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www.trinityhighway.com 2 Revision I September 2017

Table of Contents

Customer Service Contacts .......................................................................................................... 3 Important Introductory Notes ........................................................................................................ 3 Safety Rules for Assembly ............................................................................................................ 4 Safety Symbols ............................................................................................................................. 5 Limitations and Warnings .............................................................................................................. 6 Trailer Description ......................................................................................................................... 7 Safety Instructions ........................................................................................................................ 8 Trailer Safety Instructions ........................................................................................................... 11 Electric Brakes Safety Instruction ............................................................................................... 12 Tires & Axle ................................................................................................................................. 13 Controlling Skid Distance (Roll Ahead) ....................................................................................... 14 Assembly .................................................................................................................................... 15 

Preparation............................................................................................................................ 16 Welding Procedures .............................................................................................................. 16 Bolt-on Procedures ............................................................................................................... 17 

Trailer Operations ....................................................................................................................... 29 Attaching the SST® 9000 ............................................................................................................ 31 Trip Preparation Checklist ........................................................................................................... 32 Detaching the SST® 9000 ........................................................................................................... 32 Routine Maintenance .................................................................................................................. 33 

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 SST® TMA 9000 .................................................................................................................... 50 Support Frame Assembly SST® 9000 ................................................................................... 52 Hydraulic Assembly SST® 9000 ............................................................................................ 54 Misc. Hardware SST® 9000 .................................................................................................. 56 Lighting Assembly SST® 9000 .............................................................................................. 59 

Quick Reference Troubleshooting Guide .................................................................................... 64 

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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® 9000 system was tested to meet the impact criteria, requirements and guidelines of NCHRP Report 350. NCHRP Report 350 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. 820kg [1800 lb.]) to full size pickup trucks (approx. 2000 kg [4400 lb.]). The SST® 9000 system is certified to the Test Level(s) 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 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® 9000 system 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 debris from the impact should be removed from the area immediately and the specified highway product should be evaluated and restored to its original specified condition or replaced as soon as possible.

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www.trinityhighway.com 14 Revision I September 2017

Controlling Skid Distance (Roll Ahead)

THE USE OF A TMA 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 lighter weight barrier/shadow vehicles.

• Skid distance is reduced and is more consistent when heavier shadow vehicles are used.

• Required truck weight: 4500 kg [9,920 lbs] minimum. Roll-Ahead Distance for Shadow Vehicles

Weight of Shadow Vehicle (Moving)

Prevailing Speed km/h

[mph]

Weight of Impacting Vehicle to be Contained*

2,040 kg [4,500 lbs]

4,536 kg [10,000 lbs]

6,804 kg [15,000 lbs]

10,886 kg [24,000 lbs]

4,536 kg [10,000 lbs] 96-105 [60-65] 30 m [100 ft] 53 m [175 ft] 69 m [225 ft] 84 m [275 ft] 80-88 [50-55] 30 m [100 ft] 46 m [150 ft] 53 m [175 ft] 60 m [200 ft]

72 [45] 23 m [75 ft] 30 m [100 ft] 38 m [125 ft] 46 m [150 ft]

6,804 kg [15,000 lbs] 96-105 [60-65] 23 m [75 ft] 46 m [150 ft] 53 m [175 ft] 69 m [225 ft] 80-88 [50-55] 23 m [75 ft] 38 m [125 ft] 46 m [150 ft] 53 m [175 ft]

72 [45] 15 m [50 ft] 30 m [100 ft] 30 m [100 ft] 30 m [100 ft]

10,886 kg [24,000 lbs] 96-105 [60-65] 23 m [75 ft] 30 m [100 ft] 46 m [150 ft] 53 m [175 ft] 80-88 [50-55] 15 m [50 ft] 23 m [75 ft] 30 m [100 ft] 46 m [150 ft]

72 [45] 15 m [50 ft] 23 m [75 ft] 23 m [75 ft] 30 m [100 ft]

Note: Distances are applicable for shadow vehicle speeds up to 25 km/h [15 mph].

Roll-Ahead Distance for Barrier Vehicles

Weight of Barrier Vehicle (Stationary)

Prevailing Speed km/h

[mph]

Weight of Impacting Vehicle to be Contained*

2,040 kg [4,500 lbs]

4,536 kg [10,000 lbs]

6,804 kg [15,000 lbs]

10,886 kg [24,000 lbs]

4,536 kg [10,000 lbs] 96-105 [60-65] 15 m [50 ft] 30 m [100 ft] 46 m [150 ft] 60 m [200 ft] 80-88 [50-55] 8 m [25 ft] 23 m [75 ft] 30 m [100 ft] 46 m [150 ft]

72 [45] 8 m [25 ft] 15 m [50 ft] 23 m [75 ft] 30 m [100 ft]

6,804 kg [15,000 lbs]

96-105 [60-65] 8 m [25 ft] 23 m [75 ft] 30 m [100 ft] 46 m [150 ft]

80-88 [50-55] 8 m [25 ft] 15 m [50 ft] 23 m [75 ft] 30 m [100 ft]

72 [45] 8 m [25 ft] 8 m [25 ft] 15 m [50 ft] 23 m [75 ft]

10,886 kg [24,000 lbs]

96-105 [60-65] 8 m [25 ft] 15 m [50 ft] 23 m [75 ft] 30 m [100 ft]

80-88 [50-55] 8 m [25 ft] 8 m [25 ft] 15 m [50 ft] 23 m [75 ft]

72 [45] 8 m [25 ft] 8 m [25 ft] 8 m [25 ft] 15 m [50 ft]

*Weights of Typical Vehicles:

Midsize automobile - 1,020 kg [2,250 lb]/Full-size automobile - 1,500 kg [3,500 lb]

Loaded 3/4-ton pickup truck - 2,750 kg [6,000 lb]/Loaded 1-ton cargo truck - 4,500 kg [10,000 lb]

Loaded 4-yard dump truck - 11,000 kg [24,000 lb]

Source: "Use of Truck Mounted Attenuators in Work Zones" by Jack B. Humphreys, P.E. and T. Darcy Sullivan, P.E., University of Tennessee.

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www.trinityhighway.com 38 Revision I September 2017

8. Hub removal:

a. Elevate and support the trailer by the frame.

b. Remove the wheel.

c. Remove the Bearing Buddy®.

d. Remove the cotter pin.

e. Unscrew the spindle nut (counterclockwise) and remove the spindle washer.

f. Remove the hub from the spindle, being careful not to allow the outer bearing cone to fall out. The inner bearing cone will be retained by the seal.

9. Bearing adjustment:

a. If the hub has been removed or bearing adjustment is required, the following procedure must be followed:

1) After placing the hub, bearing, washers, and spindle nut back on the axle spindle in reverse order, rotate the hub assembly slowly while tightening the spindle nut to approximately 68 N-m [50 ft-lb] (12" wrench or pliers with full hand force.).

2) Loosen the spindle nut to remove torque. Do not rotate the hub.

3) Finger-tighten the spindle nut until snug.

4) Back the spindle nut out slightly until the first notch lines up with the cotter key hole and insert the cotter pin.

5) Bend the cotter pin legs over to secure the nut.

Storage 1. Storage:

a. The ideal storage is in a cool, dark garage with the tires at maximum inflation. b. Put trailer on jack stands to take the weight off the tires, lower the air pressure and

cover tires to protect from the direct sunlight.

2. Storage Preparation:

a. If the trailer is to be stored for an extended period of time or over the winter, it is important that the trailer be prepared properly.

b. Remove the emergency breakaway battery and store inside, out of the weather. Charge the battery at least every 90 days.

c. Jack the trailer and place Jack stands under the trailer frame so that the weight will be off the tires.

3. After Prolonged Storage:

a. Remove all wheels and brake drums.

b. Inspect brakes and hubs.

c. Lubricate all brake moving parts.

d. Remove any rust from braking surface.

e. Reassemble brake drums and wheels.

f. Reassemble emergency breakaway battery.

g. Remove the Jack stands.

www.trinit

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Revision

n I Septemberr 2017

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www.trinityhighway.com 45 Revision I September 2017

Troubleshooting Guide

Safety Notes

1) Always wear eye protection when working on or around machinery, power tools, and hydraulics.

In general, consult Trinity Highway Customer Service Department if problems associated with operating or repairing the 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.

1) DC Test Light

A test light is a light bulb with one lead wired to an alligator clip and the other lead connected to a metal probe. It is used to check for the presence of voltage in the electrical circuit. With the alligator clip grounded, the light glows when the probe comes into contact with a hot electrical component.

2) Continuity Tester

A continuity tester is an item of electrical test equipment used to determine if an electrical path can be established between two points. It is used for testing electrical circuits when the components are not connected to a power source.

3) Volt Meter

A DC voltmeter can be used to troubleshoot voltage problems. Two common uses are: 1) Ground one probe while using the other to probe hot leads in search of the available voltage at the point where the second probe is connected. 2) Measure a voltage drop in a wire or component by connecting one probe to one end and the remaining probe to the other end of the item in question.

4) Ohm Meter

Note: All tests conducted with an ohmmeter must be done with the power source disconnected from the TMA.

An ohm meter is used to measure resistance and is useful when working with solenoid coils. On some coils the wire resistance is large enough that a DC test light might not illuminate, falsely indicating an open circuit (infinite resistance). A successful coil test, however, should always show some non-infinite value of resistance.

5) Assorted Hoses, Pressure Fittings

These can be used to connect and/or isolate certain parts of a hydraulic circuit for diagnosing hydraulic problems.

If you suspect problems, do not operate the system. Diagnose and repair, or contact Trinity Highway Customer Service Department for assistance at (888) 323-6374.

www.trinityhighway.com 46 Revision I September 2017

Hydraulic Fluid1) Purpose

The main purpose of hydraulic fluid is to transfer energy during an impact to resist rotation. These traits are achieved when the oil has a good lubricity (slipperiness), and with additives that inhibit oxidation and the entrapment of air and water in the oil, respectively. The viscosity (thickness) of the oil must be appropriate for the operating temperature to minimize unwanted leakage, and to lubricate the close fitting parts in the system.

Additionally, the oil must be compatible with the seals used in the system. Finally, the oil must be able to pour or flow at the lowest expected operating temperature so that it can enter the reservoir and flow through the cylinders for use. For all of these reasons, automatic transmission fluid (ATF, Dexron®) has been found to be the best readily available fluid for the job in most climate conditions.

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.

When looking for fluids that can be used in place of ATF or for applications where the operating temperature is outside the range of ATF, the following specifics should be discussed with your local oil distributor:

A. Fluid must be compatible with Buna-N sealing compounds.

B. The Pour Point must be below the lowest anticipated temperature that will be encountered.

C. It should contain Rust or Oxidation inhibitors as well as other detergent type inhibitors.

D. The viscosity (SUS) should lie between 80 and 375 in the operating range, with the ideal viscosity near 200 SUS.

E. The viscosity index should be as high as possible. As an example, ATF has the following specs as listed by most oil manufacturers:

[1] Viscosity (SUS)

37 deg. C [100 deg. F] 185 to 205

99 deg. C [210 deg. F] 45 to 55

Pour Point -44 deg. C [-45 deg. F]

-37 deg. C [-35 deg. F]

Viscosity Index 145 to 165

Note: In a cold weather emergency application only, SAE 10W non-detergent oil can be mixed by volume with no more than 30% #1 fuel oil or kerosene.

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www.trinityhighway.com 48 Revision I September 2017

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 (see Hydraulic Fluid section p.46).

2) PROPER FILLING:

A. Fill the reservoir so that fluid is 1/2 on the sight glass.

B. Operate the unit several times starting with short cylinder strokes, increasing the length of each successive stroke.

C. Recheck fluid level often and add as necessary.

D. Reattach the filter/breather plug provided.

3) RESERVOIR PROBLEMS

A. Clear fluid flowing out of the filler port usually means the reservoir was completely filled before the cylinders were fully collapsed.

B. Foamy fluid flowing out of the filler port points to air present in the system; the response is usually spongy, or the cylinders may move with a jerking motion.

C. Water in the fluid:

Water can enter the reservoir through the filler port if the unit is left outdoors or washed with a high-pressure washer. Protect the unit, whenever possible, and change the fluid if you suspect contamination.

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