Safe-Stop 180 TMA (9181) Installation Operation Manual...a TMA is mounted, while positioned upstream...

Safe-Stop® 180 TMA

Compact TMA That Meets NCHRP 350, TL-3In

stal

lation

/Ope

ration

Corporate Offices:35 East Wacker Dr., 11th FloorChicago, IL 60601-2076Telephone: (312) 467-6750FAX: (312) 467-1356http://www.energyabsorption.com/

Engineering and Manufacturing Facilities:Rocklin, CAPell City, AL

A Quixote CompanySaving Lives By Design

ENERGY ABSORPTIONSYSTEMS, INC.

(Model 9181)

Safe-Stop® 180 TMA

2

Table of ContentsFunctional 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

ImporImporImporImporImportant Intrtant Intrtant Intrtant Intrtant Introductoroductoroductoroductoroductory Notesy Notesy Notesy Notesy NotesThis manual contains important information on theSafe-Stop 180 TMA (Truck Mounted Attenuator). Properinstallation and operation of the Safe-Stop 180 TMA isessential to assure maximum performance. Take the timeto 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 questionsabout the Safe-Stop 180 TMA, please call Energy Absorp-tion Systems' Customer Service Department at 1-888-32-ENERG.

RETURN GOODS POLICYBefore returning any goods for credit please contactEnergy Absorption Systems Inc. Customer ServiceDepartment at 1-888-32-ENERG or your localdistributor for proper instructions.

FFFFFunctional Descriptionunctional Descriptionunctional Descriptionunctional Descriptionunctional DescriptionThe Safe-Stop 180 TMA is a Truck Mounted Attenuatordesigned to reduce the risk of injury to passengers of anerrant vehicle and to the driver of the truck to which thesystem is attached. The system mounts on the rear of atruck and may be used in stationary applications, suchas a truck blocking a work zone and mobile operations,such as striping, sweeping, plowing, etc.

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

3

SSSSSafety Instructionsafety Instructionsafety Instructionsafety Instructionsafety Instructions

For maximum safety, the operator should stand at the rear of the truck, on the curb side, (see Figure 2). When tiltingthe TMA, care should be taken to stay clear of all moving parts.

CARTRIDGE B ASSY CARTRIDGE A ASSY

SUPPORT STRUCTURESOCKET HITCH UNDERRIDEREAR OF TRUCK

Figure 1

Figure 2

STAND HERE (FOR CONTROLSON RIGHT SIDE OF TRUCK)

MOVING PARTS DURINGFULL DESIGN IMPACTS ANDFOLDING OPERATION

CONTROLS

CONTROLS MAY BERELOCATED TO THIS SIDE

STAND HERE (FOR CONTROLSON LEFT SIDE OF TRUCK)

CARTRIDGECARTRIDGE

TRUCK

Safe-Stop® 180 TMA

4

1. The TMA should be rigidly fastened to the truck. In thehorizontal position, the bottom of the TMA should be280 to 330 mm [11" to 13"] from the ground and level(see Figure 3). *The TMA should be left in the foldedposition whenever it is not being used as an impactattenuator. The TMA can only absorb the energy of animpacting vehicle in the unfolded position.

2. Jacks may be used to support the folded TMA whenit is off the truck. The jacks must be stored while theTMA is attached to the truck. The jacks can be storedon the brackets provided on the support frame. (SeeFigure 3). If you are subject to vandalism, prepareanother storage plan.

PIVOT PIN

RETAINING PIN

Figure 4

305±25 mm [12"±1"]

Figure 3

305±25 mm [12"±1"]

STORE JACKS HERE WHILETMA IS ATTACHED TO TRUCK

3. Make sure all pivot pins are in position and that allretaining pins are installed correctly (see Figure 4).

SSSSSafety 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 aBarrier 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 compromisedmaneuverability typically when the large turning radiusclearance needed for the extended TMA is not safe.

5

4. The Safe-Stop 180 TMA is designed to safely absorba crash, and to support its own weight. Do not dragthe TMA or place anything on its top: damage mayresult. Do not sit, stand or lean on any part of theTMA (see Figures 5 & 6).

Figure 6

Figure 5

5. Before raising or lowering the TMA, the operatorshould be trained as to its proper operation. Referto the Operation Instructions in this manual.

6. Folding the TMA provides the best maneuverabilityand driving characteristics. It is permissible, duringrestricted city driving and high-speed travel, to havethe TMA folded to its 180° position. Refer to localagency policies as required for additional guidance.Unfold the system either before, or as soon as pos-sible after, entering a job site or beginning shadowvehicle operations. Remember that it is recom-mended that the support vehicle be stopped for TMAfolding and unfolding.

Figure 7

NO ONE TO BE ALLOWED BEHIND ELEVATED TMA

7. Be sure all persons are standing clear before foldingor unfolding the TMA. Be sure the system is stoppedin full folded position before allowing anyone directlybehind the folded system (see Figures 7 & 9).

8. Ballast and other heavy objects MUST BE ADEQUATELYANCHORED to the truck to prevent shifting during animpact. (The force on the tie-down straps could be 20times the weight of the ballast.)

Figure 8

Safe-Stop® 180 TMA

6

14. This system is a crash cushion and is therefore usedin high risk areas. Stay clear of traffic whenever pos-sible. If an accident is to occur, even during a designimpact, there may be fragments from the truck orimpacting vehicle that could cause injury.

15. The hydraulic assembly was designed to fold andunfold the TMA system as described. Any other usemay 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 orhauling a load. This could cause the lift mecha-nism to malfunction, and may reduce the impactperformance.

16. The system must be in the unfolded position to per-form properly during an impact. Do not leave thesystem 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 whicha TMA is mounted, while positioned upstream (towardsthe direction that traffic is approaching) of a work zone.

The SHADOW VEHICLE is the truck on which a TMA ismounted, which is following behind a moving operationsuch as striping, spraying, etc.

9. The agency responsible for the truck should inspect itfor adequate operator safety equipment (e.g., seat belts,head rests, etc.)

10. It is recommended that the Safe-Stop 180 TMA bemounted to trucks between 7300 kg [16,090 lbs.] and9000 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 TMAis not impaired by damage or corrosion.

WARNING!Failure to comply with these instructions can result inimproper TMA performance and possible personalinjury. This TMA is intended to be used as a crashattenuator on the rear of trucks which meet the designspecifications for this system.

12. Regular maintenance of the TMA is important for safeuse. Refer to the maintenance section of this manualfor additional information.

• Regular inspection of frame members, cartridgesand 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 quitfunctioning properly.

• Keep electrical connections at the pump motor/so-lenoid clean to prevent arcing. Clean any hydraulicspills or leakage to prevent bodily injury, fire, etc.

13. The driver should be extra cautious while backingthe truck with the TMA in the up or down position,so that injury and/or damage will not result.

SSSSSafety Instructions (cont’afety Instructions (cont’afety Instructions (cont’afety Instructions (cont’afety Instructions (cont’d.)d.)d.)d.)d.)

7

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

CONTROLLING SKID DISTANCE (ROLL AHEAD):

• Skid distance is significantly increased and is lesspredictable for lightweight shadow vehicles

• Skid distance is reduced and is more consistentwhen 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

SKID DISTANCE

TMAWITH TMA

WITHOUT TMA

SAM

E

Safe-Stop® 180 TMA

8

Installation InstructionsInstallation InstructionsInstallation InstructionsInstallation InstructionsInstallation Instructions

Read and understand all instructions before beginninginstallation.

The truck rating (GVW) should be 7300 kg [16,090 lbs.]min. The weight of the vehicle should be between 7300and 9000 kg [16,090 and 19,845 lbs.] for optimum im-pact performance.

The system must be attached to the truck by weldingparts to the frame. Do not weld forward of the rear leafspring hangers to ensure structural integrity of frame.Use AWS qualified welders to ensure durable attachmentof the TMA system.

The truck frame must be suitable and accessible formounting a TMA system. If there are any questions re-garding the suitability, contact the Customer Service De-partment for assistance.

1) Shipping listCheck the shipping list against the actual parts to makesure all items were received. Review the drawing pack-age and familiarize yourself with the assembly and partnumbers.

2) Assemble Necessary tools:

Recommended Recommended Recommended Recommended Recommended TTTTToolsoolsoolsoolsools1. 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

PPPPPreparationreparationreparationreparationreparation3A) Installation Must Be Performed On A

Level SurfaceThe 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 fromeither side of the truck. A level surface is required tomaintain control of the framework when it is being ex-tended to its full length.

3B) Truck ballastUse a bubble level to verify that the truck is parked on alevel surface. The truck should be as close to the finaldriving weight as possible. If ballast must be added toachieve the 7300 kg [16,090 lbs] minimum weight, addit at this time. Ballast must be properly anchored to thetruck to keep it in place during an impact. Ideally, anadequately sized truck, that requires no ballast, shouldbe used. Because the 953 kg [2100 lb] weight of therearward protruding TMA is supported by the back of theshadow vehicle, care must be taken not to exceed themanufacturer's published maximum axle loads. To en-sure that the driving characteristics of the vehicle aremaintained, the manufacturer's recommended center-of-gravity zone should also be adhered to.

4) Check for interferenceBefore attempting to install the underride, check for in-terference problems.The System folds such that the impact face is very closeto the mounting location. See Figure 32 page 28. If youare 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 undertruck frame as shown (refer to Figure 12) and check forinterference problems. Interference problems with taillights, springs, dump bodies (in the up or down posi-tions), etc., should be corrected before proceeding.

9

5) Underride AssemblyWith the truck at its actual driving weight, parked on alevel surface, measure the distance from the ground tothe 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 13and the Underride Assembly drawing on page 47).

Note: The truck’s springs may settle with theweight of the TMA, sometimes, as much as 50 mm[2"]. Adjust the height to compensate for antici-pated settling.

Measure from the back end of the frame forward to therear-most leaf spring hanger, or any other obstructionon the bottom of the frame that may interfere with thesocket 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 sothat the 76 x 387 mm [3 x 15 1/4"] flat bar is along theoutside of the frame member and the socket receiver tubeis 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) acrossthe socket receiver tube and spacer at the rear-most loca-tion (see underride assembly drawing). The top of thesocket receiver tubes must be 711 ± 25 mm [28 ± 1"] fromthe level ground for proper system height (see Figure 12).

Weld the socket receiver tube to the bottom of the truckframe with the 76 x 387 mm [3 x 15 1/4"] flat bar on theouter side of the frame (see Figure 11).

Note: All welding must be performed by a weldercertified 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 ofrear-most leaf spring hangers.Prime and paint all welded areas.

STEPS4 & 5

STEP6

STEP7

ATTACHMENTASSEMBLY

SUPPORTFRAME

STEP12

STEP11

STEPS8 & 9

UNDERRIDESOCKET

RECEIVER

SUPPORTMOUNT

Figure 10

TRUCK FRAME

FLAT BARUNDERRIDE

SOCKETRECEIVER

Figure 11

Figure 12

864 mm [34"] NOMINAL

710

mm

[28"

]NO

MIN

AL

TRUCKFRAME

FLAT BARUNDERRIDE

SOCKET RECEIVER

STEP10

Safe-Stop® 180 TMA

10

Installation Instructions (cont’Installation Instructions (cont’Installation Instructions (cont’Installation Instructions (cont’Installation Instructions (cont’d.)d.)d.)d.)d.)76

2 m

m ±

25

mm

[30"

± 1

"]

711

mm

± 2

5 m

m [2

8" ±

1"]

LEVEL GROUND

SPACER TUBES

SPACER SPLICE(USE ONLY ONREAR SPACER TUBE)

FLUSH WITHEND OF FRAME

UNDERRIDE SOCKET RECEIVER

Note: Left and right underride socket receiversmust be parallel with each other and level.

TRUCK FRAME

Figure 13Socket Hitch (Left Side Shown)

WITH SPACERS WITHOUT SPACERS

LEVEL GROUND


TRUCK FRAME

6) Socket Hitch AssemblyInstall the socket hitches and pin them into placeusing the 1 x 6 ¼" hitch pins and retainer pinsshipped with the system.

SOCKET HITCHES

HITCH & RETAINER PINS

Figure 14

11

7) Mount the Attachment Assembly to Socket HitchesMount the attachment assembly to the socket hitches as shown in Figure 15. Shims are used to level the system. Itis recommended that ¼" 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. LEVELTHE TMA BY ADJUSTING THENUMBER OF SHIMS)

3 1/4" X 3 1/4" BAR WASHER2 1/2" X 3 1/4" BAR WASHER

Figure 15

1X3 1/2" HEX BOLT

1" FLAT WASHER1" LOCK WASHER

1" HEX NUT

1" FLAT WASHER

SOCKET HITCH

12GA SHIM

Safe-Stop® 180 TMA

12

8) Attach the Support Frame / Backup tothe Attachment Assembly

Move the system to the truck and pin the supportframe/backup assembly to the attachment assembly,as shown in Figure 16. The assembly is to be installedwhile frame is still collapsed with forklift slings sup-porting the system. Use the upper set of mountingholes for the attachment.

Figure 16

BACKUP ASSEMBLY

HITCH PIN WITHHAIR 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 ACHIEVEPROPER SYSTEM GROUND CLEARANCE

SUPPORT BRACKET (RIGHT)

SUPPORT BRACKET (LEFT)

BAR WASHER1/2" X 2 1/2" X 3 1/4"

BAR WASHER1/2" X 3 1/4" X 3 1/4"

BAR WASHER1/2" X 3 1/4" X 3 1/4"1" HEX NUT

1" LOCK WASHER1" FLAT WASHER

1" X 3 1/2" HEX BOLT, G81" FLAT WASHER

1" X 3 1/2"HEX BOLT, G8

1" FLAT WASHER

SUPPORT MOUNT (LEFT)

SUPPORT MOUNT (RIGHT)

13

Figure 17

9) Extend the Support FrameWith the TMA pinned to Attachment Assembly, slowlyand evenly pull the frame out to its full extent.

WARNING!Even when supported by forklift, framecan be unwieldy. Use extreme care.

WARNING!Until the cables are installed, the systemmay shift to one side.

ALIGNMENT CABLES

ALIGNMENT CABLES

Safe-Stop® 180 TMA

14

10) Install the Bottom Release Cableacross the Arm Assemblies.

Verify that the frame is extended as far as it will go. In-stall the Bottom Release Cable across Arm Assemblies.(see Figure 18). Torque the nuts to 34 Nm (25 ft-Ibf) mak-ing sure that roughly an equal amount of threads pro-trude from nuts on both ends of cable. Lock cable in placeusing remaining fasteners as "jam" nuts.

WARNING!For proper System performance, only use ReleaseCables supplied by Energy Absorption Systems, Inc.Failure to use the correct equipment could lead tofatigue or result in poor System performance.

Figure 18

RELEASE CABLE

TORQUE TO 34 NM (25 FT-LBS.)


Installation Instructions (cont’Installation Instructions (cont’Installation Instructions (cont’Installation Instructions (cont’Installation Instructions (cont’d.)d.)d.)d.)d.)

15

11) Install CartridgesRemove one end of each alignment cable from the TMAand set aside to clear the top side of each bay. Using aforklift and sling, place Cartridge 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 19).

Figure 19

CARTRIDGE B

CARTRIDGE A

12) Install the Top Release Cables acrossthe 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 threadsprotrude from nuts on both ends of cable. Lock cable inplace using the remaining fasteners as "jam" nuts.

Safe-Stop® 180 TMA

16

SOCKET HITCHES NOTSHOWN FOR CLARITY

A B C D

Figure 20

13) Reinstall and Adjust the AlignmentCables

There are four alignment cables (two for each bay). Reat-tach the alignment cables as shown in Figure 20. Measurethe diagonals of each bay and adjust the cables so that thediagonal measurements in each bay are the same within thegiven tolerance (A = B ± 5 mm [3/16"], C = D ± 5 mm [3/16"])and taught. Cables are "taut" when they deflect 38 mm - 50mm[1 1/2" - 2"] when pressed by hand at the midpoint. Lockeach cable in place using the second nut as a “jam nut”.


17

14) Install and Tension the Cartridge Sup-port Cables

There are six cartridge support cables. Install the cablesas shown in Figure 21.

Attach thimble end of all cartridge support cables to theintermediate frame using the provided shackles. Pass thestud end of the cable through the corresponding cartridgechain loop, and attach as shown in Figure 21 using a diespring, washer and nuts.

To properly tension the cartridge support cables, tightenthe first nut on one cable until all slack is removed, thentighten it until the tensioning springs have been com-pressed to 32 mm [1 ¼"] in height. Lock this nut in placewith the second "jam" nut. Repeat this procedure withthe other cables.

15) Adjust the Height and Levelness of theSystem Frame

Verify that the system frame is 305 ± 25 mm [12" ± 1"]from the ground at the front and rear of the system. Itmay be necessary to add shims to the socket hitch inorder to adjust the levelness of the cartridge. See Fig-ures 21 & 21a.

SHACKLE

CARTRIDGESUPPORT CABLE

32 mm [1 1/4"]

WASHER

NUTS

Figure 21

305 mm ± 25 mm [12" ± 1"]

SOCKET HITCH

SHIMS MAY BE ADDED OR REMOVEDHERE AS NECESSARY TO ACHIEVE

LEVELNESS OF SYSTEM

SEE DETAIL 21a

Detail 21a

305 mm ± 25 mm [12" ± 1"]


INTERMEDIATE FRAME

Safe-Stop® 180 TMA

18

16) Connect the Lights and ControlsLocate the female TMA socket connector in a convenientlocation on the truck. Make sure that the electrical cordon the TMA can reach this location.

For support vehicles with combined tail and clearancelights, connect a jumper between pins 2 and 6 on thebackside of the male TMA plug connector (see VIEWA-A, Figure 22.) Connect the 7-pin plug to the socket onthe truck.

Note: All controls for the TMA are groundedthrough the 7-pin plug. This plug must be attachedfor the TMA to operate.

The Truck battery must be of the proper voltage. TheSafe-Stop 180 TMA is available in 12 volt and 24 volt sys-tems. Be sure the system and truck are compatible. Besure to use standard safety practices when attaching thebattery cables (e.g. do not let the ends of the cables touch,etc.) Do not run the battery cables around sharp corners

Back side of socket connectorView A-A

7 PIN FEMALE SOCKETGROUND

TAIL LAMPS

RIGHT TURN

CLEARANCE, SIDE MARKERAND IDENTIFICATION LAMPS

LEFT TURNSTOP LAMPS

Figure 22


or metal work, or in other areas that would pinch or cutthe cables. Connect the battery cable to the pump motor(see the hydraulic assembly in drawing package).

The controls at the rear of the truck should be mountedto the support frame, on the non-traffic side (side clos-est to the curb). If they are not, remove the fastenersand move the controls to the other side. Securely fastenthe controls to the existing mounting bracket, and usecable ties to secure any loose wiring to the TMA frame.Mount the cab switch box inside the cab within easy reachof the driver, and plug in the cab switch box at the matingconnector on the TMA.

Note: The cab switch box must be plugged in forthe TMA to operate.

AA

SEE VIEW A-A

REVERSE LIGHTS

19

17) Check the Hydraulic SystemThe hydraulic system is pre-assembled and tested foroperation and leaks before shipping. The pump is wiredas shown on the hydraulic assembly drawing. Beforeoperating the system, remove the vent plug from the fillport of the hydraulic reservoir and check to see if thereservoir is full. With the TMA unfolded, the fluid shouldbe just visible. Add only Dexron® III fluid if it is not. Donot overfill. Replace the vent plug in the filler port (Becareful not to cross thread it.)

Read Operation Instructions (see page 21: Folding andUnfolding the System). Making sure all electrical and hy-draulic lines will not be damaged, use the switch at therear of the truck to fold and unfold the system twice. Thispurges air from the system and verifies operation.

Note: Both "STOP" buttons must be unlocked forthe system to operate. Unlock them by twistingcounter-clockwise.

Also, cycle the system using the cab switches to verifyproper operation.

Note: Continuous operation may run down truckbattery.

RESERVOIR FILL PORT

FLOW SWITCH

Figure 23

PUMP

Safe-Stop® 180 TMA

20

STORAGE POSITIONS

Figure 24

JACKS

Note: The TMA can only be supported onjacks when completely folded.

18) Store the JacksThe jacks are provided to facilitate the attachmentand removal of a folded Safe-Stop 180 TMA fromthe truck. Retrieve jacks set aside earlier and placethem in the storage positions as shown in Figure 24.

19) Check System Lights For ProperOperation

Verify that all the turn / stop / tail / reverse lights areworking properly. Replace any bulbs that are out.

There are two light circuits on the TMA. Verify bothcircuits are operational.

Raise the system to the folded position and verifysecondary lights are working.

With the system unfolded, lights on the impact facewill be on and lights on the midframe will be off.

With the system folded, the lights on themidframe will be on and the lights on the impactface 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 SystemCheck the tightness of all of the fasteners. Doublecheck the height and levelness of the system.

22) Ready to UseThe Safe-Stop 180 TMA is now ready for use. Toensure proper and safe operation, all TMA usersshould be given operating and safety training, asgiven in this manual and as specified by the ownerand local regulations.


WARNING!Jacks are to be removed from Arm Assemblies and storedwhen TMA is in service.

21

Operation InstructionsOperation InstructionsOperation InstructionsOperation InstructionsOperation Instructions

Before operating the Safe-Stop 180 TMA, thoroughly readand understand these instructions and the safety sectionof this manual. Verify that the system is properly in-stalled and in working order. For proper impact perfor-mance, the TMA must be equipped with one Safe-StopType A Cartridge and one Safe-Stop Type B Cartridge, intheir proper positions as shown in Figure 19 on page 15.

The Safe-Stop 180 TMA has been equipped with a hy-draulic pump that can be used to fold the TMA from itsextended position. The controls are located on one sideof the support frame. A set of controls is also located inthe truck cab. The controls on the support frame shouldbe mounted to the non-traffic side of the system. Tochange the mounting, see "Connect the Lights and Con-trols" section in the Installation Instructions.

While folding or unfolding the Safe-Stop 180 TMA fromoutside the cab, the operator must stand on the non-traffic side of the truck. Always stay clear of moving parts.

FFFFFolding and Unfolding and Unfolding and Unfolding and Unfolding and Unfolding the Solding the Solding the Solding the Solding the Systemystemystemystemystem

CAUTION: Make sure the area above and be-hind the system is clear of all objects be-fore proceeding. Under no circumstancesshould anyone be allowed behind the systemwhen it is being folded or unfolded. Whenoperating from the cab, always be aware ofobjects behind the Safe-Stop 180 TMA.

Note: The Safe-Stop 180 TMA will not operateunlass the cab control pendant is plugged in.

Folding the system: There is one "FOLD" button on eachset of controls. To fold the system up, press and hold the"FOLD" button for a few seconds. Once the system hasbegun to operate, it will completely fold and then shutoff, without the need to continue holding the button.

Unfolding the system: There is one "UNFOLD" button oneach set of controls. To unfold the system, press andhold the "UNFOLD" button for a few seconds. Once it hasbegun to operate, it will completely unfold and then shutoff, without the need to continue holding the button.

The system will not serve its intended purpose whenfolded. The TMA must be unfolded during shadow orbarrier vehicle operations. The truck and Safe-Stop 180TMA combination offers the best driving characteristicswhen folded. Driving with the system in the folded posi-tion is permissible and recommended during restrictedcity driving and extended high-speed travel. Be sure tounfold the system either before, or as soon as possibleafter, entering into a site. Remember that it is recom-mended that the support vehicle be stopped for TMA fold-ing and unfolding.

The Safe-Stop 180 TMA should only be operated whilethe truck is at rest. Jarring or severe bumping of the sys-tem while folding or unfolding may cause damage to thesystem or injury to the operator.

Safe-Stop® 180 TMA

22

Limitations and Limitations and Limitations and Limitations and Limitations and WWWWWarningsarningsarningsarningsarnings

The Safe-Stop 180 TMA (Truck Mounted Attenuator) hasbeen tested and evaluated per the recommendations ofthe National Cooperative Highway Research Program(NCHRP) Report 350*. The Safe-Stop 180 TMA, as cur-rently designed, is capable of decelerating and stoppingsmall cars and light trucks of 820 and 2000 kg [1808 and4410 lbs.] when the rear of the system is impacted head-on at 100 km/h [62 mph].

To achieve optimum impact performance,the Safe-Stop 180 TMA must be mounted to a truck witha traveling weight between 7300 kg and 9000 kg[16,090 and 19,845 lbs.]. The system must be level andthe bottom of the system must be 305 ± 25 mm[12” +/- 1”] above the ground.

Impacts that exceed the design capabilities described inthis manual (vehicle weight, speed and impact angle) maynot result in acceptable crash performance as describedin NCHRP 350, relative to structural adequacy, occupantrisk and vehicle trajectory factors.

* copy may be obtained from:

Transportation Research BoardNational Research Council2101 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 employed in the un-folded position: At all times while operating as either aBarrier 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 compromisedmaneuverability typically when the large turning radiusclearance needed for the extended TMA is not safe.

23

MaintenanceMaintenanceMaintenanceMaintenanceMaintenance

Before performing any Maintenance on the Safe-Stop 180 TMA, thoroughly read and understand the MaintenanceSection and the Safety Section of this manual.

I. Routine MaintenanceI. Routine MaintenanceI. Routine MaintenanceI. Routine MaintenanceI. Routine MaintenanceDescription Interval

1. Height and Levelness - The height and levelness of the system is important to its impact perfor-mance. Check regularly and adjust as necessary: See Figure 25. A/R*

FLAT LEVEL SURFACE

Figure 25

2. Fasteners - Check the tightness of the fasteners monthly. See the drawings for the locations ofthe fasteners. Be sure to check bolts attaching the cartridges to the support structure. Lockwashers 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 length +/- 5mm (3/16") and deflect 38-50mm (1 1/2-2"). (Ref. Pg 16)

C. Release Cables - Torqued to 34 Nm (25ft-lbs). Ref. Pg 14)

4. Jacks - Check the condition of the wheels on the jacks monthly or as required.

5. Lights - Replace the lights as required.

*A/R = as required

1 month

1st day,1st week,then 1 month

1 month

A/R*

305±25 mm [12"±1"]305±25 mm [12"±1"]

Safe-Stop® 180 TMA

24

Maintenance (cont’Maintenance (cont’Maintenance (cont’Maintenance (cont’Maintenance (cont’d.)d.)d.)d.)d.)

6. Pins - Check all pins. Prior to each use, check all pins to make sure they are held in position bya retaining pin as required.

Description Interval

Each use

7. Lubrication - Lubricate as described in the Lubrication Section (Maintenance Section - III) ofthis 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 ordebris on or around the ram.

10. Clean System - Clean the frame assembly, cartridges and support structure and impact facefrom dirt and salt as required. Check monthly. The system can be cleaned with mild soapsolution. Always check lubrication after cleaning.

Varies -see Section III

1 month

1 month

1 month

25

INSTALL JACKS ONACTIVE MOUNTS

II.II.II.II.II. DetacDetacDetacDetacDetaching and hing and hing and hing and hing and AtAtAtAtAttactactactactaching thehing thehing thehing thehing theSSSSSystem to the ystem to the ystem to the ystem to the ystem to the TTTTTrucrucrucrucruckkkkk

1) Detaching the System from the truck

Be sure the TMA and the truck are on level ground.

A. Raise the system to the folded position.

B. Remove the jacks from the storage locationand install them on the active mounts asshown in Figures 26 and 27.

C. Extend the jacks until the weight of the sys-tem is supported.

D. Unplug the light harness and disconnect thepositive power cable from the pump. Unplugthe cab switch box at the mating connectoron the TMA.

E. Remove the socket hitches from the under-ride socket receivers by removing 1 x 6 ¼"hitch pins and retainer pins.* See Figure 28.(If the alignment is off, making removal diffi-cult, it may be necessary to adjust jacks ortemporarily unmount the TMA from thesocket hitches. This can be done by remov-ing the two 1 ¼ x 7 " hitch pins and retainerpins as shown in Figure 29.) Loosen the hard-ware to ease interference. Be sure to retighten.

F. Move the TMA away from the truck.

SOCKET HITCHESHITCH PIN

Figure 28


STORAGE MOUNTSFigure 26

TILTING OF THE JACK AT THE ANGLES OF±5 DEGREES FROM VERTICAL IS NORMALAND IS DUE TO THE TOLERANCE IN THEATTACHMENT PIN TO ENSURE EASE OFINSTALLATION AND REMOVAL.

5°5°

Figure 27

INSTALL JACKS ONACTIVE MOUNTS

Safe-Stop® 180 TMA

26


Figure 29

BACKUP ASSEMBLY

HITCH PIN WITHHAIR 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 ACHIEVEPROPER SYSTEM GROUND CLEARANCE

SUPPORT BRACKET (RIGHT)

SUPPORT BRACKET (LEFT)

BAR WASHER1/2" X 2 1/2" X 3 1/4"

BAR WASHER1/2" X 3 1/4" X 3 1/4"

BAR WASHER1/2" X 3 1/4" X 3 1/4"1" HEX NUT

1" LOCK WASHER1" FLAT WASHER

1" X 3 1/2" HEX BOLT, G81" FLAT WASHER

1" X 3 1/2"HEX BOLT, G8

1" FLAT WASHER

SUPPORT 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 underridesocket receivers and pin them into placeusing 1 X 6 ¼" pin and retainer pin. If align-ment is off, making the assembly difficult, itmay be necessary to adjust jacks or tempo-rarily unmount the socket hitches from theTMA. Be sure the retainer pins are installedcorrectly and cannot fall out.

C. Plug in the light harness and connect thepositive power cable to the pump. Plug inthe cab switch box at the mating connectoron the TMA.

D. Retract the jacks completely and relocatethem to the storage location.

E. Check hydraulic/electrical system for properoperation.

F. Verify system is level and 280-330 mm[11" - 13”] above level ground.

27

III.III.III.III.III. LubricationLubricationLubricationLubricationLubricationWhen handling hydraulic fluid, use appropriatemeasures to prevent spillage. Clean any spillageimmediately.

1) Add Hydraulic FluidAdd hydraulic fluid as required and check the fluid levelmonthly. The reservoir is full when TMA is unfoldedAND when the fluid level is just visible inside the fillport. Use only Dexron® III Hydraulic fluid. Figure 30shows the location of the hydraulic fluid fill port.

RESERVOIR FILL PORT -ADD HYDRAULIC FLUID HERE

FLOW SWITCH

Figure 30

PUMP

2) Oil Swivel jacksOil the swivel jacks every six months as shown inFigure 31.

Figure 31

OIL JACK HERE

3) Change Hydraulic FluidChange the hydraulic fluid every 2 years, 50,000 km[30,000 miles], or if you strongly suspect the oil iscontaminated with water. Use Dexron® III fluid only.The empty oil capacity of the reservoir, hoses, andcylinders is approximately 4 quarts (the capacity ofthe reservoir alone is approximately 2 ½ quarts).

The reservoir and hydraulic system may need to befilled and cycled several times to remove air that maybe in the system.

Caution: When refilling an empty system, donot attempt to fold or unfold the system morethan 60 degrees until after cavitation hasceased. Always stay clear of a moving TMA.

As the TMA is folded/unfolded, the pump will cavi-tate when the reservoir is emptied. Add fluid untilsystem will raise to 60 degrees without cavitating.After that, cycle the system beyond 60 degrees andadd fluid as necessary. the reservoir should be full(oil just visible at the filler port) when the TMA isfully unfolded. If this procedure is not followed, theTMA may come down faster than expected (whetherfolding or unfolding).

Safe-Stop® 180 TMA

28

IVIVIVIVIV. . . . . TTTTTececececechnical Specifhnical Specifhnical Specifhnical Specifhnical Specificationsicationsicationsicationsications1) WeightCartridge A 157 lbs. 71 kg

Cartridge B 185 lbs 84 kg

Frame Components 1672 lbs 758 kg

Jacks 86 lbs 39 kg

Total 2100 lbs 953 kg

2) Dimensions

Figure 33

Figure 32

1.3 m [4'-2"]MAX.

2.4 m [7'-10"]

4.4 m [14'-5"]

303 mm ± 25 mm [1'-0" ± 1"]711 mm [2'-4"]

3) Replacement PartsFor details on replacement parts, refer to the draw-ing package. The drawings include the part num-bers and descriptions. For replacement parts, callcustomer service: 1-(888)-32-ENERG.

4) Operating ratesThe system folds to the folded position in approxi-mately 25 seconds.

The system unfolds to the unfolded position in ap-proximately 25 seconds.

2 m

[6'-1

0"] M

AX.

2.4 m [7'-9"]

Figure 34

0.10 m [4"] MIN.


29

I. PI. PI. PI. PI. Post Impactost Impactost Impactost Impactost ImpactNote: Only the correct parts manufactured by En-ergy Absorption Systems, Inc. should be used torepair a damaged system. Failure to comply couldresult in reduced safety or damage to the system.

1) Inspect the frame for bent parts.Replace any frame members that have been damaged.Do not attempt to weld or straighten parts. Replace thearms in pairs to ensure that the system collapses prop-erly. Refer to the system drawings for the part numbersand descriptions of the parts.

2) Inspect pins and bolts for damage.Replace all bolts and pins that have been damaged. Re-fer to the system drawings for the part numbers and de-scriptions of the parts.

3) Expand system and detach one end ofeach alignment cable.

Caution: Frames may swing side to side.

Extend the frame and detach one end of each of the fouralignment cables.

4) Remove cartridges and spent releasecables.

Remove the crushed cartridges.

Do not attempt to repair a damaged cartridge. For fullimpact capacity the cartridges will need to be replacedeven if they were only crushed slightly.

Repair InstructionsRepair InstructionsRepair InstructionsRepair InstructionsRepair Instructions

5) Install the Bottom Release Cable acrossthe Arm Assemblies.

Verify that the frame is extended as far as it will go. In-stall the Bottom Release Cable across Arm Assemblies.(see Figure 35). Torque the nuts to 34 Nm (25 ft-Ibf)making sure that roughly an equal amount of threadsprotrude from nuts on both ends of cable. Lock cable inplace using remaining fasteners as "jam" nuts.

WARNING!For proper System performance, only use ReleaseCables supplied by Energy Absorption Systems, Inc.Failure to use the correct equipment could lead tofatigue or result in poor System performance.

WARNING!Until the cables are installed, the system may shift toone side.

Figure 35

RELEASE CABLE



Safe-Stop® 180 TMA

30

Repair Instructions (cont’Repair Instructions (cont’Repair Instructions (cont’Repair Instructions (cont’Repair Instructions (cont’d.)d.)d.)d.)d.)

6) Install CartridgesRemove one end of each alignment cable from the TMAand set aside to clear the top side of each bay. Using aforklift and sling, place Cartridge 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 theArm 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 equal amount of threadsprotrude from nuts on both ends of cable. Lock cable inplace using remaining fasteners as "jam" nuts.

31

Figure 37

8) Reinstall and Adjust the Alignment CablesThere are four top cables (two for each bay). Reattachthe alignment cables as shown in Figure 37. Measurethe diagonals of each bay and adjust the cables so thatthe diagonal measurements in each bay are the same(A = B ± 5 mm [3/16"], C = D ± 5 mm [3/16"]). Lock eachcable in place using the second nut as a “jam nut” (seeDetail 37).

SOCKET HITCHES NOTSHOWN FOR CLARITY

A B C D

9) Replace Side-GuidesThe Side-Guides must be inspected and replaced if dam-aged. The Side-Guides are sacrificial and can be easilyattached to their respective mounts. Side-Guides are nec-essary for proper System alignment during an impactand must be in place to ensure proper performance char-acteristics during System operation in an impact.

Safe-Stop® 180 TMA

32

Repair Instructions (cont’Repair Instructions (cont’Repair Instructions (cont’Repair Instructions (cont’Repair Instructions (cont’d.)d.)d.)d.)d.)

9) Install and Tension the Cartridge Sup-port Cables

There are six cartridge support cables. Pass the stud endof the cable through the corresponding cartridge chainloop, and attach as shown in Figure 38 using a die spring,washer, and nuts.

To properly tension the cartridge support cables, tightenthe first nut on one cable until all slack is removed, thentighten it until the tensioning springs have been com-pressed to 32 mm [1 ¼"] in height. Lock this nut in placewith the second "jam" nut. Repeat this procedure withthe other cables.

10) Adjust the Height and Levelness of theSystem Frame

Verify that the system frame is 305 ± 25 mm [12" ± 1"] fromthe ground at the front and rear of the system. It may benecessary to add shims to the socket hitches in order toadjust the levelness of the cartridge. See Figure 38a.

SHACKLE


32 mm [1 1/4"]

WASHERNUTS

Figure 38

305 mm ± 25 mm [12" ± 1"]

SOCKET HITCH

SHIMS MAY BE ADDED OR REMOVEDHERE AS NECESSARY TO ACHIEVE

LEVELNESS OF SYSTEM

SEE DETAIL 38a

Detail 38a


33

11) Verify Position of Hydraulic / ElectricalLines

Check the location of all the hydraulic and electrical linesto make sure they will not be damaged during the foldingand unfolding of the system.

12) Check System Lights For Proper Op-eration

Verify that all the turn / stop / tail / reverse lights areworking properly. Replace any bulbs that are out.

There are two light circuits on the TMA. Verify both cir-cuits are operational.

Raise the system to folded position and verify secondarylights are working.

With the system unfolded, lights on the impact face willbe on and lights on the midframe will be off.

With the system folded, the lights on the midframe willbe on and the lights on the impact face will be off.

14) Final checkCheck the tightness of all the fasteners. Check all steel cablesto verify that they are properly attached and tightened.

15) Ready to UseThe system is now ready for use.

Safe-Stop® 180 TMA

34

SSSSSafety Notesafety Notesafety Notesafety Notesafety Notes1) Always wear eye protection when working on or

around machinery or power tools, and while work-ing with hydraulics.

2) Do not attempt to control a hydraulic leak with yourhand. High-pressure hydraulic fluid can puncture theskin and cause severe injury or death. Use extremecaution when working on hydraulic systems.

In general, consult Energy Absorption Systems' CustomerService Department if problems associated with operat-ing or repairing the TMA should arise. This guide is meantto be an aide for performing minor repairs, not a detailedrepair manual. NOTE: For any problems not listed here,contact Energy Absorption Systems.

TTTTTest Eqest Eqest Eqest Eqest EquipmentuipmentuipmentuipmentuipmentThe following is a recommended list of test equipmentrequired to troubleshoot D.C. powered hydraulic systems.

1. PRESSURE GAGE

A 34450 kPa [5000 psi] pressure gage, preferablyglycerin filled, is a valuable and relatively inexpen-sive tool for checking pressure in the various sec-tions of the circuit.

2. D.C. TEST LIGHT

A test light is a light bulb with one lead wired to analligator clip and the other lead connected to a metalprobe. It is used to check for the presence of a volt-age in the electrical circuit. With the alligator clipgrounded, the light glows when the probe comes intocontact with a hot electrical component.

3. CONTINUITY LIGHT

A continuity light is like a test light but contains its ownbattery. It is used for testing electrical circuits when thecomponents are not connected to a power source.

TTTTTrrrrroubleshooting Guideoubleshooting Guideoubleshooting Guideoubleshooting Guideoubleshooting Guide

4. VOLT METER

A D.C. voltmeter can be used to troubleshoot volt-age problems. Two common uses are: 1) Groundone probe while using the other to probe hot leads insearch of the available voltage at the point where thesecond probe is connected. 2) Measure a voltagedrop in a wire or component by connecting one probeto one end and the remaining probe to the other endof the item in question.

5. OHM METER

Note: All tests conducted with an ohmmeter mustbe done with the power source disconnected fromthe system.

An ohmmeter is used to measure resistance and isuseful when working with solenoid coils. On somecoils the wire resistance is large enough that a D.C.test light might not illuminate, falsely indicating anopen circuit (infinite resistance). A successful coiltest, however, should always show some non-infi-nite value of resistance.

6. ASSORTED HOSSES, PRESSURE FITTINGS

These can be used to connect and/or isolate certain partsof a hydraulic circuit for diagnosing hydraulic problems.

If you suspect problems, do not operate the system.Diagnose and repair, or contact Energy Absorption Sys-tems' Customer Service Department for assistance.

HyHyHyHyHydraulic Fluiddraulic Fluiddraulic Fluiddraulic Fluiddraulic Fluid1. PURPOSE

The main purpose of hydraulic fluid is to transferpower from the pump to the actuators. Secondarytasks include reducing metal on metal friction, andpreventing the formation of rust and sludge. Thesetraits are achieved when the oil has a good lubricity(slipperiness), and with additives that inhibit oxida-tion and the entrainment of air and water in the oil,respectively. The viscosity (thickness) of the oil must

35

be appropriate for the operating temperature to mini-mize unwanted leakage, and to lubricate the closefitting parts in the system.

Additionally, the oil must be compatible with the sealsused in the system. Finally, the oil must be able topour or flow at the lowest expected operating tem-perature so that it can enter the reservoir and pumpfor use. For all of these reasons, automatic trans-mission fluid (ATF, Dexron®) has been found to bethe best readily available fluid for the job in mostclimate conditions.

2. SELECTING FLUIDS FOR APPLICATIONS OUTSIDEATF'S OPERATING TEMPERATURE RANGE

NOTE: Consult Energy Absorption Systems' Cus-tomer Service Department when considering andbefore changing hydraulic fluid to assure compat-ibility with existing components.

When looking for fluids that can be used in place ofATF or for applications where the operating tempera-ture is outside the range of ATF, the following specif-ics should be discussed with your local oil distributor:

A. Fluid must be compatible with Buna-N sealingcompounds.

B. The Pour Point must be below the lowest antici-pated temperature that will be encountered.

C. It should contain Rust or Oxidation inhibitors aswell as other detergent type inhibitors.

D. The viscosity (SUS) should lie between 80 and375 in the operating range, with the ideal vis-cosity near 200 SUS.

E. The viscosity index should be as high as pos-sible. As an example, ATF has the following specsas 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.

HyHyHyHyHydraulic Sdraulic Sdraulic Sdraulic Sdraulic SystemystemystemystemystemFinding & Solving Problems

CAUTION: Repair of hydraulic componentsshould only be performed by fully qualified in-dividuals or hydraulic shops. In most cases,the customer should contact Energy Absorp-tion Systems' Customer Service Department foradvice on repair or replacement of TMA parts.All replacement components must be approvedfor use or provided by Energy Absorption Sys-tems to guarantee quality and correctness.

Hydraulic system failures can occur in several ways:A gradual or sudden loss of pressure or flow, a lossof power at the pump, or other difficulties. Any ofthe system's components could be the cause. Startwith the checklist below that most applies to thesymptom at hand.

Note: Avoid the use of Teflon tape on hydraulicfittings as it can easily jam valves and cause fail-ures in the hydraulic system.

1. MOTOR DOES NOT START

• Improper ground. Check ground. Add a ground cableif necessary.

• Improper or low voltage supply. Check voltave sup-ply from truck power.

• Electrical system inoperative: Verify that cable frombattery is correctly attached. Verify that the pump isfirmly bolted to the TMA frame and that the trucklighting plug is correctly attached.

Safe-Stop® 180 TMA

36

TTTTTrrrrroubleshooting Guide (cont'd.)oubleshooting Guide (cont'd.)oubleshooting Guide (cont'd.)oubleshooting Guide (cont'd.)oubleshooting Guide (cont'd.)• Failed motor solenoid: Replace, taking note of cor-

rect wire locations for reassembly. (Call first)

2. SYSTEM OPERATES ROUGH or ERRATIC

• Insufficient or no oil in system, pump losing prime:Fill system, check for leaks.

• Ground fault: Check for loose wire leads, verify thatpump is securely mounted to TMA frame and thatthe truck lighting plug is correctly attached.

• Wrong oil in system (should be Dexron® II or III):Change oil.

• Clogged or dirty cylinder check valve: Remove theload on cylinders, disassemble cylinder check valveand clean (see section on Cylinder Check Valves).

• Oil line restricted, line dirty or collapsed: Clean orreplace oil line.

• Dirty pump: Clean exterior and check for contami-nated oil. If necessary, drain, flush, and refill systemwith approved oil.

• Worn components (valves, cylinders, etc.): Checkfor cause of wear. Replace worn parts with cor-rect components.

• Leakage: Check all components, verify tightness offittings, and inspect hoses for wear while system isidle. Replace damaged hoses or fittings.

• Excessive loading (especially any features not origi-nally installed by Energy Absorption Systems): Re-move excessive load.

3. SYSTEM OPERATES SLOWLY or CAVITATES

• Low voltage: Verify voltages with D.C. voltmeter andcheck truck charging system.

• Oil viscosity too high or cold oil: Allow oil to warmup before operating or replace with oil intended forcorrect 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 airfrom system.

• Oil leaks: Tighten fittings, replace seals or damagedlines.

• Worn components (valves, cylinders, etc.): Checkfor cause of wear. Replace worn parts with correctcomponents.

• Restriction in lines or cylinder check valves: Removethe load on cylinders, clean lines or valves, replacehoses if necessary.

• Internal fixed flow controls reversed: Contact EnergyAbsorption Systems.

4. SYSTEM OPERATES TOO FAST

• Pump output pressure higher than necessary:Adjust pressure relief valve to specifications.

• Internal fixed flow controls reversed:Contact Energy Absorption Systems.

5. OIL IN SYSTEM OVERHEATS

• Incorrect, low volume, or dirty oil: Add or change oilas necessary.

• Excessive internal leakage (pump): Replace the pump(contact Energy Absorption Systems).

• Restriction in lines or cylinder check valves: Removethe load on cylinders, clean lines or valves, replacehoses if necessary.

• Insufficient heat radiation: Clean dirt and mud fromreservoir and components.

6. NOISY PUMP

• Low oil level, incorrect or foamy oil: Replace or addoil as necessary.

• Suction line or inlet screen plugged: Consult EnergyAbsorption Systems.

• Worn or damaged pump: Replace the pump (contactEnergy Absorption Systems).

37

7. LOAD DROPS WHEN SYSTEM IS LOCKED

• Leaking cylinder seals or fittings: Remove the loadon cylinders, inspect for damaged hoses or fittings,tighten fittings or replace hoses if necessary.

• Faulty cylinder check valves / solenoid coils: Removethe load on cylinders. Clean or replace the appropri-ate cylinder check valve components.

8. LEAKY CYLINDER(S)

• Seals worn or damaged: Have cylinder repaired by aqualified hydraulics repair shop or replace the cylinder.

• Rod damaged: Have cylinder repaired by a qualifiedhydraulics repair shop or replace the cylinder.

HyHyHyHyHydraulic Sdraulic Sdraulic Sdraulic Sdraulic System Pystem Pystem Pystem Pystem PrimingrimingrimingrimingrimingSafe-Stop® 180 TMA hydraulic systems come direct fromthe factory primed and ready to operate. Priming shouldonly be necessary after changing the oil or if you haverecently repaired a leak.

1. PRIMING PROCESS

Systems that have been disassembled for repair re-quire priming for proper performance. The hydrau-lic system is said to be primed when all hoses & thecylinders are full of oil, and the air has been expelled.The reservoir should be full of oil (oil just visible atthe filler port) when the TMA is UNFOLDED. Primethe pump as follows:

A. Detach the long hoses where they connect to allfour cylinder check valves (near the middle brakelight assemblies). Note which hoses connect towhich valves.

B. Jog the pump by briefly depressing the "FOLD"button until clean oil flows from two of the hoses.

C. Repeat this process for the other two hoses bybriefly depressing the "UNFOLD" button.

D. Replace and retighten all four hoses. Note thatany NPT (pipe) style threaded fittings shouldbe lightly coated with thread sealant, prefer-ably Loctite #545.

CAUTION: Do not completely fold or unfold theTMA until it has been jogged a few times towork out any air in the system. Add oil at thefiller port any time that the pump begins tocavitate.

E. Jog the system a few times by depressing "FOLD"or "UNFOLD" (depending on the current state ofthe TMA). Note that you may need to press andthen unlock the "STOP" button to stop the sys-tem each time before reversing directions.

2. CHECK FOR THESE PROBLEMS WHEN A SYSTEMFAILS TO PRIME:

• Correct pump mounting, with the motor on topand reservoir at the bottom. All Safe-Stop 180TMAs should have vertically mounted pumps.Mounting a pump in some other orientationwould prevent the suction line from picking upoil, causing cavitation. NOTE: Vertical mountpumps have a label stating such designation.

• A solid plug in the reservoir filler port instead ofa vent plug (see Reservoir section).

ReserReserReserReserReservvvvvoiroiroiroiroirNote: Do not use a solid plug or fill cap without afilter/breather element, or damage will be causedto the pump and/or reservoir.

1. USE RECOMMENDED FLUID:

Fill reservoir with Dexron® III or ATF (See HydraulicFluid section).

2. PROPER FILLING:

A. With the TMA UNFOLDED (cylinders fully re-tracted), fill the reservoir so that oil can just beseen in the filler port.

B. Operate the unit several times starting with shortcylinder strokes, increasing the length of eachsuccessive stroke. Note that you may need topress and then unlock the "STOP" button to stopthe system each time before reversing directions.

Safe-Stop® 180 TMA

38

TTTTTrrrrroubleshooting Guide (cont'd.)oubleshooting Guide (cont'd.)oubleshooting Guide (cont'd.)oubleshooting Guide (cont'd.)oubleshooting Guide (cont'd.)

C. Recheck oil level often and add as necessary tokeep the pump from picking up air.

D. Reinstall the filter/breather plug provided.

3. RESERVOIR PROBLEMS

A. Clear oil flowing out of the filler port usually meansthe reservoir was completely filled before the cylin-ders were fully collapsed (TMA unfolded).

B. Foamy oil flowing out of the filler port points toone of the following:

1. Air present in the system; the response isusually spongy, or the cylinders may movewith a jerking motion.

2. There is no drop tube or "down spout" on thereturn line so that the oil is not returning tothe bottom of the reservoir.

C. Water in the oil:

Water can enter the reservoir through the fillerport if the unit is left outdoors or washed with ahigh-pressure washer. Protect the unit, when-ever possible, and change the oil if you suspectcontamination. In cold weather the water couldfreeze, preventing the pump from working untilthe ice melts.

Electrical PElectrical PElectrical PElectrical PElectrical Prrrrroblemsoblemsoblemsoblemsoblems

WARNING!REMOVE ALL RINGS, WATCHES, JEWELRY, ETC.PROIOR TO DOING ANY ELECTRICAL WORK!

B. Minimum voltage requirements:

1. Between the motor stud and ground: 9.0 voltsat max. load.

2. Between any valve solenoid hot wire andground: 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 batterycable.

4. Battery cable size too small for load andlength of run. Copper #2 automotive batterycable is the recommended min. size. Largercopper battery cable (#1, #0, or #00) may berequired for cable lengths over 30 feet to keepperformance from deteriorating.

5. The pump ground is established through thepump mounting bolts. Clean any dirt or rustfrom mounting holes and bolts to achieveproper ground.

6. Burnt contacts on motor solenoid.

D. Check for low voltage as follows (requires a volt-meter):

1. On alternator equipped vehicles, verify thatthe battery voltage is approximately 13.5volts with no electrical accessories operat-ing and the engine running.

2. Operate the TMA while an assistant uses thevoltmeter to probe each connection, cableend, and cable from the battery all the wayback to the motor stud. Note the voltagelosses. Make necessary repairs. Increasethe voltage above the minimum as required.

Note: Check the ground connections as well; re-move any paint, rust, and dirt that may be actingas insulators.

1. LOW VOLTAGE

Operating D.C. (direct current) power units efficientlyrequires proper voltage. Any attempt to operate be-low the minimum required voltage could cause sys-tem failure.

A. Signs that point to low voltage are:

1. Motor won't run because solenoid won't shift.

2. Motor running at reduced speed.

3. Solenoid valves not shifting.

39

2. D.C. MOTORS

Before concluding that the hydraulic pump is mal-functioning:

• Verify that all connections are secure and thatthe problem does not lie somewhere else.

• Check ground.

• Check brushes for wear, and replace if necessary.

Note: A motor that does not turn in freezingweather could be caused by frozen water in theoil.

If it has been verified that the pump is defective, con-tact Energy Absorption Systems' Customer ServiceDepartment for assistance.

3. ELECTRICAL SWITCHES

A. If you suspect that a push button switch is de-fective, use one of these three methods to testthe operation of the switch:

1. First check grounds.

2. Use a continuity light to test the switch (seeTest Equipment section).

3. Use a circuit test light to test the switch (seeTest Equipment section).

B. Motor solenoid switch:

The solenoid switch found on the hydraulic pumpis a three post "can" style solenoid. It should beconstructed and wired such that:

1. The large post marked "Bat" must be attachedto the cable from the battery.

2. The same "Bat" post (shared hot lead) pro-vides power to the control circuit.

3. The remaining large post attaches to themotor with a solid strap.

4. The small post connects to the control cir-cuit and activates the solenoid (and hencethe pump) when energized.

4. ELECTRICAL POLARITY

The pump motor and all controls have a negativeground.

PPPPPressure Relief ressure Relief ressure Relief ressure Relief ressure Relief VVVVValalalalalvvvvveeeee1. PURPOSE:

A. Limit the maximum pressure in the hydraulic sys-tem to a safe level.

B. Keep the motor amperage (and battery drain) ata minimum when the cylinders dead head (reachfull stroke).

2. ADJUSTING RELIEF VALVE (on the pump)

Note: In general, do not adjust the relief valve. It isset to the correct operating pressure at the factory.

A. Symptoms of incorrect pressure relief adjustment

1. Relief pressure too high

a. Battery current draw is excessive.

b. Motor RPM is slow.

2. Relief pressure too low.

a. Motor RPM is fast.

b. System will not fold (cylinders will notextend).

c. Excessive turbulence in reservoir.

B. Procedure

1. Loosen jam nut by turning counterclockwise.

2. Adjust relief valve setting by turning set screwwith Allen wrench.

a. Turn counterclockwise to reduce maxi-mum pump pressure.

b. Turn clockwise to increase maximumpump pressure.

3. Hold set screw in place and retighten jam nut.

Safe-Stop® 180 TMA

40

TTTTTrrrrroubleshooting Guide (cont'd.)oubleshooting Guide (cont'd.)oubleshooting Guide (cont'd.)oubleshooting Guide (cont'd.)oubleshooting Guide (cont'd.)

Note: On applications where a hydraulic compo-nent is being replaced, contact Energy AbsorptionSystems' Customer Service Department to verifycomponent compatibility.

CCCCCylinder Checylinder Checylinder Checylinder Checylinder Check k k k k VVVVValalalalalvvvvveseseseses1. PURPOSE

The cylinder check valves allow free flow of hydrau-lic oil into the cylinders, but block exit flow until asolenoid is energized. When a "STOP" button is de-pressed, power to all coils is cut, preventing oil fromescaping the cylinders and locking the system.

2. REPAIRING CHECK VALVES

A. Symptoms

If the TMA exhibits a slow drifting of the foldingbay after either of the "STOP" buttons has beendepressed, one of the following may be true:

1. Improper grounding. Check grounds.

2. Incorrect voltage. Check power supply forcorrect voltage supply.

3. The check vale poppet has become blockedby foreign debris in the oil line.

4. The piston ring seals inside the cylindershave been compromised.

WARNING!Do not exceed pressure rating for hydraulic systemcomponents! System pressure is set to 2000 psi atthe factory.

WARNING!When the system is stopped at an intermediate angle,there will be pressure on the oil in the hoses betweenthe check valves and cylinders! This pressure issupporting the load of the folding bay! ALWAYS makesure the TMA is completely folded or completelyunfolded before loosening a hose fitting or servicing anycheck valve! This will minimize the chance of injuryfrom an uncontrolled falling load, or spray of high-pressure oil.

B. Repair procedure

1. Blocked poppet

a. Again, make sure the system is com-pletely folded or completely unfolded.

b. Loosen the nut that holds the solenoidcoil on the valve body, and remove thecoil from the cartridge valve, makingnote of which coil goes to which car-tridge.

c. Remove the cartridge from the valvebody, being cautious of oil spray fromresidual pressure in the system.

d. Clean the cartridge using compressedair, making sure to direct the air awayfrom anyone's face. Avoid breathing theoil mist that this process may create.

e. Reinstall the cartridge and coil, makingsure to correctly match coil and cartridgeas they were before disassembly (thiswill affect proper operation).

2. Piston ring seal

a. Refer to the following section on Hy-draulic Cylinders.

Note: If the cartridge valve has failed in some otherway, do not attempt to repair it. Replace it with anew valve by contacting Energy Absorption Sys-tems' Customer Service Department.

41

HyHyHyHyHydraulic Cdraulic Cdraulic Cdraulic Cdraulic Cylinderylinderylinderylinderylindersssss

Caution: Never allow anyone underneath themoving portion of the Safe-Stop 180 TMA.Block out all loads and disconnect electricalcontacts prior to performing any service onhydraulic equipment.

1. TROUBLESHOOTING

If you suspect problems with the hydraulic cylinders onthe TMA, you may need to remove the cylinders from theTMA for repair or replacement. The cylinders can onlybe removed when the TMA is completely folded. Doublecheck that all electrical contacts between the TMA andsupport vehicle have been disconnected prior to perform-ing any work on the hydraulic system.

A cracked, bent, or leaky cylinder may need repair, butshould almost always be replaced to ensure proper, reli-able performance.

2. CYLINDER REPLACEMENT

A. Completely fold the TMA.

B. Unplug all electrical connections between theTMA and the support vehicle.

C. See TMA drawing 3526084-0000. Loosen (butdo not disconnect) the "Follower Link Pivot" andthe "Push Link Pivot" where they are bolted tothe "Weldment, Front Intermediate Frame" andthe "Weldment, Rear Intermediate Frame", re-spectively.

D. At the top end of the cylinder rod, loosen the setscrew and push out the short 7/8" diameter pin,making note of the alignment and location of alllinkage components for later reassembly.

E. Disconnect the hoses leading into the cylinder attwo convenient locations, and place temporarycaps on the hoses or cylinder ports to preventspillage or contamination.

F. At the bottom end of the cylinder body, removethe set screw from the frame and push out thelong 7/8" diameter pin, making note of the align-ment and location of all components for laterreassembly.

G. The cylinder should now be free. Reinstall a newcylinder in the reverse order of these removalsteps, making sure to properly align and (wherenecessary) tighten all components. Use bluethread locker (medium strength) on all fasteners.

Note: See the section on Hydraulic System Prim-ing. You will likely need to prime the system if youare installing a new or "dry" cylinder.

3. REPAIRING CYLINDERS

In most cases, replacing a damaged or faulty cylinderwith a new cylinder is the best option. Refer all cylinderrepairs to a qualified hydraulic cylinder shop. Otherwise,contact Energy Absorption Systems' Customer ServiceDepartment for replacement components.

Safe-Stop® 180 TMA

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Customer Service Department

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Safe-Stop 180 TMA (9181) Installation Operation Manual...a TMA is mounted, while positioned upstream...

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Transcript of Safe-Stop 180 TMA (9181) Installation Operation Manual...a TMA is mounted, while positioned upstream...