Grab Handle Reinforcement Replacement

Required Repair Kit
GRAB HANDLE REINFORCEMENT
1. Remove QTY: 2 bolts that secure the Side Panel to the Side Panel Hinge.

2. Disconnect the lower end of Grab Handle, if present.
3. Remove existing reinforcement. Insert the new reinforcement between panel tube and Side Panel hinge arm.

4. Reinstall the bolts removed, securing it to the Side Panel hinge arm. NOTICE Do not overtighten, as this
will crush the tube. Refer to Torque Specifications at the end of this Repair Guide.

R10-21

Grab Handle Replacement

Required Repair Kit
GRAB HANDLE KIT
1. Remove the upper bolt holding the Grab Handle to the panel hinge arm.
2. Remove the nut and bolts combination securing the lower part of the handle.
3. Remove old handle and replace with new handle.
4. Reinstall all removed hardware to secure the new Grab Handle, including the rubber spacers. Make sure that
the lower bolt is tightened until it clamps the tube and does not spin freely. NOTICE Do not over tighten this
bolt, as this will crush the tube. Refer to Torque Specifications at the end of this Repair Guide.

R10-30

Top Panel Triangle Replacement

Required Repair Kit
TOP TRIANGLE DRIVER KIT OR TOP TRIANGLE PASSENGER KIT
WARNING
Always use Safety Glasses and Face Shield when working with items above your head.
1. Place system in the recommended Safe to Service mode. After this procedure, the system is fully open and
prevented from closing by propping open the upper actuator.
2. Open the system all the way open and remove the two upper nuts and bolts securing the Triangle to Side
Panel.

3. Remove the prop from the upper actuator and move the center panel to the lowest position causing the other
Side Panel to follow to the closed position. The side that is being repaired should be all the way open.
4. Use a small ladder on the catwalk to access the two 5/16-in bolts and nuts going through the center of the
hinges, connecting the Trapezoid Panel to the Triangle being replaced.

5. Remove damaged Triangle and position new Triangle. Replace the hinge bolts now with supplied hardware.
6. Tighten the hinge bolts, until the bolt will not spin relative to the wider three-hole hinge leaf in the Trapezoid
Panel. NOTICE Make sure that there are at least 2 threads showing past the end of the nut to ensure
that the locking feature of the nut is fully engaged. Refer to Torque Specifications at the end of this Repair
Guide.
7. Pull the wings open all the way and replace the prop tool to keep panels fully open.
8. Reconnect the new Triangle to the Side Panel. Make sure that the washer or spacer on the underside is
replaced. Do not overtighten, as this will crush the tube. Refer to Torque Specifications at the end of this
Repair Guide.

R10-31

Top Panel Assembly Complete Replacement

Required Repair Kit
TOP PANEL KIT
WARNING
Always use Safety Glasses and Face Shield when working with items above your head.
1. Place system in the recommended Safe to Service mode. After this procedure, the system is fully open and
prevented from closing by propping open the upper actuator.
2. Remove the 2 bolts securing the Triangle to Side Panels on each side, disconnecting the top panel from the
side panels.
3. Use a small ladder on the catwalk to access the bolts that secure the upper panel to the frame. Remove the
bolts from the two outer hinges, leaving the two inner hinges intact.

4. Remove the hardware securing the upper actuator to Trapezoid paying attention to the orientation or the
spacers and retain them, as they might fall when the bolt is removed.

5. Lower the extended actuator down so that it is out of the way.
6. While supporting the trapezoid, remove the remaining two bolts in the hinges holding the Trapezoid to the
frame. Make sure to support the panel as it weighs about 30 lbs (13.6 kg) and is now completely
detached. It is recommended that a second person assists with this step to help hold the panel.

7. With the panel on the ground, remove the bracket from the center by removing the two bolts that secure the
bracket. Install this bracket on the new panel set with the same bolt orientation as the old panel.

8. Use a clamp, vise grip, or similar to fold Triangles over the Trapezoid and hold in place.

9. While standing on the ladder, use one arm to place the panel’s hinges back into alignment with the hinge
halves on the frame and reinstall the four (4) bolts that connect to the hinges on the upper frame. Tighten
hinge bolts until the bolt will not spin relative to the wider three-hole hinge leaf on the trapezoid panel,
making sure that there are at least 2 threads showing past the end of the nut to ensure that the locking
feature of the nut is fully engaged. Refer to Torque Specifications at the end of this Repair Guide.
10. Raise the connected panel set all the way up and reattach the upper actuator to the bracket with the
appropriate hardware. Tighten the bolt until spacers will not spin freely. Refer to Torque Specifications at the
end of this Repair Guide.
11. Remove the clamps holding the Triangles to Trapezoid and reinstall triangles to the Side Panels, tightening
only until the tube is just clamped and the bolt does not spin freely. NOTICE Do not overtighten, as this will
crush the tube. Refer to Torque Specifications at the end of this Repair Guide.
12. Remove the prop on the upper actuator and cycle the system open and close several times to ensure proper
operation. Verify all bolted connections are tightened.

R20-00 Mounts and CNG Cabinet Fairings
R20-10

Side Panel Hinge Replacement

Required Repair Kit
SIDE PANEL HINGE REPLACEMENT KIT
1. Place system in the recommended Safe to Service mode. After this procedure, the system is fully open and
prevented from closing by propping open the upper actuator.
2. Disconnect the actuator from the Side Panel Hinge, holding on to the metal spacers that will fall out when the
bolt is removed, as well as the bolt and nut.
3. Remove QTY: 5 bolts securing the Side Panel hinge to the panel. The three outer ones have rubber spacers
while the two inner ones are flush mounted to the tube. The panel will hang in place during the process.

4. Disconnect the Cab Hinge from the Side Panel Hinge by removing the long pivot bolt. Discard old Side Panel
Hinge.
5. Align new Side Panel Hinge with the cab Hinge. Insert the new Pivot Tube into the new Side Panel Hinge.
6. Add one Thrust Washer between the Side Panel Hinge and the Cab Hinge at both bottom and top flanges.
7. Insert 1/2-in x18-in bolt through Pivot Tube. Add anti seize lubricant to new bolt threads before adding a new,
1/2-in lock nut when reassembling Side Panel Hinge to Cab Hinge. Use a torque wrench to tighten to 25
ft-lbs (33.9 Nm).
8. Attach the Side Panel Hinge to the Side Panel by reinserting the 5 bolts, including the rubber spacers where
needed. Do not overtighten when reinstalling.

R20-11

Cab Hinge Replacement

Required Repair Kit
CAB HINGE KIT
1. Place system in the recommended Safe to Service mode. After this procedure, the system is fully open and
prevented from closing by propping open the upper actuator.
2. Disconnect the actuator from the Cab Hinge, holding on to the metal spacers that will fall out when the bolt
is removed, as well as the bolt and nut.
3. Disconnect the Cab Hinge from the Side Panel Hinge by removing the long pivot bolt between the two
hinges.
4. Remove QTY: 4 fasteners that secure the hinge to the side extender.

5. Remove QTY: 5 bolts that secure hinge to the cabinet.

6. Reverse removal to reinstall new Cab Hinge making sure to torque all fasteners as described in Torque
Specifications section.

R20-12

Side Panel Hinge Bushing Service

Required Repair Kit & Service Tool
SIDE PANEL HINGE BUSHING KIT, COMPLETE
BUSHING SPREADER SERVICE TOOL p/n 61300010
1. Position step ladder on vehicle to access Side Panel Hinge pivot.
2. Disconnect the Side Panel Hinge from the Cab Hinge by removing the long pivot bolt between the two hinges.
Discard hardware and pivot tube.
3. Pull Side Panel away from Cab Hinge. Remove plastic bushings from Side Panel and discard.
4. Use bushing spreader service tool p/n 61300010 to spread Cab Hinge flanges apart prior to reassembly and
install of Side Panel Hinge.
5. Install new plastic bushings in the Side Panel Hinge.
6. Insert new pivot tube through bushings and center vertically in Side Panel Hinge.
7. Add thrust washers between the Side Panel Hinge and the Cab Hinge at both bottom and top flanges.
8. Carefully place Side Panel Hinge assembly back in Cab Hinge. NOTE: Do not allow thrust washers to be
pinched or dislodged.
9. Release and remove Spreader Tool.
10. Insert ½-in x 18-in bolt through Pivot Tube. Add anti seize lubricant to new bolt threads before adding a new,
½-in lock nut when reassembling Side Panel Hinge to Cab Hinge. Use a torque wrench to tighten to 25 ftlbs (33.9 Nm).
11. Repeat for the opposite side.

R20-20

Side Extender Fairing Replacement

Required Repair Kit
SIDE EXTENDER KIT, DRIVER OR SIDE EXTENDER KIT, PASSENGER
1. Remove QTY: 2 bolts located at the top of the fairing used to secure the top fairing to the side fairing.

2. Remove QTY: 4 fasteners used at the side to secure the hinge to side extenders.

3. Unplug and remove the utility light.
4. Remove the bolts securing the fairing to the cabinet.

5. Reverse removal steps to reinstall new fairing, making sure to torque all fasteners as described in Torque
Specifications section.

R20-21

Upper Skin Replacement

Required Repair Kit
UPPER SKIN ASSY KIT
WARNING
Always use Safety Glasses and Face Shield when working with items above your head.
1. Place system in the recommended Safe to Service mode. After this procedure, the system is fully open and
prevented from closing by propping open the upper actuator.
2. Remove the upper panels per R10-31 Top Panel Assembly Complete Replacement.
3. Remove the 2 or 3 bolts located at the very edge of the top fairing that secures it to the side fairing.

4. Remove the bolts securing the top fairing to the brackets.

5. Remove old fairing, noting that some units may have a CB antenna protruding through the fairing, if so,
raise the fairing up to clear the antenna before removing.
6. Replace old fairing with new fairing.
7. Reverse removal steps to reinstall making sure to torque all fasteners to spec as described in Torque
Specifications section.

R20-22

Distance Sensor Bracket Repair

Required Repair Kit
DISTANCE SENSOR KIT
WARNING
Always use Safety Glasses and Face Shield when working with items above your head.
1. Place system in the recommended Safe to Service mode. After this procedure, the system is fully open and
prevented from closing by propping open the upper actuator.
2. Unplug the sensor from the main harness.
3. Remove QTY: 2 1/4-in bolts on both sides of the sensor body.
4. Remove all zip ties that secure the sensor harness and remove the sensor as a unit. Cut the zip ties, but do
not remove the edge clip mounts.
5. Drill out the 1/4-in rivet securing the bracket to the frame.

6. Place the bracket in a vise and straighten so that the sensor is pointing straight back at the trailer. If unable
to bend the bracket back into alignment, replace with a new Distance Sensor Bracket.
7. Reverse removal steps to reinstall. Use one high strength rivet to secure the bracket back in place.
Reconnect the distance sensor and replace zip ties.
8. Verify that sensor is functioning by using the TruckWings Controller Test Screen. On the Controller dash
unit, move Service Toggle to the MIDDLE position. The screen should display a value for Rear Sensor other
than 'Error'.

R20-30

Air Hose Hanger Replacement

Required Repair Kit
AIR HOSE MOUNT REPLACE KIT
1. Place system in the recommended Safe to Service mode. After this procedure, the system is fully open and
prevented from closing by propping open the upper actuator.
2. Remove the carabiner that holds the air hose/electric cord and place them on the catwalk.
3. Remove QTY: 4 fasteners that secure the Hose Hanger to the back of the cab.

4. If there is a Distance Sensor attached to the old Hose Hanger, remove it and reattach it to the new Hose
Hanger.
5. Reverse removal steps to reinstall, making sure to torque all fasteners as described in Torque Specifications
section.

R30-00 Airflow System
R30-10

Top Actuator Replacement

Required Repair Kit
ACTUATOR COMPLETE, TOP, KIT
1. Place system in the recommended Safe to Service mode. Note that when replacing the top actuator, you
can use the prop tool on one of the side actuators to keep the system open.
2. With a ladder, access the top actuator rod end connection to the Trapezoid actuator bracket. Remove the
pivot bolt and nut from the rod end side. Discard the used fasteners and spacers.

3. Disconnect air lines connected to the actuator fittings. Also remove any zip ties securing hoses to actuator
body.
4. Remove bolts and nut at lower actuator body bracket. Discard used fasteners and spacers.

5. Remove actuator being replaced.
6. Reverse removal steps to reinstall new actuator, including installation of zip ties securing air line routing.
Use the new fasteners and spacers from the fastener kit to reinstall.
7. Tighten bolts at both ends of actuator connections until spacers will not spin freely. Do not
overtighten, as spacers can crush. Refer to Torque Specifications at the end of this Repair Guide.
8. Ensure air lines get fully pushed in the fitting so they do not leak. Inspect for leaks with the tractor
pressurized and the engine OFF.

R30-20

Bottom Actuator Replacement

Required Repair Kit
ACTUATOR, COMPLETE, BOTTOM, KIT
1. Place system in the recommended Safe to Service mode. After this procedure, the system is fully open and
prevented from closing by propping open the upper actuator.
2. Remove the pivot bolt and nut from the rod end side. Discard the used fasteners and spacers.

3. Disconnect air lines attached to the actuator fittings. Also remove any zip ties securing hoses to actuator
body.
4. Remove the pivot bolt from the actuator fixed end. Discard used fasteners and spacers.

5. Remove actuator being replaced.
6. Reverse removal steps to install new actuator, including installation of zip ties securing air line routing. Use
new fasteners and spacers from fastener kit to reinstall.
7. Tighten bolts at both ends of actuator connections until spacers will not spin freely. Do not
overtighten, as spacers can crush. Refer to Torque Specifications at the end of this Repair Guide.
8. Ensure air lines are fully pushed in the fitting so they do not leak. Inspect for leaks with the tractor
pressurized and the engine off.

R30-30

Airflow Control Assembly Replacement

Required Repair Kit
AIRFLOW CONTROL ASSY

1. Place system in the recommended Safe to Service mode. After this procedure, the system is fully open and
prevented from closing by propping open the upper actuator.
2. Remove the truck air hoses that are retained by a carabiner on the Hose Hanger and lay them on the catwalk.
3. Open Airflow Control Box by removing the carabiner that holds it closed.
4. Unplug the 2-pin electrical harness going to the Directional Control Valve (DCV) valve.
5. Unscrew the Phillips head screw that secures the valve assembly to the box.
6. Disconnect the black 1/4-in Air Supply line and Remove all the 1/4-in blue and 5/32-in black lines.
7. Locate the additional loose fittings provided with the new Airflow Control Assembly. Replace the plug fitting
on the control valve with the appropriately sized branch fitting to match the tubing coming from the actuators.
Use the smaller OD branch fitting for systems with black and blue tubing coming from the actuators.

8. Reverse the removal procedure to reinstall.
9. Ensure all lines are pushed in fully so they do not leak. Inspect for leaks with the tractor pressurized and the
engine off.
10. Test system for operation after install.

R30-40

Actuator Hose Bundle Replacement

Required Repair Kit
ACTUATOR HOSE BUNDLE
1. Place system in the recommended Safe to Service mode. After this procedure, the system is fully open and
prevented from closing by propping open the upper actuator.
2. Remove the truck air hoses that are retained by a carabiner on the Hose Hanger and lay them on the
catwalk.
3. Open up the Airflow Control Box, undoing the carabiner that holds it closed.
4. Disconnect the hose bundle from Actuator by removing hoses from ports and cutting zip ties.

5. Cut and remove the zip ties securing the harness pair that is being replaced. Keep the Zip Tie mounts in
place for securing the new tube.
6. Disconnect the hose bundle from tee fittings in the Airflow Control Box. Remove the old hose bundle.
7. Connect the new hose bundle, starting at the Airflow Control Box. Reverse the removal procedure to
reinstall.
8. Check that all lines are pushed fully into fittings to avoid leaks.
9. Secure the tubing to the actuator bodies and ensure that the tube does not enter fittings at an angle. For
the tubing going up to the top actuator, do not trim. For tubes on side actuators, trim as necessary to match
the original installation configuration. Cut tubing so that it is square, do not cut at an angle.
10. Secure the bundle to the cab and brackets with new zip ties to the existing zip tie mounts. The new bundle
should be zip tied in the same places as the original.
11. Check that the tubing pair is secured to the actuator body before it goes to the actuator fittings. This
prevents the fittings from rotating when the TruckWings open and close.
12. Test the system for operation after install.

R30-41

Tractor Air Supply Hose Replacement

Required Repair Kit
TRACTOR AIR SUPPLY HOSE
1. Place system in the recommended Safe to Service mode. After this procedure, the system is fully open and
prevented from closing by propping open the upper actuator.
2. Remove the truck air hoses that are retained by a carabiner on the Hose Hanger and lay them on the
catwalk.
3. Open up the Airflow Control Box, by removing the carabiner that holds it closed.
4. Remove the black 1/4-in Air Supply line and clip the zip ties securing it in position. Keep the Zip Tie mounts
in place for securing the new tube.
5. Connect the new hose bundle and reverse the removal procedure to reinstall.
6. Ensure all lines are pushed in fully so they do not leak. Inspect for leaks with the tractor pressurized and
the engine off.
7. Secure the air line bundle to the cab and brackets with new zip ties to the existing zip tie mounts. The new
bundle should be zip tied in the same places as the original.
8. Test system for operation after install.

R40-00 Electronic & Harness
R40-10

Distance Sensor Replacement

Required Repair Kit
DISTANCE SENSOR KIT
WARNING
Always use Safety Glasses and Face Shield when working with items above your head.
1. Place system in the recommended Safe to Service mode. After this procedure, the system is fully open and
prevented from closing by propping open the upper actuator.
2. If the formed metal bracket is damaged or bent, perform R20-22: Distance Sensor Bracket Repair.

3. Unplug the sensor from the main harness.
4. Remove QTY: 2 1/4-in bolts on both sides of the sensor bracket.
5. Remove all zip-ties that secure the sensor harness and remove the sensor as a unit.
6. Reverse procedure to install the new sensor and reapply zip ties so that harness will not rub on sharp edges.
Pay special attention that the plug terminals are free from any corrosion.
7. Check the TruckWings Controller Test Screen by flipping the toggle switch to the middle position. Confirm
that the Rear Sensor reads distance and not ‘Error’.

R40-20

TruckLabs Telematics Replacement

Required Repair Kit
TRUCKLABS TELEMATICS
NOTICE
It is critical to follow all instructions in this procedure. If Step 6 is not followed, TruckWings will be
inoperable until registration is complete.
1. Remove dash panel to access TruckLabs Telematics device.

2. Unscrew barrel connector from CAN Harness to the Telematics.

3. Install new Telematics device. Screw on barrel connector.
4. Verify that the TruckWings Controller screen is powered up and move the Service Toggle to its middle position.
The QC Screen should display OK for all values with the vehicle ignition ON.

5. On the TruckWings Controller screen, note the Telematics ID (example: TLT_86YG32). This will be used to
register replacement with TruckLabs.

6. Contact Hexagon Agility at +1 833 4 HEX CARE or [email protected] to report Telematics swap
and register the new Telematics device. Be prepared to provide vehicle number and the new Telematics
ID shown above.
7. The tractor is OK to release after submitting the request. A confirmation message will be sent to the provided
email within 24 hours.

R40-21

TruckWings Controller Replacement

Required Repair Kit
TRUCKWINGS CONTROLLER
1. Lift up on the lid of the Controller to separate from its base.
2. Disconnect CAN Harness and Exterior Harness from lid of Controller.
3. Remove rivets and base from the dash.
4. Install new base with new rivets. Pass harnesses through base grommet.
5. Plug in Exterior Harness to the new Controller lid.
6. Plug in CAN Harness to the new Controller Lid. NOTE: If screen is blank after installing harnesses, press and
hold Reset button on bottom of lid for 2 seconds to reboot Telematics system.
7. Install Controller lid on base. If included, insert included rivets through lid and base on bottom edge.

R40-22

TruckWings Controller Test Screen Mode

The TruckWings Controller has a test screen mode to help diagnose any issues with the CAN connection, cell
connection, and Trailer Distance Sensor.
1. Lift toggle switch cover and put the toggle switch in the middle position.
2. Screen will display functions and the status of each function.

3. When done, flip the switch cover all the way down for normal operation.

R40-30

Exterior Harness Replacement

Required Repair Kit
EXTERIOR HARNESS KIT
If the exterior harness is damaged, we recommend replacing the complete harness with a new one due to the
environment it operates in.
Note: On Volvo models, this harness terminates below the BTC and connects to a Volvo factory-supplied
harness. The Volvo factory harness continues through the dash to the TruckWings Controller. Contact Volvo
dealer for service information.
1. Starting at the back and working towards the front, remove old harness and replace with new harness. Cut
the zip ties from the old harness but leave any anchored zip tie mounts such as Christmas tree zip tie mounts,
adhesive zip tie mounts or edge clip zip tie mounts that are still secure.
2. Remove old zip-ties and replace with new zip ties to secure the new harness. Note the routing of the old
harness and install new harness in the same manner while applying zip-ties every 12-in to hold secure.
Reinstall zip ties in the same locations where possible.
3. Insert the harness through the existing hole in the firewall into the cab and replace and reseal the grommet in
the firewall hole.
4. Remove any dash or instrument cluster panels needed to get access to the harness and behind the
TruckWings Controller.
5. Connect the new harness to the TruckWings Controller.
6. Check the TruckWings Controller diagnostic screen by flipping the toggle switch to the MIDDLE position.
Confirm that the Rear Sensor reads distance and not ‘Error’.

R40-31

CAN Harness Replacement

Required Repair Kit
CAN HARNESS KIT

The CAN Harness is located entirely in the interior of the cab. Repair or modification to the CAN Harness is not
recommended. However, if you believe you have a damaged or defective CAN harness, replace it with a new
one.
1. Unplug CAN harness from the TruckLabs Telematics and TruckWings Controller.
2. Follow the harness to find the other end connector, a gray RP1226 plug. The plug will be in the vicinity of
Telematics connected to the truck’s CAN bus.
3. Remove any zip-ties securing it to other harnesses in the truck.
4. Replace old CAN harness with new CAN harness. First reconnect the TruckWings Controller, and then
reconnect the RP1226 connection to the truck.
5. Turn vehicle ignition ON. Check the Telematics diagnostic screen by flipping the toggle switch to the middle
position. Confirm that Speed, Fuel and Odometer values read OK.

R40-32

Utility Light Harness

Required Repair Kit
LIGHT HARNESS
1. Disconnect harness being replaced and cut zip tie attaching it to side extender bracket. Do not remove edge
clip zip tie mount.
2. Replace with new light harness.
3. Secure new harness with a zip tie to edge clip zip tie mount.

Torque Specifications
For all repair activities, the following torque specifications must be used:
For metal-on-metal connections (mounts components), torque M8 fasteners to 215 to 255 in-lbs (24.3 to
28.8 Nm).
For composite connections (side panels to side panel hinge arms and triangle to side panel), tighten
fastener until fastener will not turn.
NOTICE Do not overtighten as panel FRP tube material can crush or FRP plastic panel can dimple or crack.

For actuator spacers (both ends of all three actuators), tighten until all slack is removed and spacers will
not spin.
NOTICE Do not overtighten as aluminum spacers can crush.
NOTE: Plastic thrust washers captive between the spacers and actuator should also be free to spin and
should have a small amount of vertical/lateral free play.

For small hinges (panel-to-panel and trapezoid to frame), tighten until all slack is removed and the bolt will
not spin relative to three-hole hinge leaf.
NOTICE Do not over tighten and deform the hinge leaf.
For composite-bumper connections (side panel to side panel hinge arms), tighten fastener until bushing
is compressed to approximately 0.75-in (19 mm).
FOR REFERENCE: Bushings have a 1-in (24.5 mm) free height.

For main side panel hinges, tighten until all slack is removed and spacers will not spin.
NOTICE Do not over tighten as aluminum spacers can crush.
NOTE: Plastic thrust washers captive between the spacers and side panel hinge arm should also be free to
spin and should have a small amount of vertical/lateral free play.