Trinity SS180 TMA 9182 Assembly Manual

Truck mounted attenuator

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SS180 TMA

(Model 9182)

Product Description

Assembly Manual

Part No. 115359B

Revision B June 2013

Table of Contents

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Page 1 ® SS180 TMA (Model 9182) Product Description Assembly Manual Part No. 115359B Revision B June 2013...
Page 2 ® SS180 TMA (Model 9182) Product Description Assembly Manual 2525 Stemmons Freeway Dallas, Texas 75207 Important These instructions are to be used only in conjunction with the ® assembly, maintenance, and repair of SS180 TMA systems. These instructions are for standard assemblies specified by the appropriate highway authority only. In the event the specified system assembly, maintenance, or repair would require a deviation from standard assembly parameters, contact the appropriate highway authority engineer.
Page 3: Table Of Contents
Table of Contents Customer Service Contacts ......................3 Important Introductory Notes ....................... 3 System Overview ......................... 4 Recommended Safety Rules for Assembly ................. 4 Safety Symbols ..........................5 Warnings and Cautions ....................... 5 Limitations and Warnings ......................6 ® Know Your SS180 TMA System ....................
Page 4: Customer Service Contacts
Customer Service Contacts Energy Absorption Systems (a Trinity Highway Products company) is committed to the highest ® level of customer service. Feedback regarding the SS180 TMA system, its assembly procedures, supporting documentation, and performance is always welcome. Additional information can be obtained from the contact information below:...
Page 5: System Overview
System Overview ® The SS180 TMA system is a Truck Mounted Attenuator (TMA) shown 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 when the system is impacted within the applicable NCHRP 350 criteria. The system mounts on the rear of a truck and may be used in stationary applications (e.g.
Page 6: Safety Symbols
Do not utilize or otherwise comingle parts from other systems even if those systems are other Energy Absorption Systems or Trinity Highway Products systems. Such configurations have not been tested, nor have they been accepted for use. Assembly, maintenance, or repairs using unspecified parts or accessories is strictly prohibited.
Page 7: Limitations And Warnings
Limitations and Warnings Energy Absorption Systems, in compliance with the National Cooperative Research Highway Program 350 (NCHRP Report 350) “Recommended Procedures for the Safety Performance of Highway Safety Features”, contracts with FHWA approved testing facilities to perform crash tests, evaluation of tests, and submittal of results to the Federal Highway Administration for review.
Page 8: Know Your Ss180 Tma ® System
® Know Your SS180 TMA System For the safety of the operator, the operator shall stand at the rear of the truck, on the curb side, (See Figure 2). When tilting the TMA, care shall be taken to stay clear of all moving parts. Figure 1 STAND HERE (FOR CONTROLS MOVING PARTS DURING FULL...
Page 9 The TMA shall be rigidly fastened to the truck. In the horizontal position, the bottom of the TMA shall be 280 to 330 mm [11" to 13"] from the ground and level (See Figure 3). The TMA must be left in the unfolded position whenever possible. The TMA can only absorb the energy of an impacting vehicle when in the unfolded position.
Page 10 ® The SS180 TMA is intended to support its own weight and dissipate the kinetic energy of errant vehicles per NCHRP 350 criteria. Do not drag the TMA or place anything on its top or damage will result. Do not sit, stand or lean on any part of the TMA (See Figures 5 &...
Page 11 Ballast and other heavy objects MUST BE ADEQUATELY ANCHORED to the truck to prevent shifting during an impact (See Figure 7). The force exerted on the tie-down straps could be 20 times the weight of the ballast. Figure 7 9. The agency responsible for the truck shall inspect it for adequate operator safety equipment (e.g., seat belts, head rests, etc.) ®...
Page 12 The Hydraulic Assembly was designed to fold and unfold the TMA system as intended. 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 support any load. ...
Page 13: Assembly
Assembly Read and understand all instructions before beginning assembly. The weight of the vehicle shall be between 7300 kg [16,090 lbs. or greater] for tested 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.
Page 14: Preparation
Preparation 3A) Assembly 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 and trigger bolts, it can swing out in an approximate 4 m [13’] radius from either side of the truck.
Page 15 5) Underride Assembly With the truck at its actual driving weight and 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 11 Underride Assembly drawing on Page 15).
Page 16 Note: Left and right Underride Socket Receivers must be parallel with each other and level. Figure 11 Socket Hitch (Left Side Shown) www.energyabsorption.com Revision B June 2013 www.highwayguardrail.com All rights in copyright reserved...
Page 17 6) Socket Hitch Assembly Assemble the Socket Hitches and pin them into place using the 1” x 6-1/4" Hitch Pins and Retainer Pins shipped with the system. Figure 12 7) Mount the Support Brackets to Socket Receivers Mount the Support Brackets to the Socket Hitches as shown in Figure 13. Shims are used to level the system.
Page 18 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 Support Brackets (See Figure 14). The system is to be assembled while the Support Frame is collapsed and forklift slings are supporting the system.
Page 19 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 assembled, the system may shift to one side. Figure 15 www.energyabsorption.com Revision B June 2013...
Page 20 10) Assemble the Bottom Release Cable across the Arm Assemblies Verify that the Support Frame is fully extended. Assemble the Bottom Release Cable across Arm Assemblies (See Figure 16). Torque the nuts to 34±3 N-m (25±2 ft-Ib/300±24 in-lb) 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"...
Page 21 11) Assemble 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.
Page 22 13) Assemble and Adjust the Alignment Cables There are four Alignment Cables (two for each Bay). Attach the Alignment Cables as shown in Figure 18. 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 (A = B±5 mm [3/16"], C = D ±...
Page 23 15) Assemble Side Guides There are four Side Guides, two for Bay 1 and two for Bay 2. Attach guides as shown in Detail 19b and tighten bolts. 16) Adjust the Height and Levelness of the System Frame Verify that the system frame is 305±25 mm [12"±1"] from the ground at the front and rear of the system.
Page 24 17) Connect the Lights and Controls Locate the female TMA Socket Connector in a convenient location on the truck, so that lifting or lowering the TMA will not damage the electrical cable. Make sure that the electrical cord on the TMA can reach this location.
Page 25 18) Check the Hydraulic System The Hydraulic Assembly is pre-assembled and tested for operation and leaks before shipping. The pump is wired as shown on the Hydraulic Assembly drawing. Before operating the system, remove the vent plug from the fill port of the hydraulic pumps reservoir and check to see if the ®...
Page 26 19) Store the Jacks ® The Jacks are provided to facilitate the attachment and removal of a folded SS180 TMA from the truck. Retrieve Jacks set aside earlier and place them in the storage positions as shown in Figure 22. Figure 22 Warning : Jacks are to be removed from Arm Assemblies and stored when...
Page 27 21) Verify the Position of the Hydraulic/Electrical Lines Check the location of all the hydraulic and electrical lines to be sure they will not be damaged during folding and unfolding of the system. 22) Final Check of System Check the tightness of all of the fasteners. Double check the height and levelness of the system.
Page 28: Operation Instructions
Operation Instructions ® Before operating the SS180 TMA , thoroughly read and understand all Operation Instructions and safety sections of this Manual. Verify that the system is properly assembled and in working ® order. For proper impact performance, the TMA must be equipped with one SS180 TMA Type ®...
Page 29: Maintenance
Maintenance ® Before performing any maintenance on the SS180 TMA , thoroughly read and understand the Maintenance Section and the Safety Section of this Manual. I. Routine Maintenance Description Interval 1. Height and Levelness - The height and levelness of the system is important to its impact performance.
Page 30 Description Interval 8. Hydraulic Pump – Clean the outside of the Hydraulic Pump as required. Check 1 month fluid level and electrical connections. Remove all residue or debris on or around the pump. 9. Hydraulic Rams – Clean the Hydraulic Rams. Remove all residue or debris on 1 month or around the rams.
Page 31: Ii. Detaching And Attaching The System To The Truck
II. Detaching and Attaching the System to the Truck Detaching the System from the Truck Be sure the TMA and the truck are on level ground Ensure the system is in the folded position. Remove the Jacks from the storage location and assemble them on the Active Mounts as shown in Figures 24 &...
Page 32 Figure 27 Attaching the System to the Truck Move the TMA to truck. Insert the Socket Hitches into the Underride Socket Receivers and pin them into place using 1” x 6-1/4” pin and retainer pin. If alignment is off, making the assembly difﬁcult, it may be necessary to adjust Jacks or temporarily uncouple the Socket Hitches from the TMA.
Page 33: Iii. Lubrication
III. Lubrication When handling hydraulic fluid, use appropriate measures to prevent spillage. Clean any spillage immediately. Add Hydraulic Fluid Add hydraulic fluid as required and check the fluid level monthly. The reservoir is full ® when the fluid level is visible inside the fill port. Use only Dexron III ATF Hydraulic fluid.
Page 34: Iv. Technical Specifications
IV. Technical Specifications 1) Weight Cartridge A 157 lbs 71 kg Cartridge B 185 lbs 84 kg Frame Components 1639 lbs 758 kg Jacks 86 lbs 39 kg Total 2067 lbs 953 kg 2) Dimensions 2.24 m [7’-4”] Figure 30 Figure 31 4.27 m [14’-0”] Figure 32...
Page 35: Repair Instructions
Repair Instructions Post Impact Note: Only parts manufactured by Energy Absorption Systems shall be used to repair a damaged system. Failure to comply will result in reduced safety or damage to the system. Inspect the frame for bent parts. Replace any frame members that have been damaged. Do not attempt to weld or straighten parts.
Page 36 Warning: For proper system performance, only use Release Cables supplied by Energy Absorption Systems. Failure to use the correct equipment could lead to improper system performance. Assemble the Bottom Release Cable across the Arm Assemblies. Verify that the frame is fully extended. Attach the Bottom Release Cable across Arm Assemblies (See Figure 33).
Page 37 Assemble 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 N-m [90 ±...
Page 38 Reassemble and Adjust the Alignment Cables There are four Top Cables (two for each bay). Reattach the Alignment Cables as shown in Figure 35. Measure the diagonals of each bay and adjust the cables so that the diagonal measurements in each bay are the same (A = B ±5 mm [3/16"], C = D ±5 mm [3/16"]).
Page 39 Assemble and Tension the Cartridge Support Cables There are six Cartridge Support Cables. Pass the stud end of the cable through the corresponding cartridge chain loop and attach as shown in Figure 36 using a die spring, washer, and nuts. To properly tension the Cartridge Support Cables, tighten the ﬁrst nut on one cable until all slack is removed then tighten it until the tensioning springs have been compressed to 32 mm [1 1/4"] in height.
Page 40 Verify Position of Hydraulic / Electrical Lines Check the location of all the hydraulic and electrical lines to make sure they will not be damaged during the folding and unfolding of the system. Check System Lights for Proper Operation Verify that all the turn / stop / tail / reverse lights are working properly. Replace any bulbs that are out.
Page 41: Troubleshooting Guide
Troubleshooting Guide Safety Notes – See Troubleshooting Decision Trees on Page 50. Always wear eye protection when working on or around machinery or power tools, and while working with hydraulics. Do not attempt to control a hydraulic leak with your hand. High-pressure hydraulic fluid can puncture the skin and cause severe injury or death.
Page 42: Hydraulic Fluid
Hydraulic Fluid Purpose The main purpose of hydraulic fluid is to transfer power from the pump to the actuators. Secondary tasks include reducing metal on metal friction and preventing the formation of rust and sludge. These traits are achieved when the oil has a good lubricity (slipperiness), and with additives that inhibit oxidation and the entrainment of air and water in the oil, respectively.
Page 43: Hydraulic System
Hydraulic System Finding & Solving Problems Caution : Repair of hydraulic components shall only be performed by fully qualiﬁed individuals or hydraulic shops. In most cases, contact Energy Absorption Systems Customer Service Department for advice on repair or replacement of TMA parts. All replacement components must be approved for use or provided by Energy Absorption Systems to guarantee quality and correctness.
Page 44 3. System Operates Slowly or Cavitates  Low voltage: Verify voltages with DC voltmeter and check truck charging system.  Oil viscosity too high or cold oil: Allow oil to warm up before operating or replace with oil as necessary. ...
Page 45: Pressure Relief Valve
Pressure Relief Valve 1. Purpose A. Limit the maximum pressure in the hydraulic system to a safe level. B. Keep the motor amperage (and battery drain) at a minimum when the cylinders dead head (reach full stroke). 2. Adjusting Relief Valve (on the pump) Note: In general, do not adjust the relief valve.
Page 46 2. Repairing Counterbalance Valve A. Symptoms If the TMA exhibits a slow drifting of the folding bay when the pump is not running, one of the following may be true: 1) The counterbalance valve has become blocked by foreign debris in the oil line. 2) The piston ring seals inside the cylinders have been compromised.
Page 47: Hydraulic Cylinders
Hydraulic Cylinders ® Caution: Never allow anyone underneath the moving portion of the SS180 TMA . Block out all loads and disconnect electrical contact prior to performing any service on hydraulic equipment. 1. Troubleshooting If you suspect problems with the hydraulic cylinders on the TMA, you may need to remove the cylinders from the TMA for repair or replacement.
Page 48: Hydraulic System Priming
Hydraulic System Priming ® SS180 TMA hydraulic systems come direct from the factory primed and ready to operate. Priming should only be necessary after changing the oil or if you have recently repaired a leak. 1. Priming Process Systems that have been disassembled for repair require priming for proper performance. The hydraulic system is said to be primed when all hoses and cylinders are full of oil and the air has been expelled.
Page 49: Electrical Problems
3 Reservoir Problems A. Clear oil flowing out of the filler port usually means the reservoir was completely filled before the cylinders were fully collapsed (TMA unfolded). B. Foamy oil flowing out of the filler port points to one of the following: 1) Air present in the system;...
Page 50 2 DC Motors Before concluding that the hydraulic pump is malfunctioning:  Verify that all connections are secure and that the problem does not lie somewhere else.  Check ground.  Check brushes for wear, and replace if necessary. Note: A motor that does not turn in freezing weather could be caused by frozen water in the oil.
Page 51: Troubleshooting Decision Trees
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Page 54: Ss180 Tma ® 9182
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Page 56: Support Frame Assembly, 9182
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Page 57: Hydraulic Assembly, 9182
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Page 59: Hydraulic Pump Assembly, 9182
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Page 60: Electrical Box Hydraulic Pump
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Page 61: Underride Assembly Receiver, Tma
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Page 62: Attachment Assembly, 9180
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Page 63: Support Frame Preassembly, 9182, 24V
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Page 66: Lighting/Wiring Assembly, 9182
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Page 69: Support Frame Assembly, 8291
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Page 70: Hydraulic Cylinder Assembly, 9182
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Page 71 Notes: www.energyabsorption.com Revision B June 2013 www.highwayguardrail.com All rights in copyright reserved...
Page 72 2525 Stemmons Freeway Dallas, Texas 75207 888-323-6374 (USA only) 214-589-8140 (Outside USA) www.energyabsorption.com www.highwayguardrail.com...