MTT13-KOM465(7) -05 Scheduled/Special Inspections & Recommended Support Parts SPECIALTY HAULAGE SOLUTIONS FOR MINING AND CONSTRUCTION MEGA CORP. 700 Osuna Rd. N.E. Albuquerque, NM 87113 1-800-345-8889 505-345-2661 Fax 505-345-6190 www.megacorpinc.com 2011 MEGA Corp., Inc. All Rights Reserved
TABLE OF CONTENTS MTT13-KOM465(7)-5 Section 1. Definitions and Abbreviations Page A. Warning, Caution and Note..... 3 B. Shall, Will and May........ 3 C. Abbreviations....... 3 Section 2. Scheduled Inspections A. Spray Heads..... 5 B. Water Pump System........ 5 C. Control System 6 D. MTT Structure.. 6 Section 3. Special Inspections A. Foam Suppression System.. 7 B. Storage/Winterization. 7 Section 4. Recommended Support Parts A. Spray Head Parts Group... 9 B. Control System Parts Group.. 9 C. Water Pump Parts Group... 10 D. Water Pump Driver Motor Part Group. 10 E. Monitor Parts Group 10 F. Miscellaneous Part Group 11 1
MTT13-KOM465(7)-5 TABLE OF CONTENTS 2(Blank)
SECTION 1 Definitions and Abbreviations MTT13-KOM465(7)-5 WARNINGS, CAUTIONS AND NOTES The following definitions are found throughout the manual and apply as follows: USE OF SHALL, WILL AND MAY Shall and Will Used when application of a procedure is mandatory. WARNING Operating procedures and techniques, which could result in personal injury and/or loss of life if not carefully followed. Should Used when application of a procedure is recommended. May - Used to indicate an acceptable or suggested means of accomplishment. ABBRIVIATIONS CAUTION Operating procedures and techniques, which could result in damage to equipment if not carefully followed. NOTE Operating procedures and techniques that are considered essential to emphasis. BFV- Butterfly Valve CW - Clockwise CCW Counterclockwise e.g. example given FPM Feet Per Minute FT - Feet GPM Gallons Per Minute HRS - Hours MTT MEGA Truck Tank PSI - Pounds Square Inch 3
MTT13-KOM465(7)-5 SECTION 1 Definitions and Abbreviations 1 3 3 REAR VIEW 2 1 WATER PUMP& HYDRAULIC MOTOR 2 HOSE REEL 3 SPRAY HEADS `` 5 4 5 CAB CONTROL HAND RAIL & WALKWAY 6 6 MONITOR 4 SIDE VIEW 4
SECTION 2 Scheduled Inspections MTT13-KOM465(7)-5 This section establishes scheduled maintenance inspections of the installed MTT 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. ** NOTE: Vehicles operated in extremely low quality water environments may require more frequent inspections. STEP 1 2 SPRAYHEADS Check spray head for damage and clean deflector ring and spray head opening. Check hydraulic lines for security, damage and leaks. WEEKLY (150 HRS) BI WEEKLY (250 HRS) FREQUENCY MONTHLY (500 HRS) QUARTERLY (1500 HRS) SEMI ANNUAL (2500 HRS) ANNUALLY (5000 HRS) 3 Check spray head drop in assembly for leaks with spray head switch OFF and water pump ON. Replace drop in assembly as required. 4 5 Check spray head base plate and upper housing mount bolts for security. Check spray head adjustable deflector ring for damage and correct adjustment. Apply dry film lubricant to the deflector inner ring. 6 STEP 1 Check spray head base plate for evidence of leaks. Replace base plate O ring as required. WATER PUMP SYSTEM Check water pump and drive motor for leaks, excessive vibration/noise and evidence of excessive heating. 2 3 4 Check rope seals for excessive water leakage. Adjust rope seal packing gland as required. Check shaft seals for excessive leakage. Lubricate water pump with a manual grease gun. When lubricating the shaft seal only apply 2 squirts (injections) of grease. Check water pump inlet and discharge piping for security, leakage and misalignment. Repair leaks as required. 5 Check water pump impeller for security and damage. 5
MTT13-KOM465(7)-5 SECTION 2 Scheduled Inspections STEP 1 2 CONTROL SYSTEM Check all electrical cables for security and damage. Clean Deutsch connectors as required. Check all hydraulic solenoids and hosing for security and leaks. WEEKLY (150 HRS) BI WEEKLY (250 HRS) FREQUENCY MONTHLY (500 HRS) Check monitor/nozzle assembly for security 3 leaks and condition. Repair as required. Check foam agent supply hoses and shut off valve for security condition and evidence of 4 suction leaks. Check all in cab control functions for proper operation. Repair and replace control 5 components as required. Check all in cab control functions for proper operation. Repair and replace control 6 components as required. 7 Check hose reel for security mounting and leaks. Unreel the entire length of hose, pressurize hose and check hose and nozzle for security, wear and 8 leaks. QUARTERLY (1500 HRS) SEMI ANNUAL (2500 HRS) ANNUALLY (5000 HRS) STEP 1 MTT STRUCTURE Check filler port trash screen for debris and inspect assembly for security and damage. Repair or replace trash screen as required. 2 3 4 5 Visually inspection tank exterior for damage and evidence of leaks. Repair as required Drain tank and remove water pump sump access cover. Remove trash and inspect sump area for damage. Check all lights (turn signal, brake, backing, parking, clearance and work) for proper operation. Replace bulbs as required. Check all interior tank structure for leaks, cracks and condition of epoxy coating (if equipped). Repair structure and coatings as required. 6
SECTION 3 Special Inspections MTT13-KOM465(7)-5 This section contains special inspection requirements for a specific system after use, an unusual event or storage. FOAM SUPPRESSION SYSTEM After Use 1. Flush foam concentrate supply hose, monitor and nozzle with fresh water. 2. Inspect foam concentrate hose for signs of collapsing, kinks, wear or leaks. 3. Wash down all MTT and vehicle surfaces that were exposed to the foam or foam concentrate. STORAGE/WINTERIZATION Entering 1. Remove any exterior dirt, grease and grime that may trap moisture. 2. Flush all water suction and discharge lines (e.g. water pump, spray heads, monitor, dump bar and hose reel). 3. Ensure all water is drained from the MTT. 4. (If equipped) Fully extend hose reel and ensure nozzle and hose are fully drained of water. 5. Remove lowest drain plugs on the water pump and the MTT. Ensure all suction and discharge lines are drained. 6. (If equipped) Inspect MTT interior epoxy coating for wear. 7. Prime and paint any exposed metal. 8. Seal all fill and discharge openings to keep foreign matter out (e.g. dirt, dust, insects, rodents and water). 9. Lubricate the water pump and any other MTT component that require grease. 10. Service all vehicle systems per Komatsu 465-7 users manual. 11. If possible, shelter the pump assembly from the elements. 12. Check to ensure all MTT solenoid and junction boxes are closed and secure. 13. If possible, shelter entire vehicle from the elements. Removing 1. Remove all covers and seals from all MTT fill/discharge openings and components. 2. Inspect interior of the tank for any foreign matter and condition of epoxy coating (if equipped). 3. Check to ensure all water pump and MTT drain plugs are installed. 4. Remove any exterior dirt, grease and grime and treat any corrosion. 5. Service all vehicle systems per Komatsu 465-7 users manual. 6. Fill MTT with water and inspect the systems for leaks. 7. (If equipped) Perform a functional check of the hose reel. 8. Perform a full functional check of all MTT cab controls systems. 7
MTT13-KOM465(7)-5 SECTION 3 Special Inspections 8(Blank)
SECTION 4 Recommended Support Parts MTT13-KOM465(7)-5 This section contains a listing of recommended support parts that should be on-hand in the warehouse for immediate issue if required. Having the recommended parts on-hand will provide for minimal down time when bringing the MTT back to operational status as well as rebuilding hot-swap parts. Once parts are issued from warehouse stock ensure depleted quantities are replenished to keep the recommended support parts package at 100%. The tables are categorized by specific sub system of the MTT. DO NOT FORGET that all MTT13s are not configured the same and there are several variations in water pumps, hydraulic drive motors and monitors due to changes in equipment and actual production dates. Ensure MTT serial numbers and actual component part numbers are checked before ordering any parts. A. SRAY HEAD PARTS GROUP PART DESCRIPTION PART NO. QTY 1. Spray Head (Hot Swap) 025610 2 2. Spray Head Drop-in Assembly 300409 6 3. Cylinder, Hydraulic 304744 2 4. Spray Head Diaphragm 300208 18 5. Guide Disk, Lower 300209 2 6. Guide Disk, Upper 300210 2 7. Stem Bolt 300211 2 8. O-Ring, Stem Bolt 300215 4 9. Stem Nut 300214 2 10. Bell Washer 300212 2 11. Spray Head Spring 300213 6 12. Cap Screw, SS, Housing 355335 16 13. Washer, Lock, SS, Housing 355337 16 14. Washer, Flat, SS, Housing 355336 16 15. Spray Head Deflector Ring 300216 6 16. Spray Head Deflector Ring Knob 302912 6 17. O-Ring, Base 354502 16 B. CONTROL SYSTEM PARTS GROUP PART DESCRIPTION PART NO. QTY 1. Joystick, Universal (Cab Control) 303041 1 2. Timer, Intermittent (Cab Control) 304751 1 3. Switch, SPST, Green Lens (Cab Control) 305019 1 4. Switch, SPST, White Lens (Cab Control) 305020 1 5. Switch, DPDT, No Lens (Cab Control) 305021 2 6. Sensor, Water Level ** Serial No. Specific Part 303822 1 7. Solenoid Valve, Hydraulic (Solenoid Box) 302118 2 9
MTT13-KOM465(7)-5 SECTION 4 Recommended Support Parts C. WATER PUMP PARTS GROUP PART DESCRIPTION PART NO. QTY 1. MEGA M-4 (Hot Swap) ** Serial No. Specific Part 304991 1 2. Ring Packing, Shaft Seal 305114 3 3. Shaft Kit 305095 1 4. Seal, Grease 304960 1 5. Ring, Snap 305103 1 6. Ring, Thrust 305104 1 7. Key, Impeller 305106 2 8. Coupling 305102 1 9. Screw, Set 305107 2 10. Seal, O-ring, Volute 305111 1 11. Wear Ring, Frame 305091 1 12. Wear Ring, Volute 305092 1 13. Washer, Impeller 305093 1 14. Bolt, Impeller 305109 1 15. Washer, Lock, Impeller 305110 1 16. Packing Gland, Set 305098 1 17. Slinger 305100 1 18. Stud, Packing Gland 305105 2 19. Nut, Packing Gland 350026 4 20. Ring, Lantern 305112 1 D. WATER PUMP DRIVE MOTOR PARTS GROUP PART DESCRIPTION PART NO. QTY 1. Motor, Drive, Hydraulic (M75 27-7) ** Serial No. Specific Part 302079 1 2. Seal Kit, (M75) 300944 1 3. Flow Control Valve 300161 1 E. MONITOR SUPPORT PARTS GROUP PART DESCRIPTION PART NO. QTY 1. Joint Rebuild Kit 305141 1 2. Electric Monitor (If Equipped) a. Motor, Electric 304618 1 3. Hydraulic Monitor (If Equipped) a. Motor, Hydraulic 304656 1 b. Solenoid Valve (Monitor Control Valve Assembly) 304858 1 c. Solenoid Coil (Monitor Control Valve Assembly) 304859 2 10
SECTION 4 Recommended Support Parts MTT13-KOM465(7)-5 F. MISCELLANEOUS PARTS GROUP PART DESCRIPTION PART NO. QTY 1. Valve, Butterfly, 3 300030 1 2. Valve, Gate, 1.5 (Spray Bar) 300106 1 3. Valve, 3/4" Ball (Spray Bar) 300627 2 4. Seal, Coupling, 4 Dresser 300820 2 5. O-Ring, #24 (Split Flange) 354816 20 11
MTT13-KOM465(7)-5 SECTION 4 Recommended Support Parts. NOTES 12