WABCO OPTIFLOW SIDEWINGS Installation Manual
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WABCO OPTIFLOW SIDEWINGS Installation Manual

WABCO OPTIFLOW SIDEWINGS Installation Manual

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OPTIFLOW
SIDEWINGS
INSTALLATION MANUAL

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Summary of Contents for WABCO OPTIFLOW SIDEWINGS

  • Page 1 OPTIFLOW SIDEWINGS INSTALLATION MANUAL...
  • Page 2 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 without notice. Version 02 / 09.2013(en) 815 010 203 3...

  • Page 3: Table Of Contents

    OptiFlow™ SideWings Table of Content Introduction ................5 Area of Application ............... 5 What is OptiFlow SideWings? ............5 Legal Requirements ..............6 Safety Instructions ..............7 Confi gurations ................9 SideWings ................. 10 Installation ................12 Requirements ................12 Preparations ................
  • Page 4 OptiFlow™ SideWings Disclaimer We assume no liability for the correctness, completeness or actuality of the information in this document. All technical information, descriptions and images are applicable for the date on which this document or respective supplements were printed. We reserve the right to make any changes as a result of continuous further development.

  • Page 5: Introduction

    What is OptiFlow SideWings? The patented OptiFlow SideWings infl uence the aerodynamic behavior of a trailer by optimizing the air fl ow behind the tractor wheels / axles. The air fl ow moves towards the center of the vehicle giving a local high angle of attack for the fl...

  • Page 6: Legal Requirements

    OptiFlow™ SideWings Introduction Legal Requirements Council Directive 74/483/EEC Rounding of components All external edges and corners are rounded with a radius not less than 2.5mm. Council Directive 89/297/EEC Lateral protection device ECE R-73 Lateral protection device The OptiFlow system fulfi lls the function of the “Lateral Protection device”...

  • Page 7: Safety Instructions

    Observe the following safety 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 the vehicle.
  • Page 8 OptiFlow™ SideWings Safety Instructions – Do not drop the SideWings, to – Never abruptly release the back avoid damage. door retainer. Top view of Flow Conductor Top view of Flow Conductor – Only close the Flow Conductor – Do not force the Flow Conductor when the landing gear crank is Rotational beyond its set-up stored in position.

  • Page 9: Confi Gurations

    OptiFlow™ SideWings Confi gurations Confi gurations In this chapter the different confi gurations of OptiFlow SideWings are described. Long This confi guration covers the side of the trailer from the landing legs to the end. This type of confi guration is usually installed to satisfy full functionality as well as aesthetic demands.

  • Page 10: Sidewings

    OptiFlow™ SideWings SideWings SideWings The OptiFlow SideWings system consists of three kinds of Skirts that are mounted on both sides of the trailer:  Flow Conductors  MidSkirts  EndSkirts Flow Conductor The Flow Conductor attached to the front part of the trailer makes the The Flow Conductor attached to the front part of the trailer makes the OptiFlow SideWings system unique.
  • Page 11 OptiFlow™ SideWings SideWings MidSkirts The MidSkirts are the main modular structural components of the OptiFlow SideWings system which can be fi tted to trailers of all lengths and wheel bases. These have integrated side markers by default. EndSkirts The EndSkirt is the fi nal panel of the SideWings system, with a tapered angle (of 11 degrees).

  • Page 12: Installation

    OptiFlow™ SideWings Installation Installation This chapter describes how individual components are installed and mounted. Sequence of Installation 5.1 Requirements 5.2 Preparations 5.3 Defi nition of Starting Point 5.4 Installation Variants 5.4.1 Top Installation (Pillars) 5.4.2 I-Beam Installation (Pillars + HHBs) 5.5 Installation of MidSkirts 5.6 Installation of EndSkirts 5.7 Installation of Flow Conductors...

  • Page 13: Preparations

    “Appendix” chapter. SideWings Positioning: In this drawing the positioning of the tailored OptiFlow SideWings confi guration is shown. All measurements are based on the wheel base and King Pin location. You will fi nd an example in the “Appendix”...

  • Page 14: Definition Of Starting Point

    OptiFlow™ SideWings Installation Definition of Starting Point The starting point must precisely be determined. The starting point must precisely be determined. The rim must be visible (c. 5mm) when the lifting axle is lowered. This will The rim must be visible (c. 5mm) when the lifting axle is lowered. 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.
  • Page 15 OptiFlow™ SideWings Installation Sequence of installation Sequence of installation – – Position the trailer at driving height. Position the trailer at driving height. – – Start with position Start with position 1 1 and mark it. and mark it. For successful installation the 1st pillar has to be installed correctly, as For successful installation the 1st pillar has to be installed correctly, as this is the starting point.

  • Page 16: Installation Variants

    OptiFlow™ SideWings Installation Installation Variants The SideWings are basically mounted on the trailer by vertical pillars. Essentially there are two different mounting options:  If your delivery includes Half Horizontal Beams and Pillars, proceed to chapter 5.4.2 “I-Beam Installation”, page 20. . ...
  • Page 17 OptiFlow™ SideWings Installation Pillar parts Pillar types Gas Spring Support Support Pillar (only when open wheels are present) Pulling Lock Hinged Pillar (only for Flow Conductors Hinged) Support Plates with 4 slots Support Plates with 4 slots Pillar for Flow Conductor Pillar for Flow Conductor Rotational Rotational...
  • Page 18 Example Example Angle brackets (not supplied Mounting plate (not supplied by by WABCO) WABCO) – – Check traverses and make sure that valves, pipes, wires, air reservoirs Check traverses and make sure that valves, pipes, wires, air reservoirs etc. are not hindering the installation.
  • Page 19 OptiFlow™ SideWings Installation The pillars must be installed in such a way that the pillar in front of the fi rst wheel is defl ected by no more than 30mm when a force of 1000N is applied to the pillar at the position of the lock, transverse to the direction of travel. The vehicle width of 2550mm for standard trailers and 2600mm for reefer trailers must not be exceeded.

  • Page 20: I-Beam Installation

    OptiFlow™ SideWings Installation 5.4.2 I-Beam Installation In this section you will fi nd a description of how to connect Half Horizontal In this section you will fi nd a description of how to connect Half Horizontal Beams to other parts. Beams to other parts.
  • Page 21 OptiFlow™ SideWings Installation Installation steps The design of counterparts such as the main chassis beam, angle brackets, The design of counterparts such as the main chassis beam, angle brackets, mounting plates or supports are the responsibility of the trailer manufacturer. mounting plates or supports are the responsibility of the trailer manufacturer.
  • Page 22 4 x M8x20 screws and 8 x ø8 washers for each half horizontal beam must 4 x M8x20 screws and 8 x ø8 washers for each half horizontal beam must be used. be used. Mounting Example Angle brackets (not supplied by WABCO)

  • Page 23: Installation Of Midskirts

    OptiFlow™ SideWings Installation Installation of MidSkirts The distance between the outer sides of tires and SideWing components should not be less than 30mm. The assembly tolerances are +/- 3mm. – – Install rubber on 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 separately.
  • Page 24 OptiFlow™ SideWings Installation CAUTION Damage to fi ngers  Be careful when sliding the Skirt into the clamping unit of the mounted pillars. Your fi ngers could be crushed. – Lift the fi rst MidSkirt up when sliding the metal rail of MidSkirt into the fi rst clamping unit of the mounted pillar.
  • Page 25 OptiFlow™ SideWings Installation – Close the MidSkirt softly and engage it. – Proceed with the adjacent MidSkirt. – – Use a rubber hammer to completely 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 –...
  • Page 26 OptiFlow™ SideWings Installation When everything is fi tted, all joints must be in the middle of the clamping When everything is fi tted, all joints must be in the middle of the clamping unit. unit. – Tighten the nuts (I and II) on all clamping units. mping units.

  • Page 27: Installation Of Endskirts

    OptiFlow™ SideWings Installation Installation of EndSkirts The distance between the outer sides of the tires and the SideWings components should not be less than 30mm. The assembly tolerances are +/- 3mm. – – Install rubber on skirts before installing on trailer. Install rubber on skirts before installing on trailer.
  • Page 28 OptiFlow™ SideWings Installation CAUTION Damage to fi ngers  Be careful when sliding the Skirt into the clamping unit of the mounted pillars. Your fi ngers could be crushed. – Slide the metal rail of the EndSkirt into the fi rst clamping unit of the mounted pillar.
  • Page 29 OptiFlow™ SideWings Installation When everything is fi tted, all joints must be in the middle of the clamping When everything is fi tted, all joints must be 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).
  • Page 30 OptiFlow™ SideWings Installation – – After EndSkirts have 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 the Endskirts.

  • Page 31: Installation Of Flow Conductors

    OptiFlow™ SideWings Installation Installation of Flow Conductors The distance between the outer sides of the tires and the SideWing components should not be less than 30mm. The assembly tolerances are +/- 3mm. Check if the crank storage position on the vehicle frame needs to be changed.
  • Page 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 fl ange points towards the back of the trailer.
  • Page 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 OptiFlow™ SideWings Installation – Open the Flow Conductor. – Before fi xing the position of the stopper, check you can use the crank for the vehicle frame. If not, it must be repositioned. With some confi gurations, 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 open.
  • Page 36 OptiFlow™ SideWings Installation – To guarantee correct usage, fi x the position of the stopper (screw with hexagon head M10 = 46Nm). – Close the Flow Conductor softly and lock it. – Close the fastener.

  • Page 37: 5.7.2 Flow Conductor Hinged

    OptiFlow™ SideWings Installation 5.7.2 Flow Conductor Hinged – Depending on your BOM (Bill Of Material) please check if you have this part or not. – – Install rubber on Flow Conductor before installing on trailer. Install rubber on Flow Conductor before installing on trailer. For OEM (Original Equipment Manufacturer) installation the top rubber may be supplied separately.
  • Page 38 OptiFlow™ SideWings Installation CAUTION Damage to fi ngers  Be careful when sliding the Flow Conductor into the clamping unit of the mounted pillars. Your fi ngers could be crushed. – – Release screws on pillar clamping units. Release screws on pillar clamping units. –...
  • Page 39 OptiFlow™ SideWings Installation – – Use a rubber hammer to completely close the gaps between Flow Use a rubber hammer to completely 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 –...

  • Page 40: Installation Of Gas Springs

    OptiFlow™ SideWings Installation Installation of Gas Springs CAUTION Damage to gas springs  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 installation.
  • Page 41 OptiFlow™ SideWings 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 the other gas springs.

  • Page 42: Installation Of Back Door Retainers

    OptiFlow™ SideWings Installation 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: Connection Of Side Markers

    OptiFlow™ SideWings Installation 5.10 Connection of Side Markers Adhere to regulation ECE R-48 regarding the distance between the side Adhere to regulation ECE R-48 regarding the distance between the side markers, tightness and electrical connection. markers, tightness and electrical connection. –...

  • Page 44: Final Check

    OptiFlow™ SideWings Final Check Final Check Before driving a vehicle with the OptiFlow SideWings system installed, ensure the following: – All side markers, operating devices and important accessories (such as the fi re extinguisher) are not covered and are working properly.

  • Page 45: Operation

    OptiFlow™ SideWings Operation Operation Hatches Opening – Press the fi rst knob.
  • Page 46 OptiFlow™ SideWings Operation – While pressing the fi rst knob turn it to a horizontal position. – Repeat procedure with second knob. – Open the hatch. The hatch cannot be locked in place when open. You must hold it open manually.

  • Page 47: Skirts

    OptiFlow™ SideWings Operation Skirts Opening – Pull the fi rst handle downwards (behind the bottom of the skirt; marked with circles on fi gures). – Pull the second handle downwards. – Open the skirt. Closing – Close the skirt. You will hear a click sound when the skirt is locked.

  • Page 48: Hinged Pillars

    OptiFlow™ SideWings Operation Hinged Pillars – Pull out the safety pin.
  • Page 49 OptiFlow™ SideWings Operation – Then pull out the securing piston. – Align the hole so you can pass the piston through the hole.
  • Page 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: Troubleshooting

    OptiFlow™ SideWings Troubleshooting Troubleshooting MidSkirts / 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 backwards and forwards. C –...

  • Page 52: Maintenance

    OptiFlow™ SideWings Maintenance Maintenance During normal operation the SideWings must be checked visually for damage. Further maintenance during the service life of the components is necessary for the following parts: Every 3 month Gas springs – Check free movement. – The Skirts and Flow Conductor Hinged must be kept open by the force of the gas springs.

  • Page 53: Appendix

    OptiFlow™ SideWings Appendix 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 “SideWings Setup” drawing...

  • Page 54: Example Of "Sidewings Positioning" Drawing

    OptiFlow™ SideWings Appendix 10.2 Example of “SideWings Positioning” drawing...
  • Page 55 With sales and efficiency of commercial vehicles. Founded nearly 150 of $2.5 billion in 2012, WABCO is years ago, WABCO continues to headquartered in Brussels, Belgium. pioneer breakthrough electronic, For more information, visit mechanical and mechatronic www.wabco-auto.com...

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