SS90 HD TMA Manual - Structural and Steel Productss-steel.com/files/SS90-Assembly-Manual.pdf · TMA...

SS90™ HD TMAProduct DescriptionAssembly Manual

Created April 2012Part No. 618542B

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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 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


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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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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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. 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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4) ChBTyosTtosp


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

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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

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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

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ence problemee Figure 38eiver hitch uo step 8. truck framence problemshould be

P STEP10

STEP 20


ntil the frameswing out iace is requirngth.

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

e manufactu

ms. 8 on Page 3nderride, ref

e as shown ms with tail lcorrected b

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Figure 12

el surface. Mom the grouequired. SpaUnderride A

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truck framexcessive hea

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TRUCK F

16

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springs may0 mm [2"].

rame forwardm of the fra"] is required

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he bottom of f the frame (

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th the weige height to

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± 25 mm [2

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e 76 x 387 m

certified to sembly draw

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TRUCK FR

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ocket Hitch

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TRU

762

± 25

mm

[30±

1”]

711

± 25

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]

H SPACERS

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ft and righand level.

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Figure 12Left

UCK FRAME

UNDERRIDSOCKET

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SPAC

S

& RETAINER

F

17

t Underride

hem into plam.

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DE T

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Figure 15

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e Socket R

ace using th

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S

WITH END

LEFT

CrAll rights in co

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e 1 x 6 1/4

TRU

WITHO

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4” Hitch Pins

UCK FRAME

UNDESOCKRECE

OUT SPACER

HT SOCKET

HITCH

2012

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ERRIDE KET EIVER

RS

HITCH


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. AttMAautie

SUPPO

SUPPORT

SUPP

1” FLAT W

” LOCK WA

1” HEX NUT


tach the SuMove the SupAssembly, as

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ORT BRACK(RIGH

T MOUNT (RIGHT)

PORT MOU(LEF

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ASHER

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upport Frampport Frames shown in Fe frame is s

mounting honeed to be

KET HT)

NT FT)

1”

me/Backup te/Backup AssFigure 17. Th

till collapsedoles for the aremoved for

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


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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10. AUa


xtend the SuWith the TMAAssembly out

Warnextrem

Warn

Attach CornUsing 1/2” bo

s shown in F

Warn

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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 SSETS

me o the Attachxtent.

when suppoailure to heed

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

ER ER UT LT

NCH OINT

CrAll rights in co

y and evenly

frame can buse serious i

could shift to

h Corner Gu

ful of pinch p


y pull the F

be unwieldyinjury or dea

o one side.

ssets four p

points.

COGU

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. Use ath.

laces

ORNER USSET

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11. A

VwaT0/eou

12. A(IaAaUCua1pF

13. A

Anfrfa


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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Bottom Rele

ning: For prgy Absorptioe or result in

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

e TMA and se of each ba

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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

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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

mblies.

y Release Carect equipmee.

lies

(See Figureal amount of n place usin

m

]

Figure

Figure 2

RTRIDGE I


ables supplieent could le

e 19). Torquthreads pro

ng the rema

RELECA

19

0

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EASE ABLE

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14. ATsdm5

15. ACTththsthaw

TCslT3wp

Figure

SDETA


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

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

Die Spring) are only ues closest t

ridge Suppo

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been com Lock this

m" nut. Rles.

ot shown for

DC

22

es. wo for eachgonals of ea

y are the samnd taut. Cabhand at the

s, Spring Sused at mido the truck.

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

ch the Alignadjust the ce given tolet" when they

nd flat washthe front tw

Detail B

/8” LONG SPACER

D 1 1/4X 1 1

SH

IDGE PORT ABLE

G SPRING


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

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es as at the B ± 5 mm -

igure ables,

1 1/2” O.D. SHER

8” I.D. RING

DGE RT CABLE E END)

WASHER

NUTS

R

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16. ATas

17. ASVmanthle&

DETA


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

m [12 ±1”]

23

r Bay 1 ides as .

e

5 ± 25 he front ay be

ms from ust the ures 24

INTERMFRA

3

Figure 24

A

SOCKET HITCH

SHIMS MHERE ASLEVELNE

MEDIATE AME

SIDE GSEE FI

CrAll rights in co

Figure 23

MAY BE ADDS NECESSAESS OF SYS

DetGUIDE

GURE 23

305 ±25


IMPAFRA

G

3

DED OR REARY TO ACHSTEM tail 24a

mm [12 ±1”

2012

erved

ACT AME

SIDE GUIDE

MOVED HIEVE

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18. CLlife

Fp2

In6ofthathpa

Tnthb


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

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

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


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

25 ft.] for a4 ft.]. (A 2 gorption Systonnected di

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

a 12V gauge tems, rectly

n the move

unting

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1

2

2

2

2


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

Cautisystemsystem

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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

and store J

s are providemove all fou

urn-Stop-Ta

e light cable

osition of th

e location of during turni

ydraulic Loc

tem is tiltedn the switch

ion: Each m is hydraum.

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

HIS HEIGHT

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


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

2012

erved

before Before

r and verfill.

not be down

Cab

m the

.

ot be

tically m.

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 To tilt threaches Switch isthat the s


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

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 FrNo. 618504

top of the mstances sn it is being

are of objec

"Raise" sidelics automat

on, the Reston for long t

e doing mainthe "up" posn in Figure 2

VE RETAININ

A

nd understanroperly attac

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 l

cts behind or

e of the Roctically lockstraining Chaterm storage

ntenance besition, be su27.

NG CHAINS

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

cker Switch the system in should bee and for ma

ehind the raiure to secure

S WHILE WO


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

ll objects bwed behind

TMA.

until the sywhen the Roe used to enaintenance.

ised systeme the system

ORK IS BEI

2012

erved

nd the er.

h one

TMA ing of erator utton,

Down” Cab

ler is

n and g the

non-ow a

an be

before or in

ystem ocker nsure

, or if m with

ING


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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MaintBefore pMaintenawith the Chain. I. RoutDescrip1. Heighto its imp28).

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 Mainption ht and Levepact perform

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305 ±25 mmFigure

29

SS90™HD TMn of this Ma

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fasteners mo check boltsuld be fully c

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Hydraulic Syworking.

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31

aulic Lockinnd operationmechanismvehicle mu

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Figure 30

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35

34

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Figure 34

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GREASFRICTBEARI

GREASFRICTLIGHT

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opriate mea

See Figure 3

SE THESE ION POINTSNG GREAS

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3. OO

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Oil and GreaOil and greas

Change the Change the Reservoir cap

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GREASE

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35

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2 years. U

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Figure 36

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6.

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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

e Figures 37

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396

CENTEGRA

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96 lbs7 & 38)

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67 mm [13”]

ER OF AVITY

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36

49 kg 73 kg 744 kg 39 kg 905 kg

he drawings For replace

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3

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Figure 38

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at the end oement parts,

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]

2362

94 mm [47”]

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ual. The drawmer Service

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RepaiParts Lis

IV. Pos

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Make a list oing section.)

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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

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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

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ease Cables

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s Across the

m performancFailure to u

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Chain to lod position. ply may resudeath.

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Verify thaArm Assthat rougin place u

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Attach Cartrove one end

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CART

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e is extendeee Figure 39al amount ofning fastene

ridges d of each Aling a forklift k washers, are for Cartrid

TRIDGE II

RQUE TO 34[25 -0/+2 ft-

ed as far as ). Torque thf threads proers as "jam" n

ignment Caband sling, p

and nuts prodge II (See F

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

CrAll rights in co

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et aside to csition and seto 120 ± 7 N


ase Cable ac-lbs) makingable. Lock C

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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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NTI-TILT CH

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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

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