Trinity SS180 TMA 9182 User manual

SS180 TMA®
(Model 9182)
.
Product Description
Assembly Manual
Revision B June 2013Part No. 115359B

Part No. 115359B
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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. This system has been accepted by the Federal
Highway Administration for use on the national highway system under strict
criteria utilized by that agency. Energy Absorption Systems representatives are
available for consultation if required.
This Manual must be available to the worker overseeing and/or assembling the product
at all times. For additional copies, contact Energy Absorption Systems at [phone]
or download from websites below.
The instructions contained in this Manual supersede all previous information and Manuals. All
information, illustrations, and specifications in this Manual are based on the latest SS180 TMA
®
system information available to Energy Absorption Systems at the time of printing. We reserve
the right to make changes at any time. Please contact Energy Absorption Systems to confirm
that you are referring to the most current instructions.

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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................................................................................................7
Assembly...................................................................................................................................12
Preparation..........................................................................................................................13
Operation Instructions ...............................................................................................................27
Folding and Unfolding the System.......................................................................................27
Maintenance..............................................................................................................................28
I. Routine Maintenance........................................................................................................28
II. Detaching and Attaching the System to the Truck...........................................................30
III. Lubrication......................................................................................................................32
IV. Technical Specifications.................................................................................................33
Repair Instructions.....................................................................................................................34
Post Impact..........................................................................................................................34
Troubleshooting Guide..............................................................................................................40
Hydraulic Fluid.....................................................................................................................41
Hydraulic System.................................................................................................................42
Pressure Relief Valve..........................................................................................................44
Counterbalance Valve.........................................................................................................44
Hydraulic Cylinders..............................................................................................................46
Hydraulic System Priming ...................................................................................................47
Reservoir.............................................................................................................................47
Electrical Problems..............................................................................................................48
Troubleshooting Decision Trees..........................................................................................50
SS180 TMA®9182 ....................................................................................................................53
Support Frame Assembly, 9182................................................................................................55
Hydraulic Assembly, 9182.........................................................................................................56
Hydraulic Pump Assembly, 9182...............................................................................................58
Electrical Box Hydraulic Pump ..................................................................................................59
Underride Assembly Receiver, TMA .........................................................................................60
Attachment Assembly, 9180......................................................................................................61
Support Frame Preassembly, 9182, 24V ..................................................................................62
Lighting/Wiring Assembly, 9182................................................................................................65
Support Frame Assembly, 8291................................................................................................68
Hydraulic Cylinder Assembly, 9182...........................................................................................69

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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:
Energy Absorption Systems:
Telephone: [phone] (USA Only)
[phone] (USA or International)
E-mail: [email protected]
Internet: Energy Absorption Systems
Trinity Highway Products, LLC http://www.energyabsorption.com http://www.highwayguardrail.com
Important Introductory Notes
Proper assembly of the SS180 TMA®system is essential to achieve performance of the system
under appropriate federal and state criteria. These instructions should be read in their entirety
and understood before assembling the SS180 TMA®system. These instructions are to be used
only in conjunction with the assembly of the SS180 TMA®system and are for standard
assemblies only as specified by the applicable highway authority. In the event your system
assembly requires or involves deviation from standard parameters or, during the assembly
process a question arises, please contact the appropriate highway authority that specified this
system at this particular location for guidance. Energy Absorption Systems is available for
consultation with that agency. These instructions are intended for an individual who is qualified
to both read and accurately interpret them as written. They are intended for the individual who
is experienced and skilled in the assembly of highway products which are specified and
selected by the highway authority. If there are deviations, alterations, or departures from the
assembly protocol specified in this Manual, the device may not perform as it was tested and
accepted.
A set of product drawings will be supplied by Energy Absorption Systems, when requested.
The drawings will be for each section of the assembly. These drawings should be reviewed and
studied thoroughly by a qualified individual who is skilled in interpreting them before the start of
any assembly.

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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. as a truck block
in a work zone) and mobile operations (e.g. striping, sweeping, plowing, etc.).
Important: Read safety instructions thoroughly and follow the assembly
directions and suggested safe practices before assembling, maintaining, or
repairing the SS180 TMA®system. Failure to follow this warning can result in
serious injury or death to the worker and/or bystanders. It further compromises
the acceptance of this system by the FHWA. Please keep these instructions for
later use and reference by anyone involved in the assembly of the product. Use
the traffic control plan set for the by the highway authority in charge of this work
area.
Warning: Ensure that all of the SS180 TMA®system Warnings, Cautions, and
Important Statements within the SS180 TMA®Manual are completely followed.
Failure to follow this warning could result in serious injury or death in the event
of a collision.
Recommended Safety Rules for Assembly
* Important Safety Instructions *
This Manual must be kept in a location where it is readily available to persons who are skilled
and experienced in the assembly, maintenance, or repair of the SS180 TMA®system.
Additional copies of this Manual are immediately available from Energy Absorption Systems by
calling [phone] or by email at custom[email protected]. This Manual
may also be downloaded directly from the websites indicated below. Please contact Energy
Absorption Systems if you have any questions concerning the information in this Manual or
about the SS180 TMA®system.
Always use appropriate safety precautions when operating power equipment, mixing
chemicals, and when moving heavy equipment or the SS180 TMA®system components.
Gloves, safety goggles, safety toe shoes, and back protection shall be used.
Safety measures incorporating traffic control devices specified by the highway authority must
be used to provide safety for personnel while at the assembly, maintenance, or repair site.

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Safety Symbols
This section describes the safety symbols that appear in this SS180 TMA®Manual. Read the
Manual for complete safety, assembly, operating, maintenance, repair, and service information.
Symbol Meaning
Safety Alert Symbol: Indicates Danger, Warning, Important, or Caution.
Failure to read and follow the Danger, Warning, Safety, or Caution indicators
could result in serious injury or death to worker(s) and/or bystanders.
Warnings and Cautions
Read all instructions before assembling, maintaining, or repairing the SS180 TMA®system.
Warning: Do not assemble, maintain, or repair the SS180 TMA®system until
you have read this Manual thoroughly and completely understand it. Ensure that
all Warnings, Cautions, and Important Statements within the Manual are
completely followed. Please call Energy Absorption Systems at [phone]
if you do not understand these instructions. Failure to follow this warning could
result in serious injury or death in the event of a collision.
Warning: Safety measures incorporating appropriate traffic control devices
specified by the highway authority must be used to protect all personnel while at
the assembly, maintenance, or repair site. Failure to follow this warning could
result in serious injury or death in the event of a collision.
Warning: Use only Energy Absorption Systems parts that are specified herein
for the SS180 TMA®system for assembling, maintaining, or repairing the SS180
TMA®system. 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. Failure to follow this
warning could result in serious injury or death in the event of a vehicle impact
with an UNACCEPTED system.
Warning: Do NOT modify the SS180 TMA®system in any way. Failure to
follow this warning could result in serious injury or death in the event of a
collision.
Warning: Ensure that the SS180 TMA®system and delineation used meet all
federal, state, specifying agency, and local specifications. Failure to follow this
warning could result in serious injury or death in the event of a collision.
Warning: Ensure that your assembly meets all appropriate Manual on Uniform
Traffic Control Devices (MUTCD) and local standards. Failure to follow this
warning could result in serious injury or death in the event of a collision.

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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.
The SS180 TMA®system was tested to meet the impact criteria, requirements, and guidelines
of NCHRP Report 350. These tests, specifically set forth by FHWA, evaluate product
performance by simulating those impacts outlined by NCHRP Report 350 involving a typical
range of vehicles on our roadways, from lightweight cars (approx. 820kg [1800 lb.]) to full size
pickup trucks (approx. 2000 kg [4400 lb.]) as specified by the FHWA. A product can be certified
for multiple Test Levels. The SS180 TMA®is certified to the Test Level as shown below:
Test Level 3: 100 km/h [62 mph]
These FHWA directed tests are not intended to represent the performance of systems
when impacted by every vehicle type or every impact condition existing on the roadway.
This system is tested only to the test matrix criteria of NCHRP 350 as approved by
FHWA.
Energy Absorption Systems does not represent nor warrant that the results of these controlled
tests show that vehicle impacts with the products would necessarily avoid injury to person(s) or
property. Impacts that exceed the specifications of the system may not result in acceptable
crash performance as outlined in NCHRP Report 350, relative to structural adequacy, occupant
risk and vehicle trajectory. Energy Absorption Systems expressly disclaims any warrant or
liability for injury or damage to persons or property resulting from any impact, collision, or
harmful contact with products, other vehicles, or nearby hazards or objects by any vehicle,
object or person, whether or not the products were installed by or under the direction of Energy
Absorption Systems or by third parties.
SS180 TMA®system is intended to be assembled, delineated, and maintained in accordance
with specific State and Federal guidelines. Energy Absorption Systems offers a reflective
delineator panel for its TMA line of products. However, the material is only intended to
supplement delineation required by the Department of Transportation’s “Manual on Uniform
Traffic Control Devices” (MUTCD). The appropriate highway authority approved engineer
should be careful to properly select, assemble, and maintain the product. Careful evaluation of
the speed, traffic direction, and visibility are some of the elements that require evaluation in the
proper selection of a safety appurtenance by the appropriate specifying highway authority.
After an impact occurs, the product must be repaired to its original condition as soon as
possible. When a safety product is impacted, it is mandatory that the highway authority inspect
all the components for damage and repair and/or replace components as necessary. If the
system is not repairable, a complete system replacement is required.

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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
Figure 2
STAND HERE (FOR CONTROLS
ON RIGHT SIDE OF TRUCK)
CONTROLS CAN BE ON EITHER
SIDE OF TRUCK
MOVING PARTS DURING FULL
DESIGN IMPACTS AND
FOLDING OPERATION
CONTROLS
TRUCK
STAND HERE (FOR CONTROLS
ON LEFT SIDE OF TRUCK)
CONTROLS CAN BE ON EITHER
SIDE OF TRUCK
CARTRIDGE
CARTRIDGE

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1. 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.
Figure 3
2. Jacks shall be used to support the TMA when it is detached from 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).
3. Make sure all pivot pins are in position and that all retaining pins are assembled
correctly (See Figure 4).
Figure 4
The SS180 TMA
®
shall be deployed in the unfolded position: At all times while operating as
either a Barrier Vehicle or Shadow Vehicle.
The SS180 TMA
®
shall be in the "unfolded" position when: transporting short distances at a
low speed, transporting at a speed much lower than adjacent traffic, and transporting in areas
where vehicle ride characteristics and maneuverability are maintainable.
The SS180 TMA
®
shall 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.

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4. 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 & 6).
Figure 5
Figure 6
5. Before raising or lowering the TMA, the operator shall be fully trained as to its proper
operation. All operators shall fully understand the contents of this Manual prior to
operating the system. The operator should never stand under the TMA when it is
raised, or attempting to lower it.
6. Folding the TMA provides the best maneuverability and driving characteristics. It is
advisable, during restricted city driving and high-speed travel, to have the TMA folded to
its storage 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. It is required that the support vehicle be stopped
for TMA folding and unfolding.
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.

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8. 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.)
10. It is recommended that the SS180 TMA
®
be mounted to trucks weighing 7300 kg
[16,090 lbs.] or greater.
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 unpredictable
TMA performance and possible personal injury or death. This TMA is intended
to be used as an impact attenuator on the rear of trucks which meet the
specifications for this system. The TMA shall not be used for any other purpose.
12. Regular maintenance of the TMA is critical for proper operation. 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 hydraulic hoses is critical. A broken or damaged hose will
cause the system to operate uncontrollably.
Warning: In the event of a hydraulic pressure loss during operation, release
button and repair immediately (REPEAT whenever necessary).
Keep electrical connections at the Pump Motor/Solenoid clean to prevent arcing.
Clean any hydraulic spills or leakage to prevent bodily injury, fire, etc.
13. The driver shall be cautious while making turns with the TMA in the unfolded position.
The TMA extends beyond the end of the truck and will swing wide while turning.
14. This system is an impact attenuator and is therefore used in high risk areas. Stay clear
of traffic whenever possible. If the system is impacted, there may be fragments from the
truck, TMA, or impacting vehicle that could cause injury.

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15. 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.
Do not use any part of the TMA for towing or hauling a load. This could cause the lift
mechanism to malfunction and permanently damage the system.
Do not use the TMA as a ladder.
16. The system must be in the unfolded position to perform properly during an impact. Do
not leave the system raised, even slightly, when positioned at a job site.
17. Be sure the truck meets the minimum requirements for attaching a TMA (See the
assembly section for further details).
Definitions: 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.
THE USE OF A TMA ON THE BACK OF A TRUCK
WILL:
Gradually decelerate the impacting vehicle
Help protect the occupants of the impacting vehicle
Help protect the barrier/shadow vehicle occupants
Help reduce damage to the barrier/shadow vehicle
WILL NOT:
Affect the skid (roll ahead) distance of an impacted truck.
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.
Required Truck + TMA weight: 8250 kg [18,190 lbs.] or greater

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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. Use AWS qualified welders
to ensure durable attachment of the TMA system. Disconnect the truck battery before any
welding on truck or TMA.
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 input as to
your specific application.
1) Shipping list
Check the shipping list against the actual parts to make sure all items were received.
2) Assemble Necessary tools:
Recommended Tools
Welding equipment (for 1/2” plate) GMAW or SMAW
Cutting torch
Hammer
Drift pin or alignment pin (12” long)
Tape measure
1/2” drive socket wrench w/6” extension
1/2” drive sockets (9/16”, 1-1/8”, 1-1/2”, 9/16” deep well)
Open end wrenches –(9/16”, 1-1/8”, 1-1/2”)
12” crescent wrenches – (2)
Marking implement (pencil, soap stone)
Floor jack
Drill for 13/16" diameter bit
13/16" diameter bit and pilot drill bit for same
Center punch
Torque wrench - 120 N-m [90 ft-lb]
Hydraulic fluid (use Dexron®III fluid only) - Shipped with system
Forklift
Work gloves and other personal protection equipment as required
Bubble level
Note: The above list of tools is a general recommendation. Depending on specific site
conditions and the complexity of the assembly specified by the appropriate highway
authority, additional or fewer tools may be required. Decisions as to what tools are
needed to perform the job are entirely within the discretion of the specifying highway
authority and the authority’s selected contractor performing the assembly of the system
at the authority’s specified assembly site.

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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. A level surface is required to maintain control of the framework
when it is being extended to its full length.
3B) Truck ballast
Use a bubble level to verify that the truck is parked on a level surface. The truck shall 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 943 kg [2080 lbs.] 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 shall be
followed completely.
4) Check for interference
Before attempting to assemble the Underride, check for interference concerns.
The System folds such that the Impact Face is very close to the mounting location (See Figure
30 Page 33). 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 (See Figure
12) and check for interference concerns. Interference concerns with tail lights, springs, dump
bodies (in the folded or unfolded positions), etc., shall be corrected before proceeding.
Figure 8

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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).
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 distance from the back end of the frame forward to the rear-most leaf spring hanger.
Look for any 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 15).
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
Assembly is flush with the end of frame. If spacers are required, weld them to the Socket
Receiver 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 and Spacer at the rear-most location (See Underride Assembly
drawing). The top of the Socket Receiver shall be 711±25mm [28±1”] from the level ground for
proper system height (See Figure 12).
Weld the Socket Receiver 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. Disconnect truck battery before welding.
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.
Figure 9 Figure 10

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Note: Left and right Underride Socket Receivers
must be parallel with each other and level.
Figure 11 Socket Hitch (Left Side Shown)
711 mm ± 25 mm [28± 1”]

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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. It is recommended that 1/2" Shims be used initially. This may be adjusted
once the system is assembled.
Figure 13

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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. Use the upper set of mounting holes for the
attachment.
Figure 14

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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

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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" nuts.
Figure 16
TORQUE TO 34 N-m
(
-0, +3
)
[25 ft - Ib
(
-0, +2
)
]
TORQUE TO 34 N-m
(
-0, +3
)
[25 ft - Ib
(
-0, +2
)
]
RELEASE CABLE