DSM.0101 Ver. 2.0 April 25, 2023

CNG TruckWings™
Preventative Maintenance Guide

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

Table of Contents
Introduction

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Operating/Use Conditions

3

Driver Inspection (Trip Inspections)

3

Maintenance Procedures

4

General Maintenance Requirements and Notes

4

Preventative Maintenance Inspection Guide

5

Recommended Maintenance Schedule

8

Airflow Cylinder Lubrication

8

Side Panel Hinge Bushing Service

9

Putting TruckWings in Service Mode
Torque Specifications
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10
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Introduction
This maintenance and use guide provides recommended operating/use conditions, intervals, and procedures for
ensuring uninterrupted operation of your TruckWings.

Operating/Use Conditions
TruckWings are designed to operate in the same on-road conditions and environments in which the truck is able
to operate.

Driver Inspection (Trip Inspections)
Before each trip, a basic inspection that includes the following items should be performed by the driver as part
of their pre-trip inspection of the truck.
1. Check that the panels are retracted against the back of cab.
 If the panels do not retract with the TruckWings Controller toggle cover DOWN, notify terminal immediately
to be reseated. Damage will occur if panels are not retracted in the presence of a trailer.
2. From the ground, check that TruckWings panels are held securely against the back of cab by pulling on
panel.
 If excessive play is noted in either side panel, prior to drive set the TruckWings Controller to the MIDDLE
position and notify terminal service or repair facility upon return.
3. Check for TruckWings components that are damaged (cracked or bent) and fasteners that appear loose,
disconnected, or are missing.
 If individual rivets or fasteners appear loose or missing, it is safe to drive but notify terminal service or
repair facility upon return.
 If severe panel or frame damage is visible that may cause parts to detach from vehicle, notify terminal
immediately to be reseated. Do not drive the vehicle in this condition.
4. From the ground, listen for any audible air leaks from the actuators behind the panels.
 If a leak is audible, it is OK to drive but notify terminal service or repair facility upon return.

Maintenance Procedures
General Maintenance Requirements and Notes
When the truck comes in for any maintenance or repair, including Preventative Maintenance Inspection (PMI),
the TruckWings should be inspected and looked over thoroughly according to the procedures specified in this
document.
TruckWings moving parts should be kept relatively clean and free from dirt and debris.
It is recommended that trucks exposed to road salt or other types of anti-icing chemicals open the Wings during
the washing process to wash the moving parts. Wings should remain closed when driving through an automated
truck wash.
It is not recommended that lubricants be applied to any of the TruckWings moving parts. They use a special antifriction material that could be damaged. Lubrication internal to the airflow system with 10W pneumatic oil is
recommended.
When replacing any bolts, nuts, or washers, Stainless Steel fasteners must not be used. Carbon steel Grade 8
fasteners plated or coated for high corrosion resistance such as Hot Dip Galvanized or Zinc Aluminum Flake
should be used to maintain the same level of corrosion resistance.
When replacing nuts, all-metal, distorted-thread lock nuts with the specified coatings above must be used.
Any replacement bolts, nuts, or washers must be Grade 8 or equivalent.
WARNING
TruckWings is a large scale aerodynamic system that functions dynamically in a continuous and
ongoing fashion throughout truck operation. Performing complete and ongoing inspections for
wear/damage and related maintenance are essential to maintaining proper running order of TruckWings
and ensuring safe operation.
Failure to properly inspect and maintain TruckWings may result in an inoperative system and/or may
lead to failures that risk damage and injury.
Be vigilant for any component that is abnormally loose or worn and report to Hexagon Agility FleetCare at
+1 833 443 9227 or via email at [email protected].

Preventative Maintenance Inspection Guide
Perform each step at every preventative maintenance (PM) event. If any of the steps below reveal an issue
requiring further diagnosis or repair, consult the TruckWings Troubleshooting & Repair Guide to resolve. If further
assistance is required, contact Hexagon Agility FleetCare.
#

Inspection Step

Inspect closed TruckWings from the back of cab
Maintain 3 points of contact and access the catwalk.
 Pull on each side panel to check for excessive play in bushings or metal-on-metal contact
(red arrows).
 Ensure grab handle and reinforcement is secure against the panel (yellow triangle).



1

Check that all panel-to-hinge fasteners are tight (green circles).
Ensure the Trailer Sensor is undamaged and pointing directly towards the trailer (orange
square).

Inspect TruckWings Controller from inside cab
Enter the cab and turn key to ON.
 Check the screen on the TruckWings Controller with the toggle cover closed in the DOWN
position.
 If the following message is displayed, the TruckWings have been disabled at the request
of a technician.
NOTICE If TruckWings appear functional with no pending repairs, contact
Hexagon Agility Tech Support to remotely restore automatic operation to the
TruckWings.

If screen displays the message above, please contact Hexagon Agility FleetCare at
[email protected] or +1 833 443-9227
2

 Flip the toggle position on the TruckWings Controller to the MIDDLE position. Screen
should show as below. NOTE: DIST (distance) value will vary.

 Check CAN values of Speed, Odometer, and Fuel read OK.
WARNING
Ensure back of cab is clear and announce “TruckWings Opening.”
 To deploy TruckWings, toggle position on the TruckWings Controller to the UP position.
 Check that TruckWings deploy fully.

Inspect open TruckWings from the ground


Check that all three panels are undamaged and flush to each other at the joints
and all hinges are connected (red circles).



Check all frame mounts are secure against the cab (purple arrows).



Listen for any leaks coming from actuator cylinders, fittings, or airflow control
assembly (blue circles).



Check for loose hardware or worn spacers in actuator-to-cab joints (orange
arrows).

Return to cab.
WARNING
Ensure back of cab is clear and announce “TruckWings Closing.”


3

Set Controller toggle position to DOWN to close TruckWings.

Recommended Maintenance Schedule
Refer to TruckWings Troubleshooting and Repair Guide for inspection, check, and replacement details.

Maintenance Step

Perform
every
150,000 mi /
240,000 km

Airflow Cylinder Lubrication
Side Panel Hinge Bushing Service

Airflow Cylinder Lubrication

▪
▪

With the TruckWings in Safe to Service Mode, apply a small amount of SAE 10W oil or equivalent into one
port on each of the bottom actuators and control valve.
1. Remove a blue and black air line from the Airflow Control Valve.
2. Apply a drop of oil into each port.
3. Replace air lines and close the Airflow Box.

4.
5.
6.
7.

Disconnect black airline on a bottom actuator.
Apply a drop of oil into the port.
Replace air line.
Repeat for the opposite cylinder.

Side Panel Hinge Bushing Service
Required Repair Kit and Special Tool
SIDE PANEL HINGE BUSHING KIT, COMPLETE
BUSHING SERVICE SPREADER TOOL. p/n 61300010
1. Position step ladder on vehicle to access Side Panel Hinge pivot.

2. Disconnect Side Panel Hinge from 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 service spreader 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 1/2-in x 18-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).
11. Repeat for opposite side.

Putting TruckWings in Safe to Service Mode
Required Repair Kit and Special Tool
ACTUATOR PROP SERVICE TOOL p/n 61300008
WARNING
Always use safety glasses and face shield when working with items above your head.
Before servicing any part on the TruckWings system or working on the back of cab, 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 TruckWings open by pushing trapezoid to fully deployed position and inserting TruckLabs prop tool
p/n 61300008 as shown below.

6. Perform required service.
7. Remove the upper cylinder holder (vise grips) and ladder. Reconnect any disconnected tubing. Wings
will return to the closed state when the secondary air tank is filled to above 50 psi (3.45 bar).

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-lb (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.