ss90™ hd tma product description assembly manual

SS90™HD TMAProduct DescriptionAssembly Manual

Rev – April 2012Part No. 618589B

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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


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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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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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.


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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Notemuch

Measure fromny other ob

Receiver. A m

STEPS 4 & 5

UNDERRRE

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st e level to verto the final d[16,090 lbs]the truck to quires no baprotruding Tto exceed

ving characed center-of-g

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mp bodies (in

sembly ck on a leve

distance fro[28±1"] is reheight (see U

: The truck’sas 50 mm [2

m the back ebstruction onminimum of 3

STEP 6

RIDE SOCKECEIVER

SUM

rify that the driving weig] minimum wkeep it in p

allast, shoulTMA is suppthe manufa

cteristics of gravity zone

ch the Underse to the mohan a standah your assem

Underride Sfor interferen the up or

el surface. Mom the grouequired. SpaUnderride As

s springs ma2"]. Adjust th

end of the frn the bottom305 mm [12

STEP 7

ATTAASS

SET

PPORT OUNT

F

15

truck is parkht as possibweight, add place during d be used.

ported by thecturer's pubthe vehicle

e should also

rride, check ounting locatard socket r

mbly, then skSocket Recence problemdown posit

Make sure tund to the bacers may bssembly dra

ay settle withe height to

rame forwardm of the fra"] is required

ACHMENT SEMBLY

SUPPORTFRAME

STEPS 8 & 9

Figure 11

A

ked on a levble. If ballasit at this timan impact. Because thee back of theblished maxie are maino be adhered

for interferetion. See Figreceiver hitckip to step 8eiver under

ms. Interferetions), etc.,

the truck is bottom of thebe added toawing).

h the weighcompensate

d to the reaame that mad (see Unde

T STEP

14

S

CrAll rights in co

vel surface. st must be ame. Ballast mIdeally, an ae 910 kg [2e shadow veimum axle lntained, thed to.

ence problemgure 38, pa

ch underride. truck framence problemshould be

at its actuae truck framo the bottom

t of the TMAe for anticipa

r-most leaf say interfere

erride Assem

P STEP10

STEP 20


The truck shadded to acmust be proadequately 000 lb] weigehicle, care oads. To en

e manufactu

ms. ge 34. If yo

e, refer to sp

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u are pecial

(refer ights,

before

eight. ce of

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P

UNS

RE


Position the 3” x 15 1/4"]

Tube is flushTube and lap

cross the SAssembly drarom the leve

Weld the Soc15 1/4"] flat

Note: AWS Dbattery

Warniapply hanger

Prime and pa

DERRIDE SOCKET ECEIVER

F

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p the Spaceocket Receiawing). The l ground for

cket Receivet bar on the o

All welding D1.1 in accoy before weld

ng: The truexcessive hrs.

aint all welde

FL

Figure 12

ceiver at thealong the outnd of frame. er Splices (piver Tube antop of the Sproper syste

er Tube to thouter side of

must be peordance withding.

ck frame is heat to the

ed areas.

LAT BAR

TRUCK F

16

e rear end otside of the If Spacers a

pieces of 10nd Spacer a

Socket Receem height (s

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high carbonbottom fla

FRAME

A

of the frameframe membare required

0 x 51 x 103at the rear-meiver Tubes see Figure 1

f the truck fra(see Figure

y a welder cride Assemb

n steel. To avange, forwa

UNDERSOC

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710NO

Figur

34±

CrAll rights in co

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ame with the12).

certified to Ably drawing.

void crackinrd of rear-m

RRIDE CKET EIVER

0 mm [28”] OMINAL

re 13

±1”


he 76 x 387Socket Rec

m to the Recx 2 x 4"] flatn (see Unde25 mm [28

e 76 x 387 m

AWS D14.3-Disconnect

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TRUCK FR

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mm [3

82 or truck

eld or spring

RAME

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H


Note: and lev

ocket Hitch

nset the SocRetainer Pins

762

25[3

01”

]

WITH

HITCH & RE

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Left and rigvel.

Assembly

cket Hitches s shipped wi

TRU

762

± 25

mm

[30±

1”]

711

± 25

mm

[28

± 1”

]

H SPACERS

ETAINER PIN

ht Underride

and pin themth the Syste

FiguL

UCK FRAME

UNDERRIDSOCKET

RECEIVE

SPAC

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NS Figure

17

e Socket Re

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re 12 – SocLeft Side Sh

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DE T R

CER TUBES

FLUSH WFRAME E

15

LEFT SO

A

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using the 1

cket Hitch hown

S

WITH END

RIGHT S

OCKET HITC

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x 6 1/4” Hitc

TRU

WITHOU

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± 25

mm

[28±

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OCKET HIT

CH


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ch Pins and

UCK FRAME

UNDESOC

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UT SPACER

TCH

2012 erved

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E

ERRIDE CKET

CEIVER

RS


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

MAautie

S

SU

SUPP

1” FLAT

” LOCK WA

1” HEX NUT


tach the Su

Move the SupAssembly, as

ttached whilpper set of mes and may

SUPPORT B(RIGH

PPORT MO(RIGHT)

PORT MOU(LEFT)

WASHER

ASHER

T

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upport Fram

pport Frames shown in Fe frame is s

mounting honeed to be

BRACKET HT)

OUNT

NT

1”

me/Backup t

e/Backup AssFigure 17. Th

till collapsedoles for the aremoved for

1” FLAT1” LOCK W

” HEX NUT

Fi

19

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

CrAll rights in co

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

SUPPO


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

RT BRACKE

2012 erved

t

e the y zip

R

T,G8

ET (LEFT)

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9. ExWA

10. AUa


xtend the SuWith the TMAAssembly out

Warnextrem

Warn

Attach CornUsing 1/2” bo

s shown in F

Warn

COGU

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upport FramA pinned tot to its full ex

ning: Even wme care. Fa

ning: Until th

er Gussets olts, nuts, flaFigure 18.

ning: When

ORNER USSETS

me o the Attachxtent.

when suppoailure to heed

he cables ar

at washers a

installing Co

Figure 18

1/2” F1/2” L

1/2” X

20

ment Assem

orted by the d this warnin

re attached,

nd lock was

orner Gusse

8

FLAT WASHLOCK WASH

1/2” HEX NX 3” HEX BO

PP

A

mbly, slowly

forklift, the fng could cau

the System

shers, attach

ets, be caref

HER HER NUT OLT

PINCH POINT

CrAll rights in co

y and evenly

frame can buse serious i

could shift t

h Corner Gu

ful of pinch p


y pull the F

be unwieldy. injury or dea

to one side.

ssets four p

points.

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2012 erved

Frame

Use ath.

laces

CORNER GUSSET

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11. A

VwaT0/eou

12. A

(IaAaUCua1pF

13. Aacros

Anfrfa


Attach the B Warnby Ento fatig

Verify that thewill go. Attac

cross Arm Torque the

/+2 ft-lbs], mqual amounn both endssing remain

Attach Cartr

f Alignmenttached, re

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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Bottom Rele

ning: For prnergy Absorpgue or resul

e Frame is ech the BottoAssembliesnuts to 34

making surnt of threadss of cable. ing fasteners

ridges

nt Cables move one able from ther the top sideorklift and n position

at washers, ovided. Torq

[90 ± 5ftfor Cartr

op ReleaseAssemblies

op Release Cm (25 ft-Ibs)n both ends "jam" nuts.

ease Cables

roper Systeption Systemt in unpredic

extended asom Releases. (see Fig4 -0/+3 Nmre that rous protrude frLock cable s as "jam" n

are alreaend of ea

e TMA and se of each ba

sling, plaand securelock washeue the nuts

ft-lbs.] Reperidge II (s

e Cables s

Cables acro, making surof cable. L

21

s across the

m performams. Failure ctable Syste

s far as it e Cables gure 19). m [25 -ughly an rom nuts in place

uts.

ady ach set

ay.) ace e it ers, to eat see

oss the Arm re that rough

Lock Releas

T

[2

CART

A

e Arm Asse

nce, use onto use the cm performa

Assemblieshly an equa

se Cables in

TORQUE TO34 -0/+3 Nm 25 -0/+2 ft-lbs]

Figure 2

CARTRID

TRIDGE II

CrAll rights in co

emblies.

nly Release correct equipnce.

s (see Figurel amount of n place usin

O ]

Figu

20

DGE I


Cables suppment could

e 19). Torquthreads pro

ng the rema

RELECA

ure 19

2012 erved

pplied d lead

ue the otrude aining

EASE ABLE

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14. A

Tsdm5

15. A

Tththsthaw

TCslT3wp

Figure 2

SEDETA


Attach and a

There are fohown in Figuiagonal mea

mm [3/16"], C0mm [1 1/2"

Note: TDetail Bcables c

Attach and a

There are fouhimble end he Frame hackles. Pashe correspottach as sho

washer, and

To properly Cables, tightelack is rem

Tensioning S2±2 mm [1

with the srocedure wit

1 (Support

EE AIL B

B A

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adjust Align

ur Alignmenure 21. Meaasurements C = D ± 5 mm" - 2"] when

he Die Spr) are only u

closest to th

adjust Cartr

ur Cartridge of all Cartrias shown

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

nment Cable

nt Cables (twsure the diain each baym [3/16"]) anpressed by h

ings, Sprinused at midhe truck.

ridge Suppo

Support Caidge Suppor

n using thend of the catridge chainre 22 using a

the Cartridgnut on one cn tighten

been com Lock this

m" nut. Rles.

shown for c

DC

22

es.

wo for eachgonals of ea

y are the samnd taut. Cabhand at the

g Spacers,d-frame, on

ort Cables.

ables. Attachrt Cables toe providedable throughn loop anda die spring

ge Supportcable until alit until the

mpressed tonut in place

Repeat this

clarity)

1 1/2S

5/16”CABL5.8” DEND

TE

A

h bay). Attacach bay and me within thbles are "tautcenter.

and flat wthe front tw

h o d h d ,

t l

e o e s

2” O.D.X 1 1/SPRING SPA

” X 81” LE WITH DIA. STUD S

CARTRISUPPO

CABL

ENSIONING

CrAll rights in co

ch the Alignadjust the ce given tolet" when they

washers (seewo Top Cab

Detail B

/8” LONG ACER

3/4

1 1/4X 1 1

SH

IDGE ORT LE

G SPRING


nment Cablecables so thaerance (A = By deflect 38

e Figure 21bles, i.e. the

4” I.D. X 1 1/FLAT WASH

4” O.D. X 5/81/2” DIE SPR

HACKLE

CARSUPPO(THIM

32±2 mm [1 1/4 ±1/6”]

Figure 22

2012 erved

es as at the B ± 5 mm -

1 and e two

/2” O.D. HER

8” I.D. RING

RTRIDGE ORT CABLE

MBLE END)

WASHER

NUTS

2

E

R

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16. A

Tas

17. ASyste

Vmanthle&

SDETA


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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Guides.

ur Side GuidBay 2. Attachure 23 and t

ht and level

e System Frfrom the gro

he System. Itadd or remoitch in order the cartridge

SIDESEE

305 ±25 m

es, two for Bh Side Guideighten bolts.

ness of the

rame is 305 ound at the ft may be ove Shims frto adjust the

e. See Figure

E GUIDE FIGURE 23

F

mm [12 ±1”]

23

Bay 1 es as .

e

± 25 front

rom e es 24

INTERF

Figure 24

A

F

SOCKET HITCH

SHIMHERLEVE

RMEDIATE FRAME

SIDE GSEE FI

CrAll rights in co

Figure 23

MS MAY BERE AS NECEELNESS OF

DetGUIDE

GURE 23

305 ±2


IMPAFRA

G

E ADDED ORESSARY TOF SYSTEMtail 24a

25 mm [12 ±

2012 erved

ACT AME

SIDE GUIDE

R REMOVEDO ACHIEVE

1”]

D

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18. C

Llife

Fp2

In6ofthathpa

Tnthb


Connect the

ocate the fefting or lowelectrical cord

or support vins 2 and 65.)

nstall the Ele7) with the 4f the proper

he system attaching the

he battery cinch or cut tssembly in d

NotelongeCable61835batter

The controls on-traffic sid

he controls racket. Mou

CL& I

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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

e Kit with fus56B.) Both ry.

at the rear de (side closto the othent the cab sw

LEARANCE, DENTIFICA

REVE

d Controls.

socket connMA will notA can reach

h combined ckside of the

to Plate mohers and nu

he SS90™HD

re compatiblles (e.g. do nd sharp coConnect thekage).

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

n the controb within easy

7-PIN FEMA

GR

side of Sock

CrAll rights in co

ocation on tl cable. Ma

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

Absorption Sbe connecte

o the Suppomove the fasols to the ey reach of th

LE SOCKET

ROUND TAIL LAM

RIGHT

STOP LAM

ket Connec


the truck, soke sure tha

a jumper betwVIEW A-A F

618586 on k battery musystems. Bey practices w, etc.) Do noareas that wsee the hyd

a 12V syste2 gauge Ba

ystems, Pared directly t

ort Frame, osteners and mexisting mouhe driver.

T

MPS

T TURN

MPS

ctor

2012 erved

o that at the

ween Figure

page ust be e sure when ot run would raulic

em. If attery rt No. to the

n the move

unting

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1

2

2

2

2


9. Check th

The Hydrshipping. operatingcheck to overfill. R

Read Opedamagedtwice. Tcycle the proper op

.

Note

0. Remove

The Jacktruck. Re

1. Verify Tu

Plug in th

2. Check po

Check thedamaged

3. Verify Hy

If the Syslock when

CautiSysteSyste

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he Hydraulic

raulic SystemThe pump the systemsee if the r

Replace the v

eration Instr, use the sw

This purges System usi

peration

: Continuous

and store J

s are providemove all fou

urn-Stop-Ta

e light cable

osition of th

e location of during turni

ydraulic Loc

stem is tiltedn the switch

ion: Each m is hydraum.

c System

m is pre-assis wired as , remove thereservoir is vent plug in t

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

FILL TO TH

25

sembled anshown on te cap from tfull. Add othe filler port

king sure allrear of the

he System.Switches to

may run dow

ate attachmeplace them

eration

all the turn/

c/Electrical

raulic and eof the syste

e Up Positio

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

ed, the opened before

F

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

es to be surewn.

ulic System waise and low

erator shouldallowing an

Figure 26


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

2012 erved

before Before

r and o not

not be down

m the

.

ot be

tically em.

at the d the


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.

www.enewww.hig

OperaBefore osafety se

For impaCartridge

The SS9up from ithe rear simply acthe TMAbutton. Controlleavailable

The comparked inTMA from

The syste

While ratraffic sidlowering

The contlocated in

Raise a

When op

Raising Switch uSystem wshould band for m


ation Insperating the

ection of this

act performae I and one C

90™HD TMA hits horizontaend of the

ctivates the A will hydrau

The Buzzeer) until the e, Part No. 6

mplete vertican congestedm the vertica

em can only

ising or lowde of the truTMA, or allo

trols are locn the truck c

and LoweCautiprocethe pa

perating from

the Systemntil the Systwhen the Roe used to en

maintenance

Cautithe Sythe ReRETA

on.com ail.com

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

m: To tilt thtem reachesocker Switchnsure that th

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.

a crash cus

MA from ous stay clear be positione

e side of theontroller Pa

ystemsure the t

er no circumSystem whe

ways be aw

e System us the 90-degh is releasedhe System s

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

are of objec

up, press angree positiond. In the 90stays in the 9

e doing mainthe "up" pos

n in Figure 2 WORK IS B

A

nd understanproperly atta

g, the TMA s as shown in

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

ab, the operparts. Nev

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.


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


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

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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


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

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he System w

m is importanSee Figure 28

e the drawingthe Cartridge.

aulic lines anunderneath f

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monthly or a


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Interva

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1 Month

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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


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

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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


Inte

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VariesSectio

1 Mon

1 Mon

1 Mo

6 Mon

Each

34

32

2012 erved

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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.


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

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are closed,

in any orienant vehicle ms a crash cuS90™HD TM

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ELECASS


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alves are opelocking the

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MA has an alure to follow

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SOLENO

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2012 erved

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is not operly n the alarm w this

CONTROL (Optional)

OID

TCH

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III. Det1. D

AB

CD

E

RETAP


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

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b Switch wire the Underri

s.* See Figu

emoval difficAttachment two 1 ¼ x

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s in Socket H

1

re 32

A

to the Tru

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cult, it may bBrackets fro

x 7” Hitch P33 and 27.)

Hitches so th

SOCKET H

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Receivers by

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ry to adjust Jket Hitches.etainer Pins

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2012 erved

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Jacks This

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2. Attac

A

B

C

D

E

F


. 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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ystem to the

TMA to the t

Socket Hitch6 ¼" Pin and

e necessary from the Suot fall out.

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Hydraulic/E

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UPPORT FRBA

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truck.

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ness and conwitch wires (

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Figure 3

RAME CKUP

33

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Underride SPin. If alignmJacks or tee. Be sure t

nnect the Po(optional) to

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280-330 mm

33

CL(ANTI

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per operatio

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1 1/4” X WITH HA

FRON

LEVIS LINK I-TILT CHAI

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er and GrouBox.

rage positio

on.

above the gro

Detail F

7” HITCH PAIRPIN COT

NT SUPPOR

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– Both Sid

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TAIL F

2012 erved

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IV. Lub1. A

Aws

2. G

G


brication Add HydraulAdd hydraulicwhen the fluidhows the loc

Notespillag

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RESERVO

FILL TO T

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lic Fluid c fluid as reqd level is clocation of the

: When hage. Clean u

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OIR FILL PO

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quired and cose to the fill hydraulic flu

ndling hydrp spillage im

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ORT

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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

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priate meas

See figure 3

REASE THESICTION POARING GRE

REASE THESICTION PO

GHT MACHIN


servoir is fulic fluid. Figu

sures to pre

35.

SE INTS USINGEASE

SE INTS USINGNE OIL

2012 erved

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G

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3. O

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4. C

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Oil and Grea

Oil and greas

Change the

Change the Reservoir cap

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without cavitaf the bleed d

GREAS

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ase Swivel J

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OIL HER

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RE

F

35

ry six month

2 years. U

may need tothe System

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Figure 36

A

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Use Dexron®

o be filled am. As the TMuid until Sysed, the Rese

CrAll rights in co

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® III fluid o

and cycled MA is raise

stem will raiservoir will ov


6.

only. The P

several timd, the Pumse to 90 degverflow at the

2012 erved

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es to p will grees e end

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V. Tech1. Weigh

Cartridge

Cartridge

Frame C

Jacks

Total

2. Dime

3. Repla

For detainclude th(888)-323

4. Opera

The SystLowering

8


hnical Spht

e I

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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”]

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pecificatio

109

162

163

86

199

e Figures 37

rts

cement partsbers and de

raised from m takes abou

m [8”]

3967

CENTEGRAV

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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”


al. The drawer Service:

0 seconds.

4013mm

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”]

2012 erved

wings

[13’-2”]

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RepaiParts Lis IV. Pos

1. InRstR

2. InRth

3. EE

4. R

5. In

6. A


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

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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


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


at the Frameemblies. (Se

ghly an equausing remain

Attach Cartr

ove one endach bay. Usiwashers, lockeat procedur

TORQUE[25

on.com ail.com

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


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.]


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


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

tension the er the SS9

osition. Tighntil all slackil the Tensio

pressed toLock this nu" nut. Repe

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.

Cartridge S90™HD TMA hten the firstk is removeoning Spring

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

me is 305 ± be necessarpport in ord

SHACKLE

S(

E )

32 mm

Figu

tail H O

G

mm [12±1”]


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


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.

www.enewww.hig

Troub(Make aTroubles

In geassoaid fprobnot Cust

Test EThe follohydraulic

1. Pres

A 34inexp

2. D.C.

A teconncircuwith

3. Con

A coelect

4. Volt

A D.Grouvoltawire othe

5. Ohm

An oOn s


bleshoota list of all shooting sect

Cautipowerand ca DangpressUse e

eneral, consociated with for performi

blems not listoperate th

tomer Servic

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ssure Gaug

4,450 kPa [5pensive tool

Test Light

est light is anected to a muit. With the a hot electri

tinuity Ligh

ontinuity lightrical circuits

Meter

C. voltmeteund one proage at the po

or componr end of the

mmeter

ohmmeter is some coils th

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000 psi] pre for checking

a light bulb metal probe.alligator clip

ical compon

ht

ht is like a s when the c

r can be useobe while uoint where tent by connitem in ques

used to meahe wire resis

de parts using

s wear eye pwhile workind result in s

t attempt toc fluid can ption when wo

Absorption Sr repairing tmaintenanc

ontact EnergDiagnose a

ent for assist

d list of test

ssure gage,g pressure i

with one l It is used top grounded,ent.

test light bcomponents

ed to troublesing the ot

the second pnecting one stion.

asure resistastance is larg

42

g part desc

protection wng with hydrerious injury

o control a puncture theorking on hy

Systems Cuthe TMA shoce, not a degy Absorptioand repair, otance.

t equipment

preferably gn the variou

ead wired to check for t

the light glo

but contains are not conn

eshoot voltaher to probprobe is conprobe to on

ance and is ge enough t

A

criptions sho

when workingraulics. Faily or death.

hydraulic le skin and cydraulic syst

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t required to

glycerin filleds sections o

to an alligahe presenceows when th

its own banected to a

ge problemsbe hot leadsnnected. 2) ne end and

useful whenthat a D.C. t

CrAll rights in co

own in Par

g on or aroulure to follow

leak with ycause severetems.

rvice DepartThis guide isair manual. If you suspeEnergy Abs

o troublesho

d, is a valuaof the circuit.

ator clip ande of a voltaghe probe co

attery. It is power sourc

s. Two comms in search Measure a v the remain

n working witest light mig


rts Lists, en

und machinew these war

your hand. e injury or d

ment if probs meant to bNOTE: For

ect problemsorption Sys

oot D.C. pow

ble and rela

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omes into co

used for tece.

mon uses aof the ava

voltage dropning probe t

ith solenoid ght not illumi

2012 erved

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High-death.

blems be an r any s, do

stems

wered

atively

lead ctrical ontact

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6. Asso

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7. High

A shpumequi

Hydrau1. THE PU

The mainmust also

First, thepossible must be minimumtoo thin properly seals useeffects ofwater selowest ex

For all ofmost cas

2. SELEC

When lootemperatlocal oil d

A. F

B. Te

C. It

D. Tvi


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Notesource

orted Hoses

se can be nosing hydra

h Pressure S

hutoff valve cp and otherpment listed

ulic FluidURPOSE OF

n purpose oo perform m

e fluid must to keep mein the prope

m but will stillwill leak paand cause ted in the syf rust, oxidatttling to the xpected tem

f the reasonses to be the

CTING FLUID

oking for fluiture is outsidistributor:

luid must be

The Pour Pncountered.

should cont

The viscosityiscosity nea

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g an open cime non-infin

: All tests ce disconnec

s and Press

used to coaulic problem

Shutoff Valv

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d HYDRAULIC

of hydraulic any other ta

have good etal to metaer range at tl allow the fl

ast seals, vathe pump toystem. Fourttion (oxygenbottom of tperature so

ns listed aboe best readily

DS FOR APPL

ids that can de the rang

e compatible

Point must

tain Rust or

(SUS) shour 200 SUS.

rcuit (infinitenite value of

conducted wcted from the

sure Fitting

onnect and/ms.

ve

d to choke ots. With the

ords the data

C FLUID

fluid is to trasks which a

lubricity or al wearing ahe operatinguid to lubricaalve spools, cavitate or th, there shon in the air che reservoirthat the fluid

ove, automaty available f

LICATIONS O

be used in pge of ATF, t

e with Buna-N

be below

Oxidation in

uld lie betwe

43

e resistance)resistance.

with an Ohme System

s

/or isolate c

off fluid flow valve attac

a for making

ansfer poweare critical to

be ''slipperyat a minimumg temperatuate the closeand the ge

starve.) Thiould also beombining wir. Fifth, the fd can reach

tic transmissluid for the jo

OUTSIDE AT

place of ATFthe following

N sealing co

the lowest

nhibitors as w

een 80 and 3

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mmeter mu

certain part

so that a "fached, it can a proper dia

er from the o a well desig

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sion fluid (Aob in most c

TF'S TEMPER

F or for applg specs sho

ompounds.

anticipated

well as other

375 in the op

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[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.


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


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


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


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


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


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


Detail Drawings

Drawing Description 6797 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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on.com ail.com

SEE D

61

DWG 61679

A

97

CrAll rights in co


2012 erved

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on.com ail.com

SEE DWG

62

G 618268 SH

A

H 1

CrAll rights in co


2012 erved

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on.com ail.com

SEE DWG63

G 618268 SH

A

H 2 Cr

All rights in coeated April, opyright rese

2012 erved

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on.com ail.com

SEE DWG64

G 618271 SH

A

H 1 Cr


2012 erved

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on.com ail.com

SE65

EE DWG 618

A

8271 SH 2Cr


2012 erved

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on.com ail.com

SEE66

DWG 6182

A

266 Cr


2012 erved

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on.com ail.com

SE67

EE DWG 61

A

8586 SH 1Cr


2012 erved

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on.com ail.com

SEE DW68

WG 618586

A

6 SH 2 Cr


2012 erved

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on.com ail.com

SEE DWG69

G 618586 SH

A

H 3 Cr


2012 erved

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on.com ail.com

SEE 70

DWG 61853

A

33 SH 1 Cr


2012 erved

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on.com ail.com

SEE DW71

G 618533 S

A

SH 2 Cr


2012 erved

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on.com ail.com

SE

72

EE DWG 618

A

8533 SH 3

CrAll rights in co


2012 erved

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on.com ail.com

SEE D

73

WG 618531

A

SH 1

CrAll rights in co


2012 erved

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on.com ail.com

SEE DW74

WG 618531

A

SH 2 Cr


2012 erved

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on.com ail.com

SEE DW75

G 618531 S

A

SH 3 Cr


2012 erved

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on.com ail.com

SEE D76

DWG 618534

A

4 SH 1 Cr


2012 erved

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on.com ail.com

SEE DWG 6177

18534 SH 2

ACr


2012 erved

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on.com ail.com

SEE DW78

G 618534 S

A

SH 3 Cr


2012 erved

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on.com ail.com

SEE D79

DWG 618505

A

5 Cr


2012 erved

2525 Stemmons FreewayDallas, Texas 75207

888-323-6374 (USA only)312-467-6750 (Outside USA)

www.energyabsorption.comwww.highwayguardrail.com

ss90™ hd tma product description assembly manual

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