PNEUMATIC SOLENOID CONTROL BOX

PNEUMATIC SOLENOID INSPECTION

CONTROL BOX
1. Inspect box for damage, leaks and security.

2. Inspect hosing and fittings for security, leaks

and condition.

3. Wire harness for security, damage and

condition.

4. Open solenoid box access cover and inspect

components for the following:
The control box assembly is mounted to the
a. Solenoid valves for security, leaks and
MTT front bulkhead and controls spray functions
condition.
as commanded by the cab control box. The
assembly contains pressure protection valve,
b. Pneumatic regulator valve for security,
manual or electric shut-off valve/pressure
leaks and condition. Drain regulator
regulator, pneumatic solenoid valve bank and
bowl.
wire terminal. The solenoids and shut-off valves
receive pneumatic pressure from the vehicle and
24 VDC power from the cab control box. Regulator Adjustment
Knob
Solenoid valves receive command signals from
cab control box to open or close the respective
spray head or BFV. The solenoid control box Regulator Bowl
also provides for spray head system over
pressurization protection.

Regulator Bowl
Drain
Shut Off/Pressure DIN Rail 40 Pin
Regulator Assy. Terminal Strip Receptacle

c. Pneumatic shut-off valve for security,

leaks and condition.

d. Pneumatic pressure protection valve for

security, leaks and condition.

e. All fittings and hoses for security and

leaks.

f. Wire terminals and wiring for security

and damage.

Air Regulator Sub-D Solenoid Bank

Pressure Gauge Connector

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REPAIR 9. Reinstall 3 side mount bolts.

Solenoid Valve Replacement
10. Reinstall solenoid bank foam gasket and top

11. cover. Secure the cover 4 mount screws.

12. Reinstall solenoid bank on mounting plate

and secure mounting bolts. Ensure solenoid
bank grounding wire is attached.

13. Reconnect the pneumatic supply hoses.

PN 304948 PN 304929
14. Reconnect the Sub-D connector to the top of
1. Ensure pneumatic pressure and electric the solenoid bank.
power is removed from the solenoid box.
15. Pressurize pneumatic spray system, check for
2. Disconnect the Sub-D connector from the top leaks as well as proper spray head operation.
of the solenoid bank.
Shut-off/Pressure Regulator Assembly
3. Disconnect the solenoid bank pneumatic
supply hoses.

4. Remove entire solenoid bank from the

mounting plate.

5. Label each solenoid valve section before

disassembly.

6. Remove 4 mounting screws from the

solenoid bank cover. Remove cover and
foam gasket from the top of the solenoid
bank.
7. Remove the 3 side mount bolts.
1. Ensure pneumatic pressure and electric
power is removed from the solenoid box.
2. Disconnect the pneumatic supply from the
right side of the regulator.

8. Remove the malfunctioning solenoid and 3. Remove 90 degree brass elbow from the
replace with serviceable solenoid. pneumatic supply hose left of the assembly.

4. Disconnect the power cable attached to the

Ensure the correct solenoid part number is top of the shut-off valve.
used to replace malfunctioning solenoid
(spray head valve #304929 versus the BFV 5. Remove the 4 mount screws securing the
#304948). Additionally, check to ensure the assembly to the mounting plate.
new solenoid is located in the correct
position within the solenoid bank stack-up.

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6. Remove the assembly.
7. Reconfigure new assembly.
8. Install new assembly and secure with 4
mounting screws to the mounting plate.
9. Reattach the shut-off valve power cable.
10. Reconnect the pneumatic supply hoses to the
pressure regulator.
11. Charge air system with 125 psi (860 kpa) of
air pressure.
12. Ensure all warning lamps are extinguished.
13. Turn SYSTEM ON.
14. Adjust air pressure regulator to 90 psi (620
kpa) and fine tune pressure regulator as
follows:
a. Install 0 – 160 psi (0 – 860 kpa) gauge to
drain valve on spray bar.
b. Make unit safe for operation.
c. Ensure all spray system switches are
OFF.
d. Start engine.
e. Turn SYSTEM ON.
f. Turn PUMP ON.
Engaging/disengaging the water pump
above LOW IDLE may result in water
pump component damage and reduced
service life.
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g. Operate water pump at HIGH IDLE
making note of peak water pressure. If
water pressure exceeds 120 psi (830 kpa)
refer to water pump tuning instructions
and ensure water pump RPMs do not
exceed 1,950 rpm)
Water pump RPM must not exceed 1,950
rpm with engine at high idle. Failure to
keep water pump speed below 1,950
RPMs will result in water pump failure.
h. Reduce engine speed to LOW IDLE.
Avoid sudden water pump stoppage
above LOW IDLE. If water pump
experiences sudden stoppage above LOW
IDLE impeller, shaft, drive motor and
water pump damage will occur.
i. Turn PUMP OFF.
Engaging/disengaging the water pump
above LOW IDLE may result in water
pump component damage and reduced
service life.
j. Note air pressure.
k. Adjust air pressure regulator. Ensure the
regulated air pressure is set 5 – 10 psi
(34-69 kpa) maximum above the HIGH
IDLE water pressure reading [e.g: water
pressure = 75 psi (520 kpa) at high idle,
regulated air pressure must be adjusted to
and set at 80 to 85 psi or 550 to 585 kpa].
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15. Pressurize pneumatic spray system, check for

leaks as well as proper spray head operation.
If spray heads partially open when water
pump is operated at HIGH IDLE, recheck air
pressure regulator setting.

16. Turn SYSTEM OFF.

17. Turn engine OFF.

18. Close and secure cover.