POP UP IQ LIFT PRO10, Maintenance & Troubleshooting Handbook

Page 1: ...PUSH AROUND MOBILE ELEVATING WORK PLATFORM PRO10 SN E21 15001 SUPO 759 REV C 44 0 1244 833 933 info popupproducts co uk popupproducts co uk MAINTENANCE TROUBLESHOOTING HANDBOOK ...

Page 2: ...NOTES MAINTENANCE TROUBLESHOOTING IQ LIFT SUPO 759 REV C 2 ...

Page 3: ...NOTES MAINTENANCE TROUBLESHOOTING IQ LIFT SUPO 759 REV C 3 ...

Page 4: ...READ AND UNDERSTOOD PRIOR TO OPERATING THE MACHINE The user operator should not accept operating responsibility until the handbook has been read and understood as well as having operated the machine under supervision of an experienced and qualified operator Because the manufacturer has no direct control over machine application and operation proper safety practices are the responsibility of the us...

Page 5: ...rmation be sure to include the MODEL and SERIAL NUMBER The serial number plate is located in the rear right wheel well Should the nameplate be missing there is an additional serial number label located inside the chassis FOREWORD MAINTENANCE TROUBLESHOOTING IQ LIFT SUPO 759 REV C 5 ...

Page 6: ...CHECKS 13 2 8 STORAGE 13 2 9 MAJOR ALTERATIONS OR REPAIRS 13 SECTION 3 INSPECTION 14 3 1 INSPECTION MAINTENANCE SCHEDULE 14 3 2 INSPECTION CHECKLIST PRE DELIVERY ANNUAL FREQUENT 16 3 3 INSPECTION CHECKLIST PRE START 17 SECTION 4 TECHNICAL REFERENCES 18 4 1 HYDRAULIC SCHEMATIC 18 4 2 ELECTRICAL SCHEMATIC 20 4 3 WIRING DIAGRAM 22 4 4 EZLIFT DIAGNOSTICS 24 4 5 TROUBLESHOOTING FLOWCHART POWER 26 4 6 T...

Page 7: ...9 FIGURE 3 Battery Charge Location 11 FIGURE 4 Battery Location 12 FIGURE 5 Cylinder Grease Points 13 FIGURE 6 Control Tray Access 15 FIGURE 7 Side Access 15 FIGURE 8 EZcal Diagnostic Connection 24 FIGURE 9 Diagnostic LED Location 24 MAINTENANCE TROUBLESHOOTING IQ LIFT SUPO 759 REV C 7 ...

Page 8: ...and instructions that have a direct impact on safety are identified with the following signals 1 2 GENERAL RULES AND PRECAUTIONS An operator of any type of work platform is subject to certain hazards that cannot be protected by mechanical means It is therefore essential that operators be competent careful physically and mentally fit and thoroughly trained in safe operation of this machine It is th...

Page 9: ...ther maintenance ALWAYS disconnect battery during replacement of electrical components ALWAYS remove all rings watches and jewelry when performing any maintenance ALWAYS keep oil grease water etc wiped from standing surfaces and handholds ALWAYS keep all support equipment and attachments stowed in their proper place ALWAYS use only approved nonflammable cleaning solvents NEVER work under an elevat...

Page 10: ...y over charged NOTE The surrounding temperature greatly affects the power reserve within a battery EXAMPLE A battery that is 100 charged at 27 C drops to 65 at 0 C At 18 C this battery will drop to 40 efficiency BATTERIES GENERATE EXPLOSIVE GASES KEEP SPARKS AND FLAME AWAY FROM BATTERIES DO NOT SMOKE WHILE CHARGING To charge the battery Park the machine on a level surface Plug charger into AC outl...

Page 11: ...uts are delivering D C current to the batteries This display indicates that power is on and that the output is finished charging and is in a float maintenance model FIGURE 3 Battery Charge Location POWER BATTERY 1 STATUS CHARGING READY Green LED ON Red LED OFF Green LED ON Green LED ON Red LED ON Green LED OFF Green LED ON Red LED OFF Green LED ON POWER BATTERY 1 STATUS CHARGING READY POWER BATTER...

Page 12: ...capacity they also accelerate corrosion and reduce overall battery life 2 3 BATTERY MAINTENANCE WET CELL BATTERIES If this unit is equipped with a deep cycle 12 volt Group 27 battery the care and maintenance of your battery has much to do with how well this unit functions Battery wiring and water level should be checked monthly Do not overfill When the cells are too full fluid will seep out when c...

Page 13: ...owering Automatic Brakes Tilt Interlock Check that the machine will not elevate if overloaded as part of routine inspection Refer to the Pre delivery Annual Checklist included in this handbook 2 8 STORAGE After periods of storage exposure to extremes of ambient conditions heat cold moisture dust etc inspect the machine Batteries will need to be charged Refer to the Pre Delivery Frequent Inspection...

Page 14: ...ery Inspection Annually or as needed Contact the manufacturer for additional information After major alterations or repairs which affect stability strength or performance FAILURE TO PERFORM INSPECTIONS AND PREVENTATIVE MAINTENANCE AT RECOMMENDED INTERVALS MAY RESULT IN THE UNIT BEING OPERATED WITH A DEFECT THAT MAY RESULT IN INJURY OR DEATH OF THE OPERATOR The following inspection checklists are r...

Page 15: ... tray can be opened for routine inspection checking hydraulic fluid level batteries etc If additional access is needed the side panel may be removed FIGURE 6 Control Tray Access FIGURE 7 Side Access MAINTENANCE TROUBLESHOOTING IQ LIFT SUPO 759 REV C 15 ...

Page 16: ... Battery Hold Downs Secure Entrance gate closes freely Battery Fully Charged Check battery Voltage 12 5V charge Anchorage point and the supporting platform floor are secure and not deformed Hydraulic Oil Level Cables in place secure Check all hydraulic hoses for leaks FUNCTIONS Y N R Check all hydraulic fittings for leaks Elevate Lower Operational Upper Lower Ctl Front and Rear wheels rotate freel...

Page 17: ...and push buttons for proper operation Emergency Stop Stops all movement Key Switch Selects Platform Control Ground Control or Off Alarm Not damaged sounds for descent Up Down Rocker Switch Elevates Lowers Enable button must be pressed Lowering Delay Delay when lowering re activate descent switch to continue Emergency Lowering functions Machine will not elevate when on a slope greater than 1 5 Whee...

Page 18: ...ASSEMBLY APPROX 1800 PSI TESTPORT HYDRAULICPUMP ASSEMBLY 0 627 CC REV 0 038 IN 3 REV PRESSURE RELIEF A B C D 5 6 7 8 8 7 6 5 THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO THE MANUFACTURER AND IS LOANED IN EXPECTATI MAINTENANCE TROUBLESHOOTING IQ LIFT SUPO 759 REV C 18 ...

Page 19: ...E HYD SCH IQ LIFT SCALE 1 1 DO NOT SCALE DRAWING ION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED SPEC MATL Schematic DRAWING HS 177 20 001 51 REV DESCRIPTION OF CHANGE DATE REV BY A INITIAL RELEASE 06 21 2018 DJS ECO 2017 0014 SHEET 1 OF 1 WEIGHT APPROX 0 00 LB A MAINTENANCE TROUBLESHOOTING IQ LIFT SUPO 759 REV C 19 ...

Page 20: ...20A FUSE 250A LWR E STOP LWR ENABLE OFF OFF LWR UP DN G 6 F 6 D 4 D 3 D 2 D 1 TAB 1 KEY SW UPR E STOP F 8 G 8 A B C D 5 6 7 8 8 7 6 5 THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO THE MANUFACTURER AND IS LOANED IN EXPECTATI MAINTENANCE TROUBLESHOOTING IQ LIFT SUPO 759 REV C 20 ...

Page 21: ... 10 A 9 B 4 B 2 B 5 B 6 B 8 C 4 C 3 C 2 C 1 G 1 F 1 TAB 2 F 5 H 1 J 1 H 2 J 2 F 7 G 7 OL LWR CTL UPR ENABLE C B A 1 2 3 4 4 3 2 1 B SIZE ORIGINALLY DRAWN BY Pop Up Products Limited DATE ELEC SCH IQ LIFT SCALE 1 1 DO NOT SCALE DRAWING ION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED SPEC MATL Schematic DRAWING WS 177 20 001 51 REV DESCRIPTION OF CHANGE DATE...

Page 22: ... SWITCH C 1 3 2 4 D 2 1 BUTT 3 1 2 BUTT 4 4 3 2 1 E UP COIL PUMP MOTOR M POW SOL LWR POWER LED LWR OL ED 1 2 3 4 1002103851 177 21 007 50 177 21 009 50 177 21 010 50 177 21 011 50 177 21 021 50 1002101650 1002101650 143 01 025 50 143 01 025 50 A B C D 5 6 7 8 8 7 6 5 THIS DRAWING IS CONFIDENTIAL AND PROPRIETARY TO THE MANUFACTURER AND IS LOANED IN EXPEC MAINTENANCE TROUBLESHOOTING IQ LIFT SUPO 759...

Page 23: ...NO 3 4 LWR ENABLE 3 2 1 4 CONNECTOR C D E 177 21 019 50 177 21 017 50 TAB1 TAB2 177 21 018 50 C B A 1 2 3 4 4 3 2 1 B SIZE ORIGINALLY DRAWN BY Pop Up Products Limited DATE WD IQ LIFT SCALE 1 1 DO NOT SCALE DRAWING CTATION THAT IT WILL BE KEPT CONFIDENTIAL AND USED ONLY FOR THE PURPOSE FOR WHICH IT IS LOANED SPEC MATL Schematic DRAWING WD 177 20 001 51 REV DESCRIPTION OF CHANGE DATE REV BY A Initia...

Page 24: ...n be connected to the diagnostic port on the lower control panel to provide access to a number of menus for diagnostic purposes FIGURE 9 Diagnostic LED Location If an EZcal is not available an LED on the control board may be viewed to display flash codes MAINTENANCE TROUBLESHOOTING IQ LIFT SUPO 759 REV C 24 ...

Page 25: ...ide the enable button to keep it in the active position or inadvertently pushed the button etc 4 4 FUNCTIONS LOCKED BATTERY Battery charge is less than 10 8V 6 3 FUNCTIONS LOCKED ELEVATION SWITCH Problem with the elevation switch Lift did not get up in the expected time 3 5 FUNCTIONS LOCKED MOTOR LOADED Problem with the pump motor 3 5 FAULT MOTOT OVERLOAD Problem with the pump motor 3 5 FAULT MOTO...

Page 26: ... and lower control locations Connect battery WARNING Any modification on this machine without the express consent of the manufacturer is prohibited See Wiring Diagram See also Wiring Diagram Or Electrical Schematic Unplug the charger Machine should not be operated while battery is charging Troubleshooting Flowchart IQ LIFT Power Troubleshooting Step 1 Main Power Is the power light on the lower con...

Page 27: ...referenced document If not continue troubleshooting If a part has been identified as needing replacement see the Parts Manual to identify part number to order If any wiring or components have been altered from the original manufacture problems may not be identifiable WARNING Failure to comply with safety precautions may result in damage injury or death Refer to Maintenance Manual for complete warn...

Page 28: ...ed position before continuing use Yes No No Yes Yes WARNI Any modification on th the express consent o is prohib See also Wiring Diagram or Electrical Schematic And Hydraulic Schematic Yes WARNING Set up for maintenance safety Remove load from platform Check for overhead obstructions Platform movement may occur Never Reach between scissors links or prop up platform unless maintenance chock is in p...

Page 29: ... problems may not be identifiable ING his machine without of the manufacturer bited WARNING Failure to comply with safety precautions may result in damage injury or death Refer to Maintenance Manual for complete warnings Check wiring connections in elevate components See Electrical Schematic Yes No No Level of skill with hydraulic maintenance Are power connections to elevate circuit and switches f...

Page 30: ...NG Any modification on this machine the express consent of the manu is prohibited See also Wiring Diagram Electrical Schematic And Hydraulic Schematic WARNING Set up for maintenance safety Remove load from platform Check for overhead obstructions Platform movement may occur Never Reach between scissors links or prop up platform unless maintenance pins are in place Yes but not properly No No WARNIN...

Page 31: ...arts Manual to identify part number to order If any wiring or components have been altered from the original manufacture problems may not be identifiable e without ufacturer WARNING Failure to comply with safety precautions may result in damage injury or death Refer to Maintenance Manual for complete warnings Check wiring connections in lowering components See Electrical Schematic tery Yes No OK N...

Page 32: ...replacement parts is included in this handbook These represent current model revisions A full parts handbook is available from Pop Up Products The following materials require special means of disposal HYDR 032 Hydraulic fluid Do not dispose in a drain to water source Take to a recycling center ELEC 047 4 or ELEC 047 5 Batteries Take to a recycling center The following list is a partial list of com...

Page 33: ...072 CONTACT BLOCK NO ELEC 603 ROCKER SWITCH ELEC 133B CHARGER 12V 06A PCS ELEC 746 GATE SPRING HARD 302 BRAKE SPRING HARD 690 HYDRAULIC OIL FLUID HYDR 032 Not available as a replacement part Replace with Flomite 150 Dexron II Mobil DTE 2 or equivalent 32 weight implement oil DOWN VALVE HYDR 007 2E 5 SWIVEL CASTER ASSEMBLY WHEE 764 WHEEL 700 MM WHEE 765 HANDBOOK BOX 8 5X11X1 W GASKET HARD 603 MAINT...

Page 34: ...AND REPAIR LOG Model _____________________________ Serial Number _____________________________ Date By Maintenance Examination or Repair Comments PLEASE DUPLICATE THIS PAGE AS NEEDED FOR YOUR OWN USE MAINTENANCE TROUBLESHOOTING IQ LIFT SUPO 759 REV C 34 ...

Page 35: ...Date By Maintenance Examination or Repair Comments PLEASE DUPLICATE THIS PAGE AS NEEDED FOR YOUR OWN USE SECTION 6 INSPECTION AND REPAIR LOG MAINTENANCE TROUBLESHOOTING IQ LIFT SUPO 759 REV C 35 ...

Page 36: ...ubleshooting Handbook 2018 Pop Up Products Limited Unit E1 Tenth Avenue Deeside Industrial Park Deeside Flintshire CH5 2UA Tel 44 0 1244 833 933 E mail support popupproducts co uk Website popupproducts co uk Revision Date June 2018 ...