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Trinity Highway SST Product Description Assembly Manual

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Summary of Contents for Trinity Highway SST

  • Page 2 SST information available to Trinity Highway at the time of printing. We reserve the right to make changes at any time. Please contact Trinity Highway to confirm that you are referring to the most current instructions.

  • Page 3: Table Of Contents

    Table of Contents Customer Service Contacts ......................3  Important Introductory Notes ......................3  Safety Symbols ..........................4  Safety Rules for Assembly ......................4  Limitations and Warnings ......................5  Trailer Description ......................... 6  Trailer Safety Instructions ......................10  Electric Brakes Safety Instruction ....................11  Tires &...

  • Page 4: Customer Service Contacts

    Customer Service Contacts Trinity Highway is committed to the highest level of customer service. Feedback regarding the ® , its assembly procedures, supporting documentation, and performance is always welcome. Additional information can be obtained from the contact information below: Trinity Highway...

  • Page 5: Safety Symbols

    SST . Additional copies of this manual are immediately available from Trinity Highway by calling (888) 323-6374 or by email at TrinityHighway.com/Contact. Please contact Trinity Highway if you have any questions ®...

  • Page 6: Limitations And Warnings

    350. These tests are designed to evaluate product performance by simulating those impacts outlined by involving a typical range of vehicles on roadways, from lightweight cars (approx. 1800 ® lb. [820kg]) to full size pickup trucks (approx. 4400 lb. [2000 kg]).. The SST is certified to the Test Level(s) shown below:...

  • Page 7: Trailer Description

    Trailer Description ® The SST has been 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 it is impacted within the applicable NCHRP Report 350 criteria.
  • Page 8 TRUCK CYLINDER MOUNT (SUPPLIED WITH TRAILER) Figure 3 *Trinity Highway recommends the use of a pintle hook with a rating of 20 tons (40,000 lbs.) or greater. Important: Check for signs of wear at the Pintle Hook and Receiver as part of normal vehicle maintenance procedures.
  • Page 9 3. Make sure all twenty-four (24) pivot pins are in position and that all retaining pins are assembled correctly (Figure 5). ® 4. The SST is designed to absorb a crash and PIVOT PIN to support its own weight if impacted within the applicable NCHRP Report 350 criteria.
  • Page 10 TMA before use on the highways. ® 8. Make sure that the performance and safety of the SST is not impaired by damage or corrosion.

  • Page 11: Trailer Safety Instructions

    Jack must be fully rotated 90 degrees to the travel position. ® 2. The driver should be extra cautious while backing the truck with the SST so that injury and/or damage will not result.

  • Page 12: Electric Brakes Safety Instruction

    SST unfit for protection. ® 1. In case of a connection failure, the SST is equipped with a breakaway cable that activates the electric brakes by pulling the breakaway pin mechanism. 2. It is the responsibility of the truck operator to set the attachment point of the breakaway cable on the truck, so that the trailer brakes do not activate during normal towing.

  • Page 13: Tires & Axle

    6. Wheels and tires offset is the distance from the mounting surface to the centerline of the ® tire. The SST axle bearing sets are designed for wheels with 0 to 1/2” [13 mm] offset. Exceeding this offset will shorten bearing life and may lead to bearing failure.

  • Page 14: Controlling Skid Distance And Roll-Ahead

    Controlling Skid Distance and Roll-Ahead ® The use of a on the back of a truck 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. ...

  • Page 15: Assembly

    Assembly Read and understand all instructions before beginning assembly. Important: The truck weight shall be 9,920 lbs [4500 kg] minimum. The system must be attached to the truck by pintle hook and cylinder attachment brackets. The truck frame must be suitable and accessible for mounting a TMA system. If there are any questions regarding the suitability, contact the Customer Service Department for assistance.

  • Page 16: Preparation

    Preparation 3A) Assembly must be performed on a level surface The TMA framework is very heavy and pivots in several areas. Until the framework is secured with the cables, it can swing out in an approximate 7’ [2 m] radius from either side of the trailer axle.

  • Page 17: Bolt-On Procedures

    Bolt-on Procedures a. Start by cutting two (2) 4" x 4" x 1/2" steel angle the height of the C channel. b. Measure and mark the angle for four (4) 1-1/16” holes (Figure 11). The spacing needs to be equal distances vertical and horizontal. Make sure the holes are spaced at least 2- 1/16”...
  • Page 18 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 pintle hook. Attach the pintle eye to the trailer at the same height with the trailer frame at 12" ± 2" [305 ± 50 mm] above the ground, front and rear. Note: The truck’s springs may settle with the weight of the TMA.
  • Page 19 Warning: Until the cables are attached, the system may shift to one side (Figure 15). ALIGNMENT CABLES ALIGNMENT CABLES Figure 15 8) Attach Fenders Attach Fenders as shown below. Do not tighten bolts yet. Attach nylon ties through hole in bracket to secure light cable.
  • Page 20 9) Mount Wheels Attach wheels as shown below using the torque sequence and stages for tightening. Lug nut torque requirements: REMOVE DUST CAP A. Start all nuts by hand to prevent WHEEL cross threading. WITH TIRE B. Torque nuts in stages as follows: 1st stage 20-25 lbf-ft LUG NUT...
  • Page 21 12) Assemble Side Guides There are four Side Guides, two for Bay 1 and two for Bay 2. Attach Side Guides as shown in Detail 19a, Detail 19c & Detail 19d and tighten bolts. BOLT, HX, 3/8X1, G5, P FTB ST 1/4X5 3/4, W/HOLES, PT WASHER, LOCK, 3/8, P BOLT, HX, 3/8X1, G5, P NUT, HX, 3/8, P...
  • Page 22 Warning: It is the operator’s responsibility to only use Release Cables supplied by Trinity Highway. Failure to use authorized parts could result in serious injury or death in the event of a vehicle impact with a system. 14) Attach the Bottom Release Cable across the Arm Assemblies.
  • Page 23 15) Verify Pintle Eye Height Verify that the system frame is 12”±2” [305±50 mm] from the ground at the front and rear of the system. It may be necessary to adjust the pintle eye and trailer Cylinder Brackets to the correct height (Figure 22).
  • Page 24 17) Attach the Cartridge Support Cables There are four Cartridge Support Cables. Attach the cables as shown in Detail 24a, Detail 24b, Detail 24c & Detail 24d. Attach thimble end of all Cartridge Support Cables to the Mid Frame using the provided shackles (Detail 24a & Detail 24b). Pass the stud end of the cable through the corresponding cartridge chain loop, and attach as shown in Detail 24c &...
  • Page 25 CABLE, 1/4X79, STUD W/THIMBLE WASHER, FLAT,1/2X1 3/8,P CABLE, 1/4X79, STUD W/THIMBLE DIE SPRING 1 1/4 ODX5/8X1 1/2 WASHER, FLAT,1/2X1 3/8,P WASHER, FLAT, 1/2X1 3/8, P DIE SPRING 1 1/4 ODX5/8X1 1/2 WASHER, FLAT, 1/2X1 3/8, P CABLE, 1/4X79,STUD W/THIMBLE CABLE, 1/4X79,STUD W/THIMBLE LICENSE PLATE LIGHT Detail 24c...
  • Page 26 Lock each cable in place using the second nut as a “jam” nut. ALIGNMENT CABLES ALIGNMENT CABLES Figure 25 23) Assemble Spare Tire Carrier (Purchase Option) ® Using the hardware provided, attach Spare Tire Carrier to the SST Tongue Assembly (Figure 26). LOCK WASHERS NUTS SPARE TIRE CARRIER SPACER...
  • Page 27 Locate the female TMA socket connector in a convenient location on the truck. Make sure that the electrical cord on the TMA can reach this location (View A-A). ® The Truck battery must be of the proper voltage. The SST is available in 12 volt and 24 volt systems.
  • Page 28 Cartridge B, in their proper positions as shown in Figure 23 (p. 22). Warning: For proper system performance, do not mount anything to the mid ® frame. The added weight could cause the SST not to perform as designed. Mount Arrowboard and spare tire to the TMA tongue. TrinityHighway.com...

  • Page 29: Assembly Checklist (Complete And File)

    Location: ____________________________________________ SST sits level with the bottom of the frame at 12” (+/- 2”) above grade (p. 9) Truck is properly setup to withstand force of impact and attachment of trailer (p. 16- Minimum 20-ton pintle and anti-rotation cylinder mounts are properly installed (p. 18) SST is fully assembled, cartridges attached and all cables assembled and properly tensioned/aligned (p.

  • Page 30: Trailer Operations

    The hydraulic cylinders must be connected during shadow or barrier vehicle operations. ® The cylinders must be attached anytime the SST is deployed. The cylinders are connected directly to the trailer hitch support frame and the rear of the truck.
  • Page 31 Typically, TMA’s are rigidly ® connected to the rear of the truck. The hydraulic system on the SST performs this function during an impact.

  • Page 32: Attaching The Tma

    Attaching the TMA ® 1. Connect the SST by moving it toward the truck and aligning the pintle eye to the pintle hook using the Jack. Close the pintle hook and insert the retaining pin. 2. Lower and rotate the Jack to the stored position.

  • Page 33: Trip Preparation Checklist

    Trip Preparation Checklist 1. Verify pintle hook and eye connection. 2. Check tire pressure and wear. 3. Verify breakaway brakes are operational. 4. Check trailer height: 12” ± 2” [305 mm ± 50 mm]. 5. Ensure hydraulic cylinders are attached properly to tow vehicle. 6.

  • Page 34: Inspection Schedule

    Inspection Schedule TrinityHighway.com Revision J January 2020...

  • Page 35: Routine Maintenance

    Routine Maintenance 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 fluid level monthly. The reservoir is full when the fluid level is between 1/2 and 3/4 on the sight gauge with the hydraulic cylinders in the stored position.
  • Page 36 Replace the adjusting hole cover and lower the wheel to the ground. Repeat the procedure above for the other brake. ® 5. The SST brakes must be inspected and serviced immediately if loss of performance is indicated. a. Magnets and shoes must be changed when they become excessively worn or scored, a condition that can reduce vehicle stopping.

  • Page 37: Electrical

    3. Wheel nuts should be torqued after each wheel removal, re-torque after 50 miles [80 km] and approximately 3,000 miles [4830 km] frequency thereafter. ® 4. The SST tire size is ST20575D14. The bias ply tire provides stiffer side walls and more resistance to sway.

  • Page 38: Axle

    Axle Important: Refer to the Dexter Axle “Operation Maintenance Service Manual” (LIT-001-00) dexteraxle.com/products/torsion-axles/Torflex-light-duty complete Torflex axle and brake servicing information. Warning: ® ® Never weld to the Torflex axle. The Torflex axle contains rubber cords to provide system suspension and can be damaged by heat generated from welding on the bracket or tube.

  • Page 39: Storage

    7. When adding grease, always use a hand grease gun. An automatic grease gun will destroy the hub's inner seal. 8. Hub removal: a. Elevate and support the trailer by the frame. b. Remove the wheel. ® c. Remove the Bearing Buddy d.

  • Page 40: Technical Specifications

    Technical Specifications 1) Weight Cartridge A Cartridge B Frame Components 2251 1021 kg Jack Total 2606 1182 kg 2) Dimensions Figure 37 1’-0” [± 2” [303 mm ±50 mm] 19’-3” [5.87 m] Figure 38 TrinityHighway.com Revision J January 2020...

  • Page 41: Repair Instructions

    Part # 606699B (2 per TMA) Important: Trinity Highway makes no recommendation whether use or reuse of any part of the system is appropriate or acceptable following an impact. It is the sole responsibility of the local highway authority and its engineers to make that determination.
  • Page 42 4) Remove crushed Cartridges and spent Release Cables from system. Important: Do not attempt to repair a damaged Cartridge. For full impact capacity, the Cartridges will need to be replaced even if slightly crushed. 5) Attach the Bottom Release Cable across the Arm Assemblies. Verify that the frame is extended as far as it will go.
  • Page 43 6) Attach Cartridges 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 90 ± 5 lbf-ft [120 N-m ± 7]. Repeat procedure for Cartridge A (Figure 40). 7) Attach the Top Release Cables across the Arm Assemblies Attach the top release cables across the Arm Assemblies (Figure 39).
  • Page 44 9) Reattach and Adjust the Alignment Cables There are four (4) Alignment Cables (two for each bay). Reattach the Alignment Cables as shown in Figure 41. Measure the diagonals of each bay and adjust the cables so that the diagonal measurements in each bay are the same (A=B ± 3/16” [5 mm], C=D ± 3/16” [5 mm]). Lock each cable in place using the second nut as a “jam”...
  • Page 45 12) Adjust the height and level of the system frame Verify the frame is 12" ± 2" [305 ± 50 mm] from the ground at the front and rear. 13) Verify position of hydraulic / electrical lines Check the location of all the hydraulic and electrical lines ensure they will not be damaged. 14) Check system lights for proper operation Verify that all lights are working properly.

  • Page 46: Troubleshooting Guide

    TMA should arise. This guide is meant to be an aide for performing minor repairs, not a detailed repair manual. Note: For any problems not listed here, please contact Trinity Highway at (888) 323-6374. Test Equipment The following is a recommended list of test equipment required to troubleshoot electrical systems.
  • Page 47 2) Selecting fluids for applications outside ATF'S operating temperature range Note: Consult with the Trinity Highway Customer Service Department when considering and before changing hydraulic fluid to assure compatibility with existing components at (888) 323- 6374.
  • Page 48 Repair of hydraulic components shall only be performed by fully qualified individuals or hydraulic shops. In most cases, the customer should contact Trinity Highway Customer Service Department for advice on repair or replacement of TMA parts. All replacement components must be approved for use or provided by Trinity Highway to guarantee quality and correctness.
  • Page 49 Reservoir Note: Do not use a solid plug or fill cap without a filter/breather element, or damage will be caused to the reservoir. 1) USE RECOMMENDED FLUID: ® Fill the reservoir with Dexron III fluid (Hydraulic Fluid section p.46). 2) PROPER FILLING: A.

  • Page 50: Electrical Problems

    Electrical Problems 1) ELECTRICAL SHORTS OR OPEN CIRCUITS A. Shorts occur when wires with power come in contact with a ground. A short will cause a fuse to blow or a wire to burn. Look for pinched or cut wires. B.

  • Page 51: Quick Reference Troubleshooting Guide

    Quick Reference Troubleshooting Guide TrinityHighway.com Revision J January 2020...
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  • Page 54: Tma

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  • Page 56: Support Frame Assembly

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  • Page 58: Hydraulic Assembly

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  • Page 60: Misc. Hardware

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  • Page 63: Lighting Assembly

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