Energy Absorption Safe-Stop 180 TMA 9181 Installation And Operation Manual Download Page 2 | Manualshive

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Safe-Stop

®

180 TMA

2

Table of Contents

Functional Description ....................................... 2

Safety Instructions .............................................. 3

Installation ......................................................... 8

Operation Instructions ....................................... 21

Limitations & Warnings ..................................... 22

Maintenance ...................................................... 23

I. Routine maintenance................................ 23

II. Detaching and Attaching......................... 25

III. Lubrication.............................................. 27

IV. Technical specifications ........................... 28

Repair ................................................................. 29

I. Post Impact ............................................... 29

Troubleshooting Guide ........................................ 34

Installation Drawings ........................................... 42

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oductory Notes

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This manual contains important information on the
Safe-Stop 180 TMA (Truck Mounted Attenuator). Proper
installation and operation of the Safe-Stop 180 TMA is
essential to assure maximum performance. Take the time
to review this entire manual thoroughly prior to install-
ing and/or operating the Energy Absorption Systems, Inc.
Safe-Stop 180 TMA.

If you need additional information, or have any questions
about the Safe-Stop 180 TMA, please call

Energy Absorp-

tion Systems' Customer Service Department at 1-888-
32-ENERG.

RETURN GOODS POLICY

Before returning any goods for credit please contact
Energy Absorption Systems Inc. Customer Service
Department at 1-888-32-ENERG or your local
distributor for proper instructions.

F

F

F

F

Functional Description

unctional Description

unctional Description

unctional Description

unctional Description

The Safe-Stop 180 TMA is a Truck Mounted Attenuator
designed to reduce the risk of injury to passengers of an
errant vehicle and to the driver of the truck to which the
system is attached. The system mounts on the rear of a
truck and may be used in stationary applications, such
as a truck blocking a work zone and mobile operations,
such as striping, sweeping, plowing, etc.

The Safe-Stop 180 TMA consists of the following basic
components: a collapsible frame assembly; two crush-
able cartridges; a support structure; an impact face and
an underride (see Figure 1).

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Summary of Contents for Safe-Stop 180 TMA 9181

Page 1: ...rporate Offices 35 East Wacker Dr 11th Floor Chicago IL 60601 2076 Telephone 312 467 6750 FAX 312 467 1356 http www energyabsorption com Engineering and Manufacturing Facilities Rocklin CA Pell City AL A Quixote Company Saving Lives By Design ENERGY ABSORPTION SYSTEMS INC Model 9181 ...

Page 2: ...A If you need additional information or have any questions about the Safe Stop 180 TMA please call Energy Absorp tion Systems Customer Service Department at 1 888 32 ENERG RETURN GOODS POLICY Before returning any goods for credit please contact Energy Absorption Systems Inc Customer Service Department at 1 888 32 ENERG or your local distributor for proper instructions F F F F Functional Descriptio...

Page 3: ...en tilting the TMA care should be taken to stay clear of all moving parts CARTRIDGE B ASSY CARTRIDGE A ASSY SUPPORT STRUCTURE SOCKET HITCH UNDERRIDE REAR OF TRUCK Figure 1 Figure 2 STAND HERE FOR CONTROLS ON RIGHT SIDE OF TRUCK MOVING PARTS DURING FULL DESIGN IMPACTS AND FOLDING OPERATION CONTROLS CONTROLS MAY BE RELOCATED TO THIS SIDE STAND HERE FOR CONTROLS ON LEFT SIDE OF TRUCK CARTRIDGE CARTRI...

Page 4: ...CK 3 Make sure all pivot pins are in position and that all retaining pins are installed correctly see Figure 4 S S S S Safety Instructions cont afety Instructions cont afety Instructions cont afety Instructions cont afety Instructions cont d d d d d The Safe Stop 180 TMA shall be employed in the un folded position At all times while operating as either a Barrier Vehicle or Shadow Vehicle The Safe ...

Page 5: ...olded to its 180 position Refer to local agency policies as required for additional guidance Unfold the system either before or as soon as pos sible after entering a job site or beginning shadow vehicle operations Remember that it is recom mended that the support vehicle be stopped for TMA folding and unfolding Figure 7 NO ONE TO BE ALLOWED BEHIND ELEVATED TMA 7 Be sure all persons are standing cl...

Page 6: ...le for the truck should inspect it foradequateoperatorsafetyequipment e g seatbelts head rests etc 10 It is recommended that the Safe Stop 180 TMA be mounted to trucks between 7300 kg 16 090 lbs and 9000kg 19 845lbs foroptimumimpactperformance This weight includes both the truck and the TMA 11 Make sure that the performance and safety of the TMA is not impaired by damage or corrosion WARNING Failu...

Page 7: ...G SKID DISTANCE ROLL AHEAD Skid distance is significantly increased and is less predictable for lightweight shadow vehicles Skid distance is reduced and is more consistent when heavier shadow vehicles are used Preferred truck GVW rating is 7300 kg 16 090 lbs to 12 000 kg 26 460 lbs Recommended Curb Weight is 7300 kg 16 090 lbs to 9000 kg 19 845 lbs DESIGN SPEED IMPACTS 100 km h 62 mph for 820 and ...

Page 8: ...ed with system 17 Forklift P P P P Preparation reparation reparation reparation reparation 3A Installation Must Be Performed On A Level Surface The system s framework is very heavy and pivots in sev eral areas Until the framework is secured with the cables it can swing out in an approximate 4 m 13 radius from either side of the truck A level surface is required to maintain control of the framework...

Page 9: ... the end of frame If spacers are required weld them to the receiver tube and lap the spacer splices pieces of 10 x 51 x 103 mm 3 8 x 2 x 4 flat bar across the socket receiver tube and spacer at the rear most loca tion see underride assembly drawing The top of the socket receiver tubes must be 711 25 mm 28 1 from the level ground for proper system height see Figure 12 Weld the socket receiver tube ...

Page 10: ...REAR SPACER TUBE FLUSH WITH END OF FRAME UNDERRIDE SOCKET RECEIVER Note Left and right underride socket receivers must be parallel with each other and level TRUCK FRAME Figure 13 Socket Hitch Left Side Shown WITH SPACERS WITHOUT SPACERS LEVEL GROUND UNDERRIDE SOCKET RECEIVER TRUCK FRAME 6 Socket Hitch Assembly Install the socket hitches and pin them into place using the 1 x 6 hitch pins and retain...

Page 11: ...It is recommended that shims be used initially This may be adjusted once the system is assembled SUPPORT BRACKET 1 4 SHIM ONE PER SIDE RECOM MENDED AT INITIAL SETUP LEVEL THE TMA BY ADJUSTING THE NUMBER OF SHIMS 3 1 4 X 3 1 4 BAR WASHER 2 1 2 X 3 1 4 BAR WASHER Figure 15 1X3 1 2 HEX BOLT 1 FLAT WASHER 1 LOCK WASHER 1 HEX NUT 1 FLAT WASHER SOCKET HITCH 12GA SHIM ...

Page 12: ...per set of mounting holes for the attachment Figure 16 BACKUP ASSEMBLY HITCH PIN WITH HAIR PIN COTTER HITCH PIN WITH HAIR PIN COTTER SHIMS 1 4 X 5 X 10 SHIMS 12GA X 5 X 10 USE SHIMS AS NECESSARY TO ACHIEVE PROPER SYSTEM GROUND CLEARANCE SUPPORT BRACKET RIGHT SUPPORT BRACKET LEFT BAR WASHER 1 2 X 2 1 2 X 3 1 4 BAR WASHER 1 2 X 3 1 4 X 3 1 4 BAR WASHER 1 2 X 3 1 4 X 3 1 4 1 HEX NUT 1 LOCK WASHER 1 F...

Page 13: ...o Attachment Assembly slowly and evenly pull the frame out to its full extent WARNING Even when supported by forklift frame can be unwieldy Use extreme care WARNING Until the cables are installed the system may shift to one side ALIGNMENT CABLES ALIGNMENT CABLES ...

Page 14: ...n both ends of cable Lock cable in place using remaining fasteners as jam nuts WARNING For proper System performance only use Release Cables supplied by Energy Absorption Systems Inc Failure to use the correct equipment could lead to fatigue or result in poor System performance Figure 18 RELEASE CABLE TORQUE TO 34 NM 25 FT LBS TORQUE TO 34 NM 25 FT LBS Installation Instructions cont Installation I...

Page 15: ... vided Torque the nuts to 120 7 Nm 90 5ft lbs Re peat procedure for Cartridge A see Figure 19 Figure 19 CARTRIDGE B CARTRIDGE A 12 Install the Top Release Cables across the Arm Assemblies Install the top release cable across the arm assemblies see Figure 18 Torque the nuts to 34 Nm 25 ft Ibf making sure that roughly an equal amount of threads protrude from nuts on both ends of cable Lock cable in ...

Page 16: ...bay and adjust the cables so that the diagonal measurements in each bay are the same within the giventolerance A B 5mm 3 16 C D 5mm 3 16 andtaught Cablesare taut whentheydeflect38mm 50mm 1 1 2 2 when pressed by hand at the midpoint Lock each cable in place using the second nut as a jam nut Installation Instructions cont Installation Instructions cont Installation Instructions cont Installation Ins...

Page 17: ...ten it until the tensioning springs have been com pressed to 32 mm 1 in height Lock this nut in place with the second jam nut Repeat this procedure with the other cables 15 Adjust the Height and Levelness of the System Frame Verify that the system frame is 305 25 mm 12 1 from the ground at the front and rear of the system It may be necessary to add shims to the socket hitch in order to adjust the ...

Page 18: ...p corners Back side of socket connector View A A 7 PIN FEMALE SOCKET GROUND TAIL LAMPS RIGHT TURN CLEARANCE SIDE MARKER AND IDENTIFICATION LAMPS LEFT TURN STOP LAMPS Figure 22 Installation Instructions cont Installation Instructions cont Installation Instructions cont Installation Instructions cont Installation Instructions cont d d d d d or metal work or in other areas that would pinch or cut the...

Page 19: ...ll Replace the vent plug in the filler port Be careful not to cross thread it Read Operation Instructions see page 21 Folding and Unfolding the System Making sure all electrical and hy draulic lines will not be damaged use the switch at the rear of the truck to fold and unfold the system twice This purges air from the system and verifies operation Note Both STOP buttons must be unlocked for the sy...

Page 20: ...midframe will be off With the system folded the lights on the midframe will be on and the lights on the impact face will be off 20 Verify the Position of the Hydrau lic Electrical Lines Check the location of all the hydraulic and electri cal lines to be sure they will not be damaged dur ing folding and unfolding of the system 21 Final Check of System Check the tightness of all of the fasteners Dou...

Page 21: ... Under no circumstances should anyone be allowed behind the system when it is being folded or unfolded When operating from the cab always be aware of objects behind the Safe Stop 180 TMA Note The Safe Stop 180 TMA will not operate unlass the cab control pendant is plugged in Folding the system There is one FOLD button on each set of controls To fold the system up press and hold the FOLD button for...

Page 22: ...t angle may not result in acceptable crash performance as described in NCHRP 350 relative to structural adequacy occupant risk and vehicle trajectory factors copy may be obtained from Transportation Research Board National Research Council 2101 Constitution Avenue N W Washington D C 20418 It is also available at http safety fhwa dot gov programs roadside_hardware htm The Safe Stop 180 TMA shall be...

Page 23: ... SURFACE Figure 25 2 Fasteners Check the tightness of the fasteners monthly See the drawings for the locations of the fasteners Be sure to check bolts attaching the cartridges to the support structure Lock washers should be fully compressed 3 Cables System unfolded A Cartridge Support Cables The spring length should be 34mm 1 1 4 Ref Pg 17 Fig 21 B Alignment Cables Crossing cables are of equal len...

Page 24: ...of this manual 8 Hydraulic Pump Clean the hydraulic pump as required Check fluid level and electrical connec tions monthly Remove all residue or debris on or around the pump 9 Hydraulic Ram Clean the hydraulic ram as required Check monthly Remove all residue or debris on or around the ram 10 Clean System Clean the frame assembly cartridges and support structure and impact face from dirt and salt a...

Page 25: ...nect the positive power cable from the pump Unplug the cab switch box at the mating connector on the TMA E Remove the socket hitches from the under ride socket receivers by removing 1 x 6 hitch pins and retainer pins See Figure 28 If the alignment is off making removal diffi cult it may be necessary to adjust jacks or temporarily unmount the TMA from the socket hitches This can be done by remov in...

Page 26: ...T MOUNT LEFT SUPPORT MOUNT RIGHT 2 Attaching the System to the Truck A Move the TMA to truck B Install the socket hitches into the underride socket receivers and pin them into place using 1 X 6 pin and retainer pin If align ment is off making the assembly difficult it may be necessary to adjust jacks or tempo rarily unmount the socket hitches from the TMA Be sure the retainer pins are installed co...

Page 27: ... you strongly suspect the oil is contaminated with water Use Dexron III fluid only The empty oil capacity of the reservoir hoses and cylinders is approximately 4 quarts the capacity of the reservoir alone is approximately 2 quarts The reservoir and hydraulic system may need to be filled and cycled several times to remove air that may be in the system Caution When refilling an empty system do not a...

Page 28: ...AX 2 4 m 7 10 4 4 m 14 5 303 mm 25 mm 1 0 1 711 mm 2 4 3 Replacement Parts For details on replacement parts refer to the draw ing package The drawings include the part num bers and descriptions For replacement parts call customer service 1 888 32 ENERG 4 Operating rates The system folds to the folded position in approxi mately 25 seconds The system unfolds to the unfolded position in ap proximatel...

Page 29: ...our alignment cables 4 Remove cartridges and spent release cables Remove the crushed cartridges Do not attempt to repair a damaged cartridge For full impact capacity the cartridges will need to be replaced even if they were only crushed slightly Repair Instructions Repair Instructions Repair Instructions Repair Instructions Repair Instructions 5 Install the Bottom Release Cable across the Arm Asse...

Page 30: ... B in position and se cure it using the flat washers lock washers and nuts pro vided Torque the nuts to 120 7 Nm 90 5ft lbs Re peat procedure for Cartridge A see Figure 36 Figure 36 CARTRIDGE B CARTRIDGE A 7 Install the Top Release Cables across the Arm Assemblies Install the top release cable across the arm assemblies see Figure 35 Torque the nuts to 34 Nm 25 ft lbs making sure that roughly an eq...

Page 31: ... 16 C D 5 mm 3 16 Lock each cable in place using the second nut as a jam nut see Detail 37 SOCKET HITCHES NOT SHOWN FOR CLARITY A B C D 9 Replace Side Guides The Side Guides must be inspected and replaced if dam aged The Side Guides are sacrificial and can be easily attached to their respective mounts Side Guides are nec essary for proper System alignment during an impact and must be in place to e...

Page 32: ...ck is removed then tighten it until the tensioning springs have been com pressed to 32 mm 1 in height Lock this nut in place with the second jam nut Repeat this procedure with the other cables 10 Adjust the Height and Levelness of the System Frame Verify that the system frame is 305 25 mm 12 1 from the ground at the front and rear of the system It may be necessary to add shims to the socket hitche...

Page 33: ...e out There are two light circuits on the TMA Verify both cir cuits are operational Raise the system to folded position and verify secondary lights are working With the system unfolded lights on the impact face will be on and lights on the midframe will be off With the system folded the lights on the midframe will be on and the lights on the impact face will be off 14 Final check Checkthetightness...

Page 34: ...e not connected to a power source T T T T Tr r r r roubleshooting Guide oubleshooting Guide oubleshooting Guide oubleshooting Guide oubleshooting Guide 4 VOLT METER A D C voltmeter can be used to troubleshoot volt age problems Two common uses are 1 Ground one probe while using the other to probe hot leads in search of the available voltage at the point where the second probe is connected 2 Measure...

Page 35: ... the following specs as listed by most oil manufacturers 1 Viscosity SUS 37 deg C 100 def F 185 to 205 99 deg C 210 deg F 45 to 55 Pour Point 44 deg C 45 deg F 37 deg C 35 deg F Viscosity Index 145 to 165 Note In a cold weather emergency application only SAE 10W non detergent oil can be mixed by vol ume with no more than 30 1 fuel oil or kerosene Hy Hy Hy Hy Hydraulic S draulic S draulic S draulic...

Page 36: ...oltage Verify voltages with D C voltmeter and check truck charging system Oil viscosity too high or cold oil Allow oil to warm up before operating or replace with oil intended for correct operating temperature range Low oil level Check reservoir and add oil as necessary Air in system Check for leaks and tighten as neces sary Cycle the system several times to relieve air from system Oil leaks Tight...

Page 37: ...o hoses by briefly depressing the UNFOLD button D Replace and retighten all four hoses Note that any NPT pipe style threaded fittings should be lightly coated with thread sealant prefer ably Loctite 545 CAUTION Do not completely fold or unfold the TMA until it has been jogged a few times to work out any air in the system Add oil at the filler port any time that the pump begins to cavitate E Jog th...

Page 38: ...olts at max load 2 Between any valve solenoid hot wire and ground 9 5 volts at max load C Causes for low voltages are 1 Improper ground Check grounds 2 Battery capacity too small 3 Cable ends not electrically secure to battery cable 4 Battery cable size too small for load and length of run Copper 2 automotive battery cable is the recommended min size Larger copper battery cable 1 0 or 00 may be re...

Page 39: ...cuit 3 The remaining large post attaches to the motor with a solid strap 4 The small post connects to the control cir cuit and activates the solenoid and hence the pump when energized 4 ELECTRICAL POLARITY The pump motor and all controls have a negative ground P P P P Pressure Relief ressure Relief ressure Relief ressure Relief ressure Relief V V V V Val al al al alv v v v ve e e e e 1 PURPOSE A L...

Page 40: ...ystem pressure is set to 2000 psi at the factory WARNING When the system is stopped at an intermediate angle there will be pressure on the oil in the hoses between the check valves and cylinders This pressure is supporting the load of the folding bay ALWAYS make sure the TMA is completely folded or completely unfolded before loosening a hose fitting or servicing any check valve This will minimize ...

Page 41: ...nt Front Intermediate Frame and the Weldment Rear Intermediate Frame re spectively D At the top end of the cylinder rod loosen the set screw and push out the short 7 8 diameter pin making note of the alignment and location of all linkage components for later reassembly E Disconnect the hoses leading into the cylinder at two convenient locations and place temporary caps on the hoses or cylinder por...

Page 42: ...Safe Stop 180 TMA 42 ...

Page 43: ...43 ...

Page 44: ... HX LOCK 8 S 4 6 2795281 0000 TIE NYLON 3 16X8 50 7 2705101 0000 RIVET ST SD612BS 3 16X3 4 DH 4 PARTS LIST ITEM STOCK NO DESCRIPTION QTY NEXT ASSEMBLY MATERIAL TOL LINEAR C 1 16 TOL ANGULAR C 1 a UNLESS OTHERWISE SPECIFIED TMA9181LC SEE PARTS LIST Revisions Date Rev Chk App By Q C ITEM 7 WAS 2705181 0000 12 29 03 A DPH DK RCB STT NOTES 1 LOCATE AND TIGHTEN ITEMS 6 APPROXIMATELY AS SHOWN TO SECURE ...

Page 45: ...DR 10 5 8 CYL BTM 1 14 2715319 0000 HOSE ASSY HYDRAULIC 16 CYL TOP 1 16 2715318 0100 ELBOW 4 M JIC X 4 M ORB LONG P 1 17 2715317 0100 ELBOW 4 M JIC X 4 M ORB P 2 20 2706014 0300 SCREW SET 1 4 20X3 4 SOCKET S 1 21 2757060 0000 SOLENOID WIRING ASSY 9180 1 22 2715336 0100 ELBOW 4M JICX 6M NPT P 2 23 2715337 0000 HOSE ASSY HYDR 7 1 2 CYL MID 1 24 2715335 0100 ELBOW 4M JIC 4F JIC S P 1 PARTS LIST ITEM ...

Page 46: ...Safe Stop 180 TMA 46 ...

Page 47: ...47 ...

Page 48: ... 2751752 0000 FLT ST 1 2X3 1 4X3 1 4 W HOLE PT 2 6 2751753 0000 FLT ST 1 2X2 1 2X3 1 4 W HOLE PT 2 7 2699541 0100 BOLT HX 1X3 1 2 G8 P 8 8 2704161 0400 NUT HEX 1 G8 P 8 9 2708241 0000 WASHER LOCK 1 G 8 10 2708191 0000 WASHER FLAT 1 x 2 1 2 G 16 11 2508031 0000 SHIM 1 4X5X10 PT 8 12 2508251 0000 SHIM 12 GA X5X10 PT 8 PARTS LIST ITEM STOCK NO DESCRIPTION QTY UPDATED BACKUP 11 19 02 B DK JME AAP UPDA...

Page 49: ...99010 0100 BOLT HX 1 2X2 3 4 G2 P 4 29 2699008 0100 BOLT HX 1 2X1 1 4 G5 P 4 30 2706814 0100 SCREW SOCKET HD 8 32X1 P 4 31 2706014 0300 SCREW SET 1 4 20X3 4 SOCKET S 2 32 2708003 0100 WASHER FLAT 1 4X5 8 P 20 33 2708041 0100 WASHER LOCK 3 8 P 14 34 2708022 0100 WASHER FLAT 3 8 ID X13 16 OD P HRD 14 35 2708181 0100 WASHER LOCK 1 2 P 12 36 2708371 0100 WASHER FLAT 8 P 4 37 2704153 0100 NUT HX NYLON ...

Page 50: ...AFESTOP 9181 APPROVED OPT TESTS 2 PARTS LIST ITEM STOCK NO DESCRIPTION QTY B D C Revisions Date Rev Chk App By Q C 12 29 03 A DPH DK RCB STT NOTES 1 LOCATE REFLECTIVE ITEM 19 AS SHOWN LENGTH ITEM 19 USED IS INDICATED NEXT TO CALLOUT 2 APPLY ALL DECALS APPROXIMATELY AS SHOWN 3 APPLY THREAD LOCKER LOCTITE 242 290 OR EQUIVALENT TO ITEMS 25 29 AND 31 9 22 37 32 25 33 34 25 16 34 38 3 19 19 19 11 19 19...

Page 51: ... 2003 5 5 2003 6 20 2003 6 20 2003 6 20 2003 352618A 0000 A 3 3 ASSEMBLY NO 352618A 0000 352618A 0000 SUPPORT FRAME PREASSEMBLY TMA9181 Revisions Date Rev Chk App By Q C SEE SHEETS 1 2 REDRAWN 12 29 03 A DPH DK RCB STT 5 6 17 18 42 17 50 43 NOTES 1 APPLY ALL DECALS APPROXIMATELY AS SHOWN FRONT ARM DETAIL REAR ARM DETAIL FRONT FRONT ...

Page 52: ...4 1473 221 105 Fax 44 1473 221 106 35 East Wacker Dr 11th Floor Chicago IL 60601 2076 Engineering and Manufacturing Facilities Rocklin California and Pell City Alabama A Quixote Company Saving Lives By Design ENERGY ABSORPTION SYSTEMS INC 2005 Energy Absorption Systems Inc Part No 2750982 0000 http www energyabsorption com Rev 7 25 05 ...

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