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 [phone]

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

MMP 4-2
5 Nov 2011

SECTION 4

Basic Hydraulics System

HYDRAULIC PUMP

The hydraulic pump is coupled to the flywheel
end of the engine. The hydraulic pump moves
the oil through the system to generate flow and
pressure needed to operate the water pump and
boom cylinders. The pump draws oil from the
hydraulic tank and moves it to the hydraulic
control valve.

HYDRAULIC CONTROL VALVE

The hydraulic control valve directs and
regulates the hydraulic pumps oil flow. The
valve operates the boom lifting cylinders by
pressurizing the rod end of the cylinder to make
the booms move up (Cylinder retract). To
lower the booms the valve opens to allow the
oil to return to the hydraulic filter through a

metering control that controls the speed of the
cylinder movement. The hydraulic drive motor
for the water pump portion of the control valve
is equipped with a detent to allow the valve
spool to stay in an open position when the lever
is moved to the ON position for normal water
pump operation. When this lever is moved to
OFF it will shut off hydraulic oil flow to the
water pump drive motor. The hydraulic control
valve is fitted with a pressure regulator that
limits the maximum pressure of the hydraulic
system to 2,100 psi (14,450 kpa). The excess
oil flow is diverted to the hydraulic oil filter.
When the control valves are in the neutral
position, all of the hydraulic oil by-passes
through the control valve to the return
hydraulic oil filter.

WATER PUMP HYDRAULIC
DRIVE MOTOR

The hydraulic drive motor is coupled to the
water pump drive shaft inside the water pump.
The drive motor is controlled by the hydraulic
control valve, water pump spool. When the
lever is moved to the ON position the fluid is
directed to the drive motor causing the water
pump impeller to rotate, moving water up the
inlet boom.

4-2

SECTION 4

Basic Hydraulics System

MMP 4-2

5 Nov 2011

HYDRAULIC CYLINDERS

The 2 hydraulic cylinders are used for lifting
the inlet and discharge booms to either the
‘stow/travel’ position or to the ‘fill’ position.
When the boom control lever is operated in the

‘UP’ position the pressurized oil retracts the

cylinder and lifts the boom. The speed of the
lifting is controlled by metering valves attached
to the hydraulic control valve. There are safety
chains at each cylinder to prevent any
unwanted movement in the boom when it is
filled with water and as a safety precaution in
case the control valve lever is operated
accidentally. The cylinder operates in the
boom down mode by moving the control valve
lever to the ‘DOWN’ position, the weight of
the boom makes the cylinder extend. The
speed of the downward motion is controlled by
a fluid metering valve attached to the hydraulic
cylinder that restricts the fluid exiting the
cylinder causing a slow, controlled lowering of
the booms.

HYDRAULIC FILTER

The spin on hydraulic oil filter is in the return
to tank hydraulic circuit. All hydraulic oil
passing through the system passes through the
filter prior to the hydraulic oil cooler. The
filter is rated at 400 psi (2,758 kpa) and has a
provision for the cylinder lower plumbing. The
filter is rated at 10 microns. The filter housing
has a built in bypass valve to bypass the filter
element when the inlet pressure is too high or
the filter becomes restricted.

4-3

MMP 4-2
5 Nov 2011

SECTION 4

Basic Hydraulics System

HYDRAULIC OIL COOLER

The hydraulic oil cooler is attached to the front
of the engine radiator. The engine cooling fan
draws cool air through the oil cooler lowering
the oil temperature. The oil cooler is in the
return to tank hydraulic circuit. Built into the
oil cooler is a bypass valve that allows oil to
bypass the cooler if the return oil pressures are
too great (e.g; when the hydraulic oil is cold).
The oil cooler and engine coolant radiator are
protected by a steel mesh guard to prevent
damage to the cooler and radiator.

HYDRAULIC HOSES

The MMP-4 is equipped with hydraulic hosing
to convey the hydraulic oil pressure and flow to
components that are operated by the hydraulic
control valve. These hoses are sized according
to the volume and pressure requirements of the
component. The hydraulic drive motor for the
water pump utilizes a 1” (-16) hose to direct the
volume of oil required to turn motor that drives
the impeller of the water pump at the rated
speed. The hydraulic cylinder hoses require a
smaller volume of fluid and do not require as
large of a hose. The makeup oil requirement
for the lift cylinders (when the booms move
down) are low pressure and low volume. The
suction side of the hydraulic pump requires
suction rated hydraulic hose, this prevents the
hose from collapsing under suction loads.

4-4

SECTION 4

OPEN

CLOSED

Basic Hydraulics System

INSPECTION

Hydraulic tank assembly

1. Inspect hydraulic oil tank for security,

damage, leaks.

2. Check hydraulic oil level and quality. The

level should be between 80% and 90% of
the level visible in the sight glass and clear.

3. Check hydraulic tank filler cap, breather

and bolt on end cover for security, damage
and leaks.

4. Check hydraulic hose fittings and shut off

valve, ensure shut off valve is open.

5. Check tank mounting bolts, ensure the bolts

are tight.

MMP 4-2

5 Nov 2011

Hydraulic Pump

1. Inspect hydraulic pump, adapter and hosing

for vibrations, unusual noises, security,
damage and leaks.

Hydraulic Control Valve

1. Check hydraulic control valve mounting for

security, damage and leaks.

2. Check control valve levers for ease of

operation, security, damage and missing
parts.

3. Check control valve fittings and metering

valves for security, damage and leaks.

4. Check pressure regulator for proper relief

pressure (2,100 psi/14,450 kpa), security
and leaks.

4-5

MMP 4-2
5 Nov 2011

SECTION 4

Basic Hydraulics System

Water Pump Hydraulic Drive Motor

1. Check water pump drive motor fittings for

security, damage and leaks.

2. Check for an oily film on water surface

(indications of hydraulic oil leak below the
surface of the water). If water pump is
submerged.

3. Check for oil residue inside of the inlet to

the water pump. If water pump is in the
travel position.

Hydraulic Cylinders

1. Check hydraulic cylinders for security,

damage and leaks.

2. Check hydraulic cylinder safety chains for

security, missing parts and damage.

3. Check hydraulic hoses and metering valves

for security, damage and leaks.

4. Check for proper operation and alignment.

Hydraulic filter assembly

1. Inspect hydraulic oil filter mounting for

security and damage.

2. Check hydraulic filter for leaks and

damage.

3. Check hydraulic filter assembly hose fitting

adapters for security and leaks.

Hydraulic Oil Cooler assembly

1. Check hydraulic oil cooler and radiator

guard for security and damage.

2. Check hydraulic oil cooler and fittings for

leaks.

3. Check hydraulic oil cooler for blockage and

debris that may interfere with proper
cooling of oil passing through cooler
assembly.

4-6

SECTION 4

Basic Hydraulics System

REPAIR

Hydraulic tank assembly

1. Repair, secure or adjust as required.

Hydraulic Pump

1. Repair or replace as required.

Hydraulic Control Valve

1. Repair, adjust or replace as required.

2. To set hydraulic relief pressure, install a 0 –

3,000 psi (0 – 21,000 kpa) pressure gauge
on the test fitting located on the retract hose
(RAISE) for the inlet boom cylinder.

3. With the engine operating at high idle,

operate the inlet boom UP lever and
observe the reading on the pressure gauge.

MMP 4-2

5 Nov 2011

4. If the hydraulic oil pressure is not within

the specifications, adjust the pressure
regulator cartridge as follows:
a. To increase the pressure, loosen the

lock nut on the regulator stem and
screw in the stem clockwise (CW) until
the pressure is at 2,100 psi (14,450
kpa), tighten lock nut on stem.

b. To reduce the pressure, loosen the lock

nut on the regulator stem and unscrew
the stem counter clockwise (CCW) until
the proper pressure is obtained, tighten
lock nut on stem.

c. Recheck hydraulic pressure.
d. Shut unit off.
e. Remove pressure gauge from test port.

4-7

MMP 4-2

Set Screw

Index Marks

5 Nov 2011

SECTION 4

Basic Hydraulics System

Water Pump Hydraulic Drive Motor

1. Repair or replace as required.

Hydraulic Cylinders

1. Repair or replace as required.

Hydraulic Cylinder Speed Control Valve

1. If the hydraulic boom cylinders raise too

slowly or lower too fast, check the
adjustment as follows;
a. Loosen set screw on knob.
b. Fully seat the flow control on the

hydraulic control valve for the cylinder
with the travel speed that needs
adjustment.

c. Rotate adjustment knob CW to fully

seat needle.

d. Rotate knob 1 full turn CCW.
e. Raise boom, check speed to ensure

speed is desired, if speed is too fast turn
knob CW 1 index mark, if the speed is
too slow turn knob CCW 1 index mark
at a time until desired speed is achieved.

f. Tighten set screw.

Hydraulic Filter Assembly

1. Repair or replace as required.

Hydraulic Oil Cooler Assembly

1. If cooling fins are dirty or plugged with

debris, remove, replace or clean cooler as
required.

2. Tighten or replace leaking or damage

adapter fittings as required.

3. Replace radiator guard if damage is present.

Hydraulic Hoses

1. Remove and replace damaged hose

assembly if damage to outer covering is
present or leaks are present.

2. Replace hose assembly if hose end is

unserviceable due to leaks or damage.

4-8

SECTION 5

Water Pump Assembly

Contents

Description ………………………......... 5-1

Hydraulic Drive Motor …………...…… 5-1
Inspection and Service ...………………. 5-2

DESCRIPTION

The water pump assembly is comprised of;
hydraulic drive motor, water pump housing,
impeller, shaft and bearings and an inlet screen.
The water pump assembly uses hydraulic oil
flow produced by the engine driven hydraulic
oil pump to turn the hydraulic drive motor
which is directly coupled to the water pump
impeller. Water pump speed is controlled by
the hydraulic control valve and pressure relief
cartridge which diverts the oil flow to the inlet
port (pressure) of the hydraulic drive motor to
the return oil hose for the hydraulic system.
The pressure relief cartridge diverts excessive
oil pressure directly to the hydraulic return
hose, returning back to the hydraulic oil to the
tank for system protection.

MMP 4-2

5 Nov 2011

Parts Breakdown of Water Pump ..…….... 5-5 Repair ………………………………... 1-1

Disassembly .............................................. 5-7

Assembly ................................................... 5-8

HYDRAULIC DRIVE MOTOR

A gear-type hydraulic motor mounted inside
the water pump assembly. The hydraulic motor
receives hydraulic oil flow from the hydraulic
system controlled by the hydraulic control
valve at 1,900 - 2,800 PSI (13,000 – 19,300
kpa) and flow rates up to 35 GPM (135 lpm)
for operation. The hydraulic motor is coupled
directly to the water pump shaft and rotates in a
clockwise (CW) direction as viewed from the
inlet of the pump. The speed and volume of the
water pump is dependent on the engine RPMs,
[e.g: higher engine RPMs yields a higher
output volume of water].

5-1

MMP 4-2

Proper Hydraulic Oil Level

5 Nov 2011

SECTION 5

Water Pump Assembly

INSPECTION
DAILY

1. Check for excessive vibration and noise.

2. Check water pump for security and leaks.

3. Check and adjust fluid levels.

4. Check hydraulic system for security and

leaks.

250 hours

1. Remove water pump from inlet boom.

2. Check water pump drive motor for security,

damage and signs of leakage.

3. Check water pump bearing oil level.

4. Check water pump bearing oil for

contamination.

5. Grease water pump suction bowl reservoir.

6. Check water pump trash screen for

blockage, security and damage.

7. Check impeller for damage.

500 hours

1. Perform all 250 hour inspections and

repairs.

2. Change oil in the 2 water pump bearing

reservoirs.

3. Check water pump housing for damage and

security.

SERVICE

1. Park unit on level ground, lower and secure

stabilizing jacks to make unit stable for
maintenance.

Ensure the MMP4 is properly positioned
and configured before maintenance is
performed. Units not configured properly
or stabilized, may rollover and cause
serious personal injury or death.

2. Remove all electrical and hydraulic power

to make the unit safe for maintenance.

Ensure the MMP4 is made safe for
maintenance. Performing maintenance on a
unit with hydraulic and electrical power
applied may result in serious personal
injury or death.

3. Ensure the use of only clean, compatible

hydraulic oil. The hydraulic system must
have a filter rated at 10 micron filtration.

4. When disconnecting and reconnecting the

hydraulic hoses to the pump, ensure the
fittings are kept clean.

5. Hydraulic fluid levels must be maintained

at 80% to 90% of the level shown in the
sight glass. Check level daily.

5-2

SECTION 5

Oil Level Check Plugs on

Axial Water Pump

Water Pump Assembly

6. Check hydraulic fluid for excessive

bubbles, foaming and water contamination
daily.

7. Use hydraulic oils with anti-wear additives

such as these recommended oils or their
equivalent:
Pennzoil AW46 Hydraulic Oil
Texaco Rando HDAZ
Shell Tellas Hydraulic Oils
Mobil D.T.E. 20 Series
Chevron EP Hydraulic Oils
Exxon Univis N Hydraulic Oils

When using this equipment in
environmentally sensitive areas the use of
bio-degradable or non-hazardous oils such
as: Chevron Clarity, Exxon Univis Bio 40
or Mobil EAL 224H are recommended.

8. Remove Item 40 on Figure 1 to gain access

to the bearing housing reservoir fill plug
(Item 34 in Figure 1) and item 23 on the
discharge bowl, with the water pump in a
vertical position.

The water pump must be removed from the
boom and set in a vertical position on the
inlet end when performing this action. Any
other position will result in incorrect
servicing and improper component oil level
will decrease the service life of the water
pump, shaft and bearings.

There are 2 bearing fluid reservoirs in the
MMP4 water pump housing.

MMP 4-2

5 Nov 2011

9. Check oil in the 2 bearing housings every

250 operating hours.

10. Slight dark discoloration of the oil in the

bearing housing is normal. This is due to
the wearing of the carbon face seal.

11. Presence of water or emulsified oil in the

bearing housing indicates immediate need
for seal replacement and inspection of
bearing. If this condition is present, refer to
MMP 4 Disassembly Instructions.

12. Change oil in the bearing housing every

500 operating hours or semi annually which
ever occurs first if no contamination or
fluid loss is present. Use clean non­detergent 10W, 20W oil, AW32 or AW46
hydraulic oil.

13. The level should be at the spill point of the

fill plug. DO NOT OVERFILL

If there is a difficulty in checking these
fluid levels, ensure that FSB-9 (Water
Pump Lube Level Modification) has been
completed.

5-3

MMP 4-2
5 Nov 2011

SECTION 5

Water Pump Assembly

14. Use a liquid pipe sealant to seal and

reinstall pipe plugs in bearing housings and
water pump housings.

The use of a high strength thread sealant
may make it difficult to remove plugs at the
next service interval. A Liquid Teflon pipe
sealant is recommended.

15. Lube suction bowl bushing at (Item 15 in

Figure 1), every 250 operating hours or
semi annually which ever occurs first.
(Mystic 5496 Marine Grease or equivalent)
1 each - 3/8” NPT grease fitting may be
required to perform this operation.

More frequent service intervals may be
required if the quality of the water being
transferred is of poor quality containing:
salts, dirt, sediments or other contaminants.

5-4

SECTION 5

Figure 1: MMP 4 Water Pump

40

30

22

20

Water Pump Assembly

MMP 4-2

5 Nov 2011

5-5

MMP 4-2

Item

Part number

Description

Item

Part number

Description

1

303910-01

Hydraulic Motor

21

303910-20

Lower Seal

2

303910-02

Discharge pipe with

flange

22

303910-21

Discharge Bowl

Assembly

3

303910-03

Grommet

23

303910-22

Pipe Plug

4

303910-04

1" Elbow

24

303910-23

Shaft

5

303910-05

Pipe

25

303910-24

Snap-Ring

6

303910-06

Shaft collar

26

303910-25

Upper Seal

7

303910-07

Bearing Housing

27

303910-26

Bearing

8

303910-08

Bolt

28

303910-27

Snap-Ring

9

(Not used on this model)

29

303910-28

Snap-Ring

10

303910-09

Bushing Lower

Discharge Bowl

30

303910-29

Coupler (male) 1"

11

303910-10

Bolt

30

303910-30

Coupler (female) 1"

12

303910-11

Bushing Suction Bowl

31

303910-31

O-Ring

13

303910-12

Suction Bowl

32

(Not used on this model)

14

303910-13

Screw 3/8" x 1-1/2" Sq.

Head Set Screw

33

303910-32

Bolt

15

303910-14

Pipe Plug

34

303910-33

Plug Bearing Housing

16

303910-15

Strainer Assembly

35

303910-34

O-Ring

17

303910-16

Snap-Ring

36

303910-35

Swivel Union (Optional)

2 req.

18

303910-17

Thrust Collar

37

303910-36

Discharge Flange

(Optional)

19

303910-18

Key

20

303910-19

Impeller

40

Pipe Plug

Table 1: MMP 4 Water Pump Parts Break Down

5 Nov 2011

SECTION 5

Water Pump Assembly

5-6

SECTION 5

Water Pump Assembly

DISASSEMBLY

Removal of the water pump assembly from the
inlet boom is necessary to properly service or
repair the water pump. The water pump
assembly is heavy (greater than 200 pounds or
91 kg). Use proper lifting devices and
techniques for this operation to preclude
personnel injury or death.

1. Place MMP4 on a firm hard packed, level

work surface.

2. Set and secure 3 landing gear legs.

3. Remove electrical power from unit.

4. Disconnect and cap hydraulic hoses from

water pump drive motor fittings.

5. Remove water pump from inlet boom.

6. Remove strainer by loosening (4) screws

(Item 14).

To inspect impeller (Item 20) remove (8)
bolts (Item 11) holding suction bowl
(Item13) to discharge bowl (Item 22).

7. Remove suction bowl and check impeller

and suction bowl face for excessive wear.
Replace if obvious wear is present or if
pump performance is poor.

8. To inspect hydraulic motor (Item 1) upper

bearing (Item 27) and upper seal (Item 26),
use the following procedure:

9. Remove hydraulic pipes (Item 5) from

drive motor.

MMP 4-2

5 Nov 2011

10. Remove (8) bolts (Item 8) holding

discharge bowl to discharge pipe (Item 2).

11. Remove discharge pipe assembly.

Remove (4) bolts (Item 33) holding
hydraulic motor to bearing housing (Item

7).

12. Remove and inspect hydraulic motor.

13. Inspect motor O-Ring (Item 31) and replace

if necessary.

14. Drain oil from bearing housing by tilting

unit on side and removing drain plug (Item
s 23, 34 and 40). Inspect condition of oil.

If oil is low or is emulsified with water, the
upper seal should be replaced (Item 26).

15. Remove snap ring (Item 29) near end of

shaft (Item 24).

16. Remove shaft collar (Item 6) by loosening

set screws on collar by inserting the
appropriate Allen wrench through the oil
plug hole in the bearing housing.

17. Remove bearing housing by lifting straight

up (bearing will remain in housing).

18. Remove snap ring (Item 28) and slide

bearing (Item 27) out of housing. Inspect
for rough spots and replace if necessary.

19. Inspect lower O-Ring (Item 35) and upper

shaft seal for damage or wear, replace if
necessary.

5-7

MMP 4-2
5 Nov 2011

SECTION 5

Water Pump Assembly

20. Remove upper shaft seal and retainer (Item

26) by sliding off shaft.

21. To remove impeller, shaft and lower seal,

use the following procedure:

22. Remove snap ring (Item 17) from end of

impeller (Item 20).

23. Push and hold drive end of shaft (Item 24)

toward discharge bowl (Item 22).

24. Slide impeller back and remove split thrust

collar (Item 18) from shaft.

25. Slide impeller forward to remove.

26. Remove shaft key (Item 19) and gently

slide shaft out of discharge bowl toward
drive end.

27. Inspect lower shaft seal (Item 21) and

replace if necessary.

28. Inspect shaft and bronze discharge bowl

bushing (Item 10) and replace if worn.
(Moderate wear [e.g: shiny areas or ridges
not more than .010" (0.254 mm) deep] on
shaft are acceptable, the upper bearing takes
most of the loading).

29. Inspect bushing (Item 12) in suction bowl

(Item 13) and replace if worn.

ASSEMBLY:

1. Assembly is performed in reverse order of

disassembly:

2. Ensure O-Rings are properly installed in

grooves (Items 31 and 35).

Use only clean grease when assembling
new seal on shaft and when installing new
seal seat in bearing housing. Apply a light
film of clean oil to seal faces when
assembling to prevent scratching surfaces.
(Extreme care and cleanliness must be used
when installing shaft seals to prevent
possible component damage). Failure to
keep items clean and use clean grease to
perform this function may result in seal,
bearing or shaft damage.

The following is the required filling
procedure for the bearing reservoirs when
the pump is in a vertical position resting on
the inlet end:

3. Fill suction bowl bushing area to bottom of

bushing with waterproof grease.

4. Fill oil hole (1/2" plug) in discharge bowl

(Item 22) to spill point (pump in vertical
position) with clean hydraulic oil. Refer to
line 5 above for oil specifications.

5. Fill oil hole (1/4" plug) in upper bearing

housing (Item 7) to spill point with clean
hydraulic oil. Refer to line 5 for above for
oil specifications.

5-8

SECTION 5

RETURN

PRESSURE

Water Pump Assembly

6. Use anti-seize compound on all threaded

fasteners when re-assembling pump.

DO NOT USE ANTI-SEIZE ON SEALS
OR BEARINGS. If an anti-seize
compound is used in this application
bearing and/or seal failure will result.

7. Ensure pressure and return pipes are

connected to proper ports on the hydraulic
motor.

8. Install strainer to pump inlet, tightening (4)

retaining bolts (Item 14).

9. Inspect mounting gasket for damage,

replace as necessary.

10. Install pump assembly to suction pipe,

tighten fasteners.

11. Hook up hydraulic hoses.

12. Check hydraulic fluid level, adjust level as

required.

13. Check to ensure hydraulic pump inlet valve

is OPEN.

MMP 4-2

5 Nov 2011

14. Run unit, engage water pump control,

ensure proper rotation of water pump and
no leaks are present.

Motor rotation is counter-clockwise looking
from discharge end of pump.

15. Shut unit off and recheck hydraulic fluid

level, at 80% to 90% of the level shown in
the sight glass, adjust level as required.

5-9

MMP 4-2
5 Nov 2011

SECTION 5

Water Pump Assembly

5-10(Blank)

SECTION 6

Axle and Suspension

Contents

Description …………………………….. 6-1
Service ..………………….…………….. 6-1

DESCRIPTION

The MMP-4 is equipped with a 6,000 lb (2,725
kg) rated single axle utilizing a double eye leaf
spring suspension. The springs are attached to
the frame by welded spring hangers. The axle
is attached to the springs by U-bolts with weld
on axle mounts. Mounted to the axle hubs by 8
lug nuts are load range E tire and rim
assemblies. Each tire and rim assembly is
protected by a steel fender that contains a front
amber marker lamp and rear red marker lamp
assembly. Current production models are not
equipped with brakes.

SERVICE

1. Park MMP-4 on firm level ground, lower

forward landing gears, raise hitch, uncouple
MMP-4 from tow vehicle.

2. Lower rear landing gear until the MMP-4 is

stabile.

3. With a jack of adequate capacity raise 1 tire

in the air high enough to remove the tire.

MMP 4-2

5 Nov 2011

Inspection ……………………………….. 6-2

Repair .......................……………..….….. 6-2

4. Place a jack stand under axle to prevent

axle from falling.

Do not lift the axle for the center, place jack
under the U-bolts towards the axle end.
Ensure jack stands of proper capacity is
used to secure the axle prior to removing
the tire assembly. Failure to properly lift
and secure the MMP-4 properly may result
in an unstable load, over loading of the jack
or damaging an MMP-4 component causing
damage to the MMP-4.

5. Lower the landing gear to re-stabilize the

MMP-4.

MMP-4 must be stable and secure on
adequate capacity jack stands and the jack
removed prior to servicing the hub
assembly. Failure to secure and ensure the
MMP-4 is stable and secure will result in
serious personal injury or death if the unit
falls.

6. Semi-annually (every 6 months), remove

rubber plug at the center of the wheel
bearing cap.

6-1

MMP 4-2
5 Nov 2011

SECTION 6

Axle and Suspension

7. Pump grease into the grease fitting in the

spindle end with a manual type grease gun
only.

Do not mix Lithium, Calcium, Sodium or
Barium complex greases due to possible
compatibility problems. When changing
from one type of grease to another, it is
necessary to disassemble the wheel bearing
and ensure all grease is removed prior to re­packing or servicing the wheel bearing.
Failure to ensure greases are not mixed may
result in wheel bearing, axle end, hub,
MMP-4 or tow vehicle damage.

8. Rotate wheel while pumping grease into

fitting.

9. Continue to pump grease until clean grease

is extruded through the outer bearing.

10. Rotate wheel while pumping grease into

fitting.

11. Clean old grease from around the bearing

cap.

12. Install the rubber plug in the grease cap.

13. Repeat on the other wheel bearing.

Manual wheel bearing greasing is only a
semi-annual service point. Failure to
perform annual wheel bearing service and
inspection may result in damage to the axle,
wheel bearings or MMP-4 if not preformed.

INSPECTION

1. Inspect axle for cracking, damage and

security.

2. Inspect springs for worn eye bushings, bent,

loose or broken shackles, mounts and bolts,
sagging or broken leafs, loose or damaged
U-bolts.

3. Check for loose wheel bearings.

4. Inspect lug nuts to ensure all are present

and torque properly to 80 to 90 ft/lbs (110
to 125 Nm).

5. Inspect for wheel seal leakage.

6. Inspect tires for inflation to 80 psi (550

kpa), cracking, uneven wear, tread and side
wall damage.

7. Inspect fender assembly for security and

damage.

REPAIR

1. Axle tube, replace as required.

2. Damaged springs or mounting hardware,

replace as required.

3. Worn spring eye bushings, loose spring

bolts and damaged or worn shackles,
replace as required.

4. Fender damage, repair as required.

5. Tire for wear or damage, replace as

required.

6-2

Axle and Suspension

Thickener Type

Lithium Complex

Dropping Point

215°C (419°F)
Minimum

Consistency

NLGI No. 2

Additives

EP, Corrosion &
Oxidation Inhibitors

Viscosity Index

80 Minimum

Nut Locking Tab

6. Wheel bearings:
a. Secure MMP-4 with jack stands and

wheel chocks.

b. Jack up 1 tire and secure axle.
c. Remove tire and rim assembly.
d. Remove wheel bearing grease cap.
e. Remove cotter pin or bend clear the nut

locking tab.

f. Remove spindle nut by turning nut

CCW.

g. Remove hub assembly.
h. Inspect hub for damaged threads,

missing or damaged studs. Replace as
required.

i. Inspect grease seal for damage (e.g;

tears, cracks, leaks and distortion).

j. To remove grease seal; pry out of hub

with a long handled screwdriver.

k. Clean and inspect wheel bearings and

bearing races for corrosion, pitting,
wear, heat discoloration and
free/smooth movement. Replace as

required.

MMP 4-2

5 Nov 2011

SECTION 6

Never spin the wheel bearing with
compressed air. The bearing may be
damaged, causing the bearing explode
causing severe personal injury or death.

REASSEMBLY

1. Pack wheel bearings with a premium,

water resistant, high speed wheel
bearing grease.

2. Apply a light coat of grease on the

bearing races.

Recommended Wheel Bearing
Lubrication Specifications are as
follows;

3. Install inner wheel bearing in hub.

4. Install new grease seal in hub using a

small hammer or proper seal installation
tool.

5. Install hub on spindle.

6. Install outer wheel bearing onto the

spindle.

7. Install bearing retaining washer and

spindle nut.

6-3

MMP 4-2
5 Nov 2011

Axle and Suspension

8. Tighten spindle nut to 50 ft/lbs (68

Nm).

9. Loosen nut to remove the torque. Do

not rotate the hub

10. Finger tighten until just snug.

11. Install and secure cotter pin or nut

locking tab.

12. Install wheel bearing grease cap.

13. Install tire and rim assembly.

14. Tighten lug nut using a cross tightening

sequence to 15 to 20 ft/lbs (20 to 27
Nm).

Use an anti-seize compound on the
threads of the lug studs. This will
prevent galling and seizure of the lug
nut to the stud.

15. Final torque lug nuts to 80 to 90 ft/lbs

(110 to 125 Nm).

16. Remove jack stands and lower wheel to

ground.

Re-torqueing of lug nuts is required
after initial 50 miles (80 km) of travel
and then again after 200 miles (320 km)
of travel. Failure to ensure proper lug
nut torque may result in tire, wheel or
hub failure that will cause damage to
MMP-4 and tow vehicle.

SECTION 6

6-4

SECTION 7

Frame and Booms

Contents

Description …………………………….. 7-1
Inspection ……………………………… 7-1

DESCRIPTION

The MMP-4 frame is constructed from steel
tubing welded together to form a rigid mounting
platform that the components of the MMP-4 are
attached to. The frame is equipped with 3
adjustable stabilizing jacks, a movable hitch,
mounting pads for the diesel engine, hydraulic
and fuel tanks, travel lock mounts for the inlet
and discharge booms, safety chain lock anchors,
hydraulic cylinder mounts, suspension mounts,
mounting structures for the boom pivot and
hydraulic control valve mounting, fenders and
lighting.

INSPECTION

1. Inspect frame for damage and missing parts.

2. Inspect all welds for cracks, rust or damage.

3. Inspect hitch assembly and coupling for
security, serviceability, damage and missing
parts.

MMP 4-2

5 Nov 2011

Repair …………………………………… 7-4

4. Inspect battery box for security and damage.

5. Inspect landing gear/stabilizer legs for

security, serviceability and damage.

6. Inspect engine mounting bolts for security.

7-1

MMP 4-2
5 Nov 2011

SECTION 7

Frame and Booms

7. Inspect discharge boom, travel locks and
mounts for security and damage.

8. Inspect fenders for security and damage.

9. Inspect lighting for security, damage and

function.

10. Inspect boom mounting, pivot point, travel

locks and Victaulic coupling for lubrication,
security, damage and leaks.

7-2

SECTION 7

Frame and Booms

11. Inspect fuel tank for mounting security and
damage, fuel level, fuel level gauge and
filler cap serviceability and damage, fuel
shut off valve for security, damage and
leaks.

12. Inspect inlet boom, travel locks and
mounting for lubrication, security, damage
and serviceability.

13. Inspect hinge pins, flanges gaskets for
lubrication, security, wear and damage.

MMP 4-2

5 Nov 2011

13. Inspect hydraulic control valve and mount

for security, damage, leaks and missing
parts.

14. Inspect suspension spring mounts for

security, damage and wear.

7-3

MMP 4-2
5 Nov 2011

SECTION 7

Frame and Booms

15. Inspect hydraulic cylinder mounting for
lubrication, security, cracks, damage, worn
pins, and missing parts.

16. Inspect safety chains and safety chain locks
for security, damage and missing parts.

REPAIR

1. Replace damaged or missing parts as

required.

2. If frame damage is noted, or you have a

question about the MMP4 contact:

MEGA Corp. Product Support Group at:

Toll free US 1-800-345-8889
Direct 1-505-345-2661

www.megacorpinc.com for more contact

information or repair options and
procedures.

3. Adjust, secure or replace parts as required.

7-4

MMP 4-2

FREQUENCY

STEP

FRAME AND

SUSPENSION

DAILY

BEFORE

TRANSPORT

FIRST

50

MILES

FIRST 200

MILES

SEMI-

ANNUALLY

ANNUALLY

1

Check frame and
suspension for cracks,
damaged or missing
components.
Repair or replace as
required.

X

2

Verify lug nut torque.
(80 to 90 ft/lbs or 110 to
125 Nm)
Re-Torque as
required.

X X

X

3

Check tires and wheel
for security, damage,
inflation (80 psi or 550
kpa) and missing parts.
Repair as required.

X

4

Service wheel bearings
with grease.

X

5

Remove and repack
wheel bearings.

X

6

Check travel locking
components for
serviceability, damage,
proper installation and
missing parts.
Repair as required.

X

5 Nov 2011

SECTION 8

Scheduled Inspections

DESCRIPTION

This section establishes scheduled maintenance inspections of the MMP-4 at designated frequencies.
Performing these inspections will identify potential system discrepancies and allow preventative
maintenance to be performed before a component or system is rendered totally inoperative.

** NOTE: Units operated in extremely low quality water environments may require more frequent

inspections.

8-1

MMP 4-2

FREQUENCY

STEP

FRAME AND

SUSPENSION

DAILY

BEFORE

TRANSPORT

FIRST 50

MILES

FIRST 200

MILES

SEMI-

ANNUALLY

ANNUALLY

7

Check lighting system.
Repair as required.

X

8

Check hitch assembly
for security, damage,
proper installation and
missing parts.
Repair as required.

X

9

Check landing gear for
security, damage and
operation.
Repair as required.

X

10

Check pipe work to
include: the Victaulic
coupling, boom flanges
and gaskets, cylinder
mounting and pivot
points for security,
damage, leaks,
serviceability and
missing parts.
Repair as required.

X

11

Check hydraulic tank
mounting bolts for
security, damage and
missing parts.
Repair as required.

X

12

Check fuel tank
mounting bolts for
security, damage and
missing parts.
Repair as required.

X

13

Check engine mounting
bolts for security,
damage and missing
parts.
Repair as required.

X

5 Nov 2011

SECTION 8

Scheduled Inspections

8-2

MMP 4-2

FREQUENCY

STEP

FRAME AND

SUSPENSION

DAILY

BEFORE

TRANSPORT

FIRST 50

MILES

FIRST 200

MILES

SEMI-

ANNUALLY

ANNUALLY

14

Check battery box and
contents for security,
damage and missing
parts.
Repair as required.

X

15

Check safety chains,
safety chain mounting
and safety chain
locking pins for
security, damage and
missing parts.
Repair as required.

X

5 Nov 2011

SECTION 8

Scheduled Inspections

8-3

MMP 4-2

FREQUENCY

STEP

HYDRAULIC SYSTEM

DAILY

250

Hours

500

Hours

1000

Hours

1

Check hydraulic oil for proper
level, clarity, foaming and signs of
contamination.
Repair, adjust or replace as
required.

X

2

Check hydraulic control valve for
security, damage, function and
leaks.
Repair as required.

X

3

Check hydraulic pump for
security, damage and leaks.
Repair as required.

X

4

Check hydraulic oil cooler for
security, damage and leaks.
Repair as required.

X

5

Check hydraulic hosing for
security, damage and leaks.
Repair as required.

X

6

Check hydraulic cylinders and flow
controls for security, damage and
leaks.
Repair as required.

X

7

Check hydraulic oil filter for
security, damage and leaks.
Repair as required

X

8

Check hydraulic pressure
regulator for function and pressure
setting (2,100 psi or 14,450 kpa).
Adjust or repair as required.

X

9

Drain and refill hydraulic reservoir
and replace hydraulic filter
element.

X

10

Check hydraulic pump drive
coupling for wear, security and
damage.
Repair as required.

X

5 Nov 2011

SECTION 8

Scheduled Inspections

8-4

SECTION 8

FREQUENCY

STEP

WATER PUMP

ASSEMBLY

DAILY

250 Hours

500 Hours

1

Check water pump for security, damage,
obstructions and operation.
Repair as required.

X

2

Check water pump trash screen for
security, obstructions and damage.
Repair as required.

X

3

Check for excessive vibrations and noise.
Repair as required.

X

4

Remove water pump assembly from inlet
boom and check for:

Hydraulic drive motor security,

damage and leaks.

Bearing oil reservoir levels.
Bearing oil reservoirs for

contamination.

Impeller damage.
Water pump housing bolts for

security, damage and missing parts.

Repair, adjust or replace as required.

X

5

Grease water pump suction bowl bearing.

X

6

Remove water pump from inlet boom and
change bearing reservoir oil.

X

Scheduled Inspections

MMP 4-2

5 Nov 2011

8-5

MMP 4-2

FREQUENCY

STEP

ENGINE AND

ENGINE CONTROLS

DAILY

250 Hours

500 Hours

1

Refer to the correct engine Operation
and Maintenance Manual for required
service intervals and procedures.
Follow and perform all required service
procedures, operations, conditions and
schedules.

X

2

Check and ensure all engine control
functions are in proper working order.
Repair as required.

X

3

Check all engine safety guards for
security, damage and missing parts.
Repair as required.

X

4

Check engine start battery and cables for
security, damage, corrosion, water level
(if required) and condition.
Repair as required.

X

5

Check engine throttle control for
security, damage and proper operation.
Repair as required.

X

6

Check engine control box for security,
damage and proper operation.
Repair as required.

X

7

Check engine MURPHY Safety switch
for security, damage and proper
operation.
Repair as required.

X

8

Check engine muffler and intake system
for security, damage, and condition.
Repair as required.

X

9

Check diesel fuel level to ensure proper
level to allow unit to run for daily
operation.
Refill as required.

X

10

Check engine control cable for security
and damage.
Repair as required.

X

5 Nov 2011

SECTION 8

Scheduled Inspections

8-6

SECTION 9

Special Inspections

DESCRIPTION

This section contains special inspection
requirements for a specific system after use, an
unusual event or storage.

STORAGE/WINTERIZATION

Entering

1. Remove any exterior dirt, grease and grime
that may trap moisture.

2. Flush all water suction and discharge tubes
(e.g. water pump,).

3. Ensure all water is drained from the tubes
and water pump.

4. Ensure all covers/caps for fluid reservoirs
are in proper operating condition and are
secured to the openings.

5. Fill Fuel tank to capacity, close fuel shut off
valves at bottom of fuel tank.

6. Check tires for proper inflation.

7. Check Boom retaining hardware, ensure it
is operational and secure.

8. Lubricate all grease points (e.g. Hinge pins,
cylinder pins water pump suction bowl).

9. Check battery fluid level and charge.

10. Disconnect battery cables from battery.

11. Service all engine systems per CAT

SEBU7276-01 service manual.

12. If possible, shelter entire unit from the

elements.

MMP4 - 2

5 Nov 2011

Removing

1. Remove all covers and seals from all

fill/discharge openings and components.

2. Inspect piping for debris that may damage

unit that water will be pumped into.

3. Check to ensure all water pump reservoirs

are filled to the correct level and the fluid is
not contaminated.

4. Remove any exterior dirt, grease and grime

and treat any corrosion.

5. Service all Engine systems per CAT

SEBU7276-01 service manual.

6. Check all fluid levels for condition and

level, replace or adjust as necessary.

7. Check Braking system (if equipped) repair

as necessary.

8. Check safety chains for damage.

9. Check lighting system for proper operation,

repair as necessary.

10. Clean and connect battery cables to battery.

11. Perform all ‘Daily’ maintenance checks,

repair as necessary.

12. Perform a full functional check of all MMP

control systems.

9-1

MMP4 - 2
5 Nov 2011

SECTION 9

Special Inspections

9-2(Blank)

MMP4 - 2

A. AXIAL WATER PUMP GROUP, 303910

PART DESCRIPTION

PART NO.

QTY

1. Gasket, 12”

304174

2

2. Grommet

303910-03

2

3. Thrush Collar

303910-17

1

4. Lower Seal

303910-20

1

5. Upper Seal

303910-25

1

6. O-Ring, Bearing, (Lower)

303910-31

2

7. O-Ring, Hydraulic Motor, (Upper)

303910-35

2

B. HYDRAULIC GROUP

PART DESCRIPTION

PART NO.

QTY

1. Cylinder, 12”, Discharge Boom

303923

1

2. Cylinder, 20”, Inlet Boom

303924

1

3. Filter, Hydraulic, 400 psi

304704

2

4. Oil, Hydraulic, Clarity (35 Gallon Capacity)

USE LOCAL

SUPPLIER

35 gal

C. WATER PIPING (BOOM) GROUP

PART DESCRIPTION

PART NO.

QTY

1. Sock, Down spout, tapered

304196

2

2. Tie Down Strap, 2”

304291

1

3. Pin, Hinge pivot

037627-05

1

4. Neoprene gasket, Boom flange

304117

2

5. Pin, Hitch, 1”

303935

2

6. Chain, 3/8”, GR 70, 6 ft.

038453-11

1

7. Shackle, 3/8”

355020

4

5 Nov 2011

SECTION 10

Recommended Support Parts

DESCRIPTION

This section contains a listing of recommended support parts that should be available in the supply
warehouse. Once parts are issued from warehouse stock ensure depleted quantities are replenished to
keep the recommended support parts package at 100%.

The tables are categorized by specific sub system of the MMP. DO NOT FORGET that all MMP’s are
not configured the same and there are some variations in systems due to changes in equipment and
actual production dates. Ensure MMP serial numbers and actual component part numbers are checked
before ordering any parts.

10-1

MMP4 - 2

D. FRAME AND SUSPENSION GROUP

PART DESCRIPTION

PART NO.

QTY

1. Wheel and Tire Assembly

303933

1

2. Hitch pin, 1”

303935

2

3. Chain, 3/8”, GR 70, 2.4 ft

038453-13

1

4. Shackle, 3/8”

355020

2

5. Bearing, Wheel, Inner

304157

2

6. Bearing, Wheel, Outer

304158

2

7. Seal, Wheel Bearing

304159

2

8. Jack stand

037708

1

E. CAT 3054B ENGINE SUPPORT PARTS GROUP

REFER TO SEBU7276-01 INDUSTRIAL ENGINE MANUAL FOR SPECIFIC PARTS AND SERVICE

INFORMATION

PART DESCRIPTION

PART NO.

QTY

1. Filter, Engine Oil

304192

1

2. Filter, Element, Fuel

304188

1

3. Filter, Element, Fuel/Water Separator

304190

1

4. Filter, Element, Air, Primary

304186

1

5. Filter, Element, Air, Secondary

304187

1

6. Seal, Filter, Fuel

304189

1

7. Seal, Filter, Water Separator Base

304191

1

5 Nov 2011

SECTION 10

Recommended Support Parts

10-2

MMP4 - 2

5 Nov 2011

SECTION 10

Recommended Support Parts

NOTES

10-3

MMP 4-2
5 Nov 2011

SECTION 10

Recommended Support Parts

10-4(Blank)