Mega MMP4 User manual

Maintenance Manual
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 [phone]
www.megacorpinc.com
® MEGA Corp., Inc. All Rights Reserved
MMP4-CAT(T4)-MX-2

MMP4-CAT(T4)-MX-2
26 Feb 2014
TABLE OF CONTENTS
A
Section 1 Definitions and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Section 2 System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Section 3 Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
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 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
Section 10 Recommended Support Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1
Section 11 Appendix A: MMP4 Build Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-A
Section 12 Appendix B: Hydraulic Pump and Engine Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-A
Page

MMP4-CAT(T4)-MX-2
26 Feb 2014
TABLE OF CONTENTS
B (Blank)

1-1
MMP4-CAT(T4)-MX-2
26 Feb 2014
SECTION 1
Definitions and Abbreviations
Contents
MANUAL USAGE
This technical manual only contains information
required to safely maintain the MMP4 powered by a
CAT 2.2l TIER 4 diesel engine. See the CAT Engine
Maintenance and Operators Safety Manual
(SEBU8312-02) for specific vehicle system
information and maintenance procedures. If your
system is not covered in this manual please contact
MEGA Corp. Product Support at:
1-800-345-8889 or visit our web site at
www.megacorpinc.com for more detailed
information.
Descriptions of the hazards are reviewed in this
section. All personnel working on or operating the
machine must become familiarized with all the safety
messages.
Due to the nature of these processes, ensure that all
safety information, warnings and instructions are
read and understood before any operation or any
maintenance procedures are performed. Some
procedures take place with heavy components and
at moderate heights, ensure proper safety
procedures are maintained when performing these
actions. Failure to use and maintain proper safety
equipment and procedures will cause injury, death or
damage to equipment.
WARNING, CAUTION AND NOTES
The following definitions are found throughout the
manual and apply as follows:
Operating procedures and techniques, which could
result in personal injury and/or loss of life if not
carefully followed.
Operating procedures and techniques, which could
result in damage to equipment if not carefully
followed.
Operating procedures and techniques that are
considered essential to emphasize.
USE OF SHALL, WILL, SHOULD AND MAY
Shall and Will – Used when application of a
procedure is mandatory.
Should – Used when application of a procedure is
recommended.
May - Used to indicate an acceptable or suggested
means of accomplishment.
Manual Usage ...................................................................1-1
Warning, Caution And Notes ......................................1-1
Use Of Shall, Will, Should And May ...........................1-1
Safety Messages ..............................................................1-2
Abbreviations ...................................................................1-3
MMP4 General Overview (Typical) ...........................1-4

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SECTION 1
Definitions and Abbreviations
1-2
SAFETY MESSAGES
There are several specific safety messages in this
section that are applicable to the MMP4. These
hazards are reviewed in this section. All personnel
working on or operating the machine must become
familiarized with all the safety messages.
(Applicable to safety labels on machine) Make sure
that all of the safety messages are legible. Clean the
safety messages or replace the safety messages if 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)
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.
BACKING RUNOVER HAZARD (3)
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.
NON-POTABLE (5)
Water held within the MMP4 is not potable. Do
not use the MMP4 for transport of water intended
for human or animal consumption, as serious
injury or death may result.

MMP4-CAT(T4)-MX-2
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SECTION 1
Definitions and Abbreviations
1-3
FALL HAZARD (7)
Do not walk on the top of tank without fall arrest
PPE. Serious injury or death could occur from a
fall.
ROTATING SHAFT (8)
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 MOTOR (11)
Hydraulic motor and supply lines contain oil
under high pressure. Improper removal and
repair procedures could cause severe injury. To
remove or repair, instructions in the Maintenance
Manual must be followed.
ABBREVIATIONS
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 operator’s position facing
forward
m - meters
MPH - Miles Per Hour
MMP - MEGA Mobile Pump
Nm - Newton meters of torque
psi - pounds per square inch
RPM - Revolutions Per Minute
RT - Right as viewed from the operator’s position
facing forward
SQ FT - Square Feet
VDC - Volts, Direct Current

MMP4-CAT(T4)-MX-2
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SECTION 1
Definitions and Abbreviations
1-4
MMP4 GENERAL OVERVIEW (TYPICAL)


18
12
7
9
5
3
1DISCHARGE BOOM
2VACUUM BREAK
3TOW HITCH
4CAT C2.2T DIESEL ENGINE
5LANDING GEAR (QTY 3)
6TIRE AND RIM ASSEMBLY
7FENDER
850 GAL. DIESEL FUEL TANK
9DISCHARGE BOOM LIFT CYLINDER
TOP VIEW
SIDE VIEW
2
4
10
11
10 TAIL LIGHTS
11 HYDRAULIC OIL TANK
12 INLET DEBRIS SCREEN AND SAFETY CHAIN
13 AXIAL WATER PUMP
14 INLET BOOM
15 HYDRAULIC CONTROL VALVE
16 INLET BOOM CYLINDER
17 ENGINE CONTROL BOX
18 BATTERY BOX
14 15 17 13
13 12
3
5
614
10
11
18
16

2-1
MMP4-CAT(T4)-MX-2
26 Feb 2014
SECTION 2
System Description
Contents
DESCRIPTION
The MEGA Mobile Pump (MMP4) is a towable water
lifting station. The MMP4 may be towed by a vehicle
capable of at least a 6,000 pound (2,725 kg) towing
capacity, 1,000 pound (450 kg) tongue weight, and
equipped with the appropriate weight rated Class IV
trailer hitch with a 2 5/16 inch ball. The MMP4 can be
transported to a water holding pond and be set up
by one individual.
The MMP4 is a self-contained pumping station fitted
with a hydraulically driven 12 inch axial water pump
that has the potential to lift water 25 feet (7.6 meters)
from pump level to fill water distribution equipment
(maximum height: 17 feet or 5.2 meters above
ground level).
MMP4s are equipped with: hydraulically lifted inlet
and discharge booms with safety retaining chains
and travel locking devices, DOT rated lighting, 16
inch load range 'E' on-highway trailer tires, a fold
away hitch with safety chains, a vacuum break with
an anti-siphon discharge sock on the discharge
boom, 23 gallon (87 liter) hydraulic oil tank filled with
Chevron Clarity AW 46 hydraulic oil, a gear type
hydraulic pump driven by a Caterpillar C2.2T series
diesel engine, and a 50 gallon (190 liter) capacity
diesel fuel tank equipped with shut off valves.
The MMP4 needs a minimum of 2.5 feet (0.76 meters)
of water above the inlet of the water pump for proper
operation.
INSPECTION
1. Inspect MMP4 exterior paint for wear and
corrosion.
2. Inspect piping for damage and leaks.
3. Inspect frame, landing gear and suspension for
damage and missing parts.
4. Inspect engine assembly for loose, missing,
damaged or leaking parts.
5. Inspect all hydraulic hoses and couplings for
security, damage and leaking.
6. Inspect fuel, engine oil, anti freeze and hydraulic
oil for contamination and proper level.
7. Inspect lighting, lug nuts, fenders and hitch
safety equipment for operation, damage and
missing parts.
8. Inspect electrical system for corrosion, damage
and missing parts.
Description ........................................................................2-1
Inspection ...........................................................................2-1
Repair ...................................................................................2-2

MMP4-CAT(T4)-MX-2
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SECTION 2
System Description
2-2
REPAIR
Paint
Remove corrosion, prime and paint.
Engine Fluid Levels and Inspections
Adjust, repair or service according to CAT C2.2T
manuals (SEBU8312-02) for engine service schedule.
Leaks
1. Remove paint and corrosion from suspected area.
2. Prep surface to be welded, weld over leak.
3. Prime and paint over weld.
4. Tighten or replace damaged or leaking
component.
Lighting
Repair as required to maintain DOT compliance.
Missing parts
Contact MEGA Corp Parts sales for assistance.
Structure
Contact the MEGA Corp. Product Support Group at:
Toll free US 1-800-345-8889
Direct 1-505-345-2661
or visit our website at www.megacorpinc.com for
more detailed contact information or assistance on
major structural repairs.

3-1
MMP4-CAT(T4)-MX-2
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SECTION 3
Engine Control System
Contents
DESCRIPTION
The Engine Control System consists of: A control box
with lockable cover, ignition switch with key, throttle
control, battery voltage gauge, engine oil pressure
gauge, engine coolant temperature gauge, hour
meter, fault indicator lamps, and an engine
tachometer.
The engine control box controls and monitors the
main engine functions. It is equipped with:
• Oil pressure gauge to monitor the engine oil
pressure.
• Engine coolant temperature to monitor the
engine coolant temperature.
• Tachometer to monitor the engine RPM’s or
speed.
• Battery voltage meter to monitor the battery
voltage.
• Battery voltage meter to indicate the state of
charge and electrical operation of system.
• Engine hour meter to indicate engine operational
hours.
• Fault Indicator Lamps to indicate 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 cabling for security,
condition and mounting.
2. Inspect switches, gauges and throttle control for
security, damage and operational condition.
REPAIR
SWITCH REPLACEMENT
1. Remove power to the engine control.
2. Remove engine control face plate to gain access
to the switch.
3. Mark wiring on old switch before removal to
ensure correct wiring configuration is
maintained.
4. Remove old switch and replace with the same
type of switch.
5. Install wiring on new switch as previously
marked.
6. Install engine control face plate in control box.
7. Apply power to the engine control and perform
functional check of the newly installed switch.

Battery
Volt-meter
Engine Oil
Pressure
Gauge
Fault
Indicator
Lamps
Engine Start/Stop
Key Switch
Engine Hour
Meter
Engine
Coolant
Temperature
Gauge
Tachometer

Hand Throttle
Description.........................................................................3-1
Inspection ...........................................................................3-1
Repair ...................................................................................3-1