MEGA Corp. MES34-OPS-1 User Manual
SPECIALTY HAULAGE SOLUTIONS FOR CONSTRUCTION AND MINING
Operators Manual
MES34-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
MES34-OPS-1
21 Feb 2014
TABLE OF CONTENTS
Page
Section 1 Definitions and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Section 2 System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Section 3 Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Section 4 Normal Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Section 5 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Section 6 MES34 Operator’s Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
A
MES34-OPS-1
21 Feb 2014
TABLE OF CONTENTS
B (Blank)
SECTION 1
Definitions and Abbreviations
Contents
MES34-OPS-1
21 Feb 2014
Manual Usage....................................................................1-1
Warning, Caution And Notes .......................................1-1
Use Of Shall, Will, Should And May............................1-1
MANUAL USAGE
This technical manual only contains information
required to safely install or service an MES34 elevator
scraper system. See the CAT 631 Operator’s Safety
Manual for tractor specific system information and
operating procedures. If your system is not covered in
this manual or you are experiencing difficulties,
please contact MEGA Corp. Product Support Group
at: US toll free: 1-800-345-8889, Direct: 1-505-3452661 or visit our website at www.megacorpinc.com
for more detailed contact information.
The exact location of the hazards and description of
the hazards are reviewed in this section. All personnel
working on or operating the machine must become
familiarized with all the safety messages.
Due to the nature of these processes, ensure that all
safety information, warnings and instructions are
read and understood before any operation or any
maintenance procedures are performed. Some
procedures take place with heavy components and
at moderate heights, ensure proper safety
procedures are maintained when performing these
actions. Failure to use and maintain proper safety
equipment and procedures will cause injury, death or
damage to equipment.
Safety Messages...............................................................1-2
Abbreviations....................................................................1-3
MES34 Overview (Typical) ............................................1-4
WARNING, CAUTION 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 emphasize.
USE OF SHALL, 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.
1-1
MES34-OPS-1
21 Feb 2014
SECTION 1
Definitions and Abbreviations
SAFETY MESSAGES
There are several specific safety messages on this
machine. The exact location of the hazards and
description of the hazards are reviewed in this
section. All personnel working on or operating the
machine must become familiarized with all the safety
messages.
Make sure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages in you cannot read the words. Replace the
illustrations if the illustrations are not legible. When
you clean the safety messages, use a cloth, water and
soap. Do not use solvent, gasoline or other harsh
chemicals to clean the safety messages. Solvents,
gasoline or harsh chemicals could loosen the
adhesive that secures the safety messages. Loose
adhesive will allow the safety messages to detach.
Replace any safety message that is damaged or
missing. If a safety message is attached to a part that
is replaced, install a new safety message on the
replacement part.
BACKING RUNOVER HAZARD (2)
This safety label is located on the rear of the scraper
and inside the cab.
The vehicle is equipped with a back-up alarm.
Alarm must sound when operating this vehicle in
reverse. Failure to maintain a clear view in the
direction of travel could result in serious injury or
death.
DO NOT OPERATE (1)
This safety label is located on the outside of the cab.
Do not open this control box unless you read and
understand the instructions and warnings in the
Operator and Maintenance Manual. Failure to
follow instructions or heed the warnings could
result in serious injury or death.
FALL HAZARD (3)
This safety label is located at the top of the scraper.
Ensure PPE fall arrest harness is worn, adjusted
properly and attached to an anchor point when
performing maintenance on top of the MES34 or
when fall hazards are present. Failure to use PPE
when fall hazards are present may result in
serious personnel injury or death.
1-2
SECTION 1
Definitions and Abbreviations
MES34-OPS-1
21 Feb 2014
HIGH PRESSURE MOTOR (4)
This safety label is located on the hydraulic motor.
Hydraulic motor and supply lines contain oil
under high pressure. Improper removal and
repair procedures could cause severe injury. To
remove or repair, instructions in the Maintenance
Manual must be followed.
ABBREVIATIONS
ft - feet
fpm - feet per minute
gpm - gallons per minute
GET - Ground Engaging Tools
KM-H - Kilometers Hour
Kg - kilograms
l - liters
lpm - liters per minute
LT - Le f t
M - meters
MES - MEGA Elevating Scraper
MPH - Miles Per Hour
PPE - Personnel Protective Equipment
psi - pounds square inch
RPM - Revolutions Per Minute
RT - Right
SQ FT - Square Feet
1-3
MES34-OPS-1
4
1
7
1
631G TRACTOR
2
DRAFT FRAME ASSEMBLY
3
ELEVATOR ASSEMBLY
4
SPILL GUARD
5
REAR BOGIE
6
ELEVATOR DRIVE MOTOR
7
SPEED DECREASER
8
FUEL TANK
9
IMPLEMENT VALVE
SIDE VIEW
TOP VIEW
9
8
5
3
2
9
6
21 Feb 2014
SECTION 1
Definitions and Abbreviations
MES34 OVERVIEW (TYPICAL)
1-4
SECTION 2
System Description
Contents
MES34-OPS-1
21 Feb 2014
Description.........................................................................2-1
Scraper Bowl ......................................................................2-1
Rotating Floor....................................................................2-2
Elevator Assembly............................................................2-2
Rear Bogie Assembly ......................................................2-3
DESCRIPTION
The MEGA 34 cubic yard elevating scraper (MES34) is
a high production unit, designed for heavy duty
continuous load/haul/spread operations. It is capable
of performing thin, precise lifts as well as heavy
excavation with little support equipment.
This new scraper bowl is combined with a currentproduction 631G scraper tractor and wheel groups to
provide the latest in power train, operator comfort,
electronic controls and emissions compliance. The
scraper bowl assembly design has been changed
from previously fielded systems to provide increased
reliability in severe duty applications.
All scraper bowl assembly hydraulics, brakes,
electrical, controls, indicating and warning systems
are integrated into the existing 631G tractor control
groups.
The scraper bowl assembly is comprised of a scraper
bowl, rotating floor, elevator, rear bogie, wheel
groups and a draft frame assembly.
Draft Frame Assembly....................................................2-3
Electrical System ..............................................................2-4
Hydraulic System .............................................................2-4
Implement Joystick.........................................................2-5
Rear Brake System...........................................................2-6
SCRAPER BOWL
The scraper bowl has
a 34 cubic yard/26
cubic meter heaped
capacity for haulage
and an adjustable full
width cutting edge
for precise cutting
and heavy excavating.
The bowl cutting
edge is designed to
support a variety of Caterpillar Ground-Engaging
Tools (GET).
The scraper bowl utilizes a
cellular design in its
construction to add strength
and dent resistance to the bowl
sides. The cellular side wall
construction also provides for
mounting of several of the
moving and stationary bowl
components. These include the
rotating floor, elevator frame
mount arms, gooseneck draft
arm trunnions, bowl lift
cylinders, as well as rear bogie
assembly. Provisions are also available for optional
wear plates that increase bowl service life.
All hydraulic hoses and electrical cables for the rear
bogie functions are routed inside the right bowl wall
to the front of the bowl to eliminate the need for
component shielding. Rubber shrouds are installed
on the outer side walls to prevent wedging of
material between draft arms and outer bowl walls, in
turn protecting draft arms and trunnion ball mounts
from cracking.
2-1
MES34-OPS-1
J-Link
Elevator
Swing Up
Elevator Adjusters
Draft Arm
21 Feb 2014
SECTION 2
System Description
ROTATING FLOOR
The rotating floor also utilizes a cellular design in its
construction for added strength and dent resistance.
Two large hydraulic cylinders connected to the j-link
rotate the door smoothly, allowing for precise
spreading of materials. The floor is designed with
close tolerances to the bowl for optimal material
removal, helping create a work alone piece of
machinery.
The frame incorporates draft arms which are used to
mount the assembly to the inside of the scraper
bowl. The draft arms, working in together with the
elevator adjusters, creates a mounting system that
protects the flights and cutting edge from rocks and
other large objects by swinging up, then quickly
returning back down to continue loading the bowl.
ELEVATOR ASSEMBLY
The elevator assembly
conditions and loads
materials into the
scraper bowl. The
assembly consists of an
elevator frame and
draft arms, a speed
reducer, sprockets,
chains, chain adjusters,
idlers and flights. The
upper corners of the
frame is designed with
a two piece steel casting that provides mounting for
the elevator drive system, as well as lever-type
elevator adjusters.
The flights are constructed of steel plates and
perform the actual conditioning and loading of the
materials. The flights are connected to dual drive
chains that are driven by a single high torque
hydraulic drive motor through the speed reducer.
2-2
SECTION 2
System Description
MES34-OPS-1
21 Feb 2014
REAR BOGIE ASSEMBLY
The bogie is a structural steel tube frame and plating
that mounts to the rear wall of the scraper bowl. The
assembly provides mounting for the rear wheel
groups, rear brake system, rotating floor cylinders
and tail lights. The rear of the bogie also incorporates
a push type bumper assembly.
The rear bumper design provides a pushing point to
assist the MES34 up a grade or in poor underfoot
conditions (wet, muddy or icy haul road). The
bumper assembly is designed to be pushed straight
on by the pushing (boosting) machine.
DRAFT FRAME ASSEMBLY
The draft frame assembly is comprised of a
gooseneck, fuel tank and draft arms. This assembly,
along with two sets of hydraulic cylinders, is what
turns the unit and raises and lowers the bowl
assembly. The assembly also provides mounting for
implement control valve assembly, hydraulic
housing, electrical harnesses, protective guards and
work light.
GOOSENECK
Routine HARD bumper contacts by the pushing
(boosting) machine will cause structural fatigue and
result in reduced bogie service life.
Angled blade contact of the bumper will reduce bull
dozer blade to MES34 wheel clearance. Extreme
blade angles will cause blade/bit to wheel contact
and damage MES34 tires. MES34 and pushing
(boosting) machine operators must communicate to
ensure correct contact and maximum wheel to
blade/bit clearance is maintained.
The gooseneck is made up of vertical hitch pin and
steering cylinder castings, a ½" top plate, ¾" side
plates and a 1½" bottom plate. The vertical hitch pin
attaches to the tractor and provides the pivot point
for the steering of the unit. The back side of the
gooseneck attaches to the fuel tank to create
mounting for the draft arms.
2-3
MES34-OPS-1
Right-Hand
Side
Left-Hand
Side
21 Feb 2014
SECTION 2
System Description
FUEL TANK
The fuel tank is constructed from a 26' mechanical
tube and two 1.5" thick flanges. The tank has a 250
gallon capacity with internal baffling to prevent
sloshing. The tank contains a fuel quantity sensor,
gravity fill port and the fast fill fuel system. The tank
also provides mounting for the draft arms,
implement control valve and the bowl lift cylinders.
DRAFT ARMS
HYDRAULIC SYSTEM
The hydraulic power used to operate all scraper bowl
functions comes from several components mounted
on the tractor and bowl assembly. These components
consist of an auger pump, elevator drive motor,
implement pump, implement control value
assembly, bowl lift cylinders and floor cylinders.
AUGER PUMP (VARIABLE PISTON)
The pump is mounted on the tractor transmission
accessory section and provides hydraulic power to
the elevator drive motor. The pump is a variable
displacement type pump with hydraulic output
being controlled by the tractor ECM.
The draft arms connect the draft frame to the bowl.
They are constructed from steel plates, mechanical
tube and cast steel trunnion bearings. The arms
connect at the trunnions and create a pivot point
between the draft frame and the bowl for raising and
lowering the cutting edge of the bowl.
ELECTRICAL SYSTEM
The electrical system of the scraper bowl assembly is
fully integrated with the existing tractor systems.
These sub systems consist of all tail braking and turn
signal lights, implement controls and all brake
indicating and warning systems.
The tractor ECM will maintain the operators selected
elevator speed within a desired range. This is
accomplished by ECM resident software designed to
control pump output based on a selected elevator
speed. See CAT Operator and Maintenance manuals
for more information.
ELEVATOR DRIVE MOTOR
The drive motor is
powered hydraulically
by the auger pump as
commanded by the
implement joystick
thumb switch. The
motor is mounted to the
speed reducer that
drives the elevator upper sprocket assembly.
2-4
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