Trinity Alpha 70K TMA 7590 User manual

Alpha 70K TMA®
(Model 7590)
Product Description
Assembly Manual
Revision B December 2013Part No. 115314B

Part No. 115314B
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Alpha 70K TMA
®
(Model 7590)
90° TILT-HYDRAULIC LOCK
Product Description
Assembly Manual
2525 Stemmons Freeway
Dallas, Texas 75207
Important: These instructions are to be used only in conjunction with the
assembly, maintenance, and repair of the Alpha 70K TMA
®
system. These
instructions are for standard assembly specified by the appropriate highway
authority only. In the event the specified system assembly, maintenance, or
repair would require a deviation from standard assembly parameters, contact the
appropriate highway authority engineer. This system has been accepted for use
by the Federal Highway Administration for use on the national highway system
under strict criteria utilized by that agency. Energy Absorption Systems
representatives are available for consultation if required.
This Manual must be available to the worker overseeing and/or assembling the product
at all times. For additional copies, contact Energy Absorption Systems at [phone]
or download from websites below.
The instructions contained in this Manual supersede all previous information and Manuals. All
information, illustrations, and specifications in this Manual are based on the latest Alpha 70K
TMA
®
system information available to Energy Absorption Systems at the time of printing. We
reserve the right to make changes at any time. Please contact Energy Absorption Systems to
confirm that you are referring to the most current instructions.

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Table of Contents
Customer Service Contacts .......................................................................................................... 3
Important Introductory Notes ........................................................................................................ 3
Recommended Safety Rules for Assembly .................................................................................. 4
Safety Symbols ............................................................................................................................. 5
Warnings and Cautions................................................................................................................. 5
Limitations and Warnings.............................................................................................................. 6
Operation Instructions................................................................................................................... 8
Raise and Lower 90 Degree Tilt Systems..................................................................................... 8
General Maintenance.................................................................................................................. 11
Recommended Tools ............................................................................................................ 12
Assembly Procedure................................................................................................................... 13
Repair Instructions ...................................................................................................................... 20
Durashell Nose Damage ....................................................................................................... 21
General Information .................................................................................................................... 22
PUMP TROUBLE SHOOTING CHART ................................................................................ 23
Quick Troubleshooting Guide ..................................................................................................... 24
Troubleshooting Guide................................................................................................................ 26
Test Equipment for DC Powered Hydraulic Systems............................................................ 26
Hydraulic Fluid ...................................................................................................................... 27
Pump Priming........................................................................................................................ 28
Reservoirs............................................................................................................................. 28
Filters .................................................................................................................................... 29
Relief Valves ......................................................................................................................... 30
Check Valves ........................................................................................................................ 32
Hydraulic Cylinders ............................................................................................................... 33
Electrical Problems ............................................................................................................... 35
Alpha 70K TMA, 90 Tilt, Hydraulic Lock................................................................................ 38
Alpha 70K TMA, 90 Tilt ......................................................................................................... 39
Underride Frame Assembly, TMA......................................................................................... 40
Jack Assembly, HD Backup, TMA ........................................................................................ 41
Support Frame Assembly, Mechanical Lock......................................................................... 42
Hydraulic Assembly for 90° Tilt Systems ..............................................................................43

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Customer Service Contacts
Energy Absorption Systems and Trinity Highway Products are committed to the highest level of
customer service. Feedback regarding the Alpha 70K TMA®system, its assembly procedures,
supporting documentation, and performance is always welcome. Additional information can be
obtained from the contact information below:
Energy Absorption Systems:
Telephone: [phone] (USA Only)
[phone] (International)
E-mail: [email protected]
Internet: Energy Absorption Systems
Trinity Highway Products, LLC
http://www.energyabsorption.com
http://www.highwayguardrail.com
Important Introductory Notes
Proper assembly, deployment, and future maintenance of the Alpha 70K TMA®are critical to
achieve tested performance under accepted criteria. Take the time to review this Manual
thoroughly before performing all necessary work. 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 Alpha 70K TMA®
system, please contact the highway authority that has planned and specified this assembly and,
if needed, contact Energy Absorption Systems Customer Service Department. This product
must be assembled in the location specified 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 may not perform as it was tested and accepted.

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Important: Read safety instructions thoroughly and follow the assembly
directions and suggested safe practices before assembling, maintaining, or
repairing the Alpha 70K TMA®system. Failure to follow this warning can result in
serious injury or death to the worker and/or bystanders. It further compromises
the acceptance of this system by the FHWA. Please keep these instructions for
later use. 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. These instructions and any attached drawings should be
reviewed and studied thoroughly by a qualified individual who is skilled in
interpreting them before the start of any assembly
Warning: Ensure that all of the Alpha 70K TMA®system Warnings, Cautions,
and Important Statements within the Alpha 70K TMA®Manual are completely
followed. Failure to follow this warning could result in serious injury or death in
the event of a collision.
Recommended Safety Rules for Assembly
* Important Safety Instructions *
This Manual must be kept in a location where it is readily available to persons who assemble,
maintain, or repair the Alpha 70K TMA®system. Additional copies of this Manual are
immediately available from Energy Absorption Systems by calling [phone]. Please
contact Energy Absorption Systems if you have any questions concerning the information in this
Manual or about the Alpha 70K TMA®system. This Manual may also be downloaded directly
from the websites indicated below.
Always use appropriate safety precautions when operating power equipment, mixing chemicals,
and when moving heavy equipment or the Alpha 70K TMA®components. Gloves, safety
goggles, safety-toe shoes, and back protection should be used.
Safety measures incorporating traffic control devices specified by the highway authority must be
used to provide safety for personnel while at the assembly, maintenance, or repair site.

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Safety Symbols
This section describes the safety symbols that appear in this Alpha 70K TMA®Manual. Read
the Manual for complete safety, assembly, operating, maintenance, repair, and service
information.
Symbol Meaning
Safety Alert Symbol: Indicates Danger, Warning, or Caution. Failure to read
and follow the Important, Danger, Warning, or Caution indicators could result in
serious injury or death to the workers and/or bystanders.
Warnings and Cautions
Read all instructions before assembling, maintaining, or repairing the Alpha 70K TMA®system.
Warning: Do not assemble, maintain, or repair the Alpha 70K TMA®system
until you have read this Manual thoroughly and completely understand it. Ensure
that all Warnings, Cautions, and Important Statements within the Manual are
completely followed. Please call Energy Absorption Systems at [phone] if
you do not understand these instructions. Failure to follow this warning could
result in serious injury or death in the event of a collision.
Warning: Safety measures incorporating appropriate traffic control devices
specified by the highway authority must be used to protect all personnel while at
the assembly, maintenance, or repair site. Failure to follow this warning could
result in serious injury or death in the event of a collision.
Warning: Use only Energy Absorption Systems parts that are specified herein
for the Alpha 70K TMA®for assembling, maintaining, or repairing the Alpha 70K
TMA®. Do not utilize or otherwise comingle parts from other systems even if
those systems are other Energy Absorption Systems or Trinity Highway Products
systems. Such configurations have not been tested, nor have they been
accepted for use. Assembly, maintenance, or repairs using unspecified parts or
accessories is strictly prohibited. Failure to follow this warning could result in
serious injury or death in the event of a vehicle impact with an UNACCEPTED
system.
Warning: Do NOT modify the Alpha 70K TMA®system in any way. Failure to
follow this warning could result in serious injury or death in the event of a
collision.
Warning: Ensure that the Alpha 70K TMA®system and delineation used meet
all federal, state, specifying agency, and local specifications. Failure to follow this
warning could result in serious injury or death in the event of a collision.
Warning: Ensure that your assembly meets all appropriate Manual on Uniform
Traffic Control Devices (MUTCD) and local standards. Failure to follow this
warning could result in serious injury or death in the event of a collision. Any
reflectivity of this system must comply with the plans and specifications or other
applicable regulations of the highway authority to determine the type of
reflectivity required.

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Limitations and Warnings
The Alpha 70K TMA (Truck Mounted Attenuator) has been tested and evaluated per the
recommendations of the national Cooperative Highway Research Program (NCHRP) report
350. The Alpha 70K TMA, as currently designed, is capable of, decelerating and stopping light
and heavy weight vehicles (820 and 2000 kg [1,808 and 4,410 lb.]) when the rear of the
Cartridge is impacted head-on at 70 km/h [43 mph] within the above referenced NCHRP criteria.
To achieve optimum impact performance, the Alpha 70k TMA must be mounted to a truck with a
traveling weight of 5000 – 12,000 kg [11,025 - 26,460 lbs.] gross vehicle weight rating (actual
weight should not exceed 9000 kg [19,845 lbs.]). The TMA Cartridge must be level and the
bottom of the Cartridge must be 305 mm ± 25 mm [12” ± 1”] above the ground.
Impacts that exceed the design capabilities described in this Manual (vehicle weight, speed and
impact angle) may not result in acceptable crash performance as described in NCHRP 350
relative to structural adequacy, occupant risk, and vehicle trajectory factors.
Follow all applicable DOT and/or applicable highway authority plans and specifications and
other regulations regarding placement and use of TMA.

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Definition-The BARRIER VEHICLE is the truck on which a TMA is mounted, while positioned
upstream (towards the direction that traffic is approaching) of a work zone.
The SHADOW VEHICLE is the truck on which a TMA is mounted, which is following behind a
moving operation such as striping, spraying, etc.
THE USE OF A TMA ON THE BACK OF A TRUCK IS INTENDED TO:
Gradually decelerate the impacting vehicle
Protect the occupants of the impacting vehicle
Protect the barrier/shadow vehicle occupants
Reduce damage to the barrier/shadow vehicle
If these impacts occur within NCHRP 350 criteria the TMA
WILL NOT:
Affect the skid (roll ahead) distance of an impacted truck.
KEEP WORK CREWS CLEAR!
CONTROLLING SKID DISTANCE (ROLL AHEAD):
Skid distance is significantly increased and is less predictable for lighter
shadow/barrier vehicles
Skid distance is reduced and is more consistent when heavier shadow/barrier
vehicles are used
Required Truck Weight: 12,000kg [26,460 lbs.] to 11350 kg [25,000 lbs.]
Recommended Curb Weight: 9000 kg [19,845 lbs.]

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Operation Instructions
The Alpha Truck Mounted Attenuator (TMA), Model TMA 7590 has been equipped with a
hydraulic pump which can be used to tilt the energy absorbing Cartridge from its horizontal
position as well as remotely latch it in the vertical position. The “tilting” feature may be used to
prevent possible scraping of the rear end of the Cartridge as the truck travels in and out of
sloped driveways. The driver simply activates the “UP” button from inside the cab to
momentarily tilt the Cartridge up. When he removes his finger from the button, it will slowly
bleed back down to its horizontal position.
The hydraulic system can also be used to tilt the Cartridge to a full 90 degree “UP” position
where it will stay locked. This feature allows the TMA equipped truck to be easily driven and
parked in congested areas. It should be remembered that for the TMA to function properly
during a crash, the Cartridge must be in the horizontal, “DOWN” position. To lower the Cartridge
from the 90 degree “UP” position, the driver must exit the cab and check behind the Cartridge to
make sure everything is clear.
A full set of procedures to operate the system follows:
Raise and Lower 90 Degree Tilt Systems
1. RAISE the Cartridge:
A. Make sure the top of the Cartridge is clear of all objects before proceeding.
B. Activate the hydraulic system to raise the Cartridge using the switch in the cab or the
switch located on the side of the Support Frame.
C. The Cartridge may be tilted a full 90 degrees where it will be locked in the up position, or
it may be tilted approximately 30 degrees to travel up sloped driveways, after which it will
bleed back down to the horizontal position.
D. To lock the Cartridge in the full up position, keep the activation switch “ON” for five (5)
seconds after the Cartridge reaches the full up position (this allows enough time for the
sequence valve to activate the locking pins).
Danger: Under no circumstances should anyone be allowed behind an
elevated Cartridge when the latch pins are not fully seated in their locked
position.
2. LOWER the Cartridge from full 90 degree position:
A. Activate the down switch to release the latch pins (this is to be accomplished from the
rear corner of the truck so that the operator can check to make sure everyone is clear).
Release the DOWN switch and the Cartridge will lower to the horizontal position.
Danger: As Cartridge starts to lower, stand clear of moving parts.
B. Cartridge will then “bleed-down” in 15 – 30 seconds, regulated by the flow control valve
attached to the cylinder.
C. The external switch and cord should be properly stored before moving the truck.

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3. ATTACH TMA to the truck: Method I (Attaches Backup and Cartridge)
A. Move Backup and Cartridge squarely toward rear of truck. If necessary, activate down
switch to retract latch pins.
B. Adjust the height of the Backup Jacks so that the 1” diameter Backup pivot pins may be
re-attached. Insert the two Pivot Pins and Retainer Pins that connect the Backup to the
Backup Support Frame. Retainer Pins should point down.*
C. Connect light harnesses and verify that all turn/stop/tail lights are working properly.
D. Insert the 1” diameter Pin and Retainer Pin that connects the hydraulic ram to the
Backup* (see Hydraulic Assembly drawing).
E. Retract the two front swivel Jacks completely and rotate them to horizontal position.
F. Raise the rear Jack and secure it in the full up position.
G. Check location of all hydraulic and electrical lines to make sure they will not be damaged
during raising and lowering of Cartridge.
H. Cycle the system to verify that everything is operating properly (see steps 1 and 2 of this
section).
Important: Do not run down the truck battery.
4. REMOVE TMA from the truck: Method I (Removes Cartridge and Backup only).
A. Lower the Cartridge to DOWN position.
B. Lower the single rear Jack so it takes the weight of the Cartridge.
C. Swing the two front swivel Jacks into position and extend them until the weight of the
Cartridge and Backup is off the 1” diameter Attachment Pins.
D. Remove the two Attachment Pins and the Pin in the hydraulic ram. Check the hydraulic
ram to make sure it is properly supported (see Hydraulic Assembly drawing).
E. Unplug the light harnesses.
F. Move the Cartridge and Backup squarely away from the truck.
G. Return the Pins and Retainer Pins removed in step D to their original holes in Support
Frame, so they will not be lost.
* Be sure Retainer Pins are attached correctly and cannot fall out:

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5. ATTACH TMA to the truck: Method II (Attaches Cartridge, Backup, Support Frame, and
hydraulics)
A. Move the TMA to truck.
B. Connect power cable and Cab Switch to pump, ground wire to truck frame, light
harnesses to truck leads, and verify that all turn/stop/tail lights are working properly.
C. Attach the two lower 1” diameter pins and Retainer Pins. *
D. Attach the two upper 1” diameter pins and Retainer Pins.*
E. Retract the two front swivel Jacks completely and rotate them to horizontal position.
F. Raise the rear Jack and secure it in the full “UP” position.
G. Check location of all hydraulic and electrical lines to make sure they will not be damaged
during raising and lowering of Cartridge.
H. Cycle the system to verify that everything is working properly (see steps 1 and 2 of this
section).
Important: Do not run down the truck battery.
6. REMOVE the TMA from the truck: Method II (Removes Cartridge, Backup, Support Frame,
and hydraulics)
A. Lower the Cartridge to DOWN position.
B. Lower the single rear Jack so it takes the weight of the Cartridge.
C. Rotate the two front swivel Jacks into position and extend them until the weight of the
TMA is supported.
D. Remove the two upper 1” diameter pins and Retainer Pins.
E. Remove the two lower 1” diameter pins and Retainer Pins.
F. Unplug the light harnesses, disconnect power cable (+) and Cab Switch from pump and
ground wire from truck frame.
G. Move the TMA away from the truck.
H. The pins and Retainer Pins removed in Steps D and E shall be returned to the original
holes in the Support Frame, so they will not be lost.
* Be sure Retainer Pins are attached correctly and cannot fall out:

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General Maintenance
DESCRIPTION INTERVAL
1. Check tightness of fasteners. 1 month or 1,000 miles
2. Oil swivel Jacks. 6 months
3. Change hydraulic fluid (Use Dexron
®
III fluid only) 2 years or 30,000 miles
4. Add hydraulic fluid (Use Dexron
®
III fluid only) As required
5. Clean hydraulic pump. As required
6. Clean hydraulic ram. As required
7. Replace light bulbs. As required
8. Clean Backup, Cartridge and Support Frame
(dirt and salt)
As required
9. Check levelness and height of Cartridge in
“DOWN” position (see sheet 1, instruction “A”.)
As required. (correct immediately)*
10. Grease friction points (moving steel parts) 6 months
11 Check the latch mechanism to make sure it moves
smoothly into its locking position.
As required (correct immediately)
12. Check all 1” diameter pins to make sure they are
held in position by a retaining pin.
As required (correct immediately)*
13. Check condition of wheels on Jacks As required
14. Check for damage or corrosion. As required *
Note: As required maintenance shall be checked monthly.
Note: For items marked with “*” check prior to each use.

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Recommended Tools
Welding equipment (for 13 mm [1/2”] plate)
Cutting torch
Hammer
Drift pin or alignment pin
Tape measure
1/2" drive socket wrench
1/2" drive sockets (9/16”, 1-1/8”, 1-1/2”)
Open end wrenches (9/16”, 1-1/8”, 1-1/2”)
12” crescent wrench – 2
Carpenter’s 600 mm [24”] bubble level
Marking implement (pencil, soap stone)
Floor jack
Center punch
Torque wrench
Hydraulic fluid (Use Dexron®III fluid only)
Drill motor for 13/16” diameter drill
13/16” diameter bit and pilot drill for same
9/16” Allen wrench
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 assembly site.

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Assembly Procedure
1. Check shipping list against actual parts to make sure all items were received. Review
drawing package and familiarize yourself with the assembly and part numbers. Read the
entire Manual before proceeding.
2. Park truck on a level surface (use bubble level). The truck should be as close to the final
driving weight as possible. If ballast must be added to achieve the 5000 kg [11,025 lbs.]
minimum weight, add it at this time. The ballast must be properly anchored to the truck to
keep it in place during an impact. Ideally an adequately sized truck that requires no ballast
should be used.
3. Before assembling the Alpha TMA, the truck must first be equipped with a rigid underride
frame attached to the rear of the truck frame. Refer to Underride Assembly drawing for
minimum requirements. An existing underride frame must be capable of withstanding an
impact load of 200 kN [45,000 lbs.] along the lower member.
Parts and materials are supplied with the TMA for assembling an underride that meets the
requirements specified (see Underride Assembly drawing) if the truck is not equipped with
an underride, or if the existing underride cannot withstand the 200 kN [45,000 lbs.] load.
Warning: All welding shall be performed by a welder certified to AWS D14.3-82
or AWS D1.1 and in accordance to Underride Assembly drawing.
Caution: The truck frame is high carbon steel. To avoid cracking, do not weld
or apply excessive heat to the bottom flange, forward of rearmost leaf spring
hangers.
4. After attaching the truck underride (or making sure the existing one can withstand the
200 kN [45,000 lbs.] load), check for interference problems as described below.
A. Place a “mark” on the rear of the truck frame 890 ±5 mm [35” ±1/4”] off the ground. Then
measure horizontally between this mark and the cross member that ties into the
outboard spring leaf hangers (this cross member should never be cut). There should be
a minimum distance of 75 mm [3”]. If this minimum distance is not available, then an
extension may need to be welded to the end of the truck frame. Consult Energy
Absorption Systems Customer Service Department for input (see page 3).

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B. Temporarily position “Upper Frame Support” (PN 615578) against the rear of the truck
frame (refer to Figure 2) and check for interference problems. Interference problems with
tail lights, dump bodies (in up position), etc. should be corrected before proceeding. (The
cross member on the Upper Frame Support may be removed after attachment to
underride.)
Figure 1 Section View Looking Outboard
LEVEL GROUND
CAUTION: Truck frame is high carbon steel. To avoid
cracking, do not weld or apply excessive heat to bottom
flange forward of rear-most leaf spring hanger.
LEAF SPRING HANGER
75 mm [3”]
MIN
TRUCK FRAME
CAUTION: Do not cut frame
cross member which ties into
outboard leaf spring hangers.
890 mm ±5 mm
[35” ±1/4”]
TRUCK UNDERRIDE
Figure 2
Cut off excess as required (leave
enough length of a 6mm [1/4”]
weld, top, and bottom).
890 mm ±5 mm
[35” ±1/4”]
Centerline of truck and
Upper Frame Support must
line up ±5mm [1/4”]
UPPER FRAME SUPPORT
(
PN 615578
)
TRUCK FRAME
BUBBLE LEVEL
A
fter attachment is completed,
an
g
le
p
iece ma
y
be cut out.
GUSSET (PN 615578)
(
4PLACES
)

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5. The Backup and Support Frame are pre-assembled at the manufacturing facility and
therefore should arrive as a complete assembly. Attach the Cartridge to the Backup and
Support Frame Assembly using the 1/2" nuts and washers attached to the Cartridge.
Tighten the nuts until the lock washers are fully compressed (refer to detail drawings).
6. Secure the Jacks on the Cartridge and Backup into the “DOWN” position and “elevate” the
Cartridge to 305 mm ± 5 mm [12” ± 1/4"] at front, 330 mm ± 5 mm [13” ± 1/4"] at rear from
the ground. The Cartridge jack may have been shipped separately from the Cartridge. See
the decal on the rear of the Cartridge for assembly instructions. Torque bolts to no more
than 35 N-m [25 ft–lb].
7. Attach the “Support Frame Attachment Bracket” (2 ea. PN 605399) to the upper holes of the
Support Frame, (PN 615554) using the 1” diameter pins. Lower holes are for height
adjustment if necessary (see Figure 4).
Figure 4
Figure 3
890 mm ±5 mm
[35” ±1/4”]
30 DEG.
GRADE
Upper Frame Support may be tilted up to 30
degrees if truck frame is cut at an angle.
Note: Adjustment must be made to assure
that final position of holes in Support Frame
Attachment Brackets (PN 605399) are 890 ±5
mm [35” ±1/4”] from level grade, if frame is
tilted.
SUPPORT FRAME
ATTACHMENT BRACKET
PINNED ATTACHMENT
PN 116294
TMA SUPPORT FRAME

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8. Attach the “Upper Frame Support” (PN 615578) to the attachment Bracket using the 1” x 3”
grade 5 bolts. Center the Upper Frame support to the Attachment Brackets before
tightening. Torque the nuts to 240 N-m [175 ft-lb].
9. Check again to assure that the front of the Cartridge is at 305 mm [12”] high and the rear of
the Cartridge is set at 330 mm [13”] high. Move the Cartridge, Backup, and Support Frame
Assembly up to the truck frame. Center the “Upper Frame Support” on the truck frame (with
underride) and tack weld in place. Note: The Upper Frame Support must be in intimate
contact with the truck frame and centered before welding.
Important: If there is interference with something on the truck which cannot be
moved, the Upper Frame Support may be disassembled from the Support
Frame Attachment Brackets and assembled to the truck frame by inverting the
Upper Frame Support as shown in Figure 5 and then locating and welding it
using the dimensions and cautions as shown in Figure 1 and 2. Angle cross
member may need to be cut out at this time in order to proceed.
10. Remove the 1” diameter Pins from the Support Frame and Support Frame Attachment
Brackets and move the Cartridge, Backup, and Support Frame Assembly away from the
truck.
11. Weld the “Upper Frame Support” to the truck frame per Underride Assembly drawing.
Note: Minimum weld length to each frame (excluding gusset welds) is 380 mm [15”] (see
Part A in Step #4). Weld the four Gussets (PN 610073) as shown making sure there is
adequate bolt clearance near the holes. Paint the exposed metal parts using the primer and
spray paints provided (see Figure 2 and 3).
12. Position Lower Truck Brackets (PN 605505) as shown in Figure 6. Place one 13 mm [1/2”]
thick Shim (PN 614055) under each Lower Truck Bracket (PN 605505). Attach with 3/4"
diameter x 4” long all thread H.H. bolts, and torque to 200 N-m [150 ft-lb].
Figure 5
NUT, HX, 1, G5
WASHER, FLAT, 1 X 2 1/2”, G5
WASHER, LOCK, 1, G5
TRIM AS REQUIRED
(SEE INSTRUCTION, FIG 2)
UPPER FRAME SUPPORT
Part may be rotated as summarized
in shaded box (step 10).
SUPPORT FRAME
A
TTACHMENT BRACKET
BOLT
,
HX
,
1 X 3
,
G5

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13. Attach Electrical Sockets (PN 117404 and PN 117406) to rear of truck per detail drawing,
Sheet 1, provided in this booklet. Make sure that the electric cords on the Backup and
Cartridge can reach this location.
14. Position and re-attach TMA Support Frame (PN 615554) to the Support Frame Attachment
Brackets (PN 605399) using the 1” diameter pins provided. The Retainer Pins should be on
the inboard side of Support Frame.* Refer to Detail Drawings.
Note: The cross member of the Upper Frame Support (PN 615578) may require removal at
this point (see Figure 2 on page 14). Torque 1” nuts until lock washers are fully compressed.
* Be sure Retainer Pins are correctly assembled:
Figure 6
(1) 13 mm [1/2”] THICK SHIM
(PN 614055)(TYPICAL)
BOLT, HX, 3/4 X 4”, G5
(Torque to 200 Nm
[150 ft-lb]
890 mm ±6 mm [33 3/4” ±1/4”]
(Inside dimension of outer tabs)
355 mm [14”] minimum
(Larger dimension preferred)
Move Lower Truck Brackets (PN 605505)
as low as possible (Minimum vertical
centerline to centerline is 355 mm [14”])
43 ±3 mm
[16 7/8” ±1/8”]

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15. Attach Struts as shown in Figure 7, using 1” diameter pins and Retainer Pins* at the Lower
Truck Brackets, and 3/4" diameter x 3 1/2" long Grade 5 Bolts at connection to Support
Frame. Torque nuts to fully compress lock washers.
* Be sure Retainer Pins are correctly assembled:
16. The hydraulic system was assembled as shown on Hydraulic Assembly drawing. The pump
was wired as shown on Hydraulic Assembly drawing. Mount one switch inside the cab within
easy reach of the driver. Place the “Caution” decal supplied with the push button near the
switch. Mount the second switch on the passenger side of the Support Frame using the
bracket provided. The latch cylinder pins should be left in their retracted positions.
17. Secure the three Jacks into the “UP” position. The Cartridge Jack may have been shipped
separately from the Cartridge. See the decal on the rear of the Cartridge for assembly
instructions. Torque bolts to no more than 35 N-m [25 ft-lb].
Figure 7 (Jacks not shown for clarity)
Levelness of Cartridge to be
adjusted here
Adjust height of
Cartridge here.
SUPPORT FRAME
CARTRIDGE
STRUT
SHIM
43 ±3 mm
[16 7/8” ±1/8”]

www.energyabsorption.com Revision B December 2013
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18. Double check the height and levelness of the Cartridge relative to the ground (305 mm
±25 mm [12 ± 1”]). If the Cartridge is not level, adjustment can be made as described under
Item 13 (see Figure 6 and 7) using 13 mm [1/2”] and 6 mm [1/4”] thick shims provided.
19. Plug in the Cartridge and Backup Plugs as well as the pump’s battery cable (to the positive
[+] terminal) and verify that all turn/stop/tail lights are working properly.
20. Check location of all hydraulic and electrical lines to make sure they will not be damaged
during raising and lowering of Cartridge.
21. The pump reservoir was filled at the factory with Dexron III hydraulic fluid (approximately 3
quarts). Remove the metal plug and check to see if it is full. Insert the plastic breather cap in
the filler hole and be careful not to cross-thread it. Read the Operating Instructions, then
cycle the system up and down several times to relieve air from the system. If necessary
adjust the bleed-down rate using the flow control valve. Cartridge should bleed down from
90 degrees to horizontal in 15-30 seconds. (Refer to Hydraulic Assembly drawing).
Caution: Do not run down truck battery.
IMPORTANT
22. Make sure the latch pin mechanism smoothly locks the Cartridge in the 90 degree “UP”
position. (Note: Problems here often can be corrected by varying the length of the large 3”
bore hydraulic cylinder by unscrewing the clevis one or two revolutions). The sequence
pressures (12.4 MPa [1800 psi]) are pre-set at the factory and usually do not require
adjustment. Turning the adjusting screws “in” will INCREASE the sequence pressure.
Turning the adjusting screws “out” will DECREASE the sequence pressure.
Caution: Each time the operator elevates the Cartridge, he/she should verify
that both Latch Pins are fully locked before allowing anyone behind the Cartridge.
23. Check tightness of all fasteners. Double check height and levelness of Cartridge.
24. The TMA system is now ready for use. To achieve intended operation, all TMA users should
be given operating and safety instructional training as given in this Manual and as required
by the specifying highway authority.
Figure 8
305 mm ±25 mm [12” ±1”]
LOCATE SHIMS HERE
355 mm [14”] MINIMUM 305 mm ±25 mm [12” ±1”]
890 mm ±5 mm [35” ±1/4”]