MEGA Corp. MCC-OPS-1 User Manual
SPECIALTY HAULAGE SOLUTIONS FOR CONSTRUCTION AND MINING
Operators Manual
MCC-OPS-1
MEGA CORP.®
700 Osuna Rd. N.E. • Albuquerque, NM 87113 • 1-800-345-8889 • 505-345-2661 • Fax 505-345-6190
www.megacorpinc.com
® MEGA Corp., Inc. All Rights Reserved
MCC35-CAT735-1
A
5 Aug 2010
TABLE OF CONTENTS
Page
Section 1. Definitions and Abbreviations .………………………………………………………. 1-1
Section 2. System Description ………………………………………………………………...… 2-1
Section 3. Normal Operations …………………………………………………………………… 3-1
Section 4. Appendix (Operators Checklist) …………………………………………………… 4-1
MCC35-CAT735-1
5 Aug 2010
TABLE OF CONTENTS
B(Blank)
SECTION 1
Definitions and Abbreviations
Contents
Manual Usage …………………..………. 1-1
Warning, Caution & Notes ……….…...… 1-1
Shall, Will, May ……………………….. 1-1
MANUAL USAGE
This technical manual only contains
information required to safely operate the
MEGA Container Carrier (MCC) system when
installed on the CAT 735. See the CAT 735
Operators Safety and Maintenance Manual for
chassis specific system information and
operating procedures.
Only current production systems are covered in
this manual. If your system is not covered in
this manual please contact MEGA Corp.
Product Support at: 1-800-345-8889 or visit our
web site at www.megacorpinc.com for more
detailed information.
MCC35-CAT735-1
5 Aug 2010
MCC35 Overview …………………..… 1-2
Abbreviations ………………………...... 1-3
WARNING, CAUTIONS AND
NOTES
The following definitions are found throughout
the manual and apply as follows:
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 that 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.
1-1
MCC35-CAT735-1
MCC35 Overview
1 2 6
3 3 8 9 4
14 7 5
12
13
11
10
15 9 10
11
12
13
14
15
Twistlock Solenoid Manifold
In-Cab Twistlock Controls
Remote Body Operation Switches
Twistlock External Status Light
Amber Flashing Beacon
Tail Lights & Accessories
Clearance Lights
1 2 3 4 5
6
7
8
Bed Assembly
Centering Guides
Twistlocks
Tailgate Restraint Assembly
Lift Cylinders
Fenders
Mud Flaps
Tailgate Operation Valve Assembly
5 Aug 2010
SECTION 1
Definitions and Abbreviations
1-2
Definitions and Abbreviations
ABBREVIATIONS
CW – Clockwise
ECM – Electronic Control Module
ft - feet
fpm – feet per minute
IN/SQ FT – Inches per Square Feet
ISO – International Organization of
Standardization
KM-H – Kilometers Hour
Kg – kilograms
LT – Left
LWB – Long Wheel Base
M – meters
MCC – Mega Container Carrier
MPH – Miles Per Hour
OEM – Original Equipment Manufacture
PPE – Personal Protective Equipment
psi - pounds square inch
RT – Right
VDC – Volts Direct Current
MCC35-CAT735-1
5 Aug 2010
SECTION 1
1-3
MCC35-CAT735-1
5 Aug 2010
SECTION 1
Definitions and Abbreviations
1-4(Blank)
SECTION 2
Fender
Mud
Flap
System Description
Contents
MCC35 Description and Usage …...…....... 2-1
Body Assembly ………………………….. 2-1
Hydraulics ……………………………….. 2-2
MCC35 DESCRIPTION AND USAGE
The MCC35 is designed to be attached to a long
wheel base (LWB) chassis after required chassis
reinforcements are completed. Once total
integration is completed, the assembly can be
used to mount, retain, transport, and dump a 20’
ISO container.
The MCC35 consists of a body assembly,
hydraulics and electrical systems as well as a
control system. The MCC35 is fully intergraded
with the chassis hydraulics, electrics and control
systems while adding additional in-cab controls,
lighting, and indicating/warning systems.
MCC35-CAT735-1
5 Aug 2010
Controls & Indicating System …………… 2-5
Theory of Operation ………………….….. 2-9
Lights & Accessories …………………..... 2-10
BODY ASSEMBLY
The assembly consists of a tubular frame,
fenders and mud flaps, tailgate assembly and
twistlock assemblies. The body also contains
mounting plates for hydraulic components,
sensors and accessories.
Tubular Frame
Constructed of tubular steel, cross tubes and
plating to form a frame used to carry the weight
of a loaded ISO container. The frame is secured
to the chassis by pins installed in the chassis
pivot bores and lift cylinders. The frame
incorporates container guides on each corner of
the frame to center the container over the frame
and the twistlock mechanisms. The frame also
provides for mounting of the tailgate restraint
assembly (stinger), twistlock assemblies, body
lift cylinders, body pads, body guides, fenders
and mud flap assemblies.
Fenders & Mud Flaps
The assembly is designed to protect the
container and body assembly from mud and
debris created by the drive tires. The fenders
and mud flaps assemblies are constructed of
rubber belting material and attached to
triangular metal stanchions. The stanchions are
mounted to the body assembly’s main
longitudinal beams and contain fender
tensioning devices to keep the belting just below
a loaded container.
2-1
MCC35-CAT735-1
Tailgate
Restraint
Assembly
(Stinger)
5 Aug 2010
System Description
Tailgate Restraint Assembly (Stinger)
A steel tube and plate assembly that mounts and
pivots on the rear of the tubular frame. The
tailgate restraint assembly (stinger) is designed
to raise and restrain container doors in a closed
position when the body assembly is down. A
hydraulic cylinder is mounted between the
tailgate and tubular frame to raise and lower the
assembly as commanded by the hoist control
lever when the vehicle is in motion. The
assembly can also be operated from the tailgate
remote body operation switches when the
vehicle is stationary.
Twistlocks Assemblies
SECTION 2
The body assembly contains 4 twistlock
mechanisms located at each corners of the body
assembly. Each twistlock mechanism consists
of the 90° rotating block, hydraulic actuator
cylinder and a position sensor. The twistlocks
are designed to slide into the ISO container floor
receptacles as the container is lowered onto the
body assembly. Once the container is resting on
body assembly the twistlocks can then be
commanded to rotate 90° by using the in-cab
twistlock switch. The twisting action will allow
the lock to engage the container and secure the
container to the body assembly.
HYDRAULICS
The MCC35 hydraulic system uses chassis hoist
pressure for body and tailgate operation while
twistlock operation is accomplished by using
hoist pilot pressure. The MCC35 hydraulic
components consist of body lift cylinders,
tailgate control valve assembly, tailgate cylinder
counterbalance valve, tailgate cylinder, chassis
mounted accumulator, twistlock solenoid
manifold, twistlock actuators and associated
hosing.
Body Lift Cylinders
The body lift cylinders are MCC specific and
are mounted to the bed and chassis like a dump
body. Cylinders hydraulic pressure and return is
routed through the chassis hoist valve as
controlled by the in-cab hoist lever. The
supplemental ECM controls the body lifting
angle and places a mid-point stop at an
application specific angle. The mid-point stop
is set to keep the tailgate from contacting the
ejected load or ground and damaging the
tailgate door. A hoist mid-point override switch
is used to reactivate the hoist valve for raising
the body to the full load ejecting position.
2-2
SECTION 2
Main Solenoid
Control Valve
Counter Balance Valve
System Description
Tailgate Restraint (Stinger) Valve Assembly
The valve assembly consists of a main solenoid
control valve and a counter balance valve.
These manifolds hosed together and mounted to
the body RT main beam and cross tube
respectively. The two valve assemblies
combine to route and control hoist valve
pressure and return for the tailgate cylinder
function.
Main Solenoid Control Valve
The main solenoid control valve contains a
pressure relief and solenoid valve. The pressure
relief valve controls the clamping pressure for
the stinger to keep the tailgate door closed.
Pressure relief settings are field adjustable for
each specific type of container or load being
transported.
Counter Balance Valve
Mounted to a plate and hosed to the main
solenoid control solenoid. The valve assists in
maintaining the holding pressure for the stinger.
Pressure relief settings are field adjustable for
each specific type of container or load being
transported.
MCC35-CAT735-1
5 Aug 2010
Theory of Operation
The tailgate restraint valve assembly functions
as commanded by the remote activation
switches while the vehicle is stationary or the
hoist lever while the vehicle is in motion.
Tailgate Restraint (Stinger) Cylinder
The cylinder is connected to the body assembly
cross tube at one end and the tailgate assembly
at the other end. The cylinder receives
hydraulic pressure from the tailgate restraint
valve assembly.
2-3
MCC35-CAT735-1
Accumulator
FORWARD
5 Aug 2010
System Description
Twistlock Hydraulic Accumulator
Mounted just to the rear of the chassis
articulation joint and is connected directly to the
hoist valve pilot pressure circuit. The
accumulator provides additional pressurized
hydraulic volume on demand for the body
twistlock manifold assembly for twistlock
operation.
Twistlock Solenoid Manifold
The hydraulic accumulator is a high pressure
charged vessel. Follow the CAT 735
Maintenance and Service Manuals for proper
charging procedures. Failure to charge this
vessel properly may result in serious personal
injury or death.
SECTION 2
Twistlock Solenoid Manifold
The manifold assembly is mounted to the body
assembly cross tube. The manifold receives
pressure from the accumulator assembly while
routing return pressure to the chassis hydraulic
tank. The manifold contains a solenoid valve to
route hydraulic pressure and return to and from
the twistlock actuators as commanded by the
twistlock controls and a pressure reducing valve
to prevent over pressurization of the twistlock
actuators.
2-4
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