Energy Absorption Systems Safe-Stop 180 Guía

Safe-Stop

180 TMA

Compact TMA That Meets NCHRP 350, TL-3

Installation/Operation

(Model 9180)

Corporate Offices:

35 East Wacker Dr., 11th Floor

Chicago, IL 60601-2076

Telephone: (888) 323-6374

FAX: (312) 467-1356

http://www.energyabsorption.com/

Engineering and Manufacturing Facilities:

Rocklin, CA

Pell City, AL

Safe-Stop®180 TMA

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

ImporImpor

Important Intrtant Intr

tant Intrtant Intr

tant Introductoroductor

oductoroductor

oductory Notesy Notes

y Notesy Notes

y Notes

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.

Functional Descriptionunctional Description

unctional Descriptionunctional 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).

Safety Instructionsafety Instructions

afety Instructionsafety Instructions

afety Instructions

For maximum safety, the operator should stand at the rear of the truck, on the curb side, (see Figure 2). When 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)

CARTRIDGECARTRIDGE

TRUCK

Safe-Stop®180 TMA

1. The TMA should be rigidly fastened to the truck. In the

horizontal position, the bottom of the TMA should be

280 to 330 mm [11" to 13"] from the ground and level

(see Figure 3). *The TMA should be left in the folded

position whenever it is not being used as an impact

attenuator. The TMA can only absorb the energy of an

impacting vehicle in the unfolded position.

2. Jacks may be used to support the folded TMA when

it is off the truck. The jacks must be stored while the

TMA is attached to the truck. The jacks can be stored

on the brackets provided on the support frame. (See

Figure 3). If you are subject to vandalism, prepare

another storage plan.

PIVOT PIN

RETAINING PIN

Figure 4

305±25 mm [12"±1"]

Figure 3

305±25 mm [12"±1"]

STORE JACKS HERE WHILE

TMA IS ATTACHED TO TRUCK

3. Make sure all pivot pins are in position and that all

retaining pins are installed correctly (see Figure 4).

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-Stop 180 TMA should be in the "unfolded" po-

sition when: Transporting short distances at a low speed,

Transporting at a speed much lower that adjacent traffic,

and Transporting in areas where vehicle ride characteris-

tics and maneuverability are maintainable.

The Safe-Stop 180 TMA should be in the "folded" posi-

tion when: Transporting long distances at a high speed,

Transporting at a speed near the speed of adjacent traf-

fic, and Transporting under conditions of compromised

maneuverability typically when the large turning radius

clearance needed for the extended TMA is not safe.

4. The Safe-Stop 180 TMA is designed to safely absorb

a crash, and to support its own weight. Do not drag

the TMA or place anything on its top: damage may

result. Do not sit, stand or lean on any part of the

TMA (see Figures 5 & 6).

Figure 6

Figure 5

5. Before raising or lowering the TMA, the operator

should be trained as to its proper operation. Refer

to the Operation Instructions in this manual.

6. Folding the TMA provides the best maneuverability

and driving characteristics. It is permissible, during

restricted city driving and high-speed travel, to have

the TMA folded 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 clear before folding

or unfolding the TMA. Be sure the system is stopped

in full folded position before allowing anyone directly

behind the folded system (see Figures 7 & 9).

8. Ballast and other heavy objects MUST BE ADEQUATELY

ANCHORED to the truck to prevent shifting during an

impact. (The force on the tie-down straps could be 20

times the weight of the ballast.)

Figure 8

Safe-Stop®180 TMA

14. This system is a crash cushion and is therefore used

in high risk areas. Stay clear of traffic whenever pos-

sible. If an accident is to occur, even during a design

impact, there may be fragments from the truck or

impacting vehicle that could cause injury.

15. The hydraulic assembly was designed to fold and

unfold the TMA system as described. Any other use

may be hazardous to people or equipment.

• Do not use the system to push a load.

• Do not use the raised end of the system to sup-

port any load.

• Do not use any part of the TMA for towing or

hauling a load. This could cause the lift mecha-

nism to malfunction, and may reduce the impact

performance.

16. The system must be in the unfolded position to per-

form properly during an impact. Do not leave the

system raised, even slightly, when on the job.

17. Be sure the truck is appropriate for attaching a TMA.

See the installation section for further details

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.

9. The agency responsible for the truck should inspect it

for adequate operator safety equipment (e.g., seat belts,

head rests, etc.)

10. It is recommended that the Safe-Stop 180 TMA be

mounted to trucks between 7300 kg [16,090 lbs.] and

9000 kg [19,845 lbs.] for optimum impact performance.

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!

Failure to comply with these instructions can result in

improper TMA performance and possible personal

injury. This TMA is intended to be used as a crash

attenuator on the rear of trucks which meet the design

specifications for this system.

12. Regular maintenance of the TMA is important for safe

use. Refer to the maintenance section of this manual

for additional information.

• Regular inspection of frame members, cartridges

and pins is necessary to ensure proper system per-

formance.

• Regular inspection of hoses is important. A bro-

ken or damaged hose will cause the system to quit

functioning properly.

• Keep electrical connections at the pump motor/so-

lenoid clean to prevent arcing. Clean any hydraulic

spills or leakage to prevent bodily injury, fire, etc.

13. The driver should be extra cautious while backing

the truck with the TMA in the up or down position,

so that injury and/or damage will not result.

Safety Instructions (cont’afety Instructions (cont’

afety Instructions (cont’afety Instructions (cont’

afety Instructions (cont’d.)d.)

d.)d.)

d.)

THE USE OF A TMA ON THE BACK OF A TRUCK WILL:

• Gradually stop the impacting vehicle*

• Protect the occupants of the impacting vehicle *

• Protect the shadow vehicle occupants*

• Reduce damage to the shadow vehicle*

WILL NOT:

• Affect the skid (roll ahead) distance of an impacted

truck (see figure 9). KEEP WORK CREWS CLEAR!

CONTROLLING 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 2000 kg

[1808 and 4410 lbs.] vehicles.

Figure 9

SHADOW VEHICLE

SKID DISTANCE

TMA

WITH TMA

WITHOUT TMA

SAME

Safe-Stop®180 TMA

Installation InstructionsInstallation Instructions

Installation Instructions

Read and understand all instructions before beginning

installation.

The truck rating (GVW) should be 7300 kg [16,090 lbs.]

min. The weight of the vehicle should be between 7300

and 9000 kg [16,090 and 19,845 lbs.] for optimum im-

pact performance.

The system must be attached to the truck by welding

parts to the frame. Do not weld forward of the rear leaf

spring hangers to ensure structural integrity of frame.

Use AWS qualified welders to ensure durable attachment

of the TMA system.

The truck frame must be suitable and accessible for

mounting a TMA system. If there are any questions re-

garding the suitability, contact the Customer Service De-

partment for assistance.

1) Shipping list

Check the shipping list against the actual parts to make

sure all items were received. Review the drawing pack-

age and familiarize yourself with the assembly and part

numbers.

2) Assemble Necessary tools:

RecommendedRecommended

Recommended

Toolsools

oolsools

ools

1. Welding equipment (for 1/2" plate) GMAW or SMAW

2. Cutting torch

3. Hammer

4. Drift pin or alignment pin (12” long)

5. Tape measure

6. 1/2" drive socket wrench w/6” extension

7. 1/2" drive sockets (9/16", 1-1/8", 1-1/2", 9/16” deep well)

8. Open end wrenches (9/16", 1-1/8", 1-1/2")

9. 12" crescent wrenches - (2)

10. Marking implement (pencil, soap stone)

11. Floor jack

12. Drill motor for 13/16" diameter bit

13. 13/16" diameter bit and pilot drill for same

14. Center punch

15. Torque wrench - 120 Nm [90 ft-lbs.]

16. Hydraulic fluid (use Dexron® III fluid only)*

*Shipped with system

17. Forklift

Preparationreparation

reparationreparation

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 when it is being ex-

tended to its full length.

3B) Truck ballast

Use a bubble level to verify that the truck is parked on a

level surface. The truck should be as close to the final

driving weight as possible. If ballast must be added to

achieve the 7300 kg [16,090 lbs] minimum weight, add

it at this time. 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. Because the 953 kg [2100 lb] weight of the

rearward protruding TMA is supported by the back of the

shadow vehicle, care must be taken not to exceed the

manufacturer's published maximum axle loads. To en-

sure that the driving characteristics of the vehicle are

maintained, the manufacturer's recommended center-of-

gravity zone should also be adhered to.

4) Check for interference

Before attempting to install the underride, check for in-

terference problems.

The System folds such that the impact face is very close

to the mounting location. See Figure 32 page 28. If you

are using something other than a standard socket re-

ceiver hitch underride refer to special instructions sup-

plied with your assembly then skip to step 8.

Temporarily position the underride socket receiver under

truck frame as shown (refer to Figure 12) and check for

interference problems. Interference problems with tail

lights, springs, dump bodies (in the up or down posi-

tions), etc., should be corrected before proceeding.

5) Underride Assembly

With the truck at its actual driving weight, parked on a

level surface, measure the distance from the ground to

the bottom of the truck frame. A distance of 711±25 mm

[28±1"] is required. Spacers may be added to the bot-

tom of the frame to achieve this height (see figure 13

and the Underride Assembly drawing on page 47).

Note: The truck’s springs may settle with the

weight of the TMA, sometimes, as much as 50 mm

]. Adjust the height to compensate for antici-

pated settling.

Measure from the back end of the frame forward to the

rear-most leaf spring hanger, or any other obstruction

on the bottom of the frame that may interfere with the

socket receiver. A minimum of 305 mm [12"] is required

(see the Underride Assembly drawing on page 47).

Position the socket receiver at the rear end of the frame so

that the 76 x 387 mm [3 x 15 1/4"] flat bar is along the

outside of the frame member and the socket receiver tube

is flush with 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 to the bottom of the truck

frame with the 76 x 387 mm [3 x 15 1/4"] flat bar on the

outer side of the frame (see Figure 11).

Note: All welding must be performed by a welder

certified to AWS D14.3-82 or AWS D1.1 in accor-

dance with the underride drawing.

CAUTION: The truck frame is high carbon steel.

To avoid cracking, do not weld, or apply ex-

cessive heat, to the bottom flange, forward of

rear-most leaf spring hangers.

Prime and paint all welded areas.

STEPS

4 & 5

STEP

ATTACHMENT

ASSEMBLY

SUPPORT

FRAME

STEP

STEPS

8 & 9

UNDERRIDE

SOCKET

RECEIVER

SUPPORT

MOUNT

Figure 10

TRUCK FRAME

FLAT BAR

UNDERRIDE

SOCKET

RECEIVER

Figure 11

Figure 12

864 mm [34"] NOMINAL

710 mm [28"]

NOMINAL

TRUCK

FRAME

FLAT BAR

UNDERRIDE

SOCKET RECEIVER

STEP

Safe-Stop®180 TMA

Installation Instructions (cont’Installation Instructions (cont’

Installation Instructions (cont’d.)d.)

d.)d.)

d.)

762 mm ± 25 mm [30" ± 1"]

711 mm ± 25 mm [28" ± 1"]

LEVEL GROUND

SPACER TUBES

SPACER SPLICE

(USE ONLY ON

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 ¼" hitch pins and retainer pins

shipped with the system.

SOCKET HITCHES

HITCH & RETAINER PINS

Figure 14

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