Upright TL49K User manual

Operator Manual
This first section of the Operator manual is the English language version.
Betriebsanleitung
Im zweiten Abschnitt dieser Betriebsanleitung finden Sie die Deutsche Version.
Manuel Utilisateur
La troisième section de ce manuel est la version en langue Française.
Manual del Usuario
El apartado cuarto de este manual del usuario corresponde a la versión en Españo.
Manuale d’Uso
La quinta sezione di questo manuale d'uso è la versione in lingua Italiana.
(EN) Manual part number 508159-000 for serial numbers 8000 to current.
(DE) Bestellnummer 508159-000 ab Seriennummer 8000 fortlaufend.
(FR) Manuel Pièce numéro 508159-000 pour numéro série 8000 jusqu'au
numéro courant.
(ES) El número de referencia para el manual es el 508159-000 para la números
de serie del 8000 hasta el actual.
(IT) Manuale Ricambi Numero 508159-000 per Numeri di Serie da 8000
all’attuale.
TL49K
Feb 08

www.upright.com
ENGLISH
When contacting UpRight for service or parts information, be sure to include the MODEL and SERIAL NUMBERS
from the equipment nameplate. Should the nameplate be missing, the SERIAL NUMBER is also stamped on top of
the chassis bhind the toe hitch.
TL49K
Serial Numbers 8000 – Current
Serial number stamped on chassis behind the
toe hitch and above the Vehical Identification
Number Plate.

TL49K 508159-000
USE OF THE AERIAL WORK PLATFORM: This aerial work platform is intended to lift persons and his tools as
well as the material used for the job. It is designed for repair and assembly jobs and assignments at overhead
workplaces (ceilings, cranes, roof structures, buildings etc.). All other uses of the aerial work platform are prohib-
ited!
THIS AERIAL WORK PLATFORM IS NOT INSULATED! For this reason it is imperative to keep a safe distance
from live parts of electrical equipment!
Exceeding the specified permissible maximum load is prohibited! See “Special Limitations” for details.
The use and operation of the aerial work platform as a lifting tool or a crane (lifting of loads from below upwards or
from up high on down) is prohibited!
NEVER exceed the manual force allowed for this machine. See “Special Limitations” for details.
DISTRIBUTE all platform loads evenly on the platform.
NEVER operate the machine without first surveying the work area for surface hazards such as holes, drop-offs,
bumps, curbs, or debris; and avoiding them.
OPERATE machine only on surfaces capable of supporting wheel loads.
NEVER operate the machine when wind speeds exceed this machine’s wind rating. See “Beaufort Scale” for de-
tails.
IN CASE OF EMERGENCY push EMERGENCY STOP switch to deactivate all powered functions.
IF ALARM SOUNDS while platform is elevated, STOP, carefully lower platform. Move machine to a firm, level
surface.
Climbing up the railing of the platform, standing on or stepping from the platform onto buildings, steel or prefab
concrete structures, etc., is prohibited!
Dismantling the swing gate or other railing components is prohibited! Always make certain that the swing
gate is closed and securely locked!
It is prohibited to keep the swing gate in an open position (held open with tie-straps) when the platform is raised!
To extend the height or the range by placing of ladders, scaffolds or similar devices on the platform is prohibited!
NEVER perform service on machine while platform is elevated without blocking elevating assembly.
INSPECT the machine thoroughly for cracked welds, loose or missing hardware, hydraulic leaks, loose wire con-
nections, and damaged cables or hoses before using.
VERIFY that all labels are in place and legible before using.
NEVER use a machine that is damaged, not functioning properly, or has damaged or missing labels.
To bypass any safety equipment is prohibited and presents a danger for the persons on the aerial work platform
and in its working range.
NEVER charge batteries near sparks or open flame. Charging batteries emit explosive hydrogen gas.
Modifications to the aerial work platform are prohibited or permissible only at the approval by UpRight.
AFTER USE, secure the work platform from unauthorized use by turning both keyswitches off and removing key.
! WARNING !
Safety Rules
All personnel shall carefully read, understand and follow all safety rules and operating in-
structions before operating or performing maintenance on any UpRight aerial work platform
NEVER
climb, stand, or sit on
p
latform
g
ua rd ra i ls or m id ra il.
NEVER
position the platform
without first checking for overhead
obst ructions or other hazards.
NE VER elevate the platform or drive
t he m ach ine while elevat ed u nless the
machine is on a firm
,
le ve l s ur face .
Electrocution Hazard Ti
p
Over Hazard Collision Hazard Fall Hazard
This Machine is NOT
Insulated

2 508159-000 TL49K
Page
Introduction 3
DescriptionofEquipment 4
Technical Specification 5
WorkingEnvelope 6
OperatorRequirements 7
WarningNotices 8
.Beaufort Scale 9
TowingInstructions 10
Hand Manoeuvring (Friction Drive Option) 12
Pre-StartChecks 13
PowerSupply 19
Batteries,&PowerPack 15
SettingUp 16
ExtendingStructure 18
.Basket Controls 18
.Ground Controls 20
SafetyHarness 21
Emergency Controls
.Emergency Stops 21
.Emergency Lower (Electronically) 22
.Emergency Lower (Manually) 23
.Emergency Raise Outriggers 24
.Emergency Cage Overload 24
.Emergency Battery Isolation 25
StowingtheMachine 26
Maintenance
.Daily Checks 27
.Weekly and Monthly Checks 28
.Slew Drive and Limit Switches 29
.Trailer Lighting Diagram 30
Appendices
Petrol/Bi-fuel Option. 31
Generator Option. 32
Mains connection. 33
CONTENTS

TL49K 508159-000 3
The UpRight TL49K is a class leader, offering several features as standard that
other manufacturers only provide as optional extras.
These include powered basket rotation and fully proportional hydraulic controls, at
both basket and ground level.
The third flick boom, with 130 DEGREES working arc, guarantees access to the
most hard to reach places, while the 90 DEGREES basket rotation provides the
precision positioning that is vital for working in tight spaces.
UpRight Powered Access has a global reputation for innovation and a proud
heritage in the design and manufacture of high quality powered access equipment.
The company was founded in the UK more than 25 years ago, on the principle of
constantly improving service excellence for end users.
Every model in our growing range of versatile, trailer mounted units is a class
leader and together they have set new industry benchmarks.
Our commitment to research and design, plus 250,000sq ft of same site
fabrication, build and support capacity, mean UpRight can offer complete solutions
to meet even the most demanding access applications.
UpRight has third party accreditation to quality standard ISO 9001 and the full
range carries the CE mark, complying with or exceeding all relevant standards and
EC directives.
UpRight Powered Access is a member of the
International Powered Access Federation (IPAF).
INTRODUCTION
The information contained in this type of box contains, WARNING
text. It gives Warnings about the risk of Damage to equipment,
and possibly personnel.
!
This type of box contains, Points of operation to NOTE.
The information contained in this type of box contains, DANGER
text. It gives Warnings about the risk of PERSONAL INJURY to the
operator and or others.
1
To ensure you are fully aware of safety and operational information, the
following symbols are used throughout this manual;

4 508159-000 TL49K
The UpRight TL49K is of the parallel linkage vertical boom design, mounted on a
road towable trailer. The unique, yet very simple boom configuration gives the
maximum safety and control ability combined with a robust construction to
withstand a heavy working environment
The TL49K machine is designed for two man capacity (200 kg S.W.L.).
The machine incorporates a bottom boom with tie-rod, a short vertical boom and a
top boom with a telescope section. The TL49K also has an independent
hydraulically operated flick-out boom and rotating cage for extra manoeuvrability.
The hydraulic system is of a failsafe design throughout, with built in hydraulic lock
valves on all of the rams as a precaution against hose failure. The machine is
controlled by means of proportional manual controls of the ‘direct hand’ lever
operating type. These valves are located at both the base and in the cage, as
standard.
Electrically operated emergency lowering valves are fitted as standard to allow the
machine to be lowered from the base and basket.
The hydraulically operated outriggers are fitted with load sensing interlocks, to
prevent the booms from being raised without the outriggers being extended and
under load. An interlock prevents the hydraulic outriggers being accidentally
retracted while the booms are raised. A simple system of warning lights show the
power supply is on and each of the outriggers is under load.
Performance.
Maximum Working Height 17.00 m
Maximum Working Outreach: 9.10 m
Capacity (2 man working): 200 kg
SlewingArc: 680°
Airborne Noise Emissions (Battery): 70 dB(A)
Construction Standards.
The machine complies fully with the requirements of the following EEC Directives:
Directive 98/37/EC – the ‘Machinery Directive’.
Directive 89/336/EEC – the ‘Electromagnetic Compatibility Directive’.
Directive 73/23/EEC – the ‘Low Voltage Directive’.
EN 6020-1/1993 ‘Safety of Machinery.’
The machine is designed and tested in accordance with all relevant B.S.I and
European Standards including EN280.
DESCRIPTION OF EQUIPMENT

TL49K 508159-000 5
Cage Dimensions
Length 1.20m
Width 0.80m
Guard-railHeight 1.10m
Toe-board Height 0.15m
Operating Dimensions
Maximum Working Height 17.00m
Maximum Cage Height 15.00m
Maximum Outreach ( From centre of rotation ) 9.10m
Travel Dimensions
Towing Length 7.10m
ClosedWidth 1.75m
ClosedHeight 2.10m
Weight (Battery Model) 2250 kg (un-laden)
(Battery Model + Friction Drive) 2395 kg (un-laden)
(Bi-fuel Model) 2300 kg (un-laden)
Operating Parameters
Safe Working Load 200 kg
Maximum Horizontal Pull 400N
Maximum Wind Speed 12.5 ms-1
Rotation 680°
CageSlew 90°
Equipment
Bottom Ram Double acting: Bore Ø 80.0 mm
Rod Ø 50.0 mm
Top Ram Double acting: Bore Ø 80.0 mm
Rod Ø 50.0 mm
Tele’ Ram Double acting: Bore Ø 65.0 mm
Rod Ø 45.0 mm
Flick Ram Double acting: Bore Ø 60.0 mm
Rod Ø 40.0 mm
Stabiliser Ram Double acting: Bore Ø 70.0 mm
Rod Ø 40.0 mm
Bottom & Top Ram Lock Valves Pilot operated over centre valves
Control Valve (Cage) Monoblock unit consisting of seven
doubleactingspools
Control Valve (Ground) Monoblock unit consisting of five
doubleactingspools
Control Valve (Stabiliser) Monoblock unit consisting of four
doubleactingspools
Bushes Acetol resin polymer with sintered
bronzebase(DX)
PivotPins StainlessSteelBrightBar
To Grade BS970 303 S31 CW, &
MecaVal147m,TuftrideTFI-AB1
coated.
TECHNICAL SPECIFICATION

6 508159-000 TL49K
OPERATING ENVELOPE
Height and Distance in Metres.
200kg

TL49K 508159-000 7
Please read this carefully, and ensure you have received the correct training
prior to operating this machine.
1. To operate the machine you must be medically fit and have no problems
with eyesight or hearing.
2. You must have a good head for heights.
3. Your primary concern must be the safe operation of the work platform, the
safety of the people working with you, and the safety of other persons in
your working area.
4. You must be familiar with the contents of this manual, and at no time
attempt to operate the machine beyond the recommended limits.
5. The proper care of the work platform is a major factor in ensuring the safety
of those who work with it.
6. You must not misuse the machine or ignore or interfere with the devices
that have been provided to maintain safety.
7. Operation of the machine should be restricted to personnel who have been
authorised to operate the equipment and have received proper training.
OPERATOR REQUIREMENTS

8 508159-000 TL49K
1. DO NOT operate this machine unless you have been fully trained in its safe
use.
2. DO NOT operate the machine on soft, slippery or sloping ground unless
adequate precautions have been taken.
The stabilisers are designed to operate on firm level ground with a minimum
bearing strength of 50N/cm2.
The maximum load imposed by an outrigger is 12.5kN.
Advice should be obtained from UpRight as to the type of supports and
precautions required before attempting to operate the machine outside
these parameters.
3. DO NOT use any equipment in the basket to increase the reach or working
height of the machine, e.g. ladders.
4. DO NOT fit any additional equipment to the machine that would increase
the wind loading, e.g. notice boards.
5. DO NOT use the machine for any application that may produce special loads
or forces: the manufacturer, UpRight Powered Access, must be consulted for
approval of special applications prior to use.
6. DO NOT use the machine close to live electrical conductors. The minimum
safe working distance for a machine working near overhead power cables is
the maximum extended length of the booms plus 15 metres, measured
with the booms pointing towards the lines, i.e. safe working distance for the
TL49K is 24 metres. It is the operator‘s responsibility to ensure that, when
working in the vicinity of live overhead high-voltage lines, the minimum safe
working distance is maintained. Erect a simple barrier tape at the safe
distance.
7. WORKING CLOSE TO POWER CABLES – if work has to be carried out at less
than the safe working distance, the operator must ensure that the
electricity supply has been switched off. Before commencing work, a
written permit to work must be obtained from the owners of the power
cables or the responsible authority.
15m
26m
15m
24m
WARNING NOTICES

TL49K 508159-000 9
8. DO NOT operate the machine unless all four outriggers are down and in full
contact with the ground. The machine must be level and the wheels lifted
visibly clear of the surface before the booms are raised.
9. DO NOT move the machine
with the basket raised and
never allow cage or booms to
slew into the path of
oncoming vehicles.
10. DO NOT operate the machine if the wind speed exceeds 12.5 m/s. Be aware
that, when working near high buildings or structures, shielding and
funnelling effects may cause high wind forces on days when the nominal
wind speed in the open is low. Wind speed can either be measured from
the work platform with a hand held anemometer or estimated using the
Beaufort Scale.
BEAUFORT WIND SPEED SCALE
The Beaufort Scale of wind force is accepted internationally and is used in communicating weather
conditions. It consists of numbers 0 - 12, each representing a certain strength of velocity of wind at
10m (33ft.) above ground in the open.
Approximate corrections for wind speeds at other heights are:
 2m subtract 30%;
 3m subtract 20%;
 6m subtract 10%
 15m add 10%;
 30m add 25%
WARNING NOTICES
Beaufort
Scale
M/Sec Ground Conditions
3 3.5-5 Leaves and small twigs in constant motion; wind extends light flag.
4 6-8 Raises dust and loose paper; small branches are moved.
5 9-10 Small trees in leaf begin to sway; crested wavelets on inland waterways.
6 11-13 Large branches in motion; umbrellas used with difficulty.
7 14-17 Whole trees in motion; inconvenience felt when walking against wind.
8 18-21 Breaks twigs off trees; generally impedes progress.
9 22-24 Slight structural damage occurs (chimney pots and slates removed)

10 508159-000 TL49K
Trailer mounted machines are fitted with suspension units that may be safely
towed behind a car or van at speeds of up 50mph (80km/h) where permitted.
1. Before towing, check the capacity of the vehicle being used.
(Machine weight will increase if optional extras are fitted)
2. Ensure that the road tyres and brakes are in good, serviceable condition.
3. Ensure that all booms are fully lowered and both the transit pins are fitted
through the loops and secured with the “R” clip on the end of the chain.
Right
Up
Righ
R
U
Rt
p
Rig t
ig
Rig
g
gh
gh
gh
i
ig
h
h
h
h
TL
TL
4
9
L4
L4
L4
49
49
49
4
T
49
T
TL49
gh
h
h
h
h
h
Ri
Rig
g
ig
g
g
g
g
g
TL
T
T
T
TL
TL
L
TL
4
4
4
L4
49
9
9
49
4
9
TOWING INSTRUCTIONS

TL49K 508159-000 11
4. Ensure that all outriggers are fully raised.
5. Use the Jockey Wheel to raise or lower the tow bar coupling to position the
machine above the 50mm ball hitch on the towing vehicle.
6. Apply the handbrake.
7. Lower the tow bar coupling down onto the ball hitch using the Jockey Wheel
8. Secure the breakaway cable,
(Ensure correct engagement of 50mm ball).
9. Fully raise the Jockey Wheel and lock in position.
10. Release the Handbrake.
11. Plug in the trailer lights (7 pin plug) and check that both vehicle and trailer
lights operate correctly.
Right
Up
Righ
R
U
Rt
p
Rig t
ig
Rig
g
gh
gh
gh
i
ig
h
h
h
h
TL
TL
4
9
L4
L4
L4
49
49
49
49
T
49
T
TL49
gh
h
h
h
h
h
Ri
Rig
g
ig
g
g
g
g
g
TL
T
T
T
TL
TL
L
TL
4
4
4
L4
49
9
9
49
4
9
TOWING INSTRUCTIONS
6
11
7
8
9

12 508159-000 TL49K
1. Ensure that the booms are fully lowered, all outriggers are fully raised
and the machine is in a menoeverable condition.
2. Engage the the friction drive cylinders against the trailer tyres by pulling
actuating levers forward and down until they lock overcentre.
3. Ensure the power selector switch is set to Base.
4. Disengage the handbrake, and ensure that the Jockey wheel directional
locking pin is removed
5. Traction is controlled via the 2 hydraulic levers on the R/H side of the
chassis.
6. The left lever controls the left motor and the right lever the right.
Operating only the left lever forward will turn the machine right and the
right lever will turn the machine left, operate both levers together for
parallel drive.
7. When the machine is in position replace handbrake.
HAND MANOEUVERING (Optional)
Ensure friction drive cylinders are disengaged prior to platform
operation or towing.
!

TL49K 508159-000 13
The following Pre-Start Checks should be carried out before taking the
machine to the place of work.
1. Damaged or Loose Fittings.
Visually Inspect the machine for signs of wear and tear, damage, loose or
missing parts.
2. Wheels. (For towing only)
Check tyres are at the correct pressure, TL49K = 76psi (5.25 bar).
3. Hydraulic fluid.
The hydraulic oil tank is located underneath the slew cover on the right
hand side of the machine (looking from the cage end), Ref, Fig.2, section J
With the booms and outriggers in the transport position, the hydraulic oil
level should be visible between the upper and lower marks of the
Sight Glass.
Top up with ISO Grade 22 hydraulic oil if necessary.
4. Safety Switches.
Visually check the cage overload switch is free from damage.
Check all limit switch arms are free from damage and move easily
(outrigger switches shown in Fig.6 ).
With outriggers in transport position, it must not be possible to operate the
extending structure. With outriggers deployed, under load and top or
bottom boom raised approximately 50mm, it must not be possible to
operate the outrigger controls.
PRE-START CHECKS
The flick boom is not interlocked with the outriggers.
Serious injury or even death may result by not carrying out the
following checks of the interlock system before the platform is
used!
Do Not Overfill the Tank
1
Right
Up
Righ
R
U
Rt
p
Rig t
ig
Rig
g
gh
gh
gh
i
ig
h
h
h
h
TL
TL
4
9
L4
L4
L4
49
49
49
49
T
49
T
TL49
gh
h
h
h
h
h
Ri
Rig
g
ig
g
g
g
g
g
TL
T
T
T
TL
TL
L
TL
4
4
4
L4
49
9
9
49
4
9

14 508159-000 TL49K
5. Emergency Stop Switches.
Emergency stop switches must operate correctly. Check that each stops the
machine’s controls and that restarting is prevented until all stop switches
are unlatched.
6. Emergency Lower/Slew.
With the top and bottom booms raised approximately 500mm each and the
unit switched off, check:
The emergency lower switch located in the basket and ground control
stations, lowers the booms when operated.
The emergency slew, telescopic boom retraction can be operated by using
the hand pump and control lever at the ground control station.
To Reset the hydraulic system after checks;
 Fully slew the Basket to the right, so that he ram is fully extended.
 Fully extend the Outriggers while still maintaining Level. (check the bubble)
 Using the ground controls, fully extend Top, Bottom and Telescopic Booms.
 Fully extend the Flick Out Boom.
All rams must be fully extended at the same time before returning them to
their transit position.
7. Emergency Hand Pump.
With the unit set up for working (i.e. outriggers down, under load and the
machine level with wheels clear of ground) it is possible to lower the cage
using the emergency hand pump.
8. Battery Power (Where applicable)
Check batteries are fully charged and topped up with distilled water (these
are fitted under the slew cover on both sides of the platform).
Hydrometer reading should be 1280-1320sg.
With machine level, the distilled water should cover the plates by
approximately 6mm.
9. Mains Power (Where applicable)
Check that the voltage and frequency of the power input matches that of the
motor. All extensions must be a minimum of 2.5mm², and no longer than
10m due to possible voltage drop.
10. Petrol/diesel Power (Where applicable)
Check that there is sufficient oil and fuel to complete a full working shift.
If the Emergency Lower is used during normal operation, DO NOT
use the machine, Contact your local UpRight representative.
PRE-START CHECKS

TL49K 508159-000 15
Battery Power, 24V DC.
Ensure batteries have been fully charged before use and that the Battery Isolating
Plug is securely connected.
Mains Power, (OPTIONAL)
Connect the mains supply, either 110V or 220/240V A.C., depending upon the
motor specification. Check the motor is running when the key is turned to the ON
position.
Petrol/diesel Power, (OPTIONAL)
Check the fuel and oil levels of the engine. Switch on the ignition using the key
switch on the slew mounted legend panel. Check the engine runs using the start
and stop buttons in the basket.
All extensions must be a minimum of 2.5mm², and no longer than
10m, due to possible voltage drop, which will damage the motor. !
Power Pack
Hand Pump
Oil Filler and Sight Glass
BATTERIES & POWER PACK
Fig. 1
Battery Charger
Batteries
Pump Handle
Fig. 2

16 508159-000 TL49K
3. With platform key switch set to ’Ground’ (Fig 3)
lower the outriggers by keeping the
‘Outrigger Motor Run’ button (Fig 4)
pushed in, operate the appropriate
‘Outrigger control lever’ (Fig 5), until all
four are 25mm to 50mm from the
ground.
1. Park the unit in an appropriate location at the workplace.
2. Apply the handbrake on the trailer and remove from the towing vehicle.
Motor Run
Booms
Motor Run
Outrigger
Do not attempt to set up the machine on steep slopes, ramps or
soft ground. 1
Emergency
Lower
SETTING UP
Fig. 3
Ground
Basket
Fig. 4
Fig. 5
Control Levers
Outriggers
Level
indicator
Control Levers
Ground