SS90™HD TMAProduct DescriptionAssembly Manual
Rev – April 2012Part No. 618589B
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www.energyabsorption.com 2 Created April, 2012 www.highwayguardrail.com All rights in copyright reserved
Table of Contents
Customer Service Contacts .......................................................................................................... 3 Important Introductory Notes ........................................................................................................ 3 Return Goods Policy ..................................................................................................................... 4 Recommended Safety Rules for Assembly .................................................................................. 4 Safety Symbols ............................................................................................................................. 4 Warning and Cautions .................................................................................................................. 5 Limitations and Warnings .............................................................................................................. 7 Safety Instructions ........................................................................................................................ 8 Attachment Instructions .............................................................................................................. 14 Operation Instructions ................................................................................................................. 27 Maintenance ............................................................................................................................... 29 Repair Instructions ...................................................................................................................... 37 Troubleshooting Guide ................................................................................................................ 42
Test Equipment ....................................................................................................................... 42 Hydraulic Fluid ......................................................................................................................... 43 Pump Priming .......................................................................................................................... 44 Reservoirs ............................................................................................................................... 45 Filters ....................................................................................................................................... 46 Hydraulic Cylinders ................................................................................................................. 47 Electrical Problems .................................................................................................................. 49
Hydraulic Quick Troubleshooting Guide ..................................................................................... 52 Parts Lists ................................................................................................................................... 54 Detail Drawings ........................................................................................................................... 60
www.energyabsorption.com 3 Created April, 2012 www.highwayguardrail.com All rights in copyright reserved
Customer Service Contacts Energy Absorption Systems (a Trinity Highway Products company) is committed to the highest level of customer service. Feedback regarding the SS90™HD TMA, its assembly procedures, supporting documentation, and performance is always welcome. Additional information can be obtained from contact information below: Energy Absorption Systems: Telephone: (888) 323-6374
(800) 467-6750 (Outside U.S.)
Fax: (916) 645-3495
E-mail: [email protected]
Internet: Energy Absorption Systems Trinity Highway Products, LLC Trinity Industries, Inc.
http://www.energyabsorption.com/ http://www.highwayguardrail.com/ http://www.trin.net/
Important Introductory Notes Proper assembly, deployment and future maintenance of the SS90™HD TMA are critical to achieve tested performance under accepted criteria. Take the time to review this Manual thoroughly before performing all necessary work. These instructions should be read in their entirety and understood before assembling the SS90™HD TMA. These instructions are to be used only in conjunction with the assembly of the SS90™HD TMA system and are for standard assemblies only as specified by the applicable highway authority.
In the event your system assembly requires or involves deviation from standard parameters or, during the assembly process a question arises, please contact the appropriate highway authority that specified this system at this particular location for guidance. Energy Absorption Systems is available for consultation with that agency. These instructions are intended for an individual who is qualified to both read and accurately interpret them as written. They are intended for the individual who is experienced and skilled in the assembly of highway products which are specified and selected by the highway authority.
Do not attempt to assemble any TMA without the proper plans and specifications from the highway authority and instructional Manual from the manufacturer. If you need additional information, or have questions about the SS90™HD TMA, please contact the highway authority that has planned and specified this assembly. This product must be assembled by the appropriate highway authority just as it was tested. If there are deviations, alterations, or departures from the assembly protocol specified in this manual, the device many not perform as it was tested and accepted.
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www.energyabsorption.com 7 Created April, 2012 www.highwayguardrail.com All rights in copyright reserved
Limitations and Warnings Energy Absorption Systems, in compliance with the National Cooperative Research Highway Program 350 (NCHRP Report 350) “Recommended Procedures for the Safety Performance of Highway Safety Features”, contracts with FHWA approved testing facilities to perform crash tests, evaluation of tests, and submittal of results to the Federal Highway Administration for review.
The SS90™HD TMA system was tested to meet the impact criteria, requirements, and guidelines of NCHRP Report 350. These tests, specifically set forth by FHWA, evaluate product performance by simulating those impacts outlined by NCHRP Report 350 involving a typical range of vehicles on our roadways, from lightweight cars (approx. 820kg [1800 lb.]) to full size pickup trucks (approx. 2000 kg [4400 lb.]) as specified by the FHWA. A product can be certified for multiple Test Levels. SS90™HD TMA is certified to the Test Level(s) as shown in Test Level III: 100 km/h [62.13 mph].
Additionally, the SS90™HD TMA was tested to meet the impact criteria, requirements, and guidelines of TD 49. These tests are specifically set forth by The UK Highway Authority. The SS90™HD TMA is certified for various speed levels as shown in TL3.UK: 110 km/h [68 mph]
These specified tests are not intended to represent the performance of systems when impacted by every vehicle type or every impact condition existing on the roadway. This system is tested only to the test matrix criteria of NCHRP 350 as approved by FHWA or TD 49 as approved by The UK Highway Authority.
Energy Absorption Systems does not represent nor warrant that the results of these controlled tests show that vehicle impacts with the products in other conditions would necessarily avoid injury to person(s) or property. Impacts that exceed the specifications of the system may not result in acceptable crash performance as outlined in NCHRP Report 350, relative to structural adequacy, occupant risk, and vehicle trajectory. Energy Absorption Systems expressly disclaims any warrant or liability for injury or damage to persons or property resulting from any impact, collision, or harmful contact with products, other vehicles, or nearby hazards or objects by any vehicle, object or person, whether or not the products were installed by third parties.
SS90™HD TMA system is intended to be assembled, delineated, and maintained in accordance with specific State and Federal guidelines. Energy Absorption Systems offers a reflective delineator panel for its TMA line of products. However, the material is only intended to supplement delineation required by the Department of Transportation’s “Manual on Uniform Traffic Control Devices” (MUTCD). The appropriate highway authority approved engineer should be careful to properly select, assemble, and maintain the product. Careful evaluation of the speed, traffic direction, and visibility are some of the elements that require evaluation in the proper selection of a safety appurtenance by the appropriate specifying highway authority.
After an impact occurs, the product must be repaired to its original condition as soon as possible. When a safety product is impacted, it is mandatory that the highway authority inspect all the components for damage and repair and/or replace components as necessary. If the system is not repairable, a complete system replacement is required.
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www.energyabsorption.com 13 Created April, 2012 www.highwayguardrail.com All rights in copyright reserved
THE USE OF A TMA ON THE BACK OF A TRUCK, WHEN IMPACTED WITHIN NCHRP 350 CRITERIA, HAS BEEN SHOWN TO:
• Gradually stop the impacting vehicle*
• Protect the occupants of the impacting vehicle*
• Protect the shadow vehicle occupants*
• Reduce damage to the shadow vehicle*
WILL NOT:
• Affect the skid (roll ahead) distance of an impacted truck. KEEP WORK CREWS CLEAR!
REDUCING SKID DISTANCE (ROLL AHEAD):
• Skid distance is significantly increased and is less predictable for lightweight shadow vehicles
• Skid distance is reduced and is more consistent when heavier shadow vehicles are used.
• Preferred truck GVW rating is: 7300 kg [16,090 lbs.] to 12 000 kg [26,460 lbs.]
• Recommended Curb Weight is: 7300 kg [16,090 lbs.] to 9000 kg [19,845 lbs.]
*TMA’S HAVE BEEN TESTED UNDER THE FOLLOWING NCHRP-350 CRITERIA: • 100 km/h [62 mph] for 820 and 2000 kg [1808 and 4410 lbs.] vehicles.
*TMA’S HAVE ALSO BEEN TESTED UNDER THE FOLLOWING UK TD 49 CRITERIA: • 110 km/h for 900 and 1500 kg vehicles.
www.energyabsorption.com 14 Created April, 2012 www.highwayguardrail.com All rights in copyright reserved
Attachment Instructions Read and understand all instructions before beginning assembly. The truck rating (GVW) should be 7300 [16,090 lbs.] min. The weight of the vehicle should be between 7300 and 9000 kg [16,090 and 19,845 lbs.] to achieve impact performance under state and federal guidelines. The system must be attached to the truck by welding parts to the frame. Do not weld forward of the rear leaf spring hangers to ensure structural integrity of frame. Use AWS qualified welders to ensure durable attachment of the TMA system. Disconnect the truck battery before any welding on truck or TMA. The truck frame must be suitable and accessible for mounting a TMA system. If there are any questions regarding the suitability, contact the agency that specified this System. Energy Absorption Systems is available for consultation through that agency.
1) Shipping list Check the shipping list against the actual parts to make sure all items were received. Review the drawing package and familiarize yourself with the assembly and part numbers.
2) Assemble Necessary Tools Recommended Tools: 10. Work gloves and other personal 1. Welding equipment (for 1/2" plate) protection equipment as required. GMAW or SMAW 11. Cutting torch 2. Hammer 12. Drift pin or alignment pin (12” long) 3. Tape measure 13. 1/2" drive socket wrench w/6” extension 4. 1/2" drive sockets (9/16", 1-1/8", 14. Open end wrenches (9/16", 1-1/8", 1-1/2") 1-1/2", 9/16” deep well) 15. Marking implement (pencil, soapstone) 5. 12" crescent wrenches - (2) 16. Drill motor for 13/16" diameter bit 6. Floor jack 17. Center punch 7. 13/16" diameter bit with pilot drill 18. Hydraulic fluid (use Dexron® III fluid only, 8. Torque wrench - 120 Nm [90 ft-lbs.] shipped with system.) 9. Forklift 19. Bubble level Note: The above list of tools is a general recommendation. Depending on specific site conditions and the complexity of the assembly specified by the appropriate highway authority, additional or fewer tools may be required. The decision as to what tools are needed to perform the job is entirely within the discretion of the specifying highway authority and the authority’s selected contractor performing the assembly of the system at the authority’s specified site. Preparation
3A) Attachment Must Be Performed On a Level Surface The system’s framework is very heavy and pivots in several areas. Until the framework is secured with the alignment cables and release cables, it can swing out in an approximate 4 m [13’] radius from either side of the truck. A level surface is required to maintain control of the framework when it is being extended to its full length.
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st e level to verto the final d[16,090 lbs]the truck to quires no baprotruding Tto exceed
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ACHMENT SEMBLY
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for interferetion. See Figreceiver hitckip to step 8eiver under
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h the weighcompensate
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CrAll rights in co
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ch underride. truck framence problemshould be
at its actuae truck framo the bottom
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STEP 20
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The truck shadded to acmust be proadequately 000 lb] weigehicle, care oads. To en
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Position the 3” x 15 1/4"]
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DERRIDE SOCKET ECEIVER
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OCKET HIT
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E
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www.energyabsorption.com 18 Created April, 2012 www.highwayguardrail.com All rights in copyright reserved
7. Mount the Attachment Assembly to Socket Receivers
Mount the Attachment Assembly to the Socket Hitches as shown in Figure 16. Shims are used to level the system. It is recommended that 1/2" Shims be used initially. This may be adjusted once the system is assembled.
SUPPORT BRACKET
1” FLAT WASHER
1” LOCK WASHER
1” HEX NUT
ANTI-TILT CHAIN
1/2” SHIM (RECOMMENDED AT INITIAL SETUP. ADJUST FINAL
THICKNESS TO LEVEL THE TMA)
1” X 3” 1/2 HEX BOLT
Figure 16
RIGHT SOCKET HITCH
LEFT SOCKET HITCH
1
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8. Att
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1” FLAT1” LOCK W
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to the Attac
sembly to thhe Support Fd, with forklifattachment. r clearance i
T WASHERWASHER
igure 17
A
chment Asse
he truck and Frame/Backft slings suppElectrical Bossues.
1SH
SHIM
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embly
pin it to the kup Assembporting the sox is tempor
HITCHHAIR P
” FLAT WASHIMS, 1/4” XMS, 12 GA X
1” X 3 1/2
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Attachmently is to be system. Userarily held by
H PIN WITH PIN COTTER
SHER X 5” X 10” *X 5” X 10” *
2” HEX BOL
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9. ExWA
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Attach CornUsing 1/2” bo
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ssets four p
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Use ath.
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CORNER GUSSET
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Attach the B Warnby Ento fatig
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cross Arm Torque the
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Alignment Caside to clear
Using a foCartridge I i
sing the fland nuts pro20 ± 7 Nm rocedure igure 20).
Attach the Tss the Arm
Attach the Touts to 34 Nm
rom nuts onasteners as "
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nt Cables move one able from ther the top sideorklift and n position
at washers, ovided. Torq
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Figure 2
CARTRID
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CrAll rights in co
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s (see Figurel amount of n place usin
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Attach and a
There are fohown in Figuiagonal mea
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Attach and a
There are fouhimble end he Frame hackles. Pashe correspottach as sho
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he Die Spr) are only u
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adjust Cartr
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ss the stud eonding cartown in Figurnuts.
tension ten the first nmoved, theSpring has 1/4±1/16”]. econd "jamth other cab
Frame not s
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nt Cables (twsure the diain each baym [3/16"]) anpressed by h
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ridge Suppo
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ort Cables.
ables. Attachrt Cables toe providedable throughn loop anda die spring
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Repeat this
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washers (seewo Top Cab
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/8” LONG ACER
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SH
IDGE ORT LE
G SPRING
eated April, opyright rese
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e Figure 21bles, i.e. the
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HACKLE
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32±2 mm [1 1/4 ±1/6”]
Figure 22
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/2” O.D. HER
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Attach Side
There are found two for Bhown in Figu
Adjust heighem Frame.
Verify that themm [12 ± 1"]
nd rear of thecessary to
he Socket Hevelness of t& 24a.
SEE AIL 24a
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e System Frfrom the gro
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SIDESEE
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es, two for Bh Side Guideighten bolts.
ness of the
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e. See Figure
E GUIDE FIGURE 23
F
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e
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INTERF
Figure 24
A
F
SOCKET HITCH
SHIMHERLEVE
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Figure 23
MS MAY BERE AS NECEELNESS OF
DetGUIDE
GURE 23
305 ±2
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25 mm [12 ±
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Connect the
ocate the fefting or lowelectrical cord
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he system attaching the
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NotelongeCable61835batter
The controls on-traffic sid
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Lights and
emale TMA ering the Td on the TMA
vehicles with on the bac
ectrical Box 4 bolts, wasr voltage. Thand truck ar
battery cabcables arounthe cables. Cdrawing pac
: A 2 gauger cable is ne
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at the rear de (side closto the othent the cab sw
LEARANCE, DENTIFICA
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socket connMA will notA can reach
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to Plate mohers and nu
he SS90™HD
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e battery cabeeded use 1sible link is aPower and
of the trucksest to the cuer side. Secwitch box in
SIDE MARKATION LIGHT
F
LEFT T
View A
ERSE LIGHT
24
nector in a ct damage thh this location
tail and cleae male TMA
ounted next tuts on the Eis available le. Be sure not let the e
orners or mee battery cab
ble is good 1/0 gauge upavailable froGround Cab
k should be urb). If they
curely fastenside the cab
7
KER TS
Figure 25
TURN
A-A – Back s
TS
A
convenient lohe electricaln.
arance lightsA plug conne
to Pump (Selectrical Boxin 12 volt ato use stan
ends of the cetal work, oble to the pu
up to 7.6 mp to 12.5 m m Energy Ables should
mounted toare not, rem
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7-PIN FEMA
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CrAll rights in co
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s, connect aector (see V
ee Drawing x. The truckand 24 volt sndard safetycables touchor in other aump motor (s
m [25 ft.] for [44 ft.]. (A
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LE SOCKET
ROUND TAIL LAM
RIGHT
STOP LAM
ket Connec
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a jumper betwVIEW A-A F
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ystems, Pared directly t
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em. If attery rt No. to the
n the move
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9. Check th
The Hydrshipping. operatingcheck to overfill. R
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.
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2. Check po
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raulic SystemThe pump the systemsee if the r
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: Continuous
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ydraulic Loc
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ructions. Mawitch at the air from th
ng the Cab
s operation
Jacks
ded to facilitaur jacks and
il Light Ope
e. Verify that
he Hydraulic
f all the hyding or tilting
cking in the
d from horizois released.
time the TMulically locke
RESERVOI
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25
sembled anshown on te cap from tfull. Add othe filler port
king sure allrear of the
he System.Switches to
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ate attachmeplace them
eration
all the turn/
c/Electrical
raulic and eof the syste
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ontal, the TM The pump
MA is raiseed and chai
R FILL POR
HIS HEIGHT
A
d tested forthe Hydraulithe fill port oonly Dexron®
t.
l electrical ae truck, pow
Also o verify
wn truck batt
ent and remin storage.
/stop/tail ligh
lines
electrical linem up or dow
on
MA’s Hydrauis used to ra
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RT
CrAll rights in co
r operation ac Assembly
of the hydrau® III fluid if
and hydraulicwer the syste
tery.
moval of the
hts are worki
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ulic System waise and low
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Figure 26
eated April, opyright rese
and leaks by drawing. Bulic reservoiit is not. Do
c lines will nem up and d
System from
ing properly.
e they will n
will automatwer the Syste
d verify thanyone behin
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.
ot be
tically em.
at the d the
www.energyabsorption.com 26 Created April, 2012 www.highwayguardrail.com All rights in copyright reserved
24. Grease Friction Points
Follow directions in the maintenance section IV parts 2 & 3 before first use of TMA.
25. Final Check of System
Check the tightness of all of the fasteners. Double check the height and levelness of the system.
26. Ready for Use
The TMA system is now ready for use. To ensure proper and safe operation, all TMA users should be given operating and safety training, as given in this manual and as specified by the owner and local regulations.
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OperaBefore osafety se
For impaCartridge
The SS9up from ithe rear simply acthe TMAbutton. Controlleavailable
The comparked inTMA from
The syste
While ratraffic sidlowering
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Raise a
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Raising Switch uSystem wshould band for m
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ation Insperating the
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mplete vertican congestedm the vertica
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ising or lowde of the truTMA, or allo
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structione SS90™HD T Manual. Ve
ance per NCCartridge II,
has been eqal position. Tsystem as t"up" button
ulically lock. er will conti
TMA is eit18504B.)
al "up" positid areas. Theal (up) positio
y perform as
ering the TMuck. Alwaysow others to
ated on onecab. (Cab C
er the Syion: Make eding. Undeath of the S
m the cab, alw
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e.
ion: If someystem is to betaining Cha
AINING CHA
ns TMA, thorougerify that the
CHRP-350 cin their prop
quipped withThe "tilting" fthe truck trato tilt the TM To lower tnue to buzther all the
ion allows the driver muson.
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MA from ous stay clear be positione
e side of theontroller Pa
ystemsure the t
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eone will bebe stored in ain as shown
AINS WHILE
27
ghly read anSystem is p
crash testingper positions
h a Hydraulicfeature may avels in andMA up. Whethe TMA, th
zz (and rockway up or
he TMA equst make sure
shion when t
tside the caof moving
ed there.
e Support Frrt N. 618504
top of the mstances sn it is being
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e doing mainthe "up" pos
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nd understanproperly atta
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c Pump thatbe used to
d out of slopn he remove
he operator ker switch
r down. (O
ipped truck e everything
the system is
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rame. An op4B)
System is hould anyog raised or
cts behind or
nd hold the n. The hydr0 degree po90 degree p
ntenance besition, be su27. NEVER BEING PER
CrAll rights in co
nd these insched and in
must be eqn Figure 20.
t can be useprevent pos
ped drivewayes his fingersimply activwith flash o
Optional In-C
to be more g is clear bef
s in the dow
rator is to stver stand be
ptional set of
clear of alone be allowlowered.
r below the T
"Raise" sidraulics automsition, the R
position for lo
hind the raisre to secureREMOVE T
RFORMED.
eated April, opyright rese
structions anworking ord
quipped with
ed to tilt the ssible scrapiys. The oper from the buvates the “Don optional
Cab Control
easily drivenfore lowerin
wn position.
tand on the ehind or bel
f controls ca
l objects bwed behind
TMA.
de of the Romatically locRestraining Cong term sto
sed Systeme the SystemTHESE
2012 erved
nd the der.
h one
TMA ing of erator utton,
Down” Cab
ler is
n and g the
non-ow a
an be
before or in
ocker ck the Chain orage
, or if m with
www.energyabsorption.com 28 Created April, 2012 www.highwayguardrail.com All rights in copyright reserved
Lowering the System: To lower the System, be sure that the Restraining Chain is placed in the "unlocked" position and that no one is behind the System. Then, press and hold the "Lower" side of the Rocker Switch.
Figure 27
WHEN THE TMA IS IN THE “UP” POSITION, STAND TO THE SIDE AND PULL THE RETAINING CHAIN OUT OF THE VERTICAL TUBE, WRAP THE CHAIN AROUND THE FRAME ARM AND SECURE IT INTO THE SLOT. VERTICAL TUBE
www.enewww.hig
MaintBefore pMaintenawith the Chain.
I. RoutDescript
1. Heighits impac
2. Fastefor the loto the Su
3. Hydrconnectiofluid drip
4. Cablein the hobeen rem1 1/4± 1/procedurFigure 22
5. Jacksrequired.
6. Light
*A/R = as
ergyabsorptihwayguardra
enance erforming anance SectionSystem in th
tine Maintion
t and Levelct performan
eners - Cheocations of thupport Struct
raulic Cylinons for leaksspots.
es - Check thorizontal posmoved. Then/16 " in heighre with the o2 on page 20
s - Check .
Bulbs - Re
s required
on.com ail.com
ny Maintenan and the Sahe vertical (
tenance
lness - The ce. Check re
eck the tightnhe fastenersture. Lock w
ders, Hoses. If the TMA
he tension insition, tightenn tighten untht. Lock this other cables0.
the conditio
place the lig
ance on the afety Sectio"up") positio
height and egularly and
ness of the s. Be sure to
washers shou
es and FittinA sits overni
n the Cartridn the first nutil the tensionut in place
s. Check and
on of the w
ght bulbs as
305 ±25 m
Figure
29
SS90™HD TMn of this ma
on, be sure t
levelness ofd adjust as n
fasteners mo check boltsuld be fully c
ngs - Inspeght, check t
dge Supportut on one caon springs he with the sed adjust mo
wheels on t
required.
mm [12 ±1”]
e 28
A
MA, thorouganual. If maito secure th
f the Systemecessary: S
monthly. Sees attaching tcompressed.
ect all hydrathe ground u
t Cables. Wiable until all have been ccond jam nunthly or whe
he Jacks m
CrAll rights in co
ghly read andntenance is
he System w
m is importanSee Figure 28
e the drawingthe Cartridge.
aulic lines anunderneath f
ith the systethe slack ha
compressed ut. Repeat then loose. Se
monthly or a
eated April, opyright rese
d understan to be perfo
with the Reta
Interva
nt to 8.
gs es
nd for
em as to
his ee
as
A/R*
1 Month
Each us
1 Montwhen lo
1 Month
A/R*
2012 erved
nd the ormed aining
al
h
se
th or oose
h
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Descript
7. Pins are held Figure 29
z w `
9. CleanStructureSystem ccleaning.
10 Hydraand electthe Pump
11. HydrRemove
12. Lub(Mainten
13. GreaSection –
14. Systthe Cylin
1
7
9
ergyabsorptihwayguardra
tion
- Check all in position
9 for pin loca
n System -e and Impaccan be clean.
aulic Pump trical connecp.
raulic Ramsall residue o
brication - ance Sectio
ase Pins – G– IV) of this M
tem Check der locks an
2
3
5 6
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pins. Prior tby a retaininations.
- Clean thect Face from ned with mild
- Clean the ctions month
s - Clean theor debris on
Lubricate on - IV) of thi
Grease as dManual.
– Run the Hnd buzzer is
4
6
10
11
12
13
15 1
21
to each useng pin as re
e Frame Asdirt and sal
d soap solut
Hydraulic Phly. Remove
e Hydraulic Ror around th
as describs Manual.
described in
Hydraulic Syworking.
Fi
8
14
17
18
19
1
23
30
, check all pequired (34 p
ssembly, Cat as requiredtion. Always
Pump as reqe all residue
Rams as reqhe Rams.
bed in the
the Grease
ystem up an
igure 29
16 22
24
25
A
pins to makeplaces). See
artridges and. Check mocheck lubric
uired. Checkor debris on
quired. Chec
e Lubricatio
Section (M
nd down to
20
26
CrAll rights in co
e sure they e
nd Support onthly. The cation after
k fluid level n or around
ck monthly.
on Section
aintenance
make sure
27
28
31
33
eated April, opyright rese
Inte
Eac
VariesSectio
1 Mon
1 Mon
1 Mo
6 Mon
Each
34
32
2012 erved
erval
h use
s– see on IV
nth
nth
onth
nths
Use
29
30
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II. HydIntroduc
The SS9in any pocomplex the SystHydraulicare electallowing in place.
ergyabsorptihwayguardra
raulic Syction
90™HD TMA isosition. This mechanical
tem from thc Solenoid Vtrically operathe hydrauli
Warnfully dengagsystemwhichwarnin
HYDRASSE
HYDRRA
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ystem Ope
s equipped simplifies th
l locking andhe cab of thValves, one ated. When tic fluid to flo
ning: Neverdown. This cge the TMAm is in the sounds whng may resu
RAULIC EMBLY
PUMP
RAULIC AMS
eration
with a Hydrahe design and unlocking he support on each of tthe TMA sys
ow. At all oth
r use the TMcan be dang
A. The systeall-the-way
en the TMAult in damage
ELECT. BHYDRAILIC
31
aulic Lockingnd operationmechanismvehicle mu
the two Hydstem is raiseher times, th
MA as a crasgerous beca
em can only-down posit
A is not fully e, injury, or d
Figure 30
BATTERYQUICK
BOX, C PUMP
A
g System ton of the TMA
ms. It also mch easier.
draulic Cylinded or lowerehese Valves
sh cushionause an erray perform astion. The Sraised or lodeath.
Y CABLE K END
CrAll rights in co
o allow the TA by eliminaakes raisingThe Systemders. Theseed, these Va
are closed,
in any orienant vehicle ms a crash cuS90™HD TM
owered. Fail
ELECASS
eated April, opyright rese
TMA to be loating the neeg and lowerim works via Solenoid V
alves are opelocking the
ntation that imay not proushion whe
MA has an alure to follow
CAB CPUMP
CTRICAL EMBLY
SOLENO
LIMIT SWI
2012 erved
ocked ed for ng of
a two Valves ened, TMA
is not operly n the alarm w this
CONTROL (Optional)
OID
TCH
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III. Det1. D
AB
CD
E
RETAP
ergyabsorptihwayguardra
aching aDetaching thA. Lower theB. Remove
shown in
C. Extend thD. Unplug th
from the PE. Remove t
1/4" Hitch
(If the aligor temporcan be dremoving
*Reinsert
HITC
AINER PIN
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nd Attachhe System fe System to the Jacks ffigure 31.
he Jacks unthe Light HaPump. Remothe Socket Hh Pins and R
gnment is ofrarily disass
done by remAnti-tilt Cha
Pins with R
CH PIN
hing the Sfrom the Truthe horizontfrom the sto
il the Systemrness and dove the CabHitches fromRetainer Pins
ff, making resemble the Amoving the ains as show
Retainer Pins
Figure 3
Figu
32
System tuck tal position.orage locati
m is supportedisconnect t
b Switch wire the Underri
s.* See Figu
emoval difficAttachment two 1 ¼ x
wn in Figure
s in Socket H
1
re 32
A
to the Tru
ion and atta
ed. the Positive es (optional)ide Socket Rre 32.
cult, it may bBrackets fro
x 7” Hitch P33 and 27.)
Hitches so th
SOCKET H
CrAll rights in co
uck
ach them to
Power and from the Co
Receivers by
be necessarom the SockPins and Re
hey will not b
HITCHES
eated April, opyright rese
o the syste
d Ground Caontrol Box. y removing 1
ry to adjust Jket Hitches.etainer Pins
be lost.
2012 erved
m as
ables
1 x 6
Jacks This
s and
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F
2. Attac
A
B
C
D
E
F
ergyabsorptihwayguardra
. Move the
ching the Sy
A. Move the T
B. Insert the Susing 1 X 6it may beBrackets fand canno
C. Plug in thePump, and
D. Retract the
E. Check the
. Verify that
S
ATTACASSEM
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e TMA away
ystem to the
TMA to the t
Socket Hitch6 ¼" Pin and
e necessary from the Suot fall out.
e Light Harnd the Cab Sw
e Jacks com
Hydraulic/E
the System
UPPORT FRBA
CHMENT MBLY
y from the tru
e Truck
truck.
hes into the d Retainer P
to adjust Jpport Frame
ness and conwitch wires (
mpletely and
Electrical Sys
is level and
Figure 3
RAME CKUP
33
uck.
Underride SPin. If alignmJacks or tee. Be sure t
nnect the Po(optional) to
remove them
stem for prop
280-330 mm
33
CL(ANTI
A
Socket Recement is off, memporarily dthe Retaine
ositive Powethe Control
m to the sto
per operatio
m [11-13”] a
1 1/4” X WITH HA
FRON
LEVIS LINK I-TILT CHAI
CrAll rights in co
ivers and pinmaking the adisassemble r Pins are i
er and GrouBox.
rage positio
on.
above the gro
Detail F
7” HITCH PAIRPIN COT
NT SUPPOR
SEE DET
N)
eated April, opyright rese
n them into assembly dif
the Attachnserted cor
und Cables t
n.
ound.
– Both Sid
IN TTER
T FRAME
TAIL F
2012 erved
place fficult, hment rectly
to the
es
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IV. Lub1. A
Aws
2. G
G
ergyabsorptihwayguardra
brication Add HydraulAdd hydraulicwhen the fluidhows the loc
Notespillag
Grease FrictGrease frictio
RESERVO
FILL TO T
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lic Fluid c fluid as reqd level is clocation of the
: When hage. Clean u
tion Points on points (mo
OIR FILL PO
THIS HEIGH
Fi
quired and cose to the fill hydraulic flu
ndling hydrp spillage im
oving steel p
ORT
T
gure 35
34
heck the fluiport. Use on
uid fill port.
raulic fluid, mmediately.
parts) every
Figure 34
A
id level monnly Dexron®
use approp
6 months. S
GRFRBEA
GRFRLIG
CrAll rights in co
nthly. The res® III Hydrauli
priate meas
See figure 3
REASE THESICTION POARING GRE
REASE THESICTION PO
GHT MACHIN
eated April, opyright rese
servoir is fulic fluid. Figu
sures to pre
35.
SE INTS USINGEASE
SE INTS USINGNE OIL
2012 erved
l re 34
event
G
G
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3. O
O
4. C
CR
Trecawof
ergyabsorptihwayguardra
Oil and Grea
Oil and greas
Change the
Change the Reservoir cap
The Pump Remove air thavitate when
without cavitaf the bleed d
GREAS
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ase Swivel J
se the Swive
Hydraulic F
hydraulic fpacity is 2 qu
Reservoir anhat may be n the Reserating. If this down cycle
OIL HER
SE HERE
Jacks
el Jacks ever
Fluid
fluid every uarts.
nd System mtrapped in
rvoir is emptprocedure is
RE
F
35
ry six month
2 years. U
may need tothe System
tied. Add flus not followe
Figure 36
A
hs as shown
Use Dexron®
o be filled am. As the TMuid until Sysed, the Rese
CrAll rights in co
in Figure 36
® III fluid o
and cycled MA is raise
stem will raiservoir will ov
eated April, opyright rese
6.
only. The P
several timd, the Pumse to 90 degverflow at the
2012 erved
Pump
es to p will grees e end
www.enewww.hig
V. Tech1. Weigh
Cartridge
Cartridge
Frame C
Jacks
Total
2. Dime
3. Repla
For detainclude th(888)-323
4. Opera
The SystLowering
8
ergyabsorptihwayguardra
hnical Spht
e I
e II
omponents
nsions (See
acement pa
ils on replache part num3-6374.
ating Rates
tem may be g the System
203 mm
889±6 mm [35±1/4”]
on.com ail.com
pecificatio
109
162
163
86
199
e Figures 37
rts
cement partsbers and de
raised from m takes abou
m [8”]
3967
CENTEGRAV
ons
9 lbs
2 lbs
39 lbs
lbs
96 lbs
7 & 38)
s, refer to thescriptions. F
the down tout 20 second
mm [13”]
ER OF VITY
Figu
36
49 kg
73 kg
744 kg
39 kg
905 kg
he drawing aFor replacem
o the up posids as well.
3re 38
A
at the end oment parts, c
ition in appro
305 mm [12”
Figure
11
CrAll rights in co
of the manucall Custome
oximately 20
”]
2362
37
194 mm [47”
eated April, opyright rese
al. The drawer Service:
0 seconds.
4013mm
2 mm [7’-9”]
”]
2012 erved
wings
[13’-2”]
www.enewww.hig
RepaiParts Lis IV. Pos
1. InRstR
2. InRth
3. EE
4. R
5. In
6. A
ergyabsorptihwayguardra
ir Instrucsts, end of Tr
st ImpactImpoEnergto comimpac
Cautibehindwork reduc
nspect the FReplace any traighten pa
Refer to the S
nspect PinsReplace all bhe manual fo
Expand the SExtend the Fr
Cauti
Remove Car
Impocapacslightl
nspect Corn
Attach the B
Warnby Ento fatig Warn
on.com ail.com
ctions (Mroubleshooti
t ortant: Onlygy Absorptiomply may recting vehicle
ion: Be surd or under tis being pered safety, to
Frame for BFrame memrts. Replace
System draw
s and Bolts olts and pins
or the part nu
System andrame and loo
ion: Frames
rtridges and
ortant: Do city, the Carty.
ner Gussets
Bottom Rele
ning: For prnergy Absorpgue or resul
ning: Until th
Make a list oing section.)
y the correctn Systems m
esult in dama, to and inclu
re to use thethe System rformed. Failo and includi
Bent Parts mbers that hae the arms inwings for the
for Damages that have bumbers and
d Loosen Oosen one en
s may swing
d Spent Rele
not attempttridges will n
s for Damag
ease Cables
roper Systeption Systemt in untested
he cables ar
37
f all damage)
t parts manumay be useage to the Suding injury
e Retaining in the raiselure to comping injury or
ave been dan pairs to ens part numbe
e been damagdescriptions
ne End of tnd of each o
g side to side
ease Cables
t to repair need to be r
ge
s Across the
m performams. Failure d System pe
re inserted, t
A
ed parts usin
ufactured sped to repair aSystem and/or death.
Chain to loced position. ply may resudeath.
amaged. Do sure that the
ers and desc
ged. Refer tos of the part
he Top cabof the four To
e.
s
a damagedreplaced eve
e Arm Asse
nce, only usto use the c
erformance.
the System
CrAll rights in co
ng part desc
pecifically foa damaged /or an untes
ck the SysteDisconnect
ult in damag
not attempt e System cocriptions of th
o the drawints.
bles op Cables.
d Cartridge. en if they w
emblies
se Release correct equip
may shift sid
eated April, opyright rese
criptions sho
or this produSystem. Fa
sted effect o
em while wot the power ge to the Sys
to weld or ollapses prophe parts.
gs at the en
For full teere only cru
Cables suppment could
de to side.
2012 erved
wn in
uct by ailure
on the
orking while stem,
perly.
d of
ested ushed
pplied d lead
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Verify thaArm Assthat rougin place u
7. A
Remoof eaflat wRepe
ergyabsorptihwayguardra
at the Frameemblies. (Se
ghly an equausing remain
Attach Cartr
ove one endach bay. Usiwashers, lockeat procedur
TORQUE[25
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e is extendeee Figure 39al amount ofning fastene
ridges
d of each Aling a forklift k washers, are for Cartrid
CARTRIDG
E TO 34 -0/+35 -0/+2 ft-lbs]
ed as far as 9). Torque thf threads proers as "jam" n
ignment Caband sling, p
and nuts prodge II (see F
Figure
CART
GE II
3 Nm
38
it will go. Ahe nuts to 34otrude from nuts.
ble from the place Cartridovided. Torqigure 40).
RELEACABL
e 39
Figure
TRIDGE I
A
Attach the Bo4 -0/+3 Nm nuts on both
TMA and sdge I in posue the nuts
ASE LE
e 40Cr
All rights in co
ottom Relea(25 -0/+2 ft-h ends of C
et aside to csition and se
to 120 ± 7 N
eated April, opyright rese
ase Cable ac-lbs) makingable. Lock C
clear the topecure it usinNm [90 ± 5ft
2012 erved
cross g sure Cable
p side g the t-lbs.]
www.energyabsorption.com 39 Created April, 2012 www.highwayguardrail.com All rights in copyright reserved
8. Attach the Top Release Cables across the Arm Assemblies
Attach the Top Release Cable across the Arm Assemblies (see Figure 39). Torque the nuts to 34 -0/+3 Nm (25 -0/+2 ft-lbs), making sure that roughly an equal amount of threads protrude from nuts on both ends of cable. Lock cable in place using remaining fasteners as "jam" nuts.
9. Reattach and Adjust the Alignment Cables There are four Top Cables (two for each bay). Reattach the Alignment Cables as shown in Figure 41. Measure the diagonals of each bay and adjust the Cables so that the diagonal measurements in each bay are the same (A = B ± 5 mm [3/16"], C = D ± 5 mm [3/16"]). Lock each Cable in place using the second nut as a “jam nut”. (See Detail 41A)
10. Replace Side Guides
The Side-Guides must be inspected and replaced if damaged. The Side-Guides are sacrificial and can be easily attached to their respective mounts. Side-Guides are necessary for proper System alignment during an impact and must be in place to ensure tested performance characteristics during System operation in an impact.
Figure 41 (Support Frame not shown for clarity)
SEE DETAIL 41A
Detail 41A
1 1/2” O.D.X 1 1/8” LONG SPRING SPACER
3/4” I.D. X 1 1/2” O.D. FLAT WASHER
5/16” X 81” CABLE WITH 5.8” DIA. STUD ENDS
1 1/4” O.D. X 5/8” I.D. X 1 1/2” DIE SPRING
B A DC
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11. A
TACpcacu
TChotigb1/sew
12. A
Rfrule
SEE DETA
ergyabsorptihwayguardra
Attach and T
There are foAttach thimblCables to th
rovided shaable throughain loop ansing a die sp
To properly Cables, lowe
orizontal pone Cable ughten it unteen comp/4±1/16"]. Lecond "jam
with other Ca
Adjust the H
Retract Jacksrom the grounder the Lo
evelness of t
IL H
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Tension the
our Cartridgle end of ale Frame asckles. Pass h the corre
nd attach as pring, washe
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osition. Tighntil all slackil the Tensio
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ables.
Height and L
s slightly off und at the froower Attachthe Cartridge
ANTI-T
SOCKE
305±25 m
e Cartridge
e Support l Cartridge Ss shown usthe stud ensponding Cshown in Fi
er, and nuts.
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o 32±2 mut in place weat this pro
Levelness o
ground. Veront and rearhment Bracke. See Figur
F
TILT CHAIN
ET HITCH
mm [12±1”]
40
Support Ca
Cables. Support sing the d of the
Cartridge gure 42 .
Support to the
t nut on ed, then gs have mm [1 with the ocedure
of the Syste
rify that the Sr of the Systket on the re 43.
CARSUPPO(THREA
Figure 43
ASSEMBLY
TENSIONIN
A
ables
em Frame
System Framem. It may bFrame Sup
RTRIDGE ORT CABLEADED END
DetY
NG SPRING
305±25
CrAll rights in co
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SHACKLE
S(
E )
32 mm
Figu
tail H O
G
mm [12±1”]
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25 mm [12"ry to place S
der to adjus
E
CARTRIDGUPPORT C(THIMBLE E
WA
NU
[1 1/4”]
ure 42
SHIMS MAYOR REMOVE
NECACHIEVE
]
2012 erved
± 1"] Shims st the
GE ABLE
END)
ASHER
UTS
Y BE ADDEED HERE A
CESSARY TOLEVELNESOF SYSTEM
D S O S M
www.energyabsorption.com 41 Created April, 2012 www.highwayguardrail.com All rights in copyright reserved
13. Reconnect Power Connections Reconnect power and ground cables from battery.
14. Check System Lights for Proper Operation
Verify that all the turn/stop/tail lights are working properly. Replace any bulbs that are out.
15. Verify Position of Hydraulic/Electric Lines
Check the location of all the hydraulic and electrical lines to make sure they will not be damaged during the tilting of the system up or down.
16. Final Check
Check the tightness of all the fasteners. Check all steel cables to verify that they are properly attached and tightened.
17. Ready to Use The System is now ready for use.
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Troub(Make aTroubles
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Test EThe follohydraulic
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42
g part desc
protection wng with hydrerious injury
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Systems Cuthe TMA shoce, not a degy Absorptioand repair, otance.
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www.energyabsorption.com 44 Created April, 2012 www.highwayguardrail.com All rights in copyright reserved
E. The viscosity index should be as high as possible. As an example, ATF has the following specs as listed by most oil manufacturers:
[1] Viscosity (SUS)
37 deg. C [100 deg. F] 185 to 205
99 deg. C [210 deg. F] 45 to 55
[2] Pour Point
-44 deg. C [-45 deg. F] to -37 deg. C [-35 deg. F]
[3] Viscosity Index 145 to 165
NOTE: In an emergency, for cold weather applications, it is permissible to use SAE 10 W non-detergent oil mixed by volume with no more than 30% #1 fuel oil or kerosene. Afterward, flush system and add fluid as outlined above.
Pump Priming 1. New Assemblies
New system assemblies, as well as those that are disassembled for repair, require proper priming to avoid possible pump failure. A pump is said to be ''primed'' when the internal cavity is full of fluid and the air has been expelled.
A. Prime a pump as follows:
1. ''Crack'' or remove the high pressure line at or near the cylinder.
2. ''Jog'' the unit until fluid flow is clear.
3. Retighten or replace hose.
2. If a System fails to prime or loses its prime, check for the following:
A. Partially clogged suction filter (see Filter section).
B. A loose or improperly installed suction hose or pickup tube.
C. Bad front pump seal (see Pump section).
D. A solid fill plug in reservoir with no vent (see Reservoir section)
E. Fluid that is too thick (see Hydraulic fluid section) or contaminated with water (see Reservoir section).
F. Occasionally a pump will not prime itself because a check valve spring in the high pressure port is too ''stiff'' or the spring retainer is turned down too far. If this condition is suspected, loosen the spring retainer (found in the high pressure outlet port), energize the pump to prime it, and then turn the retainer back to the correct depth (see section on Check Valves).
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Filters Most pump systems have filters which must be cleaned periodically or whenever flow is slow or sluggish. Some filters may be washed in cleaning solvent and blown dry with compressed air. Those which cannot be cleaned sufficiently should be replaced. External high pressure filters may be added to the system for added protection and ease of cleaning.
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4. Shorts, “Grounding Faults” and “Open Circuits”
In control wiring, shorts can only occur when ''hot'' lines (lines connected directly to the battery) come in contact with a ground. A short will either cause a fuse to blow, if there is a fuse, or burn the wire off at its weakest point. Likely spots for shorts are switches, electrical strain reliefs, electrical junction boxes, and a control cord which has been pinched or cut.
Grounding faults are much like shorts except they occur on the opposite side of the electrical component. A ''ground fault'' will cause the coil in the motor solenoid switch to remain energized. This type of failure can happen because switching is done in the ground wire due to the construction of the motor solenoid switch (See ''3 - Electrical Switches, C - 1). Likely spots for ''faults'' are the same as for shorts - See above.
An ''open'' circuit is simply a break which prohibits current flow. Likely spots for ''open'' circuits are the same as shorts - See above.
5. Solenoid Coils
Coils are used in solenoid operated valves and start switches. Failures can be caused by vibration, water, improper voltage, or corrosion. The best way to test a coil is with an ohmmeter. The meter should read some value of ohms. An infinite reading means that the coil has an open circuit. The reading between any lead on the coil and the ''can'' should be infinite unless there is only one lead wire and the coil is grounded to the ''can''.
6. Electrical Polarity
Pump motors supplied with TMA's can be used on either positive or negative ground systems.
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Hydraulic Quick Troubleshooting Guide
Finding and Solving Problems: Hydraulic system failures usually follow a similar pattern: A gradual or sudden loss of pressure or flow, followed by a loss of cylinder or motor power. Any of the systems components could be the cause. The problem may be solved by following a step by step procedure.
1. MOTOR FAILS TO START: Failed motor starter solenoid: Replace if necessary. Electrical switch inoperative: Repair or replace. "Open" circuit/Insufficient grounding: Check and correct. Motor inoperative: Repair or replace.
2. SYSTEM IS INOPERATIVE: No fluid in system; insufficient fluid in system; pump losing prime: Fill system; Check for leaks. Wrong fluid in system (Should be Dexron III): Change fluid. Clogged or dirty filter: Drain fluid and replace filter or element. Fluid line restricted: Line dirty or collapsed - Clean or replace fluid line. Air leaks in pump suction line: Repair or replace as needed. Worn or dirty pump: Clean, repair or replace; check alignment; check for contaminated fluid - drain, flush, and refill system with approved fluid Badly worn components (valves, cylinders, etc.): Examine and test for internal or external leakage. Replace faulty components. Check for cause of wear. Leakage: Check all components, especially the relief valve, for proper settings. Excessive load: Check for binding. Do not allow extra weight on lowered Cartridge. Broken pump drive: Repair or replace couplings, etc. Check for "Ground" fault.
3. SYSTEM OPERATES ERRATICALLY Air in system: Check suction side for leaks. Repair. Cold fluid: Allow system to warm up. Damaged or dirty components: Clean or repair as needed. Restricted lines or filters: Clean and /or replace lines or elements as necessary.
4. SYSTEM OPERATES SLOWLY Fluid viscosity too high or cold fluid: Allow fluid to warm up before operating or replace fluid with proper specified fluid. Low fluid level: Check reservoir & add fluid as necessary. Air in system: Check suction side for leaks - repair; cycle system several times to relieve air from system. Worn pump, valves, cylinders, etc: Replace or repair as necessary. Restriction in lines or filters: Clean or replace elements or lines. Improperly adjusted flow control valve: Replace or adjust as necessary. Oil leaks: Tighten fittings; replace seals or damaged lines. Low Voltage: Using volt meter and/or ohmmeter, check system. (See “Electrical Problems” on page 51.) Check alternator; check connections.
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Parts Lists (For ordering: see drawings, back of Manual) Frame Preassembly, Galvanized, P/N 618268B, Dwg 618268 ITEM STOCK NO. DESCRIPTION QTY. 1 618238B FRAME,HD BACKUP,SUPPORT,8292,GALVANIZED,W/DECALS 1 2 618247G FRAME,FRONT,8292,HD,GALVANIZED 1 3 618244G FRAME,MIDDLE,8292,GALVANIZED 1 4 618245G FRAME,REAR,8292,GALVANIZED 1 5 618254G ARM,FRONT W/SUPPORT,8292,GALVANIZED 2 6 618255G ARM,FRONT,8292,GALVANIZED 2 7 618262G ARM,REAR W/SUPPORT,8292,GALVANIZED 2 8 618264G ARM,REAR,8292,GALVANIZED 2 9 118386G PIN,CLEVIS,1X3 3/4,P 24 10 116276G PIN,COTTER,3/16X1 1/2,P 24 11 116249G PIN,AXLE,1 1/2X9,P 2 12 118000G WASHER,FLAT,1 1/2 SAE,P 4 13 116270B PIN,COTTER,1/4x2 1/2,S 4 14 115067B GREASE FITTING,1/4‐28,STR 4 15 113943B CABLE,5/16X81 1/2,5/8 STUD ENDS 4 16 614548W SPACER,SPRING,1 1/2 ODX1 1/8,B 2 17 118026G WASHER,FLAT,3/4 X 1 1/2,G 2 18 117459B SPRING,DIE,1 1/4 OD X5/8X1 1/2,B 2 19 614493W SPACER 1/2X3X4 1/2,W/HOLES,B 2 20 113807B BUMPER,RUBBER,3 1/8X5X3.5H,2 HOLES 2 21 113486G BOLT,HX,1/2X5 1/4,P 4 22 118083G WASHER,LOCK,1/2,P 4 23 115941G NUT,HX,1/2,P 4 24 114459B DECAL,CAUTION,STAY CLEAR 2 25 114612B DECAL,RELEASE CABLE TORQUE,SS 4
Frame Preassembly, Black, P/N 618269B, Dwg 618268 ITEM STOCK NO. DESCRIPTION QTY. 1 618242B FRAME,HD BACKUP,SUPPORT,8292,BLACK,W/DECALS 1 2 618248W FRAME,FRONT,8292,HD,BLACK 1 3 618244W FRAME,MIDDLE,8292,BLACK 1 4 61824GW FRAME,REAR,8292,BLACK 1 5 618256W ARM,FRONT W/SUPPORT,8292,BLACK 2 6 618257W ARM,FRONT,8292,BLACK 2 7 618265W ARM,REAR W/SUPPORT,8292,BLACK 2 8 618264G ARM,REAR,8292,,BLACK 2 9 118386G PIN,CLEVIS,1X3 3/4,P 24 10 116276G PIN,COTTER,3/16X1 1/2,P 24 11 116249G PIN,AXLE,1 1/2X9,P 2 12 118000G WASHER,FLAT,1 1/2 SAE,P 4 13 116270B PIN,COTTER,1/4x2 1/2,S 4
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14 115067B GREASE FITTING,1/4‐28,STR 4 15 113943B CABLE,5/16X81 1/2,5/8 STUD ENDS 4 16 614548W SPACER,SPRING,1 1/2 ODX1 1/8,B 2 17 118026G WASHER,FLAT,3/4 X 1 1/2,G 2 18 117459B SPRING,DIE,1 1/4 OD X5/8X1 1/2,B 2 19 614493W SPACER 1/2X3X4 1/2,W/HOLES,B 2 20 113807B BUMPER,RUBBER,3 1/8X5X3.5H,2 HOLES 2 21 113486G BOLT,HX,1/2X5 1/4,P 4 22 118083G WASHER,LOCK,1/2,P 4 23 115941G NUT,HX,1/2,P 4 24 114459B DECAL,CAUTION,STAY CLEAR 2 25 114612B DECAL,RELEASE CABLE TORQUE,SS 4
Frame Preassembly, Yellow, P/N 618270B, Dwg 618268 ITEM STOCK NO. DESCRIPTION QTY. 1 618238B FRAME,HD BACKUP,SUPPORT,8292,YELLOW,W/DECALS 1 2 618247G FRAME,FRONT,8292,HD, YELLOW 1 3 618244G FRAME,MIDDLE,8292, YELLOW 1 4 618245G FRAME,REAR,8292, YELLOW 1 5 618254G ARM,FRONT W/SUPPORT,8292, YELLOW 2 6 618255G ARM,FRONT,8292, YELLOW 2 7 618262G ARM,REAR W/SUPPORT,8292, YELLOW 2 8 618264G ARM,REAR,8292, YELLOW 2 9 118386G PIN,CLEVIS,1X3 3/4,P 24 10 116276G PIN,COTTER,3/16X1 1/2,P 24 11 116249G PIN,AXLE,1 1/2X9,P 2 12 118000G WASHER,FLAT,1 1/2 SAE,P 4 13 116270B PIN,COTTER,1/4x2 1/2,S 4 14 115067B GREASE FITTING,1/4‐28,STR 4 15 113943B CABLE,5/16X81 1/2,5/8 STUD ENDS 4 16 614548W SPACER,SPRING,1 1/2 ODX1 1/8,B 2 17 118026G WASHER,FLAT,3/4 X 1 1/2,G 2 18 117459B SPRING,DIE,1 1/4 OD X5/8X1 1/2,B 2 19 614493W SPACER 1/2X3X4 1/2,W/HOLES,B 2 20 113807B BUMPER,RUBBER,3 1/8X5X3.5H,2 HOLES 2 21 113486G BOLT,HX,1/2X5 1/4,P 4 22 118083G WASHER,LOCK,1/2,P 4 23 115941G NUT,HX,1/2,P 4 24 114459B DECAL,CAUTION,STAY CLEAR 2 25 114612B DECAL,RELEASE CABLE TORQUE,SS 4
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Hydraulic/Electrical Assembly, P/N 618586B, Dwg 618586 ITEM STOCK NO. DESCRIPTION QTY. 1 114413B CYLINDER,3B,12S 2 2 118320B PUMP,SEAL MOTOR,VERT,12V,HEAVY DUTY 1 3 118511G BOLT,HX,3/8X2 3/4,G2,P 2 4 118037G WASHER,FLAT,3/8X1,P 2 5 118093G WASHER,LOCK,3/8,P 2 6 618277B ELECTRICAL BOX,HYDRAULIC PUMP,12V,8292 1 7 116620B REDUCER,BUSHING,1/2X1/4 NPT,P 2 8 114825G ELBOW,MALE,1/2X3/8,P 2 9 116253G PIN,CLEVIS,1X3 1/2,P 4 10 116276G PIN,COTTER,3/16X1 1/2,P 4 11 117709B TEE,BRANCH,1/4,FEMALE,P 2 12 114838B ELBOW,STREET,4MP‐4FP,P 4 13 114836B ELBOW,STREET,3/8MALE X 1/4FEM,P 2 14 114784G ELBOW,#4M‐ORB X #4‐NPT,P 2 15 115174B HOSE ASSY,HYDRAULIC,36" 4 16 115176B HOSE ASSY,HYDRAULIC,44" 2 17 115946G NUT,HX,1/4,G 4 18 118086G WASHER,LOCK,1/4,P 4 19 118016G WASHER,FLAT,1/4X1,P 4 20 113518G BOLT,HX,1/4X3/4,G 4 23 117783B TIE,NYLON,14,BLACK 10
Lighting Assembly, 12V LED P/N 618533B, Dwg 618533 ITEM STOCK NO. DESCRIPTION QTY. 1 618289G BRACKET,LIGHT,FRONT,8292,G 2 2 618288G BRACKET,LIGHT,ICC,8292,G 1 3 618287G BRACKET,LAMP,MARKER,8292,G 2 4 618290G BRACKET,HARNESS,8292,G 4 5 116890G SCREW,HWH,1/4X1,SELF DRILL/TAP,P 19 6 118478B LIGHT AND HARNESS KIT,12V,LED,8292 1 7 117783B TIE,NYLON,14,BLACK 42
Lighting Assembly, 12V Incandescent P/N 618531B, Dwg 618531
ITEM STOCK NO. DESCRIPTION QTY.1 618289G BRACKET,LIGHT,FRONT,8292,G 2 2 618288G BRACKET,LIGHT,ICC,8292,G 1 3 618287G BRACKET,LAMP,MARKER,8292,G 2 4 618290G BRACKET,HARNESS,8292,G 4 5 116890G SCREW,HWH,1/4X1,SELF DRILL/TAP,P 19 6 118477B LIGHT AND HARNESS KIT,12V,STD,8292 1 7 117783B TIE,NYLON,14,BLACK 42
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Lighting Assembly, 24V Incandescent P/N 618534B, Dwg 618534 ITEM STOCK NO. DESCRIPTION QTY.1 618289G BRACKET,LIGHT,FRONT,8292,G 2 2 618288G BRACKET,LIGHT,ICC,8292,G 1 3 618287G BRACKET,LAMP,MARKER,8292,G 2 4 618290G BRACKET,HARNESS,8292,G 4 5 116890G SCREW,HWH,1/4X1,SELF DRILL/TAP,P 19 6 118479B LIGHT AND HARNESS KIT,24V,STD,8292 1 7 117783B TIE,NYLON,14,BLACK 42
Rear Plate Striping Assembly P/N 618505B, Dwg 618505 1 618485B STRIPING ASSY,BLACK,4",8292 1 2 116890G SCREW,HWH,1/4X1,SELF DRILL/TAP,P 19
Miscellaneous Hardware Kit, Galvanized P/N 618266B, Dwg 618266 ITEM STOCK NO. DESCRIPTION QTY.1 117069G SHACKLE,ANCHOR,1/4 5 3 113917B CABLE,1/4X73,STUD W/THIMBLE 4 4 117460B SPRING,DIE,1 1/4 ODX9/16X1 1/2,Y 4 5 118008G WASHER,FLAT,1/2X1 3/8,P 4 6 614052B SHIM KIT,TMA8291,GALVANIZED 1 7 610100G GUSSET,CORNER,8291,GALVANIZED 4 8 610025G GUIDE,FRAME,8291,GALVANIZED 4 9 113587G BOLT,HX,3/8X1 1/2,G5,P 16 10 118093G WASHER,LOCK,3/8,P 32 11 115963G NUT,HX,3/8,P 16 12 113476G BOLT,HX,1/2X3,G2,G 8 13 118082G WASHER,LOCK,1/2,G 8 14 115939G NUT,HX,1/2,G 8 15 613712B RELEASE CABLE ASSEMBLY,8291 4 16 005678B TMA‐JACK (1200#,XP10) 4 17 113598G BOLT,HX,3/8X1,G5,P 16 18 115961G NUT,HX,3/8,G5,P 16 20 115674B MATERIAL SAFETY INFORMATION NOTICE 1 21 618542B INSTALLATION INSTRUCTIONS,TMA8292 1 21 618294B CHAIN,W/COVER,24 1
1 Miscellaneous Hardware Kit, Black P/N 618267B, Dwg 618266 ITEM STOCK NO. DESCRIPTION QTY.1 117069G SHACKLE,ANCHOR,1/4 5 3 113917B CABLE,1/4X73,STUD W/THIMBLE 4 4 117460B SPRING,DIE,1 1/4 ODX9/16X1 1/2,Y 4
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Miscellaneous Hardware Kit, Black P/N 618267B, Dwg 618266 (cont’d) ITEM STOCK NO. DESCRIPTION QTY.5 118008G WASHER,FLAT,1/2X1 3/8,P 4 6 614051B SHIM KIT,TMA8291,BLACK 1 7 610101W GUSSET,CORNER,8291,BLACK 4 8 610026W GUIDE,FRAME,8291,BLACK 4 9 113587G BOLT,HX,3/8X1 1/2,G5,P 16 10 118093G WASHER,LOCK,3/8,P 32 11 115963G NUT,HX,3/8,P 16 12 113476G BOLT,HX,1/2X3,G2,G 8 13 118082G WASHER,LOCK,1/2,G 8 14 115939G NUT,HX,1/2,G 8 15 613712B RELEASE CABLE ASSEMBLY,8291 4 16 005678B TMA‐JACK (1200#,XP10) 4 17 113598G BOLT,HX,3/8X1,G5,P 16 18 115961G NUT,HX,3/8,G5,P 16 20 115674B MATERIAL SAFETY INFORMATION NOTICE 1 21 618542B INSTALLATION INSTRUCTIONS,TMA8292 1 21 618294B CHAIN,W/COVER,24 1
1 Miscellaneous Hardware Kit, Yellow P/N 618275B, Dwg 618266 ITEM STOCK NO. DESCRIPTION QTY.1 117069G SHACKLE,ANCHOR,1/4 5 3 113917B CABLE,1/4X73,STUD W/THIMBLE 4 4 117460B SPRING,DIE,1 1/4 ODX9/16X1 1/2,Y 4 5 118008G WASHER,FLAT,1/2X1 3/8,P 4 6 618274B SHIM KIT,TMA8291,YELLOW 1 7 610101Y GUSSET,CORNER,8291,YELLOW 4 8 610026Y GUIDE,FRAME,8291,YELLOW 4 9 113587G BOLT,HX,3/8X1 1/2,G5,P 16 10 118093G WASHER,LOCK,3/8,P 32 11 115963G NUT,HX,3/8,P 16 12 113476G BOLT,HX,1/2X3,G2,G 8 13 118082G WASHER,LOCK,1/2,G 8 14 115939G NUT,HX,1/2,G 8 15 613712B RELEASE CABLE ASSEMBLY,8291 4 16 005678B TMA‐JACK (1200#,XP10) 4 17 113598G BOLT,HX,3/8X1,G5,P 16 18 115961G NUT,HX,3/8,G5,P 16 19 604395B ATTACHMENT ASSY,TMA8290 1 20 115674B MATERIAL SAFETY INFORMATION NOTICE 1 21 618542B INSTALLATION INSTRUCTIONS,TMA8292 1 21 618294B CHAIN,W/COVER,24 1
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Miscellaneous Hardware Kit, Black P/N 616797B, Dwg 616797 ITEM STOCK NO. DESCRIPTION QTY.1 614467B SOCKET RECEIVER,UNDERRIDE,L 5 2 614472B SOCKET RECEIVER,UNDERRIDE,R 4 3 611413B MOUNT,SUPPORT,TMA,L 4 4 611415B MOUNT,SUPPORT,TMA,R 4 5 116295G PIN,HITCH,1X6 1/4,W/SNAP PIN 1 6 617780B TUBE,SPACER 4 7 614590B SPLICE,SPACER 4 8 605506B BRACKET,LOWER TRUCK, W/HOLES 16 9 116104B PAINT,BLACK,ENAMEL,GLOSS,SPRAY 32 10 115252B INSTALL INSTRUCTIONS,RECEIVER UNDERRIDE 16 11 116505G PRIMER,SPRAY CAN 8
Attachment Assembly, SST P/N 604395B, Dwg 604395 ITEM STOCK NO. DESCRIPTION QTY.1 605584W BRACKET,SUPPORT,RIGHT,TMW 9180,PT 1 2 605581W BRACKET,SUPPORT,LEFT,TMW 9180,PT 1 3 113532G BOLT,HX,1X3 1/2,G8,P 8 4 115932G NUT,HX,1,G8,P 8 5 118080G WASHER,LOCK,1,G 8 6 118004G WASHER,FLAT,1X2 1/2,G 12 7 116293G PIN,HITCH,1/1/4X7,PW/HAIRPIN COTTER 2 8 614059W SHIM,1/4X5X10,PT 8 9 614063W SHIM,1/2X5X10,PT 8 10 613758W RESTRAINT,SUPPORT FRAME,BACKUP,SST,PT 2 11 114121G CLEVIS LINK,DOUBLE,5/16 2
Attachment Assembly, SST P/N 604395B, Dwg 604395 ITEM STOCK NO. DESCRIPTION QTY.1 605583G BRACKET,SUPPORT,RIGHT,TMW 9180,PT 1 2 60558OG BRACKET,SUPPORT,LEFT,TMW 9180,PT 1 3 113532G BOLT,HX,1X3 1/2,G8,P 8 4 115932G NUT,HX,1,G8,P 8 5 118080G WASHER,LOCK,1,G 8 6 118004G WASHER,FLAT,1X2 1/2,G 12 7 116293G PIN,HITCH,1/1/4X7,PW/HAIRPIN COTTER 2 8 614059W SHIM,1/4X5X10,PT 8 9 614063W SHIM,1/2X5X10,PT 8 10 613729G RESTRAINT,SUPPORT FRAME,BACKUP,SST,PT 2 11 114121G CLEVIS LINK,DOUBLE,5/16 2
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Detail Drawings
Drawing Description Page 616797 UNDERRIDE ASSY 61
618268 PRE-ASSY,FRAME,8292 62
618271 PRE-ASSY,FRAME,8292,EUG 64
601266 MISCELLANEOUS HARDWARE 66
618586 HYDRAULIC/ELECTRICAL ASSY 68
618533 LIGHTING ASSY,LED,12V 71
648531 LIGHTING ASSY,INCANDESCENT,12V 73
618534 LIGHTING ASSY,INCANDESCENT,24V 76
618505 REAR PLATE ASSY,W/STRIPING 79
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SEE D
61
DWG 61679
A
97
CrAll rights in co
eated April, opyright rese
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SEE DWG
62
G 618268 SH
A
H 1
CrAll rights in co
eated April, opyright rese
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SEE DWG63
G 618268 SH
A
H 2 Cr
All rights in coeated April, opyright rese
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SEE DWG64
G 618271 SH
A
H 1 Cr
All rights in coeated April, opyright rese
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SE65
EE DWG 618
A
8271 SH 2Cr
All rights in coeated April, opyright rese
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SEE66
DWG 6182
A
266 Cr
All rights in coeated April, opyright rese
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SE67
EE DWG 61
A
8586 SH 1Cr
All rights in coeated April, opyright rese
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SEE DW68
WG 618586
A
6 SH 2 Cr
All rights in coeated April, opyright rese
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SEE DWG69
G 618586 SH
A
H 3 Cr
All rights in coeated April, opyright rese
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SEE 70
DWG 61853
A
33 SH 1 Cr
All rights in coeated April, opyright rese
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SEE DW71
G 618533 S
A
SH 2 Cr
All rights in coeated April, opyright rese
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SE
72
EE DWG 618
A
8533 SH 3
CrAll rights in co
eated April, opyright rese
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SEE D
73
WG 618531
A
SH 1
CrAll rights in co
eated April, opyright rese
2012 erved
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SEE DW74
WG 618531
A
SH 2 Cr
All rights in coeated April, opyright rese
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SEE DW75
G 618531 S
A
SH 3 Cr
All rights in coeated April, opyright rese
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SEE D76
DWG 618534
A
4 SH 1 Cr
All rights in coeated April, opyright rese
2012 erved
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SEE DWG 6177
18534 SH 2
ACr
All rights in coeated April, opyright rese
2012 erved
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SEE DW78
G 618534 S
A
SH 3 Cr
All rights in coeated April, opyright rese
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SEE D79
DWG 618505
A
5 Cr
All rights in coeated April, opyright rese
2012 erved
2525 Stemmons FreewayDallas, Texas 75207
888-323-6374 (USA only)312-467-6750 (Outside USA)
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