Operator Manual

TL49
SERIAL NO. 1001 TO CURRENT

WARNING
Safety Rules and Operating Instructions

Safety Rules and Operating Instructions

All personnel shall carefully read, understand and follow all safety rules, operating instructions and
the Scaffold Industry Association’s MANUAL OF RESPONSIBILITIES (ANSI 92.2) before
operating or preforming maintenance on any UpRight aerial work platform.

SAFETY RULES

NEVER operate this NEVER elevate the NEVER position the NEVER sit, stand or
machine within 10 feet of Platform until all four (4) platform without first climb on guard rail or
power lines or cables. Outriggers have been checking for overhead midrail of the
THIS MACHINE IS NOT correctly deployed. obstructions or other platform.
INSULATED. hazards.
ALL occupants must wear an approved fall restraint properly attached to a designated platform anchorage point. Attach
only one fall restraint to each anchorage point.
NEVER operate the machine without first surveying the work area for surface hazards such as holes, drop-off’s (curbs),
bumps and debris.
NEVER exceed the safe working load of 475 lbs (215 kg), (max. 2 persons plus 120 lbs (55 kg) of equipment).
DO NOT increase wind loadings by fitting items such as sign boards, flags etc. to the cage or boom.
DISTRIBUTE all loads evenly on the platform. See the Specifications Table on Page 16 for the maximum platform load.
NEVER operate the machine unless you have been fully trained in its safe use, are medically fit and have read and fully
understood these instructions.
OPERATE the machine on firm level ground with a minimum bearing capacity of 11,500 lbs / ft2 (550 kN / m2).
DO NOT use in winds exceeding 27 mph (12.5 m/s - Beaufort Force 6).
NEVER use ladders or scaffolding on the platform.
DO NOT attach overhanging loads, increase the size of the working platform, use the machine as a crane or for any
other application involving additional loads or forces.
NEVER change or modify operating or safety systems.
INSPECT the machine thoroughly for missing decals, cracked welds, loose hardware, hydraulic leaks, damaged cables,
loose wire connections or wheel bolts. NEVER use damaged equipment. (Contact UpRight Irl. Ltd. for instructions).
NEVER climb down an elevating assembly with the platform elevated.
NEVER use this machine unless the platform entrance drop bar is in position.
NEVER perform service on or in the elevating assembly while the platform is elevated without first blocking the
elevating assembly.
NEVER recharge batteries near sparks or open flame; Charging batteries emit highly explosive hydrogen gas.
SECURE the work platform against unauthorized use by turning Keyswitch off, and then remove key from the switch.
NEVER replace any component or part with anything other than original UpRight replacement parts without the
manufacturer’s consent.
All Outrigger Pads must be in contact with a firm surface and the Chassis levelled before elevating the Platform.
IF ALARM SOUNDS while the platform is elevated, STOP. Carefully retract the booms, using the emergency
1 machine to a firm, level surface.
functions and lower the platform without slewing. Move the
 surface (See Figure 1). Care should be exercised
Introduction that the Foot Pads are orientated correctly. When all
four Outriggers are in contact with the surface the
This Manual covers the operation of the TL49 Trailer Chassis can then be elevated. This should be done
Mounted Work Platform. This manual must be stored on by extending each Outrigger one at a time in small
the machine at all times. increments until both of the Road Wheels have just
cleared the ground.
11. The Chassis must then be levelled using the
Pre-Operation & Safety Bubble Level on the rear of the Chassis as a
Inspection reference. When carrying out these minor
adjustments the last operation on the Outriggers
must be an extension so as to avoid the possibility of
WARNING minor settling in the Hydraulic Fluid.
For a more detailed description of this procedure the
Carefully read, understand and follow all safety instructions in the Operation Section of this
rules and operating instructions. Perform the Operators Manual should be followed.
following steps each day before use. DO NOT
perform service on the Work Platform with the WARNING
platform elevated unless the elevating assembly is
Do not use a machine that is damaged or
properly supported.
malfunctioning. Tag and remove the unit from
service until it is repaired.
1. Remove module covers and inspect for damage, oil
leaks or missing parts.
2. Check the level of the hydraulic oil with the platform SYSTEM FUNCTION INSPECTION
fully lowered and the Outriggers fully stowed. Oil
should be visible on the filler cap dip stick. If
NOTE:
necessary top-up using ISO#46 hydraulic oil.
Refer to Figure 2, Figure 3 & Figure 4 for the
3. Check that the electrolyte level in the batteries
Outrigger Control, Lower Control and Platform
is correct. (Battery Maintenance, Page 9)
Control locations.
4. Verify batteries are charged.
5. Check that the A.C. extension cord has been
disconnected from the charger. WARNING
6. Carefully inspect the entire machine for damage STAND CLEAR of the Work Platform while
such as cracked welds or structural members, loose
performing the following checks.
or missing parts, oil leaks, damaged cables or hoses,
loose connections and tyre damage. BEFORE operating the Work Platform survey the
7. Move machine, if necessary, to an unobstructed area work area for surface hazards such as holes, drop-
where machine can be fully elevated. off’s (curbs), bumps and debris.
8. Check that the surface is capable of supporting
the outrigger loads, and is generally level. Apply the CHECK in all directions, including above the
handbrake. Work Platform, for obstructions and power lines or
9. Ensure that no leaks are present on the hydraulic cables.
hoses to the Outrigger cylinders and that they are
properly secured. Check that there is no physical CORDON off the area within the platform’s
damage to the cylinder body or ram. IF THERE IS working area to keep passers-by clear of the
ANY DAMAGE DO NOT PROCEED IN booms.
USING THE MACHINE.
10. To extend the Hydraulic Outriggers an Operator
must first ensure that all Emergency Stop Buttons 12. Turn both of the Chassis and the Platform
are released (turned clockwise). Then turn the Emergency Stop buttons ON (rotate clockwise).
Keyswitch to the chassis position and deploy the Turn the Keyswitch on the Outrigger Control box to
Outriggers using the Toggle Switches until the the position marked CHASSIS (anticlockwise
Outrigger Foot Pads come into contact with the position).
2
13. Using the chassis control Toggle Switches, fully alarm should sound and normal controls should
ELEVATE Booms 1 & 2 and EXTEND the cease. By turning the Platform Selector Switch to
Telescopic Boom. the Emergency Override position the DOWN
14. Visually inspect the elevating assembly and cage functions, RETRACT functions and SLEW
mounting/structure, lift cylinders, cables and hoses functions only will be activated.
for leaks, damage or erratic operation. Check for The Emergency Override functions should also give
missing or loose parts such as nuts, bolts and the Down & Slew functions only when an
circlips. Outrigger Limit Switch is deactivated. Carry out
15. Test the Emergency Lowering Valves on the Upper the tests as outlined in Item No.17 in this section.
and Lower Lift Cylinder are operating correctly as The System Function Inspection is then complete.
detailed on Page 6. PUSH/TURN the Emergency
Stop Button to identify that functions will indeed PRE-TRANSPORT INSPECTION
cease when depressed.
16. Check the SLEW left and right function. 20. Lower the jockey wheel until it is in contact with the
17. Return the machine to an elevated position just surface.
above the Boom Rest 1 ft (300 mm). To confirm 21. Retract the Outriggers fully. To do this the operator
that the Outriggers and Outrigger Limit Switches must use the Toggle Switches on the Outrigger
will operate correctly while the machine is elevated, Control Box to raise each Outrigger individually in
it is then vital that each Outrigger Limit Switch is small increments until the road wheels are taking the
individually tested. Work Platform’s weight. Raise the Outriggers until
Retract the Rear Left Outrigger using the Toggle they are locked in the required vertical position. The
Switches on the Outrigger Control Box (will simulate Outriggers are now correctly stowed.
an Outrigger out of deployment). At this point the 22. Return the Keyswitch to the OFF (centre) position.
TL49 should have the following characteristics; Check tyre pressures and thread depth. These
the alarm will sound and the DOWN, RETRACT & procedures are further detailed on Page 8.
SLEW Boom functions only will be operable from the
Lower Controls.
The above test should be repeated for all Outriggers.
WARNING
18. Lower each boom until the Elevating Assembly is If there are any concerns about the safe use or
fully stowed. Repeat all the above tests from
operation of the TL49 following this
the Platform Controls.
Pre-Operation Inspection DO NOT USE THE
19. While testing the Platform Controls it is also
necessary to test that the Emergency Override TL49 WORK PLATFORM. Contact your
functions will work. While elevated in the Platform supplier or UpRight’s Product Support
request a colleague to activate the Tilt Sensor. The Department.

Outrigger Raised

To activate the Outrigger Control Box the Keyswitch

must be turned to the CHASSIS position. For each
Outrigger there will be a toggle switch. Each toggle
switch will have its corresponding graphic.

To deploy (lower) an Outrigger it’s toggle switch

should be held down. To retract (raise) an
Outrigger Lowered Outrigger it’s toggle switch should be held up.

Figure 1: Deploying the Outriggers

3
 The On/Off/
Emergency 3
Override Switch 2
is located on the
left side of the
4
Upper Control 6
Box. 5
To utilize the 1
Emergency
Override feature
turn and hold
the Switch to the 7
‘EMERGENCY’
position.

Figure 2 : Upper Control Box

17
8 15
10 11 13
9 12

16 18

14

To operate the Toggle Switches above the Keyswitch (13) To operate the Toggle Switches above the Keyswitch (13)
must be turned to the anticlockwise position - CHASSIS. must be turned to the anticlockwise position - CHASSIS.

Figure 3 : Lower Control Box Figure 4 : Ourtrigger Control Box

INDEX NAME FUNCTION INDEX NAME FUNCTION INDEX NAME FUNCTION
NO. NO. NO.
1 SWITCH : Turn clockwise for power 'ON', in 6 BATTERY This red L.E.D. (Light Emitting Diode) 13 KEYSWITCH Turn the Key anticlockwise to select
ON/OFF/ centre position for power 'OFF' and CONDITION indicates the condition of the the CHASSIS controls or clockwise to
EMERGENCY anticlockwise for 'EMERGENCY INDICATOR batteries. It is constantly illuminated select the PLATFORM controls.
OVERRIDE OVERRIDE'. (Must be held against when the batteries are more than Power OFF is in the centre position.
spring pressure in this position) 80% discharged. It flashes repeatedly
when the batteries are 70%
discharged. It is not illuminated when
the batteries are fully charged.
2 SELECTOR Select function to be operated. Left 7 LEVEL This toggle switch allows the Platform 14 EMERGENCY Push red button to cut off power to all
SWITCH Hand position for BOOM1, the next SWITCH to have its 'level' adjusted either STOP functions (OFF). Turn clockwise to
position for BOOM2 and the next forwards or backwards. To activate SWITCH release and restore power.
position for TELESCOPE. The SLEW this switch the Platform must be
function is the Right Hand position. stowed and the ON/OFF/
Only one function can be selected at EMERGENCY OVERRIDE Switch
any one time. must be held to the Emergency
Override Position.
3 JOYSTICK Squeeze the Interlock Switch, 8 EMERGENCY Push red button to cut off power to all 15 OUTRIGGER The Outrigger assembly can be
CONTROL coloured red. This will activate the STOP functions (OFF). Turn clockwise to TOGGLE extended by holding toggle switch
LEVER controller. To activate the BOOM1 UP, SWITCH release and restore power. SWITCH DOWN, and retracted by holding
BOOM2 UP, TELESCOPE Rear Left switch UP.
RETRACT or ROTATE RIGHT 9 BOOM 1 Boom1 can be raised by holding 16 OUTRIGGER The Outrigger assembly can be
functions the controller should be TOGGLE toggle switch UP, and it can be TOGGLE extended by holding toggle switch
pushed forward. SWITCH lowered by holding toggle switch SWITCH DOWN, and retracted by holding
To activate the BOOM1 DOWN, DOWN. Rear Right switch UP.
BOOM2 DOWN, TELESCOPE 10 BOOM 2 Boom2 can be raised by holding 17 OUTRIGGER The Outrigger assembly can be
EXTEND or ROTATE LEFT functions TOGGLE toggle switch UP, and it can be TOGGLE extended by holding toggle switch
the controller should be SWITCH lowered by holding toggle switch SWITCH DOWN, and retracted by holding
pulled back. The speed that each DOWN. Front Left switch UP.
function operates is related to how far
the Joystick is moved from the centre
position.
4 EMERGENCY Push red button to cut off power to all 11 TELESCOPE The Telescopic Boom can be 18 OUTRIGGER The Outrigger assembly can be
STOP functions (OFF). Turn clockwise to TOGGLE extended by holding toggle switch UP, TOGGLE extended by holding toggle switch
SWITCH release and restore power. SWITCH and it can be retracted by holding SWITCH DOWN, and retracted by holding
toggle switch DOWN. Front Right switch UP.
5 SYSTEM OK Illuminates to indicate that the 12 SLEW The elevating assembly can be
INDICATOR Outrigger Switches are activated, i.e. TOGGLE slewed LEFT by holding toggle switch
the Outriggers have been properly SWITCH LEFT, and
deployed and that power is now RIGHT by holding switch RIGHT.
available to the Upper Control Box.

NOTES :
* An alarm is located in the Upper Control Box. This will sound when Tilt Sensor is activated, and while this alarm is on only
the Emergency Override controls can be used. This alarm will also sound when an Outrigger Limit Switch opens.

4
 DEPLOYING THE OUTRIGGERS
Operation
Position the TL49 on a firm, level surface. Apply the
Before operating the TL49 Work Platform it is handbrake and then lower the Jockey Wheel until it comes
imperative that the Pre-Operation Inspection has into contact with the surface and retighten the clamp. As
been completed and any deficiencies have been the Jockey Wheel is further lowered release the locking
corrected. The operator must also be fully trained mechanism on the Tow Hitch Receiver. When clear of the
on this machine. tow bar move the towing vehicle a small distance away
from the TL49. Next ensure that the TL49 is switched to
TOWING the ON position using the Keyswitch on the Outrigger
Control Box and that the Emergency Stop Buttons are also
WARNING OFF (turned clockwise to release).

Before Towing, ensure that the Elevating Assembly DANGER

is properly stowed and secured using the Locking
It is important that all outriggers are correctly
Pin, and that the Outriggers are raised, retracted
deployed on a firm surface capable of withstanding
and locked into position. See Pre-Transport
the loads imposed. The Chassis MUST be
Inspection on as before. Ensure the tyres are free
correctly levelled before elevating the platform.
from damage, inflated to the correct pressure and
have sufficient thread depth. Ensure the breakaway
cable is properly attached to the towing vehicle
before driving away.
WARNING
DO NOT use the TL49 Work Platform unless the
System OK LED (Outriggers Ready) is illuminated.
Adjust the Jockey Wheel using the screw handle until
the Towhitch is just above the height of the tow ball on
the towing vehicle. 1. Before deploying the Hydraulic Outriggers it is
Position the tow vehicle and fit the breakaway cable to necessary that the area be cleared of any objects or
a suitable attachment point on the towing vehicle (not personnel that may infringe on the Outriggers
the tow ball stem or towing pin). deployment radius.
While pushing the release button on the Towhitch lower 2. Turn the Keyswitch located on the Outrigger Control
the Receiver onto the Tow Bar using the screw handle Box to the ‘Chassis’ position and deploy the
on the Jockey Wheel, until the catch snaps into position. Outriggers using the Toggle Switches until the
Then when the receiver is secure and the Tow Bar is Outrigger Foot Pads come into contact with the
taking some of the machines weight retract the Jockey surface. Care should be exercised that the Foot
Wheel to its full extent, at which point the Jockey Pads are orientated correctly.Reference Figure 1.
Wheel will be in its locked position. Retighten the 3. When all four Outriggers are in contact with the
clamp. This will negate the possibility of the wheel surface the Chassis can then be elevated. This
moving and so the possibility of the Jockey Wheel should be done by extending each Outrigger one at a
screwing down during transport. time in small increments until both of the Road
Connect the electrical lead to the tow vehicles socket. Wheels have just cleared the surface.
Check all lights for correct operation before transporting 4. Ensure that the machine is level in all planes using
the machine. the Bubble Level located at the rear of the Chassis.
NOTE: The last operation to be carried out before entering the
Exercise caution during brake “Running In” period Platform should be to check each of the Outriggers
(First 500 miles or 850 Km). When parking on individually for their stability and that in each instance the
slopes fully tension the Hand Brake. When moving Outrigger Limit Switch is activated. When the Keyswitch
the TL49 in reverse ensure that the Hand Brake is in the ‘CHASSIS’ position and the Outriggers are
spring is fully compressed. Check that the TL49 is properly deployed there should be no warning alarm.
moving in reverse. When not in use it is advisable to
chock wheels to prevent movement.

5
 illuminated. If not, and/or an audible alarm sounds,
DANGER check that the Outriggers are correctly deployed and
When carrying out final adjustments in the levelling that the machine is level. The boom functions, nor
of the chassis it is important that the last operation the slew function will operate if this is not correct.
5. Select “Boom 1” on the Function Selector Switch.
on each Outrigger be an extension. This is to avoid
Check for overhead obstructions and when satisfied
creating a reduced hydraulic pressure within the squeeze the red Interlock control on the Joystick.
Outriggers and hence negate the possibility of Slowly move the Joystick forward to elevate
minor settling. Boom 1. The further the joystick is moved, the
faster the boom will move. Pressure must be applied
to the Interlock at all times while operation is
ELEVATING & LOWERING THE TL33 required.
WORK PLATFORM 6. Select “Boom 2”, “Telescope” or “Rotate” as
required using the ‘Function Selector Switch’ and
When the TL49 has been thoroughly inspected, and has operate as described above. For boom one or two
been set up in accordance with the correct Outrigger functions the controls will be forward for UP and
Deployment procedures, the Elevating Assembly can then backward for DOWN. For telescope retract the
be used. Controller Joystick should be moved forward and for
rotate Telescope extend move the Controller
Joystick backward. To rotate (Slew) RIGHT the
WARNING Controller Joystick should be moved forward and to
rotate (Slew) LEFT move the Controller Joystick
LOOK up and around for obstructions before backward.
performing the lift function. 7. Before lowering, check beneath the Platform floor
for obstructions. Operate as described above,
ENSURE that the Elevating Assembly is clear of moving the Joystick to lower the Booms.
the Chassis before engaging the Slew operation.
DO NOT overload the platform
LEVELLING

DO NOT operate within 10 feet (3 metres) of any NOTE:

electrical power cables. THIS WORK The Cage Levelling function will only work when the
PLATFORM IS NOT INSULATED. Boom Rest Limit Switch has been activated i.e. when
the Booms are stowed.
Cordon off the area within the platform’s working
area to keep passers-by clear of the booms. The platform can be levelled from the Upper controls using
the levelling switch (See Figure 1). To activate this switch
the ‘ON/OFF/OVERRIDE’ switch, also located on the
NOTE: Chassis controls are for service use only. Upper Control Box, must be held to the OVERRIDE
position.
1. Enter the Platform through the entrance provided This switch is for fine adjustment of the slave levelling
and ensure that the Drop Bar is in position. Where cylinder. Care should be taken when performing this
applicable lock the Entry Step in the raised position. operation. The switch should be operated cautiously to
2. Before using the machine all local Safety level the cage slowly. Activate the switch in a careful,
Regulations involving helmets and restraining controlled manner.
devices should be observed. Safety harness
lanyards, not exceeding 1 m in length, should be EMERGENCY SITUATIONS &
attached to the anchor points on the Platform floor. EMERGENCY OVERRIDE
3. Ensure the ‘ON/OFF/OVERRIDE’ switch on
the Upper Control Box switch is turned to the ON In any emergency situation, the first action to be taken
, the Keyswitch on the Outrigger Control Box is should be to hit the red “Emergency Stop” button. This will
turned to CHASSIS position and all Emergency give instant cutout of all functions. It will then be required
Stop Buttons are OFF (twisted clockwise). to twist the button clockwise to release before the machine
4. Check the green “System OK” L.E.D. is can be operated again.
6
If the Audible warning alarm sounds, normal control
functions will cease to operate. This will be due to one of
the following problems ;

z deactivation of an Outrigger Limit Switch.

z the activation of the Tilt Sensor.

In this situation the procedure is to turn the Platform “ON/

OFF/OVERRIDE” Switch to the ‘EMERGENCY
OVERRIDE’ position, and hold it in this position while
using the boom controls as normal to descend in a
controlled manner to ground level. Do not begin to rotate
until close to the ground.
Before operating the Emergency
After leaving the Platform, check all Outriggers and adjust Lowering Valves the surrounding
to ensure each is correctly deployed. Note that during area should first be cleared of any
emergency operation, controls will operate only at a potential obstructions. It is also
important that when the valve is
fixed, slow speed and will not allow the raising of the pushed/turned, it is initially done
Booms. The Booms can only be lowered. slowly. This is so that sudden
movement will not occur in the
Elevating Assembly, leading to a
Emergency Lowering potentially unstable machine.

CAUTION Figure 5: Emergency Lowering

When operating this function, extreme care must be
taken to ensure that the person carrying out the task
does not become trapped by the Elevating
Assembly.

Should the machine become inoperable when elevated

request a person on the ground to lower the platform using
the emergency lowering valves.

These are red knobs (push or twist type) mounted at the

Gerabox Manual
base of the 2 Main Hydraulic Lift Cylinders (See Figure 5 Rotation Shaft
opposite). The decal located on the TL49’s Lift Cylinder’s
will identify the Emergency Lowering Valves as either a
‘PUSH’ type or a ‘TWIST’ type. To rotate the Elevating Assembly first apply a 17 mm
(13 mm) socket wrench to the shaft and turn to rotate
the Elevating Assembly. When finished remove the
Operate the lower boom first by pushing (turning wrench.
anticlockwise) slowly until the boom starts to descend. The
speed of descent iscontrolled by the amount the valve is Figure 6: Manual Rotation
pushed (turned anticlockwise) - ensure that the rate of
descent is kept slow and under control. Descent can be MANUAL ROTATION
halted at any time by removing pressure from the red knob
for the ‘PUSH’ type, or turning the ‘TWIST’ type 1. Retract the Telescopic Boom and lower Boom2
clockwise. fully. Ensure also that Boom1 is lowered as far as
possible, but just clear of the Tow Bar Weldment,
Repeat the operation if necessary for the upper boom and that the Emergency Stop Button is pressed to
when the cylinder is in reach of the ground. prevent any accidental powered operation.
With both main booms lowered fully it should then be 2. Apply a or 17 mm (or 13 mm if required) socket
possible to leave the Platform safely. A small step ladder wrench to the Gearbox Drive Shaft and turn to
can be used if necessary. rotate the Elevating Assembly. The Gearbox Drive
7
 Shaft for the 17 mm type gearbox is shown in The TL49 may be lifted by an overhead hoist/crane in the
Figure 6. following manner:
3. Remove the wrench. Four lifting straps capable of safely supporting the total
weight of the TL49 (4,189 lbs (1,900 Kg)), and at least 8
CONTROL FROM GROUND LEVEL feet (2.5 m) long are required. This minimum length is
important to ensure the correct lifting angle. The straps
1. Chassis Boom Controls are fitted in the Control should be positioned as shown in Figure 7.
Module of the TL49 Work Platform. These should
only be used when no operator is in the Platform The four lifting straps (Positions 1, 2, 3 & 4) should be
(for maintenance/service or inspection purposes), or positioned at the points indicated in Figure 7. Care must be
if the operator has become incapacitated. taken to ensure the straps do not interfere with any other
2. It should be noted that in order to activate any of the parts of the TL49.
Lower Control Toggle Switches on the Lower The four straps should be routed between the Outrigger
Control Box the Keyswitch, located on the Outrigger Footpad’s and the Outrigger Weldment.
Control Box, must be turned anticlockwise to the Minimum sling length
CHASSIS position. - 8 feet (2.5 m)
3. Use the appropriate toggle switch to raise or lower
Straps to be through
Boom 1, Boom 2, Telescope or rotate as required. Footpad as indicated
by the arrows
shown.
AFTER USE EACH DAY
1. Ensure that the Platform is fully lowered.
2. Park the machine on a level surface, preferably Outrigger
Footpad
undercover, secure against vandals, children or
unauthorised operation. Apply the Hand Brake.
3. Turn the Keyswitch to OFF and remove the key to
prevent any unauthorised operation.
4. Recharge the batteries in accordance with the
instructions on Page 9.

Transportation Figure 7: Lifting the TL49

BY FORKLIFT BY ROAD

CAUTION CAUTION
The TL49 is not designed to be forklifted, and does It is important that before commencing transport
not have provision on the Chassis to allow this to ensure the vehicle used is capable of towing
method of lifting. UpRight recommends the 4,189 lbs (1,900 Kg).
procedure below for handling the machine.
The TL49 is a road approved vehicle and therefore may be
transported behind a motor vehicle of suitable towing
BY CRANE capacity. It is recommended that the vehicle used should
have a tow bar where the top of the ball is at a height of
WARNING between 1.42 ft (435 mm) and 1.64 ft (500 mm) above
surface level. These dimensions are also indicated below in
See specifications (Page 16) for the weight of Figure 8. This is for the following reasons;
the work platform and be certain that lifting
apparatus is of adequate capacity to lift the z the bottom of the Platform may be in danger of
platform. hitting the surface while driving if the tow hitch is
above the upper limit.

8
z the towing vehicle will support too much weight if If the TL49 is to be transported by other means then it
the Towhitch is too low. must be securely tied down to the transporting unit at
several points.
1.64 ft (500 mm) Recommended securing points are the four outrigger
support members on the Chassis and the Tow Bar
1.42 ft (435 mm)
Weldment. Further securing points should be used if the
terrain on which the unit is travelling is rough or uneven.
Care should be taken when using tie downs that sensitive
parts of the TL49 (i.e. hosing, cabling etc.) are not
affected.
ALWAYS ensure that the Hand Brake is fully applied, that
all the booms are FULLY stowed and that the Boom Lock
Down Pin is in place.
Figure 8: Allowable Tow Hitch Height
Care should always be taken while towing the TL49 on an Maintenance
uneven or sloped surface. It is recommended that the set
of procedures that follow should be incorporated into a
normal working practice for towing the TL49 Work
BATTERY MAINTENANCE
Platform. The Procedures which should be followed when
transporting the TL49 are: Electrical energy for the motor is supplied by four 6 volt
1. The Platform is to be fully lowered, retracted and batteries wired in series to give a 24 volts DC supply.
slewed in the correct position. Proper care and maintenance of the batteries and motor
2. The Platform is to be securely stowed by inserting will ensure maximum performance from the work
the Boom Lock Down Pin in its place. This is platform.
located at the bottom of the Second Post.
3. The Jockey Wheel that is fitted to the Towhitch is WARNING
to be extended until the Receiver is close to the
height of the vehicle’s tow bar. Hazard of explosive gas mixture. Keep
4. The Hand Brake is pulled to engage the brakes sparks, flames and smoking materials away from
(important if the machine is not on a level surface). batteries
5. The Outriggers are to be fully retracted and secured Always wear safety glasses when working
in position. with batteries.
6. The key is turned to the off position. Battery fluid is highly corrosive. Rinse away
7. Move the vehicle as close as possible to the any spilled fluid thoroughly with clean water.
Receiver.
8. Lift the Towhitch on to the tow bar and make sure
the Receiver is properly secured.
9. Release the Hand Brake and retract the Jockey
BATTERY INSPECTION AND
Wheel. CLEANING

CAUTION Check battery fluid level daily, especially if work platform

is being used in a warm, dry climate. If required, add
It is important that the Jockey Wheel is retracted as distilled water; use of tap water with a high mineral content
fully as possible so that the wheel will not slew (turn) will shorten battery life.
while being transported. Failure to do so could
result in damage to the Jockey Wheel. CAUTION
10. The tailboard harness is connected to the vehicle’s If battery water level is not maintained, batteries will
braking system by means of a 7 Pin Plug. not fully charge, creating a low discharge rate which
11. Attach the Breakaway Safety Cable to the towing will damage Motor/Pump unit and void warranty.
vehicle.

The TL49 may then be towed.

9
Batteries should be inspected periodically for signs of 2. Extension cord is in good condition, is no longer than
cracks in the cases, electrolyte leakage and 26 ft. (8 m) and is 12 ga (1.5 mm2) or larger.
corrosion of the terminals. Inspect cables for worn spots or 3. Charger will have an adequate time to allow a full
breaks in the insulation and for broken cable terminals. charge i.e. ensure that power supply will not be
switched off overnight.
Clean batteries that show signs of corrosion at the 4. A.C. Voltage Selector Switch (110/220V) is in the
terminals or onto which electrolyte has overflowed during correct position.
charging. Use a baking soda solution to clean the batteries,
taking care not to get the solution inside the cells. Rinse All UpRight battery operated Work Platforms, including the
thoroughly with clean, warm water. Clean battery and TL49, are suitable for use in freezing and low temperature
cable contact surfaces to a bright metal finish whenever a conditions (to a value of -4ºF (-20ºC)). However for this
cable is removed. there are two provisions which must be met.
z The ISO#46 grade of hydraulic oil normally used in
Basic Rule for maximum duty cycle of deep cycle UpRight Work Platforms must be replaced with a
traction batteries: grade suitable for these low temperature conditions.
z When ambient temperatures fall below 65ºF (18ºC)
z Use the machine until it shows signs of weak / slow batteries cannot deliver 220 Ampere hours and so
performance. should be placed on charge as soon after use as
z Allow the charger to charge the batteries until it possible. Under such conditions a 4 hour equalize
automatically shuts off. charge once a week in the early afternoon will
z Avoid intermittent charging as the batteries develop improve state of charge and battery life.
a memory effect similar to Nicad batteries. Charging
1. Check battery fluid level. If electrolyte level is
BATTERY CHARGING lower than 3/8 in (10 mm) above plates add
distilled water only. (DO NOT OVERFILL)
Batteries do not have their full potential until they have 2. Connect battery charger lead to properly
been through 50 charge/discharge cycles (however the earthed outlet of correct voltage and frequency.
rate at which the potential increases is exponential, and the 3. The Charger will turn on automatically after a
batteries will normally have 95% potential after 15 charge/ short delay. The LED’s will indicate the rate
discharge cycles). Hence do not use a new battery in a of charging.
battery pack that already has more than 15 cycles. Charge 4. Charger turns off automatically when batteries
batteries at the end of each work shift or sooner if are fully charged.
batteries have been discharged. A battery is considered to
have a faulty cell if it has less than 80% of the potential of HYDRAULIC OIL
the other batteries in the pack while measured under load.
With the Platform fully lowered i.e. stowed, oil should be
visible on the dipstick. If oil is NOT visible, fill the tank
WARNING until oil is then visible on the dipstick. DO NOT fill above
the upper line on the dipstick or when the platform is
Charge batteries in a well-ventilated area. elevated.
Do not charge batteries in the vicinity of sparks or
flames. LUBRICATION
Permanent damage to batteries will result if they are
not immediately recharged after discharging. Refer to the Service & Parts Manual for the lubrication
Never leave charger operating unattended for more chart and guidelines.
than two days. Keep charger dry.
Never disconnect cables from batteries when DECALS
charger is operating.
Refer to Figure 9 on Pages 12 & 13 for the locations of the
Decals used on the TL49 Work Platform. These Decals
To ensure a proper charge several items must first be must be present and in good condition before operating the
checked. Work Platform. Be sure to read, understand and follow
1. Correct voltage and current available to the charger. these Decals when operating the Work Platform.
10
ROUTINE SERVICE COMPONENT INSPECTION OR SERVICES INTERVAL Y N R

Tyres / Check tyre press. 65 psi (4.5 bar) Daily

Use the following table as a guide for routine maintenance. Wheels Check for damage. Daily
Inspection and maintenance shall be performed by Check thread depth. Daily
personnel who are trained and familiar with Check/torque nuts 74 ft lbs-100 Nm Daily
mechanical and electrical procedures. Refer to the Platform Check welds for cracks. Daily
Service & Parts Manual for complete service instructions. Deck and Check condition of floor. Daily
Guardrails Check that securing bolts are Daily
Interval tightened.
Check drop bar on cage entrance. Daily
Daily = each shift or every day
Slew Grease slew gear. 50h/30d
50h/30d = every 50 hours or 30 days
System Check slew motor for leaks and 50h/30d
mounting bolts for proper torque.
Y=Yes/Acceptable Slew Check torque on all bolts, 15 outer 50h/30d
N=No/Not Acceptable System/ ring and 20 inner ring.
R=Repaired/Acceptable First Post Retorque to 88 ft lbs (120 Nm).
Elevating Inspect for structural cracks. Daily
Assembly Check hoses for pinch or rubbing Daily
points.
Preventative Maintenance Report
Check pivot pins for damage. 50h/30d
Check pivot pin retaining rings. 50h/30d
Date :________________________________ Lift Check cylinder rod for wear. 50h/30d
Owner : ______________________________ Cylinders Check pivot pin retaining rings. 50h/30d
Model No : ____________________________ Grease all fittings as section 4.4. 50h/30d
Chassis Inspect for structural cracks. Daily
Serial No :____________________________
Assembly Check hoses for pinch or rubbing Daily
Serviced By :__________________________ points.
Service Interval :________________________ Entire Unit Function check Emergency stop Daily
switches at control boxes.
Perform pre-operation inspection. Daily
Check for/repair collision damage. Daily
Signature of Service Engineer Lubricate. 50h/30d
Grease all fittings. 50h/30d
Outriggers Check outrigger cylinders for Daily
_____________________________
damage.
Check interlock switch function. Daily
Lubricate. 50h/30d
Grease all fittings. 50h/30d
COMPONENT INSPECTION OR SERVICES INTERVAL Y N R
Tow Hitch Check coupling for function and Daily
Battery Check electrolyte level Daily wear.
System Check battery cable condition. Daily Inspect breakaway cable for Daily
Charge batteries. Daily proper attachment.
Check specific gravity. 50h/30d Grease all fittings as per the 50h/30d
Hydraul. Oil Check oil level. Daily Service & Parts Manual Section 4.4
Hydraulic Wipe clean. 50h/30d Road Check all trailer lights and Daily
Pump Check for hose fitting leaks 50h/30d Lights connecting plug
Check for leaks at mating surfaces. 50h/30d Brake Apply handbrake and check Daily
Check mounting bolts for proper 50h/30d function.
torque. Check brake shoes for wear. 50h/30d
Hydraulic Check for leaks. Daily Test auto reverse function. 50h/30d
System Check hose connections. 50h/30d Adjust brake shoes. 50h/30d
Check for exterior wear. 50h/30d
Emer. Open the emergency lowering Daily
Hydraulic valves and check for proper
System operation.
Control Check switch operation. Daily
Cable Check the exterior of cable for Daily
pinching, binding or cable wear.

11
 058750-000
2 REQUIRED 057418-000 058186-000
4 REQUIRED 1 REQUIRED

057385-000
8 REQUIRED

057382-000
2 REQUIRED

057433-000
2 REQUIRED
057424-000 057427-000
3 REQUIRED 2 REQUIRED
057429-000

12
2 REQUIRED

057416-000 057430-000
2 REQUIRED 058534-000
2 REQUIRED
2 REQUIRED

058011-000
1 REQUIRED

Figure 9: Decal Identification

058539-000
1 REQUIRED 058533-000
2 REQUIRED

058010-000
1 REQUIRED

058532-000
1 REQUIRED
057428-000

THESE DECALS WHEN OPERATING THE WORK PLATFORM.

1 REQUIRED 058760-000
2 REQUIRED

058761-000
1 REQUIRED

057507-010
2 REQUIRED
058536-000 058535-000

OPERATING THE WORK PLATFORM. BE SURE TO READ, UNDERSTAND AND FOLLOW

057421-000 1 REQUIRED 2 REQUIRED

TL49 DECALS: THESE DECALS SHALL BE PRESENT AND IN GOOD CONDITION BEFORE
2 REQUIRED
 057432-000
2 REQUIRED

058012-000
1 REQUIRED

058760-000
2 REQUIRED
057422-000 058538-000 058080-000
2 REQUIRED 1 REQUIRED 1 REQUIRED

057420-000
1 REQUIRED

057431-001
1 REQUIRED

057425-001
1 REQUIRED

13
057424-000
3 REQUIRED

058802-000
1 REQUIRED

057426-000
057417-010 1 REQUIRED
4 REQUIRED

057435-000
1 REQUIRED

NOT SHOWN NOT SHOWN

BOOM LOCK PIN MOS90 DECAL
057434-000 058992-000 057387-000
1 REQUIRED 1 REQUIRED 1 REQUIRED

Note: Decals can be ordered by using the Part Numbers located beneath each decal.
This Operators Manual (Part Number 058651-000) is located in the Manual Holder within the Platform
Notes:

14
Notes:

15
16