Energy Absorption Safe-Stop 180 TMA 9181 Installation And Operation Manual

Safe-Stop® 180 TMA

(Model 9181)

Compact TMA That Meets NCHRP 350, TL-3

Corporate Offices:
35 East Wacker Dr., 11th Floor
Chicago, IL 60601-2076
Telephone: [phone]
FAX: [phone]

ENERGY ABSORPTION

SYSTEMS, INC.

A Quixote Company

Saving Lives By Design

http://www.energyabsorption.com/

Engineering and Manufacturing Facilities:
Rocklin, CA
Pell City, AL

Installation/Operation

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

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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 install­ing 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 1-888­32-ENERG.

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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.

FF

unctional Descriptionunctional Description

F

unctional Description

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unctional Descriptionunctional 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 crush­able cartridges; a support structure; an impact face and
an underride (see Figure 1).

2

SS

afety Instructionsafety Instructions

S

afety Instructions

SS

afety Instructionsafety 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.

REAR OF TRUCK
SOCKET HITCH UNDERRIDE

TRUCK

CARTRIDGE B ASSY CARTRIDGE A ASSY

SUPPORT STRUCTURE

Figure 1

STAND HERE (FOR CONTROLS
ON RIGHT SIDE OF TRUCK)

CONTROLS MAY BE
RELOCATED TO THIS SIDE

MOVING PARTS DURING
FULL DESIGN IMPACTS AND
FOLDING OPERATION

CARTRIDGECARTRIDGE

CONTROLS

STAND HERE (FOR CONTROLS
ON LEFT SIDE OF TRUCK)

Figure 2

3

Safe-Stop® 180 TMA

SS

afety Instructions (cont’afety Instructions (cont’

S

afety Instructions (cont’

SS

afety Instructions (cont’afety Instructions (cont’

d.)d.)

d.)

d.)d.)

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.

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

PIVOT PIN

RETAINING PIN

Figure 4

*The Safe-Stop 180 TMA shall be employed in the un­folded position: At
Barrier Vehicle or Shadow Vehicle.

The Safe-Stop 180 TMA should be in the "unfolded" po­sition when: Transporting short distances at a low speed,
Transporting at a speed much lower that adjacent traffic,
and Transporting in areas where vehicle ride characteris­tics and maneuverability are maintainable.

The Safe-Stop 180 TMA should be in the "folded" posi­tion when: Transporting long distances at a high speed,
Transporting at a speed near the speed of adjacent traf­fic, and Transporting under conditions of compromised
maneuverability typically when the large turning radius
clearance needed for the extended TMA is not safe.

all times while operating as either a

305±25 mm [12"±1"]

STORE JACKS HERE WHILE
TMA IS ATTACHED TO TRUCK

305±25 mm [12"±1"]

Figure 3

4

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 5

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).

NO ONE TO BE ALLOWED BEHIND ELEVATED TMA

Figure 7

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 6

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 pos­sible after, entering a job site or beginning shadow
vehicle operations. Remember that it is recom­mended that the support vehicle be stopped for TMA
folding and unfolding.

Figure 8

5

Safe-Stop® 180 TMA

SS

afety Instructions (cont’afety Instructions (cont’

S

afety Instructions (cont’

SS

afety Instructions (cont’afety Instructions (cont’

d.)d.)

d.)

d.)d.)

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 per­formance.

• 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.

14. This system is a crash cushion and is therefore used
in high risk areas. Stay clear of traffic whenever pos­sible. 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 mecha­nism to malfunction, and may reduce the impact
performance.

16. The system must be in the unfolded position to per­form 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.

6

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

• Gradually stop the impacting vehicle*

• Protect the occupants of the impacting vehicle *

SHADOW VEHICLE

WITH TMA

TMA

• 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.

SKID DISTANCE

WITHOUT TMA

SAME

SKID DISTANCE

Figure 9

7

Safe-Stop® 180 TMA

Installation InstructionsInstallation Instructions

Installation Instructions

Installation InstructionsInstallation 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 im­pact 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 re­garding the suitability, contact the Customer Service De­partment for assistance.

1) Shipping list

Check the shipping list against the actual parts to make
sure all items were received. Review the drawing pack­age and familiarize yourself with the assembly and part
numbers.

2) Assemble Necessary tools:

Recommended Recommended

Recommended

Recommended Recommended

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

TT

oolsools

T

ools

TT

oolsools

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

PP

reparationreparation

P

reparation

PP

reparationreparation

3A) Installation Must Be Performed On A

Level Surface

The system’s framework is very heavy and pivots in sev­eral 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 en­sure 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 in­terference 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 re­ceiver hitch underride refer to special instructions sup­plied 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 posi­tions), etc., should be corrected before proceeding.

8

STEPS

4 & 5

STEP

STEP

ATTACHMENT

STEP

6

ASSEMBLY

7

SUPPORT
FRAME

12

STEP

11

UNDERRIDE

RECEIVER

SOCKET

SUPPORT

MOUNT

STEPS

8 & 9

Figure 10

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 bot­tom 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
[2"]. Adjust the height to compensate for antici­pated 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 loca­tion (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 accor­dance with the underride drawing.

STEP

10

CAUTION: The truck frame is high carbon steel.
To avoid cracking, do not weld, or apply ex­cessive heat, to the bottom flange, forward of
rear-most leaf spring hangers.

Prime and paint all welded areas.

TRUCK FRAME

UNDERRIDE

SOCKET

RECEIVER

FLAT BAR

Figure 11

864 mm [34"] NOMINAL

UNDERRIDE

SOCKET RECEIVER

NOMINAL

710 mm [28"]

TRUCK
FRAME

FLAT BAR

Figure 12

9

Safe-Stop® 180 TMA

Installation Instructions (cont’Installation Instructions (cont’

Installation Instructions (cont’

Installation Instructions (cont’Installation Instructions (cont’

762 mm ± 25 mm [30" ± 1"]

LEVEL GROUND

711 mm ± 25 mm [28" ± 1"]

WITH SPACERS

TRUCK FRAME

SPACER TUBES

SPACER SPLICE
(USE ONLY ON
REAR SPACER TUBE)

FLUSH WITH
END OF FRAME

UNDERRIDE SOCKET RECEIVER

LEVEL GROUND

TRUCK FRAME

UNDERRIDE SOCKET RECEIVER

WITHOUT SPACERS

d.)d.)

d.)

d.)d.)

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

Figure 13

Socket Hitch (Left Side Shown)

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.

HITCH & RETAINER PINS

SOCKET HITCHES

10

Figure 14

7) Mount the Attachment Assembly to Socket Hitches

Mount the attachment assembly to the socket hitches as shown in Figure 15. Shims are used to level the system. It
is recommended that ¼" shims be used initially. This may be adjusted once the system is assembled.

SUPPORT BRACKET

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

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

1X3 1/2" HEX BOLT

1" FLAT WASHER

12GA SHIM

1/4" SHIM (ONE PER SIDE RECOM-

SOCKET HITCH

1" FLAT WASHER

1" LOCK WASHER

1" HEX NUT

MENDED AT INITIAL SETUP. LEVEL
THE TMA BY ADJUSTING THE
NUMBER OF SHIMS)

Figure 15

11

Safe-Stop® 180 TMA

8) Attach the Support Frame / Backup to
the Attachment Assembly

Move the system to the truck and pin the support
frame/backup assembly to the attachment assembly,
as shown in Figure 16. The assembly is to be installed
while frame is still collapsed with forklift slings sup­porting the system. Use the upper set of mounting
holes for the attachment.

SUPPORT BRACKET (RIGHT)

SUPPORT MOUNT (RIGHT)

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

BAR WASHER

1/2" X 2 1/2" X 3 1/4"

SUPPORT MOUNT (LEFT)

1" HEX NUT

1" LOCK WASHER

HITCH PIN WITH

HAIR PIN COTTER

1" FLAT WASHER

SUPPORT BRACKET (LEFT)

*SHIMS, 12GA X 5" X 10"

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

BACKUP ASSEMBLY

HITCH PIN WITH
HAIR PIN COTTER

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

1" FLAT WASHER

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

1" FLAT WASHER

*SHIMS, 1/4" X 5" X 10"

*USE SHIMS AS NECESSARY TO ACHIEVE
PROPER SYSTEM GROUND CLEARANCE

12

Figure 16

9) Extend the Support Frame

With the TMA pinned to 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.

Figure 17

ALIGNMENT CABLES

ALIGNMENT CABLES

13

Safe-Stop® 180 TMA

Installation Instructions (cont’Installation Instructions (cont’

Installation Instructions (cont’

Installation Instructions (cont’Installation Instructions (cont’

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.

10) Install the Bottom Release Cable

across the Arm Assemblies.

Verify that the frame is extended as far as it will go. In­stall the Bottom Release Cable across 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 place
using remaining fasteners as "jam" nuts.

TORQUE TO 34 NM (25 FT-LBS.)

TORQUE TO 34 NM (25 FT-LBS.)

d.)d.)

d.)

d.)d.)

RELEASE CABLE

Figure 18

14

11) Install Cartridges

Remove one end of each alignment cable from the TMA
and set aside to clear the top side of each bay. Using a
forklift and sling, place Cartridge B in position and se­cure it using the flat washers, lock washers and nuts pro­vided. Torque the nuts to 120 ± 7 Nm [90 ± 5ft-lbs.] Re­peat procedure for Cartridge A (see Figure 19).

CARTRIDGE A

CARTRIDGE B

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
place using the remaining fasteners as "jam" nuts.

Figure 19

15

Safe-Stop® 180 TMA

Installation Instructions (cont’Installation Instructions (cont’

Installation Instructions (cont’

Installation Instructions (cont’Installation Instructions (cont’

13) Reinstall and Adjust the Alignment
Cables

There are four alignment cables (two for each bay). Reat­tach the alignment cables as shown in Figure 20. Measure
the diagonals of each bay and adjust the cables so that the
diagonal measurements in each bay are the same within the
given tolerance
and taught.

[1 1/2" - 2"] when pressed by hand at the midpoint. Lock
each cable in place using the second nut as a “jam nut”.

SOCKET HITCHES NOT
SHOWN FOR CLARITY

(A = B ± 5 mm [3/16"], C = D ± 5 mm [3/16"])

Cables are "taut" when they deflect 38 mm - 50mm

d.)d.)

d.)

d.)d.)

16

A

B

Figure 20

C

D