SS90 HD TMA Manual - Structural and Steel Productss-steel.com/files/SS90-Assembly-Manual.pdf · TMA...
Transcript of SS90 HD TMA Manual - Structural and Steel Productss-steel.com/files/SS90-Assembly-Manual.pdf · TMA...
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SS90™ HD TMAProduct DescriptionAssembly Manual
Created April 2012Part No. 618542B
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www.energyabsorption.com Created April 2012 www.highwayguardrail.com 2 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 Warnings 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 ............................................................................................................................... 44 Filters ....................................................................................................................................... 45 Hydraulic Cylinders ................................................................................................................. 45 Electrical Problems .................................................................................................................. 46
Hydraulic Quick Troubleshooting Guide ..................................................................................... 49 Underride Assembly, Receiver, TMA ...................................................................................... 51 Pre-Assembly, Frame, 8292 .................................................................................................... 52 Pre-Assembly, Frame, 8292, EUG .......................................................................................... 54 Miscellaneous Hardware, 8292 ............................................................................................... 56 Hydraulic/Electrical Assembly, 8292 ....................................................................................... 57 Lighting Assembly, LED, 12V, 8292 ........................................................................................ 60 Lighting Assembly, Incandescent, 12V, 8292 ......................................................................... 63 Lighting Assembly, Incandescent, 24V, 8292 ......................................................................... 66 Rear Plate Assembly, w/Striping, 8292 ................................................................................... 69
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www.energyabsorption.com Created April 2012 www.highwayguardrail.com 3 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 (USA Only) (312) 467-6750 (USA or International)
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 Created April 2012 www.highwayguardrail.com 7 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. The 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 Created April 2012 www.highwayguardrail.com 13 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.
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www.energyabsorption.com Created April 2012 www.highwayguardrail.com 14 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. Decisions as to what tools are needed to perform the job are 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.
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Preparat3A) A
Tisam
3B) TUbthatrthbthre
4) ChBTyosTtosp
ergyabsorptihwayguardra
tion Attachment The system’ss secured wapproximate maintain con
Truck BallasUse a bubble
e as close the 7300 kg nchored to t
ruck, that reqhe rearward e taken not
hat the drivecommendeheck for InteBefore attemThe system rou are usingpecial instru
Temporarily po Figure 12) prings, dumroceeding.
STEPS 4 & 5
UNDERRRE
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Must Be Pes frameworkwith the ali4 m [13’] ra
ntrol of the fr
st e level to verto the final d[16,090 lbs]the truck to quires no baprotruding Tto exceed
ving characed center-of-gerference pting to attarotates very g somethingctions supplposition the and check
mp bodies (in
STEP 6
RIDE SOCKECEIVER
SUM
erformed Ok is very heaignment cabadius from eramework wh
rify that the driving weig] minimum wkeep it in p
allast, shoulTMA is suppthe manufa
cteristics of gravity zone
ch the Undeclose to the
g other than lied with youUnderride Sfor interferen the up or
STEP 7
ATTAASS
ET
PPORT OUNT
F
15
On a Level Savy and pivobles and re
either side ofhen it is bein
truck is parkht as possibweight, add place during d be used.
ported by thecturer's pubthe vehicle
e should also
erride, checke mounting a standard
ur assembly,Socket Recence problemdown posit
ACHMENT SEMBLY
SUPPORTFRAME
STEPS 8 & 9
Figure 11
A
Surface ots in severaelease cablef the truck. Ang extended
ked on a levble. If ballasit at this timan impact. Because thee back of theblished maxie are maino be adhered
k for interferelocation (Sesocket rece
, then skip toeiver under
ms. Interferetions), etc.,
T STEP
14
S
CrAll rights in co
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vel surface. st must be ame. Ballast mIdeally, an ae 910 kg [2e shadow veimum axle lntained, thed to.
ence problemee Figure 38eiver hitch uo step 8. truck framence problemshould be
P STEP10
STEP 20
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The truck shadded to acmust be proadequately 000 lb] weigehicle, care oads. To en
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ms. 8 on Page 3nderride, ref
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UND
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Imposometanticip
Measure fromny other ob
Receiver. A m
Position the S5 1/4"] flat b
s flush with tnd lap the S
Socket Recerawing). The
evel ground f
Weld the Soc15 1/4"] flat
ImpoD14.3Disco
Warnweld spring
Prime and pa
DERRIDE SOCKET
ECEIVER
F
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sembly ck on a leve
distance fro[28±1"] is reheight (See
ortant: Thtimes, as mpated settlin
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Socket Recebar is along tthe end of fr
Spacer Spliceiver Tube ae top of the for proper sy
cket Receivet bar on the o
ortant: All 3-82 or AWSonnect truck
ning: The tor apply exg hangers.
aint all welde
FL
Figure 12
el surface. Mom the grouequired. SpaUnderride A
he truck’s smuch as 50g.
end of the frn the bottom305 mm [12
eiver at the rthe outside orame. If Spaes (pieces ond Spacer aSocket Rec
ystem heigh
er Tube to thouter side of
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truck framexcessive hea
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LAT BAR
TRUCK F
16
Make sure tund to the bacers may b
Assembly dra
springs may0 mm [2"].
rame forwardm of the fra"] is required
rear end of tof the frameacers are reof 10 x 51 x 1at the rear-mceiver Tubest (See Figur
he bottom of f the frame (
must be perfccordance wefore weldin
e is high caat to the bo
RAME
A
the truck is bottom of thebe added toawing).
y settle witAdjust the
d to the reaame that mad (See Unde
the frame soe member anquired, weld103 mm [3/8most locatios to be 711 re 13).
f the truck fra(See Figure
formed by with the Undng.
arbon steel.ottom flange
UNDERSOC
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Figur
34±
CrAll rights in co
at its actuae truck framo the bottom
th the weige height to
r-most leaf say interfere erride Assem
o that the 76nd the Socked them to th8 x 2 x 4"] flaon (See Und
± 25 mm [2
ame with the12).
a welder cderride Ass
To avoid ce, forward o
RIDE CKET IVER
0 mm [28”] OMINAL
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±1”
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e 76 x 387 m
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TRUCK FR
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RAME
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6. So
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Impowith e
ocket Hitch
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WITH
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ortant: Lefeach other a
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cket Hitchess shipped wi
TRU
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± 25
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1”]
711
± 25
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[28
± 1”
]
H SPACERS
HITCH &
ft and righand level.
s and pin thth the system
Figure 12Left
UCK FRAME
UNDERRIDSOCKET
RECEIVE
SPAC
S
& RETAINER
F
17
t Underride
hem into plam.
2 – Socket HSide Shown
E
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ER
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FLUSH WFRAME E
R PINS
Figure 15
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ace using th
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S
WITH END
LEFT
CrAll rights in co
Receivers m
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WITHO
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± 25
mm
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1”]
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4” Hitch Pins
UCK FRAME
UNDESOCKRECE
OUT SPACER
HT SOCKET
HITCH
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E
ERRIDE KET EIVER
RS
HITCH
-
www.energyabsorption.com Created April 2012 www.highwayguardrail.com 18 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
-
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8. AttMAautie
SUPPO
SUPPORT
SUPP
1” FLAT W
” LOCK WA
1” HEX NUT
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tach the SuMove the SupAssembly, as
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ORT BRACK(RIGH
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PORT MOU(LEF
WASHER
ASHER
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mounting honeed to be
KET HT)
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1”
me/Backup te/Backup AssFigure 17. Th
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1” FLAT1” LOCK WA HEX NUT
Fig
19
to the Attacsembly to th
he Support Fd, with forklifattachment. Er clearance i
T WASHERASHER
gure 17
A
chment Assehe truck and Frame/Backuft slings suppElectrical Bossues.
1SH
SHIM
CrAll rights in co
embly pin it to the
up Assemblyporting the sox is tempora
HITCH PHAIR PI
” FLAT WASHIMS, 1/4” XMS, 12 GA X
1” X 3 1/2
SUPPO
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Attachmenty is to be system. Usearily held by
PIN WITH IN COTTER
SHER X 5” X 10” *X 5” X 10” *
2” HEX BOL
RT BRACKE
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9. ExWA
10. AUa
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xtend the SuWith the TMAAssembly out
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Warn
Attach CornUsing 1/2” bo
s shown in F
Warn
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upport FramA pinned tot to its full ex
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ning: Until th
er Gussets olts, nuts, flaFigure 18.
ning: When
ORNER SSETS
me o the Attachxtent.
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he cables ar
at washers a
installing Co
F
1/2” FL1/2” LO
11/2” X
20
ment Assem
orted by the d this warnin
re attached,
nd lock was
orner Gusse
igure 18
LAT WASHEOCK WASHE1/2” HEX NU3” HEX BOL
PINPO
A
mbly, slowly
forklift, the ng could cau
the system
shers, attach
ets, be caref
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NCH OINT
CrAll rights in co
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could shift to
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be unwieldyinjury or dea
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ssets four p
points.
COGU
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. Use ath.
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ORNER USSET
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11. A
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12. A(IaAaUCua1pF
13. A
Anfrfa
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Attach the B WarnEnergfatigue
Verify that thewill go. Attac
cross Arm Torque the
/+2 ft-lbs], mqual amounn both endssing remain
Attach Cartrf Alignmenttached, re
Alignment Caside to clear
Using a foCartridge I i
sing the fland nuts pro20 ± 7 N-mrocedure igure 20).
Attach the T
Attach the Touts to 34 N-
rom nuts onasteners as "
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e Frame is ech the Botto
Assembliesnuts 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. Torqm [90 ± 5f
for Cartr
op Release
op Release Cm (25 ft-Ibs)
n both ends "jam" nuts.
ease Cables
oper systemon Systems. n unpredicta
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are alreaend of ea
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sling, plaand securelock washeue the nutsft-lbs.] Reperidge II (S
e Cables acr
Cables acro), making su
of cable. L
21
s across the
m performancFailure to u
ble system p
s far as it e Cables ure 19). m [25 -ughly an rom nuts in place
uts.
ady ach set
ay.) ace e it ers, to eat
See
ross the Arm
ss the Arm Aure that rougLock Releas
TO
[2
CART
A
e Arm Asse
ce, use onlyuse the corrperformance
m Assembl
Assemblies ghly an equase Cables in
ORQUE TO 34 -0/+3 N-m
25 -0/+2 ft-lbs]
CAR
TRIDGE II
CrAll rights in co
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y Release Carect equipmee.
lies
(See Figureal amount of n place usin
m
]
Figure
Figure 2
RTRIDGE I
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ables supplieent could le
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RELECA
19
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EASE ABLE
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14. ATsdm5
15. ACTththsthaw
TCslT3wp
Figure
SDETA
ergyabsorptihwayguardra
Attach and aThere are fohown in Figuiagonal mea
mm [3/16"], C0mm [1 1/2"
Impo21 ani.e. th
Attach and aCables. 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
21 (Suppor
SEE AIL B
B A
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adjust Alignur Alignmenure 21. Meaasurements C = D ± 5 mm" - 2"] when
ortant: The nd Detail B)he two cable
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
rt Frame no
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ridge Suppo
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the Cartridgnut on one cn tighten
been com Lock this
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ot shown for
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22
es. wo for eachgonals of ea
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ort
ables. Attachrt Cables toe providedable throughn loop anda die spring
ge Supportcable until alit until the
mpressed tonut in place
Repeat this
r clarity)
1 1/2
5/16CAB5.8”END
TE
A
h bay). Attacach bay and me within thbles are "tautcenter.
Spacers, and-frame, on .
h o d h d ,
t l
e o e s
2” O.D.X 1 1SPRING
6” X 81” BLE WITH ” DIA. STUDDS
CARTRISUPP
CA
ENSIONING
CrAll rights in co
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nd flat washthe front tw
Detail B
/8” LONG SPACER
D 1 1/4X 1 1
SH
IDGE PORT ABLE
G SPRING
reated April opyright rese
nment Cablecables so thaerance (A = By deflect 38
hers (see Fiwo Top Ca
3/4” I.D. X FLAT WAS
4” O.D. X 5/81/2” DIE SP
HACKLE
CARTRIDSUPPOR(THIMBLE
32±2 mm [1 1/4 ±1/6”]
Figure 22 2012
erved
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igure ables,
1 1/2” O.D. SHER
8” I.D. RING
DGE RT CABLE E END)
WASHER
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16. ATas
17. ASVmanthle&
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Attach Side There are fou
nd two for Bhown in Figu
Adjust heighSystem FramVerify that thmm [12 ± 1"
nd rear oecessary to
he Socket evelness of & 24a).
SEE IL 24a
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Guides. ur Side GuidBay 2. Attacure 23 and t
ht and levelme. he system F] from the g
of the syso add or reHitch in orthe cartridg
SIDESEE
305 ±25 m
des, two forch Side Guiighten bolts.
ness of the
Frame is 30ground at thtem. It m
emove Shimrder to adjue (See Figu
E GUIDE FIGURE 23
F
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23
r Bay 1 ides as .
e
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INTERMFRA
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Figure 24
A
SOCKET HITCH
SHIMS MHERE ASLEVELNE
MEDIATE AME
SIDE GSEE FI
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Figure 23
MAY BE ADDS NECESSAESS OF SYS
DetGUIDE
GURE 23
305 ±25
reated April opyright rese
IMPAFRA
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3
DED OR REARY TO ACHSTEM tail 24a
mm [12 ±1”
2012
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ACT AME
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MOVED HIEVE
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18. CLlife
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In6ofthathpa
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Connect theocate 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
ImposystemBatterPart Nto the
The controls on-traffic sid
he controls racket. Mou
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Lights andemale 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
ortant: A 2 m. If longer cry Cable Kit No. 618356B
battery.
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™HDre compatiblles (e.g. do nd sharp coConnect thekage).
gauge battcable is neewith fusible
B.) Both Pow
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
tery cable iseded use 1/0e link is avawer and Grou
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
s good up 0 gauge up tilable from Eund Cables
mounted toare not, rem
n the controb within easy
7-PIN FEMA
GR
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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
to 7.6 m [2o 12.5 m [44Energy Absshould be c
o the Suppomove the fasols to the ey reach of th
LE SOCKET
ROUND TAIL LAM
RIGHT
STOP LAM
ket Connec
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the truck, soke sure tha
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ort Frame, osteners and mexisting mouhe driver.
T
MPS
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MPS
ctor
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n the move
unting
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1
2
2
2
2
ergyabsorptihwayguardra
9. Check thThe Hydrshipping. operatingcheck to sReplace t
Read Opedamagedtwice. TSwitches
Impo
0. Remove
The Jacktruck. Re
1. Verify Tu
Plug in th
2. Check po
Check thedamaged
3. Verify Hy
If the syslock when
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he Hydraulicraulic SystemThe pump the systemsee if the resthe vent plug
eration Instr, use the sw
This purges to verify pro
ortant: Con
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s are providemove all fou
urn-Stop-Ta
e light cable
osition of th
e location of during turni
ydraulic Loc
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c System m is pre-assis wired as , remove theservoir is fulg in the filler
ructions. Mawitch at the air from th
oper operatio
ntinuous ope
Jacks
ded to facilitaur jacks and
il Light Ope
e. Verify that
he Hydraulic
f all the hyding or tilting
cking in the
from horizois released.
time the TMulically locke
RESERVOI
FILL TO TH
25
sembled anshown on te cap from tl. Add only Dport.
king sure allrear of the
e system. on.
eration may r
ate attachmplace them
eration
all the turn/
c/Electrical
raulic and eof the syste
e Up Positio
ontal, the TM The pump i
MA is raiseed and chain
R FILL POR
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A
d tested forthe Hydraulithe fill port oDexron® III f
l electrical ae truck, pow
Also cycle
run down tru
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 hydraufluid if it is no
and hydraulicwer the syste
the system
uck battery.
moval of the
hts are worki
es to be surewn.
ulic system waise and low
erator shouldallowing an
Figure 26
reated April opyright rese
and leaks by drawing. Bulic reservoiot. Do not ov
c lines will nem up and dm using the
system from
ing properly.
e they will n
will automater the syste
d verify thanyone behind
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erved
before Before
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Cab
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.
ot be
tically m.
at the d the
-
www.energyabsorption.com Created April 2012 www.highwayguardrail.com 26 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.
-
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 To tilt threaches Switch isthat the s
ergyabsorptihwayguardra
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 Lowe
DANGprocethe pa
perating from
the systeme system upthe 90-degre
s released. Isystem stays
Cautithe sythe Re DANG
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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 Co
er the Sy
GER: Makeeding. Undeath of the s
m the cab, alw
p: Press anee position. n the 90 des in the 90 d
ion: If somystem is to betaining Cha
GER: NEVPER
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 thentroller Part
ystem
e sure the er no circumystem when
ways be aw
d hold the "The hydrau
egree positiodegree positi
meone will bebe stored in ain as shown
VER REMOVRFORMED.
27
ghly read ansystem is p
crash testingper positions
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www.energyabsorption.com Created April 2012 www.highwayguardrail.com 28 All rights in copyright reserved
Lowering the system When lowering the system, be sure that the Restraining Chain is placed in the “unlocked” position and that no person 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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29
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Figure 30
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Figure 33
EVIS LINK -TILT CHAIN
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34
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Figure 34
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Figure 36
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V. Tech1. WeighCartridgeCartridgeFrame CJacks Total 2. Dime
3. ReplaFor detainclude tPage 3).
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889±6 mm [35±1/4”]
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10916216386 199
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396
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67 mm [13”]
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he drawings For replace
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RepaiParts Lis
IV. Pos
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2. InRth
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6. A
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Cautibehindwork reduc
nspect the FReplace any traighten pa
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Expand the SExtend the Fr
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ion: Be sud or under tis being pered safety, to
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System andrame and loo
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Make a list oing section.)
y the correcon Systems esult in dam, to and inclu
re to use ththe system rformed. Faio 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
oper systemon Systems. n untested sy
he cables ar
37
f all damage)
ct parts manmay be useage to the suding injury
e Retaining in the raisedlure to comping injury or
ave been dan pairs to enspart numbe
e been damagdescriptions
ne End of tnd of each o
g side to side
ease Cables
t to repair need to be r
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s Across the
m performancFailure to u
ystem perfo
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A
ed parts usin
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Chain to lod position. ply may resudeath.
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he Top Cabof the four To
e.
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Verify thaArm Assthat rougin place u
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e is extendeee Figure 39al amount ofning fastene
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TRIDGE II
RQUE TO 34[25 -0/+2 ft-
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F
F
CAR
4 -0/+3 N-m -lbs]
38
it will go. Ae nuts to 34
otrude from nuts.
ble from the place Cartrid
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R
Figure 39
Figure 40
RTRIDGE I
A
Attach the Bo4 -0/+3 N-m nuts on both
TMA and sdge I in posue the nuts t
RELEASE CABLE
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2012 erved
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-
www.energyabsorption.com Created April 2012 www.highwayguardrail.com 39 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 N-m (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
1 1/4” O.D. X 5/8” I.D. X 1 1/2” DIE SPRING
3/4” I.D. X 1 1/2” O.D. FLAT WASHER
5/16” X 81” CABLE WITH 5.8” DIA. STUD ENDS
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11. ATACpcacuTChotigb1/sew
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ergyabsorptihwayguardra
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EVELNESS
S
-
www.energyabsorption.com Created April 2012 www.highwayguardrail.com 41 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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6. Assorted Hoses and Pressure Fittings These can be used to connect and/or isolate certain parts of a hydraulic circuit for diagnosing hydraulic problems.
7. High Pressure Shutoff Valve A shutoff valve can be used to choke off fluid flow so that a "false" load can be put on the pump and other components. With the valve attached, it can be slowly shut off while the equipment listed above records the data for making a proper diagnosis.
Hydraulic Fluid 1. THE PURPOSE OF HYDRAULIC FLUID
The main purpose of hydraulic fluid is to transfer power from the pump to the actuators but it must also perform many other tasks which are critical to a well-designed system.
First, the fluid must have good lubricity or be ''slippery'' so that the friction will be as low as possible to keep metal to metal wearing at a minimum. Second, the viscosity or ''thickness'' must be in the proper range at the operating temperature so that unwanted leakage will be at a minimum but will still allow the fluid to lubricate the close fitting parts in the system. (Fluid that is too thin will leak past seals, valve spools, and the gears; fluid that is too thick will not flow properly and cause the pump to cavitate or starve.) Third, the fluid must be compatible with the seals used in the system. Fourth, there should also be additives in the fluid to slow down the effects of rust, oxidation (oxygen in the air combining with the fluid to form sludge) foaming, and water settling to the bottom of the reservoir. Fifth, the fluid must be able to pour or flow at the lowest expected temperature so that the fluid can reach or get into the pump.
For all of the reasons listed above, automatic transmission fluid (ATF, Dexron III) was found in most cases to be the best readily available fluid for the job in most climate conditions. 2. SELECTING FLUIDS FOR APPLICATIONS OUTSIDE ATF'S TEMPERATURE RANGE When looking for fluids that can be used in place of ATF or for applications where the operating temperature is outside the range of ATF, the following specs should be discussed with your local oil distributor:
A. Fluid must be compatible with Buna-N sealing compounds.
B. The Pour Point must be below the lowest anticipated temperature that will be encountered.
C. It should