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WABCO OPTIFLOW SIDEWINGS, Installation Manual

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OptiFlow™ SideWings

 

Table of Content

1 Introduction 

................................................................................ 5

1.1 Area 

of 

Application 

....................................................................... 5

1.2 

What is OptiFlow SideWings? ...................................................... 5

1.3 Legal 

Requirements 

..................................................................... 6

2 Safety 

Instructions 

..................................................................... 7

3 Confi gurations ........................................................................... 9

4 SideWings 

................................................................................. 10

5 Installation 

................................................................................ 12

5.1 Requirements 

............................................................................. 12

5.2 Preparations 

............................................................................... 13

5.3 Defi nition of Starting Point ......................................................... 14

5.4 Installation 

Variants 

.................................................................... 16

5.4.1 Top 

Installation 

........................................................................... 16

5.4.2 I-Beam 

Installation 

..................................................................... 20

5.5 

Installation of MidSkirts .............................................................. 23

5.6 

Installation of EndSkirts ............................................................. 27

5.7 

Installation of Flow Conductors .................................................. 31

5.7.1  

Flow Conductor Rotational ......................................................... 31

5.7.2  

Flow Conductor Hinged ............................................................. 37

5.8 

Installation of Gas Springs ......................................................... 40

5.9 

Installation of Back Door Retainers ............................................ 42

5.10 

Connection of Side Markers ....................................................... 43

6 Final 

Check 

............................................................................... 44

7 Operation 

.................................................................................. 45

7.1 Hatches 

...................................................................................... 45

7.2 Skirts 

.......................................................................................... 47

7.3 Hinged 

Pillars 

............................................................................. 48

8 Troubleshooting 

....................................................................... 51

9 Maintenance 

............................................................................. 52

10 Appendix 

................................................................................... 53

10.1 

Example of “SideWings Setup” drawing .................................... 53

10.2 

Example of “SideWings Positioning” drawing ............................ 54

Summary of Contents for OPTIFLOW SIDEWINGS

Page 1: ...OPTIFLOWTM SIDEWINGS INSTALLATION MANUAL...

Page 2: ...1 This publication is not subject to change procedures New versions can be found under the following link http www wabco info 8150102033 2013 WABCO Europe BVBA All rights reserved Subject to change wi...

Page 3: ...16 5 4 2 I Beam Installation 20 5 5 Installation of MidSkirts 23 5 6 Installation of EndSkirts 27 5 7 Installation of Flow Conductors 31 5 7 1 Flow Conductor Rotational 31 5 7 2 Flow Conductor Hinged...

Page 4: ...s long as there has been no respective intention or gross negligence on our part or any forced legal provisions in opposition Text and graphics are subjected to our utilization rights copying or distr...

Page 5: ...no known limitations to conventional brake systems conventional wheels and tires conventional suspension systems 1 2 What is OptiFlow SideWings The patented OptiFlow SideWings influence the aerodynami...

Page 6: ...f the Lateral Protection device according ECE R 73 The MidSkirts in front of the first wheel withstand a lateral force of 1000N on the pillars with a max deflection of 50mm Type approval with the appr...

Page 7: ...y instructions when dealing with the OptiFlow SideWings system to avoid personal injury or damage to components Do not move the vehicle if SideWings are open and a technician is performing any work on...

Page 8: ...stored in position Otherwise the Flow Conductor could be damaged Top view of Flow Conductor Do not force the Flow Conductor Rotational beyond its set up position Do not lean on the open Flow Conductor...

Page 9: ...ity as well as aesthetic demands Open Wheel This configuration is meant to give access to steering axle trailers Therefore the wheels will have enough space to move freely without any interference fro...

Page 10: ...ensures that OptiFlow SideWings system unique The wing shaped profile ensures that the inwards bending airflow behind the truck is caught and converted into a the inwards bending airflow behind the t...

Page 11: ...The EndSkirts with hatches offer the additional function of accessibility in the rear area of the trailer behind the wheels for operating the air suspension or PREV Park Release Emergency Valve Acces...

Page 12: ...ps will slide the skirts close to another Never use a screwdriver to separate skirt edges This will damage Never use a screwdriver to separate skirt edges This will damage aluminum parts aluminum part...

Page 13: ...Beams thus giving room for the MidSkirts to be positioned Keep connections for side markers on the MidSkirts Ensure that important accessories such as the extinguisher or control elements remain acce...

Page 14: ...wered This will guarantee that the SideWings will not touch the ground in the event of a tire guarantee that the SideWings will not touch the ground in the event of a tire bellows burst bellows burst...

Page 15: ...is no closer than 655mm The only condition is that it is no closer than 655mm Starting point for 3 axle trailers Starting point for 3 axle trailers It is standard for the distance between the axles to...

Page 16: ...of the pillar parts and an overview of In this section you will find a description of the pillar parts and an overview of different pillar types different pillar types The pillars connect the SideWin...

Page 17: ...th 4 slots Connecting with I Beam or Half Horizontal Beams E Pillar for Flow Conductor Pillar for Flow Conductor Rotational Rotational Installation steps The design of counterparts such as angle brack...

Page 18: ...magnetic drill Drill the bore holes preferably with a magnetic drill Fix all mounting plates to the bottom of the trailer I Beam M8 27 0Nm Fix all mounting plates to the bottom of the trailer I Beam...

Page 19: ...r the last 4550mm of a semi trailer for docking reasons The ground clearance must be a max 500mm in front of the first wheel The minimum clearance between tires and SideWings must be at least The mini...

Page 20: ...n of how to connect Half Horizontal Beams to other parts Beams to other parts HHBs will be used for bridging the pillars to the I beam of the trailer A C D E B B Connection of Half Horizontal Beam to...

Page 21: ...e of the trailer I Beam Drill the bore holes preferably with a magnetic drill Drape the Half Horizontal Beams with pre installed pillars on the ground Drape the Half Horizontal Beams with pre installe...

Page 22: ...moving lift axles Fix every Half Horizontal Beam to the frame with 6 x M12x35 8 8 screws The beams must also be fixed to the trailer undersurface using an angle bracket For the installation of angle b...

Page 23: ...rts before installing on trailer Install rubber on skirts before installing on trailer For OEM Original Equipment Manufacturer installation the top rubber may be supplied separately Pull the slider th...

Page 24: ...amping unit of the mounted pillars Your fingers could be crushed Lift the first MidSkirt up when sliding the metal rail of MidSkirt into the first clamping unit of the mounted pillar Hold the first Mi...

Page 25: ...close the gaps between two skirts Use a rubber hammer to completely close the gaps between two skirts This is not a matter of force just a couple of taps will slide the skirts This is not a matter of...

Page 26: ...he middle of the clamping When everything is fitted all joints must be in the middle of the clamping unit unit Tighten the nuts I and II on all clamping units mping units I II Once you have finished o...

Page 27: ...n skirts before installing on trailer Install rubber on skirts before installing on trailer For OEM Original Equipment Manufacturer installation the top rubber may be supplied separatel Pull the slide...

Page 28: ...pillar Slide the EndSkirt into its final position until there is a connection with the last MidSkirt Use a rubber hammer to completely close the gaps between two skirts Use a rubber hammer to complete...

Page 29: ...e in the middle of the clamping unit unit When all skirts are mounted tighten the nuts I and II on the clamping units SW13 M8 24Nm M8 24Nm I II When one side of the trailer is finished repeat the proc...

Page 30: ...ave been secured install the plastic end covers on each After EndSkirts have been secured install the plastic end covers on each end of the Endskirts Use the plastic rivet to fasten the part end of th...

Page 31: ...t the Flow Conductor so the landing legs can be operated easily when the Flow Conductor is open 5 7 1 Flow Conductor Rotational Depending on your BOM Bill Of Material please check if you have this par...

Page 32: ...32 OptiFlow SideWings Installation Undo the screws on the slider Remove the slider...

Page 33: ...OptiFlow SideWings Installation Detach the rotating axis from the Flow Conductor Fix the rotating axis on the Half Horizontal Beam Make sure that the metal flange points towards the back of the trail...

Page 34: ...34 OptiFlow SideWings Installation Slide the Flow Conductor into the hole in the rotating axis Tighten the nuts with M10 46Nm Insert the Slider the Slider...

Page 35: ...ame If not it must be repositioned With some configurations you can request a crank of a different length Mount the Flow Conductor so the landing legs can be operated easily when the Flow Conductor is...

Page 36: ...36 OptiFlow SideWings Installation To guarantee correct usage fix the position of the stopper screw with hexagon head M10 46Nm Close the Flow Conductor softly and lock it Close the fastener...

Page 37: ...railer Install rubber on Flow Conductor before installing on trailer For OEM Original Equipment Manufacturer installation the top rubber may be supplied separately Pull the slider thread plates of the...

Page 38: ...amping unit on the mounted pillar Hold the Flow Conductor up when sliding the metal rail on the Flow Conductor into the first and second clamping unit on the mounted pillar Slide the open Flow Conduct...

Page 39: ...mpletely close the gaps between Flow Conductor and MidSkirt Conductor and MidSkirt This is not a matter of force just a couple of taps will slide the skirts This is not a matter of force just a couple...

Page 40: ...Handle the gas springs with care Install the gas springs after installing all Skirts and Flow Conductors Gas springs have a great force and can change the alignment Two workers are required for the i...

Page 41: ...Installation Open the skirt as far as possible to get the perfect distance Put the shoulder bolt back in position while holding the gas spring Screw in the nut to fasten the gas spring Proceed with t...

Page 42: ...42 OptiFlow SideWings Installation 5 9 Installation of Back Door Retainers Insert the back door retainer into its socket Insert the back door retainer into its socket Fix with the supplied bolts...

Page 43: ...ightness and electrical connection markers tightness and electrical connection Make the electrical connection for the Side Markers integrated in MidSkirts as standard on both sides of the trailer Min...

Page 44: ...er are not covered and are working properly All OptiFlow SideWing components must be firmly secured Ensure that all Skirts Hatches and Flow Conductors are closed and the locks are closed with the lock...

Page 45: ...45 OptiFlow SideWings Operation 7 Operation 7 1 Hatches Opening Press the first knob...

Page 46: ...ontal position Repeat procedure with second knob Open the hatch The hatch cannot be locked in place when open You must hold it open manually Closing Close the hatch Press the first knob While pressing...

Page 47: ...Skirts Opening Pull the first handle downwards behind the bottom of the skirt marked with circles on figures Pull the second handle downwards Open the skirt Closing Close the skirt You will hear a cl...

Page 48: ...48 OptiFlow SideWings Operation 7 3 Hinged Pillars Pull out the safety pin...

Page 49: ...49 OptiFlow SideWings Operation Then pull out the securing piston Align the hole so you can pass the piston through the hole...

Page 50: ...50 OptiFlow SideWings Operation The piston acts like a blocking mechanism so that the bottom part of the pillar will not rotate Position of hinged pillar when retracted...

Page 51: ...Lock alignment MidSkirts Lock alignment If the skirts cannot be locked you have 3 options for solving the problem A You can move the complete pillar backwards and forwards B You can move the lock back...

Page 52: ...as springs Check free movement The Skirts and Flow Conductor Hinged must be kept open by the force of the gas springs Locks Check free movement Check free movement The Skirts and Flow Conductor must b...

Page 53: ...Appendix 10 Appendix Please only use the drawings supplied with your customized SideWings system The following drawings are only examples and do not apply to every SideWings system 10 1 Example of Si...

Page 54: ...54 OptiFlow SideWings Appendix 10 2 Example of SideWings Positioning drawing...

Page 55: ...es of 2 5 billion in 2012 WABCO is headquartered in Brussels Belgium For more information visit www wabco auto com WABCO NYSE WBC is a leading global supplier of technologies and control systems for t...

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