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TTMA-100

Assembly Manual

Gregory Industries, Inc.

4100 13th Street, SW • Canton, Ohio 44710 • Phone 330-477-4800

www.gregorycorp.com

June 2010

Summary of Contents for TTMA-100

Page 1: ...i TTMA 100 Assembly Manual Gregory Industries Inc 4100 13th Street SW Canton Ohio 44710 Phone 330 477 4800 www gregorycorp com June 2010...

Page 2: ...replacement of damaged components Please read and understand the recommendations contained in this manual thoroughly before actual assembly and keep it handy for future reference If you have any ques...

Page 3: ...future changes or upgrades to the TTMA 100 If you have any comments or questions regarding this product please contact Gregory Industries via telephone e mail or conventional mail Telephone 330 477 48...

Page 4: ...orbing Tubes to A Frame 10 Insert Connecting Block for Axle and Fender Assembly 12 Install Mandrels 14 Attach Impact Head 14 Align and Tighten Connections between Energy Absorbing Tubes and A Frame 13...

Page 5: ...ent and the tongue weight Note the small tongue weight of the trailer which would not affect the load carrying capacity of the tow vehicle The capacity and mounting height of the pintle hook Informati...

Page 6: ...2...

Page 7: ...o top of light bar 37 in Ground Clearance to bottom of impact head 13 in Weight Basic Trailer Weight with No Optional Equipment 1 450 lb Approximate Tongue Weight 190 lb Pintle Hook Capacity Rating Mi...

Page 8: ...EMS ITEM PART QUANTITY DESCRIPTION a B0516070A 6 5 16 x 7 Grade 5 Hex Bolt b W0516 6 5 16 Washer c LW0516A 6 5 16 Heavy Lock Washer d N0516A 6 5 16 Grade 5 Hex Nut e B0816020A 8 1 2 x 2 Grade 5 Hex Bo...

Page 9: ...5...

Page 10: ...any given situation RECOMMENDED TOOL LIST The following is the recommended tool list for assembling the TTMA 100 Socket wrenches 13 16 15 16 Open end wrenches 13 16 15 16 Pneumatic wrench Drift pin Wi...

Page 11: ...the pintle hook with a wide margin of safety It is the obligation of the users to ensure that their particular pintle hook attachment system meets these strength requirements CLEARING OF EXCESS ZINC A...

Page 12: ...8 Use electric drill pin to remove excess zinc...

Page 13: ...and steel toed boots are recommended Warning The parts of trailer may have sharp asperities from the welding and galvanizing processes Use of appropriate gloves is recommended The major steps in the...

Page 14: ...roximate positions for assembly as shown in the following photograph Note that the A frame and the first energy absorbing tubes should be placed on benches The following are close up photographs of ea...

Page 15: ...11 Connection between energy absorbing tubes and A frame Axle assembly with push rods fenders and wheels and tires Impact head mandrels and light bar assembly...

Page 16: ...rs and nuts Place a spacer between the end of A frame and the end of energy absorbing tube for one of the four flanges and align bolt holes Insert bolts and nuts with washers on both sides Repeat the...

Page 17: ...absorbing tube The axle assembly is then attached to the energy absorbing tubes using these protruding bolts To facilitate placing of the connecting block inside the energy absorbing tube a tool simil...

Page 18: ...by tapping on the bolts and cleaning out the holes of excess zinc from galvanizing Slide the tool with the connecting block into the open end of the energy absorbing tube until the two protruding bolt...

Page 19: ...e and the mandrel are aligned When the holes are aligned use the drift pin to hold mandrel in place Two plastic guide plates as shown in the photograph are used to keep the mandrel from bouncing up an...

Page 20: ...mandrel and white plastic guide plate in place Slide the top black plastic guide plate between the mandrel and the energy absorbing tube Adjust mandrel and plastic guide plate until the holes for the...

Page 21: ...les through the top of the energy absorbing tube the black plastic guide plate the mandrel the white plastic guide plate and the bottom of the energy absorbing tube Insert nut with washer to shear bol...

Page 22: ...nnecting plates on the open ends of the mandrels Align the holes on the impact head and the connecting plate on one mandrel Insert drift pin to hold the alignment in place Insert bolts and nuts with w...

Page 23: ...19 Repeat the process for the other mandrel Tighten bolts and nuts to specified torque...

Page 24: ...rbing tubes and the A frame Before tightening the bolts make sure that the trailer is aligned properly Check to make sure the A frame the energy absorbing tubes and the top of the impact head are leve...

Page 25: ...ecked by measuring the distance diagonally from front center of the A frame to the corner of the end of the energy absorbing tube while the tape measure is aligned with the corner of mandrel The diago...

Page 26: ...make minor adjustments on the alignment of the trailer frame Remove bolts and spacer on flange needing adjustment Insert plastic shim with spacer between the flanges and insert tighten and torque the...

Page 27: ...of the axle assembly Align the holes and insert bolts and nuts with washers Lift the axle assembly with the attached fenders and align the holes on the axle assembly and fenders with the protruding b...

Page 28: ...heck to make sure that axle is lined up perpendicular to the trailer frame Measure the distance from cross member of the A frame to the center of the axle The measurements on both sides should be the...

Page 29: ...Install wheels and tires onto axle assembly Measure to make sure that the face of tire is separated from the fender by a couple of inches to avoid any potential influence between the fender and the wh...

Page 30: ...26 Tighten and torque all bolts and nuts Insert plastic end caps into all tubular members with open ends...

Page 31: ...light bar is attached to the top of the impact head with four bolts As shown in the photographs screw inserts are incorporated into the bottom of the light bar with corresponding pre drilled holes on...

Page 32: ...ted installation Install the wiring for the light bar next A separate section on wiring instructions is provided and will not be repeated herein Please refer to the Wiring Instructions section for det...

Page 33: ...A frame including lunette ring safety chains end caps and jack Instructions for installing each of these accessories are outlined as follows Lunette Ring Align holes on the base plate of the lunette r...

Page 34: ...rque bolts Safety Chains Align hole on anchor plate of safety chain with that on the gusset plate Inserts bolt and nut with washers Tighten and torque Repeat process for the safety chain anchor plate...

Page 35: ...f the tubes After completing the wiring place the end cap into the open end of the tube Align the holes on the end cap with those on the open end of the tubular member Inserts bolts and nuts with wash...

Page 36: ...32 Jack The trailer is equipped with a sidewind jack A connection is provided on the cross member of the A frame for the jack When not in use the jack is stalled in the horizontal position...

Page 37: ...tep instructions on installing the chevron panels and conspicuity tape are provided as follows Chevron Panel The chevron panels may have pre drilled holes and straps are welded to the front of the imp...

Page 38: ...sides of the A frame tubes Two on the angled members of the A frame The process for attaching the conspicuity tapes are the same for all locations and are described as follows Mark the locations of wh...

Page 39: ...35 Cut the conspicuity tape to the required length...

Page 40: ...the side of the tubular member Make sure that the surface is clean and free of contaminants that could adversely affect the attachment of the tape Peel the backing off the tape and paste the tape ont...

Page 41: ...palletized shipment of 3 trailers ready for overseas transport These trailers were pre assembled at the factory then partially de assembled to be properly palletized Many of the preceding installation...

Page 42: ...OF JACK STAND TO A FRAME ASSEMBLY OF ENERGY ABSORBING TUBES Check for square of trailer frame ASSEMBLY OF AXLE TO FRAME ASSEMBLY OF WHEELS TO AXLE ASSEMBLY OF FENDERS TO FRAME INSTALATION OF IMPACT HE...

Page 43: ...39 ASSEMBLY OF ENERGY ABSORBING TUBES TO A FRAME...

Page 44: ...40 ALLIGNMENT OF ENERGY ABSORBING TUBES ASSEMBLY OF ENERGY ABSORBING TUBES...

Page 45: ...41 ASSEMBLY OF FENDERS TO FRAME Check for square of trailer frame...

Page 46: ...42 INSTALLATION OF IMPACT HEAD TO MANDRILS...

Page 47: ...IRING HARNESS NOTE ALL LIGHTS ARE 12 Volt For 24 Volt usage a 12 volt to 24 volt converter must be installed Not supplied by Gregory Industries Inc If used without converter the lights WILL BE DAMAGED...

Page 48: ...44 INSTALLATION OF LIGHT BAR...

Page 49: ...45 INSTALATION OF REFLECTIVE CHEVERON PANELS TO IMPACT HEAD 16 X36 Optional reflective panels can be installed on tabs Panels are not supplied by Gregory Industries Inc...

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