At POP-UP PUSH 6 ECO 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
Page 3
POP-UP PUSH 6 ECO PUSH 6 ECO
Operator’s Safety and Maintenance
Contents
Section 1 Page
DESCRIPTION
Introduction 3
Description 3
Intended use 3
Training 3
Modifications 3
Terminology 5
Section 2
SPECIFICATION
Technical data 6
Operating site 7
Noise and vibration 7
Limitations 7
Section 3
SAFETY RULES
Safety Rules 8
Section 4
OPERATING INSTRUCTIONS
Daily checks 9
Manoeuvring the platform 9
Engaging the brakes 10
Powering up 10
Entering and leaving the platform 11
Control pendant 11
Emergency stop 12
Emergency lowering 12
Battery charging 12
Loading and unloading 19
Lifting 20
Preparation for transport 20
Section 7
MAINTENANCE AND
REPAIR RECORD
Maintenance and repair record 21
Notes 22
Daily checks – operator checklist 23
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 4
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.
An abridged set of instructions in the form of a training card and a training sticker
can also be found attached to the POP-UP PUSH 6 ECO PUSH 6 ECO at the control pendant and toe board respectively.
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 PUSH 6 ECO Products Ltdoperate a policy of continuous improvement
and therefore reserve the right to make product changes at any time without obligation.
Section 1
DESCRIPTION
Description
The POP-UP PUSH 6 ECO PUSH 6 ECO is a scissor lift type work platform, which
is manoeuvred manually into work positions and elevated and lowered using an
electro-hydraulic control system.
The standard machine includes the following standard features:
• 240kg safe working load• Steerable wheels
• 3.63 metre working height• Brakes on two wheels
• 1.65 metre stowed height• Battery powered with
• Easily manoeuvrablebuilt-in battery charger
• Weighs just 225kg• Emergency lowering facility
• Pass through standard doors• Easily transportable
• Simple operation• Low maintenance
• Steel guard rails• Complies with EN280:2001
• Non-slip platform
Intended use
The machine has been designed to comply with the safety requirements of the
Machinery Directive 98/37/EC taking guidance from the European Standard
EN280:2001 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
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 5
Section 1
DESCRIPTION
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 6
Training
Section 1
DESCRIPTION
Since POP-UP PUSH 6 ECO
PUSH 6 ECO is classed as ‘work
equipment’ it also falls within the
scope of the Provision and Use of
Work Equipment Regulations 1998
(PUWER). Regulation 9 of PUWER
requires that persons using this
equipment have received adequate
training.
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
A full Operator’s Safety & Maintenance handbook is provided with
the equipment which forms the basis
of training on and familiarisation of
the equipment. Safety decals are
also fitted to the machine to warn
the operator and other personnel of
potential hazards whilst the machine
is in use.
WARNING
OPERATION OF THIS MACHINE
BY UNTRAINED OPERATORS
MAY RESULT IN SERIOUS INJURY
OR DEATH
Modifications
Page 5 of 23
Page 7
Technical data
Section 2
SPECIFICATION
Safe working load (SWL)
equivalent to
Maximum platform height1.63 metres
Maximum working height3.63 metres
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 8
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 PUSH 6 ECO PUSH 6 ECO 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.
2. Ground flatness
The POP-UP PUSH 6 ECO PUSH 6 ECO must only be operated on flat (0º chassis
inclination) and level surfaces. The allowable chassis inclination is indicated when
the bubble spirit level is within the marked limits. All castor wheels must be in full
contact with the ground.
3. Overhead obstructions
Ensure that adequate clearance is available above and around the platform before
elevation.
Section 2
SPECIFICATION
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 2.5 m/s2.
Limitations
The POP-UP PUSH 6 ECO PUSH 6 ECO is intended for use INDOORS ONLY,
and must not be used outdoors as wind forces may make it unstable.
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
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 9
Safety Rules
NEVER Exceed the rated capacity (Safe Working Load or SWL) of the platform
(240kgs).
NEVER Use the POP-UP PUSH 6 ECO PUSH 6 ECO 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 Operate the POP-UP PUSH 6 ECO PUSH 6 ECO if the bubble spirit
level is outside the marked limits.
NEVER Manoeuvre the POP-UP PUSH 6 ECO PUSH 6 ECO on an inclined
surface otherwise it may become uncontrollable.
NEVERManoeuvre the POP-UP PUSH 6 ECO PUSH 6 ECO whilst in its
elevated position, as this may cause instability.
NEVER Manoeuvre the POP-UP PUSH 6 ECO with a person or materials in
the platform.
NEVER Enter or exit the platform unless the platform is in the lowered and
transport position.
Section 3
SAFETY RULES
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 (unless in an emergency situation).
NEVER Operate the POP-UP PUSH 6 ECO outdoors, it has not been
designed to withstand wind loading.
ALWAYSUndertake the daily checks recommended in this handbook p.9 prior
to operation of the machine.
ALWAYSEnsure that all instructions, Safe Working Load and warning decals
are clean and legible.
ALWAYSEnsure the POP-UP PUSH 6 ECO is positioned on adequate ground
to support the weight of the machine.
ALWAYSEnsure that sufficient clearance is given if working near to live
conductors.
ALWAYSEnsure that the castor brakes have been locked before elevating the
work platform.
ALWAYSEnsure 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 areas to prevent persons entering the danger
area).
ALWAYS Ensure hands are kept within the confines of the handrail when
operating the machine.
ALWAYS Ensure that the area below the platform is clear of obstruction before
lowering.
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 10
OPERATING INSTRUCTIONS
Daily checks
Prior to operating the POP-UP PUSH 6 ECO, the following items must be checked:
If the above checks reveal malfunctions or damage on the POP-UP PUSH 6
ECO, 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.
WARNING
BEFORE OPERATING YOUR POP-UP PUSH 6 ECO, 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
• Oil leaks
• Battery condition
• Raise and lower functions
• Emergency stop and lowering
functions
• Safety decals and
training card
Manoeuvring the platform
Manoeuvre the platform into position using both hands on the guard rails at
gate end. Take care to avoid trapping hands or feet whilst manoeuvring the
platform.
Never manoeuvre the POP-UP PUSH 6 ECO whilst it is elevated or with a
person, tools or materials in the platform.
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 11
OPERATING INSTRUCTIONS
Engaging the brakes
Always ensure that both castor brakes are locked before elevating the work platform to prevent any inadvertent movement.
The brakes are engaged by pushing down on the lever and pulling up the lever as
shown.
Brake off Brake on
Section 4
Powering up
The POP-UP PUSH 6 ECO 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, first turn the Maintenance Isolater switch to
position ‘1’ (ON) and insert the key into the emergency stop button. Turn clockwise
to release the button. Ensure that when the machine is not in use, the emergency
stop button is depressed and the key is removed. Turn the Maintenance Isolator
switch to position ‘0’ (OFF).
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 12
OPERATING INSTRUCTIONS
Entering and leaving
the work platform
Always use three points of contact when entering or exiting the platform, using the
guard rails 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.
Take care to avoid repeated jerky movements which could cause
unnecessary impact loads on the structure.
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 13
OPERATING INSTRUCTIONS
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 Maintenance Isolator switch to the ‘0’ position also has the effect of
isolating power to the raise and lower functions.
Section 4
Emergency lowering
To lower the platform in the event of an emergency, a control is provided at
the chassis.
Turning the knob in an ANTICLOCKWISE direction, as shown, opens the
lift valve. Once the valve is fully open the platform will lower, at this point
please stand back to ensure your safety. Always close the valve after use.
Battery charging
A battery condition meter is fitted to the POP-UP PUSH 6 ECO as shown.
To check the battery condition, elevate the platform from ground level
whilst at the same time pressing the red button above the battery condition
meter. This is the only way to obtain an accurate reading. The battery will
require charging if there is less than 4 bars on the display. Do not attempt
to use the machine in this state as battery damage may occur. Never
allow the battery to run completely flat as this damages the cells and can
lead to premature battery failure. It is good practice to charge the battery
daily to ensure optimum battery condition. The POP-UP PUSH 6 ECO is
supplied with a built-in multi voltage automatic battery charger, for supply
voltages between 90V and 240V AC. The battery charger is located on the
underside of the platform.
To charge the battery, follow these steps:
1. Turn the Maintenance Isolator switch to ‘0’ (OFF) position.
2. Connect the battery charger lead to the POP-UP PUSH 6 ECO at the
point shown.
3. Connect the battery charger to the power supply (either 110V or 240V
AC at 50 Hz depending on the mains supply).
4. Turn the Maintenance Isolator switch to ‘2’ (CHARGE) position.
5. The battery should be fully recharged once the 95% LED is illuminated
on the charging indicator.
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 14
Safety during maintenance
When performing maintenance on the POP-UP PUSH 6 ECO 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
Section 5
MAINTENANCE
Periodical maintenance and checks
The following checks should be undertaken at the recommended intervals shown:
Daily/Pre-useMonthly6 Monthly12 Monthly
Inspect structure
Inspect platform
Check castors
Check brake function
Inspect for oil leaks
Check battery condition
Check raise/lower functions
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 PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 15
Periodical maintenance and checks
(continued)
Prior to first use of the POP-UP PUSH 6 ECO, 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 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 PUSH 6 ECO, 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 PUSH 6 ECO.
Failure to do so may result in an unsafe or unstable machine.
Storage
Section 5
MAINTENANCE
The electrical components of this POP-UP PUSH 6 ECO 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 listed as per the table on the preceding page.
These include: roller guides, grease nipples, pivot pins and castor mounts.
The lubricant recommended for use with this POP-UP PUSH 6 ECO is: standard
machine grease.
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 16
Hydraulic oil
The hydraulic oil level can be checked by removing the filler cap fitted to the
hydraulic oil tank shown below. The correct amount of oil is in the tank when
hydraulic fluid appears on the tip of the dipstick. This check must be carried out
with the platform in the fully lowered position.
The hydraulic oil can be topped up by adding oil to the filler as highlighted
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 4 bolts as
highlighted below 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
Filler cap/dipstick Oil filler Bolts
The hydraulic oil recommended for use with this POP-UP PUSH 6 ECO
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 viscosity15cts (23oE / 77,39 SSU at 100oF)
Max. viscosity at starting up800cts (105,6oE / 3708 SSU at 100oF)
Max. working viscosity100cts (13,2 E / 463,5 SSU at 100oF)
Suggested viscosity range25 ÷ 40 cts = (3,47 ÷ 5,35o E / 119,3 ÷ 186,3 SSU a 100oF)
Allowed temperatureMax 80oC (176oF)
Recommended temperature30 ÷ 60oC (86 ÷ 140oF)
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 17
Electrical schematic
Pendant Control
Section 5
MAINTENANCE
Lock Out Switch
Emergency Stop
Warning Buzzer
Switch
Limit Switch
Stroke Travel
Panel
Meter
63A Fuse
4A Fuse
Hydraulic Pack DC Motor
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
Changeover Switch
Charger Cycle Mete r
Page 16 of 23
Page 18
Hydraulic schematic
CYLINDER
512610-000
DAMPER
VALVE 512728-000
Section 5
MAINTENANCE
CHECK VALVE
MOTOR
VALVE
FILTER
RELIEF VALVE
PUMP
FILTER
RESERVOIR
HYDRAULIC CIRCUIT
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 19
Troubleshooting
ProblemCauseRepair
Section 5
MAINTENANCE
Platform does not raise
(hydraulic pack motor
not running)
Platform does not raise
(hydraulic pack motor
running)
Platform creeps
(uncontrolled lowering)
Oil leakage from cylinderFaulty sealingReplace sealing
Oil leakage from hydraulic pipesInsufficient tightening or seal
Oil leakage from air breather
( ller cap)
1. Faulty wiring1. Check the wiring by referring
to the electrical schematic
diagram p.16
2. Battery is disconnected2. Reconnect the battery
3. Battery charge is insufficient3. Charge the battery
1. Faulty adjustment of relief
valve
2. Faulty hydraulic pump2. Replace power pack
3. Insufficient hydraulic oil3. Add hydraulic oil
1. Oil leakage in power pack1. Replace lowering valve
2. Oil leakage from hydraulic
circuit
invalid
Excessive quantity of oilReduce oil quantity
1. Adjust relief valve
2. Check hydraulic circuit and
repair
Tighten joint again or replace
seal
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 20
TRANSPORT INSTRUCTIONS
Loading and unloading
When loading or unloading the POP-UP PUSH 6 ECO, use one of the methods
Forklift Tail lift
shown.
Section 6
When using a forklift to lift the POP-UP PUSH 6 ECO, ensure the forks are
sufficiently inserted into the forklift pockets in the base of the machine. Please see
the location of the forklift pockets below.
When using a tail lift to load or unload the POP-UP PUSH 6 ECO ensure that
brakes are applied to both castors. Ensure that the capacity of the tail lift is
sufficient to handle the POP-UP PUSH 6 ECO. Take care when manoeuvring the
machine on the tail lift.
Fork lift pocket Winch point
When winching the machine onto or off a vehicle, ensure that the winch is
connected to the winch point as shown below. Ensure personnel are available to
guide the machine whilst the winch is in operation.
WARNING
NEVER ATTEMPT TO LOAD OR UNLOAD THE POP-UP PUSH 6 ECO BY
MANUAL EFFORT ONLY, SERIOUS INJURY, MACHINE OR PROPERTY
DAMAGE COULD RESULT
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 21
TRANSPORT INSTRUCTIONS
Lifting
No lifting attachment points are provided on the POP-UP PUSH 6 ECO and therefore lifting of the machine (e.g. with a crane or straps) is prohibited. If lifting of the
machine is required, please contact the manufacturer for further details.
Preparation for transport
Prior to transporting the POP-UP PUSH 6 ECO 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 the control pendant is in its cradle.
3. Ensure brakes are engaged on both castors.
4. Secure the POP-UP PUSH 6 ECO to the transport vehicle using straps through
the forklift pockets as shown below.
Section 6
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 22
MAINTENANCE AND
REPAIR RECORD
Maintenance
DateScheduled maintenance undertaken By
Section 7
Repairs
DateRepairs undertaken By
Examinations/tests
DateExaminations/tests undertaken By
PLEASE PHOTOCOPY THIS PAGE FOR YOUR OWN USE, AS REQUIRED.
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 23
Notes
Section 7
MAINTENANCE AND
REPAIR RECORD
At POP-UP Products we welcome any feedback and suggested improvements
for our product. Please email us at feedback@popupproducts.co.uk
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 24
Daily checks – operator checklist
The following checklist has been provided to enable daily checks to be
undertaken prior to use of this POP-UP PUSH 6 ECO. 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 PUSH 6 ECOGOING 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.
Section 7
MAINTENANCE AND
REPAIR RECORD
Machine number
1. Prior to operating the platform, the following items must be checked:
(please refer to the relevant sections in this handbook for more detail.)
OK? (please tick)OK? (please tick)
StructureBattery condition
PlatformRaise and lower
CastorsEmergency stop
BrakesEmergency lower
Oil leaksSafety decals and training card
Date
Checked by
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 supervisor or
employer. It may be necessary to seek further 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.
Pop-Up PUSH 6 ECO Operator’s Safety and Maintenance Handbook (v.0.4.0409)
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Page 25
At POP-UPProducts 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