TTMA-100 User's Manual
Contents
1. 000 eee nee 23 Axle Assembly Detached but No Damage to Trailer A Frame 24 Bursting Reaches Trailer A Frame serere onea CERRAR 25 Technical ASSISEABGGO oeisio aae S 25 Version 2 01 5 7 10 IV LIST OF FIGURES Figure Page l Schematic and Parts Layout of TIMA 100 2 20 2 2 TTMA 100 Wiring and Light Layout Lee 6 3 Photographs of RV and Heavy Duty Truck Plugs 7 4 Standard Wiring Layouts of RV and Heavy Duty Truck Plugs 7 5 Tobe Butstitie Process 3 4 ere doti aneksa net p ete ee hee a Taa 9 6 Photographs Illustrating the Bursting Process 9 7 Simulation of Vehicle Disengaging from a Trailer 10 8 TTMA 100 Impact Head ss tcccceee sonar wend BB SE ae o al 10 9 Final Rest Locations of Trailer TMA Systems 0 0 00 0 ee eee 12 10 Mounting Position of Lunette Ring 14 11 Bursting of Energy Absorbing Tube 0 20 12 Damage from Medium Speed Impact 0 0 eee eee eee 21 LIST OF TABLES Table Page l Technical Specifications 2420 410404464 i ekwa ia 205 0542050595524 Ru 3 2 Trailer Component and Parts List 4i uere ioe hee A a a RE Wn 6 3 Standard Wiring Layouts of RV and Heavy Duty Truck Plugs 8 4 Calculated Roll Ahead Distances for Shadow Vehicles 15 mph 16 5 Calculated Roll Ahead Distances for Barrier Vehicles 17 Version 2 01 5 7 10 V TTMA 100 DESI2. 5 16 Washer 5 16 Heavy Lock Washer 5 16 Grade 5 Hex Nut 1 2 x 2 Grade 5 Hex Bolt 1 2 Washer 1 2 Heavy Lock Washer 1 2 Grade 5 Hex Nut 9 16 x 3 Grade 5 Hex Bolt 9 16 SAE Washer 9 16 Heavy Lock Washer 9 16 Grade 5 Hex Nut 5 8 x 2 1 2 Grade 5 Hex Bolt 5 8 Washer 5 8 Heavy Lock Washer 5 8 Grade 5 Hex Nut Rear View of Light Bar 4 for Standard Lights and 2 Wires for 3 Wires from 7 Pin Connector S T T Light Power for Optional Arrow Board and Front Running Lights License Plate Light and Bracket F Red Marker A Lights p py omun EN m L Figure 2 TTMA 100 Wiring and Light Layout Version 2 01 5 7 10 6 WIRING INSTRUCTIONS The only item that may require attention of the user is the wiring of the trailer plug for connection to the tow vehicle There are two distinctly different wire plugs that are not compatible one is the RV plug and the other is the heavy duty truck plug It is necessary to first determine which type of plug is used with the tow vehicle 1 e an RV plug or a heavy duty truck plug The shapes of the two plug types are easier distinguishable as shown Figure 3 Also the RV plug uses blades and the truck plug uses round pins Note that the wiring scheme for the two plug types are totally different details of which are shown in the following tables Heavy Duty Truck Plug Figure 3 Photographs of RV and Heavy Duty Truck Plugs Figure 4 shows the different standa
3. Warning The TTMA 100 device does not have brakes All braking will be dependent on the tow vehicle Thus additional distance should be allowed for in braking and stopping of the tow vehicle Warning Do not use the TTMA 100 for hauling Objects on the trailer would be a hazard for vehicles impacting the TTMA 100 Warning Attachment of the TTMA 100 results in wider turns Drivers should be aware of this need for wider turning radius and adjust their driving accordingly Warning Attachment of any trailer TMA will result in different handling for the tow vehicle while backing up Drivers should be aware of this difference in vehicle handling characteristics and adjust their driving accordingly Warning Tow vehicles should be equipped with head rests lap belts and shoulder straps to provide proper crash protection for the driver and passengers Operators should adjust their head rest to contact the center of the head and should wear seat belt and shoulder strap at all times Warning Do not attach any item to the trailer or hitch without explicit approval from the manufacturer Contact Gregory Industries Technical Support for any question regarding attachments to the trailer TTMA TechnicalSupport gregorycorp com Phone 330 477 4800 This manual does not cover the operation of optional equipment such as arrow boards variable message sign boards and other approved hitch mounted equipment Please see appropriate operating manuals accomp
4. is appropriate As mentioned previously there are two distinctly different wire plugs that are not compatible one is the RV plug and the other is the heavy duty truck plug Make sure that you have the correct type of plug and that the plug is wired properly Also check to confirm that the lights are functioning properly prior to putting the TTMA into Service Check to make sure that the pintle hook is mounted properly Due to the wide variations in the frame structures of different tow vehicles there is not a single standard means of mounting the pintle hook assembly to the frame of the tow vehicle The major considerations in mounting of the pintle hook are the strength of the attachment and the mounting height The pintle hook assembly may be welded or bolted to the frame of the tow vehicle Regardless of the method of mounting or attachment to the tow vehicle it 1s critical to ensure that the strength of the attachment exceeds the rated capacity of the pintle hook with a wide margin of safety It is the obligation of the users to ensure that their particular pintle hook attachment system meets these strength requirements Version 2 01 5 7 10 15 There are two mounting positions for the lunette ring The nominal height of the upper mounting position is 28 inches and the nominal height for the lower position is 23 5 inches The TTMA 100 can accommodate a variation of up to 4 inches from the nominal height Hence when the lunette ring is in t
5. roll ahead distance would be 11 ft This is the distance from the front of the tow vehicle to the work area that should be provided Version 2 01 5 7 10 17 ATTACHMENT OF TTMA 100 TO TOW VEHICLE The TTMA 100 is attached to the tow vehicle via a pintle hook with a minimum capacity of 8 tons Warning Verify that the retaining pin for the pintle hook is properly locked to avoid accidental release of the pintle hook and the TTMA 100 Warning Make sure that the trailer lights are connected to the tow vehicle and are operating properly Warning Ensure that the safety chains properly secure the TTMA 100 to the tow vehicle Version 2 01 5 7 10 18 Table 4 Calculated Roll Ahead Distances for Moving Operation 15 mph Tow Traffic Vehicle Operating Impact Vehicle Weight Weight Speed 4500 Ib 10000 Ib 15000 Ib 24000 Ib 65 mph 119 ft 205 ft 261 ft 333 ft 10000 Ib 55 mph 97 ft 158 ft 198 ft 247 ft 45 mph 77 ft 118 ft 143 ft 174 ft 65 mh 93 ft 161 ft 211 fi 278 fi 150001b 55 mph 78 fi 127 ft 162 ft 209 fi 45 mph 65 ft 120 ft 150 ft Version 2 01 5 7 10 19 Table 5 Calculated Roll Ahead Distances for Stationarv Operation Tow Traffic Impact Vehicle Weight Vehicle Operating Weight Speed 4500 Ib 10000 Ib 15000 Ib 24000 Ib 10000 Ib 109 f 155 fi Version 2 01 5 7 10 20 OPERATION OF TTMA 100 Operation of the Trailer TMA is similar to that of other trailers Special attention should be given to the following issues
6. to trailer e Energy absorbing tubes Part C bursted but axle assembly Part E not detached e Energy absorbing tubes Part C bursted and axle assembly Part E detached but the bursting does not reach the trailer A frame Part D e Bursting reaches trailer A frame Detailed discussions on the required repair and replacement parts for each level of damage are presented as follows Version 2 01 5 7 10 25 No Apparent Damage to Trailer Inspect shear bolts Part a holding mandrels Part B in place with the energv absorbing tubes Part C If the shear bolts are bent or broken replace the bolts Inspect trailer lighting system for damage If the lighting system sustains only minor damage such as a broken lens or light bulb repair the damaged items which may be readily purchased from automotive supplies stores Make sure that all the lights are working properly prior to returning the trailer to service The following replacements parts are typically required for repair with this severity of damage sustained by the trailer Items in Package NHRC _ Shear bolts nuts washers and plastic guide plates Replacement of the shear bolts and plastic guide plates for the mandrels and repair of the lights may be conducted in the field by the user without involving the distributor or manufacturer Version 2 01 5 7 10 26 Axle Assembiv not Detached e Replace energy absorbing tubes Part C and shear bolts Parts a b c d
7. C a b c d g and h T100 LB Basic light system Version 2 01 5 7 10 27 Axle Assembly Detached but No Damage to Trailer A Frame Replace energy absorbing tubes Part C and shear bolts Parts a b c d g and h Inspect the breakaway axle assembly Part E for damage Replace axle if visibly bent If the axle is not damaged but the push rods are bent straighten out the push rods Make sure that the push rods are attached to the axle properly If the axle is not damaged but the fenders are severely bent replace only the fenders Inspect trailer lights for damage If the lighting system sustains only minor damage such as a broken lens or light bulb repair the damaged items which may be readily purchased from automotive supplies stores Make sure that all the lights are working properly prior to returning the trailer to service If the lighting system is severely damaged and no longer functional replace the entire lighting system Inspect impact head Part A and mandrels Parts B for damage For this severity of impact it is unusual for either the impact head or the mandrels to be damaged to the extent that they are no longer usable and needs to be replaced Nonetheless check to make sure that the impact head and mandrels are not severely bent and are properly aligned with the energy absorbing tubes Inspect lunette ring and pintle hook for damage For this severity of impact it is unusual for either the lunette ring or t
8. GN AND MAJOR COMPONENTS GENERAL A schematic of the TTMA 100 is shown in Figure 1 The major components of the TTMA 100 as shown in Figure 1 are as follows Component Description A Impact Head B Bursting Mandrel C First Energy Absorbing Tube D Trailer Frame E Axle Assembly F Plastic Guide Plates G End Caps H Hitch Assembly J Spacer K Jack Assembly Table 1 presents the technical specifications for the TTMA 100 including Overall dimensions Capacity of the trailer Capacity and mounting height of the pintle hook Information on the axle assembly Construction of the trailer Safety performance of trailer and Warranty Table 2 provides a list of parts with legends and part numbers Please refer to these part numbers and legends for ordering of spare parts Note that this is not a complete parts list Please inquire about the complete parts list and pricing from the manufacturer distributor or reseller of the TTMA 100 Figure 2 shows the schematic of the wiring details of the TTMA 100 Also detailed instructions on the wiring of the TTMA 100 are provided in a separate Wiring Manual and will not be repeated herein However the TTMA 100 is fully wired at the time of delivery The only item that may require attention of the user is the wiring of the trailer plug for connection to the tow vehicle More detailed instructions on are provided in the next section Version 2 01 5 7 10 1 8 2 4m 23 6 7 2m
9. Gregorv TTMA 100 Innovative Flexible and Affordable User s Manual Gregory Industries 4100 13th Street SW 9 Canton Ohio 44710 Phone 330 477 4800 WWW gregorvcorp com Mav 2010 FOREWORD Thank you for your purchase of the Trailer Truck Mounted Attenuator Model 100 from Gregory Industries herein referred to as the TTMA 100 The TTMA 100 is a Test Level 3 TL 3 crash cushion designed for use with a support truck in both stationary and moving work zones We are committed to providing our customers with highway safety products that have the best performance and value for your money as well as the highest level of customer service The TTMA 100 is one of the most innovative TMA s in the market offering a higher level of performance with heavy tow vehicles and requiring no modification of the tow vehicle It has successfully passed all required and optional crash tests set forth in NCHRP Report 350 and is fully approved for use on the National Highway System by the Federal Highway Administration This manual has been written to help you with the operation and maintenance of the TTMA 100 Please read and understand the recommendations contained in this manual thoroughly before use and keep it handy for future reference If you have any questions or comments regarding the operation and maintenance of this product please do not hesitate to contact us by telephone at 330 477 4800 e mail at RMauer gregorycorp com or conven
10. a b c d m a b c d JHE J 2 S aa li 1 u i 2 4 711mm Upper Position Figure 1 Schematic and Parts Layout of TTMA 100 Version 2 01 5 7 10 2 Table 1 TTMA 100 Technical Specifications Trailer e Overall Dimensions CUN No dee rr 23 6 CO VIG oue ace tr a a D epa Said T T 8 0 o Height to top of impact head uide vd dieto o o rode baked 31 Ge Heieht to top OF Wet Dat iii jis be dia a ted 37 o Ground Clearance to bottom of impact head 13 e Capacity o Trailer Weight w o Optional Equipment cece eee e eee eens 1 450 Ib o Approximate Tongue Weight w o Optional Equipment 190 Ib o Minimum support truck weight e eeeennnzennnnnkennnnz nani 10 000 Ib o Maximum support truck weight 0c cece ceccc eee e eee e eee eeeeenn ees Unlimited e Pintle Hook Haber e Ad Lunette ring with no other structural attachment 6 Capacity Ratins Minimum fi iii dia Kati i a caw v PEE ER 8 tons Oc Mounting TICIGHE 15 etiseet io ual genos met tidset iuuat pire ipis iode 19 5 32 0 e Breakaway Axle oM n Mr acttesuealeaace 1 750 Ib oM bn e A m PEE 205 75D15 SE TA ee 15x5JJ o Cold Tire Inflation Pressure 2 v orerehet ia ki bib n ww Ga ha 30 psi e Lighting rns T Integrated light bar jLis tine Stand oeuiescouo etd reader Eae tAR Ub O MU Eee FMVSS 108 Construction a CHRISTUM Open design e All energy absorbing components e eennne
11. act head shown in Figure 8 utilizes vertical steel angles to prevent impacting vehicles from sliding horizontally along the face of the trailer The impact head also utilizes steel channels with the legs oriented toward traffic to prevent vertical motion on the front of an impacting vehicle to eliminate the risk of diving under or riding over the attenuator The effectiveness of this mechanical interlock system can be illustrated by comparing final rest locations from NCHRP Report 350 pickup truck offset and angled tests tests 3 52 and 3 53 respectively for the three trailer TMA systems that have received FHWA approval Figure 9 shows the final rest locations of the three trailer TMA systems for the optional offset and angled tests as developed from FHWA approval letters Version 2 01 5 7 10 11 Figure 7 Simulation of Vehicle Disengaging from a Trailer Version 2 01 5 7 10 12 Figure 8 TTMA 100 Impact Head As shown in the figure the final rest positions for the three designs are not substantially different even though the T TMA 100 was tested under much more severe condition with the support truck blocked against forward movement The other two trailer TMA systems were tested with 20 000 Ib support trucks which were allowed to roll ahead during the crash Figure 9 clearly demonstrates that the TTMA 100 s simple pintle hook attachment and its vehicle capturing impact head are able to perform very well during offset and angled im
12. anying those devices for instructions Version 2 01 5 7 10 21 MAINTENANCE GUIDELINES Proper maintenance of the T TMA 100 is eritical to assure continuing safe operation and long term durabilitv of the device Even though the unit is galvanized the outside of the TTMA 100 should be washed periodically particularly during winter usage to eliminate salt and other road contaminants The inside of the frame should also be washed annually The end caps Item G can be removed to allow rinsing the inside of the frame Care should be taken with the wiring for the side marker lights during this process Note that all critical parts of the TTMA 100 are hot dip galvanized thus require minimal maintenance The following preventive maintenance schedule is recommended Baoe 3 Months 12 Months Item Function Required Weekly or 3 000 or 12 000 Each Use Miles Miles Lighting System Test that all lights are operational e Pintle Hook Check capacity and verify that the retaining pin is properly inserted Safty Chains Safty Chains Check tnat hy are propery attached that they are properly attached Check iat hey are propery tached ee f Mandrel Restraining Check that the restraining bolts are Bolts not missing bent or broken and tightened to the specified torque Tire ENTM IT I to 30 IT I Inspect for cracks dents distortion or other signs of wear Check that the splice bolts are not Splice Bolts missing bent or broken and tightened to t
13. ct speed and weights of the support truck and impacting vehicle The space between the support vehicle and the workers should exceed the roll ahead distance under the prevailing operating conditions Please follow the following steps to determine the appropriate roll ahead distance 1 Assess the nature of the operation 1 e moving or stationary operation In a moving operation the tow vehicle is moving at slow speed such as 15 mph In a stationery operation the shadow vehicle is stopped with the parking brakes on Use Table 4 for moving operations and Table 5 for stationary operations 2 Select the weight that best approximates the actual weight of the tow vehicle 10 000 15 000 24 000 40 000 60 000 or 80 000 Ib Note that the weight of the support truck should include the weights of items to be carried on the truck during the operation and the weight of the TTMA 100 3 Select the range of prevailing speed of the traffic at the work zone 45 55 or 65 mph 4 Select the weight of the impact vehicle to be contained 10 000 15 000 or 24 000 Ib 5 Select from the appropriate table the expected roll ahead distance For example If you are operating a tow vehicle with a gross weight of 15 000 Ib as a stopped shadow vehicle in an area where the operating traffic speed 1s 45 mph and there are few if any large trucks in the mix of traffic You would start with Table 5 select the appropriate values from above and determine that the maximum
14. de assessment of the trailer or required repair parts it would be most helpful if you can send photographs of the damaged trailer both showing the overall damages and damages to the specific areas or parts in question Version 2 01 5 7 10 20
15. e Inspect trailer lights for damage If the lighting system sustains only minor damage such as a broken lens or light bulb repair the damaged items which may be readily purchased from automotive supplies stores Make sure that all the lights are working properly prior to returning the trailer to service If the lighting system is severely damaged and no longer functional replace the entire lighting system e Inspect impact head Part A and mandrels Parts B for damage For this severity of impact it is unusual for either the impact head or the mandrels to be damaged to the extent that they are no longer usable and needs to be replaced Nonetheless check to make sure that the impact head and mandrels are not severely bent and are properly aligned with the energy absorbing tubes e Inspect lunette ring and pintle hook for damage For this severity of impact it is unusual for either the lunette ring or the pintle hook to be damaged to the extent that they are no longer usable and needs to be replaced Nonetheless check to make sure that the lunette ring and the pintle hook are not severely bent and can be hooked up properly e The following replacements parts are typically required for repair with this severity of damage sustained by the trailer It is recommended that such repairs be conducted by a manufacturer certified technician either at the facility of a distributor or at the facility of the user Items in Package LSRC 2 each Parts
16. he pintle hook to be damaged to the extent that they are no longer usable and needs to be replaced Nonetheless check to make sure that the lunette ring and the pintle hook are not severely bent and can be hooked up properly Version 2 01 5 7 10 28 e The following replacements parts are typically required for repair with this severity of damage It is recommended that such repairs be conducted by a manufacturer certified technician either at the facility of a distributor or at the facility of the user Items in Package LSRC 2 each Parts C a b c d g and h T100 AA Axle Assembly Part E TIOOEF Fenders 2 TIOO LB Basic lighting system Bursting Reaches Trailer A Frame For this high severity of impact it is not advisable to repair the trailer It is recommended that the user should consider purchasing a new trailer First the cost for the replacement parts would approach that of a new trailer Second extensive assembly would be required which may pose some problems for someone not familiar with the details of the trailer TECHNICAL ASSISTANCE If you have any questions regarding these inspections and assessment of damage to the trailer or required repair parts please contact your distributor or Gregory Industries Technical Help by telephone at 330 477 4800 e mail at TIMATechnicalSupport gregorycorp com or conventional mail at 4100 13th Street SW Canton Ohio 44710 In order for Technical assistance to better provi
17. he specified torque Wheel Nuts Nuts Tighten to manufacturer specified torque values NE CM ECE lo eea for corrosion or wear and lc Clean and lo Swali Check for cracks call Gregory Frame Welds Industries immediately for instruction if cracks are detected Version 2 01 5 7 10 22 REPAIR OF DAMAGED TRAILER IMPACT BX ERRANT VEHICLE The TTMA 100 is designed to reduce the impact severitv for both the occupants of the impacting vehicle and the tow vehicle by dissipating the impact energy in a gradual and controlled manner When the TTMA 100 is impacted by an errant vehicle the following sequence of events will occur all references to parts are depicted in Figure 1 and described in Table 2 1 For impacts of 5 mph or less which are generally termed as nuisance hits results from crash testing have shown that there 1s typically no damage to the energy absorption assembly of the TTMA 100 2 For higher speed impacts the shear bolts holding the mandrels Part a to the energy absorbing tubes will be sheared off thus releasing the mandrels to move forward 3 The mandrels Part B are pushed forward by the impacting vehicle and engage the ends of the energy absorbing tubes Part C 4 Asthe mandrels are pushed forward bursting of the energy absorbing tubes into four strips of metal is initiated as shown in Figure 11 thereby dissipating the energy from the impacting vehicle Version 2 01 5 7 10 23 Figure 11 Bursting
18. he upper position the TTMA 100 can be attached to a pintle hitch ranging from a minimum of 24 in to a maximum of 32 in in height When the lunette ring is in the lower position the TTMA 100 can be mounted on pintle hooks ranging from a minimum of 19 5 in to a maximum of 27 5 in in height Figure 10 shows the lunette ring in the lower position Note the bolt holes that can be used with the upper position Figure 10 Mounting Position of Lunette Ring MINIMUM AND MAXIMUM WEIGHT OF TOW VEHICLE The minimum recommended weight for the tow vehicle 1s 10 000 Ib gross vehicle weight GVW There is no specified maximum weight for the tow vehicle All TTMA 100 crash tests including the required and optional crash tests specified under NCHRP Report 350 were conducted with the Trailer TMA attached to a tow vehicle that was blocked against any forward movement Version 2 01 5 7 10 16 TOW VEHICLE ROLL AHEAD DISTANCES One of the major safety considerations 1s the roll ahead distance of the shadow vehicle when impacted by an errant vehicle When the tow vehicle with a TTMA 100 attached is impacted by an errant vehicle it will move forward It is therefore important to allow sufficient space between the tow vehicle and the workers so that the roll ahead of the tow vehicle would not pose a safety concern for the workers Tables 4 and 5 show the expected roll ahead distances for rolling and stationary tow vehicles respectively as a function of impa
19. hics shown in figure 5 illustrate this bursting process Figure 5 Tube Bursting Process The setup of the mandrel and the actual bursting process are demonstrated in the photographs shown in Figure 6 Tapered and dice sized The mandrel cracks the Close up view of mandrel mandrel inserted into the energy absorbing tube at and energy absorbing tube energy absorbing tube the corners and split it into four flat straps of metal Figure 6 Photographs Illustrating the Bursting Process Version 2 01 5 7 10 9 This bursting process 1 e cracking of the tube at the corners and splitting it into four straps of flat metal dissipates the energy of the impacting vehicle The level of energy dissipation can be regulated by using different thickness of tubing and scoring of the tube 1 e cutting grooves into the tubes at the corners reduce the energy dissipated during cracking By adjusting the level of energy dissipation and the lengths of the energy absorbing tubes the amount of energy dissipation and the rate of vehicle deceleration can be controlled to bring the impacting vehicle to a gradual and safe stop Tube bursting technology allows the TTMA 100 to use the trailer frame as the energy absorber thus eliminating the need for a separate energy absorbing material This simplifies the design and reduces the costs of the TTMA 100 Also the straps of metal have no structural strength and curl up and away from the impacting vehicle thus eli
20. hone 866 994 4929 Monday to Friday 9 00 a m to 5 00 p m Eastern Standard Time Fax 330 477 0626 Email TTMATechnicalSupport gregorycorp com Or TTMASales gregorycorp com Web Site http www gregorycorp com Mail 4100 13th Street SW Canton Ohio 44710 Version 2 01 5 7 10 ili TABLE OF CONTENTS Page PORE OR A a ganas a E li CUSTOMER SERVICE CONTACTS sartana eana a e a a ar iii TTMA 100 DESIGN AND MAJOR COMPONENTS leeeeeee rens l Ce L ao ase tak EE FEM M MU I Waris InsttHetlOfls ouo donee OR po REESE PRESERVAR MT HOV UEF OR b dita iiu eon oan A EA dts dE 9 T be Bu rstine Technology vua dae vae E biza ar EE wane ESOS 9 Pintle Hook AILULCBITIe DL ue is nata a ar RU e Ta e n IE e reis 10 OPERATION GUIDELINES eriei bbw bed cive pande head ee bles be oria hee Ree 13 PDA TA SCs OT 13 Minimum and Maximum Weight of Tow Vehicle 00 0 ee eee 14 Tow Vehicle Roll Ahead Distances eee 14 Attachment of TTMA 100 to Tow Vehicle 20 0 cee eee eee 15 Operation of TTMA 100 1 2 Ike RRREREReRLRPeXGReRERSGXIRbeNERCES 18 MAINTENANCE GUIDELINES bie ei ii a o e a A oan 19 REPAIRGUIDEDENE Sa i 4s 292 93 3 t SEES 20 lmpactox Errant Vehicle 2 44 2025454420R2450024203860045 a a 054 20 EA NIG ROPA is iet d dati rd ei tti de koe et tly ardt a 22 Damage Assessment and Repair Parts Packages LL Lee 22 No Apparent Damage to Trailer 6 000 22 Axle Assembly Not Detached
21. minating any hazard posed to the impacting vehicle Furthermore the straps of metal remain securely attached to the un bursted section of the tube Thus there are no detached elements that can be thrown forward and pose hazard to workers and adjacent traffic Version 2 01 5 7 10 10 PINTLE HOOK ATTACHMENT Another major improvement in TMA safety technology is the TTMA 100 s ability to rotate While competing trailer attenuators utilize rotational restraints to prevent the attenuator from rotating the T TMA 100 allows the trailer to rotate in order to keep the system aligned with the impacting vehicle to maximize energy dissipation It is this innovative approach to energy management that has allowed the TTMA 100 to become the only TMA system to successfully pass NCHRP Report 350 optional offset and angled tests when attached to a support truck blocked against forward motion The primary concern about allowing a trailer to rotate is that the impacting vehicle could push the trailer out of its path and directly strike the rear of the support truck However as shown in Figure 7 an impacting vehicle must slide along the trailer s impact face in order to disengage from the trailer The patented innovation that eliminates this risk is the way the TTMA 100 engages an impacting vehicle The T TMA 100 s impact plate is designed to capture the front of a vehicle and lock the trailer between the impacting vehicle and the tow vehicle The TTMA 100 s imp
22. nnnnennznnnnnnnnnn Heavv gage steel e All structural members in impact system cece cece eee ees Hot dipped galvanized AIS weudasteaaaavtiny ea iecie tik ika te haan Mid mounted breakaway DEMO A Full fender Version 2 01 5 7 10 3 Table 1 TTMA 100 Technical Specifications Continued Safety Performance NCHRP 50 required testi 22 seeders a bia ansia eb ib i b t FHWA approved e NCHRP 350 optional tests xasupits rein kd A vere ta bb ad FHWA approved e Support truck weight NCHRP Report 350 Tests 3 50 amp 3 51 Unlimited e Support truck weight NCHRP Report 350 Tests 3 52 amp 3 53 Unlimited e Energy Absorbing System sse eeeeneneennzznnnnnnnnna Bursting Tube Technology Warranty e Warranty against defects in material and workmanship One year Version 2 01 5 7 10 4 ITEM TRAILER COMPONENTS A B C D E F G H J K HARDWARE ITEMS a b C d C f g h J k m n O p q r Version 2 01 5 7 10 Table 2 Trailer Component And Parts List PART f B0516070A W0516 LW0516A N0516A B0816020A W0816 LW0816A N0816A B0916030A W09165 LW0916A N0916A B1016025A W1016 LWIOI6A NIO16A QUANTITY go 2 n HR me n N me DESCRIPTION Impact Head Bursting Mandrel First Stage Energy Absorber Trailer A Frame Axle Assembly Plastic Guide Plates End Caps Hitch Assembly Spacer Jack Assembly 5 16 x 7 Grade 5 Hex Bolt
23. of Energy Absorbing Tube 5 The sequence of events from here on depends on the speed and weight of the impacting vehicle Low speed impact a The impacting vehicle comes to a complete stop prior to the mandrels Part B reaching the breakaway axle Part E Medium speed impact a The mandrels Part B reach the breakaway axle and shear off the bolts connecting the axle assembly to the energy absorbing tube thus releasing the axle b The impact head Part A contacts the axle push rods and move the axle forward as the bursting process continues e The impacting vehicle comes to a complete stop prior to the mandrels reaching the splice connecting the energy absorbing tubes and the trailer frame Part D Figure 12 Damage from Medium Speed Impact High speed impact a The mandrels Part B continue past the splice connecting the energy absorbing tubes Part C and the trailer frame Part D The vehicle is eventually brought to a safe stop against the impact head or disengages from the impact head and spins out prior coming to a complete stop Version 2 01 5 7 10 24 TTMA 100 REPAIR For impacts requiring repair and replacement of parts on the TTMA 100 Gregory Industries Inc offers different parts packages depending on the extent of damage sustained by the unit These parts packages come with specific instructions regarding repair of your damaged trailer These parts packages are available through STI or a designated distribu
24. pacts even when attached to an infinitely heavy support truck In fact the combination of the simple pintle hook attachment and the trailer s connection with the support vehicle forces the trailer to rotate and align itself with the impacting force which would in turn maximize energy dissipation Hence the TTMA 100 provides maximum energy dissipation for impacts at any angle to provide maximum safety to both motorists and construction workers Version 2 01 5 7 10 13 Eeoran Traltar estimatod fran Final Resting Position for impact Vohicha Enorgy Absorption s Safe Stop Trailer TMA Final Resting Position for Impact Vehicle MA 100 Final Reating Position Tor Impact Vehicle TTMA Final Resting Position for Impact Vehicle Energy Absorption s Safe Stop Trailer THA l NCHRP Report 350 Optional Test 3 53 Figure 9 Final Rest Locations of Trailer TMA Systems Version 2 01 5 7 10 14 OPERATION GUIDELINES INITIAL SETUP This TTMA 100 should be delivered fully assembled If there are problems with the delivered trailer please contact Gregory Industries immediately There are three items that will require your attention prior to utilizing the trailer Check to make sure that there are no missing bolts and the bolts are tightened to the specific torque The following are the recommended torques to the bolts according to the bolt size Check to make sure that the wiring of the trailer plug for connection to the tow vehicle
25. rd wiring layouts for the RV plug and the heavy duty truck plug Details of the wiring layouts are shown in Table 3 RV Plug Heavy Duty Truck Plug Figure 4 Standard Wiring Layouts of RV and Heavy Duty Truck Plugs Version 2 01 5 7 10 7 Table 3 Standard Wiring Lavouts of RV and Heavv Dutv Truck Plugs RV Plugs with Separate Brake Wire Plug Labels Function Trailer Wire Color Number l Tail Marker lights Brown Brown 12V Power supply ON Heavv Dutv Truck Plugs Plug Labels Function Trailer Wire Color Brake light Tail Marker lights 12V Power supply Left Turn Yellow Red Right Turn Gre Brown O uA Note that the above wiring patterns represent standard wiring for the tow vehicle The above pattern may need to be adjusted if the tow vehicle does not use standard wiring Version 2 01 5 7 10 8 HOW IT WORKS TUBE BURSTING TECHNOLOGX The TTMA 100 uses a patented tube bursting technology to dissipate the energy of the impacting vehicle The basic concept is quite simple When a tapered mandrel with a square cross section 1s forced into a square tube with smaller inside dimensions the mandrel pushes against the inside of the tube The outward forces on the inside of the tube concentrate stresses in the corners creating a controlled cracking of the steel As the mandrel proceeds forward the tube is split into four flat straps of metal that are curled outward by the flared portion of the mandrel The grap
26. tional mail at 4100 13th Street SW Canton Ohio 44710 This manual is divided into five sections e TIMA Design and Major Components An overview of the TTMA 100 design and major components are presented in this section including the product specifications and parts list Also instructions for wiring the trailer plug for connection to the tow vehicle are provided e How It Works A brief explanation of the innovative features of the TTMA 100 and how it works to absorb and dissipate the energy from an impacting vehicle are outlined and illustrated 1n this section e Operation Guidelines Guidelines pertaining to the operation of the TTMA 100 are presented in this section such as minimum support truck weight roll ahead distances connections and other operational items e Maintenance Guidelines Considerations on the routine maintenance of the TTMA 100 are outlined in this section e Repair of Damaged Trailer Discussion of impacts by an errant vehicle and the associated repair and replacement of trailer parts are presented in this section Version 2 01 5 7 10 li CUSTOMER SERVICE CONTACTS Gregory Industries is committed to providing the best service and care to our customers You are automatically registered with your purchase and you will be notified of any future changes or upgrades to the TTMA 100 If you have any comments or questions regarding this product please contact us via telephone e mail or conventional mail Telep
27. tor in your area FOR A LIMITED TIME REBATES OF 20 PERCENT OFF THE MSRP WILL BE OFFERED ON REPLACEMENT PARTS IN EXCHANGE FOR DOCUMENTATION OF THE IMPACTS AND OR ACCIDENTS To facilitate our evaluation of the in service performance of the TTMA 100 we offer for a limited time a rebate equal to 20 percent off the MSRP of the repair parts packages if complete records of the incident are forwarded to Gregory Industries within 30 days of the occurrence These records include a completed Gregory Industries incident report available on our web site www gregorycorp com or by calling 330 477 4800 and one or more of the following items photographs of damaged trailer photographs of the impacting and tow vehicles and police accident report if available DAMAGE ASSESSMENT AND REPAIR PARTS PACKAGES Inspect the TTMA 100 to assess the extent of the damage and the necessary repairs Due to the simple design of the TTMA 100 damages to the trailers are usually very evident Nevertheless the trailer should be thoroughly inspected to assure that it is in proper working order prior to returning the trailer into service The extent of damage to the trailer will vary greatly depending on the nature and severity of the impact It would not possible to cover all situations that could potentially be encountered in real world crashes Thus the instructions are presented in general terms for the following levels of damage to the trailer e No apparent damage
Download Pdf Manuals
Related Search