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Trinity Alpha 70K TMA 7590 Product Description And Assembly Manual

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

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Summary of Contents for Trinity Alpha 70K TMA 7590

  • Page 1 Alpha 70K TMA ® (Model 7590) Product Description Assembly Manual Part No. 115314B Revision B December 2013...
  • Page 2 ® 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.

  • Page 3: Table Of Contents

    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 ........................

  • Page 4: Customer Service Contacts

    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...

  • Page 5: Recommended Safety Rules For Assembly

    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.

  • Page 6: Safety Symbols

    ® . 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.

  • Page 7: Limitations And Warnings

    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.
  • Page 8 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.

  • Page 9: Operation Instructions

    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.
  • Page 10 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.
  • Page 11 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.

  • Page 12: General Maintenance

    General Maintenance DESCRIPTION INTERVAL Check tightness of fasteners. 1 month or 1,000 miles Oil swivel Jacks. 6 months ® Change hydraulic fluid (Use Dexron III fluid only) 2 years or 30,000 miles ® Add hydraulic fluid (Use Dexron III fluid only) As required Clean hydraulic pump.

  • Page 13: Recommended Tools

    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”) ...

  • Page 14: Assembly Procedure

    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.
  • Page 15 CAUTION: Do not cut frame cross member which ties into 75 mm [3”] outboard leaf spring hangers. LEAF SPRING HANGER TRUCK FRAME 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.
  • Page 16 30 DEG. 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”...
  • Page 17 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]. Part may be rotated as summarized in shaded box (step 10).
  • Page 18 (1) 13 mm [1/2”] THICK SHIM (PN 614055)(TYPICAL) BOLT, HX, 3/4 X 4”, G5 (Torque to 200 Nm [150 ft-lb] 43 ±3 mm [16 7/8” ±1/8”] 355 mm [14”] minimum (Larger dimension preferred) 890 mm ±6 mm [33 3/4” ±1/4”] (Inside dimension of outer tabs) Move Lower Truck Brackets (PN 605505) as low as possible (Minimum vertical...
  • Page 19 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. SUPPORT FRAME Adjust height of CARTRIDGE...
  • Page 20 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. LOCATE SHIMS HERE 355 mm [14”] MINIMUM 305 mm ±25 mm [12”...

  • Page 21: Repair Instructions

    Repair Instructions The following instructions are given by first presenting a problem and then giving a possible solution. Cartridge cannot be elevated Consult hydraulic schematic in this manual. Clogged filters or improperly adjusted “internal pump relief valve” could be the problem. There may not be enough hydraulic fluid in the ®...

  • Page 22: Durashell Nose Damage

    Durashell Nose Damage The Durashell Nose is a resilient plastic nose that normally recovers its shape after nuisance hits. However, if either the left or right side is damaged, it must be replaced in the following manner. A. Remove the bolts and washers attaching the nose to the Cartridge. B.

  • Page 23: General Information

    General Information Energy Absorption Systems personnel are available to assist in evaluating damaged TMA Cartridges. Several photos of the damaged area, taken at different angles, should be submitted for evaluation (see page 3). Standard Cartridge base color is highway yellow. 305 mm [1’...

  • Page 24: Pump Trouble Shooting Chart

    www.energyabsorption.com Revision B December 2013 www.highwayguardrail.com All rights in copyright reserved...

  • Page 25: Quick Troubleshooting Guide

    Quick Troubleshooting Guide (Williams/Monarch Pumps) NEVER STAND BENEATH THE TMA WHEN IT IS BEING LOWERED OR SOMEONE IS AT THE CONTROLS Finding and Solving Problems: Hydraulic system failures usually follow a similar pattern: A gradual or sudden loss of pressure or flow, followed by a loss of cylinder or motor power.
  • Page 26 5. System Operates too Fast □ Incorrectly adjusted flow control valve: Replace or adjust as necessary. 6. Oil in System Overheats □ Incorrect, low or dirty oil: Add or change oil as necessary. □ Excessive component internal leakage: Repair or replace as necessary. □...

  • Page 27: Troubleshooting Guide

    Troubleshooting Guide Safety Notes Warning: Always wear eye protection when working on or around machinery or power tools and while working with hydraulics. Warning: Do not attempt to control a hydraulic leak with your hand. High- pressure hydraulic fluid can puncture the skin and cause severe injury or death. Use extreme caution when working on hydraulic systems.

  • Page 28: Hydraulic Fluid

    Assorted Hoses, Pressure Fittings These can be used to connect and/or isolate certain parts of a hydraulic circuit for diagnosing hydraulic problems. If you suspect problems do not operate the system. Diagnose and repair, or contact Energy Absorption Systems Customer Service Department for assistance. High-Pressure Shut-Off Valve The shut off valve can be used to choke off oil flow so that a "false"...

  • Page 29: Pump Priming

    Pump Priming New Assemblies New system assemblies, as well as those that are disassembled for repair, require proper priming to avoid possible pump failure. A pump is said to be ''primed'' when the internal cavity is full of oil and all air has been expelled. A.

  • Page 30: Filters

    Clear oil flowing out of fill-hole usually means cylinders were not fully collapsed when reservoir was filled. Foamy oil flowing out of the fill-hole points to the following: Air is present in the system; that is, cylinders and fluid lines. The response usually is ''spongy'' and the cylinder moves with a ''jerking'' motion.

  • Page 31: Relief Valves

    Relief Valves The Purpose of a Relief Valve is to: A. Limit the maximum pressure in the system to a safe level. B. Keep the current draw and battery drain at a minimum when the cylinder “deadheads” (reaches full stroke). The Pump relief Valves on TMA’s are Basically the Same Except: An internal cavity is drilled into the pump base on Monarch pumps for the relief valve.
  • Page 32 2. Repair procedure a. There are two possible causes for lack of pressure. [1] The adjusting screw has backed up. [2] Debris or “dirt” is trapped between the seat and the ball or cone. b. Repair as follows: Using a pressure gauge teed into the pressure line turn the adjusting screw clockwise a turn or two and watch the gauge;...

  • Page 33: Check Valves

    Check Valves The Purpose of a Check Valve is to Allow Free Flow in one Direction but Block Reverse Flow. Two Types of Check Valves are Used: A. Ball type B. Poppet type Styles of Check valves Used: Internal style In an ''internal'' style, a cavity is drilled in the pump base into which the parts are assembled (inside pipe port cavity).

  • Page 34: Hydraulic Cylinders

    Hydraulic Cylinders 1. Diagnosing and Troubleshooting Hydraulic Cylinders A. Single acting (Ram type) Most ram type failures are caused by one of the following reasons: a. Excessive side load b. Stroking the rod to full extension Excessive side load can be diagnosed by observing the following: a.
  • Page 35 Note: If it is possible to stroke the cylinder after repairing, turn gland nut until it contacts the V-rings and stroke the cylinder to allow the rings to seat and align, then re- tighten as described above. B. Double-acting cylinder 1.

  • Page 36: Electrical Problems

    Electrical Problems Caution!!! Remove all Rings, Watches, Etc. Prior to Doing Any Electrical Work!!! Operating DC (direct current) power units efficiently requires proper voltage. Any attempt to operate below the minimum required voltage could cause system failure. A. Signals which point to low voltages are: 1.
  • Page 37 2. DC Motors Motors should be serviced periodically to ensure good performance. Service as follows: A. Remove head assembly from motor. B. Check sleeve bearing in head assembly for wear. C. Place a few drops of oil on felt liner in head assembly. D.

  • Page 38: Www.energyabsorption.com Revision B December

    4. Shorts, Grounding Faults, and Open Circuits In control wiring, shorts can only occur when ''hot'' lines (lines connected directly to the battery) come in contact with a ground. A short will either cause a fuse to blow, if there is a fuse, or burn the wire off at its weakest point.

  • Page 39: Alpha 70K Tma, 90 Tilt, Hydraulic Lock

    www.energyabsorption.com Revision B December 2013 www.highwayguardrail.com All rights in copyright reserved...

  • Page 40: Alpha 70K Tma, 90 Tilt

    www.energyabsorption.com Revision B December 2013 www.highwayguardrail.com All rights in copyright reserved...

  • Page 41: Underride Frame Assembly, Tma

    www.energyabsorption.com Revision B December 2013 www.highwayguardrail.com All rights in copyright reserved...

  • Page 42: Jack Assembly, Hd Backup, Tma

    www.energyabsorption.com Revision B December 2013 www.highwayguardrail.com All rights in copyright reserved...

  • Page 43: Support Frame Assembly, Mechanical Lock

    www.energyabsorption.com Revision B December 2013 www.highwayguardrail.com All rights in copyright reserved...

  • Page 44: Hydraulic Assembly For 90° Tilt Systems

    www.energyabsorption.com Revision B December 2013 www.highwayguardrail.com All rights in copyright reserved...
  • Page 45 www.energyabsorption.com Revision B December 2013 www.highwayguardrail.com All rights in copyright reserved...
  • Page 46 Notes: www.energyabsorption.com Revision B December 2013 www.highwayguardrail.com All rights in copyright reserved...
  • Page 47 Notes: www.energyabsorption.com Revision B December 2013 www.highwayguardrail.com All rights in copyright reserved...
  • Page 48 2525 Stemmons Freeway Dallas, Texas 75207 888-323-6374 (USA only) 312-467-6750 (Outside USA) www.energyabsorption.com www.highwayguardrail.com...

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