DSM.0100 Ver. 2.0 April 25, 2023

CNG TruckWings™

Troubleshooting and Repair Guide

The following guide applies to TruckWings models: XS-203402-1, XS-203402-2

Table of Contents
Visual Glossary
Troubleshooting Guides
T00-10

TruckWings Do Not Deploy Using Controller

T00-20

TruckWings Do Not Deploy on Highway

T00-30

Trailer Distance Sensor Error

T00-40

No Power to TruckWings Controller

T00-50

Identifying Airflow System Leaks

Repair Guides
R00-00

Service Modes

R00-10

Switching System to Safe To Service Mode

R00-20

Adding or Removing System from Remote Hold Closed Mode

R00-30

Securing TruckWings in the Event of Emergency

R10-00

Panels

R10-10

Side Panel Replacement

R10-11

Side Panel Upper Tube Repair

R10-12

Side Panel Tube Rivet Replacement

R10-20

Grab Handle Reinforcement Replacement

R10-21

Grab Handle Replacement

R10-30

Top Panel Triangle Replacement

R10-31

Top Panel Assembly Complete Replacement

R20-00

Mounts and CNG Cabinet Fairings

R20-10

Side Panel Hinge Replacement

R20-11

Cab Hinge Replacement

R20-12

Side Panel Hinge Bushing Service

R20-20

Side Extender Fairing Replacement

R20-21

Upper Skin Replacement

R20-22

Distance Sensor Bracket Repair

R20-30

Air Hose Hanger Replacement

R30-00

Airflow System

R30-10

Top Actuator Replacement

R30-20

Bottom Actuator Replacement

R30-30

Airflow Control Assembly Replacement

R30-40

Actuator Hose Bundle Replacement

R30-41

Tractor Air Supply Hose Replacement

R40-00
R40-10

Electronic & Harness
Distance Sensor Replacement

R40-20

TruckLabs Telematics Replacement

R40-21

TruckWings Controller Replacement

R40-22

TruckWings Controller Test Screen Mode

R40-30

Exterior Harness Replacement

R40-31

CAN Harness Replacement

R40-32

Utility Light Harness

Torque Specifications

This repair guide provides instructions and procedures for troubleshooting, repairing and replacing various
TruckWings components and subsystems.
For more information, contact Hexagon Agility FleetCare at +1 833 443 9227 or via email at
[email protected]

Visual Glossary

No.

Part

Description

1

Trailer Distance Sensor

Ultrasonic sensor used to detect cab-to-trailer gap.

2

Airflow Control Box

Houses Directional Control Valve, regulator, & ball valve.

3

Exterior Harness

Harness connecting (1) and (2) to (4) on dash.

4

TruckWings Controller

Mounted to the vehicle dash.

5

TruckWings CAN Harness

Connects to vehicle RP1226 connection.

6

TruckLabs Telematics

Mounted behind the vehicle dash.

Troubleshooting Guides
T00-10

TruckWings Do Not Deploy Using Controller

CAUTION
For safety, before attempting to manually deploy TruckWings, ensure the area behind the TruckWings
is entirely clear of all personnel and equipment
If the TruckWings do not open manually from the TruckWings Controller toggle switch on the dash, check the
following:
1. Check that the TruckWings Controller is connected. Pull out the TruckWings Controller from the dash and
ensure that each of the two connectors and the individual wires are securely and fully connected.

2. Ensure the air valve located in the Airflow Control Box is turned open to allow air flow (with valve lever pointing
down) as shown.
CAUTION If the valve is found to be closed, return to the TruckWings Controller and flip the switch down to
“AUTO”. If this step is not performed, TruckWings will extend when the valve is moved to the open position with
a person standing immediately behind the wings. With TruckWings Controller in “AUTO”, the valve can be
opened, then, with no one on the catwalk behind TruckWings, TruckWings Controller toggle can be flipped all
the way up to “MANUAL EXTEND” mode.

3. Check that the system has more than 85 psi (5.86 bar) in the secondary air tank.
4. Turn vehicle ignition ON and check the TruckWings Controller display. With the toggle cover DOWN in
AUTO, and no trailer hooked up, the screen should display as shown with ‘DIST: No Trailer’.

I. If DIST reads ‘Error’, see T00-20: Trailer Distance Sensor Error
II. If ‘OK’ or ‘Too Close’, something is blocking the sensor. Clear obstruction and try again.
5. If problem persists with ‘DIST: No Trailer’, remove installed TruckWings Controller and replace with known
working TruckWings Controller. Flip the toggle up to “Manual Extend” and check for functionality.
6. If problem persists with replacement TruckWings Controller, disconnect the Exterior Harness from the
Directional Control Valve in the Airflow Control Box. Use a voltmeter to check for 12V at the output of the
Exterior Harness, as shown at arrow below.
Voltage is only sent if ‘DIST: No Trailer’ & Controller toggle is all the way UP.
I. If 12V is present, replace the Directional Control Valve assembly.
II. If 12V is not present, investigate Exterior Harness continuity.

T00-20

TruckWings Do Not Deploy on Highway

1. Verify TruckWings can be deployed manually by flipping the toggle switch UP on the TruckWings Controller
while the tractor is stationary and unhooked from trailer. If TruckWings do not deploy, follow steps in T00-10:
TruckWings Do Not Deploy Using Controller.
2. Flip the toggle cover DOWN and check the display. If the display shows the following, the TruckWings are
disabled by software at the request of a technician. Follow instructions in R00-20: Adding or Removing
System from Remote Hold Closed Mode to return TruckWings to automatic operation.

3. TruckWings require a minimum distance between cab and trailer. If the Fifth Wheel is slid too far forward, the
Distance Sensor will detect the trailer as “Too Close” and disable deployment. Move the Fifth Wheel back
until “DIST” reads OK on the display screen when hooked up to a trailer.
If “DIST” reads “Error”, proceed to T00-30: Trailer Distance Sensor Error.

T00-30

Trailer Distance Sensor Error

If the TruckWings Controller screen shows ‘DIST: Error’ when the toggle is closed in “AUTO” as shown below:

1. Confirm the Exterior Harness is connected at both the Distance Sensor and TruckWings Controller.
2. Confirm that power is supplied to the sensor through blinking blue LED on back of the sensor, visible while
standing on the tractor’s deck plate, shown below.

3. If the Distance Sensor LED is OFF, check pin integrity on the Molex connector of Exterior Harness going into
the TruckWings Controller.
If all connections appear OK and error persists, disconnect the Exterior Harness from the TruckWings Controller.
 Disconnect the Telematics from vehicle power.
 Attach a standalone, known working Exterior Harness and Distance Sensor, as shown below.
 Reconnect the Telematics to vehicle power.
I. If the test Harness and Distance Sensor produce a valid sensor reading, replace the Distance Sensor on
the vehicle with the one tested. Reconnect installed Exterior Harness and confirm full system functionality.
II. If the test Harness and Distance Sensor still produce an ‘Error’, replace the TruckWings Controller and
repeat. Confirm full system functionality. Reconnect the Exterior Harness installed in the vehicle and again
confirm full system functionality.
III. If ‘Error’ remains after installing both a new Distance Sensor and new TruckWings Controller, investigate
Exterior Harness for faults.

T00-40

No Power to TruckWings Controller

If the TruckWings Controller screen is blank, use the following table to troubleshoot.
Controller
Screen
is off

Controller Power
LED
is solid green

Telematics Cloud
LED
is pulsing blue

Troubleshooting Tips





is off

is off

is off

is off

is pulsing blue

is off

Press and hold the reset
button on the bottom of the
Controller for five seconds to
reboot the system.
Swap in known working
Controller (R40-21:
TruckWings Controller
Replacement).



Check harness connection
between Telematics and
Controller.



Swap in known working
TruckWings Controller.



Swap in known working
Telematics (R40-20:
TruckLabs Telematics
Replacement).



Check connection to vehicle
12V at RP1226 connector.



Check fuse for vehicle’s
accessory circuit providing
power to RP1226 connector.



Swap in known working
Telematics.

T00-50

Identifying Airflow System Leaks

If an air leak is heard, locate the leaking component and perform the following:
If the leak is coming from the Airflow Control Box located in the center back of the fuel cabinet:
1. Open and close the TruckWings rapidly using the toggle switch on the TruckWings Controller. Switch UP to
“MANUAL EXTEND” and down to “AUTO” quickly about 5 times. Check if the leak persists. If so, continue
to the next step.
2. Open TruckWings and open the white airflow control box in the center where the leak is coming from.
3. If the leak is at a tubing to fitting connection, try pushing the tubing in more. If leak persists, take tubing out
and cut it square. If the leak persists, replace the Airflow Control Assembly per R30-30: Airflow Control Assy
Replacement.
4. If the leak is coming from around fitting or component threads, try tightening the threaded connection. If the
leak persists, replace the Airflow Control Assembly.
5. If the leak is coming from the Airflow Directional Control Valve (DCV) exhaust ports, apply SAE 10W oil to all
actuator ports to lubricate the actuator internals. Open and close the TruckWings another 5 times. If the leak
persists, continue to the next step.

6. Use a pair of needle nose pliers to start pinching off airlines going to actuators until the leak stops and you
identify the actuator with an internal seal leak. Replace cylinder per R30-10: Top Actuator Replacement or
R30-20: Bottom Actuator Replacement.
If the leak is coming from a cylinder fitting, replace fitting using thread sealant on fitting threads.
If the leak is coming from a cylinder end seal, replace the cylinder per R30-10: Top Actuator Replacement or
R30-20: Bottom Actuator Replacement.

Repair Guides

R00-00 Service Modes
R00-10

Switching System to Safe To Service Mode

Required Repair Kit
ACTUATOR PROP SERVICE TOOL, p/n 61300008
WARNING
Always use Safety Glasses and Face Shield when working with items above your head.
Before servicing internal components of the TruckWings system, place the system in Safe to Service mode by
performing the following:
1. Drain the air tanks by pumping brake pedal repeatedly until air pressure gauge on dash reads 0 psi / bar.
2. Remove keys from ignition to prevent any unwanted attempts of starting the motor and truck building up air
pressure.
3. Open the wing system by pulling the panels open. NOTE: If panels do not readily open, disconnect tubing
entering the rod end side of one of the actuators.
4. Set up a small ladder in the center to reach up to the Upper Cylinder, under the Trapezoid.
5. Prop the TruckWings open by pushing trapezoid to fully deployed position and inserting actuator prop
service tool p/n 61300008 as shown below.

6. Perform the required service action.
7. Remove the upper cylinder prop tool and ladder. Reconnect any disconnected tubing. Wings will return to
the closed state when the secondary air tank is filled to above 85 psi (5.86 bar).

R00-20

Adding or Removing System from Remote Hold Closed Mode

TruckWings can be disabled remotely by software in the event of damage while waiting on repairs. This will
disable TruckWings from deploying at any speed.
Note: If airflow system is leaking, follow procedure in R00-30: Securing TruckWings in the Event of Emergency
to physically restrain TruckWings in addition to adding system to Remote Hold Closed.
If the following message is displayed on the Telematics controller, the system is set to Hold Closed and
TruckWings will not deploy at highway speeds.

To add or remove a unit from Remote Hold Closed Software, contact Hexagon Agility FleetCare at
[email protected] or +1 833 443 9227.

R00-30

Securing TruckWings in the Event of Emergency

Required Tool
6 ft Ratchet Strap
In the event of an accident resulting in damage to the TruckWings, disable TruckWings by setting Controller
toggle to the middle position until repairs can be made. Notify your terminal maintenance department or repair
facility of damage and/or functional loss as soon as possible so repairs can be evaluated and scheduled.
If TruckWings have incurred structural damage and need to be secured, follow the procedure below:
1. Close ball valve found inside the Airflow Control Box.
2. Strap the TruckWings shut using ratchet straps across points shown below. Repeat the same on both sides
to secure each Side Panel.
3. Ensure the strap is snug and cannot slip.

4. Pull on each of the large TruckWing panels to verify it is secure and cannot be moved or opened.
5. Stow excess strap so it will not move around in the wind and/or catch on other portions of TruckWings or
tractor.

R10-00 Panels
R10-10

Side Panel Replacement

Required Repair Kit
SIDE PANEL DRIVER KIT OR SIDE PANEL PASSENGER 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 two 1/4-in bolts and nuts located at the top tube of the wing. They secure the Triangle to the
Wing. Keep all fasteners. NOTE: There may be flat spacers on the underside that need to be kept and reused.

3. With an assistant, remove the bolts holding the side panel to the main hinge. Make sure the Panel is supported
during this step, as it will be loose at this point and can fall.

4. Reverse procedure after transferring any hardware or handles that were used on the discarded panel to the
new replacement panel. Make sure that the bolts are tightened until they clamp and do not spin freely.
At locations with a composite tube, do not overtighten, as this will crush the tube. For locations with a
rubber bumper, tighten until the bumper is compressed 25%. Refer to Torque Specifications at the end of
this Repair Guide.

R10-11

Side Panel Upper Tube Repair

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 Triangle from the Side Panel by removing the 2 bolts connecting the hinge to the Side Panel
tube, if the tube is still attached to the wing.

3. Place the tube at the top of the Wing if it has been detached from the Wing. Hold it in place with a clamp.
4. Drill QTY: 4 1/4-in diameter holes spaced evenly across the top.
5. Secure tube using 1/4-in x 1.75-in bolts and lock nuts to reattach tube to top of side panel.

6. Reattach the 2 Triangle to Wing bolts and nuts that secure the Triangle to the Side Panel. Only tighten until
parts are 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.

R10-12

Side Panel Tube Rivet Replacement

Rivets can pull through the panel tubes, resulting in the exterior sheet becoming separated from the support
tube.

It is recommended that the rivet be removed and replaced with a 1/4-in nut and bolt to secure the panel to the
support tube. A new hole can be drilled near the rivet if the rivet hole is oversized or damaged.
Do not overtighten, as this will crush the tube. Refer to Torque Specifications at the end of this Repair Guide.

R10-20