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SPECIALTY HAULAGE SOLUTIONS FOR CONSTRUCTION AND MINING

PRODUCT INFORMATION BULLETIN

ANALOG SPRAY SYSTEM WATER LEVEL SENSOR UPDATE

Applicable to:
• All MEGA Analog spray control systems with
FRC water level gages using part number
303822 or 304414 3 pin sensors
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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.

Operating procedures and techniques, which are considered essential to emphasis.

USE OF SHALL and WILL, SHOULD 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.

COMMON DEFINITIONS AND ABBREVIATIONS:

VDC – Volts Direct Current,

DESCRIPTION:
The MEGA control system uses a pressure transducer to provide a voltage signal to the spray
system water level gauge, the gauge will display the volume of water left in the tank. The
original sensors (304414 and 303822) now has limited availability. MEGA Corp has created an
updated wiring and sensor kit (053281) to upgrade to the new (308740) 4 pin sensor. This
Product Information Bulletin will illustrate the process to update the sensor and wiring for the
MEGA spray control water level display system.

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UPDATE PROCEDURE

REQUIRED TOOLS
1. Pipe wrench or large slip joint pliers
2. Medium sized adjustable wrench wrenches
3. Thin blade, small flat tip screw driver
4. Quality wire strippers
5. Deutsch pin/socket crimping tool
6. Heat gun for heat shrink connectors
7. Teflon pipe thread sealant

INSTRUCTIONS
1. Isolate tractor electrical power source.
a. Ensure tank is empty.
2. Ensure water level sensor is the cause of the failure.
a. Refer to the technical manuals for troubleshooting information.
3. Locate water level sensor protective tube at rear of tank if equipped.

Typical location for water level

sensor protective tube

4. Loosen cord grip.

5. Remove protective tube cap.
6. Remove protective tube.

Cord Grip
Protective Tube

Protective Tube Cap

7. Disconnect water level sensor cable from sensor.

8. Remove water level sensor from threaded boss.
9. Apply thread sealant to threads of new sensor and install in threaded boss.

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10. Locate water level sensor cable wiring diagram and connector kit.

053281 WLI Sensor upgrade kit

11. Cut old 3 pin connector from cable.

a. Inspect wiring for signs of corrosion or other damage.
i. If cable shows signs of corrosion or damage, replace cable assembly.
b. Ensure there is sufficient cable to install the connector in the new sensor without
pulling or stretching the cable.
i. If this is not possible it is recommended that a new water level sensor
cable be installed.
12. Following the wiring diagram, install sockets to water level sensor cable.
13. Route cable through the cord grip in the protective cap.
14. Slide heat shrink tubing over cable.
15. Insert sockets in correct pin locations according to the wiring diagram.
16. Shrink heat shrink tubing on cable and plug.
17. Route cable and connector through protective tube.
18. Insert new 4 pin connector into new water level sensor.

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Water Level Gauge Replacement 1. Fill water tank to maximum capacity.

1. Ensure that the unit is shut off, chocked, and safe
for maintenance before proceeding. 2. Turn SYSTEM ON and allow the system to warm
up for at least 2 minutes.
2. Remove power to the cab control.
3. Swipe the magnet four (4) times at C 1 and four
3. Remove cab control face plate to gain access to (4) times at C 2 to enter the linear calibration
the backside of the water level indicator. mode.

4. Disconnect the 8 pin connector from the

backside of the indicator.
Do not wait more than six seconds in-between
5. Remove the old water level indicator. swipes, or the session will time out and you will
have to start over.
6. Install new water level indicator and secure with 4. Once the calibration code has been entered and
mount screws. The new water level indicator is a linear calibration mode is active, wait for five
direct replacement for the old water level seconds.
indicator in terms of installation.
a. Reconnect the 8 pin connector to the new
5. After five seconds, the top four and bottom four
water level indicator.
display LEDs should flash alternately on and off to
b. Reinstall the cab control face plate.
indicate that the code has been accepted. While
the LEDs are still flashing, hold the magnet
7. Apply power to the cab control box and allow the steadily at C 2 for five seconds in order to set the
new indicator to warm up for at least 2 minutes. calibration into memory.
Perform water level indicator linear calibration.
6. After a few seconds, the calibration mode will
Water Level Indicator Calibration terminate, and all LEDs will illuminate to show
(Current production models) that the water tank is at full capacity.
7. After performing calibration, if and only if the
gauge shows 1 or 2 lights LESS than FULL,
perform the Full Tank Correction calibration as
The term ‘swipe’ means to move the tip of the
follows:
calibration magnet tool up to and then away from
a. Swipe the magnet five (5) times at C 1 and five
either the C 1 or the C 2 sensor on the front right-
(5) times at C 2 to enter the linear calibration
hand side of the display:
mode. The top and bottom five display LEDs
should flash on and off.

Do not wait more than six seconds in-between

swipes, or the session will time out and you will
have to start over.

b. Wait three seconds, then hold the magnet tool

Slowly Swipe in either
at C 2 for five seconds to complete the
direction
calibration.

c. After six seconds, the calibration mode will

terminate and all of the LEDs should illuminate
to show that the water tank is at full capacity.

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Water Level Indicator Diagnostic Codes • Top four LEDs flash alternately with the bot-
Using the 9 LEDs in the Primary Display tom four
Indication: Pressure Sensor High Output
Voltage (voltage > 4.6V)
1st LED Meaning: Shorted wire on sensor cable or
primary display failure
2nd LED Solution: Check cable for short or replace
cable, or replace primary display if
3rd LED
no short is present, and repeat
4th LED CALIBRATION procedure

5th LED • Top 2/3 and bottom 2/3 LEDs alternately flash
Indication: Memory Failure
6th LED Meaning: Primary display failure
Solution: Replace primary display and
7th LED
repeat CALIBRATION procedure
8th LED
Water Level Indicator Display Adjustment
9th LED

• Down-chasing LEDs, then bottom two (2) flash The term ‘swipe’ means to move the tip of the
Indication: Tank EMPTY words calibration magnet tool up to and then away from
Meaning: Gauge sees an EMPTY tank either the C 1 or the C 2 sensor on the front right-
Solution: Fill tank with water or repeat hand side of the display:
CALIBRATION procedure

• First (1) & last (9) LEDs flash alternately

Indication: No Sensor
Meaning: No sensor connected, or the
sensor is defective, or an OPEN
circuit in the sensor wiring
Solution: Check all connections and wiring
for damage, or replace cable, or
correct connection, or replace
sensor, and then repeat Slowly Swipe in either direction
CALIBRATION procedure

• Third (3) & fifth (5) LEDs flash

Indication: Data Entry Error
Meaning: Calibration was not performed
properly
Solution: Repeat CALIBRATION procedure

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Brightness Adjustment 3. Enable brightness setting entry by holding the

A light sensor allows the indicator display to switch magnet tool at C 2 for 5 seconds.
automatically between the two modes.
4. Adjust the brightness by swiping the magnet tool
at C 1 until the brightness level reaches its
It is highly recommended to set the brightness levels minimum value (1).
of both modes to the minimum value (brightness
level 1 on a scale of 1-10 with 10 being the brightest) 5. Save the new brightness setting by holding the
as the default setting is bright enough to induce magnet tool at C 2 for 5 seconds.
discomfort.
Color Pattern Selection
The water level indicator display has six (6) total color
To adjust day-time brightness (default is 8)
patterns to select from. The default is Pattern 1:
1. Turn SYSTEM ON and allow the system to warm
up for at least two (2) minutes.

2. Swipe the magnet three (3) times at C 1 and one

(1) time at C 2 to enter the linear calibration
mode. After a few seconds, the top three LEDs
and the very bottom LED should flash on and off.

Do not wait more than six seconds in-between

swipes, or the session will time out and you will
have to start over.

3. Enable brightness setting entry by holding the PATTERN 1: One solid color, color changes depending
magnet tool at C 2 for 5 seconds. on water level:
• FULL – green
4. Adjust the brightness by swiping the magnet tool • 3/4 tank – blue
at C 1 until the brightness level reaches its • 1/2 tank – orange
minimum value (1). • 1/4 tank – red
• EMPTY – red.
5. Save the new brightness setting by holding the
magnet tool at C 2 for 5 seconds. PATTERN 2: All red

To adjust night-time brightness (default is 2) PATTERN 3: Top 1/8 water level is green, below that is
1. Turn SYSTEM ON and allow the system to warm red
up for at least 2 minutes.
PATTERN 4: Three colors: blue\orange\red
2. Swipe the magnet three (3) times at C 1 and two
(2) times at C 2 to enter the linear calibration PATTERN 5: All green, turns red when water level is
mode. After a few seconds, the top three LEDs detected to be at or below 1/4 tank.
and the bottom two LEDs should flash on and off.
PATTERN 6: Four fixed colors for each 1/4 tank
increment: green\blue\orange\red
Do not wait more than six seconds in-between
swipes, or the session will time out and you will
have to start over.

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1. Turn SYSTEM ON and allow the system to warm PREVIOUS MODEL WATER LEVEL GAUGE
up for at least 2 minutes.
1. Remove power to the cab control.
2. Select one of the color pattern settings as follows:
a. Swipe the magnet one (1) time at C 1 and one 2. Remove cab control face plate to gain access to
(1) time at C 2 to select Pattern 1 the backside of the water level gauge.

b. Swipe the magnet one (1) time at C 1 and two 3. Disconnect the 8 pin connector from the
(2) times at C 2 to select Pattern 2 backside of the gauge.

c. Swipe the magnet one (1) time at C 1 and three 4. Remove the old water level gauge.
(3) times at C 2 to select Pattern 3
5. Installed new water level gauge and secure with
d. Swipe the magnet one (1) time at C 1 and four mount screws.
(4) times at C 2 to select Pattern 4
6. Reconnect the 8 pin connector to the new water
e. Swipe the magnet one (1) time at C 1 and five level gauge.
(5) times at C 2 to select Pattern 5
7. Reinstall the cab control face plate.
f. Swipe the magnet one (1) time at C 1 and six (6)
times at C 2 to select Pattern 6 8. Apply power to the cab control and allow the
new gauge to warm up for 3 to 5 minutes.

9. Perform water level gauge QUICK calibration with

the magnet calibration tool as follows:
Do not wait more than six seconds in-between
swipes, or the session will time out and you will a. Fill water to maximum capacity.
have to start over.
b. Turn SYSTEM ON for at least 2 minutes.
3. Wait five (5) seconds.
c. Slowly swipe the magnet 4 times over the
4. After five seconds, the very top LED and between CAL label at the bottom of the gauge as
1-6 (matching the number of times C 2 was shown below. Each time you swipe a red
swiped) of the bottom display LEDs should flash flashing light will illuminate on the gauge.
alternately on and off to indicate that the code
has been accepted. While the LEDs are still
flashing, hold the magnet steadily at C 2 for five
seconds in order to set the calibration into
memory.

Slowly Swipe in
either direction
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d. Wait 3 seconds with four lights illuminated on 1. Down-chasing LEDs, then bottom two (2) flash
the gauge and swipe a magnet 4 times again Indication: Tank EMPTY
over the CAL label. Meaning: TANK VISION sees an EMPTY tank
Solution: Fill tank with water or repeat
e. Wait 2 seconds and the gauge should read CALIBRATION procedure
full.
2. First (1) & last (9) LEDs flash alternately
Indication: No Sensor
Meaning: NO sensor connected, or the sensor is
IF, after performing calibration the gauge
defective, or an OPEN circuit in the
shows 1 or 2 lights LESS than FULL, swipe the
sensor wiring
magnet five (5) times, wait 3 seconds then
Solution: Check all connections and wiring for
swipe five (5) times again to correct the scale.
damage or replace cable or correct
connection or replace sensor and
DIAGNOSTIC CODES
repeat CALIBRATION procedure
(There are 9 LEDs in the Primary Display)
1 3. Third (3) & fifth (5) LEDs flash
Indication: Data Entry Error
2 Meaning: Calibration was not performed
properly
3 Solution: Repeat CALIBRATION procedure
4. Top four LEDs flash alternately with the
5 bottom four
Indication: Pressure Sensor High Output Voltage
(voltage > 4.6V)
Meaning: Shorted wire on sensor cable or
primary display failure
Solution: Check cable for short or replace cable,
or replace primary display if no short is
present, and repeat CALIBRATION
9 (LAST) procedure

5. Top 2/3 and bottom 2/3 LEDs alternately flash

Indication: Memory Failure
Meaning: Primary display failure
Solution: Replace primary display and repeat
CALIBRATION procedure
1. Down-chasing LEDs, then bottom two (2) flash
Indication: Tank EMPTY
Meaning: TANK VISION sees an EMPTY tank
Solution: Fill tank with water or repeat
CALIBRATION procedure

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