"service manual"
Contents
1. 4 2 Brake System Parts Group 4 1 DESCRIPTION This section contains a listing of recommended support parts that should be available in the supply warehouse The tables are categorized by specific sub system of the MHT DO NOT FORGET that all MHTs are not configured the same and there are several variations of hydraulic systems door cylinder configurations and turn limit indicators Ensure MHT serial numbers and actual component part numbers are checked before ordering any parts Once parts are issued from warehouse stock ensure depleted quantities are replenished to keep the recommended support parts package at 100 PART DESCRIPTION PART NO s T Older Fyd MHT Serial No Specific Part 4 Cylinder Con 303299 2 Valve Counterbalance Door os 1 _ EL a 4 Bushing Rexnord Door Pivot PART DESCRIPTION PART NO QTY 1 Filter 7G 5000 303191 2 Temp Sensor 7N 7854 303189 3 O Ring 115 Temperature Sensor 303192 PART DESCRIPTION PART NO QTY 1 Shim Set 18 Ball Ball Hitch 038904 4 Screw Cap 7 8 x 5 5 MHT175 CAT777 G 5 4 Feb 2014 SECTION 4 Recommended Support Parts PART DESCRIPTION PART NO QTY 1 Seal O ring 20 354815 2 Seal O ring 24 354816 6 3 Seal O ring 32 354817 4 Seal O ring 40 354818 5 Light Work 24 VDC 300777 1 1 6 Light LED Clearance Red 355374 7 Light LED Clearance Amber 355375 If y2. application of a procedure is mandatory Should Used when application of a procedure is recommended May Used to indicate an acceptable or suggested means of accomplishment MHT175 CAT777 G 5 4 Feb 2014 SECTION 1 Definitions and Abbreviations SAFETY MESSAGES There are several specific safety messages on this machine The exact location of the hazards 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 if 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 clean the safety messages Solvents gasoline or harsh chemicals could loosen the adhesive that secures the safety messages Loose adhesive will allow the safety messages to detach Replace any safety message that is damaged or missing If a safety message is attached to a part that is replaced install a new safety message on the replacement part TOXIC GAS HAZARD 1 This safety label is located on the side of the tank and at all water fill entrances Cutting or welding operation on the inside of the tank can cause the accumulation of toxic gases Read and understand instructi
3. T Feet Kg kilograms liters m meters MHT MEGA Coal Hauler MHT MEGA Hauler with Truck psi pounds square inch SQ FT Square Feet VDC Volts Direct Current MHT175 CAT777 G 5 4 Feb 2014 SECTION 1 Definitions and Abbreviations MHT 175 GENERAL OVERVIEW TYPICAL B A ef et E SS d LLL H 12 2 12 5 1 GOOSENECK DECK amp FENDER 2 LOWER HOPPER 8 TURN LIMIT INDICATOR 3 SIDE WALL 9 SPILL GUARD REAR BOGIE 10 SIDE BOARDS 5 REAR AXLE amp WHEEL GROUP 11 END OF LOAD INDICATOR 6 HITCH amp SADDLE 12 JACKING PADS MHT175 CAT777 G 5 4 Feb 2014 SECTION 2 Scheduled Maintenance Inspections Contents 14 616 er 2 1 Electrical System 2 2 Suspension amp Brake System 2 1 MHT Structure amp Hitch Assembl 2 2 DOOr SVS lE uu 2 2 DESCRIPTION This section establishes scheduled maintenance inspections of the MHT175 trailer MHT and associated sys tems 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 inop erative Once again these inspections are in addition to and do not replace existing CAT scheduled inspection requirements Check trailer ax
4. VIMI172 N F gt SPECIALTY HAULAGE SOLUTIONS FOR CONSTRUCTION AND MINING SCH EDULED SFECIAL INSPECTIONS coRECONIMENDED SUPPORT PARIS MEGA CORP 700 Osuna N E Albuquerque NM 87113 1 800 345 8889 505 345 2661 Fax 505 345 6190 www megacorpinc com MEGA Corp Inc All Rights Reserved Poe ETC NR NUS AMT B Section 1 Section 2 Section 3 Section 4 175 777 5 TABLE CONTENTS Definitions and ADDrevidtlolis sss u ai 22 ERR 1 1 Scheduled Maintenance Inspections 2 1 SOCClal MSDE CTION cT TT 3 1 Recommended 4 1 4 Feb 2014 MHT175 CAT777 G 5 4 Feb 2014 TABLE OF CONTENTS B Blank MHT175 CAT777 G 5 4 Feb 2014 SECTION 1 Definitions and Abbreviations Contents Manual Usage 1 1 Safety Messages 1 2 Warning Caution And 1 1 Abbreviations 1 3 Use Of Shall Will Should And May 1 1 175 General Overview Typical 1 4 MANUAL USAGE This technical manual only contains information required to safely install or service an MTT See the appropriate Maintenance and Operators Safety Manual for
5. angle brackets for cracks and loose hardware Contact MEGA Product Support at 1 800 345 8889 for any major structural repair issues HITCH BALL OVER OSCILLATION The hitch ball assembly is designed to oscillate 12 degrees within the lower socket assembly as shown below This allows the MHT175 a large range of motion when operating in the pit on haul road on coal piles and when unloading the trailer MHT Retention Plates i Ball Hitch Retention Plates Ball to Retention Plate Contact MHT175 CAT777 G 5 4 Feb 2014 SECTION 3 Special Inspections When operating the MHT175 beyond the allowable 12 degree limit the ball will contact the upper retention plate and potentially damage several components of the system Repeated and hard contacts will damage upper retaining plates upper brass bushings mount bolts and in severe cases cause structural damage to the gooseneck INSPECTION 1 Remove hitch ball skirt assembly 2 Check for broken bolts on the upper retaining plate If mount bolts are missing have been sheared off or laying on the lower receiver severe contact has occurred 3 Check upper retaining plates and hitch ball for damage Inspect retaining plates and hitch ball for evidence of hard contacts as shown below Ball Contact Retention Plate Contact 3 2 4 If hard contact is confirmed remove upper retention plates and inspect the upper retention plates brass bushings a
6. ctions STEP Check gooseneck components flow divider pressure regulator valves counter balance valve and manifolds for Check all door cylinders for damage security and leaks Attaching hardware and pins for damage and evidence of lubrication Check all door activation hoses for damage security and leaks Ensure the tractor integration points are also inspected e g junction manifolds hoist valve and tank damage security and leaks Check tractor integration manifolds for damage and security I LX o STEP 1 Check all MHT tail and clearance lights for damage security and proper operation Check door indicator switch and cabling for damage and security Check MHT rear bogie electrical junction box for damage and security Inspect all wire terminals strips for security Check gooseneck electrical cabling for damage and security from the boom collar to the tractor integration point Check electric turn stop indicator lights backup alarms cab light alarm assembly for damage security and proper operation STEP RS RS 1 Check MHT rear axle mounting structure and upper rear deck for damage and cracks Check MHT rear bumper assembly for damage security and cracks Check lower hopper assembly and dump doors for security damage and cracks Check all MHT interior and exterior walls for damage and cracks Check gooseneck assembly for damage and cracks Inspect gooseneck turn limit cheeks for evi
7. dence of turn limit indicator contact Check ball hitch skirt assembly for damage security and cracks Remove ball skirt and inspect upper retention plate for broken 7 bolts and evidence of spherical ball contact with the upper retention plate Ensure upper spherical ball shows evidence of lubrication Check clearance between hitch spherical ball and upper brass bushing If gap is more than 0 010 shim upper brass bushing as described in MHT175 CAT777 G 4 Check tractor fender assemblies for damage security and BEEN cracks 2 2 MHT175 CAT777 G 5 4 Feb 2014 SECTION 2 Scheduled Maintenance Inspections Check hitch receiver and saddle assembly mounts for damage and security Inspect pivot pins and hitch clamp assemblies for security Check deck assembly for damage security and cracks Inspect deck mounts for cracks and mounting bolts for security Check turn stop indicator for damage security and cracks Inspect chassis rail mount plates for cracks and all mounting hardware for security cracks 2 3 MHT175 CAT777 G 5 4 Feb 2014 SECTION 2 Scheduled Maintenance Inspections 2 4 Blank MHT175 CAT777 G 5 4 Feb 2014 SECTION 3 Special Inspections Contents D CIDE ua 3 1 Hitch Ball Over Oscillation 3 1 Turn Limit Indicator Contact 3 1 DESCRIPTION 3 Check adjoining gooseneck interior and ex
8. le and wheel group components as defined in CAT 777F Service Manual Service individual components as required After initial installation or and system component replacement follow chassis required initial maintenance schedule for that component or system Service as required Check trailer axle struts a frame and pan hard rod for security damage and evidence of lubrication Inspect lubrication lines for damage and security Check rear axle housing and access plate for damage security and leaks Inspect axle sump breathers for evidence of oil leakage Inspect axle final drives for proper fluid level If more than 3 Quarts 2 84 liters are added at any inspection remove axle inspection cover to check spindle vent cover plates security and signs of leakage Repair as required rear bogie brake cooling filter assemblies and manifolds for leaks damage and security Replace MHT rear axle brake cooling oil filters rear bogie brake accumulators and relay for damage security and leaks All brake system cooling and activation hoses for damage security and leaks Ensure the tractor integration points are also inspected e g junction manifolds scavenge pump tank E brake proportional group accumulators oil cooler union MHT bolster side wall tunnels containing hydraulic hoses cavity drain holes for evidence of leaking 2 1 MHT175 CAT777 G 5 4 Feb 2014 SECTION 2 Scheduled Maintenance Inspe
9. nd lower receiver as follows a Inspect upper retention plates for mushrooming of flat mating ends Lay the retention plate on a flat surface and check for warpage If retention plate is mushroomed or warped the retention plate set must be replaced Mushrooming b Check upper brass bushings for over oscillation ball contact as shown below If contacted and deformed replace upper bushing set SECTION 3 Special Inspections c Inspect lower receiver assembly for elongated pulled upper retention plate bolt holes and deformation of the lower receiver mount ring as shown below If either condition is noted replace lower receiver assembly Contact MEGA Product Support for lower receiver replacement options Deformed Mount Ring Elongated Pulled Threads Check interior and exterior gooseneck structure and plating for damage Inspect gooseneck structure and plating for weld cracking and evidence of steel plate buckling If either condition is noted contact MEGA Product Support at 1 800 345 8889 MHT175 CAT777 G 5 4 Feb 2014 MHT175 CAT777 G 5 4 Feb 2014 SECTION 3 Special Inspections 3 4 Blank MHT175 CAT777 G 5 4 Feb 2014 SECTION 4 Recommended Support Parts Contents D CIDE 4 1 Hitch Assembly Parts Group 4 1 Door System Parts Group 4 1 Miscellaneous Parts Group
10. ons and warnings in the Maintenance Manual Failure to provide proper ventilation or breathing apparatus while conducting these operations may result in serious injury or death 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 BACKING RUNOVER HAZARD 3 This safety label is located on the rear of the tank and inside the cab oret The vehicle is equipped with a back up alarm Alarm must sound when operating this vehicle in reverse Failure to maintain a clear view in the direction of travel could result in serious injury or death MHT175 CAT777 G 5 4 Feb 2014 SECTION 1 Definitions and Abbreviations FALL HAZARD 4 This safety label is located at the top of the front and rear of the tank Do not walk on the top of tank without fall arrest PPE Serious injury or death could occur from a fall HIGH PRESSURE CYLINDER 5 This safety label is located on the hydraulic motor Hydraulic cylinders and supply lines contain oil under high pressure Improper removal and repair procedures could cause severe injury To remove or repair instructions in the Maintenance Manual must be followed ABBREVIATIONS e g example given F
11. our system is not covered in this manual or are having difficulties locating the necessary components please contact MEGA Corp Product Support Group at US Toll Free 1 800 345 8889 or Direct 1 505 345 2661 or visit our website at www megacorpinc com for more detailed contact information
12. specific vehicle system information and maintenance procedures If your system is not covered in this manual please contact MEGA Corp Product Support Group at US toll free 1 800 345 8889 Direct 1 505 345 2661 or visit our website at www megacorpinc com for more detailed contact information The exact location of the hazards and description of the hazards are reviewed in this section All personnel working on or operating the MAC MAT must become familiarized with all the safety messages Due to the nature of these processes ensure that all safety information warnings and instructions are read and understood before any operation or any maintenance procedures are performed Some procedures take place with heavy components and at moderate heights ensure 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 WARNING CAUTION AND NOTES The following definitions are found throughout the manual and apply as follows A Operating procedures and techniques which could result in personal injury and or loss of life if not carefully followed Operating procedures and techniques which could result in damage to equipment if not carefully followed Operating procedures and techniques that are considered essential to emphasize USE OF SHALL WILL SHOULD AND MAY Shall and Will Used when
13. terior This section contains special inspection requirements for exceeding an establish system limit The established inspections are designed to reveal any damage sustained and determine serviceability of the MHT175 system TURN LIMIT INDICATOR CONTACT The metal turn limit indicator is designed to provide a visual indication to the operator they have reached the maximum rotation of the MHT This is noted by the gooseneck cheek contacting the turn limit indicator as shown below Gooseneck Cheek Me q Les Metal Turn Limit 3 Indicator When the system experiences high impact loads damage may occur to both the gooseneck cheek plates and the turn limit indicator The gooseneck cheek plates may buckle or begin to weaken and eventually cause further damage to adjoining gooseneck plate structure The turn limit indicator may experience excessive bending moments and begin to tear or weaken lower mount plate and horse collar welds INSPECTION 1 Remove a gooseneck access cover Check gooseneck cheek structure for damage Inspect welds for evidence of cracking and metal plates for signs of buckling 3 1 structure for damage Inspect gooseneck structure and plating for weld cracking and evidence of steel plate buckling 4 Check turn limit indicator for damage Inspect plates and welds for cracks and deformities 5 Check turn limit indicator deck and horse collar mounts for damage Inspect rail mounting plates and
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