS
Lifting
Preparation for transport
Loading and unloading
Section 7
MAINTENANCE AND
REPAIR RECORD
Maintenance and repair record
Notes
Daily checks – operator checklist
Pop-Up+ Operator’s Safety
and Maintenance Handbook
Contents
Page 2 of 25
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Page Page
Pop-Up+ Operator’s Safety and Maintenance Handbook
0120723
Deploying the stabilisers
10
(dual use machine rev.0.0.1.0210)
Introduction
This handbook provides information on the safe operation of this work
platform. Operators should read and understand all of the information
contained within this manual prior to operating the work platform.
The handbook contains several warnings, these indicate situations which if not
avoided could result in serious injury or death to persons, or damage to the
machine or property.
Additional copies of this handbook are available from the manufacturer at the
address below. Information contained in this handbook is based on the latest
product information at time of publication.
Pop-Up Products Ltd operate a policy of continuous improvement and therefore
reserve the right to make product changes at any time without obligation.
Description
The Pop-Up+ is a scissor lift type work platform, which is manoeuvred
manually into work positions and elevated and lowered using an electrohydraulic control system.
The standard machine includes the following standard features:
Intended use
The machine has been designed to comply with the safety requirements of the
Machinery Directive 2006/42/EC taking guidance from the European Standard
BS EN280:2001 + A2:2009 Mobile Elevating Work Platforms.
The machine is intended to be used to lift persons, plus essential tools and
materials, to enable work to be undertaken at height. Typical applications will include
maintenance, cleaning, painting, etc. at varying heights above ground level.
WARNING
THE MACHINE MUST NOT BE USED IN APPLICATIONS OR FOR USES OUTSIDE
OF THE SCOPE OF THIS HANDBOOK. SHOULD A CERTAIN APPLICATION NOT
BE COVERED, THEN THE MANUFACTURER SHOULD BE CONTACTED
Page 3 of 25
• 240kg safe working load
• 4.5 metre working height
• 1.72 metre stowed height
• Easily manoeuvrable
• Pass through standard doors
• Simple operation
• Steel guard rails
• Non-slip platform
• Steerable wheels
• Manual brakes on rear swivel wheels
• Auto brakes on front fixed wheels
• Anti-crushing lowering delay
• Integral battery charger
• Emergency lowering facility
• Easily transportable
• Low maintenance
• Complies with EN280:2001
• Stabilisers (optional if auto brakes fitted)
Section 1
DESCRIPTION
Operator’s Safety and Maintenance Handbook
0120723
Pop-Up+ (dual use machine rev.0.0.1.0210)
Training
It is essential that persons operating this Pop-Up+ are fully trained in the
setting up, safe use and inspection of the machine. Please download a copy of
our free Pop-Up & Pop-Up+ Familiarisation Guide from www.popupproducts.co.uk
The guide has been designed to assist competent people in safely operating our
range of low-level push around scissor lifts.
WARNING
OPERATION OF THIS MACHINE BY UNTRAINED OPERATORS MAY
RESULT IN SERIOUS INJURY OR DEATH
Modifications
No modifications must be made to this machine unless the manufacturer has
given full written approval. If in doubt contact the manufacturer for advice.
Manufacturer’s address:
Pop-Up Products Limited
2 Deeside Point
Tenth Avenue
Deeside Industrial Park
Deeside
CH5 2UA
UK
Tel +44 (0)1244 833 933
Fax +44 (0)1244 833 934
Email feedback@popupproducts.co.uk
www.popupproducts.co.uk
Page 4 of 25
Section 1
DESCRIPTION
Operator’s Safety and Maintenance Handbook (
0120723
Pop-Up+ dual use machine rev.0.0.1.0210)
Terminology
0120723
3
Section 1
DESCRIPTION
1
2
4
18
19
20
5
6
21
7
22
8
23
24
25
9
10
Stabilisers are optional
if auto brakes fitted
26
11
13
15
12
16
14
17
1. Control pendant 10. Emergency plunger valve
2. Emergency stop button & key 11. Maintenance props
3. Gate 12. Bubble spirit level
4. Guard rail
14. Forklift pocket (1 of 4)
5. Handbook
6. Platform
7. 110V and 240V charger leads
8. Scissor pack
9. Main lift cylinder
Pop-Up+ dual use machine rev.0.0.1.0210)
Operator’s Safety and Maintenance Handbook (
17. Manual brake (1 of 2)
13. Stabilisers
23. Battery condition meter
15. Chassis
16. Auto front brakes
18. Hydraulic tank
19. Battery
20. Hydraulic pack
21. Battery charger
22. Chassis plate
24. Battery charging indicator
25. Battery charger socket
26. Power selector
27. Emergency lowering valve
27
Page 5 of 25
Technical data
Page 6 of 25
Safe working load (SWL)
equivalent to
Maximum platform height
Maximum working height
Platform length
Platform width
Platform guard rail height
Toe board height
Maximum allowable manual force
Maximum allowable wind speed
Maximum allowable chassis inclination
Electrical system
Motor
Batteries
Battery charger
Hydraulic system
Maximum pressure
Reservoir capacity
Function speeds (approx.)
Raise
Lower
Approx. no. of lifts (fully charged with SWL)
Overall length
Overall height (stowed)
Overall width (with stabilisers deployed)
Overall width (without stabilisers)
Overall mass (GVW) without stabilisers
Overall mass (GVW) with stabilisers
Weight (without stabilisers)
Section 2
SPECIFICATION
240kg
1 person + 160kg tools and materials
2.5 metres
4.5 metres
1.01 metres
0.52 metres
1.10 metres
0.15 metres
200 Newtons
0 metres/sec*
0 degrees
12 volt DC
0.7 kW
1 x 80 Ah
Universal 90V to 240V AC
13 MPa
1.22 litre
24 seconds
25 seconds
120
1.26 metres
1.72 metres
1.30 metres
0.70 metres
343kg
365kg
Maximum wheel load
350kg
Operator’s Safety and Maintenance Handbook (
343kg
0120723
For use in indoor exposed areas up to 12.5m/sec wind speed – pack available on request
*
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Section 2
SPECIFICATION
Page 7 of 25
Operating site
Select a site for the machine from which the platform will be able to reach the
required work area. A visual inspection of the operating site should be made
before setting up the machine. Particular attention should be given to the
following items:
1. Ground conditions
Ensure that the ground on which the Pop-Up+ is to operate is capable of
supporting the weight of the machine (including the weight of the operator plus
tools and materials). Be aware of floors or coverings (e.g. manhole covers) that
may not withstand point loadings exerted by the castor wheels.
and legs are fully deployed before the work platform can be raised. It is essential
that each of the four stabiliser feet are located on firm, solid ground. The Pop-Up+
auto brake kit enables the removal of stabilisers for use in 0m/sec wind conditions.
2. Ground flatness
The Pop-Up+ must only be operated on flat (0º chassis inclination) and level
surfaces. The allowable chassis inclination is indicated when the spirit level
bubble is within the marked limits. All castor wheels must be in full contact with
the ground.
Noise and vibration
Noise levels emitted from this machine do not exceed 70 dB(A). Hand and
arm vibration experienced on this machine does not exceed 0.5 m/s
2
.
Limitations
The Pop-Up+ is limited to operation indoors. The machine must not be used
outdoors. Please consult the manufacturer if you are unsure of any application
for which the machine is to be used.
This machine has been tested for Electromagnetic Compatibility (EMC)
however, operation near to high powered radio transmission apparatus
(e.g. radar, antennae) or within strong electrical and/or magnetic fields may
affect some features of this product
WARNING
THIS MACHINE HAS NOT BEEN DESIGNED FOR OPERATION WITHIN
POTENTIALLY EXPLOSIVE ATMOSPHERES
WARNING
THIS MACHINE IS NOT ELECTRICALLY INSULATED AND MUST NEVER
BE USED FOR LIVE LINE WORKING. DEATH OR SERIOUS INJURY CAN
RESULT FROM CONTACT WITH, OR INADEQUATE CLEARANCE FROM,
ELECTRICAL CONDUCTORS
Operator’s Safety and Maintenance Handbook (
0120723
In indoor exposed areas with wind speeds up to 12.5m/sec the Pop-Up+ can be
used with a stabiliser pack. An interlock system ensures that the stabiliser beams
3. Obstructions
When manoeuvring, raising and lowering, ensure that there are no obstructions
or persons that may be struck by the platform.
Pop-Up+ dual use machine rev.0.0.1.0210)
Section 3
SAFETY RULES
Page 8 of 25
Safety Rules
NEVER Exceed the rated capacity (Safe Working Load or SWL) of the platform (240kgs).
NEVER Use the Pop-Up+ as a ‘crane’ (e.g. by suspending loads from beneath the platform).
NEVER Make any attempt to increase the working height or outreach of the platform (e.g. by use
of stepladders in the platform).
NEVER Manoeuvre the Pop-Up+ on an inclined surface otherwise it may become uncontrollable.
NEVER Manoeuvre the Pop-Up+ whilst in its elevated position, as this may cause instability.
NEVER Manoeuvre the Pop-Up+ with a person or materials in the platform.
NEVER Enter or exit the platform unless the platform is in the lowered and transport position.
NEVER Apply external side loads to the platform or scissor structure.
NEVER Allow persons at ground level to operate the controls whilst the platform is occupied
NEVER Operate the
NEVER Attempt to overreach.
NEVER Interfere with, wedge or attempt to override hydraulic, electrical or mechanical safety devices.
Pop-Up+ outdoors.
ALWAYS Undertake the daily checks recommended
ALWAYS Check that there are no obstructions or persons that may be struck by the platform before
and during the raising and lowering of the platform.
ALWAYS Ensure that the access gate is closed once the operator has entered the work platform.
in this handbook prior to operation of the machine.
ALWAYS Ensure that all instructions, warning and Safe Working Load decals are clean and legible.
ALWAYS Ensure the Pop-Up+ is positioned on adequate ground to support the weight of the machine.
ALWAYS Ensure that sufficient clearance is given if working near to live conductors.
ALWAYS Ensure the manual rear brakes have been engaged before elevating the work platform.
ALWAYS Ensure that auto front brakes are functioning correctly before attempting to use the machine.
ALWAYS Ensure that the platform does not come into contact with fixed objects (e.g. buildings, etc.) or
moving objects (e.g. vehicles, other plant equipment, etc.).
ALWAYS Replace any removable guard rails (e.g. close and lock access gate) to enable full edge
protection to be maintained.
ALWAYS Ensure that the load is evenly distributed within the platform.
ALWAYS Ensure the safety of persons that may enter the area around the platform (e.g. cordon off
the area to prevent persons entering the danger area).
ALWAYS Ensure hands are kept within the confines of the guard rails whilst elevating the work platform.
Operator’s Safety and Maintenance Handbook (
0120723
NEVER Operate the Pop-Up+ if the bubble spirit level is outside the marked limits.
(unless in an emergency situation).
ALWAYS Ensure that another responsible person on site knows how to use the emergency controls.
Pop-Up+ dual use machine rev.0.0.1.0210)
Daily checks
Prior to operating the Pop-Up+
* The raise and lower functions can be tested by removing the upper control
box from its holder in the work platform and using the controls whilst at
ground level. (NOTE: unless in an emergency situation, this practice must
not be employed when a person is in the work platform).
If the above checks reveal malfunctions or damage on the Pop-Up+,
then the machine must not be used until the problem is rectified.
If in doubt, seek further assistance from the manufacturer.
If safety decals are no longer legible or missing, please contact the
manufacturer for replacements.
The Daily Checks page in Section 7 of this handbook may be
photocopied to provide an aide memoir for operators when undertaking
these important checks.
Manoeuvring the platform
Manoeuvre the platform into position using both hands on the platform
rails as shown. Take care to avoid trapping hands or feet whilst
manoeuvring the platform.
Never manoeuvre the whilst it is elevated or with a person,
tools or materials in the platform.
, the following items must be checked:
Section 4
OPERATING INSTRUCTIONS
Page 9 of 25
• Structure (e.g. damage,
cracks, corrosion, abrasion,
welds, connections)
• Platform (floor, rails)
• Castors (smooth movement, damage)
• Rear manual brakes
• Auto front brakes
• Hydraulic oil
• Oil leaks
• Battery condition
• Raise and lower functions
(including descent delay) *
• Emergency stop and
lowering functions
• Limit switch
• Safety decals
WARNING
BEFORE OPERATING YOUR YOU MUST ENSURE THAT
YOU HAVE BEEN ADEQUATELY TRAINED IN ITS USE AND HAVE
FULLY READ AND UNDERSTOOD THIS OPERATOR’S HANDBOOK,
PAYING PARTICULAR ATTENTION TO SECTION 3 - SAFETY RULES
• Stabilisers (optional if
Pop-Up+ is fitted with
auto brakes)
Pop-Up+
POP-UP+,
Operator’s Safety and Maintenance Handbook (
0120723
Pop-Up+ dual use machine rev.0.0.1.0210)
Section 4
0120723
OPERATING INSTRUCTIONS
Engaging the brakes
Always ensure that both rear manual castor brakes are engaged before elevating the work platform to
prevent any inadvertent movement. The brakes are engaged by pushing down on the lever as shown.
Releasing the brake is simply a reversal of the engaging procedure. Before operating please ensure that
both of the manual rear brakes are engaged.
ReleaseEngage Auto brakes
Auto brakes
On the latest models Pop-Up+ is fitted with a secondary automatic brake system acting on the front fixed
wheels. Pop-Up+ does not require stabilisers if these auto brakes are fitted. An auto brake kit is available
to purchase. This system should be checked for functionality before attempting to use the machine. To
check, leave the rear manual brakes ‘OFF’ and elevate the machine approximately 150mm. Hold the
handrail on both sides at the gate end and attempt to push the machine. It should be difficult to push the
machine if the auto brakes are functioning correctly. Please consult the manufacturer if the machine is
easily pushed. Before operating please ensure the manual rear brakes are engaged. An auto brake kit is
available for Pop-Up+ for the safe removal of stabilisers.
Stabilisers
Deploying the stabilisers
Models of Pop-Up+, without auto brakes, are fitted with four stabilisers,
one at each corner. Models without autobrakes shall have all four
stabilisers fully deployed before the platform can be raised, as follows:
1. Pull out the red knob on the stabiliser beam housing
2. Extend the beam until it locks into position
3. Pull out the blue plunger on the stabiliser leg so that the foot
drops to the ground
4. Ensure that the plunger pin engages into the radial slot at the
top of the leg
5. Wind the handle clockwise until it is hand-tight
6. Ensure that the yellow stabiliser indicator lamp is lit
Once the stabilisers are in position, the platform can be raised to the
desired height.
Retracting and stowing the stabilisers
When work is finished on the Pop-Up+, the platform should be lowered
into its resting position and the worker should exit the platform. Only
then should the stabilisers be retracted and stowed. To do so:
1. Turn the handle anti-clockwise to loosen the stabiliser foot
2. Pull out and hold the blue plunger
3. Lift the stabiliser leg until it is in the raised position
4. Release the blue plunger until it is
5. Pull the red knob on the stabiliser beam outwards
6. Push the beam back into its housing until it locks into the ‘transport’ position
Operator’s Safety and Maintenance Handbook (Pop-Up+
seated in the radial ring around the bottom of the stabiliser leg
dual use machine rev.0.0.1.0210)
Page 10 of 25
Section 4
OPERATING INSTRUCTIONS
Page 11 of 25 Operator’s Safety and Maintenance Handbook (
Battery isolation switch
The Pop-Up+ is provided with a key operated switch which is used to isolate
the battery and therefore the electrical system, preventing unauthorised use.
To enable the electrical system, insert the key and turn clockwise, as shown
below, making sure the emergency stop button is fully released.
Ensure that when the machine is not in use, the emergency stop button
is depressed and the key removed. Further electrical isolation can be achieved
by selecting ‘0’ on the power selector switch. Position ‘1’ is for normal operation
and position ‘2’ is for charging the machine.
0120723
Pop-Up+ dual use machine rev.0.0.1.0210)
OPERATING INSTRUCTIONS
0120723
Entering and leaving
the work platform
Always use three points of contact when entering or exiting the platform,
using the handholds provided. For example, use two hands and one foot,
as shown below. Use the step provided on the base of the machine.
On entering the platform, ensure that the gate is closed behind you.
Section 4
Control pendant
The control pendant houses the platform raise and lower controls.
Pressing the ‘UP’ button raises the platform.
Pressing the ‘DOWN’ button lowers the platform.
To avoid crushing and shearing hazards, a delay feature is fitted which
actuates when the platform is lowered to the transport position. The platform
will momentarily stop to enable the operator to look around the machine
to determine whether any persons are adjacent to the scissor mechanism.
After a time delay, the lowering control will be enabled once
more to permit the operator to continue to lower to the transport position.
Take care to avoid repeated jerky movements which could cause
unnecessary impact loads on the structure.
Page 12 of 25 Operator’s Safety and Maintenance Handbook (Pop-Up+ dual use machine rev.0.0.1.0210)
Emergency stop
An emergency stop button is provided on the control pendant.
Once depressed, this isolates power to the raise and lower functions.
To restore functionality, twist the emergency stop button clockwise to release
the button, as shown below.
Turning the Power Selector to the ‘0’ position also has the effect of isolating
power to the raise and lower functions.
Emergency lowering
1. Pull out Plunger ‘A’ and rotate through 90 degrees.
2. Turn valve ‘B’ anticlockwise until platform starts to lower.
To stop the platform at any time, turn valve clockwise
until platform stops descending.
3. Once platform has descended full
4. Also ensure that the plunger valve is reset before operating, see
instructions for plunger valve resetting.
y, please ensure valve ‘B’
is closed off by turning clockwise.
Section 4
OPERATING INSTRUCTIONS
Page 13 of 25 Operator’s Safety and Maintenance Handbook (
Plunger ‘A’ Valve ‘B’
0120723
Pop-Up+ dual use machine rev.0.0.1.0210)
OPERATING INSTRUCTIONS
0120723
Emergency plunger valve
The plunger valve must be reset to enable the machine to operate correctly.
To reset the valve firstly ensure Valve’B’ has been fully closed. Depress
the raise button on the pendant control and raise the platform until the
maintenance stands can be deployed. Once the stands have been deployed
simply pull Plunger ‘A’ and turn through 90 degrees. Push the plunger back
into the slot as shown left.
Depress the raise button once again and reset the maintenance stands. The
machine is now able to operate correctly.
Section 4
Battery charging
A battery condition meter is fitted to the Pop-Up+ as shown. This meter
displays the amount of charge in the battery.To accurately check the battery
condition, a load must be applied across the battery, elevating the machine
from ground level will achieve this. Stand away from the machine with the
control pendant and press the UP button whilst observing the bars on the
meter. All bars illuminated shows that the battery is fully charged. If less
than four bars are on the display, the battery requires charging.
The Pop-Up+ is supplied with a dedicated battery charger, which is
separate to the machine. Do not use any other type of battery charger to
charge your Pop-Up+ machine.
To charge the battery, follow these steps:
1. Turn the power selector switch to ‘0’ (OFF) position.
2. Connect either the 240V or 110V lead (depending on mains supply)
to the Pop-Up+ at the point shown.
3. Connect the mains lead to a suitable power supply (either 110V or 240V)
4. Turn the power selector to ‘2’ (CHARGE) position and leave the charger
to complete the charging cycle. It will shut off automatically once finished.
The battery should be fully recharged after a period of 12 hours, which
is indicated by the 95% light illuminating on the battery charging indicator
panel as shown.
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Page 14 of 25 Operator’s Safety and Maintenance Handbook (
Safety during maintenance
When performing maintenance on the Pop-Up+ with the platform elevated,
always ensure that the maintenance props are engaged as shown.
WARNING
FAILURE TO ENGAGE THE MAINTENANCE PROPS MAY RESULT
IN THE PLATFORM LOWERING WITHOUT WARNING
Periodical maintenance and checks
The following checks should be undertaken at the recommended intervals shown:
Section 5
MAINTENANCE
Page 15 of 25 Operator’s Safety and Maintenance Handbook (
0120723
Daily/Pre-use Monthly 6 Monthly 12 Monthly
Inspect structure
Inspect platform
Check castors
Check manual rear brakes function
Check auto brakes function
Inspect for oil leaks
Check battery condition
Check raise/lower functions
Check emergency stop
Check emergency lower
Check stabilisers and lights function
Inspect training card and safety decals
Check hydraulic oil level
Inspect limit switches
Inspect wiring
Check electrical connectors
Lubricate roller guides
Lubricate grease nipples
Lubricate pivot pins
Lubricate castor mounts
Replace hydraulic oil
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Pop-Up+ dual use machine rev.0.0.1.0210)
Periodical maintenance and checks
(continued)
Prior to first use of the Pop-Up+, all daily/pre-use checks must be undertaken.
If the machine has been in storage for a long period of time, it may be necessary
to undertake additional checks and tests as per the table on the preceding page
(e.g. lubrication, hydraulic oil, battery condition).
The Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) require
that lifting equipment for lifting persons must be THOROUGHLY EXAMINED
every six months.
Following any maintenance on the Pop-Up+, a full function test should be
undertaken to ensure correct operation of the machine.
It is essential that only manufacturer’s approved replacement parts are used
when maintaining and servicing the Pop-Up+. Failure to do so may result in an
unsafe or unstable machine.
Storage
The electrical components of this Pop-Up+ are not protected from external
weather conditions and the machine should therefore not be stored outdoors.
Storage in a clean, dry indoor environment is recommended.
Frequent checks on the condition of the machine should be made to ensure
no excessive deterioration occurs due to the environment in which the
machine is housed.
Lubrication
The required lubrication points are shown opposite.
Lubrication points are to be found on the end of the scissor pack
at both ends of the machine.
The lubricant recommended for use with this Pop-Up+
Pop-Up+
is:
standard machine grease
Section 5
MAINTENANCE
Page 16 of 25 Operator’s Safety and Maintenance Handbook (
0120723
dual use machine rev.0.0.1.0210)
Hydraulic oil
The hydraulic oil level can be checked by removing the filler cap. The correct amount
of oil is in the tank when the tip of the level rod has hydraulic oil on it. This check must
be carried out on a level surface.
The hydraulic oil can be topped up by adding oil to the filler as shown below. Take
care not to spill hydraulic fluid over any of the surrounding machine components.
The hydraulic oil can be drained by removing the tank. Remove the bolts as shown
above and separate the tank from the pump body. The hydraulic fluid can then be
correctly disposed of.
Reassembly is the reverse of above.
Section 5
MAINTENANCE
Page 17 of 25
The hydraulic oil recommended for use with this Pop-Up+ is:
mineral basis hydraulic oil with lubricating, antifoaming, anti-corrosive,
antioxidant HL-HLP (ISO and UNI HM)-HV-HLPD performances
according to DIN51524 part 1-2 standards
Minimum viscosity
Max. viscosity at starting up
Max. working viscosity
Suggested viscosity range
Allowed temperature
Recommended temperature
15cts (23oE / 77, 39 SSU at 100oF)
800cts (105,6
o
E / 3708 SSU at 100oF)
100cts (13,2 E / 463,5 SSU at 100
o
F)
25 ÷ 40 cts = (3,47 ÷ 5,35
o
E / 119,3 ÷ 186,3 SSU a 100oF)
Max 80
o
C (176oF)
30 ÷ 60
o
C (86 ÷ 140oF)
BoltsFiller cap
Operator’s Safety and Maintenance Handbook (
0120723
Pop-Up+ dual use machine rev.0.0.1.0210)
Electrical schematic
0120723
tube Ø8, length 550
6 heat shrinked cables
A10
A6
A10
A6
international electronic line，length 450, red
international electronic line，length 450, green
2
0.3
0.3
close connect 4 lines returning from switch
and cover with pyrocondention tube Ø8, length 240
and indicating lamp with 3 lines connection terminal,
BLUE
Y
R
1010
9 9
R
V
Battery Capacity Meter
L11
FU2
L12
Electric box B
Limit Switch
Control Pendant
-880)black spring line
2
5(RV-0.5
tube Ø8, length
120 outer air plug
11 cables covered with
Heat Shrink
1
2
3
4
8 7 6 5
blue
9
blue
10
blue
11
blue G G G G G R B
blue
2
4
3
1
SQ 1
R
blue
G
Up
button
Down
button
-1100)B
2
2(RVV-0.5
2
Y
G
7
KT
TIMER
DESCENT
8
5
international elctronic line，length 450, black
2
0.3
R
BLUE
2
R
Y
Stop
button
-4100)B
2
Terminal Block
SQ (Limit switch)
BLUE
2
1
R
FM (Buzzer)
-650)B
2
2(RVV-0.5
4(RVV-0.75
G
G
R
33
1
2
1
2
BLUE
R
R
2(RVV-12-250)W
-750)B
2
3(RVV-0.75
-650)W
2
2(RVV-1
R
Y
BLUE
BLUE
B
R
88
55
44
77
66
Y
R
BLUE
2
-800)B
2(RVV-1
R
Solenoid
BLUE
-2150)B
2
2(RVV-1
YA2
L11
FU1
L12
2
-450)R
1(RV-1
B4
international electronic
2
0.3
B8
Front Stabilisers
B5
B9
2
B6
international
2
electronic line，length
0.3
1000, blue
B10
international
2
0.3
B07B11
international electronic
2
0.3
line，length 1050, red
international electronic
2
0.3
line，length 1050, black
international electronic
2
0.3
line，length 850, green
line，length 850, blue
international electronic
2
0.3
line，length 1300, green
international electronic
2
0.3
line，length 1300, blue
international electronic
2
0.3
line，length 1200, red
international
0.3
electronic line，length
1200, black
international
2
0.3
electronic line，length
1000,green
electronic line，length
1450, blue
international
2
electronic line，length
0.3
1450, blue
2
international
0.3
international electronic
2
0.3
2
international electronic
2
0.3
electronic line，length
Section 5
MAINTENANCE
SQ7 SQ6
SQ8
SQ9
+--+
SQ2
SQ3
+--+ +-+ - - ++ -
SQ4
SQ5
-++ - + -
HL3
international electronic line，length 780, red
2
0.3
international electronic line，length 780, black
2
-+
0.3
HL4
between switch
tube Ø8, length 440,
heat shrinked cable
HL1
international electronic line，length 780, red
2
0.3
international electronic line，length 780, black
2
0.3
HL2
line，length 250, red
international electronic
0.3
line，length 250, red
line，length 250, red
1450, red
Starter Solenoid
2
-100)R
1(RV-1
KM
Pump
-150)B
2
2(RVV-1
2
-750)R
1(RV-10
HL
1(RV-42-700)B（with charger）
SA1
2
2
-150)R
2
1(RV-4
-250)R
1(RV-1
-100)B
1(RV-1
-950)R
2
1(RV-1
ZN (3 position switch)
2
4
8
6
3
1
7
5
SA2
SA0
tube Ø8, length 700
6 heat shrinked cables
plug
connector, blue,
purchase according object
plug
+ -
Heat shrink tube Ø8
between switch, length 440
1
1
1
4
8
Qty
1
1
2
1
1
1
1
1
1
11111
1
40〜50
-700)R（with charger）
2
1(RV-4
CDK (Charger Socket)
*
CDZ
Charge cycle meter
The indicating lamp connector installs schematic drawing
connector, blue,
purchase according object
Diagram Key
LED Indicator
Stabiliser Switch
Stroke Limit Switch
Descent Delay Trip Switch
Timer Relay
Buzzer
Emergency Stop
Solenoi d
Article No. Description
HL1 - 4
KT
SQ
FM
SQ2 - 9
SQ1
YA1 - 2
AN3
Descent Button
AN2
Isolator Switch
Lifting Button
Fuse 10amp
DC Motor
Magnetic Switch
Power Indicator
Fuse 63amp
Charge Indicator
Charger
Battery Condition Meter
Battery
M
ZN
AN1
FU2
KM01A - KM01B
FU1
V
HL1 -
E
CDZ
CDK
-400)R
2
1(RV-10
1(RV-102-400)
2
Y
Y
YA1
R
R
1
R
Blue
B
E (Battery)
1(RV-10
-550)B
2
Page 18 of 25 Operator’s Safety and Maintenance Handbook (Pop-Up+ dual use machine rev.0.0.1.0210)
Hydraulic schematic
Section 5
MAINTENANCE
Page 19 of 25 Operator’s Safety and Maintenance Handbook (
0120723
Pop-Up+
dual use machine rev.0.0.1.0210)
Troubleshooting
Section 5
MAINTENANCE
Page 20 of 25
Platform does not raise
(motor not running)
Platform does not raise
(motor running)
Platform creeps
(uncontrolled lowering)
Oil leakage from cylinder
Oil leakage from piping or joint
Oil leakage from air breather
Problem Cause Repair
1. Faulty wiring
2. Battery is disconnected
3. Battery charge is insufficient
1. Faulty adjustment
of relief valve
2. Faulty hydraulic pump
3. Insufficient hydraulic oil
1. Oil leakage in power pack
2. Oil leakage from
hydraulic circuit
Faulty sealing
Insufficient tightening
or seal invalid
Excessive quantity of oil
1. Check the wiring referring
to the electrical schematic
2. Reconnect the battery
3. Charge the battery
1. Adjust relief valve
2. Replace power pack
3. Add hydraulic oil
1. Replace lowering valve
2. Check hydraulic circuit
and repair
Replace sealing
Tighten joint again
or replace seal
Reduce oil quantity
Operator’s Safety and Maintenance Handbook (
0120723
Pop-Up+ dual use machine rev.0.0.1.0210)
Lifting
No lifting attachment points are provided on the Pop-Up+ and therefore
lifting of the machine (e.g. with a crane or straps) is prohibited.
Preparation for transport
Prior to transporting the Pop-Up+ on a vehicle, ensure that the following
precautions are taken in order to avoid damage to the machine or damage
to the transporting vehicle.
1. Ensure that the platform is fully lowered to its rest position.
2. Ensure that loose items (e.g. control pendant, battery charger)
are secured to the platform.
3. Ensure brakes are engaged on both rear castor wheels.
4. Secure the Pop-Up+ to the transport vehicle using straps across the
platform as shown below.
Section 6
TRANSPORT INSTRUCTIONS
Page 21 of 25 Operator’s Safety and Maintenance Handbook (
0120723
Pop-Up+ dual use machine rev.0.0.1.0210)
Section 6
TRANSPORT INSTRUCTIONS
Loading and unloading
When loading or unloading the Pop-Up+, use one of the methods shown.
Page 22 of 25
When using a forklift to lift the Pop-Up+, ensure the forks are sufficiently
inserted into the forklift pockets in the base of the machine. Safety
decals applied to the Pop-Up+ show the location of the forklift pockets.
When using a tail lift to load or unload the Pop-Up+ ensure that the manual
brakes are applied to both rear castor wheels. Ensure that the capacity of the
tail lift is sufficient to handle the Pop-Up+. Take care when manoeuvring the
machine on the tail lift.
WARNING
NEVER ATTEMPT TO LOAD OR UNLOAD THE POP-UP+ BY
MANUAL EFFORT ONLY, SERIOUS INJURY, MACHINE OR
PROPERTY DAMAGE COULD RESULT
Forklift Tail lift
Operator’s Safety and Maintenance Handbook (
0120723
Pop-Up+ dual use machine rev.0.0.1.0210)
Date
Date
Date
Scheduled maintenance undertaken
Repairs undertaken
Examinations/tests undertaken
By
By
By
Maintenance
Repairs
Examinations/tests
Page 23 of 25
PLEASE PHOTOCOPY THIS PAGE FOR YOUR OWN USE, AS REQUIRED.
Section 7
MAINTENANCE AND
REPAIR RECORD
Operator’s Safety and Maintenance Handbook (
0120723
Pop-Up+ dual use machine rev.0.0.1.0210)
Page 24 of 25
Section 7
MAINTENANCE AND
REPAIR RECORD
Notes
Operator’s Safety and Maintenance Handbook (
0120723
Pop-Up+ dual use machine rev.0.0.1.0210)
Section 7
MAINTENANCE AND
REPAIR RECORD
Page 25 of 25
Daily checks – operator checklist
The following checklist has been provided to enable daily checks to be
undertaken prior to use of this Pop-Up+. These checks should be carried
out each working day or at the beginning of each shift. The purpose of the
checks is to identify any wear and tear or malfunction of the machine’s
components and systems.
WARNING
FAILURE TO UNDERTAKE THESE CHECKS MAY RESULT IN DEFECTS
ON, OR DETERIORATION OF THIS POP-UP+ GOING UNDETECTED AND
POSSIBLY RESULTING IN AN UNSAFE MACHINE
Note that Regulation 8 of the Lifting Operations and Lifting Equipment
Regulations 1998 (LOLER) require that persons using lifting equipment
have appropriate training and instructions to enable them to identify
whether lifting equipment is safe to use.
Machine number
1. Prior to operating the platform, the following items must be checked:
2. Use raise, lower and emergency stop functions to ensure correct operation.
Should any defects be identified in any of the above areas, these should be
reported to your employer. It may be necessary to further seek assistance from
the supplier of the machine, this may be the hire company or the manufacturer.
You should only rectify any defects if you are authorised and competent to do so.
Do not use the machine unless each of the items above is checked and
stated OK.
Structure
Platform
Castors
Rear manual brakes
Front auto brakes
Hydraulic oil
Oil leaks
Date
Checked by
Battery condition
Raise and lower
Emergency stop
Emergency lower
Limit switch
Safety decals
Stabilisers
(optional if Pop-Up+ is fitted with auto brakes)
OK?
(please tick) OK? (please tick)
Operator’s Safety and Maintenance Handbook (
0120723
Pop-Up+ dual use machine rev.0.0.1.0210)
At Pop-Up Products we welcome
any feedback and suggested
improvements for our products.
Please email us at
feedback@popupproducts.co.uk
You can also download a copy
of this handbook online at
www.popupproducts.co.uk
0120723
Pop-Up Products Limited
2 Deeside Point, Tenth Avenue, Deeside Industrial Park, Deeside CH5 2UA
Tel +44 (0) 1244 833 933 Fax +44 (0) 1244 833 934 Email contact@popupproducts.co.uk
www.popupproducts.co.uk
Pop-Up Products Limited
Call +44 (0) 1244 833933
Email contact@popupproducts.co.uk
www.popupproducts.co.uk
IPS Service, Parts & Warranty
Service +44 (0)1952 671 400
Parts & Warranty +44 (0) 1952 607 660
www.ips-ltd.biz
0120723
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