Trinity Highway SST Manuale utente

SST

is a registered trademark of Energy Absorption Systems, Inc. Part No. 115313

TrinityHighway.com 1 Revision J January 2020

SST

Trailer

The SST

Trailer (“SST

”) has been tested pursuant to National Cooperative Highway Research

Program (“NCHRP”) Report 350 specifications. The SST

has been deemed eligible for federal-aid

reimbursement on the National Highway System by the Federal Highway Administration (“FHWA”).

Product Description

Assembly Manual

2525 N. Stemmons Freeway

Dallas, Texas 75207

Warning:

The local highway authority, distributors, owners, contractors,

lessors, and lessees are RESPONSIBLE for the assembly, maintenance, and

repair of the SST

. Failure to fulfill these RESPONSIBILITIES with respect to

the assembly, maintenance, and repair of the SST

could result in serious

injury or death.

Important:

These instructions are for standard assembly specified by the

appropriate highway authority. In the event the specified system assembly,

maintenance, or repair would require a deviation from standard assembly

parameters, contact a Trinity Highway representative.

This manual must be available to the worker overseeing and/or assembling the product at

all times. For additional copies, contact Trinity Highway at (888) 323-6374 or visit

TrinityHighway.com.

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 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.

TrinityHighway.com 2 Revision J January 2020

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 & Axle................................................................................................................................. 12

Controlling Skid Distance and Roll-Ahead .................................................................................. 13

Assembly .................................................................................................................................... 14

Preparation............................................................................................................................ 15

Welding Procedures.............................................................................................................. 15

Bolt-on Procedures ............................................................................................................... 16

Assembly Checklist (Complete and File) .................................................................................... 28

Trailer Operations ....................................................................................................................... 29

Attaching the TMA ...................................................................................................................... 31

Trip Preparation Checklist........................................................................................................... 32

Detaching TMA ........................................................................................................................... 32

Inspection Schedule.................................................................................................................... 33

Routine Maintenance .................................................................................................................. 34

Lubrication............................................................................................................................. 34

Brakes................................................................................................................................... 34

Electrical................................................................................................................................ 36

Tires & Wheels...................................................................................................................... 36

Wheel Attachment................................................................................................................. 36

Axle ....................................................................................................................................... 37

Storage.................................................................................................................................. 38

Technical Specifications ............................................................................................................. 39

Repair Instructions ...................................................................................................................... 40

Troubleshooting Guide................................................................................................................ 45

Electrical Problems ............................................................................................................... 49

Quick Reference Troubleshooting Guide.................................................................................... 50

TMA....................................................................................................................................... 53

Support Frame Assembly

...................................................................................................... 55

Hydraulic Assembly............................................................................................................... 57

Misc. Hardware ..................................................................................................................... 59

Lighting Assembly................................................................................................................. 62

TrinityHighway.com 3 Revision J January 2020

Customer Service Contacts

Trinity Highway is committed to the highest level of customer service. Feedback regarding the

SST

, its assembly procedures, supporting documentation, and performance is always welcome.

Additional information can be obtained from the contact information below:

Trinity Highway

Telephone (888) 323-6374 (USA)

+1 312 467 6750 (International)

E-mail TrinityHighway.com/Contact

Website TrinityHighway.com

Important Introductory Notes

Proper assembly, deployment, and future maintenance of the SST

is critical to achieve

performance of the system that has been evaluated and deemed eligible for reimbursement by

the FHWA per NCHRP Report 350. These instructions should be read in their entirety and

understood before assembling the SST

. These instructions are to be used only in conjunction

with the assembly of the SST

and are for standard assemblies only as specified by the applicable

highway authority. If you need additional information, or have questions about the SST

system,

please contact the highway authority that has planned and specified this assembly and, if needed,

contact Trinity Highway’s Customer Service Department. This product must be deployed in the

location specified by the appropriate highway authority. If there are deviations, alterations, or

departures from the assembly instructions specified in this manual, then the device may not

perform as tested.

Important:

DO NOT use any component part that has not been specifically

specified herein for this system during assembly or repair.

This product has been specified for use by the appropriate highway authority and has been

provided to that user who has unique knowledge of how this system is to be assembled. No

person should be permitted to assemble, maintain, or repair this system that does not possess

the unique knowledge described above. These instructions are intended for an individual qualified

to both read and accurately interpret them as written. These instructions are intended only for an

individual experienced and skilled in the assembly of highway products that are specified and

selected by the highway authority.

A manufacturer’s drawing package will be supplied by Trinity Highway upon request. Details

contained in the drawing package must be studied thoroughly by a qualified individual who is

skilled in interpreting them before the start of any product assembly.

TrinityHighway.com 4 Revision J January 2020

Safety Symbols

This section describes safety symbols that may appear in the

SST

manual. Read the manual for

complete safety, assembly, operating, maintenance, repair, and service information.

Symbol Meaning

Safety Alert Symbol:

Indicates Danger, Warning, Caution, or Important. Failure

to read and follow the Danger, Warning, Caution, or Important indicators could

result in serious injury or death to the workers and/or bystanders.

Warning:

Read safety instructions thoroughly and follow the suggested safe

practices before assembling, maintaining, or repairing the SST

. Failure to follow

this warning can result in serious injury or death in the event of a vehicle impact

with a system.

Important:

Please keep up-to-date instructions for later use and reference by

anyone involved in the assembly of the product.

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 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

concerning the information in this manual or about the SST

Important:

It is the responsibility of the installer to use proper safety precautions

when operating power equipment and when moving heavy equipment or SST

components. Hand, eye, foot, and back protection shall be used.

Warning:

Safety measures incorporating appropriate traffic control devices

specified by the highway authority must be used to protect all personnel while the

TMA is in use. The traffic control plan established by the highway authority must

always be observed when deploying this product.

TrinityHighway.com 5 Revision J January 2020

Limitations and Warnings

Trinity Highway contracts with FHWA approved testing facilities to perform crash tests, evaluation

of tests, and submit of the results to the FHWA for review.

The SST

was tested to meet the impact criteria, requirements and guidelines of NCHRP Report

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:

Test Level 3: 62 mph [100 kph]

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 to the test matrix criteria of NCHRP Report 350 as approved by

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.

The SST

is intended to be assembled, delineated, and maintained within specific state and

federal guidelines. It is important for the highway authority specifying the use of a highway product

to select the most appropriate product configuration for its site specifications. The customer

should be careful to properly select, assemble, and maintain the product. Site lay out, vehicle

population type; speed, traffic direction, and visibility are important elements that require

evaluation in the selection of a highway product.

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.

Warning:

Do not assemble, maintain, or repair the SST

until you have read this

manual thoroughly and completely understand it. Ensure that all Danger, Warning,

Caution, and Important statements within the manual are completely followed.

Please call Trinity Highway Customer Service if you do not understand these

instructions (p. 3).

TrinityHighway.com 6 Revision J January 2020

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. The system attaches to the rear of a truck and may be used in

stationary applications, such as a truck blocking a work zone or mobile operations, such as

striping, sweeping, plowing, etc.

The SST

consists of the following basic components: A collapsible frame assembly, two

crushable cartridges, an impact face, cylinder hitch assembly, intermediate frame suspension,

wheels and tires (Figures 1 and 2).

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.

Figure 1

Figure 2

CARTRIDGE B CARTRIDGE A

IMPACT FACE

TRUCK

PINTLE HOOK

CYLINDER ASSEMBLY

SUSPENSION, AXLE, WHEELS

TrinityHighway.com 7 Revision J January 2020

Warning: Ensure that no one is near or behind the SST®when in operation.

Warning: Do not operate the SST®while wearing loose fitting clothing which may

become entangled during operation.

Warning: Deploy appropriate traffic-control devices while the SST®is in

operation.

1. It is the operator’s responsibility to ensure hydraulic cylinders are attached to the truck

hydraulic brackets and locked in place with the hairpin cotter pins when the SST®is in the

work zone or being used for protection (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.

REAR OF SUPPORT TRUCK

TRUCK MOUNTING PLATE

(ATTACHED DIRECTLY TO TRUCK FRAME RAILS)

HYDRAULIC CYLINDER

TRUCK PINTLE HOOK (*20 TON OR GREATER CAPACITY)

TRUCK CYLINDER MOUNT

(SUPPLIED WITH TRAILER)

Figure 3

TrinityHighway.com 8 Revision J January 2020

2. The TMA should be securely fastened to the truck. In the horizontal position on level

ground, the bottom of the TMA should be 12” ± 2” [305 mm ± 50 mm] from the ground and

level (Figure 4).

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

to support its own weight if impacted within

the applicable NCHRP Report 350 criteria. Do

not drag the TMA or place anything on its top:

damage may result (Figures 6 and 7).

Caution:

Do not sit, stand or lean on any part of the TMA.

Figure 6

Figure 7

Figure 4

12” ± 2” [305mm ± 50 mm]

Figure 5

PIVOT PIN

RETAINING PIN

TrinityHighway.com 9 Revision J January 2020

5. Ballast and other heavy objects MUST BE ADEQUATELY ANCHORED to the truck to

prevent shifting during an impact. The force on the tie-down straps could be 20 times the

weight of the ballast (Figure 8).

6. The agency or highway authority responsible for the truck should inspect it for adequate

operator safety equipment (e.g., seat belts, head rests, etc.).

7. Make certain that the applicable highway authority’s current specifications as to TMA

reflectivity are evaluated and complied with. It is the operator’s responsibility to make sure

that all applicable reflectivity standards are met and the appropriate taping of indicators is

placed on the TMA before use on the highways.

8. Make sure that the performance and safety of the SST

is not impaired by damage or

corrosion.

Warning:

Failure to comply with these instructions can result in improper TMA

performance and possible personal injury. This TMA is intended to be used as an

impact attenuator on the rear of trucks which meet the minimum requirements for

this system (p. 13).

9. Regular maintenance of the SST

is important for safe use. Refer to the Routine

Maintenance section of this manual for additional information (p. 33).

a. Regular inspection of frame members, cartridges, and pins is necessary to ensure

proper system performance.

b. Regular inspection of hoses, cylinders, and tires is important. A broken or damaged

hose or cylinder will cause the system to function improperly. Low tire pressure could

cause a blowout.

c. Keep electrical connections clean to prevent arcing. Clean any hydraulic spills or

leakage to prevent bodily injury, fire, etc.

10. This system is a crash cushion and is therefore used in high traffic areas as directed by

the appropriate highway authority. Stay clear of traffic whenever possible. If an accident

is to occur, even during an NCHRP Report 350 criteria impact, there may be fragments

from the truck or impacting vehicle that could cause injury.

11. Do not use any part of the TMA for towing or hauling a load.

12. Ensure your truck is appropriate for attaching an SST

. See the Assembly section on page

14 for further details.

13. Mindfulness when moving hydraulic cylinders is encouraged so as not to pinch hands or

drop cylinders on your feet.

14. When cylinders are not in use, make sure they are stored on the cylinder storage pins with

the lynch pins fastened to keep the cylinders secure.

15. Periodically check the hydraulic fluid level.

Figure 8

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