WABCO OptiFlow Tail User manual

INSTALLATION MANUAL

Table of contents

3
Table of contents
Table of contents
1 General information ......................................................................................................................................... 4
2 Information on the publication ....................................................................................................................... 6
3 Safety information............................................................................................................................................ 6
4 Requirements ................................................................................................................................................... 7
5 Installation ........................................................................................................................................................ 8
5.1 Safety information ................................................................................................................................... 8
5.2 Work steps .............................................................................................................................................. 8
5.3 Final checks .......................................................................................................................................... 13
6 Operation ........................................................................................................................................................ 15
7 Maintenance ................................................................................................................................................... 19
8 Spare parts ..................................................................................................................................................... 20
Edition 1
(10.2018)
815 010 221 3 (en)
This publication is not subject to any update service.
You will nd the current version on the internet at
http://www.wabco.info/i/313

4
General information General information
1 General information
Symbols used in this document
DANGER
Description of an immediate situation which will result in irreversible injury or death if the warning is
ignored.
WARNING
Description of a possible situation which may result in irreversible injury or death if the warning is
ignored.
CAUTION
Description of a possible situation which may result in irreversible injury if the warning is ignored.
NOTICE
Description of a possible situation which may result in material damage if the warning is ignored.
Important information, notes and/or tips
Reference to information on the internet
– Action step
ÖConsequence of an action
Action sequence
1. Action step 1
2. Action step 2
List
• List
Note on the use of a tool / WABCO tool
WABCO Academy
https://www.wabco-academy.com/home/
WABCO Online product catalogue
http://inform.wabco-auto.com/

5
General information
Your direct contact to WABCO
WABCO Belgium BVBA
‘t Hofveld 6 B1-3
1702 Groot-Bijgaarden
Belgium
T: [phone]
WABCO GmbH
Am Lindener Hafen 21
D-30453 Hanover, Germany
Germany
T: [phone]
WABCO Austria GesmbH
Rappachgasse 42
1110 Vienna
Austria
T: [phone]
WABCO (Schweiz) GmbH
Freiburgstrasse 384
3018 Bern
Switzerland
T: [phone]
WABCO Automotive BV
Rhijnspoor 263
Capelle aan den IJssel (Rot-
terdam) 2901 LB
Netherlands
T: [phone]
WABCO brzdy k vozidlům
spol. s r.o.
Pražákova 1008/69, Štýřice,
639 00 Brno
Czech Republic
T: [phone]
WABCO France SAS
1, cours de la Gondoire
77600 Jossigny
France
T: [phone]
WABCO Automotive Italia
S.r.L.
Corso Pastrengo 50
10093 Colegno/Torino/
Italy
T: [phone]
WABCO Technical Ofce,
Sales Ofce & Training
Centre
Siedlecka 3
93 138 Łódź
Poland
Tel: [phone]
WABCO España S. L. U.
Av de Castilla 33
San Fernando de Henares
Madrid 28830
Spain
T: [phone]
WABCO Automotive AB
Drakegatan 10, Box 188 SE
401 23 Gothenburg
Sweden
T: [phone]
WABCO Automotive U.K.
Ltd
Unit A1 Grange Valley
Grange Valley Road, Batley,
W Yorkshire,
England, WF17 6GH
T: [phone]
WABCO Australia Pty Ltd
Unit 3, 8 Anzed Court
Mulgrave, Victoria 3170
Australia
T: [phone]
Hotline: 1300-4-WABCO
(1300 4 92226)
WABCO INDIA LIMITED
Plot No. 3 (SP), III Main
Road
Ambattur Industrial Estate
Chennai 600 058, India
T: [phone]
WABCO Middle East
and Africa FZCO Vehicle
Control System
DWC Business Park,
Building A3, Room NO :
115,
PO.Box 61231,
Dubai- UAE
E-mail: info.dubai@wabco-
auto.com
Head ofce:
WABCO Europe BVBA, Chaussée de la Hulpe 166, 1170 Brussels, Belgium, T: [phone]

6
Safety information Requirements
2 Information on the publication
This publication describes the installation of WABCO OptiFlowTM Tail systems.
Target group of this publication
This publication applies to employees of workshops for repairing and equipping commercial vehicles.
3 Safety information
Observe all required provisions and instructions:
Read this publication carefully.
Adhere to all instructions, information and safety information to prevent injury to persons and
damage to property.
WABCO will only guarantee the security, reliability and performance of their products and systems
if all information in this publication is adhered to.
Always follow the specications and instructions of the vehicle manufacturer.
Observe all accident regulations of the respective company as well as regional and national
regulations.
Make provisions for a safe work environment:
Only trained and qualied technicians are allowed to perform work on the vehicle. OptiFlowTM Tail
must be installed by two trained persons.
Install OptiFlowTM Tail in an enclosed environment.
Use personal protective equipment if required (protective goggles, respiratory protection, ear
protectors, etc.).
Pedal actuations can lead to severe injuries if persons are in the vicinity of the vehicle. Make sure
that pedals cannot be actuated as follows:
• Switch the transmission to “neutral” and actuate the park brake.
• Secure the vehicle against rolling with chocks.
• Fasten a visible note to the steering wheel indicating that work is being performed on the vehicle
and that the pedals are not to be actuated.
Observe the following safety instructions when dealing with the OptiFlowTM Tail system to avoid
personal injury or damage to components:
Secure the portal doors against unintended movement.
Keep the portal doors closed while OptiFlowTM Tail is deployed.
At wind speeds above 80 km/h fold OptiFlowTM Tail together to avoid damage to the system.
Fold the OptiFlowTM Tail down while standstill (in accordance with EU regulation 1230/2012).
During the winter period snow and ice can accumulate on the top panels and injure the driver
when folding down the system.
Only drive with open portal doors if you do not exceed the legally required total width of 2650 mm
(in accordance with EU regulation 1230/2012).
Never drive into a vehicle washing system with OptiFlowTM Tail deployed, because the system
could be damaged.

7
Requirements
4 Requirements
Legal requirements
The following legal requirements need to be taken into account for the installation of OptiFlowTM Tail:
LEGAL REQUIREMENTS CONTENT
96/53/EEC Weights and dimensions
Maximum permitted trailer height:
4000 mm
1230/2012 EU Requirements relating to the aerodynamic systems at the rear
of the O3 and O4 vehicles:
Foldable system
Extension of the trailer width: 50 mm on each side while
driving, total width may not exceed 2650 mm.
Extension of the trailer length by
500 mm while driving, and during standstill at folded posi-
tion up to
200 mm.
ECE R 48 Regulations relating to contour marking
Other requirements
Consult the vehicle manufacturer if the portal doors and hinges of the vehicle are laid-out for
an installation of OptiFlowTM Tail with a total weight of 65 kg.

8
Installation Installation
5 Installation
5.1 Safety information
Consult the trailer manufacturer regarding torques. The torques and connecting elements
specied in these instructions are minimum recommendations. If a higher tightening torque is
used, the screws / portal doors could be overstrained / damaged.
Use of additional screws, additional fastening materials or modication of any part of this product
is the responsibility of the vehicle manufacturer.
Always use a soft-face hammer for the installation.
Prior to installation, ensure that the semitrailer is standing on a horizontal surface so that the body
is not in a twisted state. This could inuence the panel alignments.
5.2 Work steps
OptiFlowTM Tail consists of 2x 3 subassemblies9.
Installation tolerances: +/- 3 mm at a temperature of 18°C.
Install OptiFlowTM Tail in a windless environment – Indoors where appropriate.
OptiFlowTM Tail must be installed by two trained persons.
Preparations
– If external components (e.g. rear view cameras) are already installed, make sure they do not impair
the installation and function of the OptiFlowTM Tail system.
– Make sure you have the outline drawing of your Tail variant at hand before you start the installation.
If the outline drawing is not available, contact your WABCO partner.
– Check if the dimensions of the outline drawing match the trailer type to be equipped.
– Check the regulations concerning the contour marking and provide the corresponding materials
section „Contour marking“, page 14.
– Make sure that all subassemblies required for the installation are included in the delivery.

9
Installation
Subassemblies of the OptiFlowTM Tail system
1
2
3
LEGEND
1Top panel, left & right 2Side panel, left & right 3Lifting rods, left & right

10
Installation Installation
Components of the subassemblies
Complete tail 2693 ±5
Side panel 2693
499 87
Maximum 4000
NOTES:
ECOTAIL AS MOUNTED ON A BOX SEMI-TRAILER AT A FIX HEIGHT OF 4000mm
2.0
20-Mar-15
20-Mar-15
Luis Ramirez
A0
SHEET 1 OF 2
DWG NO.
TITLE:
DATE
SIGNATURE
NAME
APPV'D
CHK'D
DRAWN
EcoTail General
overview - B05
Luis C Ramirez
REVISION
DO NOT SCALE DRAWING
DEBUR AND
BREAK SHARP
EDGES
FINISH:
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
SCALE:
C:\OptfiFlow\EcoTail\Directives\
CONFIG TYPE:
TA-1275-00X-B05
1:10
BOX
C
A
C
B B
BB
A
COMPONENTS OF THE SUBASSEMBLIES
ALevers (2x) BGas spring (4x) CFork (2x)
Installation
The assembly steps described below apply to the right and left side of the portal doors.
1. Mark the drill positions on the portal doors in accordance with the outline drawing.
The outside edges of the trailer are the reference edges for the drilling.
2. Drill the guide holes using a Ø 4 mm drill bit.
3. Expand the hole to Ø 11 mm.

11
Installation
1. Installation of the subassembly for the top panels
1. Install the subassembly of the top panels (1) using M10 screws and nuts of at least strength class
8.8.
Recommended torque: 25 ±3 Nm
2. You may need to tip the top panels (1) slightly.
3. After assembly, remove the protective lm of the top panels (1).
4. Now t the lifting rods holder using 2 screwssection „“, page 9, in area A.
5. Connect the lifting rod (3) to the forksection „“, page 9, in area C.
6. Fix the screw (C). Recommended torque: 3 +0.5 Nm.
Avoid any gap between trailer and sealing lip of the top panels (2).
Correct position of the top panel (side view) Incorrect position of the top panel (side view)
Make sure that the general trailer dimensions are not exceededchapter „4 Requirements“,
page 7.
2. Installation of the subassembly for the side panels
1. Install the subassembly of the side panels (2) using M10 screws and nuts of at least strength class
8.8.
Recommended torque: 25 ±3 Nm
• Recommended: Where appropriate use a workshop crane to hold the side panels (2) during
installation.
NOTICE
Damage to the side panels through workshop crane
–Use retaining straps to avoid damaging the side panels.
Avoid any gap between trailer and sealing lip of the side panels (2).

12
Installation Installation
Correct position of the side panel (top view) Incorrect position of the side panel (top view)
2. Deploy the side panels (2)chapter „6 Operation“, page 15.
3. Installation of the gas springs
WARNING
Risk of injury due to pre-tensioned gas springs (B)
The gas springs (B) are supplied pre-tensioned and can cause serious injuries if handled incorrectly.
–Only remove the cable ties and metal holder from the gas springs (B) once the gas springs are
secured in their holders.
1. Connect the gas springs (B) (at the central and bottom door bracket) to the ball heads. The system
includes 4 gas springs.
ÖAn audible click sound ensures that the gas springs (B) are rmly secured at the bracket.
Example: Installation of the gas springs on the right side panel
C
l
i
c
k
2. Remove the cable ties and metal holder from the gas springs (B).
3. Repeat the above work step for the left side panel.

13
Installation
5.3 Final checks
Mechanics and alignment
Before you drive the vehicle with the OptiFlowTM Tail system, ensure the following:
– All OptiFlowTM Tail components must be rmly secured.
– Check if all mechanisms on the panels function with free movement. Operation of the panels must
be possible without restriction.
– Check if each bracket is fastened with the correct torque.
– Check if the panels t closely on the trailer without a gap when the system is deployed.
– Check if the top panel (1), when folded out, is below the respective side panel (2).
If you have identied a misalignment, align the side panels correctly using the stopper by adjusting the
distance to the trailer’s outer edge:
1. Unscrew the screw M8 (a).
2. Position the stopper (b) so that the top panel is ushing with the side panel, see gure below
3. Tighten the screw M8 with 10 +/-2 Nm (c).

14
Installation Operation
c
bb
a
4. Check if the dimensions of your vehicle comply with legal regulationschapter „4 Requirements“,
page 7.
Contour marking
– Check the contour marking according to ECE R 48 (chapter „4 Requirements“, page 7) and
correct this if necessary.
Example for contour marking:

15
Operation
6 Operation
CAUTION
Risk of crushing ngers/hands
When operating the OptiFlowTM Tail system there is a risk of crushing your ngers/hands.
–When folding out the side panels, make sure that your ngers/hands do not get crushed.
NOTICE
Damage to the OptiFlowTM Tail system
The system could be damaged if your open the portal doors while the OptiFlowTM Tail system is
folded out.
–Always fold in the panels of the system before you open the portal doors.
Folding out
When the OptiFlowTM Tail system is folded, the Tail is deployed as follows:
Deploying the side panels
– Manually pull the side panel (2) from inside to outside.

16
Operation Operation
Folding out the top panels
– Move the lever (A) up until it snaps into the clip (see gure).
C
l
i
c
k
Continue with the other side and carry out the same steps.

17
Operation
Folding
NOTICE
Damage to the OptiFlowTM Tail system
The OptiFlowTM Tail system can be damaged if you rst fold in the side panels (2).
–Always fold in the top panels (1) rst and then the side panels (2).
Folding in the top panel
1. Pull the lever (A) out of the holder.
2. Move the lever (A) up until the top panel (1) is completely folded.

18
Operation Maintenance
Folding in the side panel
– Manually pull the side panel (2) to the centre of the trailer.
Continue with the other side and carry out the same steps.

19
Maintenance
7 Maintenance
During normal operation the OptiFlowTM Tail system must be checked for visible damage.
All maintenance measures are required over the entire service life of the components and should be
carried out at 6 month intervals.
Gas springs
– Check the gas springs (B) for ease of movement.
– Check if the panels (2) t closely on the trailer without a gap.
Lifting rod
– Check the correct function of the top panel (1) by operating the lifting rod via the lever (A). Check
the mechanism for ease of movement.
ÖThe lifting rod (2) must be connected to the top panel (1) .
ÖIf the lever (A) does not engage correctly, the clip lock may need to be replacedchapter „8
Spare parts“, page 20.
– Check if the position of the lifting rods (3) is vertical and the connected crossbar to the top panel (1)
is not deformed.
ÖCheck the positioning of the door bracket to avoid further damage.
Stopper
– Check the correct alignment of the side panels (2).
ÖThe installed side panels (2) must run parallel to the outer edge.
ÖIf you have identied a misalignment, align the side panels (2) correctly using the stopper by
adjusting the distance to the trailer’s outer edge, section „Mechanics and alignment“, page
13.
Fine adjustment of the stopper:
– Check if the rubber element is attached to the stopper.
– Re-tighten the torque (M8 screw – 10 +/-2 Nm).
Rust may develop on some components but will not impair the function.

20
Spare parts Spare parts
8 Spare parts
The table below provides an overview of the most important spare parts at a glance:
PART NUMBER WABCO NAME FIGURE DESCRIPTION
181 010 010 4 Tail Prole Rubber-1 Rubber lip (9 m sufcient for an OptiFlowTM Tail
set)
181 020 069 4 Tail Fork-1 Fork (link between the lifting rod and the top
panel)
181 020 070 4 Tail Dist Rng Lftg Rod-1 Spacer, lifting rod mechanism, counterpart of the
clip lock
181 020 071 4 Tail Lock-1 Clip lock
810 511 109 4 Split Pin ISO1234 -
3,2x20
Split pin (for securing the bolt connection to the
bracket)
181 020 080 4 Tail Cover of Hdl-1 Handle (cover of the lever)
181 020 081 4 Tail Spacer-1 Spacer
181 210 007 2 Tail Prt Gas Spg-1 Gas spring (pre-tensioned and secured for in-
stallation)
181 210 008 2 Tail Stopper-1 Stopper (for adjusting the side panel)
181 020 073 4 Tail Sqr Gloss Caps-1 Protection cap (for installation on the lever or lift-
ing rod)