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Installation Manual Maxx Installation Manual Freight Wing Incorporated 4101 West Marginal Way SW Suite B4 Seattle, WA 98106 [email protected] TOLL FREE INSTALLATION HELP LINE: 866-464-9464 (Office hours are 8 AM - 5 PM PST) Copyright © 2013, Freight Wing Inc. Rev 2/1/13 READ THIS FIRST About This Manual This installation guide describes the necessary steps to complete the proper installation of your AeroFlex Maxx side skirt. Following each step is important to avoid potential personal, and/or property damage. If any step is unclear feel free to contact Freight Wing with any questions or comments at the toll free number 866-464-9464. Please read the instructions completely before attempting to install this product and do not skip any steps. Information about Caution, Warning, and Danger statements This book may contain the following statements: CAUTION - A caution statement describes a situation that could potentially result in damage to tools, equipment or possible injury. WARNING - A warning statement describes a situation that if not avoided could potentially result in harm to you. DANGER - A danger statement describes an imminent hazard that could result in severe injury or death. 2 Contents • Introduction 3 • What You Will Need 4 • Parts and Fastener Lists 5 • Installation Instructions 8 • Refrigerated Installation Guide 21 • Maintaining The Fairing 23 • Operation and Drivers Notes 24 Introduction Thank you for outfitting your trailer with the Freight Wing AeroFlex Maxx DMP Plastic or Composite. We look forward to helping you save fuel. The following manual will guide you through the installation procedure. You can expect the procedure to take approximately 5 man hours. However, experienced installers can reduce the install time to approximately 4 man hours. Before getting started, take a look at the “What You Will Need” section on the next page to make sure you have the necessary tools and equipment. If you have questions or if we may be of any assistance, please give us a call: TOLL FREE INSTALLATION HELP LINE: 866-464-9464 (8AM - 5PM PST) The illustration below provides an example of a typical mounting position for the AeroFlex Maxx on a 53’ trailer. The exact fit on the trailer and ground clearance can vary due to different trailer makes, models and configurations. This manual will enable you to customize the fit for different trailers. What You Will Need 3 The following tools are needed to install the Freight Wing AeroFlex Maxx Fairing: 1. Drill, preferably high speed. 2. Impact wrench, preferably light duty 3. 7/16” & 1/2" deep sockets 4. 7/16” & 1/2" wrenches 5. 5/16" drill bits (high speed bit for drilling steel, we recommend Fastenal # 3199336) 6. Clamps - ideally at least sixteen 3” C clamps (other sizes of clamps or vice grips will also work) 7. A string chalk line 8. Safety glasses 9. 2" metal separation tape (used when top aluminum channel is mounted to steel cross members for corrosion protection. Clear packing tape is sufficient) 10. 5” and 2.5” diameter hole saws, and/or a jigsaw. If installing on a refrigerated trailer: 11. A square ruler You may also want: 12. Degreaser Cleaner. D-Limonene or Dupont 381 are the two best cleaners to use. You may also use Spray Nine, Purple Power, Lysol 3/1, or Pine-Sol 100% concentration. Danger: Follow all manufacturer instructions in use of products above . Do not use any acid based products or brake cleaner. 13. Knee pads or scooter chair (to help work faster and more ergonomically) Please follow the following safety advisements: 1. Install in a well lit, well ventilated area. 2. Wear personal protective equipment when using power tools as advised by tool manufacturer. 3. Several steps are easier with a 2 man installation Complete Unit Part Numbers • 76-50188-90: AeroFlex Maxx DMP Plastic kit packaged, pre-assembled standard unit • 76-50188-91: AeroFlex Maxx DMP Plastic bulk packaged unit • 76-50188-45: AeroFlex Maxx Composite kit packaged, pre-assembled standard unit • 76-50188-46: AeroFlex Maxx Composite bulk packaged unit 4 Parts and Fastener Lists Freight Wing DMP Plastic Description Qty/Unit Part Number 58-50142-00 AF DMP Plastic Right Rear Panel 1 58-50143-00 AF DMP Plastic Left Rear Panel 1 58-50144-00 AF DMP Plastic Right Middle Panel 2 58-50145-00 AF DMP Plastic Left Middle Panel 2 58-50150-00 AF Maxx DMP Plastic Right Front Panel 1 58-50151-00 AF Maxx DMP Plastic Left Front Panel 1 Freight Wing Composite Description Qty/Unit Part Number 58-50142-04 AF Composite Right Rear Panel 1 58-50143-04 AF Composite Left Rear Panel 1 58-50144-04 AF Composite Right Middle Panel 2 58-50145-04 AF Composite Left Middle Panel 2 58-50150-04 AF Maxx Composite Right Front Panel 1 58-50151-04 AF Maxx Composite Left Front Panel 1 5 Freight Wing Component Description Qty/Unit Part Number 68-50142-00 90” L-Channel 6 68-50144-00 36” L-Channel 2 68-50141-00 90” Aluminum Backing Strip 6 68-50143-00 36” Aluminum Backing Strip 2 68-50140-00 Saddle Mount 5/16” 40 68-50182-00 Support Rod 5/16” 20 68-50183-00 Saddle Clamp Bottom Plate 20 68-50184-00 Saddle Clamp Top Plate 20 68-50135-00 Aluminum Square Washer 30 68-50145-00 Crank Handle Holder 1 6 Freight Wing Qty/ Bulk QTY/Kitted Fasteners Description Part Number Unit Unit 10475-03629 1/4 x .875 Shouldered CB (DMP Plastic Only) 70 0 74421 1/4-20 x .75 S/S Carriage Bolt (Composite Only) 70 0 71170 1/4-20 x 1.25 S/S Tap Bolt 80 80 10475-04009 1/4-20 x 1 S/S Custom Overlap Hex Bolt 18 18 0197944 1/4 S/S Bonded Washer 58 58 0172787 1/4 x 1.5 OD S/S Fender Washer 18 18 01900458 1/4-20 YZ Nylock Flanged 168 98 70057 5/16 x 1.25 S/S HCS 30 30 10475-03774 5/16-18 x 1.6 Custom Hex Bolt 40 0 71015 5/16 x .75 OD S/S Flat Washer 30 30 01900515 5/16-18 YZ Nylock Flanged 70 30 7 Installation Instructions Step 1: Assembly and Preparation 1a. (This step is completed in kitted units) Slide the support rod (68-50182-00) into the saddle (68-50140-00) as shown below. Note that the saddle extends away from the body of the rod. Insert 5/16 x 1.6 custom hex bolt (10475-03774) and firmly tighten the 5/16-18 YZ Nylock flanged nut (01900515) until it hits the shoulder. Repeat for opposite end of rod. Repeat the process for all 20 rods in each unit. 1b. On one end of the rod, assemble the saddle clamp bottom plates and top plates (68-50183- 00 and 68-50184-00) with two 1/4-20 x 1.25 tap bolts (71170) and 1/4-20 YZ Nylock nuts (01900458) as shown below. Half (10) of the clamps should be oriented to the left side of the saddle mount as shown below in the illustration on the left, and half (10) should be oriented to the right side as show below in the illustration on the right. When placed on the trailer, optimal clamp placement on one side of the trailer will mirror the other side, so that 10 of each clamp orientation will be used. 1c. When mounting the faring on trailers with steel cross members (typically dry vans), apply a “barrier” tape across the top of the L-channels to separate the metals, thus preventing corrosion. This step is not necessary for trailers with aluminum cross members (typically reefers). Any corrosion barrier tape will work for this step, and standard 2” wide clear packing tape (polypropylene tape) is an effective option (preferably heavy duty packing tape that is thicker than standard packing tape). 8 Step 2: Determine the Starting Rear Position of the AeroFlex Fairing Properly positioning the AeroFlex Maxx fairing on the trailer is important for aerodynamic effectiveness and unobstructed operation of the trailer. Because trailers have different axle and slider configurations, the position of the fairing can vary. In general, the placement of the rearward edge of the rear panel determines the fairings overall position. This rearward edge should be as close to the tires as possible but must leave enough room for sliding tandems to move into their most forward position with a minimum of 3” of clearance to the tires. It should also be flush with the outer trailer wall. From that rear position, the fairing is then mounted in a straight line, though angled, so that the forward tip is just outside (2 inches) the landing gear legs or any obstructions created by the landing gear (wing plates, leg supports, etc). Caution: Improper fairing positioning could interfere in proper operation of the trailer. 2a. Identify the trailer cross member best suited to start mounting the rearward corner of the fairing. First, slide the axles to the most forward pin position (if necessary). (After this is completed, sliding them to the rearward most position will allow better access under the trailer during install) Make a mark on the trailer side rail directly above the front edge of the forward tire. From this mark, measure a minimum of 3” along the side rail, towards the front of the trailer as illustrated below. Use the closest cross member in front of this point to mount the rearward corner of the fairing. Typically, this will be the cross member directly forward of the welded stop or bar in the slider rail.
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