MEGA Corp. MMP4-2 User Manual
MMP4-2
SPECIALTY HAULAGE SOLUTIONS FOR CONSTRUCTION AND MINING
Maintenance Manual
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
MMP 4-2
5 Nov 2011
TABLE OF CONTENTS
Page
Definitions and Abbreviations ……………………………………….………………..….. 1-1
MEGA Mobile Pump (MMP 4) ...……………………………….……………………….. 2-1
Hydraulic Control System ………………………………….…………………………….. 3-1
Basic Hydraulics System …………………………………..……….………….………… 4-1
Water Pump Assembly ..…………………………..…………….……………….………. 5-1
Axle and Suspension ………………………………………….………………….………. 6-1
Frame and Booms ………..………………………………………………………….….… 7-1
Scheduled Inspections ...….…………….………………………….……………….……. 8-1
Special Inspections ………..……………………………………….………………….….. 9-1
Recommended Spare Parts ………………………………………………………….….… 10-1
Appendix ……………………………………………………………….………………... 11-1
A
MMP 4-2
5 Nov 2011
TABLE OF CONTENTS
B(Blank)
SECTION 1
Definitions and Abbreviations
Contents
Warning, Caution & Notes ………………. 1-1
Shall, Will, Should and May ……………. 1-1
Safety Messages ………………………… 1-2
MANUAL USAGE
This technical manual only contains
information required to safely maintain the
MMP-4 powered by a CAT 3054B diesel
engine. See the CAT 3054B Engine
Maintenance and Operators Safety Manual for
specific engine system information and
maintenance procedures. 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.
If your system is not covered in this manual or
are having difficulties please contact the
MEGA Corp. Product Support Group at:
Toll free US 1-800-345-8889
Direct 1-505-345-2661
or visit our website at www.megacorpinc.com
for more detailed contact information.
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. This service function takes place
with heavy components and at moderate
heights, ensure proper safety procedures are
maintained when performing this service.
Failure to use and maintain proper safety
MMP 4-2
5 Nov 2011
Abbreviations ………………………..… 1-5
MMP 4 General Overview …………….. 1-6
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, 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
MMP 4-2
5 Nov 2011
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.
Toxic Gas Hazard (1)
This safety label is located on the side of the tank
and at all water fill entrances.
Cutting or welding operation on the inside of
the tank can cause the accumulation of toxic
gases. Read and understand instructions and
warnings in the Maintenance Manual.
Failure to provide proper ventilation or
breathing apparatus while conducting these
operations may result in serious injury or
death.
Do Not Operate (2)
This safety label is located on the outside of the
front and rear control boxes. (If equipped)
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.
1-2
SECTION 1
Definitions and Abbreviations
Backing Runover Hazard (3)
This safety label is located on the rear of the tank
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.
Freezing (4)
This safety label is located on the side of the
tank, at the sump drain, and on the pump.
Drain tank, fill pipe and valve in freezing
weather. Refer to the Operator and
Maintenance Manual for the procedure to
follow.
MMP4-5
5 Nov 2011
Non-Potable (5)
This safety label is located on the side of the tank
and sump drain.
Water held within tank is not potable. Do not
use tank for transport of water intended for
human or animal consumption or serious
injury or death may result.
Do Not Hoist While in Motion (6)
This safety label is located inside the cab.
Do not engage hoist cylinders while vehicle is
in motion. Before engaging hoist STOP the
vehicle. Do not engage hoisting cylinders
unless you read and understand the
instructions and warnings in the Operator or
Maintenance Manual. Failure to follow
instructions or heed the warnings will result
in injury or death.
1-3
MMP 4-2
5 Nov 2011
SECTION 1
Definitions and Abbreviations
Fall Hazard (7)
This safety label is located at the top of the front
and rear of the tank.
Do not walk on the top of tank without fall
arrest PPE. Serious injury or death could
occur from a fall.
Rotating Shaft (8)
This safety label is located on the pump.
Do not place your hand or tools within pump
bell while pump is rotating and/or pressure
held within the motor supply hose. Refer to
the Operator and Maintenance Manual for
the procedures to operate and maintain the
pump. Failure to follow proper procedures
could result in serious injury.
High Pressure Sprayheads (9)
This safety label is located on the spraybar.
Do not operate sprayheads until all personnel
are a safe distance away from the vehicle.
High Pressure Monitor (10)
This safety label is located on top of the cab
control box.
Do not operate the monitor until all personnel
are a safe distance away from the vehicle.
1-4
SECTION 1
Definitions and Abbreviations
High Pressure Motor (11)
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.
Confined Space (12)
This safety label is located near water tank
access and fill ports.
Do not enter confined spaces without
following established site specific
procedures. Failure to follow proper safety
procedures will result in serious injury or
death.
MMP 4-2
5 Nov 2011
ABBREVIATIONS
BFV – Butterfly Valve
cc – Cubic Centimeters
CCW – Counter Clockwise
CW - Clockwise
fl. oz. – Fluid Ounce
FT - Feet
FPM – Feet Per Minute
GPM – Gallons Per Minute
IN/SQ FT – Inches per Square Feet
KM-H – Kilometers Per Hour
Kg – kilograms
Kpa - Kilopascals
l – liters
lpm – Liters per minute
LT – Left as viewed from the operators
position facing forward
m - meters
MPH – Miles Per Hour
MTT – Mega Truck Tank
Nm – Newton meters of torque
psi - pounds per square inch
RPM – Revolutions Per Minute
RT – Right as viewed from the operators
position facing forward
SQ FT – Square Feet
VDC – Volts, Direct Current
1-5
MMP 4-2
MMP 4 GENERAL OVERVIEW
DISCHARGE BOOM
5
DISCHARGE SOCK
3
1
2
4
INLET BOOM
WATER PUMP
HYDRAULIC CONTROL VALVE
6
7
HITCH ASSEMBLY
3054 CAT ENGINE ASSEMBLY
8
HYDRAULIC TANK
9
50 GALLON FUEL TANK
10
AXLE AND SUSPENSION
SIDE
VIEW
1
2
3 4 7 6 9
10
REAR
VIEW
1
2
4 5 7 8 10
5 Nov 2011
SECTION 1
Definitions and Abbreviations
1-6
SECTION 2
MMP-4 Overview
Contents
Description ……………………………… 2-1
Inspection ……………………………..... 2-1
DESCRIPTION
The MEGA Mobile Pump is a towable water
lifting station. The MMP 4 may be towed by a
vehicle capable of at least a 6,000 pound (2,725
kg) towing capacity, 1,000 pound (450 kg)
tongue weight and equipped with the
appropriate weight rated Class IV trailer hitch
with a 2 5/16” ball. The MMP 4 can be
transported to a water holding pond and be set
up by 1 individual. MMP 4’s are a self
contained pumping station fitted with a
hydraulically driven 12” axial water pump that
has the potential to lift water 25’ (7.62 meters)
from pump level to fill water distribution
equipment (maximum height, 17’ [5.2 meters]
above ground level). MMP 4’s are equipped
with: hydraulically lifted inlet and discharge
booms with safety retaining chains and travel
locking devices, DOT rated lighting, 16” load
range ‘E’ on-highway trailer tires, a fold away
hitch with safety chains, a vacuum break with
an anti-siphon discharge sock on the discharge
boom, 23 gallon (87 liter) hydraulic oil tank
filled with Chevron Clarity AW 46 hydraulic
oil, a gear type hydraulic pump driven by a
Caterpillar 3054B series diesel engine and a 50
gallon (190 liter) capacity diesel fuel tank
equipped with shut off valves.
MMP 4-2
5 Nov 2011
Repair …………..............………….......... 2-2
The MMP 4 needs a minimum of 2.5’ (0.762
meters) of water above the inlet of the water
pump for proper operation.
INSPECTION
1. Inspect MMP 4 exterior paint for damage
and corrosion.
2. Inspect piping for damage and leaks.
3. Inspect frame, landing gear and suspension
for damage and missing parts.
4. Inspect engine assembly for loose, missing,
damaged or leaking parts.
5. Inspect all hydraulic hoses and couplings
for security, damage and leaking.
6. Inspect fuel, engine oil, anti freeze and
hydraulic oil for contamination and proper
level.
7. Inspect lighting, lug nuts, fenders and hitch
safety equipment for operation, damage and
missing parts.
8. Inspect electrical system for corrosion,
damage and missing parts.
2-1
MMP 4-2
5 Nov 2011
SECTION 2
MMP-4 Overview
REPAIR
Paint
Remove corrosion, prime and paint as required.
Engine Fluid Levels and Inspections
Adjust, repair or service according to CAT
SEBU7276-01 manuals for engine service
schedule.
Leaks
1. Remove paint and corrosion from suspected
area.
2. Prep surface to be welded, weld over leak.
3. Prime and paint over weld.
4. Tighten or replace damaged or leaking
component.
Lighting
Repair as required to maintain DOT
compliance.
Missing parts
Contact MEGA Corp Parts sales for assistance.
Structure
Contact the MEGA Corp. Product Support
Group at:
Toll free US 1-800-345-8889
Direct 1-505-345-2661
or visit our website at www.megacorpinc.com
for more detailed contact information or
assistance on major structural repairs.
2-2
SECTION 3
Control
Function
IGNITION
SWITCH WITH
KEY
Controls engine
electrical system to start,
run and shut down
engine.
GLOW PLUG
BUTTON
Operates the cold
weather starting aid
system.
MURPHY
SWITCH
A magnetic switch that
shuts the engine down in
the event of: low engine
oil pressure and/or over
heating of the engine
cooling system.
Control
Function
SYSTEM FUSE
Protects the engine
control electrical system
in the event of an
electrical short circuit.
EMERGENCY
STOP BUTTON
Disengages the Murphy
switch to shut engine
down.
THROTTLE
CONTROL
Controls and locks
engine throttle lever to a
fixed RPM.
BATTERY
VOLTAGE
GAUGE
Displays electrical
system voltage.
ENGINE OIL
PRESSURE
GAUGE
Displays engine oil
pressure.
ENGINE
COOLANT
TEMPERATURE
GAUGE
Displays engine coolant
temperature.
ENGINE
TACHOMETER
Displays engine RPM’s.
Engine Control System
Contents
Description ……………………………. 3-1
Inspection ……………………………... 3-2
DESCRIPTION
The Engine control system consists of: A
Control box with lockable cover, Ignition
switch with key, Glow plug button, Murphy
switch, System fuse, Emergency stop button,
Throttle control, Battery voltage gauge, Engine
oil pressure gauge, Engine coolant temperature
gauge and an Engine Tachometer.
The control functions operate as follows:
MMP 4-2
5 Nov 2011
Repair …………………………………. 3-2
INSPECTION
1. Inspect control box and cabling for security,
condition and mounting.
2. Inspect switches, gauges and throttle
control for security, damage and
operational condition.
3-1
MMP 4-2
5 Nov 2011
SECTION 3
Engine Control System
REPAIR
Switch Replacement
1. Remove power to the engine control.
2. Remove engine control face plate to gain
access to the switch.
3. Mark wiring on old switch before removal
to ensure correct wiring configuration is
maintained.
4. Remove old switch and replace with the
same type of switch.
5. Install wiring on new switch as previously
marked.
6. Install engine control face plate in control
box.
7. Apply power to the engine control and
perform functional check of the newly
installed switch.
Indicator Gauge Replacement
1. Remove power to the engine control.
2. Remove engine control face plate to gain
access to gauge and wiring.
3. Mark wiring on old gauge before removal
to ensure correct wiring configuration is
maintained.
4. Remove old gauge and replace with the
same type of gauge.
5. Install wiring on new gauge as previously
marked.
6. Install engine control face panel in control
box
7. Apply power to the engine control and
perform functional check of newly installed
indicator gauge.
Engine Tachometer Replacement
1. Remove power to the engine control.
2. Remove engine control face plate to gain
access to the backside of the tachometer.
3. Mark wiring on old tachometer before
removal to ensure correct wiring
configuration is maintained.
4. Remove old tachometer and replace with
the same type tachometer.
5. Installed wiring on new tachometer as
previously marked.
6. Install engine control plate in control box.
7. Apply power to engine control and perform
functional check of newly installed
tachometer.
Throttle Control replacement
1. Remove power to the engine and engine
Control system.
2. Loosen cable locking screw on throttle
lever on fuel injection pump.
3. Remove cable jam nut on lever side of the
fuel pump mounting bracket.
4. Remove cable jam nut on throttle adjusting
end of cable.
5. Remove cable assembly.
3-2
SECTION 3
Engine Control System
6. Install new throttle cable assembly in
mounting bracket.
7. Thread jam nut on throttle cable adjusting
end behind mounting bracket.
8. Route throttle cable to the fuel pump cable
mounting bracket.
9. Run cable through fuel pump mounting
bracket.
10. Install jam nut on fuel pump throttle lever
side of bracket.
11. Insert throttle cable in the pivot on the
throttle lever of the fuel pump.
12. Ensure throttle cable and fuel pump throttle
lever is in the idle position.
13. Secure the throttle cable locking screw on
the new cable.
14. Ensure the new throttle cable is routed
away from moving parts.
15. Ensure throttle cable is secure.
16. Check operation of newly installed cable
for smooth operation.
MMP 4-2
5 Nov 2011
17. Ensure newly installed throttle cable allows
engine throttle lever to fully contact the
LOW idle stop.
18. Ensure the newly installed throttle cable
allows engine throttle to fully contact the
HIGH idle stop.
3-3
MMP 4-2
5 Nov 2011
SECTION 3
Engine Control System
19. Place throttle control cable in the low idle
position.
20. Apply power to engine control box and
engine.
21. Ensure hydraulic ball valve at hydraulic
tank is OPEN.
22. Perform functional check to ensure proper
engine low and high idle RPMs. If engine
RPMs are out of specified range, check
throttle cable adjustment again and refer to
CAT SEBU7276-01 manual for correct
RPM specifications and adjustment
procedures.
3-4
SECTION 4
Basic Hydraulics System
Contents
Description …………………………..... 4-1
Hydraulic Tank………………………….. 4-1
Hydraulic Pump………………………… 4-2
Hydraulic Control Valve……………...... 4-2
Water Pump Hydraulic Drive Motor .... 4-2
Hydraulic Cylinders ………………....... 4-3
DESCRIPTION
The MMP 4 hydraulic system originates at a
hydraulic pump coupled to a CAT 3054B
Diesel engine. The system draws hydraulic oil
from a hydraulic tank mounted at the rear of the
MMP 4 frame through a inlet screen inside of
the tank and a shut off valve on the outside of
the tank. The hydraulic pump moves the oil to
a hydraulic control valve mounted to the right
side of the unit. The control valve diverts and
regulates the oil flow and pressure through the
MMP 4 system. The Hydraulic control valve is
used to control the raising and lowering of the 2
hydraulic cylinders attached to the inlet and
discharge booms. The hydraulic control valve
also controls the hydraulic drive motor inside
of the water pump at the end of the inlet boom,
this control feature is equipped with a detent to
allow the lever to stay in the ON position
during water pump operation and is equipped
with a pressure relief valve to protect against
over pressurization of the hydraulic system.
The return hydraulic oil is passed through a
hydraulic oil filter, oil cooler then a diffuser
mounted inside of the hydraulic oil tank.
MMP 4-2
5 Nov 2011
Hydraulic Oil Filter.……………….….. 4-3
Hydraulic Oil Cooler……………….…. 4-4
Hydraulic Hoses ………………….….. 4-4
Inspection ……………………………... 4-5
Repair ……………………………….… 4-7
HYDRAULIC TANK ASSEMBLY
The hydraulic tank consists of an inlet screen,
return oil diffuser, internal baffle, shut off
valve, oil level sight gauge, reservoir cap and
breather. The system draws oil from the
bottom of the tank through an inlet screen to
pre-filter the oil. The shut off valve holds the
oil inside of the tank when servicing the
hydraulic system. The sight gauge is used as a
visual indicator of the hydraulic oil quality and
quantity. The Internal baffle allows for oil
movement with in the tank to evenly distribute
the return oil trough out the reservoir. The
return diffuser inside of the hydraulic tank just
below the normal oil level reduces the potential
for hydraulic oil foaming in the tank. The
reservoir cap and breather allow filling of the
hydraulic tank and prevent dirt and debris from
entering the hydraulic system.
4-1
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