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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
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M4B (306200/306201)-2
12 Sept 2013
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M4B (306200/306201)-2
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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
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Definitions and Abbreviations
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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.
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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.
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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
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Definitions and Abbreviations
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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
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M4B Water Pump
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.
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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
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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
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Shaft & Bearing Assembly 4. Disassemble shaft assembly as follows:
a. Remove snap ring and thrust ring from
drive end of shaft.
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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.
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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.
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.
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Seal Plate Installation 4. Install one rope seal at a time while indexing
the seal gaps 180 degrees from each other.
Seal Split
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M4B Water Pump
6. Install slinger onto shaft. 9. Line up jack bolt holes in frame and seal
plate.
Slinger
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M4B Water Pump
Impeller Installation 3. Thread impeller onto shaft.
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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.
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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.
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M4B Water Pump
REPAIR
Manifold Seal Replacement
1. Ensure vehicle hydraulic system is not in
operation.
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M4B Water Pump
Metered Flow
To REDUCE SPEED
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M4B Water Pump
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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.
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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.
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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.
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.
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Functional Check and RPM Adjustment
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.
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Functional Check and RPM Adjustment
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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
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Recommended Support Parts
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