Vorteq Trailer TMA - Structural & Steel Productss-steel.com/files/Vorteq-Assembly-Manual.pdf ·...

Vorteq® TrailerTMA

Product DescriptionAssembly Manual

Revision F July 2012Part No. 115297B

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Table of Contents Customer Service Contacts .......................................................................................................... 3 Important Introductory Notes ........................................................................................................ 3 System Overview .......................................................................................................................... 4 Recommended Safety Rules for Assembly .................................................................................. 4 Safety Symbols ............................................................................................................................. 5 Warnings and Cautions ................................................................................................................. 5 Limitations and Warnings .............................................................................................................. 6 Know Your Vorteq® Trailer TMA System ...................................................................................... 7 Trailer .......................................................................................................................................... 11 Tires & Axle ................................................................................................................................. 12 Controlling Skid Distance ............................................................................................................ 12 Recommended Tools .................................................................................................................. 14 Uncrating Instructions ................................................................................................................. 15 Impact Head Assembly ............................................................................................................... 17 Right Collar Attachment (May be Pre-Assembled) ..................................................................... 18 Left Collar Attachment (May be Pre-Assembled) ........................................................................ 19 Axle Assembly (May be Pre-Assembled) .................................................................................... 20 Shaper Rail Assembly ................................................................................................................. 21

How to Determine Left/Right ................................................................................................... 21 Shaper Rail Attachment .............................................................................................................. 22 Lock Bar Washer Attachment ..................................................................................................... 24 Tongue Assembly ....................................................................................................................... 25 X-Brace Assembly ...................................................................................................................... 27 Bolt Tightening Sequence ........................................................................................................... 28 Fender Assembly ........................................................................................................................ 30 Wheels & Tires ............................................................................................................................ 33 Pintle Ring ................................................................................................................................... 34 European Hitch Adapter .............................................................................................................. 35 Jack Assembly ............................................................................................................................ 36 Impact Face ................................................................................................................................ 37 Impact Face Attachment ............................................................................................................. 38 Oversized Impact Face (Optional) .............................................................................................. 39 Oversized Impact Face Attachment (Optional) ........................................................................... 40 Spare Tire Carrier Assembly ....................................................................................................... 41 Truck Preparation ....................................................................................................................... 42 Operation Instructions ................................................................................................................. 47 Maintenance ............................................................................................................................... 48

Maintenance Chart .................................................................................................................. 49 Repair Instructions ...................................................................................................................... 54

Vorteq® Fastener Reference Chart .......................................................................................... 55 Reference Drawings ................................................................................................................... 56

Impact Head Assembly, Vorteq®, G ........................................................................................ 56 Shaper Rails, Vorteq®, G ......................................................................................................... 57 X-Brace, Vorteq®, G ................................................................................................................ 58 X-Brace, Vorteq®, G ................................................................................................................ 59 Fender Assembly, Square, Vorteq®, G .................................................................................... 60 Hitch, US, Vorteq® ................................................................................................................... 61 Hitch Adapter, Euro, Vorteq® ................................................................................................... 62 Impact Face, Vorteq® .............................................................................................................. 63 Spare Tire Mount, Vorteq® ...................................................................................................... 64


Customer Service Contacts Energy Absorption Systems (a Trinity Highway Products company) is committed to the highest level of customer service. Feedback regarding the Vorteq® Trailer TMA, its assembly procedures, supporting documentation, and performance are always welcome. Additional information can be obtained from the contact information below:

Energy Absorption Systems:

Telephone: (888) 323-6374 (U.S. only) (312) 467-6750 (Outside U.S.)

E-mail: [email protected]

Internet: Energy Absorption Systems Trinity Highway Products, LLC Trinity Industries, Inc.

http://www.energyabsorption.com http://www.highwayguardrail.com http://www.trin.net

Important Introductory Notes Proper assembly of the Vorteq® Trailer TMA is essential to achieve performance of the system under appropriate federal and state criteria. These instructions should be read in their entirety and understood before assembling the Vorteq® Trailer TMA. These instructions are to be used only in conjunction with the assembly of the Vorteq® Trailer TMA and are for standard assemblies only as specified by the applicable highway authority. In the event your system assembly requires or involves deviation from standard parameters or, during the assembly process a question arises, please contact the appropriate highway authority that specified this system at this particular location for guidance. Energy Absorption Systems is available for consultation with that agency. These instructions are intended for an individual who is qualified to both read and accurately interpret them as written. They are intended for the individual who is experienced and skilled in the assembly of highway products which are specified and selected by the highway authority.

A set of product and project shop drawings will be supplied by Energy Absorption Systems. The shop drawings will be for each section of the assembly. These drawings should be reviewed and studied thoroughly by a qualified individual who is skilled in interpreting them before the start of any assembly.

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Limitations and Warnings Energy Absorption Systems, in compliance with the National Cooperative Research Highway Program 350 (NCHRP Report 350) “Recommended Procedures for the Safety Performance of Highway Safety Features”, contracts with FHWA approved testing facilities to perform crash tests, evaluation of tests, and submittal of results to the Federal Highway Administration for review. The Vorteq® Trailer TMA system was tested to meet the impact criteria, requirements, and guidelines of NCHRP Report 350. These tests, specifically set forth by FHWA, evaluate product performance by simulating those impacts outlined by NCHRP Report 350 involving a typical range of vehicles on our roadways, from lightweight cars (approx. 820kg [1800 lb.]) to full size pickup trucks (approx. 2000 kg [4400 lb.]) as specified by the FHWA. A product can be certified for multiple Test Levels. Vorteq® Trailer TMA is certified to the Test Level(s) as shown in: Test Level 3: 100 km/h [62 mph]. These specified 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 only to the test matrix criteria of NCHRP 350 as approved by FHWA or TD 49 as approved by the Highway Agency. Additionally, the Vorteq® Trailer TMA was tested to meet the impact criteria, requirements, and guidelines of TD 49. These tests, specifically set forth by the Highway Agency, evaluate product performance by simulating those impacts outlined by TD 49 involving a typical range of vehicles on their roadways, from lightweight cars (approx. 900 kg [1984 lb.]) to heavier cars (approx. 1500 kg [3307 lb.]) as specified by the Highway Agency. A product can be certified for various speed levels as shown below: TL3.UK: 110 km/h [68 mph] Energy Absorption Systems does not represent nor warrant that the results of these controlled tests show that vehicle impacts with the products in other conditions would necessarily avoid injury to person(s) or property. Impacts that exceed the specifications of the system may not result in acceptable crash performance as outlined in NCHRP Report 350 or TD 49, relative to structural adequacy, occupant risk, and vehicle trajectory. Energy Absorption Systems expressly disclaims any warrant 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 by or under the direction of Energy Absorption Systems or by third parties. The Vorteq® Trailer TMA is intended to be assembled and maintained in accordance with specific State and Federal guidelines. Energy Absorption Systems offers a reflective delineator panel and has reflective tape for the Vorteq®. However, the material is only intended to supplement delineation required by the Department of Transportation’s “Manual on Uniform Traffic Control Devices” (MUTCD) or local jurisdiction. The appropriate highway authority approved engineer should be careful to properly select, assemble, and maintain the product. Careful evaluation of the host vehicle, vehicle population type, speed, traffic direction, and visibility are some of the elements that require evaluation in the proper selection of a safety appurtenance by the appropriate specifying highway authority. After an impact occurs, the product must be repaired to its original condition prior to placing back in service. 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.

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3. The Vorteq® Trailer TMA shall be securely fastened to the truck. On level ground, the bottom of the Impact Head shall be 350 mm +/- 50 mm [14" +/- 2"] from the ground and level (See Figure 4).

4. The Vorteq® Trailer TMA is designed to safely absorb a crash and to support its own weight. Do not sit, stand or lean on any part of the system.

Note: Do not drag the system or place anything on its top: damage may result (See Figures 5 & 6). 5. Ballast and other heavy objects MUST BE ADEQUATELY ANCHORED to the truck to

prevent shifting during an impact. The tie-down straps should be strong enough to hold 20 times the weight of the ballast (See Figure 7).

6. The agency responsible for the truck shall inspect it for adequate operator safety equipment (e.g., seat belts, head rests, etc.).

7. Make sure that the performance and safety of the Vorteq® Trailer TMA is not impaired by damage or corrosion.

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15. Twist safety chains equally from hook ends to take up slack.

16. The truck operator is completely responsible for monitoring the condition of the system components as they relate to safe highway transit of their vehicle.

17. Check that the lighting harnesses are properly connected and not touching the road, but loose enough to make turns without disconnecting or damaging the wires.

18. Do not modify or change the Vorteq® Trailer TMA in any way.

19. Never weld, bolt or modify anything to the Vorteq® Trailer TMA. Modifications to the system are strictly prohibited.

20. The Vorteq® Trailer TMA could contact the vehicle used to tow it while making excessively sharp turns or backing up while turning. Take care to avoid contact between the tow vehicle and the Vorteq® Trailer TMA.

Tires & Axle 1. Periodically check and correct tire pressure.

2. All trailer tires have a maximum speed rating of 105 km/h [65 mph].

3. Three to five years is the projected life of a normal trailer tire.

4. The mileage expectation of a trailer tire would be 19,300 km [12,000 miles].

5. Always replace trailer tires with (ST) Special Trailer rated tires.

6. Wheel and tire offset is the distance from the mounting surface to the centerline of the tire. The Vorteq® Trailer TMA axle bearing sets are designed for wheels with 0 to 13 mm [1/2"] offset. Modifying this offset will shorten bearing life and may lead to bearing failure.

7. Wheels and tires must be matching pairs.

8. Confirm that the wheel lug nuts are tightened to the correct torque.

9. Use the frame when jacking up the trailer. Do not jack up trailer from suspension components.

10. Never weld to the Torflex® axle. The Torflex® axle contains rubber cords for the suspension system and will be damaged by heat generated from welding on the bracket or tube.

Controlling Skid Distance 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 lightweight shadow

vehicles. • Skid distance is reduced and is more consistent when heavier shadow vehicles are used. • Required truck weight: 9,920 lbs. or greater.


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]


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


72 [45] 15 m [50 ft] 23 m [75 ft] 23 m [75 ft] 30 m [100 ft] Note: Distances are appropriate 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]


72 [45] 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] Shadow or Barrier Vehicle Recommended Weight Recommended minimum Barrier/Shadow vehicle weight: 4,500 kg [9,920 lbs].

*Weights of Typical Vehicles: Midsize automobile - 1,020 kg [2,250 lbs] Full-size automobile - 1,500 kg [3,500 lbs] Loaded 3/4-ton pickup truck - 2,750 kg [6,000 lbs] Loaded 1-ton cargo truck - 4,500 kg [10,000 lbs] Loaded 4-yard dump truck - 11,000 kg [24,000 lbs]

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


Recommended Tools • Steel Tape Measure 15 m (50 ft.)

• Spirit Level

• Alignment Tool 12 mm (1/2")

• Torque Wrench 120 N-m [90 ft-lbf]

• Hammer

• Wire Cutters

• Circular Saw (Cut up pallets)

• Screw Gun or Drill

• 1/2" Drive Socket Wrench

• 1/2" Drive Sockets 1/4" thru 1”

• Same size open end wrenches as above

• Pipe Wrench 405 mm (16")

• 1/2" Drive Air Impact Wrench with Air Compressor

• 36" Crow Bar

• Floor Jack

Note: The above list of tools is a general recommendation. Depending on specific site conditions and the complexity of the assembly specified by the appropriate highway authority, additional or fewer tools may be required. Decisions as to what tools are needed to perform the job are entirely within the discretion of the specifying highway authority and the authority’s selected contractor performing the assembly of the system at the authority’s specified assembly site.

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Maintenance Before performing any maintenance on the Vorteq® Trailer TMA, thoroughly read and understand the Maintenance Section and the Safety Section of this manual. Appropriate service methods and proper repair procedures are essential for the safe and reliable operation of the Vorteq® Trailer TMA. This manual provides general directions for performing service and repair work. Following these guidelines will help assure reliability.

There are numerous variations in procedures, techniques, tools, parts for servicing, as well as in skill of the individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Anyone who departs from the instructions provided in this manual must first establish that they neither compromise their personal safety nor the Vorteq® Trailer TMA integrity by their choice of methods, tools, or parts.

I. General a. Always replace any fastener with one specified by Energy Absorption Systems.

b. Check the nuts, bolts, and other fasteners to ensure that the hitch remains secured to the truck and the coupler remains secured to the trailer.

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IV. T1. A

2. T

3. In

4. Ctr

Wea

5. W

A

B

C

6. M


Tires & WAlways replac

Tire pressure

nspect tires f

Check inflatioread wear.

Cautipatterthe un

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r Pattern

Center Wear

Edge Wear

Side Wear

Toe Wear

Cupping

Flat Spots

Wheel attach

A. Start all b

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age: 27 to 34

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age: 95 ± 7

per lug nut to

es with ST (S

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use is correc

nuts or bolels.

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ver inflation

nder inflation

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correct toe-in

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orque.

51

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frequently btire; it is dif

tightened a

Action

Adjust pressload per tire

Adjust pressload per tire

Align at align

Align at align

Check beaand balance

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7. Wheel nuts should be torqued after each wheel removal, re-torque after 80 km [50 miles] and approximately 4830 km [3,000 miles] frequently thereafter.

8. The standard Vorteq® Trailer TMA tire size is ST20575D14*. The bias ply tire provides stiffer side walls and more resistance to sway.

Note: *Tire size may vary. 9. Replace tires every three to five years, whether they look like they are worn out or not.

Trailer tires lose about 1/3 of their strength in 3 to 5 years.

10. Be sure that necessary adjustments are made and any damaged or worn parts are replaced.

V. Storage 1. Storage Instructions

a. The ideal storage is in a cool, dark garage.

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. After Prolonged Storage

a. Remove wheels.

b. Inspect hubs.

c. Reinstall wheels.

d. Remove the jack stands.

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VI. T1. W

FJaT

2. DWLL


TechnicalWeight

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Notes

2525 Stemmons FreewayDallas, Texas 75207

888-323-6374 (USA only)312-467-6750 (Outside USA)

www.energyabsorption.comwww.highwayguardrail.com

Vorteq Trailer TMA - Structural & Steel Productss-steel.com/files/Vorteq-Assembly-Manual.pdf ·...

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