Lindsay Barrier Systems X-LITE User manual

X-LITE®FLARED
NCHRP 350 TL-3 Redirective, Gating, End Terminal
INSTALLATION MANUAL

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Installation Manual
X-LITE FLARED END TERMINAL
TABLE OF CONTENTS
Preface -------------------------------------------------------------------------------------------- 3
System Overview -------------------------------------------------------------------------------- 3
Before Installation -------------------------------------------------------------------------------- 3
Limitations and Warnings ----------------------------------------------------------------------- 3
Preparation ---------------------------------------------------------------------------------------- 4
Soil Conditions ----------------------------------------------------------------------------------- 4
Before Starting ----------------------------------------------------------------------------------- 4
Required Tools ------------------------------------------------------------------------------------ 4
Standard Warranty ------------------------------------------------------------------------------- 5
Parts Identification ------------------------------------------------------------------------------- 6
Step 1 – Assembling Components -------------------------------------------------------------- 8
Step 2 – Post and Blockout Installation --------------------------------------------------------- 10
Step 3 – Install Ground Strut Assembly --------------------------------------------------------- 13
Step 4 – Hang Rails ------------------------------------------------------------------------------- 14
Step 5 – Install Impact Head --------------------------------------------------------------------- 17
Step 6 – Install Cable ---------------------------------------------------------------------------- 18
Final Inspection ----------------------------------------------------------------------------------- 20
APPENDICES
Appendix A - System Configuration Drawings ------------------------------------------------- 21

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Preface
The X-Lite Guardrail End Terminal, Flared System
incorporates the latest roadside safety technologies and
engineering processes.
As with any roadside safety device, the X-Lite
System must be installed in accordance with the
manufacturer’s specifications to ensure proper
performance. Thoroughly review and fully
understand the installation instructions and product
limitations before starting the installation. Do not
start the installation without the proper plans and
tools required.
System Overview
The X-Lite System is a redirective, gating end
terminal designed for shielding the ends of guardrail
systems. The system offers exceptional vehicle
control, energy absorbing capabilities in head on
impacts, and is re-directive starting at Post 3. The
X-Lite is comprised of a head unit, specially designed
crimped posts, tension rods, cable assembly, slider
assembly, and other standard guardrail components.
Before Installation
Placement and use of the X-Lite System should
be done in accordance with the guidelines and
recommendations set forth in the “AASHTO
Roadside Design Guide,” FHWA memoranda, and
other state and local standards.
Depending on the application and the circumstances
at the site, installation should take an experienced
two person crew with proper tools approximately
two hours to complete.
The X-Lite System is a highly engineered safety device
made up of a relatively small number of parts. It is
available in both tangent and flared versions. Before
starting installation, ensure that one is familiar with
the make up of the system that is being installed.
Prior to installation, ensure that proper manuals and
components are on site.
Limitations and Warnings
The X-Lite System has been rigorously tested and
evaluated per the recommendations in the National
Cooperative Highway Research Program Report 350
(NCHRP Report 350) guidelines for end terminals and
crash cushions. The impact conditions recommended
in NCHRP Report 350 are intended to address in-
service collisions.
When properly installed and maintained, the system
is capable of stopping, containing, and redirective
impacting vehicles in a predictable and safe manner
under NCHRP Report 350 impact conditions. Vehicle
impacts that vary from the NCHRP Report 350 impact
conditions for gating, redirective end terminals may
result significantly different than those experienced in
testing.
Vehicle impact characteristics different than or in
excess of those encountered in NCHRP Report 350
testing (speed and angle) may result in system
performance that may not meet NCHRP Report 350
evaluation criteria.
If you need additional information, or have
questions about the X-Lite System, please call the
Lindsay Transportation Solutions Customer Service
Department at [phone] (U.S. toll free) or
[phone].
X-LITE® FLARED END TERMINAL

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Preparation
Before installing the X-Lite System, ensure that all
materials required for the system are onsite and have
been identified.
Soil Conditions
The X-Lite has been designed to be installed in soil
that meets or exceeds the AASHTO “standard soil”
specification. If rock or stiff soil is encountered, the
posts may be installed by augering and backfilling the
hole. Extra care must be taken to prevent settlement
or lateral displacement of the post. Backfill material
shall be compacted to optimum compaction.
Before Starting
For all applications, begin the installation from the
trailing / back end of the system where it joins the
standard guardrail system at Post 7.
Required Tools
The system uses standard tools required to
install typical guardrail; the list below is a general
recommendation.
• Post driver
• Tape measure
• String line
• Hammer
• Stakes
• Pry bar
• Crescent wrench
• Vice grips or clamps
• 1-5/8” (42 mm) Wrench
• ½” Ratchet
• 1-1/4” (32 mm) Socket
• Air impact wrench (optional)
• Pick ax
• Pipe wrench or large pliers
• Torque wrench
(capable of applying 60 ft. lbs. torque)
Note: The tools list is a general recommendation.
Depending on the specific characteristics of the job
site, more or less tools may be necessary.
The tools listed are for US/Imperial fasteners. If
metric hardware is used, use metric equivalents for
the hardware as required.
APPROACH /
FRONT
TRAILING /
BACK
The picture of the X-Lite System above illustrates
how the System is referred to throughout
this manual.
Required Tools
INSTALLATION MANUAL

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X-LITE® FLARED END TERMINAL
STANDARD LIMITED WARRANTY
Lindsay Transportation Solutions, Inc. “LTS” ( formerly Barrier Systems ) has tested the impact
performance of its barriers and crash cushion systems, and other highway safety hardware under
controlled conditions, however, LTS does not represent nor warrant that the results of those controlled
conditions would necessarily avoid injury to persons or property. LTS EXPRESSLY DISCLAIMS ANY
WARRANTY OR LIABILITY FOR CLAIMS ARISING BY REASONS OF DEATH OR PERSONAL
INJURY OR DAMAGE TO PROPERTY RESULTING FROM ANY IMPACT, COLLISION OR
HARMFUL CONTACT WITH THE PRODUCTS OR NEARBY HAZARDS OR OBJECTS BY ANY
VEHICLE, OBJECTS OR PERSONS.
LTS warrants that any product or component part manufactured by LTS will be free from defects in
material or workmanship. LTS will replace free of cost any Product or component part manufactured by
LTS that contains such a defect.
THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES
NOT EXPRESSLY SET FORTH HEREIN, WHETHER EXPRESS OR IMPLIED BY OPERATION
OF LAW OR OTHERWISE, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
LTS’ LIABILITY UNDER THIS WARRANTY IS EXPRESSLY LIMITED TO REPLACEMENT
FREE OF COST (IN THE FORM AND UNDER THE TERMS ORIGINALLY SHIPPED), OR TO
REPAIR OR TO MANUFACTURE BY LTS, PRODUCTS OR PARTS NOT COMPLYING WITH
LTS SPECIFICATIONS, OR, AT LTS’ ELECTION, TO THE REPAYMENT OF AN AMOUNT
EQUAL TO THE PURCHASE PRICE OF SUCH PRODUCTS OR PARTS, WHETHER SUCH
CLAIMS ARE FOR BREACH OF WARRANTY OR NEGLIGENCE. LTS SHALL NOT BE LIABLE
FOR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL LOSSES, DAMAGES OR EXPENSES
OF ANY KIND, INCLUDING, WITHOUT LIMITATION, ANY SUCH LOSSES, DAMAGES OR
EXPENSES ARISING DIRECTLY OR INDIRECTLY FROM THE SALE, HANDLING OR USE OF
THE PRODUCTS FROM ANY OTHER CAUSE RELATING THERETO, OR FROM PERSONAL
INJURY OR LOSS OF PROFIT.
Any claim by the Buyer with reference to Products sold hereunder for any cause shall be deemed waived
by the Buyer unless LTS is notified in writing, in the case of defects apparent on visual inspection,
within ninety (90) days from the delivery date, or, in the case of defects not apparent on visual
inspection, within twelve (12) months from the said delivery date. Products claimed to be defective may
be returned prepaid to LTS’ plant for inspection in accordance with return shipping instructions that
LTS shall furnish to the Buyer forthwith upon receipt of the Buyer’s notice of claim. If the claim is
established, LTS will reimburse that Buyer for all carriage costs incurred hereunder.
The forgoing warranty benefits shall not apply to (i) any Products that have been subject to improper
storage, accident, misuse or unauthorized alterations, or that have not been installed, operated and
maintained in accordance with approved procedures and (ii) any components manufactured by the
Buyer.
W030587 Rev. 8 revised February 4, 2013
180 River Road •Rio Vista, CA 94571 •Tel. [phone] •Fax. [phone]

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Blockouts (QTY. 5)*
B090534
Slider Panel (Front)
BSI-1012093-00
Slider Bracket
BSI-1012090-00
Cable Anchor Assembly
BSI-1012104-00
Ground Strut Kit BSI-1102097-00 (QTY. 2), Nut
4001116 (QTY.4), Angle BSI-1012098-00 (QTY. 1)
Slider Panel (Back)
BSI-1012096-00
Impact Head
BSI-1012103-00
Square Washer (used on Post 1)
BSI-1102027-00
Shear Bolt Kit (8 yellow bolts per kit)
K080123
Crimp Post #1 & #3 (QTY. 2)
BSI-1310024-00
INSTALLATION MANUAL
Post 2
BSI-1012086-00
Parts Identification
A Complete Bill of Materials for Systems and Kits Can be Found in Appendix A
* Denotes Shipped With Full System Only
Crimp Post # 4-6 (QTY. 3)
BSI-1310027-00

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Guardrail Bolts (QTY. 16)*
4001115
5/8” x 10” Bolt (QTY. 5)*
2001635
W-Beam Guardrail (QTY. 3)*
4000443
5/8” x 2” Bolt (QTY. 1)*
(used on Post 1) 2000302
Guardrail Nut (QTY. 22)*
4001116
1” Washer (Used on Slider Panel-Back)*
(QTY. 1) 2001580
5/8” x 3 ½” Bolt (QTY. 2)
(used on Soil Plate) 2000220
5/8” Nut (QTY. 2)
(used on Soil Plate) 2000312
5/8” Washer (QTY. 4)
(used on Soil Plate) 2001636
Soil Plate
BSI-1312100-00
L-Bracket
(used on cable at Post 2) BSI-1303005-00
X-LITE® FLARED END TERMINAL
* Denotes Shipped With Full System Only
Parts Identification
A Complete Bill of Materials for Systems and Kits Can be Found in Appendix A

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Step 1 – Assembling Components
• Components required:
• (1) Post 2 – BSI-1012086-00
• (1) Soil Plate – BSI-1312100-00
• (2) W-Beam – 4000443
• (1) Slider Panel (FRONT)– BSI-1012093-00
• (1) Slider Bracket – BSI-1012090-00
•
• Hardware Required:
• (2) 5/8” x 3 ½” Bolt - 2000220
• (8) 5/8” x 1 ¼” Guardrail Bolt - 4001115
• (4) 5/8” Washer - 2001636
• (8) 5/8” Guardrail Nut - 4001116
• (2) 5/8” Hex Nut - 2000312
Some components require assembly and it is
recommended that this step be completed prior to
the start of the system assembly.
Post II Assembly:
1. Attach the soil plate to the trailing / back side of
Post 2 using two (2) 5/8” x 3 ½” bolts, washers
(4), and nuts (2). The trailing / back end of the
post is identified by the open slots on the top of
the post.
The bolts should be installed from back to front
so that the head of the bolts rests on the soil
plate.
Depending on your post driver equipment,
Post 2 may need to be partially driven before
this step can be accomplished.
Notes:
Open Slots
Attach Soil Plate to Post II
Trailing / Back
INSTALLATION MANUAL

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Slider Bracket and Panel Assembly:
2. Attach the slider bracket to the inside of the
approach / front end of Rail 2 using four (4) 5/8”
x 1 ¼” guardrail bolts.
Bolts should be installed with the bolt head on
the outside and the nuts the inside.
Note: When properly installed, a portion of the
bracket will extend beyond the end of the rail and
should face the trailing / back of the system when
assembled in step 18.
3. Attach the Slider Panel (Front) to the outside of
the trailing / back end of Rail 1 using four (4) 5/8”
x 1 ¼” guardrail bolts.
Bolts should be installed with the bolt head on
the inside and the nuts on the outside.
The angled portion of the Slider Panel should
extend beyond the end of the rail and should
face the trailing / back of the system when
assembled in step 18.
Attach Slider Bracket to Rail 2.
Attach Slider Panel (Front) to Rail 1.
Angled Portion
Extends Beyond the
End of the Rail.
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Step 2 – Post and Blockout Installation
Components required:
• (2) Crimp post w/ Slots (Post 1, 3) - BSI-1310024-00
• (1) Post 2 Assembly with Soil Plate
• (3) Crimp Post w/ Holes (Post 4-6) - BSI-1310027-00
• (5) Blockout – B090534
• (1) Slider Panel (Back) – BSI-1012096-00
Hardware Required:
• (2) 5/8” x 10” Bolt - 2001635
• (2) 5/8” Guardrail Nut - 4001116
• (1) 1” Washer - 2001580
Always start the installation at the existing
W-beam barrier and assemble the system toward
the impact head.
When driving the posts into stiff/rocky soil, place
close attention not to bend the posts. If rock or
stiff soil is encountered, the posts may be installed
by augering and backfilling the holes. Extra care
must be taken to prevent settlement or lateral
displacment of the post. Backfill material shall be
compacted to optimum compaction.
4. Begin by running a string line from the existing
posts at a 4ft. offset (1.2m). No other offset is
acceptable on a Flared system.
The string should follow the roadside edge of the
posts.
Note: The front of Posts 2-6 will be 7 5/8” (195mm)
from the backside of Rails 2 and 3 as blockouts are
used.
Post 1 does not require a blockout and will align
with the backside of Rail 1.
Post 3 requires up to an additional 2” (50mm) offset
away from the rail to allow space for the slider
assembly (See Step 5).
Notes:
POST 6
GROUND STRUT ASSEMBLY BETWEEN POSTS 1 AND 2
POST 1
POST 2
POST 3
POST 4POST 5POST 7
REV.
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POST 6 POST 2 POST 1
POST 3
NO BLOCKOUT ON POST 1
POST 4POST 5POST 7
194
7 5/8"
POST 7 POST 6 POST 1POST 2
POST 3
POST 4POST 5
RAIL DOES NOT ATTACH TO POSTS 3 OR 5
POST 7 POST 1POST 2
POST 3
POST 4POST 5POST 6
RAIL 3 RAIL 2 RAIL 1
Post Identification
Existing Trailing / Back Guardrail
Post Layout
INSTALLATION MANUAL

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5. Begin installing the posts at standard highway
post spacing, 75” (1905mm) and post height,
28 1/4” (720mm) or 31 3/4” (805mm). Post
spacing and post height are found on drawing
BSI-1012105-00 in Appendix A.
Post 4-6: Crimped Posts
**Please note, if you are installing a 50 FT.
system, the systems will have an additional 2
posts and an additional section of guardrail.
Please reference Appendix A for detail of a 50 FT.
system.
Post 3: Crimped Post
Offset Post 3 up to 2” (up to 50mm) back from
the string line to allow sufficient space for the
slider bracket assembly.
Post 3 is identified by the post having a crimp
and slots instead of holes. These slots are used
to bolt the guardrail on a later step. In addition,
Post 3 can be easily identified by having yellow
paint near the bottom.
6. Post 2: Post 2 Assembly with Soil Plate
Soil Plate should be on the trailing / back side of
the system.
Post 2 includes a blockout, and should be aligned
with Posts 4-6.
Depending on your post driver equipment, it may
be necessary to partially drive Post 2 prior to
attaching the Soil Plate. Begin to drive Post 2
approximately 18” (450mm), more if necessary.
If the post is driven more than 18” (450mm)
it will be necessary to use a pick ax or other
digging tool to remove some of the soil in order
to install the soil plate.
Once the soil plate is installed, continue driving
the post to the desired height.
Post 3 Offset
Drive Post 2
It may be neces-
sary to remove
/ dig out some
soil in order to
install the
Soil Plate
Trailing / Back
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Post 1: Crimped Post
Post 1 does not require a blockout, therefore, align
the post with the backside of the rail. Position the
outside edge of the post roughly 8” (200mm) from
the string line on the rail side of the string.
Post 1 is identified by the post having a crimp and
slots instead of holes. These slots are used to bolt
the guardrail on a later step. In addition, Post 1
can be easily identified by having yellow paint near
the bottom.
7. Install blockouts on Posts 2-6.
Blockouts at Posts 3 and 5 must be bolted on
before hanging the rails.
8. At Post 5, attach the blockout using the 5/8” x 10”
bolt. Secure blockout using the approach / front
hole on the post. The rail does not attach at Post
5.
See diagram below for post identification.
8. At Post 3, attach blockout and Slider Panel (Back)
using the 5/8” x 10” bolt and 1” washer. The slot
on the slider panel should point toward the front
of the system. Secure blockout using the trailing /
back slot on the post.
Blockouts at Posts 2, 4 and 6 are secured when the
rail is bolted to the posts.
POST 6
GROUND STRUT ASSEMBLY BETWEEN POSTS 1 AND 2
POST 1
POST 2
POST 3
POST 4POST 5POST 7
REV.
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C
D
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POST 6 POST 2 POST 1
POST 3
NO BLOCKOUT ON POST 1
POST 4POST 5POST 7
194
7 5/8"
POST 7 POST 6 POST 1POST 2
POST 3
POST 4POST 5
RAIL DOES NOT ATTACH TO POSTS 3 OR 5
POST 7 POST 1POST 2
POST 3
POST 4POST 5POST 6
RAIL 3 RAIL 2 RAIL 1
Installed Posts
Slider Panel (Back) and Blockout on Post 3
Approach / Front
INSTALLATION MANUAL
Approach / Front
Ensure the 1”
washer is used here.
Arrow should point
to front of system.
Install Blockouts
Open Slots

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Step 3 – Install Ground Strut Assembly
Components required:
• (2) Tension Rods – BSI-1012097-00
• (1) Ground Strut Angle – BSI-1012098-00
Hardware Required:
• (4) 5/8” Guardrail Nut - 4001116
9. Install tension rods between Posts 1 and 2 by
sliding the rods through the openings on the
bottom of Post 2.
10. Secure the rods at Post 1 by passing the rods
through the small piece of angle with the angle
sitting flush on the ground just above the crimp
on the post.
The small piece of angle will sit flush with the
ground on 28” systems only. On 31” height
systems, the small piece of angle will sit
approximately 3” (75mm) off the ground.
11. Tighten the rods so that there are equal amount
of threads exposed at both ends of the rods.
Note: Post 2 includes a blockout while Post 1
does not; this creates a curve in the tension rods
once installed.
POST 6
GROUND STRUT ASSEMBLY BETWEEN POSTS 1 AND 2
POST 1
POST 2
POST 3
POST 4POST 5POST 7
REV.
A
B
C
D
A
B
C
D
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BSI-1102002-00
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2 OF 2
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POST 6 POST 2 POST 1
POST 3
NO BLOCKOUT ON POST 1
POST 4POST 5POST 7
194
7 5/8"
POST 7 POST 6 POST 1POST 2
POST 3
POST 4POST 5
RAIL DOES NOT ATTACH TO POSTS 3 OR 5
POST 7 POST 1POST 2
POST 3
POST 4POST 5POST 6
RAIL 3 RAIL 2 RAIL 1
Tension Rods Installed at Post 2
Tension Rods Attached at Post 1
Slight Bend on Tension Rods
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Step 4 – Hang Rails
Components required:
• (3) W-Beam Guardrail - 4000443**
Hardware Required:
• (3) 5/8” x 10” Bolt -2001635
• (12) 5/8” x 1 ¼” Guardrail Bolt - 4001115
• (1) 5/8” x 2” Bolt - 2000302
• (8) Shear Bolts – K080123 (Kit of 8; 1 Required)
• (15) 5/8” Guardrail Nut - 4001116
• (1) 5/8” Nut - 2000468
• (1) Square Washer – BSI-1102027-00
• (8) 5/8” x 1 1/4” Guardrail Bolt - NOT INCLUDED
**If installing a 50 ft system, the system uses 4
sections of rail in stead of 3.
If you are attaching to an MGS rail system, a transition
guardrail panel is necessary.
Please reference Appendix A for 50 ft. or MGS system
details.
Note: For the system to telescope properly, the
forward most guardrail panel should always be on the
outside.
12. Before installing Rail 3 ensure that the blockout
at Post 5 has already been bolted on. Attach Rail
3 using the 5/8” x 10” bolt at Post 6, pass bolt
through the approach / front hole of post.
Note: Rail 3 is not attached to Post 5.
13. Splice Rail 3 with the existing rail using standard
5/8” x 1 1/4” bolts. [NOT SUPPLIED WITH THE
SYSTEM.]
Ensure that the 10” bolt used secure the rail and
blockout passes through both sections of guardrail,
blockout and post.
Notes:
Rail Identification
POST 6
GROUND STRUT ASSEMBLY BETWEEN POSTS 1 AND 2
POST 1
POST 2
POST 3
POST 4POST 5POST 7
REV.
A
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C
D
A
B
C
D
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2 OF 2
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POST 6 POST 2 POST 1
POST 3
NO BLOCKOUT ON POST 1
POST 4POST 5POST 7
194
7 5/8"
POST 7 POST 6 POST 1POST 2
POST 3
POST 4POST 5
RAIL DOES NOT ATTACH TO POSTS 3 OR 5
POST 7 POST 1POST 2
POST 3
POST 4POST 5POST 6
RAIL 3 RAIL 2 RAIL 1
Attach Rails to Posts
Standard Bolts at Rail 3 and 4 Connection
Approach / Front
INSTALLATION MANUAL

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14. Before installing Rail 2 ensure that the blockout
and Slider Panel (Back) at Post 3 has already
been bolted on. Attach Rail 2 using the 5/8”
x 10” bolt at Post 4, pass bolt through the
approach / front hole of post.
15. Splice Rail 2 with Rail 3 using the special yellow
shear bolts. The rails do not attach to Post 5.
DO NOT USE AND AIR IMPACT WRENCH TO
TIGHTEN SHEAR BOLTS.
16. Attach Rail 1 using the 5/8” x 9” guardrail bolt at
Post 2, pass bolt through the trailing / back slot
of post.
17. Connect Rails 1 and 2 using 5/8” x 1 ¼”
guardrail bolts by connecting the slider panel
assembly (front and back parts together).
Ensure that the angled portion of the Slider
Panel points toward the trailing / back end of
the system.
Attach Rail 2 at Post 4
Shear Bolts at Rail 2 and 3 Connection
Connect Rails 1 and 2 at Slider Assembly
Approach / Front
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18. Install the bolts from back to front with the nuts
on the front side.
19. Attach Rail 1 to Post 1 using the 5/8” x 2”
bolt and square washer, pass bolt through the
approach / front slot of post.
Attach Rail 1 at Post 1
Use square washer
here
INSTALLATION MANUAL
Angled portion to point trailing / back
Arrow should point
to front of system.
Slider Panel Assembly Installed

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Step 5 – Install Impact Head
Components required:
• (1) Impact Head – BSI-1012103-00
Hardware Required:
• (4) 5/8” x 1 ¼” Guardrail Bolt - 4001115
• (4) 5/8” Guardrail Nut - 4001116
20. Install Impact Head to the approach / front end of
Rail 1 using 5/8” x 1 ¼” guardrail bolts.
Place Impact Head on the outside of the rail.
21. Install bolts from outside in with nuts on the
inside.
Notes:
Install Impact Head at the End of Rail 1
Impact Head Installed
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Step 6 – Install Cable
Components required:
• (1) Cable – BSI-1012104-00
The cable is attached to the bottom of Post 2 and at
the Slider Bracket at Post 3.
22. Begin to install the cable by passing the threaded
end through the slot at the bottom of Post 2.
23. Thread the nut so that 1” of the threads are
protruding.
Ensure to install the small L-Shaped bracket
and round washer included with the cable. This
bracket and washer are critical components and
help keep the cable engaged in the slot.
Proceed to thread the nut while not exposing any
threads. This will ensure you can achieve the
required to torque for the cable nut in a subse-
quent step.
Notes:
Install Cable at Post 2
L-Bracket installed at Post 2 Prior to Tightening
Install L-Bracket
Install L-Bracket
and round
washer here
INSTALLATION MANUAL

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24. Pass the other end of the cable through the slider
bracket at Post 3.
Install the nut. Tightening of the cable should
be done at the bottom of Post 2 in the following
step.
25. Tighten the cable nut at Post 2. I will be
necessary to use a pipe wrench or large pliers on
the backside of the cable to hold it in place while
tightening. If the cable is not held in place with a
pipe wrench or large pliers, it will spin while you
attempt to tighten the cable and you will not be
able to tighten it.
Apply approximately 60 FT-Lb torque. Continue
to tighten the cable nut until the cable is tight
and the approximate torque is achieved.
When tightening, ensure that the L-Bracket
does not shift, turn and move out of position.
Note: Standard BCT cables used on other systems
may not require a specific torque on the cable nuts.
The X-LITE® Flared System requires a tensioned
cable to maintain engagement in the slot on
Post 2.
If a torque wrench is not available, use the
following method to ensure cable is adequately
tensioned:
Tighten cable nut until a Maximum 1/2” cable
deflection is measured at the midpoint when
pressure is applied by hand.
Install Trailing / Back End of Cable Through
Bracket at Post 3
Torque cable nut to 60 ft.-lb. at Post 2
Cable Installed
X-LITE® FLARED END TERMINAL

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20
Final Inspection Checklist
Inspection
Date
Inspection
By:
Item
Post 1 & 3, use slotted holes
Rail bolted at posts 1, 2, 4 and 6 Only
Rails not bolted to posts at Posts 3 and 5
Square washer used at Post 1
Blockout and Back Slider Panel attached to post 3 using the
trailing / back slot on the post
Post 2, rail bolted using trailing / back slot on post
Posts 1, 4, 6, rails bolted using approach / front hole or slot
on posts
Rails 3 and 4 spliced using standard guardrail bolts
Rails 2 and 3 spliced using special yellow shear bolts
Slider assembly properly assembled with bolts from back to
front with nuts on the outside
Angled portion of Slider panel points toward the trailing / back
end of the system.
Arrows on slider should point toward the front of the system
Cable bracket and washer installed on Cable at Post 2
Approximately 60 ft.-lb. torque applied to cable nut at Post 2
Blockout at Post 2
Offset = 4ft (1.2m)
INSTALLATION MANUAL