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Mega MMP4, Maintenance Manual

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Mega MMP4 Maintenance Manual Download Page 67

12-A

MMP4-CAT(T4)-MX-2

26 Feb 2014

SECTION 12

Appendix B: Hydraulic Pump and Engine Control

DESCRIPTION

This section contains supplementary documentation
regarding hydraulic pump service and CAT C2.2T
engine operation, service, maintenance, and
troubleshooting. 

If your system is not covered in this manual, you are
having difficulties with the installation or need
additional information or assistance, please contact
The MEGA Corp. Product Support Group at: 
U.S. Toll Free: 1-800-345-8889
Direct: 1-505-345-2661 
or visit our website at www.megacorpinc.com for
more contact information. 

Summary of Contents for MMP4

Page 1: ...SPECIALTY HAULAGE SOLUTIONS FOR CONSTRUCTION AND MINING MEGA CORP 700 Osuna Rd N E Albuquerque NM 87113 1 800 345 8889 505 345 2661 Fax 505 345 6190 www megacorpinc com MEGA Corp Inc All Rights Reserv...

Page 2: ...Section 4 Basic Hydraulics System 4 1 Section 5 Water Pump Assembly 5 1 Section 6 Axle and Suspension 6 1 Section 7 Frame and Booms 7 1 Section 8 Scheduled Inspections 8 1 Section 9 Special Inspectio...

Page 3: ...MMP4 CAT T4 MX 2 26 Feb 2014 TABLE OF CONTENTS B Blank...

Page 4: ...s 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...

Page 5: ...rsh 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 messa...

Page 6: ...pply lines contain oil under high pressure Improper removal and repair procedures could cause severe injury To remove or repair instructions in the Maintenance Manual must be followed ABBREVIATIONS cc...

Page 7: ...NGINE 5 LANDING GEAR QTY 3 6 TIRE AND RIM ASSEMBLY 7 FENDER 8 50 GAL DIESEL FUEL TANK 9 DISCHARGE BOOM LIFT CYLINDER TOP VIEW SIDE VIEW 2 4 10 11 10 TAIL LIGHTS 11 HYDRAULIC OIL TANK 12 INLET DEBRIS S...

Page 8: ...iler 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 hydrauli...

Page 9: ...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 p...

Page 10: ...ate potential unsafe operating conditions and to show fault in individual systems Hand throttle to adjust the engine operating RPM s Remote Engine Stop Button INSPECTION 1 Inspect control box and cabl...

Page 11: ...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...

Page 12: ...ontact the HIGH idle stop 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 f...

Page 13: ...MMP4 CAT T4 MX 2 26 Feb 2014 SECTION 3 Engine Control System 3 4 Blank...

Page 14: ...rotect against over pressurization of the hydraulic system The return hydraulic oil is passed through a hydraulic oil filter oil cooler and then a diffuser mounted inside of the hydraulic oil tank HYD...

Page 15: ...aulic control valve where the control valve directs the oil flow to the selected components INSPECTION Inspect hydraulic pump adapter and hosing for vibrations unusual noises security damage and leaks...

Page 16: ...mage and leaks 4 Check pressure regulator for proper relief pressure 2 800 psi 19 300 kpa security and leaks REPAIR Hydraulic Control Valve 1 Repair adjust or replace as required 2 To set hydraulic re...

Page 17: ...too fast turn knob CW 1 16th of a turn at a time if the speed is too slow turn knob CCW 1 16th of a turn at a time until desired speed is achieved 8 seconds to full rise f Tighten jamb nut g Reinstall...

Page 18: ...eck hydraulic filter assembly hose fitting adapters for security and leaks REPAIR Repair adjust or replace as required HYDRAULIC OIL COOLER The hydraulic oil cooler is attached to the front of the eng...

Page 19: ...or 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...

Page 20: ...l 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 a...

Page 21: ...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...

Page 22: ...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 in...

Page 23: ...rew 15 303910 14 Pipe Plug 16 303910 15 Strainer Assembly 17 303910 16 Snap Ring 18 303910 17 Thrust Collar 19 303910 18 Key 20 303910 19 Impeller 21 303910 20 Lower Seal 22 303910 21 Discharge Bowl A...

Page 24: ...e 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 repla...

Page 25: ...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 b...

Page 26: ...e 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 l...

Page 27: ...MMP4 CAT T4 MX 2 26 Feb 2014 SECTION 5 Water Pump Assembly 5 8 Blank...

Page 28: ...capacity is used to secure the axle prior to removing the tire assembly Failure to properly lift and secure the MMP4 properly may result in an unstable load over loading of the jack or damaging an MM...

Page 29: ...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 bushin...

Page 30: ...t 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...

Page 31: ...MMP4 CAT T4 MX 2 26 Feb 2014 SECTION 6 Axle and Suspension 6 4 Blank...

Page 32: ...t 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...

Page 33: ...ge boom travel locks and mounts for security and damage 8 Inspect fenders for security and damage 9 If equipped Inspect lighting for security damage and function 10 Inspect boom mounting pivot point t...

Page 34: ...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 securi...

Page 35: ...ety 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 The MEGA Corp Produ...

Page 36: ...or 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...

Page 37: ...eaks 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...

Page 38: ...dures Use SEBU8312 02 for engine maintenance requirements Follow and perform all required service procedures operations conditions and schedules X 2 Check and ensure all engine control functions are i...

Page 39: ...MMP4 CAT T4 MX 2 26 Feb 2014 SECTION 8 Scheduled Inspections 8 4 Blank...

Page 40: ...ect battery cables from battery 11 Service all engine systems per CAT C2 2T Diesel engine service manual SEBU8312 02 12 If possible shelter entire unit from the elements REMOVING 1 Remove all covers a...

Page 41: ...MMP4 CAT T4 MX 2 26 Feb 2014 SECTION 9 Special Inspections 9 2 Blank...

Page 42: ...66 or visit our website at www megacorpinc com for more detailed contact information A AXIAL WATER PUMP GROUP 303910 PART DESCRIPTION PART NO QTY 1 Gasket 12 inch 304174 2 2 Grommet 303910 03 2 3 Thru...

Page 43: ...AND SUSPENSION GROUP PART DESCRIPTION PART NO QTY 1 Wheel and Tire Assembly 303933 1 2 Hitch pin 1 inch 303935 2 3 Chain 3 8 inch GR 70 2 4 ft 038453 13 1 4 Shackle 3 8 inch 355020 2 5 Bearing Wheel...

Page 44: ...used in conjunction with previous section information to successfully produce a fully operational MMP4 system If your system is not covered in this manual you are having difficulties with the installa...

Page 45: ...MMP4 CAT T4 MX 2 26 Feb 2014 SECTION 11 Appendix A MMP4 Build Drawings 11 B Blank...

Page 46: ...APPENDIX A MMP4 Build Drawings MMP4 CAT C22T TIER 4 11 1...

Page 47: ...APPENDIX A MMP4 Build Drawings MMP4 CAT C22T TIER 4 11 2...

Page 48: ...APPENDIX A MMP4 Build Drawings MMP4 CAT C22T TIER 4 11 3...

Page 49: ...APPENDIX A MMP4 Build Drawings MMP4 CAT C22T TIER 4 11 4...

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Page 54: ...APPENDIX A MMP4 Build Drawings MMP4 CAT C22T TIER 4 11 9...

Page 55: ...APPENDIX A MMP4 Build Drawings MMP4 CAT C22T TIER 4 11 10...

Page 56: ...APPENDIX A MMP4 Build Drawings MMP4 CAT C22T TIER 4 11 11...

Page 57: ...APPENDIX A MMP4 Build Drawings MMP4 CAT C22T TIER 4 11 12...

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Page 65: ...APPENDIX A MMP4 Build Drawings MMP4 CAT C22T TIER 4 11 20...

Page 66: ...APPENDIX A MMP4 Build Drawings MMP4 CAT C22T TIER 4 11 21...

Page 67: ...d CAT C2 2T engine operation service maintenance and troubleshooting If your system is not covered in this manual you are having difficulties with the installation or need additional information or as...

Page 68: ...MMP4 CAT T4 MX 2 26 Feb 2014 SECTION 12 Appendix B Hydraulic Pump and Engine Control 12 B Blank...

Page 69: ...APPENDIX B Hydraulic pump and Engine Control MMP4 CAT C22T TIER 4 12 1...

Page 70: ...APPENDIX B Hydraulic pump and Engine Control MMP4 CAT C22T TIER 4 12 2...

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