Related Manuals for Trinity Highway INGAL SS180 M
Summary of Contents for Trinity Highway INGAL SS180 M
- Page 1 PN 626198 Revision B March 2020 SS180 SS180 M Product Description Assembly Manual TRINITY HIGHWAY ® Ahead of the Curve...
- Page 2 SS180 information available to Trinity Highway at the time of printing. We reserve the right to make changes at any time. Please contact Ingal Civil Products to confirm that you are referring to the most current instructions.
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Page 3: Table Of Contents
Table of Contents Customer Service Contacts......................3 Important Introductory Notes ...................... 3 System Overview........................4 Safety Symbols........................... 4 Safety Rules for Assembly ......................4 Limitations and Warnings ......................5 ® Know Your SS180 M System ....................6 Assembly ...........................11 Recommended Tools ......................11 Preparation ..........................12 Operation Instructions ...................... -
Page 4: Customer Service Contacts
Customer Service Contacts Trinity Highway is committed to the highest level of customer service. Feedback regarding the ® SS180 M 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
M. Additional copies of this manual are available from Trinity Highway by calling (888) 323-6374 or contact us using TrinityHighway.com/Contact. Please contact Trinity Highway if you have any questions concerning the information in this manual. Important: It is the responsibility of the installer to use proper safety precautions when operating power equipment, mixing chemicals, and when moving heavy ®... -
Page 6: Limitations And Warnings
MASH as approved by the FHWA. Trinity Highway expressly disclaims any warranty 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 assembled in consultation with Trinity Highway or by third parties. -
Page 7: Know Your Ss180 ® M System
Know Your SS180 M System ® For the safety of the operator, the operator shall stand at the rear of the truck, on the curb side, (Figure 2). When tilting the TMA, care shall be taken to stay clear of all moving parts. TYPE A CARTRIDGE TYPE B CARTRIDGE SUPPORT STRUCTURE... - Page 8 ® SS180 shall be rigidly fastened to the truck. In the horizontal position, the bottom of the shall be 11" to 13" [280 to 330 mm] from the ground to the bottom of the Rear Impact Face (Figure 3). Warning: ®...
- Page 9 ® The SS180 M is intended to support its own weight and dissipate the kinetic energy of errant vehicles per MASH 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 (Figures 4 & 5). Figure 4 Figure 5 4.
- Page 10 Ballast and other heavy objects MUST BE ADEQUATELY ANCHORED to the truck to prevent shifting during an impact (Figure 6). The force exerted on the tie-down straps could be 20 times the weight of the ballast. Figure 6 8. The agency responsible for the truck shall inspect it for adequate operator safety equipment (e.g., seat belts, head rests, etc.) ®...
- Page 11 The Hydraulic Assembly was designed to fold and unfold the TMA. Any other use may be hazardous to people or equipment. a. Do not use the system to push a load. b. Do not use the raised end of the system to support any load. c.
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Page 12: Assembly
Assembly Read and understand all instructions before beginning assembly. The weight of the vehicle shall be between 6,120 kg and 11,340 kg for tested performance. Refer to the Australian Design rules – Vehicle Standards Bulletin 6 (VSB6) for the Australian regulations regarding chassis modifications and attachments. -
Page 13: Preparation
Preparation 1A) Assembly Must Be Performed On Level Surface The system’s framework is very heavy. 1B) 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 minimum weight, add it at this time. - Page 14 3) 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 711mm ± 25 mm is required. Spacer Tubes may be added to the bottom of the frame to achieve this height (p.
- Page 15 An example of modified Underride Socket Receiver mounts are shown below. They are a suggested guide on how to install the Underride Socket Receivers without welding to the vehicle chassis. Installation of the Underride Socket Receivers may vary on each vehicle due to chassis, suspension and body variations.
- Page 16 Important: Left and right Underride Socket Receivers must be parallel and level with each other. TRUCK FRAME TRUCK FRAME SPACER TUBES FLUSH WITH FRAME END UNDERRIDE SOCKET RECEIVER UNDERRIDE SOCKET RECEIVER WITHOUT SPACERS WITH SPACERS Figure 10 – Socket Hitch Left Side Shown 4) - Socket Hitch Assembly Insert the Socket Hitches and pin them into place using the 1”...
- Page 17 5) Mount the Support Brackets to Socket Receivers Mount the Support Brackets to the Socket Hitches as shown in Figure 12. Shims are used to level the system. It is recommended that two (2) 1/4" Shims per side be used initially. This may be adjusted once the system is assembled.
- Page 18 7) Adjust the Height of the System Frame Verify that the system frame is 305mm ± 25 mm from the ground at the rear of the system. It may be necessary to add shims to the Socket Hitch in order to level the Frame (Figures 3 & 12). 8) 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.
- Page 19 9) 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 (pp. 53-56). Before operating the system, check to see if the reservoir has adequate fluid. The fluid level of a folded system should be approximately half full.
- Page 20 10) Store the Jacks ® The Jacks are provided to facilitate the attachment and removal of a folded SS180 M from the truck. Retrieve Jacks set aside earlier and place them in a storage location (Figure 16). Figure 16 Important : Unbolt, remove, and store Jacks when the TMA is in service.
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Page 21: Operation Instructions
Operation Instructions ® Before operating the SS180 M, 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 Type A Cartridge ®... -
Page 22: Maintenance
Maintenance Before performing any maintenance on the SS180 M, thoroughly read and understand the ® Maintenance Section and the Safety Section of this manual. Routine Maintenance Description Interval 1. Height - The height of the system is important to its impact performance. As Required Check regularly and adjust as necessary (Figure 18). -
Page 23: Detaching And Attaching The System
Detaching and Attaching the System 1) Detaching the System from the Truck Ensure the TMA and the truck are on level ground System is in the folded position Attach Jacks as shown in Figures 19 & 20 Crank the Jacks until the weight of the system is supported Figure 19 Unplug the light harness and disconnect the positive and negative cables from the pump. - Page 24 1-1/4” x 7” HITCH PIN Figure 22 2) Attaching the System to the Truck Roll the TMA to the truck. Insert the Socket Hitches into the Underride Socket Receivers and pin them into place using 1 x 6-3/4” pin and retainer pin (Figure 21). If alignment is off, making the assembly difficult, it may be necessary to adjust Jacks or temporarily uncouple the Socket Hitches from the TMA.
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Page 25: Lubrication
Lubrication When handling hydraulic fluid, use appropriate measures to prevent spillage. Clean any spillage immediately. 1) Add Hydraulic Fluid Add hydraulic fluid as required and check the fluid level monthly. The reservoir is full when the fluid level is filled to the location indicated below when the system is unfolded. Use only Dexron™... -
Page 26: Technical Specifications
Technical Specifications 1) Weight Type A Cartridge Type B Cartridge Frame Components Jacks Total 2) Dimensions Figure 25 Figure 26 14’-7” [4.46 m] Figure 27 3) Replacement Parts Refer to the drawing package for replacement part numbers and descriptions. Contact customer service for replacement parts (p. -
Page 27: Repair Instructions
Important: Only the correct parts manufactured specifically for this product by Trinity Highway may be used to repair a damaged system. Failure to comply may result in damage to the system and/or an untested effect on the impacting vehicle, to and including injury or death. - Page 28 Adjust the Height and Levelness of the System Frame Verify that the System Frame is 305mm ± 25 mm from the ground at the front and rear of the system. It may be necessary to add shims to the Socket Hitches in order to adjust the levelness of the Cartridge (Figure 28).
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Page 29: Troubleshooting Guide
Use extreme caution when working on hydraulic systems. In general, consult Trinity Highway Customer Service if problems with operating or repairing the TMA arise (p. 3). This guide is meant to be an aid for performing minor repairs, not a detailed repair manual. -
Page 30: 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 31: Hydraulic System Check
Leakage: Check all components, verify tightness of fittings, and inspect hoses for wear while system is idle. Replace damaged hoses or fittings. Excessive loading (especially any features not originally installed by Trinity Highway): Remove excessive load. trinityhighway.com... - Page 32 Low voltage at pump: Check battery and wiring Incorrect, low volume, or dirty oil: Add or change oil as necessary Excessive internal leakage (pump): Replace the pump (contact Trinity Highway). Restriction in lines or cylinder check valves: Remove load on the cylinder, clean lines or valves, and replace hoses if necessary.
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Page 33: Pressure Relief Valve
Motor RPM is fast b. System will not fold (cylinder will not extend). c. Excessive turbulence in reservoir. Important: Contact the Trinity Highway Customer Service Department for all replacement parts or components. Warning: Do not exceed pressure rating for hydraulic system components. -
Page 34: Counterbalance Valve
Refer to the following section on the Hydraulic Cylinder. Important: If the counterbalance valve has failed in some other way, do not attempt to repair it. Replace it with a new valve by contacting Trinity Highway Customer Service Department (p. 3). trinityhighway.com... -
Page 35: Hydraulic Cylinder
Hydraulic Cylinder Warning: ® Never allow anyone underneath the moving portion of the SS180 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 cylinder on the TMA, you may need to remove the cylinder from the TMA for repair or replacement. -
Page 36: Hydraulic System Priming
Hydraulic System Priming ® SS180 M 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 the cylinder are full of oil and the air has been expelled. -
Page 37: Electrical Problems
3 Reservoir Problems A. Clear oil flowing out of the filler port usually means the reservoir was completely filled before the cylinder was 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 38 A motor that does not turn in freezing weather may indicate frozen water in hydraulic system. If it has been verified that the pump is defective; contact Trinity Highway Customer Service Department for input as to your specific application (p. 3).
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Page 39: Troubleshooting Decision Trees And System Drawings
Troubleshooting Decision Trees and System Drawings trinityhighway.com Revision A November 2019... - Page 40 trinityhighway.com Revision A November 2019...
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Page 41: Ss180 ® M
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Page 42: Support Frame Assembly
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Page 45: Cartridge A
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Page 46: Cartridge B
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Page 47: Miscellaneous Part Assembly
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Page 48: Impact Face Assembly
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Page 49: Hydraulic Control Assembly
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Page 52: Hydraulic Cylinder Assembly
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Page 53: Pump Assembly
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Page 54: Electrical Box, Hydraulic
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Page 58: Led Lighting Assembly
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Page 61: Underride Assembly
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Page 62: Attachment Assembly
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