FSB-11

2 Dec 2009

FIELD SERVICE BULLETIN

SHORT TITLE:

Hydraulic Control Box Modification

Applicable to:
All rear mounted hydraulic spray system control boxes.
Condition:
Wire and/or connector damage inside of control box,
caused by water and/or corrosive elements infiltrating
connectors or exposed wire connections.
Symptom:
1) Spray system malfunctions
2) Over heated wires inside of cab control box
3) Corrosion and/or wire damage present

FSB-11
2 Dec 2009

A. DEFINITIONS:
WARNINGS, CAUTIONS AND NOTES

Operating procedures and techniques, which

could result in personal injury and/or loss of life if
not carefully followed.

Operating procedures and techniques, which

could result in damage to equipment if not
carefully followed.

Operating procedures and techniques, which are

considered essential to emphasis.

USE OF SHALL, WILL AND MAY

SHALL and WILL Used when application of a procedure is mandatory.
SHOULD Used when application of a procedure is recommended.
MAY Used to indicate an acceptable or suggested means of accomplishment.

FSB-11
2 Dec 2009

B. DESCRIPTION:
The MEGA spray system hydraulic solenoid control box is typically mounted on the rear bulkhead of
the water tanker. The box contains several solenoid valve assemblies and associated components
mounted to the base of the steel enclosure. The respective solenoid valve wiring is routed to a
junction rail (Din rail) then onto a 40 pin Deutsch connector. The Din rail assembly and wiring is
exposed to the elements and may experience deterioration when exposed excessive moisture and
corrosive elements. This deterioration will be accelerated greatly when exposed to highly corrosive
environments without routine maintenance. The absence of routine maintenance will result in Din rail
terminal failure, wire deterioration and pooling of corrosive elements around the 40 pin Deutsch
connector.

Din Rail
Terminal block

Figure 1: Typical Din Rail Terminal Block

C. SOLUTION:
Harden wire junctions and connections from the corrosive environment.
D. CORRECTIVE ACTION:
1) Remove Din rail terminal block, internal 40 pin connector and wiring harness
2) Install connectors for each hydraulic control solenoid.
3) Repair or replace 40 pin plug at control box.
4) Relocate the cable connection point in a horizontal position and to a more protected environment.

FSB-11
2 Dec 2009

E. KIT CONTENTS

# 29 BLUE/YELLOW
System Ground

Work light
Connectors

Spare
wires
Solenoid connectors

40 pin Receptacle

Figure 2: Din Rail Elimination Harness

Table 1: Din Rail Eliminator Kit Contents

QUANTITY
1
13
26
13
37
1
1
3
1

PART
NUMBER
043420
304284
304289
304385
304288
305026
305024
304471
040702

DESCRIPTION
DIN RAIL TERMINAL BLOCK ELIMINATOR HARNESS
2 PIN RECEPTACLE
PIN
LOCK
SOCKET
40 PIN PLUG
SEALING BOOT
BLANK SEALING PLUG
40 PIN ADAPTER PLATE

FSB-11
2 Dec 2009

F. WATER TANKER STANDARD WIRING

Table 2: Standard Wire Number/Color/Function Table
WIRE # WIRE COLOR
1
BLACK
2
RED
3
BLUE
4
ORANGE
5
YELLOW
6
BROWN
7
RED
8
BLUE
9
ORANGE
10
YELLOW
11
BROWN
12
BLACK
13
BLUE
14
ORANGE
15
YELLOW
16
BROWN
17
BLACK
18
RED
19
ORANGE
20
YELLOW

/STRIPE

BLACK
BLACK
BLACK
BLACK
BLACK
RED
RED
RED
RED
RED
BLUE
BLUE
BLUE
BLUE

FUNCTION
SOLENOID SOLENOID +
WORK LIGHT +
LEFT BUMPER ON
LEFT BUMPER OFF
LEFT VSS ON
LEFT VSS OFF
LEFT REAR ON
LEFT REAR OFF
LEFT CENTER ON
LEFT CENTER OFF
RIGHT CENTER ON
RIGHT CENTER OFF
RIGHT REAR ON
RIGHT REAR OFF
MONITOR RIGHT
MONITOR DOWN
MONITOR LEFT
MONITOR UP
MONITOR BFV OPEN

WIRE # WIRE COLOR

21
BROWN
22
BLACK
23
RED
24
BLUE
25
YELLOW
26
BROWN
27
BLACK
28
RED
29
BLUE
30
ORANGE
31
BROWN
32
BLACK
33
RED
34
BLUE
35
ORANGE
36
YELLOW
37
BLACK
38
RED
39
BLACK
40
RED

/STRIPE
BLUE
ORANGE
ORANGE
ORANGE
ORANGE
ORANGE
YELLOW
YELLOW
YELLOW
YELLOW
YELLOW
BROWN
BROWN
BROWN
BROWN
BROWN
14 GA
14 GA
14 GA

FUNCTION
MONITOR BFV CLOSE
RIGHT VSS ON
RIGHT VSS OFF
RIGHT BUMPER ON
RIGHT BUMPER OFF
WATER LEVEL # 4 WHITE
WATER LEVEL # 3 RED
WATER LEVEL GROUND
GROUND
DUMP BAR OPEN
DUMP BAR CLOSE
DRAIN OPEN
DRAIN CLOSE
NOZZLE STREAM
NOZZLE FOG
FOAM OPEN
FOAM CLOSE
WORK LIGHT B +
CHASSIS GROUND BATTERY +

GREEN WIRE AT SOLENOID IS OPEN

YELLOW WIRE AT SLOENOID IS CLOSE

G. MODIFICATION
1. Park unit on level ground, remove electrical and hydraulic power. Make unit safe for maintenance.
Acquire necessary safety equipment to perform the following tasks.
2. Remove control box cover. 6 ea -20 bolts.

Do not remove this cover without the use of

proper safety equipment (harness, restraints and
lifting devices). The cover is heavy and will
cause personal injury if not restrained or
controlled.

FSB-11
2 Dec 2009
Hydraulic Solenoid
Control Box

Figure 3: Hydraulic Solenoid Control Box Location (Typical)

Horizontal Din Rail Configuration

Vertical Din Rail Configuration

Din Rail
Terminal
Block

40 Pin
Connector
and
Harness

Figure 4: Din Rail Terminal Block Location and Configuration (Typical)

3. Disconnect the 40 pin connectors at the control box.

Carefully inspect the plug to ensure there is no

damage to the wires or pins. If wiring or
terminal damage is noted, replace plug assembly.
6

FSB-11
2 Dec 2009
4. Mark the green and yellow wires from each solenoid with the corresponding circuit (wire) number
and solenoid function. If the water tanker is 2007 or newer refer to Table 2 Water Tanker
Standard Wiring to assist in.

Locate and use the appropriate control wiring

diagram for the control system of the unit
receiving this modification. The color code chart
provided (Table 2) is only for current production
units. If there is an issue with determining the
configuration of the tanker, provide a MEGA
unit number and contact MEGAs Product
Support Group at 1-800-345-8889 (USA) or visit
our WEB site at www.megacorpinc.com.

Green and
Yellow solenoid

Circuit/wire
numbers
Figure

5: Typical Hydraulic Control box

Solenoid function labels

Figure 5: Hydraulic Control Box Configuration (Typical)

5. When removing wires from the Din rail terminal block, inspect wire for corrosion damage. Trim
wire as needed to expose clean wire.
6. Install pins on each solenoid wire and install in corresponding receptacles.

Use proper Deutsch crimping tool and settings

for 16 gauge wire.
7. Install solenoid wires as follows:
a. The green wire (spray head ON) will be placed in position 1 of the receptacle.
b. The yellow wire (spray head OFF) will be placed in position 2 of the receptacle.

FSB-11
2 Dec 2009
8. Connect the corresponding plug from the solenoid bank into the eliminator harness receptacles.

You may have to reconfigure the eliminator

harness receptical wiring for non-standard
configurations. Contact MEGAs Product
Support Group at: 1-800-345-8889 (USA) or
visit our WEB site at www.megacorpinc.com if
further assistance is required.

Figure 6: Standard Wiring Labeling & Pin Location

9. Ensure that the # 29 wire, System Ground (BLUE/YELLOW) is connected securely to the control
box grounding screw as shown below.

System
Grounding
Screw
# 29 wire
(BLUE/YELLOW)
System ground

Figure 7: System Ground (Typical)

FSB-11
2 Dec 2009
10. Modify work light wiring to a standard or optional configuration as shown and described below.
Standard
a. Install 2 pin receptacle to existing 2 conductor work light cable. Ensure the work light
ground is connected to the system ground. (Figure 8)

Figure 8: Harness Work Light Wiring

Optional Work Light Wiring
b. Route work light cables from the hydraulic solenoid control box directly to the front junction
box. Using an appropriate length of 14 ga wire 2 conductor cable to route positive (+) and
negative (-) feed into front junction. Connect the positive (+) wire to terminal # 3 (standard)
or appropriate work light terminal. Next connect the negative (-) wire to a grounding point
inside the front junction box. This procedure will require an additional hole and strain relief to
be installed in the front junction box. (Figure 9)

Figure 9: Typical front junction box

# 3 Work Light
Power (+)

# 29 Ground (-)

Figure 9: Front Junction Box (Typical)

9

FSB-11
2 Dec 2009
11. When all connections have been made, remove Din Rail Terminal Block, old 40 pin connector and
harness.

40 Pin Connector
and Harness

40 Pin Connector Holder

040679

Figure 10: 40 Pin Connector & Wire Configuration (Typical)

12. The 40 pin connector holder will need to be cut off and either welded or bolted in a position to
keep the new connector in a horizontal orientation.

The 40 pin connector should be oriented in a

horizontal position. This position will prevent
water or corrosive elements from coming into
contact with and pooling in the connector
boots.

New Din Rail

Eliminator
Harness

Typical solenoid
wire hook up
Suggested 40 pin
connector holder
location

Figure 11: 40 Pin Connector & Wire Reconfiguration

10

FSB-11
2 Dec 2009
13. When the 40 pin connector holder has been secured in place, reuse existing #6 32 screws (4
each) and nuts to reattach the Din Rail Eliminator Harness 40 pin connector to the relocated
connector holder.
14. Connect tank side of the control cable to the new harness.

Main control cable relocation may be necessary

to place tank side connector inside of the control
box.
15. Secure wiring to ensure there is no rubbing or chaffing of the cables.
16. Fill the water tank to an appropriate level required to perform operational checks the spray system.
17. Restore power to the unit.
18. Operate all of the cab control box functions to check for proper operation of all system functions
to ensure repair is complete.

Operating the water pump in a dry sump will

result in shaft seal damage.

19. Once satisfactory operation of the unit is complete, reinstall the control box cover.

11

FSB-11
2 Dec 2009

Figure 12 Din Rail Eliminator Harness

12