MEGA Corp. MSC-OPS-1 User Manual

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SPECIALTY HAULAGE SOLUTIONS FOR CONSTRUCTION AND MINING

OPERATORS MANUAL

MSC/MST-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

MSC/MST-OPS-1

31 Dec 2013

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 Employment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Section 7 MSC/MST Operator’s Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

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TABLE OF CONTENTS

B (Blank)

SECTION 1

Definitions and Abbreviations

Contents

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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 MSC/MST. See the appropriate Maintenance and Operators Safety Manual for specific vehicle system information and maintenance 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: 1-505-345-2661 or visit our website at

www.megacorpinc.com

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.

for more detailed contact

Safety Messages...............................................................1-2

Abbreviations....................................................................1-5

MSC/MST General Overview (Typical)......................1-6

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.

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.

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.

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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.

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.

TOXI C GAS HA Z ARD (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.

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.

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SECTION 1

Definitions and Abbreviations

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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.

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.

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.

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.

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SECTION 1

Definitions and Abbreviations

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 WATER CANNON (10)

This safety label is located on top of the cab control box.

Do not operate the water cannon until all personnel are a safe distance away from the vehicle.

HIGH PRESSURE SPRAY HEADS (9)

This safety label is located on the spray bar.

Do not operate spray heads until all personnel are a safe distance away from the vehicle.

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.

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SECTION 1

Definitions and Abbreviations

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CONFINED SPACE (12)

This safety label is located near the 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.

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 MSC/MST - Mega Scraper Conversion 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

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WATER PUMP & HYDRAULIC MOTOR

DUMP BAR

SPRAY HEADS

CAB CONTROLS

SUCTION PUMP STATION

HAND RAIL & WALKWAY

FOAM CONCENTRATE TANK

HOSE REEL

WATER CANNON

SOLENOID BOX

REAR VIEW

SIDE VIEW

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SECTION 1

Definitions and Abbreviations

MSC/MST GENERAL OVERVIEW (TYPICAL)



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SECTION 2



System Description

Contents

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Water Tank (MSC/MST) ..................................................2-1

Water Pump........................................................................2-1

Hydraulic Drive Motor....................................................2-2

Cab Controls (Analog) ....................................................2-3

Cab Controls (Digital)......................................................2-5

Ground Speed Sensing (GPS) Control ......................2-9

Water Cannon System ....................................................2-11

WATER TANK (MSC/MST)

The MEGA steel water tank consists of a water tunnel, primary floor, vertical baffles, bulkheads, outer skins, internal piping and external piping. The tank design is patented and known as the MEGA Anti-surge Stabilization Tube (MAST).

The MAST is the backbone of the structure and provides mounting for transverse baffles. The baffles add to tank strength and dampen water surges. The forward and rear baffles are reinforced with vertical beams to provide mounting for the gooseneck and rear axle bogie respectively. External and internal piping is also used to carry water from the water pump to spray heads, water cannon, spray bar, hose reel, dump bar and tank drain.

Spray System.....................................................................2-12

Dump Bar............................................................................2-13

Hose Reel ............................................................................2-13

Tank Drain...........................................................................2-14

Fire Suppression System ...............................................2-14

Suction Loading (If Equipped) ....................................2-14

Braking System.................................................................2-15

M-4 WATER PUMP

M-4 Water Pump major components and their functions are:

Early MSC/MST's may have a Berkley water pump (B4J) installed. Contact MEGA Corp for more information.

WATER PUMP

MSC/MST units are configured with different types of water pumps and are based on the size of the water tank. Typically the 5,000 - 7,000 gallon tanks are configured with a smaller pump (4 inch inlet & 3 inch outlet) while the 8,000 - 12,000 gallon tanks are configured with the larger water pump (6 inch inlet & 4 inch outlet). The water pumps are very similar in design and for the purposes of this manual the M-4 (6 inch inlet & 4 inch outlet is used to present component information.

1. Bracket – Main frame of the pump that allows a

pump to be bolted to the tanker and provides the means to direct mount the hydraulic drive motor.

2. Volute Case – A “snail shell” shaped case that

encloses the impeller. It is narrow at the center and enlarges from there to the discharge area.

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MSC/MST-OPS-1

CASE DRAIN PORT

PRESSURE RETURNTEST PORTS

FLOW CONTROL CROSSOVER HOSE

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SECTION 2

System Description

3. Wear Ring – Acts as a bearing surface between the impeller and volute case. Constructed of bronze material.

4. Impeller – Rotating wheel attached to the shaft that accelerates the speed of the water producing water flow and pressure.

5. Shaft Seal – Confines grease to the inner and outer bearing area while keeping foreign material from entering the bearing area and seals water inside the volute case.

6. Rope Seal – Provides a seal around the rotating pump shaft at the volute case. Constructed of a graphite rope material that is designed to drip water and allow shaft lubrication.

7. Upper/Lower Bearings - Provide roller surface for the pump shaft.

HYDRAULIC DRIVE MOTOR

M-4 PUMP DRIVE MOTOR AND CROSSOVER ASSEMBLY

The M-4 pump rotates clockwise as viewed from the drive end of the assembly.

Hydraulic Drive Motor Port Identification

The hydraulic drive motor requires hydraulic flow from a valve to the motor pressure port, return oil flow to the hydraulic reservoir and a free to tank case drain.



Hydraulic Drive Motor Speed Control (Crossover Assembly)

The hydraulic drive motor speed control (Crossover Assembly) consists of a flow control valve, 2 hydraulic manifolds, crossover hose and test ports.

Clockwise rotation as viewed from

the drive end of the water pump

assembly.

The hydraulic drive motor may be installed in 4 different orientations depending on the water pump location or application.

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SECTION 2

ADJUSTING

KNOB

System Description

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31 Dec 2013

Hydraulic Flow Control Valve

The hydraulic flow control is directional. The arrow on the body indicates the direction of oil flow to meter the bypassing oil. The adjusting knob on the valve will allow adjustment of the oil flow to bypass the drive motor, up to135 LPM (35 GPM) or up to 700 RPMs (RPM increase/decrease will vary depending on the size of hydraulic drive motor the unit is equipped with). If the flow control is reversed, the flow control adjusting knob will not function and the full flow capacity of the valve will bypass. This can result in water pump rpm being below specifications with no adjustment capability of the adjusting knob. By turning the adjusting knob clockwise the hydraulic oil that is bypassing will be reduced, increasing the speed of the water pump. Turning the knob counterclockwise will increase the volume oil being bypassed reducing the water pump speed. The flow control valve is typically mounted on the PRESSURE manifold of the hydraulic drive motor.

HYDRAULIC DRIVE MOTOR ACTIVATION

The hydraulic drive motor on MSC/MST's are typically driven by the chassis implement hydraulic system. The activation can be controlled by the following;

Pilot Operated Diversion Valve - A remote mounted diversion valve that receives an electric signal from the cab control pump switch to activate a pilot control to move a spool within the diversion valve redirecting the hydraulic oil to flow to the water pump drive motor. Typically this type of valve is installed between the hoist pump and the hoist valve.

Existing Mechanically Operated Implement Valve - Typically used on early model trucks with a

pneumatic system. This system is operated by the existing cab control lever. When the lever is moved to move a spool valve which divert hydraulic oil to the water pump drive motor.

CAB CONTROLS (ANALOG)

MSC/MST units can be configured with a manual pneumatic, electro-pneumatic or electro-hydraulic control system.

Typical 135 lpm (35 gpm) Adjustable

Hydraulic Flow Control

MANUAL PNEUMATIC

Multi-function control box mounted in the cab to control all water tank functions. Spray system head and auxiliary functions are controlled by using manual pneumatic levers, accessory switches and embedded joystick. The cab control requires 24 VDC power to operate.

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SECTION 2

System Description

ELECTRO-PNEUMATIC]

Multi-function control box that is mounted in the vehicle cab to control all water tank functions. Controls are available for the water cannon, intermittent spray, water pump, work lights, foam suppression, adjustable nozzle, system, spray heads, spray bar, gravity dump bar, and tank drain valve. The control box also provides indications of tanker water level and a system fuse holder. The cab controls requires 24 VDC vehicle power to operate.

The control functions operate as follows:

Control Function

Joystick Sends command signals to the

logic box (electric water cannon) or hydraulic control valve assembly (hydraulic water cannon) to move the water cannon left, right, up and down.

TIMER ON Sets ON time (variable adjust-

ment 5-100 sec) of selected spray heads and dump bar when the timer switch is in the intermittent position

TIMER OFF Sets OFF time (variable adjust-

ment 5-100 sec) between timer cycles of selected spray heads and dump bar when the timer switch is in the intermittent position.

Control Function

MONITOR Opens the water cannon BFV.

LIGHTS Provides power to work lights.

FOAM Open or closes the foam concen-

trate tank in-line control valve.

INTERMITTENT/ CONSTANT

AUX Reserved for specialized func-

ADJUSTABLE NOZZLE

AUX Reserved for specialized func-

WATER LEVEL Indicates tank water level.

SYSTEM Provides power for all cab control

LT BUMPER Opens or closes left front bumper

LT VSS Opens or closes left vertical side

LT REAR Opens or closes left rear spray

LT CENTER Opens or closes left center rear

RT CENTER Opens or closes right center rear

RT REAR Opens or closes right center rear

RT VSS Opens or closes right vertical side

RT BUMPER Opens or closes right front

DUMP BAR Opens or closes dump bar BFV.

DRAIN Opens or closes tank drain BFV.

Activates or deactivates system timer function.

tions.

Adjusts water cannon nozzle from FOG/FAN to STREAM.

tions.

functions.

spray head.

head.

spray head.

bumper spray head.

PUMP Routes vehicle hydraulic system

pressure and flow to the water pump hydraulic drive motor.

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SECTION 2

Master

Switch Box

Joystick Box

System Description

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CAB CONTROLS (DIGITAL)

MSC/MST units with fully hydraulic systems MUST be configured with the Mega Digital Spray Control System (DiSCS).

ELECTRO-HYDRAULIC SYSTEM (CAT 621H/K only)

This system is designated as a Digital Spray Control System (DiSCS). The system is comprised of control boxes, logic controllers, sensors, and cabling. It is a multi-function control system with a separate joystick box that is mounted in the vehicle cab. These two boxes control all water tank functions. The master switch box operates the water pump, spray heads, intermittent spray, work lights, hose reel, dump bar, suction loading, and tank drain valve. The master switch box also provides indications of tanker water level and water pump protection features. The remote mounted joystick box operates the water cannon, adjustable nozzle and foam suppression. The cab controls require 12/24 VDC vehicle power to operate.

ABBREVIATIONS AND DEFINITIONS AUX1 – Auxiliary or additional optional function BFV – Butterfly Valve DMPBAR – Dump bar for heavy spray of water close

to ground. Can be either a gravity or pressure dump bar (pressure dump bar requires water pump activation to operate).

DRAIN – Drain (gravity or pressure) for evacuation of

water from tank, mounted typically at the rear of the tank.

KPH – Kilometers per hour LT VSS – Left Vertical Side Spray LTC – Left Center Spray Head

LTR – Left Rear Outer Spray Head MPH – Mile per hour RAMP – Ramping Control feature. Rate of increase or

decrease in speed of water flow during PUMP engagement or disengagement

RT VSS – Right Vertical Side Spray RTC – Right Center Spray Head RTR – Right Rear Outer Spray Head

The master switch box control functions operate as follows:

Control Function

POWER Provides power for all cab control

functions.

PUMP Routes vehicle hydraulic system

pressure and flow to the water pump hydraulic drive motor.

INTMNT Intermittent setting.

Activates or deactivates system timer function.

LIGHTS Provides power to work lights.

t ON (Intermittent timer—manual mode)

RATE (GPS Auto Mode)

t OFF (Intermittent timer—manual mode)

SPEED (GPS Auto Mode)

WATER LEVEL Indicates tank water level.

AUTO Controls activation of GPS Auto

AUX 1 Reserved for user-added option.

AUX 2 Reserved for specialized function.

Sets ON time of selected spray heads when the timer switch is in the intermittent (INTMNT) position. Scale: adjustable from 5 seconds to 30 seconds.

Increases or decreases amount of water dispersed during a cycle when AUTO switch is on (see extended description).

Sets OFF time between timer cycles of selected spray heads when the timer switch is in the intermittent (INTMNT) position. Scale: adjustable from 5 seconds to 30 seconds.

Sets desired ground speed for maximum flow (OPEN continuously) of selected spray heads (see extended description).

mode.

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SECTION 2

System Description

Control Function

HOSE Controls activation of hose reel func-

tion ONLY.

SUCTION LOAD Controls activation of suction load

station ONLY.

LT VSS Opens or closes left vertical side

spray head.

DRAIN Opens or closes tank drain BFV.

DUMP BAR Opens or closes dump bar BFV.

RT VSS Opens or closes right vertical side

spray head.

LT REAR Opens or closes left rear spray head.

LT CENTER Opens or closes left center rear spray

head.

RT CENTER Opens or closes right center rear

spray head.

RT REAR Opens or closes right rear spray

head.

The joystick box functions operate as follows:

Control Function

Joystick (L EFT-RIGHT-UPDOWN)

FOAM Open or closes the foam concentrate

NOZZLE Adjusts water cannon nozzle from

BFV Opens or closes the water cannon

Sends command signals to the hydraulic control valve assembly to move the water cannon.

tank in-line control valve.

FOG to STREAM.

butterfly valve.

Cab control power is then activated by turning the cab control POWER switch ON while logic controllers are switched on when the chassis ignition switch is turned ON.

The spray system will function normally when cab control power is applied (cab control POWER switch ON) and sufficient water level (water level EMPTY light not flashing) is present. Activation of a specific function is accomplished by depressing the selected function switch on the master switch box or joystick box.

Depressing the switch sends a signal to the logic control panel in the solenoid box to activate a given function. The logic control then receives the signal and provides an output command to the given coil or function.

Once the logic control panel output is processed, the logic control sends a feedback signal back to the cab control box to illuminate the LED on the selected function switch. If the switch LED does not illuminate, a malfunction may exist in the logic control, wiring harness or cab control box.

If a function switch is depressed with no corresponding switch LED, check to ensure system power switch is ON and the water level empty LED is not flashing. If the switch LED is not illuminated, a malfunction may exist.

BASIC SYSTEM THEORY OF OPERATION

Spray system power is provided by chassis 12/24 volt DC power. Power is routed to cab controllers and logic control panels by turning on the switched power via the ignition key switch.

When the chassis ignition switch is turned ON, the master switch box will undergo a functional self-test. During this process, ALL LEDs will first turn ON, then off. While this is occurring, the water level indicator lights will initially register a FULL tank, and will then decrease down to EMPTY. The EMPTY light will blink, and then the water level indicator will count up to register the current water level of the tank.

If the selected function switch LED illuminates and the component on the water tanker is not functioning, the component (water-way valve, spray head or water cannon) may have malfunctioned.

As functions are turned on and off, the water pump switch will remain illuminated unless all spray system functions (water-way valves, spray heads or water cannon) are turned off. The logic control will automatically turn the water pump off if all valves are closed to prevent over-temp of the water pump volute case. As the water level of the tank drops and the EMPTY LED begins to flash, the logic controls will deactivate the water pump to prevent cavitation or dry running of the water pump.

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SECTION 2

System Description

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31 Dec 2013

WATER PUMP PROTECTION FEATURES

Soft Start and Stop from sudden starts and stops whenever the pump is turned ON or OFF via the switch or any auto/logic control feature. This is accomplished by the logic control system slowly commanding the appropriate proportional hydraulic control valve to open or close slowly to prevent hard starts or stops that can reduce water pump service life.

Low Water Protection automatically turned off by the logic control system when a low water condition is detected. The logic control system monitors tank water level and commands the water pump to turn off when a predetermined low water condition is noted. This prevents the water pump from running in a dry sump that will over-heat shaft seals due to lack of water. Continued use will damage the shaft seals.

No-Flow Conditions automatically turned off after about 100 seconds, whenever all water discharge valves are closed. The logic control system monitors all discharge valves and begins a TIME OUT cycle to turn off the water pump after about 100 seconds. Any time a discharge valve is opened during the timing cycle, the clock is reset. This feature prevents the water from heating up due to the water pump impeller spinning in a sump with no flow. The heating of the static water will also heat the water pump causing deterioration of grease and premature bearing failure.

– The water pump is protected

– The water pump is

MASTER SWITCH BOX EXTENDED FUNCTION DESCRIPTIONS

POWER – Turns POWER ON and OFF to cab controls

and digital controllers.

PUMP – Sends request for pump engagement/ disengagement to the digital control processor. The digital controllers will activate the hydraulic circuit to slowly ramp-up or ramp-down the water pump.

The water pump switch will flash whenever the switch is on and the following conditions apply:

• Low water condition is sensed (EMPTY LED is flashing).

• No flow condition is sensed (for about 100 seconds, no waterway valves are open)

Engaging/disengaging the water pump above LOW IDLE will result in water pump component damage and reduced service life.

INTMNT (Intermittent Function)

Intermittent spray function sends request for adjustable timing of spray head and dump bar as commanded by the tON and tOFF dials.

Intermittent will only operate if at least 1 discharge function (spray head or dump bar) switch is activated. Water discharge can be stopped at any time when in INTMNT mode by turning discharge function switches OFF. The timer will continue to cycle even if no water is being sprayed

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MSC/MST-OPS-1

3s - 15s

min

max

15s - 30s

3 o’clock

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SECTION 2

System Description

The tON and tOFF adjusting knobs command timing as follows:

• t ON – Adjusts spray head ON time.

• t OFF – Adjusts spray head OFF time.

The relationship between dial rotation and ON/OFF time is as follows:



– min to 3 o’clock position: 3 sec to 15 sec – 3 o’clock to max position: 15 sec to 30 sec

The above time ON/OFF scale applies to firmware versions 3.7.0 and above. For firmware versions 3.6.x and below, the range is 5 seconds to 30 seconds, scaled linearly across the rotation of the dial.

The intermittent function will turn selected spray head or dump bar on and off. Duration of tON and tOFF cycle times are selected by setting the appropriate dials on the master switch box. When the INTMNT switch is ON and functions are selected, the operator will observe different switch LEDs conditions to indicate operation within the tON and tOFF cycles. When a selected function switch (spray head or dump bar) is operating during an ON cycle, the selected function switch LED will be illuminated as well as the INTMNT switch LED. When the INTMNT cycles automatically to an OFF cycle, INTMNT switch and function switch LEDs will extinguish. As the ON cycle is about ready to engage, the INTMNT switch LED will flash 3 times at the end of the OFF cycle to indicate the selected spray functions are about to be turned ON. These light conditions will change back and forth until intermittent or function switches are turned off.

Water Level Indicator – Indicates tank water level as

sensed by the water level pressure sensor in the rear of the water tank. When the red EMPTY LED light flashes, the tank is at minimum water level. This low level signal is also sent to the logic control to automatically rampdown the water pump to prevent component damage. Water pump operation can only be restored if sufficient water is in tank to

extinguish the EMPTY light.

In order to re-activate the water pump after lowwater shut-off, first fill the water tank with sufficient water capacity to permit pump operation. Then turn the PUMP and POWER switches OFF. Cycle the chassis ignition key OFF/ON. Wait for the Master Switch Box to complete its lights check. Then, if the water level gauge reads above EMPTY, turn the POWER and the PUMP switches on.

Certain terrains and water level fluctuations may allow low water protection to capture a low water level condition, causing the pump ramp-down. If conditions allow water pump activation after water level/terrain fluctuations have ceased, then the water pump may be re-activated by following the steps in the previous note.

Pressure Discharge Function Descriptions:

Spray Heads – Control opening or closing of the

associated valve when selected, or automatically controlled when INTMNT function is selected.

Dump Bar (Pressure) – Controls opening or closing of the BFV when selected, or automatically controlled when INTMNT function is selected.

Suction Load - Allows continuous hydraulic water pump drive circuit flow during a low water level condition. Also disables use of any other master switch box waterway valve

2-8

SECTION 2

Joystick Box Functions

System Description

AUX FUNCTIONS



AUX 1 – Sends request for operation of auxiliary functions or additional non-standard options of spray system. This function is unique to a specific tank serial number.

AUX 2 (Suction Load Station) – If equipped, sends a request to the hydraulic water pump drive circuit to allow suction load pump drive motor operation during a low water level condition while also disabling the timed-out function. When turned ON, the AUX2 switch LED will flash rapidly and all pressure discharge functions are disabled.

HOSE – Allows continuous water pump operation for hose reel use while also disabling the use of any other master switch box waterway valves.

Ensure all discharge function switches are OFF when using HOSE function. Activating the HOSE switch requests all discharge function to turn OFF (All Spray heads, Water Cannon BFV, Drain, Dump Bar and FOAM).

Non-Pressure Discharge Function Descriptions:

Dump Bar (Gravity) – Controls opening and closing

of the BFV when selected, or automatically controlled when the INTMNT function is selected.

JOYSTICK BOX EXTENDED FUNCTION DESCRIPTIONS

The joystick box houses logic controls for the joystick and the FOAM, NOZZLE, and BFV switches. These switches and the joystick control requests for water cannon operation.

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31 Dec 2013

BFV – Sends request to open or close butterfly valve.

The butterfly valve controls water flow to the Water Cannon. Activating the BFV switch requests the water PUMP to stay ON with NO other pressure discharge functions activated providing, sufficient water is in tank to allow command to be sent.

JOYSTICK – Sends requests for rotation and elevation motion for water cannon operation.

GROUND SPEED SENSING (GPS) CONTROL

The MEGA ground speed sensing control system is an independent and self-contained GPS unit and antenna that provides speed information to the existing Mega Digitally Integrated Spray Control System (DiSCS). The DiSCS’s logic control uses the ground speed signal to automatically cycle and pulse spray heads to obtain a desired lay-down of water regardless of ground speed. The system contains controls to adjust maximum water discharge speed as well as actual rate of flow. This automatic control reduces water usage and prevents over-watering of haul roads and intersections.

FOAM – Sends request for FOAM agent valve to open or close.

NOZZLE – Sends request for adjustable nozzle on water cannon to move from FAN/FOG to STREAM spray patterns.

The system will automatically close all discharge functions (spray heads) below 5 KPH/3 MPH to prevent puddling of water at intersections. The system also opens selected discharge functions when accelerating above 5KPH/3 MPH.

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System Description

The system warns the operator of all malfunctioning system functions and provides full manual control of all spray system functions in the event of an AUTO mode failure. All automatic system protection features of low water level conditions, no-flow conditions and water pump soft start/stop feature still operate normally in the AUTO mode.

GPS EXTENDED FUNCTION DESCRIPTIONS

SPEED – Above what vehicle speed the command is

sent for maximum flow of all selected discharge functions (spray heads). Below this vehicle speed, timed cycles and/or reduced water volume flow occur.

The scale for the SPEED function is 0 KPH/0 MPH (Full LEFT) to 48 KPH/30 MPH (Full RIGHT).

When vehicle speed goes below the set SPEED, application rate of water discharged will be either pulse the requested discharge functions and/or reducing the number of discharge functions based on the RATE selected.

IF vehicle speed is GREATER than set SPEED the RATE has little or no effect on water discharge. Typically all requested pressure discharge functions are ON and no timing cycle.

AUTO – This function has priority over intermittent mode. The intermittent light will illuminate steadily when operating conditions are met and AUTO is ON. AUTO enables vehicle speed signal from the GPS module to activate the speed sensing mode, and operates the spray system based on RATE and SPEED adjustments. Pulse will begin when the AUTO function requests reduced volume.

Near or below 4.8 KPH/3 MPH, AUTO will switch to INTERMITTENT mode and discharge functions may operate continuously or ramp down the water pump to OFF. When vehicle speed rises above 4.8 KPH/3 MPH, AUTO will resume control of the system.

RATE – Is the distance traveled/time for spray head ON cycle.

•Knob turned counterclockwise reduces ON distance/ ON time

• Knob turned clockwise increases ON distance/ ON time

Reduced Volume Mode – Reduction in discharge volume by reducing the number of spray heads requested to activate.

• If 4 rear spray heads are requested, reduced volume allows only the 2 outer spray heads to turn ON and the 2 center spray heads are OFF.

• If 3 rear spray heads are requested 1 spray head will be OFF, typically the center head adjacent to the outer head requested.

• If 2 spray heads are requested 1 spray head will be OFF typically the center spray head unless no center spray heads are requested, then NO spray heads will be OFF.

Pulsing – Reference to Pulse Width Modulation or ON/OFF cycle.

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System Description

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WATER CANNON SYSTEM

The system is comprised of a water cannon (hydraulic or electric), hydraulic control valve assembly or logic box, butterfly valve assembly, nozzle and controls.

WATER CANNON (Hydraulic)

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cannon is threaded to a flanged pipe that mounts directly above the BFV. The water cannon also provides mounting for a variety of different nozzles.

HYDRAULIC CONTROL VALVE ASSEMBLY

the cab control box. A pressure relief valve is incorporated in the manifold block to protect the water cannon system against any over pressurization conditions. The assembly is mounted to the tank lower flange and receives hydraulic pressure from the vehicle hydraulic pump.

A metal waterway that directs a stream of water in both elevation (up-down) and rotation (right-left). Hydraulic motors move the waterway based upon hydraulic flow from the hydraulic control valve assembly as commanded by the cab control joystick. The water

The assembly contains three hydraulic solenoid valves that direct hydraulic pressure to the hydraulic motors on the water cannon and BFV cylinder as commanded by

WATER CANNON (ELECTRIC)

A metal waterway that directs a stream of water in both elevation (up-down) and rotation (right-left). 24 VDC electric motors move the waterway based upon filtered electronic signals from the logic box as commanded by the cab

control joystick. The water cannon is threaded to a flanged pipe that mounts directly above the BFV. The water cannon also provides mounting for a variety of different nozzles.

ELECTRO-PNEUMATIC BFV ASSEMBLY

An electro-pneumatic valve that controls the flow of water to the water cannon. A 24 volt DC solenoid receives commands from a cab control MONITOR / BFV switch through the logic

box to route pressurized air to an air chamber which opens or closes a 3” valve. The assembly is clamped between upper and lower pipe flanges.

WATER CANNON NOZZLES AND STREAM SHAPERS Smooth Bore Nozzle

A cone shaped 1.5” diameter nozzle that directs water flow. The nozzle has a built in stream shaper that smooths water flow to increase water stream distance.

HYDRAULIC BFV ASSEMBLY ASSEMBLY

A hydraulically operated valve that opens or closes to control water flow to the water cannon. The hydraulic cylinder receives hydraulic pressure from

the hydraulic control valve or solenoid control box assembly as commanded by the cab control water cannon switch. The assembly is clamped between upper and lower pipe flanges.

Smooth Bore (Stackable)

A segmented cone shaped nozzle that directs water flow. The nozzle opening is adjusted by removing segments to acquire the most efficient nozzle opening for a given water pump operating pressure. Nozzle segment diameters are 1?”, 1½”, 1¾” and 2”. The nozzle requires and in-line stream shaper to increase

water stream distance.

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System Description

In-Line Stream Shaper

A performance enhancer that is mounted between the water cannon outlet and the selected straight bore nozzle. The stream shaper pathway is a honeycomb style channel designed to efficiently shape a water stream to maximum water stream distance.

Manual Adjustable Nozzle

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Fog/Stream: allows the operator to manually adjust selected water stream patterns from fog to stream. Some nozzles are configured for fire suppression foam eduction.

Fan/Stream: allows the operator to manually adjust selected water stream patterns from flat fan to stream. The flat fan pattern orientation is adjustable from horizontal to vertical by reorienting the nozzle on the water cannon.

Remote Adjustable Nozzle (Electric/Hydraulic)

A modified straight bore nozzle that

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Fan/Stream

A modified straight bore nozzle that allows the operator to remotely adjust selected water stream patters from flat fan to stream from the cab control. The nozzle inner or outer barrel is moved by an electric actuator to obtain the fan or stream pattern. The flat fan pattern orientation is adjustable from horizontal to vertical by reorienting the nozzle on the water cannon.

SPRAY SYSTEM

The spray head system consists of 4, 6 or 8 hydraulic or pneumatic actuated spray heads, cab controls, solenoid control box assembly, and hydraulic or pneumatic hosing.

PNEUMATIC SPRAY HEAD

A two piece aluminum valve body and adjustable ring mounted to a water supply header pipe. The upper portion of the valve body is an air chamber with a

diaphragm and guide disk assembly attached to the bottom. The air chamber receives pressurized air from the solenoid control box as commanded by the cab control switch. When the upper portion of the valve body is pressurized the guide disk will seal the opening on the lower portion of the valve and stop water flow.

A modified straight bore nozzle that allows the operator to remotely adjust selected water stream patterns from fog to stream from the cab control. The nozzle inner or outer barrel is moved by an electric or hydraulic actuator to obtain the fog or stream pattern. Some nozzles are configured for fire suppression foam eduction.

When the cab control system is OFF and the water pump is OFF the air chamber incorporates a spring that will apply pressure to the guide disk assembly and seal the opening on the lower portion of the valve and stop flow. When air pressure is removed from the upper portion of the valve body when the water pump is ON and the cab control switch ON, pressurized water from the header pipe will unseat the guide disk and water will flow from the lower portion of valve.

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1/4” Opening

3/8” Opening

Pneumatic

Hydraulic

System Description

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HYDRAULIC SPRAY HEAD

A two piece aluminum valve body, hydraulic cylinder and adjustable ring mounted to a water supply header pipe. The upper portion of the valve body contains a hydraulic cylinder

that receives hydraulic pressure from the system solenoid control box as commanded by the cab control switch. When the hydraulic cylinder on the upper portion of the valve body is pressurized the cylinder extends to contact the guide disk and seal the opening on the lower portion of the valve and stop water flow. When the cab control system is OFF and the water pump is OFF the upper valve body incorporates a spring to apply pressure to the guide disk to seal the opening on the lower portion of the valve and stop flow. When the spray head switch is turned on hydraulic pressure retracts the hydraulic cylinder and pressurized water from the header pipe will unseat the guide disk and water will flow from the lower portion of valve.

SOLENOID CONTROL BOX

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The control box assembly is mounted to the forward bulkhead or the rear of the gooseneck of the MSC/ MST. The assembly contains pneumatic or hydraulic solenoid valves that direct pneumatic or hydraulic pressure to the spray head as commanded by the cab control box. The solenoids receive pneumatic pressure from the vehicle or hydraulic pressure from water pump oil circuit and 24 VDC power from the cab control box.

DUMP BAR

Spray Head Adjustable Rings

The adjustable ring is used to control fan width and water flow. The ring may be loosened and rotated to expose more or less of the lower valve opening to control water fan width from 15° to 90°. The ring also may be used rotated to a 1/4” or 3/8” slot (as shown below) to increase or decrease overall water flow. The greater the opening, the greater the water flow.

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A spray bar that contains several rows of 3/8” drain holes to dispense water. A hydraulically operated BFV controls the water supply to the dump bar. The BFV is controlled electrically from the cab control box and is actuated by a hydraulic cylinder. The actuators receive hydraulic pressure from the solenoid control box assembly. Dump bars can be either gravity or pressure fed.

HOSE REEL

A reel assembly that is located on the bottom aft end of the water tank fitted with a 1” or 1.5” diameter reinforced rubber hose and a fire fighting style nozzle. The hose reel assembly receives pressurized water from the pressurized

manifold on the back of the tank to operate.

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System Description

TANK DRAIN

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A hydraulic BFV attached to the water tank pressure pipe is used to drain water from the water tank. The BFV is controlled electrically from the cab control box and is actuated by a hydraulic actuator. The actuators receive hydraulic pressure from the solenoid control box assembly. Tank drains can be either gravity or pressure fed.

FIRE SUPPRESSION SYSTEM

A system that consists of a 120 or 60 gallon stainless steel holding tank, an electric or pneumatic actuated shut-off valve, in-cab control switch, hosing and a foam eduction nozzle mounted to the water cannon.

FOAM EDUCTION NOZZLE

A manual or remote adjustable (fog/stream) nozzle is attached to the water cannon waterway. The nozzle inner housing uses high pressure water to create a venture effect that will

create a suction force, pulling foam concentrate from the holding tank. Once foam concentrate is flowing, the nozzle proportions foam concentrate, water and air to produce finished foam. The nozzle can be adjusted to allow control of foam solution at a rate of 1%, 3% or 6%. Rate adjustment is obtained by replacing a removable disk.

SUCTION LOADING (IF EQUIPPED)

FOAM CONCENTRATE TANK

A stainless steel tank mounted in the forward upper portion of the water tank. The holding tank contains a supply tube that extends to the bottom of the

tank and connected to a flexible hose at the top of the tank and then routed to the foam agent shut-off valve. The tank also contains a pressure/vacuum cap which keeps foreign matter out of the tank while providing for pressure relief and air displacement during temperature changes.

ELECTRIC/PNEUMATIC SHUT-OFF VALVE

The in-line shut-off valve is mounted on the foam tank upper lip and is controlled by the in-cab control FOAM switch. The shut-off valve is actuated by either an electric or pneumatic actuator that is controlled by the in-cab control switch. Once the shut-off valve is opened, foam concentrate will flow from the holding tank to the water cannon nozzle if the water cannon and water pump switches are ON.

A second water pump mounted typically to the water pump sump at the rear of the MAC. The suction loading station is equipped with a manual diversion valve that will switch the hydraulic oil flow from the main discharge pump drive motor to the suction loading pump drive motor. When oil is diverted to the suction loading drive motor, it can pull water from a holding pond and fill the MAC. The suction loading option includes lengths of 4” suction hose equipped with quick couplers and a check valve inlet foot with a debris screen. The suction hoses are typically stored in tubes either built into the MAC or a hanging tube arrangement.

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System Description

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BRAKING SYSTEM

MSC/MST PRIME MOVERS

See the prime mover Operator and Service Manual for brake system information.

MSC/MST 611/615

See the CAT 611/615 Operator and Service Manual for brake system information.

MSC/MST 613

See the CAT 613 Operator and Service Manual for braking system information

MSC/MST 621H/K

See the CAT 621H/K Operator and Service Manual for braking system information.

For further information contact MEGA Corp. Product Support Group at: US toll free: 1-800-345-8889 Direct: 1-505-345-2661 or visit our website at www.megacorpinc.com for more detailed contact information.

AIR TANKS

The MSC/MST is equipped with two 8 inch x 32 inch air cylinder mounted to the MSC/MST rear bogie that store 110-130 psi air. The cylinders receive pressurized air from the tractor primary air tank mounted under the tractor cab.

TANK PRESSURE SENDING UNIT

A 24 VDC pressure sending unit is mounted to the rear MSC/MST air tank and is wired into existing tractor brake pressure indicating and warning systems. The sending unit provides air pressure sensing for the tractor air pressure gauge mounted in the dash. The sending unit also provides a signal to the brake low pressure warning system that sounds an audible warning tone when brake supply pressure drops below allowable limits.

MSC/MST 621G & 631G

The MSC/MST rear brake system is integrated with the existing tractor parking, service and emergency brakes. All three systems are activated with the existing brake controls located in the tractor cab. See the CAT 621G and 631G operator and service manual for additional tractor brake information.

The MSC/MST rear brake system consists of a wheel group, two additionally air tanks, pneumatic manifold assembly, pneumatic brake relay valve, brake pods, solenoid valve, pressure switch, pressure sending unit and hosing.

PNEUMATIC MANIFOLD ASSEMBLY

A pneumatic manifold mounted in the rear bogie used to route air pressure for service, parking and emergency brake operation. The

manifold also provides mounting for a check valve, parking brake/ emergency solenoid valve and parking brake pressure switch.

CHECK VALVES

A spring operated valve allowing air flow in a predetermined direction. A one-way check valve is located at the MSC/MST rear air tank tractor air supply in. A double-check valve is located on the pneumatic manifold.

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System Description

PARKING /EMERGENCY BRAKE SOLENOID

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brake pods. This release of air pressure will cause the parking/emergency brakes to be applied.

PARKING BRAKE PRESSURE SWITCH

A 24 VDC electrical solenoid that opens or closes to control the parking or emergency brake function. The solenoid valve responds to electrical signals as commanded by the parking or emergency brake in the tractor cab. The solenoid valve will open to bleed off parking/emergency brake release pressure from the

A 24 VDC pressure switch used to illuminate the parking brake warning light in the tractor cab. The sensor will turn on the parking brake warning light when parking brake release pressure drops below allowable limits.

BRAKE PODS

A pneumatic cylinder designed to extend or retract and apply service, parking or emergency brakes. The pods are mounted to the MSC/MST rear bogie and are connected to the wheel group brake activation lever. The pod contains a coil spring and responds to pressure received from the brake relay valve as commanded by service brake pedal. The pod will also apply parking or emergency brakes when one side of the cylinder is depressurized when commanded by the activation of the parking or emergency brakes. Lose of pneumatic pressure allows the brake pod coil spring to extend the rod end.

SERVICE BRAKE RELAY VALVE

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generated by activating the service brake pedal located in the tractor cab.

A pneumatic relay that controls and routes air tank activation pressure to both brake pods. The relay controls air pressure applied to the brake pods as commanded by a pneumatic signal

THEORY OF OPERATION

Parking Brake

The parking brake is applied by activating the parking brake switch in the tractor cab. Once the switch is moved to the park position an electrical signal is sent to the parking brake solenoid valve mounted on the rear bogie pneumatic manifold. The sent signal will open the solenoid valve allowing pneumatic pressure to decrease from one side of the brake pod. The brake pod coil spring can now overcome air pressure and extend the brake pod rod end attached to the wheel group brake lever and apply the brakes. Once parking brake pneumatic pressure drops below allowable limits, the parking brake pressure switch mounted on the pneumatic manifold will close and illuminate the parking brake warning light in the cab of the tractor.

The parking brake is released by activating the parking brake switch. Once the switch is moved an electric signal is sent to close the parking brake solenoid valve. The valve closing will allow

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SECTION 2

System Description

pneumatic pressure from the pneumatic manifold to be routed to the brake pod. This pressure increase will eventually overcome the brake pod coil spring and retract the brake pod cylinder rod end attached to the brake pod releasing the brakes. As pressure increases above allowable limits, the parking brake pressure switch will turn off the parking brake warning light in the tractor cab once pressure is above allowable limits.

Service Brake

The service brake is applied by pressing down on the service brake pedal in the tractor cab. Pressing down on the pedal will send a pneumatic pressure signal to the service brake relay valve mounted on the rear bogie. The sent signal will release pneumatic pressure from the brake pod chamber allowing the pod coil spring to extend the rod end and apply service brakes.

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31 Dec 2013

The service brake is released by releasing the brake pedal. Once the pedal released a pneumatic signal is received by the brake relay to increase air pressure to the brake pod. As pneumatic pressure increases the force of the brake pod coil spring is overcome and the service brake is released.

Emergency Brake

The emergency brake theory of operation is the same as the parking brake except for the means of activation. Activation is accomplished by using the emergency brake foot switch located on the floor of the tractor cab just left of the service brake pedal.

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System Description

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SECTION 3

Limitations

Contents

Water Pump.......................................................................3-1

WATER PUMP

The following cautions are operational limitations of Mega water pumps. Failure to heed these cautions may result in reduced pump life and severe water pump damage.

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31 Dec 2013

Water pump RPM must not exceed the specifications listed below with engine at HIGH IDLE. Failure to ensure water pump speed is at or below specifications will result in reduced spray system component service life.

Do not operate the water pump in a dry sump. Operating the water pump with a dry sump will result in water pump component damage and reduced service life.

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

Limit water pump operation to 2.5 minutes when in a no-flow condition (not flowing water through spray heads, dump bar, water cannon, drain valve or hose reel). Water pump operation in a no flow condition will cause overheating of the water pump and damage to the shaft bearings and seals.

PUMP MODEL RPM

M-3 PUMP 2350 ± 50

M-4 PUMP 1,900 ± 50

M-4B PUMP 2,000 ± 50

If water pump RPM is to out of the desired range, adjust the water pump hydraulic drive motor flow control valve to obtain specified RPM.

The suction loading pump has a maximum vertical lift capability of 8-10 feet. Attempting to pump water into the tank from a reservoir that is more than 8-10 feet below the pump station will result in reduced suction loading performance.

Avoid any sudden stoppage of water pump e.g.; disengaging water pump above LOW IDLE. Stopping water pump suddenly above LOW IDLE will result in shaft, impeller and drive motor damage.

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SECTION 3

Limitations

3-2 (Blank)

SECTION 4

Normal Operations

Contents

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Description.........................................................................4-1

Before Operations............................................................4-1

Operations..........................................................................4-1

DESCRIPTION

This section provides the vehicle operator with step by step operating procedures for the installed MSC/MST system. The information is separated into before operations, operations, and after operations. A pocket size checklist of all listed procedures is also provided in the Appendix for use in the vehicle cab.

BEFORE OPERATIONS

These procedures are used to perform a walk-around inspection of the MEGA water tanker system before use or the beginning of a shift. This inspection is in addition to and does not replace the vehicle manufacturer’s inspection requirements.

1. Chocks – As Required

2. Vehicle Parking Brake – ON

3. Cab Control Switches – SET OFF

4. Bumper Spray Heads – SECURED & SET

5. Vehicle Hydraulic Tank – SERVICED

After Operations...............................................................4-5

Cold Weather Operation And Storage .....................4-5

10. Tank Drain Petcocks – CLOSED

11. Spray Heads – SECURED & SET

12. Water Pump Assembly – CHECKED

a. Water Pump – Check to ensure volute case

drain valve is closed.

b. Water pump and drive motor for evidence of

overheating.

13. Hose Reel – CHECKED

OPERATIONS

Use these procedures to safely operate the standard and optional systems installed on the MEGA water tanker.

6. Gooseneck Lines & Hoses – CHECKED & SECURED

7. Solenoid Control Box – CHECKED AND SECURED

8. Water Cannon – CHECKED & SECURED a. Nozzle – Check for security and kinking of

foam concentrate supply line.

9. (If Equipped) Foam Concentrate Level – CHECKED. At least 1” from the top of the foam tank.

Ensure PPE fall arrest harness is worn, adjusted properly and attached to an anchor point. Failure to use PPE properly may result in personnel injury or death.

SPRAY HEAD SYSTEM

Operating more than 4 spray heads simultaneously will greatly reduce the width and flow of active spray heads.

1. Cab Control SYSTEM/POWER Switch – ON

2. INTERMITTENT TIMER – SET a. TIMER ON/OFF Dials – SET b. INTERMITTENT Switch – SET

3. PUMP Switch – ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

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SECTION 4

Normal Operations

4. Individual Spray Heads – SELECTED

Once operations are complete:

5. PUMP Switch – OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

6. Cab Control SYSTEM/POWER Switch – OFF

GPS AUTO MODE

1. Cab Control POWER Switch – ON

2. PUMP Switch ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

3. PUMP Switch – ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

4. DUMP Bar Switch – ON

Once operations are complete:

5. PUMP Switch – OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

6. Cab Control SYSTEM/POWER Switch – OFF

WATER CANNON

1. Cab Control SYSTEM/POWER Switch – ON

3. AUTO – SET AS REQUIRED a. RATE and SPEED Dials – SET b. AUTO Switch – ON

4. Individual Spray Head Switches – ON

Once operations are complete:

5. Individual Spray Head Switches – OFF

6. PUMP Switch – OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

7. Cab Control POWER Switch - OFF

DUMP BAR

1. Cab Control SYSTEM/POWER Switch – ON

2. INTERMITTENT – SET AS REQUIRED a. TIMER ON/OFF Dials – SET b. INTERMITTENT Switch – SET

2. PUMP Switch – ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

3. Water Cannon – Pointed in a safe direction.

4. MONITOR/BFV Switch – ON

5. Water Cannon Joystick – As Required.

6. MONITOR/BFV Switch – OFF

Once operations are complete:

7. Water Cannon Nozzle - STOW

Manual and remote adjustable nozzles must be stowed pointing vertically to reduce wear on water cannon joints. Leaving the nozzle in any other position will cause increased wear on water cannon joints and result in premature joint failure.

4-2

Normal Operations

8. PUMP Switch – OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

9. Cab Control SYSTEM/POWER Switch – OFF

FIRE SUPPRESSION SYSTEM

1. Cab Control SYSTEM/POWER Switch – ON

2. PUMP Switch – ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

3. Water Cannon – Pointed in a safe direction.

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SECTION 4

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

12. Cab Control SYSTEM/POWER Switch – OFF

13. Vehicle – Wash or fresh water rinse areas exposed to the foam spray.

TANK DRAIN

1. Cab Control SYSTEM/POWER Switch – ON

2. PUMP Switch – ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

4. FOAM Switch – ON

5. MONITOR/BFV Switch – ON

6. Water Cannon Joystick – As Required.

Once operations are complete:

7. FOAM Switch – OFF

8. Water Cannon – Flow water through the water cannon nozzle with the FOAM switch off to flush foam from the nozzle.

9. MONITOR/BFV Switch – OFF

10. Water Cannon Nozzle – STOW

11. PUMP Switch – OFF

3. DRAIN Switch – ON

4. Water Level – Drain to desired level.

Do not operate the water pump in a dry sump. Dry running operation will cause water pump failure.

Once operations are complete:

5. DRAIN Switch – OFF

6. PUMP Switch – OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

7. Cab Control SYSTEM/POWER Switch – OFF

HOSE REEL

1. Hose Nozzle – CLOSED

2. Hose – Deploy desired length.

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OPEN

CLOSED

OPEN

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SECTION 4

Normal Operations

3. Gate Valve – OPEN

4. Cab Control SYSTEM/POWER Switch – ON

5. PUMP Switch – ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

6. Vehicle RPM – SET

7. Hose Nozzle – OPEN as desired.

Once operations are complete:

8. Hose Nozzle – CLOSE

9. Vehicle RPM – LOW IDLE

10. PUMP Switch – OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

6. Position all butterfly valves as indicated in the following pictures and in the order as follows: a. SUMP VALVE - CLOSE b. SUCTION VALVE - OPEN c. SPRAY BAR VALVE - CLOSE d. TANK FILL VALVE - OPEN

11. (If Equipped) Cab Control SYSTEM/POWER Switch- OFF

12. Gate Valve – CLOSED

13. Hose – Reel in and stow hose nozzle.

SUCTION LOAD STATION

1. Place vehicle near water holding pond.

2. Secure vehicle and make unit safe for exiting cab.

3. Foot Valve – Serviceable

4. Suction Hoses – Inspect suction hoses for serviceability. Ensure suction hoses are connected properly to each other and the suction load inlet to prevent air leaks while in use.

5. Suction Hoses – Immerse in water supply.

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Opening and closing valves in this sequence allows the water in the suction loading sump built inside of the tank to flood the water pump and suction hose. This will allow water pump to lift water from pond.

7. Ensure water pump and suction hoses are full of water before operating pump.

Operating the water pump in a dry sump will result in shaft seal damage.

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Normal Operations

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31 Dec 2013

8. Ensure foot valve remains submerged in water.

9. Start chassis engine.

10. At LOW IDLE turn SYSTEM/POWER switch ON.

11. (DiSCS Only) AUX2 - ON

12. Turn PUMP Switch – ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

13. Increase engine RPM to HIGH IDLE.

When unit is full of water

14. Reduce engine RPM to LOW IDLE.

3. Chocks – As Required

4. Bumper Spray Heads – SECURED & SET

5. Gooseneck Hoses & Lines – CHECKED & SECURED

6. Solenoid Control Box – CHECKED

7. Water Cannon – CHECKED & SECURED

8. Vehicle Hydraulic Tank - CHECKED AS REQUIRED

9. Tank Drain Petcocks – As Required.

10. Tank Lines and Hoses – SECURED

11. Spray Heads – SECURED & SET

12. Water Pump – CHECKED a. Water Pump – Check for damage and volute

case drain valve set as required.

15. PUMP Switch – OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

16. AUX2 - OFF

17. SYSTEM/POWER Switch OFF.

18. Turn engine OFF.

19. Disconnect, drain and stow suction hoses.

AFTER OPERATIONS

These procedures are used to perform a walk-around inspection after using the MEGA water tanker systems. This inspection is in addition to and does not replace the vehicle manufacturer’s inspection requirements.

1. Vehicle parking brake – ON

2. Cab Control Switches – SET OFF

13. Hose Reel – CHECKED

COLD WEATHER OPERATION AND STORAGE

Ice will cause serious damage to water pump, spray heads, butterfly valves, water-to-oil cooler, and the water cannon if water is allowed to freeze in the volute case, water piping, or on top of a closed butterfly valve. Ensure all water is drained from system when the temperatures are expected to fall below 4.4°C (40°F) for any period of time. Failure to ensure all systems are drained and free from standing water will result in shaft, operator, diaphragm, drive motor, water pump, or butterfly valve damage when operation is attempted with ice in the housings.

To ensure all water is drained from tank check the following:

1. Park unit on a slight nose up angle to allow water to flow to the rear of the tank.

2. Drain the tank using an appropriate method until the Water Level Gauge reads EMPTY.

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SECTION 4

Normal Operations

3. Open all drain petcocks (water pump, spray bars, etc.).

4. Remove water pump sump cover.

5. Start engine.

6. Cab Control SYSTEM/POWER Switch – ON

7. MONITOR/BFV Switch – ON

8. DUMP BAR Switch – ON

9. DRAIN Switch – ON

10. Water Cannon Nozzle – Pointed fully DOWN

11. Turn engine off.

12. Cab Control SYSTEM/POWER Switch – OFF

13. Hose Reel – DRAIN a. Hose – UNWIND b. Nozzle – Fully OPEN c. Gate Valve – OPEN d. Allow water to drain. e. Hose – REWIND f. Gate Valve – CLOSED g. NOZZLE – CLOSED

7. Individual Spray Head Switches – OFF

8. DUMP BAR Switch – OFF

9. DRAIN Switch – OFF

10. MONITOR/BFV Switch – OFF

11. Turn engine off.

12. Cab Control SYSTEM/POWER Switch – OFF

14. Check to ensure all water has drained from tank.

TO REACTIVATE UNIT:

1. Lubricate water pump bearings as instructed in -2 technical manual.

2. Inspect tank interior to ensure it is clean, if the tank is coated, ensure coating integrity, clean or repair as required.

3. Install sump cover with new gasket.

4. Close all drain valves and petcocks.

5. Start engine.

6. Control SYSTEM/POWER Switch – ON

4-6

SECTION 5

36 - 57 meters

120 - 190 feet

90 degrees

60 feet

18 meters

Performance

Contents

MSC/MST-OPS-1

31 Dec 2013

Spray Pattern and Reach .............................................5-1

Typical Spray System Duration ..................................5-1

Precision Watering ........................................................5-2

Fire Suppression System .............................................5-7

SPRAY PATTERN AND REACH (TYPICAL 9’ SPRAY BAR)

The figures below illustrate width and reach of spray heads and water cannon. Typical spray head deflector fan adjustments are also depicted.



TYPICAL SPRAY SYSTEM DURATION

The table below contains a standard vehicle spray duration based on spray head deflector opening, vehicle speed and 18,927 liter (5,000 gallon) capacity.

Number of Spray Heads

and Opening Width

2 Spray Heads@ 1/4” 3611/954 16/10 2.4/1.5

2 Spray Heads@ 1/4” 3611/954 24/15 3.3/2.1

2 Spray Heads@ 3/8” 4705/1243 16/10 1.7/1.1

2 Spray Heads@ 3/8” 4705/1243 24/15 2.5/1.6

4 Spray heads @ 1/4” 5693/1504 16/10 1.4/0.9

4 Spray heads @ 1/4” 5693/1504 24/15 2.0/1.3

4 Spray heads @ 3/8” 5950/1572 16/10 1.2/0.8

4 Spray heads @ 3/8” 5950/1572 24/15 2.0/1.3

LPM/GPM

Ground Speed

(KPH/MPH)

5-1

Max. Distance

(Km./Miles)

MSC/MST-OPS-1

31 Dec 2013

SECTION 5

Performance

PRECISION WATERING

The following tables provide precision watering calculations for the installed spray system. Each table is categorized by size of spray head deflector opening at a full fan width for 2 or 4 spray heads.

1/4 OPENING & FULL FAN (18,927 lit/5,000 gal TANK)

2 SPRAY HEADS (FLOW 3611 lpm/954 gpm) 4 SPRAY HEADS (FLOW 5693 lpm/1504 gpm)

SPRAY

SPEED

MPH FPM (FT) (SQ FT) (GAL/SQ FT) (IN/SQ FT) (FT) (SQ FT) (GAL/SQ FT) (IN/SQ FT)

2 176 1600 96000 0.052 0.084 880 52800 0.095 0.152

5 440 4000 240000 0.021 0.033 2200 132000 0.038 0.061

10 880 8000 480000 0.010 0.017 4400 264000 0.019 0.030

15 1320 12000 720000 0.007 0.011 6600 396000 0.013 0.020

KPM MPM (METER) (M SQ) (L/M SQ) (MM) (METERS) (M SQ) (M/M SQ) (MM)

3 53 675 12147 2.181 2.67 371 6679 3.968 4.65

8 134 1706 30712 0.863 1.07 938 16885 1.569 1.84

16 268 3412 61423 0.431 0.53 1876 33771 0.785 0.94

24 402 5119 92135 0.288 0.35 2814 50656 0.523 0.61

DISTANCE

TOTAL

COVERAGE

DISPERSAL

WATER

LAYER

MAX

DISTANCE

TOTAL

COVERAGE

DISPERSAL

WATER

LAYER

3/8 OPENING & FULL FAN (18,927 lit/5,000 gal TANK)

2 SPRAY HEADS (FLOW 4705 lpm/1243 gpm) 4 SPRAY HEADS (FLOW 5950 lpm/1572 gpm)

SPRAY

SPEED

MPH FPM (FT) (SQ FT) (GAL/SQ FT) (IN/SQ FT) (FT) (SQ FT) (GAL/SQ FT) (IN/SQ FT)

2 176 1354 81231 0.062 0.099 880 57200 0.087 0.140

5 440 3385 203077 0.025 0.039 2200 143000 0.035 0.056

10 880 6769 406154 0.012 0.020 4400 286000 0.017 0.028

15 1320 10154 609231 0.008 0.013 6600 429000 0.012 0.019

KPM MPM (METER) (M SQ) (L/M SQ) (MM) (METERS) (M SQ) (M/M SQ) (MM)

3 53 571 10276 2.579 3.68 371 6679 3.968 5.59

8 134 1443 25980 1.020 1.47 938 16885 1.569 2.23

16 268 2887 51960 0.510 0.74 1876 33771 0.785 1.11

24 402 4330 77940 0.340 0.48 2814 50656 0.523 0.74

DISTANCE

TOTAL

COVERAGE

DISPERSAL

WATER

LAYER

MAX

DISTANCE

TOTAL

COVERAGE

DISPERSAL

WATER

LAYER

5-2

MSC/MST-OPS-1

SECTION 5

Performance

1/4 OPENING & FULL FAN (30,283 lit/8,000 gal TANK)

2 SPRAY HEADS (FLOW 3611 lpm/954 gpm) 4 SPRAY HEADS (FLOW 5693 lpm/1504 gpm)

SPRAY

SPEED

MPH FPM (FT) (SQ FT) (GAL/SQ FT) (IN/SQ FT) (FT) (SQ FT) (GAL/SQ FT) (IN/SQ FT)

2 176 1476 122499 0.065 0.105 936 70213 0.114 0.183

5 440 3690 306247 0.026 0.042 2340 175532 0.046 0.073

10 880 7379 612495 0.013 0.021 4681 351064 0.023 0.037

15 1320 11069 918742 0.009 0.014 7021 526596 0.015 0.024

KPM MPM (METER) (M SQ) (L/M SQ) (MM) (METERS) (M SQ) (M/M SQ) (MM)

3 53 444 11112 2.725 2.67 282 6484 4.670 4.65

8 134 1124 28094 1.078 1.07 713 16394 1.847 1.84

16 268 2248 56188 0.539 0.53 1426 32788 0.924 0.94

24 402 3371 84283 0.359 0.35 2138 49183 0.616 0.61

DISTANCE

TOTAL

COVERAGE

DISPERSAL

WATER

LAYER

MAX

DISTANCE

TOTAL

COVERAGE

DISPERSAL

31 Dec 2013

WATER

LAYER

3/8 OPENING & FULL FAN (30,283 lit/8,000 gal TANK)

2 SPRAY HEADS (FLOW 4705 lpm/1243 gpm) 4 SPRAY HEADS (FLOW 5950 lpm/1572 gpm)

SPRAY

SPEED

MPH FPM (FT) (SQ FT) (GAL/SQ FT) (IN/SQ FT) (FT) (SQ FT) (GAL/SQ FT) (IN/SQ FT)

2 176 1133 88354 0.091 0.145 896 58219 0.137 0.220

5 440 2832 220885 0.036 0.058 2239 145547 0.055 0.088

10 880 5664 441770 0.018 0.029 4478 291094 0.027 0.044

15 1320 8496 662655 0.012 0.019 6718 436641 0.018 0.029

KPM MPM (METER) (M SQ) (L/M SQ) (MM) (METERS) (M SQ) (M/M SQ) (MM)

3 53 341 8187 3.699 3.68 270 5395 5.613 5.59

8 134 862 20699 1.463 1.47 682 13640 2.220 2.23

16 268 1725 41399 0.731 0.74 1364 27280 1.110 1.11

24 402 2587 62098 0.488 0.48 2046 40920 0.740 0.74

DISTANCE

TOTAL

COVERAGE

DISPERSAL

WATER

LAYER

MAX

DISTANCE

TOTAL

COVERAGE

DISPERSAL

WATER

LAYER

5-3

MSC/MST-OPS-1

31 Dec 2013

SECTION 5

Performance

1/4 OPENING & FULL FAN (37,854 lit/10,000 gal TANK)

2 SPRAY HEADS (FLOW 3611 lpm/954 gpm) 4 SPRAY HEADS (FLOW 5693 lpm/1504 gpm)

SPRAY

SPEED

MPH FPM (FT) (SQ FT) (GAL/SQ FT) (IN/SQ FT) (FT) (SQ FT) (GAL/SQ FT) (IN/SQ FT)

2 176 1845 153124 0.065 0.105 1170 87766 0.114 0.183

5 440 4612 382809 0.026 0.042 2926 219415 0.046 0.073

10 880 9224 765618 0.013 0.021 5851 438830 0.023 0.037

15 1320 13836 1148428 0.009 0.014 8777 658245 0.015 0.024

KPM MPM (METER) (M SQ) (L/M SQ) (MM) (METERS) (M SQ) (M/M SQ) (MM)

3 53 556 13890 2.725 2.67 352 8105 4.670 4.65

8 134 1405 35118 1.078 1.07 891 20493 1.847 1.84

16 268 2809 70236 0.539 0.53 1782 40986 0.924 0.94

24 402 4214 105354 0.359 0.35 2673 61479 0.616 0.61

DISTANCE

TOTAL

COVERAGE

DISPERSAL

WATER

LAYER

MAX

DISTANCE

TOTAL

COVERAGE

DISPERSAL

WATER

LAYER

3/8 OPENING & FULL FAN (37,854 lit/10,000 gal TANK)

2 SPRAY HEADS (FLOW 4705 lpm/1243 gpm) 4 SPRAY HEADS (FLOW 5950 lpm/1572 gpm)

SPRAY

SPEED

MPH FPM (FT) (SQ FT) (GAL/SQ FT) (IN/SQ FT) (FT) (SQ FT) (GAL/SQ FT) (IN/SQ FT)

2 176 1416 110442 0.091 0.145 1120 72774 0.137 0.220

5 440 3540 276106 0.036 0.058 2799 181934 0.055 0.088

10 880 7080 552212 0.018 0.029 5598 363868 0.027 0.044

15 1320 10619 828319 0.012 0.019 8397 545802 0.018 0.029

KPM MPM (METER) (M SQ) (L/M SQ) (MM) (METERS) (M SQ) (M/M SQ) (MM)

3 53 426 10234 3.699 3.68 337 6744 5.613 5.59

8 134 1078 25874 1.463 1.47 853 17050 2.220 2.23

16 268 2156 51749 0.731 0.74 1705 34100 1.110 1.11

24 402 3234 77623 0.488 0.48 2558 51151 0.740 0.74

DISTANCE

TOTAL

COVERAGE

DISPERSAL

WATER

LAYER

MAX

DISTANCE

TOTAL

COVERAGE

DISPERSAL

WATER

LAYER

5-4

MSC/MST-OPS-1

31 Dec 2013

SECTION 5

Performance

FIRE SUPPRESSION SYSTEM

The table below shows consumption rates and duration of foam suppression concentrate and water based upon a standard flow rate 1893 lpm/500 gpm and 3% foam proportioning.

Foam Concentrate

liters/gallons

57/15 1893/500 1 minute 114/30 3786/1000 2 minutes 228/60 7571/2000 4 minutes 341/90 11,357/3000 6 minutes

455/120 15,142/4000 8 minutes

Water

liters/gallons

Duration

5-5

MSC/MST-OPS-1

31 Dec 2013

SECTION 5

Performance

5-6 (Blank)

MSC/MST-OPS-1

31 Dec 2013

SECTION 6

Employment

Contents

Description .......................................................................6-1 GPS Ground Speed Sensing .......................................6-1

DESCRIPTION

This section provides descriptions, guidance, and techniques used when employing the MEGA spray system. These best practices will provide operators with several different choices that will result in maximum system performance in most applications with ever changing conditions.

GPS GROUND SPEED SENSING

The resident software provides a consistent layer of water on haul roads regardless of ground speed. The software minimizes water usage and prevents puddling at stops and haul ramps. Nominal settings produce about 3 liters per cubic meter regardless of ground speed. This maximizes water usage and extends the duration of a given load of water. Adjustments are provided to increase or decrease the layer of water dispersed, as well as setting maximum water flow at a desired ground speed. All automatic system protection features are active regardless of auto or manual modes.

EXAMPLE 2

Setup:

1. RATE - Set at midpoint (50%)

2. SPEED - Set at mid-point (approximately 24 KPH/15 MPH)

3. AUTO – ON

4. Spray heads - Select all 4 spray heads

5. Vehicle speed – Greater than 27 KPH/16 MPH

Observed Operation:

1. All 4 requested spray heads ON, NO timed cycle

EXAMPLE 3

Setup:

1. RATE - Set LESS than midpoint (≤50%)

2. SPEED - Set at mid-point (approximately 24 KPH/15 MPH)

3. AUTO – ON

4. Spray heads - Select all 4 spray heads

5. Vehicle speed – Less than 21 KPH/14 MPH

Here are several examples of initial system setup and adjustments:

EXAMPLE 1

Setup:

1. RATE - Set at midpoint (50%)

2. SPEED - Set at mid-point (approximately 15 MPH/24 KPH)

3. AUTO – ON

4. Spray heads - Select all 4 spray heads

5. Vehicle speed – Less than 21 KPH/14 MPH

Observed Operation:

1. 2 Outer spray heads on with a timed cycle, shortened ON cycle durations

2. 2 Center spray heads OFF (reduced volume)

Observed Operation:

1. 2 Outer spray heads on with a timed cycle, shortened ON cycle durations

2. 2 Center spray heads OFF (reduced volume)

EXAMPLE 4

Setup:

1. RATE - Set at GREATER than midpoint (≥50%)

2. SPEED - Set at mid-point (approximately 24 KPH/15 MPH)

3. AUTO – ON

4. Spray heads - Select all 4 spray heads

5. Vehicle speed – Less than 21 KPH/14 MPH

Observed Operation:

1. 2 Outer spray heads on with a timed cycle, increased ON cycle durations

2. 2 Center spray heads OFF (reduced volume)

6-1

MSC/MST-OPS-1

31 Dec 2013

SECTION 6

Employment

6-2 (Blank)

MSC/MST-OPS-1

31 Dec 2013

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013



MSC/MST

OPERATOR’S

CHECKLIST

7-1

MSC/MST-OPS-1

31 Dec 2013

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

TABLE OF CONTENTS

Title Page

1. BEFORE OPERATIONS . . . . . . . . . . . . . . . . . . . N-2

2. OPERATIONS

A. Spray Head System. . . . . . . . . . . . . . . . . . N-4

B. GPS AUTO Mode . . . . . . . . . . . . . . . . . . . . N-5

C. Dump Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . N-7

D. Water Cannon. . . . . . . . . . . . . . . . . . . . . . . N-8

E. Fire Suppression System. . . . . . . . . . . . . N-9

F. Tank Drain . . . . . . . . . . . . . . . . . . . . . . . . . . N-11

G. Hose Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . N-12

3. AFTER OPERATIONS. . . . . . . . . . . . . . . . . . . . . N-14

4. COLD WEATHER OPERATION

AND STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . N-15

N-1

7-2

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

BEFORE OPERATIONS

These procedures are used to perform a walk-around inspection of the MEGA water tanker system before use or beginning of a shift. This inspection is in addition to and does not replace the vehicle manufacturer’s inspection requirements.

1. Chocks – As Required

MSC/MST-OPS-1

31 Dec 2013

2. Vehicle Parking Brake – ON

3. Cab Control Switches – SET OFF

4. Bumper Sprayheads – SECURED & SET

5. Vehicle Hydraulic Tank – SERVICED

6. Gooseneck Lines & Hoses – CHECKED & SECURED

7. Solenoid Control Box – CHECKED AND SECURED

8. Water Cannon – CHECKED & SECURED a. Nozzle – Check for security and kinking of

foam concentrate supply line.

N-2

7-3

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31 Dec 2013

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

9. (If Equipped) Foam Concentrate Level – CHECKED. At least 1” from the top of the foam tank.

Ensure PPE fall arrest harness is worn, adjusted properly and attached to an anchor point. Failure to use PPE properly may result in personnel injury or death.

10. Tank Drain Petcocks – CLOSED

11. Spray Heads – SECURED & SET

12. Water Pump Assembly – CHECKED a. Water Pump – Check to ensure volute case

drain valve is closed.

b. Water pump and drive motor for evidence of

overheating.

13. Hose Reel – CHECKED

N-3

7-4

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

OPERATIONS

Use these procedures to safely operate the standard and optional systems installed on the MEGA water tanker.

Limit water pump operation to 2.5 minutes when in a no-flow condition (no flow from spray heads, dump bar, water cannon, drain valve or hose reel). Water pump operation in a no flow condition will cause overheating of the water pump and damage to the shaft bearings.

MSC/MST-OPS-1

31 Dec 2013

SPRAY HEAD SYSTEM

Operating more than 4 spray heads simultaneously will greatly reduce the width and flow of active spray heads.

1. Cab Control SYSTEM/POWER Switch – ON

2. INTERMITTENT – SET AS REQUIRED a. TIMER ON/OFF Dials – SET b. INTERMITTENT Switch – SET

N-4

7-5

MSC/MST-OPS-1

31 Dec 2013

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

3. PUMP Switch – ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

4. Individual Spray Head Switches – ON

Once operations are complete:

5. Individual Spray Head Switches – OFF

6. PUMP Switch – OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

7. Cab Control SYSTEM/POWER Switch – OFF

GPS AUTO MODE

1. Cab Control POWER Switch – ON

2. RATE and SPEED Dials - SET

N-5

7-6

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

3. AUTO – ON AS REQUIRED

4. Desired Spray Head Switches – ON

5. PUMP Switch ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

MSC/MST-OPS-1

31 Dec 2013

Once operations are complete:

6. PUMP Switch OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

7. AUTO – OFF

8. Individual Spray Head Switches – OFF

9. Cab Control POWER Switch - OFF

N-6

7-7

MSC/MST-OPS-1

31 Dec 2013

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

DUMP BAR

1. Cab Control SYSTEM/POWER Switch – ON

2. INTERMITTENT – SET AS REQUIRED a. Timer ON/OFF Dials – SET b. INTERMITTENT Switch – SET

3. PUMP Switch ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

4. DUMP BAR Switch – ON

Once operations are complete:

5. DUMP BAR Switch – OFF

6. PUMP Switch OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

7. Cab Control SYSTEM/POWER Switch – OFF

N-7

7-8

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

WATER CANNON

1. Cab Control SYSTEM/POWER Switch – ON

2. PUMP Switch ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

MSC/MST-OPS-1

31 Dec 2013

3. Water Cannon – Pointed in a safe direction.

4. MONITOR/BFV Switch – ON

5. Water Cannon Joystick – As Required.

6. MONITOR/BFV Switch – OFF

Once operations are complete:

7. Water Cannon Nozzle - STOW

N-8

7-9

MSC/MST-OPS-1

31 Dec 2013

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

8. PUMP Switch OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

9. Cab Control SYSTEM/POWER Switch – OFF

FIRE SUPPRESSION SYSTEM

1. Cab Control SYSTEM/POWER Switch – ON

2. PUMP Switch ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

3. Water Cannon – Pointed in a safe direction.

4. FOAM Switch – ON

5. MONITOR/BFV Switch – ON

6. Water Cannon Joystick – As Required.

N-9

7-10

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

Once operations are complete:

7. FOAM Switch – OFF

8. Water Cannon – Flow water through the water cannon nozzle with the FOAM switch off to flush foam from the nozzle.

MSC/MST-OPS-1

31 Dec 2013

9. MONITOR/BFV Switch – OFF

10. Water Cannon Nozzle - STOW

11. PUMP Switch OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

12. Cab Control SYSTEM/POWER Switch – OFF

N-10

7-11

MSC/MST-OPS-1

31 Dec 2013

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

13. Vehicle – Wash or fresh water rinse areas exposed to the foam spray.

TANK DRAIN

1. Cab Control SYSTEM/POWER Switch – ON

2. PUMP Switch ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

3. DRAIN Switch – ON

4. Water Level – Drain to desired level.

Do not operate the water pump in a dry sump. Dry running operation will cause water pump failure.

Once operations are complete:

5. DRAIN Switch – OFF

N-11

7-12

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

6. PUMP Switch OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

7. Cab Control SYSTEM/POWER Switch – OFF

MSC/MST-OPS-1

31 Dec 2013

HOSE REEL

1. Hose Nozzle – CLOSED

2. Hose – Deploy desired length.

3. Gate Valve – OPEN

4. Cab Control SYSTEM/POWER Switch – ON

5. PUMP Switch ON

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

6. Vehicle RPM – SET

7. Hose Nozzle – OPEN as desired.

N-12

7-13

MSC/MST-OPS-1

31 Dec 2013

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

Once operations are complete:

8. Hose Nozzle – CLOSED

9. Vehicle RPM – LOW IDLE

10. PUMP Switch OFF

Engaging/disengaging the water pump above LOW IDLE may result in water pump component damage and reduced service life.

11. Cab Control SYSTEM/POWER Switch – OFF

12. Gate Valve – CLOSED

13. Hose – Reel in and stow hose nozzle.

N-13

7-14

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

AFTER OPERATIONS

1. Vehicle parking brake – ON

MSC/MST-OPS-1

31 Dec 2013

2. Cab Control Switches – SET OFF

3. Chocks – As Required.

4. Water Cannon – CHECKED AND SECURED

5. Vehicle Hydraulic Tank – CHECKED

6. Tank Lines and Hoses – SECURED

7. Tank Drain Petcocks – As Required.

8. Spray Heads – SECURED AND SET

9. Water Pump Assembly – CHECKED a. Water Pump – Check for damage and volute

case drain valve set as required.

10. Hose Reel – CHECKED

N-14

7-15

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31 Dec 2013

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

11. Solenoid Control Box – CHECKED

COL D W E AT HER OPERATION AND STO R AGE

To ensure all water is drained from tank check the following;

1. Park unit on a slight nose up angle to allow water to flow to the rear of the tank.

2. Drain the tank using an appropriate method until the Water Level Gauge reads EMPTY.

3. Open all drain petcocks (water pump, spray bars, etc.).

N-15

7-16

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

4. Remove water pump sump cover.

5. Start engine.

6. Cab Control SYSTEM/POWER Switch – ON

7. MONITOR/BFV Switch – ON

MSC/MST-OPS-1

31 Dec 2013

8. DUMP BAR Switch – ON

9. DRAIN Switch – ON

10. Water Cannon Nozzle – Pointed fully DOWN

11. Turn engine off.

12. Cab Control SYSTEM/POWER Switch – OFF

13. Hose Reel – DRAIN a. Hose – UNWIND b. Nozzle – Fully OPEN c. Gate Valve – OPEN d. Allow water to drain. e. Hose – REWIND f. Gate Valve – CLOSED g. NOZZLE – CLOSED

14. Check to ensure all water has drained from tank.

N-16

7-17

MSC/MST-OPS-1

31 Dec 2013

SECTION 7

Appendix

MSC/MST-OPS(CL)-1

31 Dec 2013

TO REACTIVATE UNIT:

1. Lubricate water pump bearings as instructed in the Maintenance (-2) technical manual.

2. Inspect tank interior to ensure it is clean, if the tank is coated, ensure coating integrity, clean or repair as required.

3. Install sump cover with new gasket.

4. Close all drain valves and petcocks.

5. Start engine.

6. Control SYSTEM/POWER Switch – ON

7. Individual Spray Head Switches – OFF

8. DUMP BAR Switch – OFF

9. DRAIN Switch – OFF

10. MONITOR/BFV Switch – OFF

11. Turn engine off.

12. Cab Control SYSTEM/POWER Switch – OFF

N-17

7-18

MEGA Corp. MSC-OPS-1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Definitions and Abbreviations

MANUAL USAGE

WARNING, CAUTION AND NOTES

USE OF SHALL, WILL, SHOULD AND MAY

SAFETY MESSAGES

ABBREVIATIONS

MSC/MST GENERAL OVERVIEW (TYPICAL)

System Description

WATER TANK (MSC/MST)

WATER PUMP

HYDRAULIC DRIVE MOTOR

CAB CONTROLS (ANALOG)

CAB CONTROLS (DIGITAL)

GROUND SPEED SENSING (GPS) CONTROL

WATER CANNON SYSTEM

SPRAY SYSTEM

DUMP BAR

HOSE REEL

TANK DRAIN

FIRE SUPPRESSION SYSTEM

SUCTION LOADING (IF EQUIPPED)

BRAKING SYSTEM

Limitations

WATER PUMP

Normal Operations

DESCRIPTION

BEFORE OPERATIONS

OPERATIONS

AFTER OPERATIONS

COLD WEATHER OPERATION AND STORAGE

Performance

SPRAY PATTERN AND REACH (TYPICAL 9’ SPRAY BAR)

TYPICAL SPRAY SYSTEM DURATION

PRECISION WATERING

FIRE SUPPRESSION SYSTEM

Employment

DESCRIPTION

GPS GROUND SPEED SENSING