Mega B-4Z Manual

SPECIALTY HAULAGE SOLUTIONS FOR CONSTRUCTION AND MINING
PRODUCT INFORMATION BULLETIN
PIB-05
SUCTION LOADING STATION
• Operations
• Troubleshotting
• Installation
• Commissioning
• Schedule of Inspections & Maintenance Parts
• Recommended Support Parts
B-4Z Splined Shaft, CW
302430
Applicable to:
The B-4Z Berkeley water pump and covers:

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
Contents
1-1
DESCRIPTION
This document outlines the operation procedures,
commissioning, schedule of inspection and
maintenance, and support parts for the B4Z Suction
Loading Station. If you have any questions, concerns,
or issues regarding this system, contact Mega
Product Support at US Toll free: 1-800-345-8889 or
Direct: 1-505-345-2661.
OPERATIONS
SUCTION LOAD STATION WITH B4Z PUMP
1. Place vehicle as close to the water source as
possible.
2. Secure the vehicle by applying all parking brakes,
setting wheel chocks, and making the unit safe
for operation.
3. Remove suction hose from storage tubes and
assemble.
Ensure that all gaskets on the coupling joints are
present, in good condition, clean, and free from
distortion and damage. Presence of dirt and
debris on the gasket or coupling will decrease or
prevent pump priming or loading by allowing air
leakage.
4. Suction Hoses – Immerse in pond or water
supply.
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.
5. 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.
6. Submerge hose end with the foot valve into the
water source.
The removal/absence of foot valve will not allow
pump to be or stay primed and will reduce
performance of the pump. Ensure that it is
installed on the water source end of the pump
and not submerged in mud or silt.
7. Connect assembled suction hose to suction load
pump ensuring all connections are air tight and
secure.


Typical Inlet Foot Valve (Check Valve)
STEPS CONTINUE ON
NEXT PAGE
Description.........................................................................1-1
Operations..........................................................................1-1
Troubleshooting...............................................................1-3
Installation..........................................................................1-4
Water Pump Tuning........................................................1-11
Scheduled Maintenance Inspections....................... 1-13
Recommended Support Parts .................................... 1-14
Illustrated Parts Breakdown.........................................1-15

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-2
8. If the pump is dry, (no water inside the volute
case or loading hoses) remove the 1 inch plug
from the top of the pump and fill it full of water.
Do not operate suction loading pump when volute
case contains no water. Operating suction loading
pump without water will damage shaft and shaft seal
Suction loading pump and loading hoses must be full
of water before filling operation is to begin. It may be
necessary to disconnect loading hoses and fill them
separately before priming is complete.
9. Activate the suction loading pump by pulling the
handle on the diverter valve out and away from
the valve.
10. Start chassis engine.
11. At LOW IDLE turn SYSTEM/POWER switch ON.
12. (DiSCS Only) AUX2 - ON
13. Turn PUMP Switch – ON
Engaging/disengaging the water pump above
LOW IDLE may result in water pump component
damage and reduced service life.
14. Increase engine RPM to HIGH IDLE.
When unit is full of water
15. Reduce engine RPM to LOW IDLE.
16. PUMP Switch – OFF
Engaging/disengaging the water pump above LOW
IDLE may result in water pump component damage
and reduced service life.
17. (DiSCS Only) AUX2 - OFF
18. SYSTEM/POWER Switch - OFF.
19. Turn engine OFF.
20. Return the diverter valve handle to the discharge
pump operating position.
21. Disconnect, drain and stow suction hoses.
AFTER OPERATIONS
These procedures are used to perform a walk-around
inspection after using MEGA water tank 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
3. Chocks – As Required
4. Water Cannon – CHECKED & SECURED
5. Vehicle Hydraulic Tank - CHECKED
6. Tank Lines and Hoses – SECURED
7. Tank Drain Petcocks – As Required.
8. Spray Heads – SECURED & SET
9. (If Equipped) Heat Exchanger – CHECKED FOR
SECURITY AND LEAKS
10. Water Pump – CHECKED for damage, and volute
case drain valve SET as required.
11. Hose Reel – CHECKED
12. Solenoid Control Box – CHECKED

1 Inch
Plug

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-3
TROUBLESHOOTING
This troubleshooting guide to assist in locating the
root cause of a failure or performance issue with the
Suction Loading Station. If following these steps does
not resolve your issue, contact Mega Product
Support immediately at: US Toll free: 1-800-345-8889
or Direct: 1-505-345-2661
1. Inspect the hose ‘Foot’ (the check valve attached
to the immersed end of the hose sections) for:
• Clean screen. If screen is plugged, clean as
required.
• Check valve proper operation. If check valve does
not hold water. Repair or replace as required.
• Placement in holding pond. If the Foot valve has
settled into the sand or silt on the bottom of the
pond, the ability for the valve to pass water is
greatly diminished, reducing the volume of water
it can lift. Correct condition as required.
The Foot Valve is required in order to ensure that
water remains in suction hoses during priming.
2. Inspect for air leaks in the inlet hose assemblies.
• Each connector has a gasket, ensure the gaskets
are serviceable and intact. Inspect each connector
for damage that may allow air to be pulled into
pump inlet.
• Ensure Foot valve is fully submerged in water at
least 20 inches (0.5 meters).
• Inspect suction hose assemblies for damage
including collapse, dry rot, cracking, punctures, or
holes, and kinks and obstructions. Replace as
required.
3. Inspect water pump check valve for wear,
condition and damage. The “Clack” and gasket
must be intact for volute to hold water while
priming. Replace as required.
4. Inspect and ensure water pump volute case and
hoses are full of water. Correct as required.
5. Inspect water pump shaft mechanical seal for
leaks or damage. Repair or replace as required.
The performance of the Suction Loading Station
diminishes with lifting height, discharge height, and
altitude as follows:
• The higher in elevation the unit is operating, the
lower the flow rate will be and the more vertical
lift is required. Consequently, performance will be
reduced.
• The shorter the vertical displacement is between
the water source and the pump station, the
better the suction loading station will perform.
• If the pump outlet is filling the tank from near the
bottom of the tank, performance will decrease as
the water level within the tank increases.
The maximum performance of this pumping station
with a minimum lift distance and at sea level in
elevation is approximately 450 gallons per minute.
1. Ensure the water pump shaft rotates the correct
direction, as identified by the casting on the
volute case.
2. Ensure the water pump RPM is set to correct
specifications (2,200 ± 50 RPM at engine high
idle).
3. Ensure the diversion valve is set for suction
loading.
4. Ensure the Foot Valve and inlet screen are free
from debris and in operational condition.
5. Ensure there are no air leaks in the inlet hoses or
connections.
6. Ensure inlet hoses are serviceable and free from
damage, kinks, and holes.
7. Ensure the Foot is submerged at least 20 inches
(0.5 meters) below the surface of the water.
8. Ensure the impeller is not plugged with debris
and is defect free.
9. Repair, replace or adjust as required.
Suction Loading Pump does not prime.
Suction Loading Pump fills the tank slowly.

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-4
INSTALLATION
PREPARATION
1. Drain the water tank.
2. Clean rear area of tank where work is to be performed.
3. If possible park the machine on a small incline to allow water to drain to the rear sump.
4. Remove water pump sump clean-out cover and fully drain the tank.
5. Make the unit safe for maintenance and perform lock-out-tag out.
6. Open shipping container and familiarize yourself with kit contents.
a. Suction hose – 2 per unit
b. Suction hose foot valve – 1 per unit
c. 2-piece storage tubes – 2 per unit
d. Storage tube mount brackets – 2 per unit (long and short)
e. Suction pump station – 1 per unit
f. Suction pump support tear pad and support channel – 2 per unit (right and left)
g. Pump station discharge tube to tank - 1 per unit
h. Pump station discharge pipe clamp coupling (Dresser coupling) - 1 per unit
i. Diversion Valve – 1 per unit
j. Hydraulic return manifold – 1 per unit
k. Complete hose assemblies – 5 per unit
l. 50% assembled hose assemblies – 3 per unit
m. Hardware package – 1 per unit
7. Locate and position all tools, jacks, clamps, buckets, grinders and welding equipment.
8. Protect existing hose and wiring on the rear of the tank from welding damage.
9. Perform a risk assessment and team briefing.

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-5
MODIFICATION
Pump Station
1. Position pump station in preparation for jacking/hoisting. Rig station for selected means of positioning
under left rear of the water tanker.
2. 2. Locate tank weld areas for pump station and pump station support brackets.
3. 3. Grind paint off applicable tank areas and components to be installed.
4. 4. Grind paint off pump station and pump station applicable weld areas. See drawing 048855 sheet 1 of 2
for reference dimensions.
5. Lift/hoist pump station into mounting position a. Reference drawing 048855 for location dimensions.
6. Tac weld station horizontal C-channels to lower tank skin.
7. Position station upper C-channel supports (items 4 and 8 on drawing 048855 sheet 1 of 2) to tear plates
(Item 1 on drawing 048855 (sheet 1 of 2), Center channel on plate and tac weld into position.
8. Position tear pad and channel assembly on horizontal pump station mounting channels (Item 5 on drawing
048855 sheet 1 of 2) and tac weld into place.
9. Locate discharge pipe elbow assembly on station to determine where to cut access into the rear of the
tank. Ensure proper gap and alignment is obtained between discharge elbow assembly and discharge pipe
on suction pump outlet, 0.5 inch or 13 mm is recommended between the outlet of the pump station and
the inlet of the elbow assembly.
10. Cut hole in rear bulkhead for discharge pipe.
11. Install Dresser coupling (Item 5 on drawing 04856 sheet 1 of 2) before welding discharge pipe to rear
bulkhead. If pipe is welded before coupling is installed the pump station must be lowered for installation of
coupling.

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-6
12. Tac weld discharge tube elbow assembly in place to rear tank bulkhead.
13. Assemble 2 piece storage tubes and weld out. Storage tubes were cut for shipping purposes. a. Assemble
and align for straightness, prepare tube sections for welding, weld sleeve to inserted tube section.
14. Mount storage tube brackets on the sump assembly (048855-01) and pump station (048855-02)
15. Test fit storage tubes on storage tube brackets. Check for fit and alignment.
16. Position storage tubes on brackets and weld out. Reference drawing 048862 for location dimensions.
17. Once satisfied with fit-up of the entire station, weld out.
18. Position and tighten Dresser coupling on suction loading station discharge pipe.
19. Position and weld hydraulic return manifold mounting plate to bottom skin of tank on the right side as
referenced to on drawing 048855 sheet 1 of 2, item 2.
20. Prepare recently welded areas for prime and paint.
21. Prime and paint newly welded areas.

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-7
Hydraulics
1. Remove all existing hydraulic hoses from lower water tank rear manifold to the discharge pump drive
motor
2. Mount hydraulic return manifold to mounting plate. Item 3 on drawing 048863 sheet 1 of 2.
3. Install diverter valve on pump station.
4. Install fully assembled hoses. Use drawing 048863 for hose references and locations.
5. Temporarily install partially assembled hoses with uncrimped ends.
6. Position and index uncrimped hose ends to match manifolds.
7. Mark uncrimped hose ends and remove hoses.
8. Crimp hose ends onto appropriate hoses.
9. Ensure O-rings are in place on fittings before installing.

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-8
10. Install and secure all hoses.
11. Service chassis hydraulic system.
Suction Hoses
1. Installfootvalveonsuctionhose.Useliquidpipesealantonpipethreads.
2. Stow hoses in the storage tubes.
CONFIGURATION OF CAB CONTROL SWITCH BOX FOR SUCTION LOADING STATION (DiSCS ONLY)
Every DiSCS Gen 1.5 system is given a specific 10 digit line code (found in the Installation Drawing Package)
that determines what options that specific tank has available. Existing can control systems must be configured
to work with the suction loading station.
Switch Installation
Remove the blank AUX2 cover switch and replace it with the supplied black on/off switch (Mega Part
No. 306968). The AUX2 switch is located in the second row of switches from the top, as shown below:
The following is the procedure for replacement of a switch in the Gen. 1.5 main switch box.
This procedure must be followed to reduce the potential for damage to the box and components contained in
the box. Failure to follow this procedure may result in component damage and spray system malfunction.
1. Secure unit. Ensure unit is safe for service.
2. Locate replacement switch (Mega Part No. 306968).
AUX2
Add Switch (Mega Part Number 306968)

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-9
3. Using a Phillips head screwdriver, remove the four (4) box cover screws. Lift off the cover.
4. Remove cover plate where the new switch will be installed.
5. Install replacement switch. Place switch in position and press firmly to seat switch on cover plate.
Reconnect switch to the circuit board.

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-10
DIP Switch Configuration
6. Before replacing the Master Switch Box cover, the Tank Configuration DIP Switches must be set for
compatibility with Suction Loading. Switches 3, 4, and 5 of the Master Board Tank Configuration DIP
Switches control the Pump Coil Voltage setting. If these switches are set incorrectly, the hoist valve
solenoid coil will fail, causing the hoist valve to not operate. Change the DIP switch configuration from C
to G as shown below. Switch 3 must be OFF, and Switches 4 and 5 must be ON.
7. Carefully place cover plate on the Master Switch Box. Ensure ribbon cable and other wiring is not pinched
under cover.
8. Install four (4) cover plate screws.
Correct DIP Switch Settings

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-11
WATER PUMP TUNING
1. Clean water pump shaft and install reflective
tape.
2. Ready a hand-held or install a photo tachometer
to sense water pump shaft speed.
3. Start up vehicle.
4. In order to commission the suction loading
station, normal operation procedures must be
followed to set up the suction loading station.
Follow the procedures outlined in “Operations” to
set up and activate the suction loading station.
5. Turn the Cab Control PUMP switch ON.
Engaging/disengaging the water pump above
LOW IDLE will result in water pump component
damage and reduced service life.
6. Operate vehicle at HIGH IDLE. Note water
pump RPM. Water pump RPM should be set to:
B3Z PUMP: 2,200 ± 50 RPM
Water pump RPM must not exceed the above
specifications 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.
7. If water pump RPM is to out of the specified
range, adjust the water pump hydraulic drive
motor flow control valve to obtain specified RPM.
Typically, the label on the knob refers to the
amount of oil being bypassed, not motor speed.
By turning the adjustment knob CLOCKWISE
(BLUE ARROW) the oil being bypassed is reduced,
increasing the speed of the pump. By turning the
adjustment knob COUNTER-CLOCKWISE (RED
ARROW) the oil being bypassed is increased,
reducing the speed of the water 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 will result in
serious personal injury.
The flow control valve can control as much as 35
gpm or about 700 RPM.


Flow Control
Adjustment Knob
To INCREASE Speed
To REDUCE Speed

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-12
8. Once specified RPM is obtained, tighten flow
control jam nut.
9. Follow normal After Operations procedures (In
the “Operations” section) to shut down the
Suction Loading Station.
10. Cab Control Pump Switch - OFF.
Engaging/disengaging the water pump above
LOW IDLE will result in water pump component
damage and reduced service life.
11. Cab Control SYSTEM/POWER Switch – OFF.
12. Shutdown vehicle.
13. Remove photo tachometer, hydraulic gauges,
and water pressure gauge.


PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-13
SCHEDULED MAINTENANCE INSPECTIONS
This section establishes scheduled maintenance inspections of the installed Suction Loading Station at the
designated frequencies. Performing these inspections will identify potential system discrepancies and allow
preventative maintenance to be performed before a component or system is rendered totally inoperative.
Systems operated in extremely low quality water environments may require more frequent inspections.
STEP
B4Z WATER PUMP, SUCTION LOADING 150HRS
(WEEKLY)
250HRS
(BI‐WEEKLY)
500HRS
(MONTHLY)
1,000HRS
(QUARTERLY)
5,000HRS
(ANNUALLY)
MANHOURS
PER
INSPECTION
TOTAL
ANNUAL
MANHOURS
1
CheckSuctionLoadingStationmounting
andframeforcracks,damageand
security.Repair,replaceoradjustas
required.
X0.3 15.6
2
Checkshaftsealsforexcessivelubricant
leakage.Lubricatewaterpumpwitha
manualgreasegunonly.Whenlubricating
thedrivemotorsideshaftbearingandthe
impellerendbearing,apply16to20
squirts(injections)ofgrease(2fl.oz.or60
cc)toeach.
Adjust,repairorreplaceasrequired.
X0.3 6
3
Checkwaterpumpanddrivemotorfor
leaks,excessivevibration/noiseleaksand
evidenceofexcessiveheating.Repairas
required.
X0.3 6
4
Checkshaftmechanicalsealforexcessive
waterleakageandoverheating.Replace
mechanicalsealandwearsleeveas
required.
X0.3 15.6
5
Checkwaterpumpinletanddischarge
pipingandcouplingsforsecurity,leakage,
anddamage.Repairasrequired. X0.2 2
6
Checksuctionloadingstoragetubes,hose
assemblies,checkvalvefoot,gaskets,
quickreleaseleversandclampsfor
security,damage,overallcondition.Repair
orreplaceasrequired.
X0.3 6
7
Checkdivertervalveforsmooth
operation,leaksandsecurity.Repairas
required. X0.2 2
8
Removeandinspectsuctionloading
stationinletcheckvalvefordamage,
functionandsecurity.Replaceasrequired. X1.5 6
59.2
Total

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-14
RECOMMENDED SUPPORT PARTS
In the table below is a listing of recommended support parts that should be made available in the supply
warehouse. Once parts are issued from warehouse stock, ensure that the depleted quantities are replenished in
order to keep the recommended support parts package at 100%.
Several support parts are designated as a "Quick Change Component" (QCC) and should be used to minimize
repair time of an operational Suction Loading Station. Broken assemblies can be repaired by maintenance
repair facilities and later returned to the supply warehouse as a serviceable part.
SUCTION LOADING STATION PARTS GROUP
PART DESCRIPTION PART NO. QTY
1. B4Z Suction Pump ** MTT Serial No. Specific Part (QCC) 302430 1
2. Mechanical Shaft Seal 302452 1
3. Shaft Kit 302485 1
4. Gasket, Clack Weight 300576 1
5. Clack Weight 300580 1
6. Clack Washer 300578 1
7. Bolt, Clack Weight 350143 1
8. Nut, Clack Weight 350025 1
9. Gasket, Outlet Flange 300582 1
10. Locknut, Impeller 302480 1
11. Gasket, Volute Case 300556 1
12. Slinger 300558 1
13. Wear Sleeve, Shaft 303952 1
14. Motor Coupling, Splined 301927 1
15. Impeller, 9 Inch 300575 1

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-15
ILLUSTRATED PARTS BREAKDOWN
47
Order Parts either by calling Parts Sales at 1-800-345-8889 or by going online @ www.megacorpinc.com
Mega Water Pumps
47
ITEM PART
NO. DESCRIPTION QTY
302430 %HUNHOH\%=:DWHU3XPS&:6SOLQHG6KDIW 1
1 302004 Bracket 1
2 302483 *Retainer Ring 1
3 302482 *Retaining Ring 1
4 302009 *Thrust Washer 1
5 302450 *Bearing, Drive Side 1
6 302453 *Bearing Cap, Drive Side 1
7 302446 *Oil Seal, Motor Side 1
8 302448 *Spacer Sleeve 1
9 300384 *Bearing, Ball 1
10 302006 *6KDIW6SOLQH 1
11 300379 *Washer, Lock, Impeller 1
12 300378 *Locknut 1
13 302447 **Oil Seal, Impeller Side 1
14 302451 *Bearing Cap, Impeller Side 1
15 300558 **Water Slinger 1
16 303952 *:HDU6OHHYH6KDIW 1
17 302484 *Retaining Ring 1
18 302480 Locknut, Impeller 1
19 350284 &6;LQFK 4
ITEM PART
NO. DESCRIPTION QTY
20 300581 Companion Flange 1
21 300582 Gasket, Companion Flange 1
22 300519 Fitting, Grease 2
23 350144 &DS6FUHZ;LQFK 8
24 302452 **0HFKDQLFDO6KDIW6HDO 1
25 300575 Impeller, 9 inch, CW 1
26 300556 Volute Case, B42 1
27 300385 Gasket, Case 1
28 350856 Plug, Pipe, 1 1/2 inch 2
29 350852 Plug, Pipe, 1/2 inch 1
30 350025 Nut, Hex 1
31 300580 Weight, Clack 1
32 300576 Check Value, Gasket 1
33 300578 Weight, Clack 1
34 350143 &6; 1
35 300579 Suction, Cover 1
36 350146 &6; 7
37 301927 †Coupling 1
38 302485 6KDIW.LW 1
%HUNHOH\VWDQGDUGRSHQFHQWULIXJDOZDWHUSXPSZLWKGLUHFWPRWRUPRXQW0HFKDQLFDOVKDIWVHDO
ȏ&ORFNZLVH5RWDWLRQȏΖQOHWLQFK137ȏ2XWOHWLQFK137ȏLQFKΖPSHOOHU
%HUNHOH\%=6HOI3ULPLQJ:DWHU3XPS
&:6SOLQHG6KDIW3DUW1R
$69Ζ(:(')520
+<'5$8/Ζ&02725
02817
12
6
93
C
l
o
c
k
w
i
s
e
R
o
t
a
t
i
o
n
342
7
6
5
8
9
13
30 31 32
33
34 35
11
12
10
14
15
16
17
18
21
19
20
26
36
23
22
24
25
27
1
28
29
ΖILOOXVWUDWLRQGRHVQRWPDWFK\RXUFRQȴJXUDWLRQSOHDVHFDOOSURGXFWVXSSRUWDW
RU
* 7KHVHSDUWVDUHLQFOXGHGLQWKHVKDIWNLW7KHVKDIWLVQRWVROGVHSDUDWHO\ 
 DQGLVRQO\VROGDVDVKDIWNLW
** *DVNHWDQGVHDOVUHTXLUHGIRUSXPSUHEXLOGDVVHPEO\
† Replacement parts only. Parts sold seperately and not included
 ZLWKWKHZDWHUSXPS
SHAFT KIT-302485
INCLUDES PARTS:
2-12,14,16,17
38
37 †301927

PIB-05
18 Feb 2015
PRODUCT INFORMATION BULLETIN
Suction Loading Station
1-16 (Blank)