MTT20-KOM785(7)-4

15 OCT 2008

Field Installation Manual

 MTT20-KOM785(7)-4
15 Oct 2008
TABLE OF CONTENTS

Section 1. Definitions and Abbreviations Page

A. Warnings, Cautions and Notes………….……………………….…….. 3
B. Shall, Will, and May………....……………………….……………….. 3
C. Abbreviations……..………………………….…………………..……. 3

Section 2. Support Equipment & Manhour Requirements ……………………………… 5

Section 3. Job Site Selection & Preparation………..……….……………………….…… 7

Section 4. Unpacking and Parts Identification ….……………………………………….. 9

Section 5. MTT Preparation ………………………………………………………….…... 11

Section 6. Truck Preparation …………………………………………………………….. 15

Section 7. MTT to Truck Mating …………………..…………………………………….. 21

Section 8. Final Assembly ……………………………………………………………….. 27

Section 9. Functional Check Procedures …………….……………..…………………… 29

Section 10. Drawings ……………………………………………………………………… 33

1
MTT20-KOM785(7)-4
15 Oct 2008
TABLE OF CONTENTS

2(Blank)
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 1
Definitions and Abbreviations

WARNINGS, CAUTIONS AND NOTES USE OF SHALL, WILL AND MAY

The following definitions are found Shall and Will – Used when application
throughout the manual and apply as follows: of a procedure is mandatory.

Should – Used when application of a

procedure is recommended.

WARNING May - Used to indicate an acceptable or

suggested means of accomplishment.
Operating procedures and
techniques, which could result in
personal injury and/or loss of life if HOIST DEFINITIONS
not carefully followed.
Non-Hoist Compatible – The truck
hoist cylinders and hosing are removed
so the MTT can not be raised.
CAUTION
Hoist Compatible – The truck hoist
Operating procedures and cylinders are attached to the MTT so the
techniques, which could result in tank can be raised for maintenance.
damage to equipment if not carefully
followed.

ABBRIVIATIONS
NOTE
BFV – Butterfly Valve
Operating procedures and techniques CW - Clockwise
that are considered essential to EPC – Electronic Proportional Control
emphasis. FT - Feet
FPM – Feet Per Minute
GPM – Gallons Per Minute
MPH – Miles Per Hour
MTT – Mega Truck Tank
PSI - Pounds Square Inch
RPM – Revolutions Per Second

3
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 1
Definitions and Abbreviations

4(Blank)
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 2
Support Equipment & Manhour Requirements

The following information is provided to GENERAL HAND TOOLS AND

assist in the successful installation of the EQUIPMENT
MEGA MTT 20. These guidelines are
essential planning tools for both supervision 1. Basic hand tools for mechanical
and work crews to complete the entire assembly and wiring (wrenches,
installation in a timely and safe manner. hammers, pliers, wire strippers, rackets,
and an assortment of screw drivers).
CRANE
Use at least a 21 ton capacity crane to lift the 2. At least a 10 lbs sledge hammer.
tank onto truck chassis. Ensure the crane
can move the tank to the required 3. Electric drill capable of using a hole
dimensions as shown below. saw.

4. Truck mounted boom crane (optional)

LADDER/SCAFFOLDS

Select ladders and/or build scaffolds based

on dimensions given in figure 2-1

WELDING EQUIPMENT

1. FCAW-E71-T1 with 100% C0² or 75/25

AR/C0² mix.

2. SMAW (stick) E7018 1/8” and 5/32”

diameter.

3. Oxygen fuel or Plasma cutter.

CREW MEMBERS
Use a minimum of 2 crew members in the
TANK WEIGHT = 41,500 LBS/18,825KG hoisting process and 4 crew members for
lifting and positioning of all other assembly
Figure 2-1 Vehicle dimensions items.
and weight
MANHOURS
Actual installation may vary greatly due to
location of assembly (truck shop or green
field). See figure 2-2 for typical manhour
requirements.

5
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 2
Support Equipment & Manhour Requirements

M T T 2 0 T AN K IN S T ALLAT IO N
CREW T O T AL SUB
STEP O P E R AT IO N S IZ E HOURS HOURS T O T AL
1 P R E P E R AT IO N
A. Job Site 2 2.0 4.0
B. Unpacking 2 1.0 2.0
6.0
2 M T T P R E P AR AT IO N
A. Hydraulic 2 6.0 12.0
B. Electrical 2 4.0 8.0
C. Tiedown 1 1.0 1.0
D. Monitor (Optional) 1 0.5 0.5
F. Foam Concentrate Tank (Optional) 1 0.5 0.5
22.0
3 T R U C K P R E P AR AT IO N
A. Electrical 1 0.5 0.5
A. Hydraulic 2 6.0 12.0
B. Controls 1 5.0 5.0
17.5
4 M T T T O T R U C K M AT IN G
A. Hoisting 3 1.0 3.0
B. Pinning 3 1.0 3.0
C. Shimming 2 1.5 3.0
D. Forward Mounts 2 2.5 5.0
E. Hydraulic Hook-up 2 3.0 6.0
F. Electrical Hook-up 2 2.0 4.0
24.0
5 F IN AL AS S E M BLY
A. Mud Flaps 2 1.0 2.0
B. Rock Ejector 2 0.5 1.0
C. Ladder/Rails 1 0.5 0.5
D. Hose Reel 2 1.0 2.0
E. Spray Bar 2 2.0 4.0
F. Dump Bar 2 1.5 3.0
G. Conical Fill 1 1.0 1.0
13.5

F U N C T IO N AL C H E C K
6 PROCEDURES
A. Commissioning 2 3.0 6.0
6.0

T O T AL M AN H O U R S 89.0

Figure 2-2 Manhour Requirements (Typical)

6
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 3
Job Site Selection & Preparation

JOB SITE SELECTION

Select a location that requires minimal
preparation and provides unobstructed
access for all required people and
equipment.

Ensure the selected site contains:

1. Level ground.

2. Hard packed surface able to support 21

ton heavy equipment cranes and a
161,700lbs/73335kg assembled vehicle.

3. Shelter (highly recommended).

SITE PREPERATION
Prior to bringing the tank and the truck to
the assembly location prepare the selected
assembly area with are resources required to
complete the mating of the tank to the truck.

Prepare the site by:

1. Clear all unneeded equipment from the

assembly site area.

2. Ensure all required access ways are open

to move required equipment and parts in
and out of the area.

3. Preposition all required cranes, hand

tools, welding equipment, ladders,
scaffolds, required electricity and shelter
(if available).

4. Preposition the MEGA tank and

associated parts boxes.

5. Preposition truck chassis.

7
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 3
Job Site Selection & Preparation

8(Blank)
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 4
Unpacking & Parts Identification

1. Remove all parts from the shipping crate

and discard excess packing material.

2. Identify each part, annotate packing list

and sort parts by hydraulic, electrical,
pneumatic and other.

3. Identify any shipping list shortages and

obtain required parts.

4. If possible, locate assembly parts close

to there intended installation location on
the vehicle or MTT.

9
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 4
Unpacking & Parts Identification

10(Blank)
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 5
MTT Preparation

Preparation of the MTT is the first essential 1. Locate monitor, hydraulic control
element in completing a timely mating of assembly, BFV, flanges, cables and
the tank and truck. The time spent preparing hoses a shown in Section 10 Figure 10-6
the MTT is essential in reducing time delays Bolt-on Assemblies (Monitor)
later in the installation process due to lost
parts, support equipment requirements or 2. (Hydraulic Monitor Only) Position the
required sub assembly. Follow the steps monitor hydraulic control solenoid
listed below to fully prepare the tank for assembly on lower water pipe supply
installation. line.

TIEDOWNS 3. Stack 3” BFV assembly on top of lower

flange above hydraulic control solenoid
MTT forward lower tiedowns may interfere assembly.
with vehicle muffler or other equipment.
4. Install the monitor and flange assembly
1. Remove lower forward tiedowns with as indicated by index markings on the
cutting equipment. flange assembly. Install 4 bolts and
tighten evenly to provide clamp-up of
CAUTION entire monitor assembly and
Overheating of the lower tank floor components.
surface will result in damage to the
tank interior epoxy coating (if 5. Connect wiring harness Deutsch
equipped). If welding equipment is connector to the forward junction box
used to remove tiedowns, ensure Deutsch connector as shown in Section
sufficient distance from the bottom 10 Figure 10-3 Control System
of the tank is maintained during the (Overview).
cutting process.

2. Prime and paint remaining tiedown HYDRAULICS

material to prevent corrosion.
1. (If Required) Weld on the rear torque
MONITOR ASSEMBLY tube manifold base plate and install
torque tube manifold as shown below
and in Section 10 Figure 10-2 Hydraulic
System.
Manifold Base Plate

Torque Tube Manifold

11
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 5
MTT Preparation
2. (If Required) Attach the water pump ELECTRICAL
pressure, return and case drain hydraulic
hoses to the torque tube manifold as Water Level Sensor
shown below and in section 10 Figure 1. Install the water level sensor and cable
Hydraulic System. in the front bulkhead as shown below
and in Section 10 Figure 10-4 Control
System (Water Level).

Water level Sensor

Water Pump Hoses 2. (If Required) wire MTT work lights as

shown in Section 10 Figure 10-4 Lights
(Work Lights).

FOAM CONCENTRATE TANK

Solenoid box return line
1. If required, install foam concentrate
shut-off valve and foam supply hose as
3. (Hydraulic Monitor Only) Connect and shown in Section 10 Figure 10-8 Fire
route pressure and return hoses as shown Suppression System.
in Section 10 Figure 10-3 Hydraulic
System (Monitor Circuit). 2. Install foam concentrate supply hose
from the foam shut-off valve to the
monitor as shown in Section 10 Figure
10-8 Fire Suppression System.

NOTE

Ensure foam concentrate hose slack in

kept to a minimum to prevent hose
collapse during monitor/foam operation.

12
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 5
MTT Preparation

NOTE

Ensure foam concentrate hose length is

sufficient to allow the monitor to operate
through full range of motion without
kinking the hose.

13
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 5
MTT Preparation

14(Blank)
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 6
Truck Preparation

Preparation of the truck is the second 2. Disconnect #12 ORF steering hose as
essential element in completing a timely shown below and remove existing #12
mating of the tank and truck. The time spent ORF from the manifold.
preparing the truck is essential in reducing
time delays later in the installation process Steering Hose
due to lost parts, support equipment
requirements or required sub assembly.
Follow the steps listed below to fully
prepare the truck for installation.

CAUTION

Truck ECM will be damaged when #12 ORF 90°

Elbow
arc welding is performed while ECMs
are connected to truck systems.
Ensure ECMs are disconnected from
wiring harnesses before welding 3. (MEGA provide Hydraulic Tank
begins. Replacement Tube Assembly Only)
Remove the existing hydraulic tank tube
assembly and install the MEGA
HYDRAULICS provided tube assembly as shown in
Section 10 Figure 10-2 Hydraulic
1. (Non-Hoist Compatible Only) Remove System.
both hoist cylinders and associated
pressure and return hoses. Also remove 4. (Hydraulic Tank Replacement Tube
the hoist valve RAISE port manifold and Assembly NOT Included) Modify
solid line as shown below and in Section hydraulic tank return manifold to accept
10 Figure 10-2 Hydraulic System (Non- a #20 ORB T-Fitting as shown below
Hoist Compatible). Cover all open and in Section 10 Figure 10-2 Hydraulic
hoses to prevent contamination. System.

Hoist Valve
Return Manifold

#20 ORB T-fitting

Elbow
Manifold & Solid Line

15
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 5
Truck Preparation
5. Install #20 ORB T-fitting and ORS 10. (Hoist Compatible Only) Remove the
steering hose adapters as shown in existing hoist valve RAISE manifold and
Section 10 Figure 10-2 Hydraulic hard line. Plug hoist valve opening and
System. disconnected pressure hose to prevent
contamination.
6. Reconnect #12 ORF steering hose as
shown in Section 10 Figure 10-2
Hydraulic System.

7. Install a cap on the remaining open #20

JIC port on the T-fitting.

8. (MEGA provided Tank Cover Only)

Remove existing hydraulic tank cover
and configure the MEGA provided tank
cover as shown in Section 10 Figure 10-
2 Hydraulic System. Reinstall the new
tank cover.
Manifold & Solid Line
9. (Hydraulic Tank Cover NOT
Included) Remove the hydraulic tank
cover and modify cover to accept a 1/4”
NPT -#6 JIC elbow as shown below and 11. (Hoist Compatible Only) Install the
in Section 10 Figure 10-2 Hydraulic MEGA provided hoist compatible
System. manifold and bracket on the aft end of
the hydraulic tank as shown below and
in Section 10 Figure 10-2 Hydraulic
System (Hoist Compatible). Connect the
existing cylinder extend hose to the #12
ORS fitting on the MEGA manifold.

1/4" NPT Elbow

16
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 6
Truck Preparation

Hosing CONTROLS
Most all MEGA kits contain bulk hose and
the required fittings to fabricate hose EPC Valve
assemblies. Hoses can be measured then 1. Remove the coil from the directional
fabricated using Section 10 Figure 10-2 control solenoid located on the EPC
Hydraulic System. valve as shown below and in Section 10
Figure 10-3 Control System (Hoist EPC
12. (Hoist Compatible Only) Fabricate and Controls). Secure the coil to a stand-off
install the pressure hose from the hoist with a bolt and DO NOT disconnect the
valve raise port to the open port on the 3 pin deutsch connector from the vehicle
MEGA manifold as shown below and in wire harness.
Section 10 Figure 10-2 Hydraulic
System (Hoist Compatible).

Directional Control
Coil

2. Disconnect the 2 pin deutsch connector

from the EPC cut-off/dump solenoid as
shown below and in Section 10 Figure
10-3 Control System (Hoist EPC
Controls). Connect the MEGA supplied
dummy coil to the vehicle 2 pin deutsch
connector and secure the MEGA dummy
coil to a stand-off with a bolt.

Cut-off/Dump Solenoid

17
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 5
Truck Preparation
Cab Controls 3. Modify an unused deutsh connector exit
mount to accept to cab control 40 pin
1. Install cab control pedestal as shown bulkhead fitting as shown below. Mount
below and in Section 10 Figure 10-3 the bulkhead fitting.
Control System (Cab Control &
Cabling).

40 Pin Connector

4. Connect the cab control 40 pin cable

RED wire to vehicle spare battery fuse
as shown below.

+24 VDC Power

Spare Battery
Fuse

2. Route the 40 pin cable through the jump

seat base as shown below. Then route
the cable towards the cab cable exit
plates. 5. Connect the cab control 40 pin cable
BLACK wire to compartment grounding
stand-off as shown below.

18
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 6
Truck Preparation

6. Connect 21’ control cable to the newly Body Position Sensor

installed 40 pin connector in the drivers’ 1. Rig the body position sensor to indicate
side wheel well as shown below. a body down position to the vehicle
controller. Secure bellcrank.

21’ Control Cable

7. (Electric Monitor Equipped Only)

Install the logic box as follows:

a. Mount the logic box to the

compartment with Velcro or
mount bolts.

b. Route and connect 8 pin

joystick and monitor cables to
the cab control cable as shown
in Section 10 Figure 10-3
Control Systems (Electric
Monitor Control Overview).

c. Route the logic 12 gauge 2

conductor cable to a 20 amp
spare battery fuse.

d. Connect the WHITE wire to the

24 VDC 20 amp fuse.

e. Connect the BLACK wire to a

solid compartment ground.

19
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 6
Truck Preparation

20(Blank)
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 7
MTT to Truck Mating

HOISTING 7. Once tank is level when hoisted, raise

MTT to the required height to clear truck
1. Move the selected crane (at least 21 ton chassis.
capability) into position for the lifting of 8. Move MTT over the truck and lower to
the MTT. allow MTT mounting holes to align with
truck mounting bores.
2. Rig a 4-point lifting harness that will
span the MTT for hoisting.

3. Clean and lubricate the MTT and truck

mounting bores.

PINNING THE MTT

4. Locate and identify the following parts

from Section 10 Figure 10-1 Tank
Mounting
a. Main Pins
b. Pin Keepers
c. Fastners
d. Lock Back Pins 1. With MTT over chassis, determine the
e. MTT and Truck forward amount of shims required on each mount
mounts. to provide equal shimming.
f. Body Pads
g. Body Shims

5. Install body pads without shims onto the

MTT forward rails approximately were
the chassis will contact the tank. Also
install rocker pad body pads without
shims.

6. Hoist MTT to ensure the tank is hanging

level. Adjust harness setup as required.

21
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 7
MTT to Truck Mating
2. Align one side of the mount, insert shims 6. Position left and right forward mount
as previously determined and insert one assemblies on the upper deck.
pin until the pin begins to engage the
vehicle mounting bore.
TANK SHIMMING

1. After rear pins are installed, but before

final lowering of the MTT, ensure the
body pads are located correctly on the
chassis rails and rockers without shims.

2. Lower the MTT until chassis MTT body

pads contact the chassis rails. Position
the forward deck mounts to match MTT
rocker mounts.

3. Align the other side of the mount, insert 3. Step back from the MTT/truck assembly
shims as previously determined and and observe the alignment of the tank to
insert the other pin until fully seated. chassis. Make sure the tank appearance
is correct. The tank should roughly align
at the same angle as the chassis. Shims
may be adjusted on the rocker pads to
align tank to chassis.

4. After alignment of tank to chassis is as

desired, shim main body pads as
required. Amount of shims required
may vary greatly. Shims should be
installed to distribute weight evenly
between front rocker pads and main
body pads.
4. Drive the right side pins until fully
seated. 5. After all shimming is complete, install
fasteners and torque properly.
5. Install lock back pins and keepers.

22
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 7
MTT to Truck Mating

6. (Hoist Compatible Only) Connect lift 10. Remove lifting harness.

cylinders to the MTT mounts with pins
as shown in Section 10 Figure 10-1 Tank HYDRAULICS
Mounting (Hoist Compatible).
1. (Hoist Compatible Only) Perform a
functional check of the vehicle hoisting
FORWARD MOUNTS system by lifting the MTT the lift
cylinders.
7. Check to ensure forward mounts are
still positioned correctly and the 2. (Hoist Compatible Only) Once
required gap is maintained as shown functional checks are complete,
in Section 10 Figure 10-1 Tank reconfigure the MEGA dual flange
Mounting (Forward Mount). manifold for water pump operation as
shown below and in Section 10 Figure
8. Position forward mount plates and 10-2 Hydraulic System (Hoist
gussets to obtain location and gap as Compatible).
shown in Section 10 Figure 10-1
Tank Mounting (Forward Mount).
Spot weld components to forward
mounts

9. Raise tank and weld forward mounts

to the upper deck and mount bolt
components as shown in Section 10
Figure 10-1 Tank Mounting.

CAUTION

Truck ECM will be damaged when

arc welding is performed while
ECMs are connected to truck
systems. Ensure ECMs are
disconnected from wiring harnesses
before welding begins.
Hosing
Most all MEGA kits contain bulk hose and
NOTE the required fittings to fabricate hose
assemblies. Once the MTT is matted to the
Forward mount bolts are installed truck chassis hoses can be measured and
later in the assembly process after fabricated to fit as required. See Section 10
hydraulic hosing and final hoisting Figure 10-2 Hydraulic System for all hose
checks are completed. information and use the following steps to
complete the hydraulic system installation.

23
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 7
MTT to Truck Mating

3. Fabricate and install case drain hose 4. Fabricate and install return hose from
from the MTT torque tube manifold to MTT torque tube manifold to the
the hydraulic tank cover as shown below hydraulic tank return manifold fitting as
and in Section 10 Figure 10-2 Hydraulic shown below and in Section 10 Figure
System. 10-2 Hydraulic System.

FORWARD
FORWARD

Case Drain to Hydraulic Tank

#20 JIC T-fitting
Elbow

24
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 7
MTT to Truck Mating

5. (Non-Hoist Compatible Only) Fab- 6. (Hoist Compatible Only) Fabricate and

ricate and install pressure hose form the install pressure hose form the MTT
MTT torque tube manifold to the hoist torque tube manifold to the MEGA dual
valve RAISE port as shown below and flange manifold located on the side of
in Section 10 Figure 10-2 Hydraulic the hydraulic tank as shown below and
System (Non-Hoist Compatible). in Section 10 Figure 10-2 Hydraulic
System (Hoist Compatible).

FORWARD
FORWARD

FORWARD FORWARD

25
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 7
MTT to Truck Mating
ELECTRICAL

1. Complete the wiring of the forward

junction box as shown in Section 10
Figure 10-3 Control System.

2. Connect the MTT forward junction box

PUMP cable to the EPC Cut-off/Dump
valve solenoid as shown below and in
Section 10 Figure 10-3 Control System
(Hoist EPC Controls).

Cut-off/Dump Solenoid

3. (If equipped) Connect water level

sensor cabling as shown in Section 10
Figure 10-3 Control System (Water
Level).

4. (If equipped) Connect foam concentrate

shut-off valve cabling as shown in
Section 10 Figure 10-8 Fire Suppression
System.

5. Wire tail lights, backup alarm and

clearance lights as shown in Section 10
Figure 10-4 Lights.

26
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 8
Final Assembly

FORWAD MOUNTS SPRAY BAR

1. Install mount bolts and springs. Tighten 1. Locate spray bar, mounts, mounting
bolts until springs are compressed 1” hardware, adapters, soft hosing and
from original length as shown in Section clamps.
10 Figure 10-1 Tank Mount (Front
Mount). 2. Install spray bar assembly as shown in
Section 10 Figure 10-5 Bolt-on
Assemblies (Standard).
MUD FLAPS

1. Remove mounting bar bracket and DUMP BAR

mount bolts.
1. Locate dump bar assembly, mounts,
2. Install mud flaps, mounting bar bracket adapters and mounting hardware.
and mount bolts as shown in Section 10
Figure 10-5 Bolt-on Assemblies 2. Mount dump bar assembly as shown in
(Standard). Section 10 Figure 10-5 Bolt-on
Assemblies (Dump Bar).

ROCK EJECTORS
HOSE REELS
1. Locate rock ejector and mounting
hardware. 1. Locate hose reel, mounting hardware,
adapters, soft hosing and clamps.
2. Mount rock ejectors as shown in Section
10 Figure 10-5 Bolt-on Assemblies 2. Install the hose reel as shown in Section
(Rock Ejectors). 10 Figure 10-5 Bolt-on Assemblies
(Hose Reel).

LADDERS & RAILINGS

CONICAL FILL
1. Locate ladders, railings and mounting
hardware. 1. Locate conical fill assembly and
mounting hardware.
2. Mount ladders/railings as shown in
Section 10 Figure 10-5 Bolt-on 2. Mount conical fill as shown in Section
Assemblies (Hand Rails). 10 Figure 10-5 Bolt-On Assemblies
(Conical Fill).

27
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 8
Final Assembly

SUCTION LOADING

1. Complete installation of suction loading

components as shown in Section 10
Figures 10-2 Hydraulic System (Suction
Loading), Figure 10-5 Bolt-on
Assemblies (Suction Loading) and
Figure 10-7 Suction Load Pump &
Motor Assembly.

2. (If Required) Fabricate and install

pressure, return and case drain hoses
as shown in Section 10 Figure 10-2
Hydraulic System (Suction Loading).

28
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 9
Functional Check Procedures

The functional check procedures of the 9. Turn the cab control box SYSTEM
newly assembled MTT20 KOMATSU 785-7 Switch ON and allow the water level
is designed to perform static checks of all system to warm up for 2 minutes.
systems then move to dynamic checks of all Ensure water level gauge is showing
systems under loaded conditions and finally FULL (all LEDs illuminated)
perform required system adjustments.
NOTE
1. Install hydraulic test gauges on the water
pump hydraulic drive motor test ports. If the water level gauge upper and
lower indicator lights flash alternately,
2. Adapt a water pressure gauge to the the water level indicating circuit is
spray bar gate valve. open. Ensure all water level cables and
connectors are securely attached.
3. Fill water tank to maximum capacity for
dynamic check of the entire spray
system 10. If the water level gauge is not indicating
FULL, perform the following:
CAUTION
a. With the tank full of water
Operating the water pump in a dry calibrate the water level gauge
sump will result in shaft seal damage using the calibration magnet and
the QUICK METHOD (full tank)
instructions attached to the
4. Once tank is full, check pump couplings magnet.
for static water leaks.
11. (Electric Monitor Only) Turn
5. Adjust all spray head adjustment rings MONITOR Switch ON and operate
for full flow and maximum pattern width monitor through full range of motion
to allow free flow of metal contaminants (up/down/left/right). Point the monitor
during testing. in a safe direction for upcoming checks
of monitor actual water flow.
6. Ensure all cab control switches are OFF.
12. (Electric Adjustable Nozzle Only)
7. Ensure vehicle battery power is Operate the adjustable nozzle from FOG
connected. to STREAM to ensure the outer barrel of
the nozzle moves in and out.
8. Turn vehicle key switch ON. Ensure the
vehicle cycles through recommended 13. Turn MONITOR Switch OFF.
ECM functions per Komatsu Operators
Manual and all warning and advisory 14. Ensure the area around the vehicle is
lights extinguish. well clear and ample space is available
to operate spray heads and monitor.

29
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 9
Functional Check Procedures
15. Start up the vehicle and ensure all 22. Operate all remaining cab control box
required warning and advisory lights functions and check for proper
extinguish per Komatsu Operators operation.
Manual. 23. Once all cab control functions are
checked, turn PUMP switch OFF and
16. While the vehicle is running inspect all SYSTEM switch OFF.
installed hydraulic components
(hydraulic tank, hoist valve, torque tube CAUTION
manifold, water pump hydraulic drive
motor, and rear solenoid box) Disengaging the water pump above
connections and hoses for leaks. LOW IDLE may result in water
pump component damage and
17. Ensure all spray heads, dump bar, drain reduced service life.
valve, monitor and foam switches are
OFF. 24. With the vehicle still running perform a
walk around inspection of the entire
18. Turn the cab control box PUMP switch vehicle and inspect all hydraulic system
ON. Inspect all installed hydraulic components and hosing for leaks.
components (hydraulic tank, hoist valve,
torque tube manifold, water pump 25. Shutdown the vehicle and service
hydraulic drive motor, and rear solenoid hydraulic system as required.
box) connections and hoses for leaks.
26. Ensure all panels and covers are closed
CAUTION and secured.

Engaging the water pump above 27. Restart vehicle and operate all cab
LOW IDLE may result in water control systems at HIGH IDLE to flow
pump component damage and large amounts of water through all tank
reduced service life. piping and components to expel all metal
contaminants that could damage spray
19. Ensure water pump shaft is turning in a head diaphragms and butterfly valves.
CW direction.

20. (Hydraulic Monitor Only) Turn WATER PUMP TUNING

MONITOR switch ON and operate the
monitor through full range of motion 1. Clean water pump shaft and install
(up/down/left/right). reflective tape.

21. Activate each spray head control switch 2. Install a photo tachometer to sense
one a time and ensure spray head is water pump shaft speed.
operating normally.
3. Start up vehicle.

30
 MTT20-KOM785(7)-4
15 Oct 2008
SECTION 9
Functional Check Procedures

4. At LOW IDLE, turn the cab control box 10. Remove photo tachometer, hydraulic
SYSTEM then PUMP switch ON. gauges, and water pressure gauge.

CAUTION
Engaging the water pump above
LOW IDLE may result in water
pump component damage and
reduced service life.

5. Note water pump RPM and spray bar

water pressure.

6. Operate vehicle at HIGH IDLE. Note

water pump speed and water pressure.
Water pump speed should range from
1950 - 2000 RPM and spay bar pressure
should range from 100-110 PSI.

7. If water pump RPM is to out of the

desired range, adjust the water pump
hydraulic drive motor flow control
valve to obtain desired RPM.

NOTE

The flow control valve can control as

much as 35 GPM or about 700 RPM.

8. Once desired RPM is obtained, lock

down adjustment knob and shutdown
the vehicle.

9. At LOW IDLE turn Pump and System

Switch OFF.

CAUTION

Disengaging the water pump above

LOW IDLE may result in water
pump component damage and
reduced service life.

31
MTT20-KOM785(7)-4
15 Oct 2008
SECTION 9
Functional Check Procedures
NOTES

32