SOLENOID DRIVER FIP (Fault Isolation Procedure) and INSTALLATION INSTRUCTION

SOLENOID DRIVER CARD COMPONENT Indicator LED functions:

IDENTIFICATION
This portion is to identify components and
wiring on Driver Card to assist with
troubleshooting and replacement. The driver
card limits current to hoist coil to prevent
potential early failure. The card is Pre-set at
MEGA and no field adjustments are
recommended.
Solenoid Driver Card
#3 – POWER, this LED indicates SYSTEM power
switch has been turned ON
#2 – INPUT LEVEL, this LED indicates PUMP switch
has been turned ON
#4 – OUTPUT, this indicates output signal going to
solenoid coil, this LED will go from OFF to partial
illumination gradually indicating the driver card is
ramping the solenoid coil is slowly engaging. This
LED will also indicate a slow ramp to OFF when
PUMP switch has been turned OFF.

5
FIP (Fault Isolation Procedures)
6
7 Hoist Valve coil does not engage (No PUMP
operation
8
1. Check and ensure 24VDC input on RED wire 40
into control box.
2. Check and ensure SYSTEM fuses are good.
9 3. Ensure control system GROUND is good.
4. Check and ensure SYSTEM switch and
10 connections are good.
0 5. Check and ensure solenoid coil is good.
6. Check and ensure solenoid cable connections
are good.
1 2 3 4 7. Check and ensure solenoid cable is good.
8. Check and ensure 24VDC is going to item 5
(POWER) terminal.
1. Pre-set card controls (These are preset at MEGA) 9. Check and Ensure POWER LED illuminates when
2. INPUT – PUMP switch indication SYSTEM/POWER switch is turned ON.
3. POWER – SYSTEM/POWER switch indication 10. Check and ensure 5VDC is present at item 7, +5V
4. OUTPUT – Signal going OUT to solenoid coil Reference.
5. 24VDC+ Input from SYSTEM switch 11. Turn PUMP switch ON, ensure +5V Reference is
6. GROUND to chassis present at item 8.
7. 5V reference to PUMP switch 12. Check and unsure INPUT LED illuminates and
8. 5V Reference voltage back from PUMP switch OUTPUT LED slowly grows brighter.
9. SOLENOID – 13. Check and ensure 24VDC is present at
10. SOLENOID + SOLENOID+.
14. Check and ensure GROUND is present at
SOLENOID -.

1
 SOLENOID DRIVER FIP (Fault Isolation Procedure) and INSTALLATION INSTRUCTION

POWER LED (Item 3) does not Illuminate when
SYSTEM/POWER switch is turned ON
1. Check and ensure 24VDC is present at
SYSTEM/POWER wires entering cab control box.
2. Check and ensure 24VDC is present at
SYSTEM/POWER switch.
3. Check and ensure SYSTEM/POWER switch and
connections are good.
4. Check and ensure 24VDC is supplied to correct
terminals on driver card.
5. Check and ensure driver card terminals are tight.
6. Check and ensure driver card GROUND is good.
INPUT LED does not illuminate when PUMP switch
is turned ON (POWER LED is ON, OUTPUT LED is
OFF)
1. Check and ensure 5V reference is being supplied
from driver card (Item 7) to PUMP switch.
2. Check and ensure PUMP switch and connections
are good.
3. Check and ensure hoist valve coil, is good.
4. Check and ensure PUMP cable and connections
are good.
5. Check and ensure 5V reference is returning to
driver card to Item 8.
6. Verify OUTPUT LED is illuminated.
7. Check and ensure 24VDC power is supplied to
host valve coil (Item 10).
POWER and OUTPUT LEDS are illuminated when
SYSTEM/POWER switch is turned ON (POWER
switch is ON, INPUT LED is OFF, PUMP switch is
OFF, OUTPUT LED is bright)
1. Check and ensure PUMP switch is OFF.
2. Check and ensure system power and ground are
good.
3. Check and ensure PUMP cable, connection and
coil is good.
4. Check and ensure NO POWER is supplied to hoist
valve coil.
5. Check and ensure driver card is not cracked or
damaged.
REPLACEMENT OF DRIVER CARD
1. Remove all electrical power from unit.
2. Disconnect the 40 pin connector from the cab
control box.
3. Remove cab control box from mounting
platform.
4. Remove six screws from cab control box face
panel and carefully flip face panel down to gain
access to the driver card.
5. Mark driver card terminal wires to ensure they
are reconnected correctly.

POWER and INPUT LEDS are illuminated when

SYSTEM/POWER switch is turned ON (OUTPUT LED
is OFF, PUMP switch is OFF)

1. Check and ensure hoist valve coil, cable and

cable connections are good.
2. Check and ensure driver card terminals are tight
and properly wired.
3. Ensure PUMP switch is OFF.

2
 SOLENOID DRIVER FIP (Fault Isolation Procedure) and INSTALLATION INSTRUCTION

6. Using a thin blade flat tip screwdriver, remove
the 6 wires from the white terminal strip.
7. Remove four nuts that secure driver card to the
control box
8. Carefully remove the card while ensuring the
spacer nuts remain on the mount screws.
9. Carefully install new driver card on the four
mount screws.
Dropping, bending or crushing of the driver card
will damage circuitry and result in card
malfunctions.
10. Reinstall and tighten the four retaining nuts to
the board.
Over tighten the retaining nuts may damage
board circuitry and result in card malfunctions.
11. Reinstall the six wires in the white terminal strip
J1 as previously marked.
Standard Wiring Schematic
TERMINAL WIRE
POW+ (28 VDC +) RED
12. Secure all wires as required with wire tie straps.
Ensure that there are no stray wire strands that
may contact the driver card circuit board.
13. Reinstall the control box face panel with the six
mount screws.
14. Reinstall the cab control box on the mounting
platform.
15. Connect the 40 pin cab control cable to control
box.
16. Apply electrical power to cab control system.
17. Check water pump operation to ensure water
pump engages and disengages properly.
If you are having trouble or are in need of
assistance please contact us with the tank serial
number:
The MEGA Corp Product Support Group at:
US Toll free: 1-800-345-8889
Direct at: 1-505-345-2661

POW - (28 VDC -) BLACK

+5V REFERENCE ORANGE or BLUE
+5V INPUT PURPLE or BROWN
AGND (NOT USED)
I IN (NOT USED)
ENABLE (NOT USED)
F GND (NOT USED)
SOL- BLACK
SOL+ RED