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M4B (306200/306201)-2

12 Sept 2013

M4B
M4B
(306200 Standard Casting)
(306201 Corrosion Resistant)
Service, Repair and Adjustment
M4B (306200/306201)-2
12 Sept 2013
M4B (306200/306201)-2
12 Sept 2013

TABLE OF CONTENTS

Page

Section 1. Definitions and Abbreviations 1-1

Section 2. M4B Water Pump 2-1

Section 3. Functional checks and RPM adjustment . 3-1

Section 4. Recommended Spare Parts . 4-1

A
M4B (306200/306201)-2
12 Sept 2013

B(Blank)
M4B (306200/306201)-2
12 Sept 2013
SECTION 1
Definitions and Abbreviations

Contents
Warning, Cautions & Notes ..... 1-1 Safety Messages .............. 1-1
Shall, Will, Should and May ... 1-1 Abbreviations ...... 1-5

MANUAL USAGE WARNING, CAUTION AND NOTES


This technical manual only contains information The following definitions are found throughout
required to safely install or Service an MTT. See the manual and apply as follows:
the appropriate Maintenance and Operators
Safety Manual for specific vehicle system
information and maintenance procedures. The
exact location of the hazards and description of Operating procedures and techniques, which
the hazards are reviewed in this section. All could result in personal injury and/or loss of life
personnel working on or operating the MTT if not carefully followed.
must become familiarized with all the safety
messages.

If your system is not covered in this manual


please contact MEGA Corp. Product Support Operating procedures and techniques, which
Group at: could result in damage to equipment if not
US toll free: 1-800-345-8889 carefully followed.
Direct: 1-505-345-2661 or visit our website at
www.megacorpinc.com for more detailed
contact information.
Operating procedures and techniques that are
See the proper manufacture specific Operation & considered essential to emphasize.
Maintenance, Safety Manuals and Service
Manuals for detailed chassis specific system
information and chassis specific maintenance USE OF SHALL, WILL, SHOULD AND
procedures. MAY

Shall and Will Used when application of a


procedure is mandatory.
Due to the nature of these processes, ensure that
all safety information, warnings and instructions Should Used when application of a procedure
are read and understood before any operation or is recommended.
any maintenance procedures are performed.
Some procedures take place with heavy May - Used to indicate an acceptable or
components and at moderate heights, ensure suggested means of accomplishment.
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.

1-1
M4B (306200/306201)-2
12 Sept 2013
SECTION 1
Definitions and Abbreviations

SAFETY MESSAGES Toxic Gas Hazard (1)


There are several specific safety messages on This safety label is located on the side of the tank
this machine. The exact location of the hazards and at all water fill entrances.
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 Cutting or welding operation on the inside of
clean the safety messages. Solvents, gasoline or the tank can cause the accumulation of toxic
harsh chemicals could loosen the adhesive that gases. Read and understand instructions and
secures the safety messages. Loose adhesive warnings in the Maintenance Manual.
will allow the safety messages to detach. Failure to provide proper ventilation or
breathing apparatus while conducting these
Replace any safety message that is damaged or operations may result in serious injury or
missing. If a safety message is attached to a part death.
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.

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SECTION 1
Definitions and Abbreviations
Backing Runover Hazard (3) Non-Potable (5)
This safety label is located on the rear of the tank This safety label is located on the side of the tank
and inside the cab. and sump drain.

The vehicle is equipped with a back-up alarm. Water held within tank is not potable. Do not
Alarm must sound when operating this use tank for transport of water intended for
vehicle in reverse. Failure to maintain a clear human or animal consumption or serious
view in the direction of travel could result in injury or death may result.
serious injury or death.

Freezing (4) Do Not Hoist While in Motion (6)


This safety label is located on the side of the This safety label is located inside the cab.
tank, at the sump drain, and on the pump.

Do not engage hoist cylinders while vehicle is


Drain tank, fill pipe and valve in freezing in motion. Before engaging hoist STOP the
weather. Refer to the Operator and vehicle. Do not engage hoisting cylinders
Maintenance Manual for the procedure to unless you read and understand the
follow. instructions and warnings in the Operator or
Maintenance Manual. Failure to follow
instructions or heed the warnings will result
in injury or death.

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SECTION 1
Definitions and Abbreviations
Fall Hazard (7) High Pressure Sprayheads (9)
This safety label is located at the top of the front This safety label is located on the spraybar.
and rear of the tank.

Do not operate sprayheads until all personnel


are a safe distance away from the vehicle.
Do not walk on the top of tank without fall
arrest PPE. Serious injury or death could
occur from a fall.

Rotating Shaft (8) High Pressure Monitor (10)


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

Do not place your hand or tools within pump


bell while pump is rotating and/or pressure Do not operate the monitor until all personnel
held within the motor supply hose. Refer to are a safe distance away from the vehicle.
the Operator and Maintenance Manual for
the procedures to operate and maintain the
pump. Failure to follow proper procedures
could result in serious injury.

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SECTION 1
Definitions and Abbreviations
High Pressure Motor (11) ABBREVIATIONS
This safety label is located on the hydraulic
motor. 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
Hydraulic motor and supply lines contain oil lpm Liters per minute
under high pressure. Improper removal and LT Left as viewed from the operators position
repair procedures could cause severe injury. facing forward
To remove or repair, instructions in the m - meters
Maintenance Manual must be followed. MPH Miles Per Hour
MTT Mega Truck Tank
nm Newton meters of torque
psi - pounds per square inch
Confined Space (12) RPM Revolutions Per Minute
This safety label is located near water tank RT Right as viewed from the operators
access and fill ports. position facing forward
SQ FT Square Feet
VDC Volts, Direct Current

Do not enter confined spaces without


following established site specific procedures.
Failure to follow proper safety procedures
will result in serious injury or death.

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SECTION 1
Definitions and Abbreviations

1-6(Blank)
M4B (306200/306201)-2
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SECTION 2
M4B Water Pump

Contents
Description 2-1 Hydraulic Drive Motor . 2-7
Inspection .. 2-2 Crossover Assembly 2-8
Water Pump Repair And Disassembly . 2-2

DESCRIPTION 2. Volute Case A snail shell shaped case


The water pump assembly is comprised of a that encloses the impeller. It is narrow at the
hydraulic drive motor, water pump and a cross- center and enlarges from there to the
over assembly. The water pump assembly uses discharge area.
vehicle hydraulic oil flow to turn the hydraulic 3. Wear Ring (Contains 2) Acts as bearing
drive motor which is directly coupled to the surfaces between the impeller and volute
water pump. Water pump speed is controlled by case as well as the impeller and the seal plate
adjusting the cross-over assembly which routes (seal mount). Constructed of stainless steel
excess oil flow from the inlet port (pressure) of material.
the hydraulic drive motor to the return oil hose 4. Impeller Rotating wheel attached to the
for the hydraulic drive motor. shaft that accelerates the speed of the water
producing water flow and pressure.
5. Seal plate (Seal Mount) Mounts to the
M4B WATER PUMP
pump bracket and faces the impeller.
Reduces dynamic impeller vibrations and is
used to hold the Volute seal and shaft seals.
6. Packing Rings 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 and cooling.
7. Upper/Lower Bearings - Provide roller
bearing surface for the pump shaft.

An open centrifugal type water pump mounted to


the water tank supplies water pressure and flow
for tank mounted spray heads, monitor, dump 6
bar, and hose reel. The water pump shaft is
driven clockwise (CW) by a hydraulic motor
mounted to the water pump bracket.
1
Water pump major components and their 5
function are: 3
1. Bracket (Bearing Frame) Main frame of 4
the pump that allows a pump to be bolted to 3
the tanker and provides the means to direct 2
mount the hydraulic drive motor.

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SECTION 2
M4B Water Pump

INSPECTION QUARTERLY (500 - 1000 hours)

DAILY 1. Perform all MONTHLY inspections.

1. Check for excessive vibration and noise. 2. Manually lubricate water pump bearings.
Add approximately 5.5 ounces (150 cc) of
2. Check pump bracket for excessive heat. grease to drive end bearing and 2.5 ounces
(75 cc) of grease to the impeller end bearing
3. Inspect for hydraulic leaks. grease fittings.

4. Inspect assembly for damage and security.


Do not over lubricate bearings. Over
5. Inspect shaft seal for excessive water lubricating bearing will cause bearings to run
leakage. hot and overheat causing bearing, shaft and
a. Rope Packing Seal approximately 60 to pump failure.
120 drops per minute. Water must not be
steaming or spraying out of seal area.
Adjust or replace as required. Grease requirements: Lithium-based NGLI
No 2 Extra Pressure Ball Bearing Grease is
required. The following are factory approved
Over tightening of the packing gland will brands of grease for the M4B water pump:
cause premature failure of the rope Alvania EP2 (Shell Oil), Mobilith AW2
packing seal. (Mobile Oil) , Ronex MP (Exxon), Litholine
EP2 (Atlantic Richfield) and Amolith EP2
b. Mechanical Seal Mechanical seals (Amoco).
should not leak water, if leaking is Two (2) Grease Fittings
present, replace seal assembly.

MONTHLY (200-250 hours)

1. Perform all DAILY inspections.

2. Inspect water piping, couplings and gaskets


for leakage, damage and misalignment.

The M4B water pump can be lubricated by


the chassis Auto-Lube system by attaching
the grease lines from 2 injectors to the grease
fitting ports on the pump frame.

3. Inspect all pump mounting bolts for security.


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SECTION 2
M4B Water Pump

REPAIR 6. Tighten gland nuts evenly until leakage is


reduced to 60 to 120 drops per minute.
ROPE SEAL REPLACEMENT AND
ADJUSTMENT
Water should not be streaming or
spraying from seal area, inspection,
This procedure can be done without removing adjustment or replacement will be required if
water pump from tank and is considered routine these conditions exist.
maintenance
1. Ensure water tank is empty.

2. Remove packing gland. WATER PUMP REMOVAL

3. Remove old rope seals. 1. Ensure water tank is empty.

2. Remove all electrical/hydraulic power and


make the vehicle safe for maintenance.

3. Remove hydraulic motor and associated


hydraulic lines.

Ensure all open hydraulic lines are capped to


prevent hydraulic system contamination.
Packing Mount Removed From Pump For Clarity

4. Install one rope seal at a time while indexing


the seal gaps 180 degrees from each other.
Some water pump installations allow the
5. Install packing gland and hand tighten nuts hydraulic motor to be detached without
evenly, fill unit with water, operate water removing associated hydraulic lines.
pump and allow packing to liberally leak for
a few moments. 4. Remove system piping from the discharge
port of the volute case.

5. Remove water pump to sump mount bolts


Operating the water pump in a dry sump will
result in shaft seal damage. 6. Remove frame mounting bolts and remove
water pump.

Additional components may be required to


be removed depending on tank configuration.

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SECTION 2
M4B Water Pump
WATER PUMP DISASSEMBLY AND 4. Inspect the volute case for the following:
INSPECTION a. Case for cracks, corrosion, wear and
excessive pitting.
Volute Case b. Wear ring for scoring and condition.
c. Inspect threaded bolt holes and sealing
surfaces for damage, condition, cracks
and corrosion.

Impeller

1. Remove volute case mounting bolts and


separate volute case from pump bracket.

2. Use jack bolt (2) holes to unseat volute case


from frame.

1. Hold impeller stationary and remove impeller


mount bolt, impeller washer, lock washer and
O-ring.

2. Hold shaft stationary and turn impeller


Clockwise to remove impeller from the
shaft.

Use existing Volute case retaining TO REMOVE

bolts for jack bolts as shown

3. Inspect and clean O-ring groove in volute


case.

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SECTION 2
M4B Water Pump
3. Inspect impeller for the following: 5. Inspect the seal plate as follows:
a. Impeller face for cracks, corrosion and a. Seal plate for cracks, corrosion, scoring
condition. and condition.
b. Impeller edge for damage, cracks and b. Wear ring for damage and condition.
condition. c. Packing gland studs and nuts for damage
c. Inspect bolt, washers, O-ring and threads and condition.
for damage and condition. d. Packing seal bore for damage and
d. Inspect seal mount wear ring and rear condition.
surface of impeller for damage and e. Volute O-Ring sealing surface for
condition. damage and condition.
e. Inspect impeller shaft threads for damage
and condition. Packing Assembly

Seal Plate Packing


Gland

1. Remove seal plate mount bolts (2).


Rope Packings Metallic Seal Plate
Ring
1. Remove packing gland nuts and remove
packing gland.

2. Remove packing rings.

3. Remove Metallic ring.


2. Remove the existing 2 plate retaining
bolts and install longer -20 bolts and 4. Inspect the assembly for the following:
thread into seal plate (approximately 4 long a. Packing gland for cracks, corrosion and
bolts). condition.
b. Packing rings for wear, damage and signs
3. Using a soft face mallet, strike each bolt until of overheating.
seal plate is free from pump frame. c. Metallic ring for wear, damage and signs
of overheating.
4. Remove bolts from seal plate. d. Wear sleeve for wear, damage, corrosion
and signs of overheating.

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SECTION 2
M4B Water Pump
Shaft & Bearing Assembly 4. Disassemble shaft assembly as follows:
a. Remove snap ring and thrust ring from
drive end of shaft.

1. Remove drive coupling from shaft.

2. Remove drive motor mount from frame.

Snap Ring and Thrust Washer

b. Remove drive end bearing.


c. Remove impeller end bearing.

5. Inspect shaft and bearing assembly for the


following:
a. Shaft for cracks, condition and any signs
of overheating.
b. Bearings for damage, condition, freedom
3. With a soft face mallet drive shaft and of rotation, excessive play and any signs
bearing assembly out of the frame towards of overheating, water infiltration or lack
the drive end. of lubrication.
c. Wear sleeve for damage, scoring,
corrosion, signs of overheating and wear.
d. Impeller threads for damage, condition
and wear.
e. Drive end splines for damage, cracking,
condition and wear.

6. Inspect frame for damage, condition, cracks,


corrosion, signs of overheating and wear.

7. Inspect drive motor mount for damage,


cracks, condition and signs of overheating.

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SECTION 2
M4B Water Pump

WATER PUMP REASSEMBLY Install thrust ring and snap ring to retain drive
end bearing.
Shaft Assembly
Snap Ring
1. Ensure frame, shaft and bearings are clean
and free of debris.

2. Dress shaft with fine emery cloth and wipe


clean.

3. Slip new wear sleeve onto shaft for trial fit


(sleeve should slip onto shaft smoothly)
remove sleeve. Thrust Ring
4. Apply Loctite 277 to inside of sleeve.
Shaft Installation

1. Install impeller end frame seal. This seal is


installed lip side towards the inside of the
frame. Ensure seal is flush with outside of
frame casting. Liberally lubricate seal lip
with grease.

5. Install sleeve onto shaft, wipe away excess


Loctite.

6. Pack bearings with a lithium based grease


NLGI No. 2 Extra Pressure ball bearing
grease. Ensure the bearing cage and bearings
are lubricated prior to installing shaft into
frame.

7. Press bearings onto shaft.

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SECTION 2
M4B Water Pump
2. Install motor mount seal. This seal is 8. Manually lubricate water pump bearings with
installed with the lip facing away from the lithium based grease NLGI No. 2 Extra
frame. Ensure seal lip direction is correct Pressure ball bearing grease; 5.5 fl oz (150
and ensure seal is flush with the motor mount cc) of grease to the drive end bearing and 2.5
casting. Liberally lubricate seal lip with fl oz (75 cc) of grease to the impeller end
grease. bearing.

Approved grease for the M4B pump:

Alvania EP2, (Shell Oil), Mobilith AW2


(Mobile Oil), Ronex MP (Exxon), Litholine
EP2 (Atlantic Richfield), Amolith EP2
(Amoco).

Manually grease water pump bearings, do


not use an auto lube device or power grease
gun. Using an auto lube or power grease gun
will result in over lubrication or excessive
pressure causing bearing, seal, shaft and
3. Coat inside of bearing bores with grease to water pump damage or failure.
ease installation of shaft assembly.

4. Insert shaft assembly into frame from the The M4B pump is equipped with a frame
drive end. Carefully slide shaft through the vent hole in the bottom of the frame. This
impeller end seal, using caution not to port is used to vent excess pressure and
damage or invert seal lip. grease from frame. Do not plug this hole.

Use caution to install shaft through the


impeller end seal. Damaging or inverting
seal lip will result in bearing and water pump
failure.

5. Using a soft face mallet, drive shaft into


frame until fully seated.

6. Apply Loctite 277 to threads of motor


mount bolts.

7. Install motor mount and torque bolts to 50


ft/lbs (68 nm). Use caution when installing
mount to not damage seal lip.

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SECTION 2
M4B Water Pump
Seal Plate Installation 4. Install one rope seal at a time while indexing
the seal gaps 180 degrees from each other.

1. Install rope seal packing in seal plate as


follows.

2. Ensure seal plate is clean and in good


condition.

3. Install metallic ring in seal bore.


Seal Split

5. Install packing gland and hand tighten nuts


evenly.

Seal Split

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SECTION 2
M4B Water Pump
6. Install slinger onto shaft. 9. Line up jack bolt holes in frame and seal
plate.
Slinger

7. Apply Anti-Seize to seal plate mounting


surface on frame.
Use Bolt to Line Up Jack Bolt Holes

10. Evenly, gently tap plate with a soft face


mallet until it seats on frame.

11. When seated remove line up bolts and install


seal plate retaining bolts.

8. Install seal plate to end of frame.

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SECTION 2
M4B Water Pump
Impeller Installation 3. Thread impeller onto shaft.

4. Hold shaft in place and tighten impeller


Counter Clockwise until tight.

1. Liberally apply grease to balance ring


bushing on seal plate. To Tighten

M4B water pumps have LEFT Hand threads


for the impeller.

5. Stack lock washer, impeller washer and O-


2. Apply Anti-Seize to impeller threads. Ring on retaining bolt.

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SECTION 2
M4B Water Pump
6. Apply Loctite 277 to retaining bolt and 2. Install volute case O-Ring seal to seal plate.
lubricate O-Ring with a light coat of grease. Coat liberally with grease.

Volute Case O-Ring

3. Install volute case on pump frame. Ensure


7. Install impeller retaining bolt and torque to volute outlet is in the orientation required for
50 ft/lbs (68 nm). installation.

4. Apply Loctite 277 to volute case bolt


threads.

Volute Case Installation


1. Liberally apply grease to the wear surface on
the inlet of impeller.
5. Torque volute case bolts to 100 ft/lbs (135
nm).

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SECTION 2
M4B Water Pump
WATER PUMP INSTALLATION 9. Allow new water pump rope seal to leak
liberally for several minutes before adjusting
1. Remove old gasket material from mounting rope packing seal to allow 60 to 120 drops of
flanges. water leakage per minute. See rope seal
replacement and adjustment procedure.
2. Locate water pump on inlet flange with the
required gaskets. Tighten inlet flange and
pump mount bolts.

3. Remove old gasket material from water pipe


discharge pipe.

4. Install discharge pipe gasket and mount


bolts. Tighten all mounting hardware.

5. Inspect shaft coupling for damage and


replace if required.

6. Install hydraulic drive motor and associated


hosing. Tighten all mounting bolts.

7. Fill tank with water.

Ensure the tank is filled with sufficient water


to perform operational test. Maximum
capacity is recommended. Operating the
water pump in a dry sump will result in shaft
seal damage.

Ensure volute is full of water before water


pump is activated. Failure to ensure water
has flooded the volute will result in seal
damage or failure.

8. Perform operational checks and verify water


pump rpms. If water pump rpms are higher
than recommended, adjust rpms to
specifications before releasing unit to work.

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SECTION 2
M4B Water Pump

HYDRAULIC DRIVE MOTOR Drive Motor Removal


1. Ensure vehicle hydraulic system is not in
operation.

2. Disconnect manifold assembly and cover


open ports.

3. Remove drive motor mount bolts.

Drive Motor Installation


1. Inspect water pump to drive motor coupling
A gear-type hydraulic motor mounted to the for wear and replace if required.
water pump bracket. The hydraulic motor
receives hydraulic pressure from the vehicle 2. Mate drive motor shaft to water pump
hydraulic system at 1800-3400 PSI (12,500- coupling.
23,500 kpa) and flow rates up 120 GPM (450
lpm) to operate. The hydraulic motor is coupled 3. Install and secure drive motor mount bolts.
directly to the water pump shaft and rotates in a
clockwise (CW) direction. The drive motor 4. Attach manifold assemblies and secure
speed is controlled by the cross-over assembly. mount bolts.

INSPECTION 5. Pressurize hydraulic system and check for


1. Inspect drive motor for security, leaks and leaks as well as component operation.
overheating.

2. Inspect hydraulic manifolds, hoses, flanges


and fittings for security and leaks.

REPAIR
Manifold Seal Replacement
1. Ensure vehicle hydraulic system is not in
operation.

2. Ensure all safety policies and procedures are


followed prior to servicing equipment.

3. Disconnect manifold assembly.

4. Replace manifold o-ring and reinstall


manifold assembly.

5. Pressurize hydraulic system and check for


leaks as well as component operation.

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SECTION 2
M4B Water Pump

CROSS-OVER ASSEMBLY By turning 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.

Metered Flow

A flow control valve, adapters and hose attached To INCREASE SPEED


to the pressure and return manifolds of the
hydraulic drive motor. The flow control is
adjusted to bypass oil flow from the pressure
side and route oil into the return manifold. The
assembly can control as much as 35 GPM (135
lpm) or about 700 RPM.

To REDUCE SPEED

Typically, the label on the knob refers to the


amount of oil being bypassed, not motor speed.
E.g; Increase oil bypass Slower motor speed,
Decrease oil bypass Faster motor speed.

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SECTION 2
M4B Water Pump

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M4B (306200/306201)-2
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SECTION 3
Functional Check and RPM Adjustment

FUNCTIONAL CHECK AND RPM 5. Adjust all spray head adjustment rings to
ADJUSTMENT full flow and maximum pattern width to
allow free flow of potential contaminants
during testing.
These procedures are designed to perform
dynamic checks of the water pump system
6. Open spray bar drain valve to purge air
and perform RPM adjustments as required.
from water pump volute case and spray bar.
This process also provides information in
troubleshooting water pump systems. It is
7. Ensure all cab control switches are in the
recommended that if any component
OFF position.
replacement to hydraulic system or water
pump assembly is done that an RPM
ELECTRICAL POWER ON AND ENGINE
adjustment is preformed prior to the release
OFF
of the machine to work.
1. Ensure vehicle battery power is connected.

2. Ensure vehicle is safe to start.


Ensure MTT and truck is configured for
water truck application before proceeding
3. Ensure all cab control switches are in the
with this test. Damage to chassis and tank
OFF position.
may result.
4. Turn vehicle key switch ON (engine off).
1. Install hydraulic test gauges on the
Ensure the vehicle cycles through
hydraulic motor quick disconnect test ports.
recommended ECM functions per chassis
specific Operators Manual and all warning
2. Install water pressure gauge on the spray bar
and advisory lights extinguish.
assembly ball or gate valve.
ELECTRICAL POWER ON AND ENGINE
3. Fill water tank with a sufficient amount of
ON
water to perform water pump RPM
adjustment and functional check of all water
1. Ensure the area around the vehicle is well
spray systems to include the monitor (if
clear and ample space is available to operate
equipped).
spray heads and monitor.

Operating the water pump in a dry sump


Use caution when performing this test.
will result in shaft seal damage.
Water may be discharged from any of the
available openings when performing this
4. Once tank is full, check pump couplings for
test function.
static leaks.
2. Ensure wheels are chocked, parking brake is
set and vehicle is safe to operate and all
other safety policies are followed.

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M4B (306200/306201)-2
12 Sept 2013
SECTION 3
Functional Check and RPM Adjustment
3. Start up the vehicle and ensure all required 11. Increase engine RPM to normal operating
warning and advisory lights extinguish per range and check all installed water pump
chassis specific Operators Manual. components and hoses for leaks.

4. While the vehicle is running inspect all 12. Note hydraulic pressure and return readings
installed water pump hydraulic components as well as water pump pressure at about
and hoses for leaks. 2,100 engine RPM on work sheet provided
in the rear of this tech manual.
5. Ensure all spray heads, dump bar, drain
valve, monitor and foam switches are in the 13. Reduce engine speed to LOW IDLE.
OFF position.
14. Turn water PUMP switch OFF.
6. Turn SYSTEM switch ON.

7. Turn water PUMP switch ON.


Engaging/disengaging the water pump
above LOW IDLE may result in water pump
component damage and reduced Service
Engaging/disengaging the water pump life.
above LOW IDLE may result in water pump
component damage and reduced Service 15. Turn SYSTEM switch OFF.
life.
16. Shutdown vehicle.
8. Inspect all water pump and associated water
components (torque tube manifold, water WATER PUMP RPM ADJUSTMENT
pump hydraulic drive motor and cross-over)
connections and hoses for leaks. 1. Clean water pump shaft and install
reflective tape just above the packing gland.
9. Ensure water pump shaft is rotating in a CW
direction. 2. Install a photo tachometer to measure water
pump shaft speed or prepare hand-held
10. Inspect vehicle hydraulic tank to ensure device.
sufficient fluid level is available for
continuing test. If sufficient fluid is not 3. Adapt a water pressure gauge to the rear
available shutdown vehicle, Service spray bar ball or gate valve.
hydraulic tank and restart vehicle.
4. Ensure vehicle is safe to start.

5. And unit is full of water


Ensure the MTT is filled with sufficient
water to perform operational test. Maximum 6. Start up vehicle.
capacity is recommended. Operating the
water pump in a dry sump will result in 7. With engine at LOW IDLE, turn the cab
shaft seal damage. control SYSTEM switch ON.

3-2
M4B (306200/306201)-2
12 Sept 2013
SECTION 3
Functional Check and RPM Adjustment
8. Turn water PUMP switch ON. 11. 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.
Operating the water pump in a dry sump
will result in shaft seal damage.
Limit water pump operation to 2.5 minutes
when in a no-flow condition (not using the
spray heads, power dump bar, monitor or
Engaging/disengaging the water pump hose reel). Water pump operation in a no
above LOW IDLE may result in water pump flow condition will cause overheating of the
component damage and reduced Service water pump and damage to the shaft
life. bearings.

9. Ensure the water pump is turning in a CW


rotation. Note water pump RPM and spray
bar water pressure. The flow control valve can control as much
as 35 GPM (135 lpm) or about 700 RPM.

12. Once desired RPM is obtained, tighten jam


Do not place your hand or tools within nut on flow control valve.
pump bracket while pump is rotating and/or
pressure held within the motor supply hose. 13. Reduce engine speed to LOW IDLE.
Failure to follow proper safety procedures
could result in serious injury. 14. Turn water PUMP switch OFF.

10. Operate vehicle at HIGH IDLE. Note water


pump speed and water pressure. Water pump
speed should range from 1950-2100 RPM Engaging/disengaging the water pump above
and spar bar pressure should range from 90- LOW IDLE may result in water pump
120 PSI (620 830 kpa). component damage and reduced Service life.

Water pump RPM must not exceed 2,100 Avoid sudden water pump stoppage above
rpm with engine at high idle. Failure to keep LOW IDLE. If water pump experiences
water pump speed below 2,100 RPMs will sudden stoppage above LOW IDLE impeller,
result in water pump failure. shaft, drive motor and water pump damage
will occur.

12. Turn SYSTEM switch OFF.

13. Shutdown vehicle.

14. Remove photo tachometer and water and


hydraulic pressure gauges.
3-3
M4B (306200/306201)-2
12 Sept 2013
SECTION 3
Functional Check and RPM Adjustment

3-4(Blank)
M4B (306200/306201)-2
12 Sept 2013
SECTION 3
Functional Check and RPM Adjustment

WATER PUMP NOTES:

ENGINE RPM (LOW IDLE)

WATER PUMP DRIVE MOTOR HYDRAULIC PRESSURE - ___________ PSI

WATER PUMP DRIVE MOTOR HYDRAULIC RETURN - ___________ PSI

ENGINE RPM (HIGH IDLE)

WATER PUMP SHAFT SPEED - _______________ RPM

DO NOT EXCEED 2.100 RPM, WATER PUMP SHAFT SPEED.


Failure to keep water pump shaft speed below 2.100 RPM will
result in water pump damage or failure.

WATER PRESSURE AT SPRAY BAR - _______________ PSI

DRIVE MOTOR PRESSURE - _______________ PSI

DRIVE MOTOR RETURN - _______________ PSI

If your system is not covered in this manual or you are having difficulties with the installation 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.

3-5
M4B (306200/306201)-2
12 Sept 2013
SECTION 3
Functional Check and RPM Adjustment

3-6(Blank)
M4B (306200/306201)-2
12 Sept 2013
SECTION 4
Recommended Support Parts

PART RECOMMENDED
DESCRIPTION
NUMBER QUANTITY
M-4B, Standard Cast Water Pump Assembly ** Serial
306200 1
No. Specific Part (QCA)
M-4B, Corrosion Resistant Water Pump Assembly **
306201 1
Serial No. Specific Part (QCA)
306664 Impeller Kit, M-4B 1
306666 Seal Kit, M-4B 2
306663 Shaft Kit, M-4B 1
306669 Overhaul Kit, M-4B 1
302527 Gasket, Pump Inlet (6) 1
012930 Gasket, Pump Outlet (4) 1
040922 Gasket, Sump Flange 1
300460 Petcock, Volute Drain, NPT 1
301927 Coupling, Splined Drive 1

4-1
M4B (306200/306201)-2
12 Sept 2013
SECTION 4
Recommended Support Parts

4-2(Blank)

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