Trinity Alpha 70K TMA 7590 Product Description And Assembly Manual Download Page 3

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Revision B December 2013

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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

Summary of Contents for Alpha 70K TMA 7590

Page 1: ...Alpha 70K TMA Model 7590 Product Description Assembly Manual Revision B December 2013 Part No 115314B ...

Page 2: ...em 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 888 32...

Page 3: ...ded 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 ...

Page 4: ... 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 yo...

Page 5: ...rtant 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 th...

Page 6: ...low 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...

Page 7: ...d 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 ...

Page 8: ...radually 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...

Page 9: ... 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 ap...

Page 10: ...e 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 p...

Page 11: ...g 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 ...

Page 12: ... 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 t...

Page 13: ...er 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 w...

Page 14: ... 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...

Page 15: ...ction 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 enou...

Page 16: ...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...

Page 17: ... 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 pe...

Page 18: ... 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...

Page 19: ...bly 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 sepa...

Page 20: ... 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 ...

Page 21: ...ackup when in the full up position by unscrewing the large cylinder s clevis up to two revolutions IV Lights will not work A Replace affected light bulb s B Check wire s for damage C Using a volt ohmmeter troubleshoot and locate the problem V Cartridge is not level A Check for cause of problem 1 Temporary extra load in truck 2 Support Frame improperly assembled 3 Weakening truck springs B Adjust C...

Page 22: ...mm 6 deep may be repaired by applying appropriately sized aluminum reinforcement to cover the damaged area Use 0 8 mm 032 thick aluminum on damaged top and bottom skins and 1 6 mm 063 thick aluminum on damaged Side Covers Pop riveting is the recommended fastening method for attaching new parts B Damage to the front of the Cartridge because this is the area that supports the cantilevered weight of ...

Page 23: ... 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 Figure 9 EXAMPLES OF MINOR DAMAGE CAN BE REPAIRED REAR OF CARTRIDGE TMA CARTRIDGE 305 mm 1 0 305 mm 1 0 REAR 2100 mm 7 0 MAJOR DAMAGE DO NOT ATTEMPT TO REPAIR ...

Page 24: ...www energyabsorption com Revision B December 2013 www highwayguardrail com 23 All rights in copyright reserved PUMP TROUBLE SHOOTING CHART ...

Page 25: ... needed Worn or dirty pump Clean repair or replace check alignment check for contaminated oil drain flush and refill system with approved oil Badly worn components valves cylinders etc Examine and test for internal or external leakage Replace faulty components Check for cause of wear Leakage Check all components especially the relief valve for proper settings Excessive load Broken or slipping pump...

Page 26: ... and components Malfunctioning component Replace or repair 7 Foaming of Oil Incorrect low or dirty oil Replace or add oil as needed Air leaks Check suction lines component seals for leaks Replace 8 Noisy Pump Low oil level incorrect or foamy oil Replace or add oil as necessary Suction line or inlet screen plugged Clean or replace Worn or damaged pump Repair or replace 9 Leaky Pump or Motor Damaged...

Page 27: ... 2 DC Test Light A test light is a light bulb with one lead wired to an alligator clip and the other lead connected to a metal probe It is used to check for the presence of a voltage in the electrical circuit With the alligator clip grounded the light glows when the probe comes into contact with a HOT electrical component 3 Continuity Light The continuity light is a test light which contains its o...

Page 28: ...t flow properly and cause the pump to cavitate or starve Third the oil must be compatible with the seals used in the system Fourth there should also be additives in the oil to slow down the effects of rust oxidation oxygen in the air combining with the oil to form sludge foaming and water settling to the bottom of the reservoir Fifth the oil must be able to pour or flow at the lowest expected temp...

Page 29: ...bad front pump seal see Pump section E A solid fill plug in reservoir with no vent see Reservoir section F Oil that is too thick see Hydraulic fluid section or contaminated with water see Reservoir section G Occasionally a pump will not prime itself because a check valve spring in the high pressure port is too stiff or the Spring Retainer is turned down too far If this condition is expected loosen...

Page 30: ...ugh the fill hole if the unit is left outdoors or washed with high pressure washers Protect the unit whenever possible and change oil regularly to minimize problems In cold weather the water will freeze and the pump will not work until the ice melts 4 Tips and Comments A In most cases the reservoir is made to be mounted either vertically or horizontally and improper mounting will not allow it to b...

Page 31: ...sting or making adjustments on the relief valve the system must be deadheaded cylinder at full stroke or in a position where cylinder movement is zero A Relief valve pressure too high 1 Symptoms a Current draw and battery drain excessive when system is deadheaded b Motor RPM is slow in comparison to full load system operation 2 Repair procedure Turn relief valve adjusting screw counterclockwise us...

Page 32: ...etting 2 If the pressure does not climb when the adjusting screw is tightened Turn the adjusting screw counterclockwise all the way out energize the pump to flush the dirt past the seat Caution Use hand or a piece of hose to divert oil into a container Do not look into the port Inspect the cone or ball for nicks and replace if necessary re seat the ball or cone using a small drift punch and hammer...

Page 33: ...ee cylinder section A bad piston seal will give the same symptom 2 Repair procedure a Remove the Spring Retainer Note Measure the depth to the Spring Retainer so it can be re assembled to the same depth after repair a Remove spring b Remove ball or poppet c Start pump to flush dirt from the seat area Caution use hand or a piece of hose to divert oil into a container do not look into the port d Ins...

Page 34: ...the hold position Troubleshoot in the following manner a Put the cylinder in the hold position b Place a jack under the load c Remove the high pressure hose from the cylinder port on the side opposite the holding end d Let the jack down slowly If the position seal is bad oil will escape from the port Caution Do not get near the load USE CAUTION 2 Repairing Hydraulic Cylinders A Single Acting cylin...

Page 35: ...there is a retaining ring assembled just below the threaded area of the tube assembly This ring must be removed in order to remove the rod assembly 2 Double acting cylinders have two piston cups on the internal threaded end of the chrome rod If these cups are worn they must be replaced to ensure a proper seal It is also advisable to check the piston O ring and the stuffing box O ring and replace i...

Page 36: ...ble size too small for load and length of run Copper 2 automotive battery cable is the recommended minimum size Larger copper battery cable 1 0 or 00 may be required for cable lengths over 30 feet to keep performance from deteriorating 4 Grounding is established through the pump mounting bolts Clean any dirt or rust from mounting holes and bolts to achieve proper ground 5 Bad joints where cable en...

Page 37: ...n toggle rocker or manual motor start switches Defective switches are a common cause of electrical malfunction What SEEMS to be a serious system defect can often be caused simply by a faulty switch especially where the switch controls two functions e g start the motor and shift a valve in those cases one half the switch might be defective while the other half operates correctly and the fault appea...

Page 38: ...ed This type of failure can happen because switching is done in the ground wire due to the construction of the motor solenoid switch See 3 Electrical Switches above Likely spots for faults are the same as the shorts See above An open circuit is simply a break which prohibits current flow Likely spots for open circuits are the same as shorts See Above 5 Solenoid Coils Coils are used in solenoid ope...

Page 39: ...www energyabsorption com Revision B December 2013 www highwayguardrail com 38 All rights in copyright reserved Alpha 70K TMA 90 Tilt Hydraulic Lock DWG TMA7590 Sheet 1 of 2 ...

Page 40: ...www energyabsorption com Revision B December 2013 www highwayguardrail com 39 All rights in copyright reserved Alpha 70K TMA 90 Tilt DWG TMA7590 Sheet 2 of 2 ...

Page 41: ...www energyabsorption com Revision B December 2013 www highwayguardrail com 40 All rights in copyright reserved DWG 616820 Underride Frame Assembly TMA ...

Page 42: ...www energyabsorption com Revision B December 2013 www highwayguardrail com 41 All rights in copyright reserved Jack Assembly HD Backup TMA DWG 610984 ...

Page 43: ...www energyabsorption com Revision B December 2013 www highwayguardrail com 42 All rights in copyright reserved Support Frame Assembly Mechanical Lock DWG 615551 ...

Page 44: ...www energyabsorption com Revision B December 2013 www highwayguardrail com 43 All rights in copyright reserved Hydraulic Assembly for 90 Tilt Systems DWG 610285 Sheet 1 of 2 ...

Page 45: ...www energyabsorption com Revision B December 2013 www highwayguardrail com 44 All rights in copyright reserved DWG 610285 Sheet 2 of 2 ...

Page 46: ...www energyabsorption com Revision B December 2013 www highwayguardrail com 45 All rights in copyright reserved Notes ...

Page 47: ...www energyabsorption com Revision B December 2013 www highwayguardrail com 46 All rights in copyright reserved Notes ...

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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