-4

MTT20-KOM785(7)-4
5 JAN 2011

Field Installation Manual

SPECIALTY HAULAGE SOLUTIONS FOR CONSTRUCTION AND MINING

MEGA CORP.®
700 Osuna Rd. N.E. • Albuquerque, NM 87113 • 1-800-345-8889 • 505-345-2661 • Fax 505-345-6190
www.megacorpinc.com
® 2010 MEGA Corp., Inc. All Rights Reserved
 MTT20-KOM785(7)-4
5 Jan 2011
TABLE OF CONTENTS

Page

Section 1. Definitions and Abbreviations ………………………………………………. …1

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 …………………………………………………………….. 13

Section 7. MTT to Truck Mating …………………..…………………………………….. 19

Section 8. Final Assembly ……………………………………………………………….. 25

Section 9. Functional Check Procedures …………….……………..…………………… 27

Section 10. Drawings ……………………………………………………………………… 31

A
MTT20-KOM785(7)-4
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TABLE OF CONTENTS

B (Blank)
 MTT20-KOM785(7)-4
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SECTION 1
Definitions & Abbreviations
Contents
Manual Usage …………………..……….. 1-1 Safety Messages ..............……….….…..... 1-2
Warning, Caution & Notes ……….….…… 1-1 Abbreviations…………………….……...... 1-5
Shall, Will and May ……………………... 1-1

MANUAL USAGE WARNING, CAUTION AND NOTES

This technical manual only contains The following definitions are found throughout
information required to safely install the MTT the manual and apply as follows:
on the KOMATSU 785-7. See the KOMATSU
785-7 Maintenance and Operators Safety
Manual for detailed chassis specific system
information and maintenance procedures. Operating procedures and techniques, which
could result in personal injury and/or loss of
The exact location of the hazards and life if not carefully followed.
description of the hazards are reviewed in this
section. All personnel working on or operating
the MTT must become familiarized with all the
safety messages.

If your system is not covered in this manual
please contact MEGA Corp. Product Support
at: 1-800-345-8889 or visit our web site at
www.megacorpinc.com for more detailed
information.
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.
Operating procedures and techniques, which
could result in damage to equipment if not
carefully followed.
Operating procedures and techniques that are
considered essential to emphasis.
USE OF SHALL, WILL AND MAY
Shall and Will – Used when 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.

1-1
MTT20-KOM785(7)-4
5 Jan 2011
SECTION 1
Definitions & Abbreviations
SAFETY MESSAGES Toxic Gas Hazard (1)
There are several specific safety messages on This safety label is located on the side of the
this MTT. The exact location of the hazards tank and at all water fill entrance.
and description of the hazards are reviewed in
this section. All personnel working on or
operating the MTT 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 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 is attached to a part that is
replaced, install a new safety message on the
replacement part.
Cutting or welding operation on the inside of
the tank can cause the accumulation of toxic
gasses. Read and understand instructions
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.

1-2
 MTT20-KOM785(7)-4
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SECTION 1
Definitions & Abbreviations
Backing Runover Hazard (3) Non-Potable (5)
This safety label is located on the rear of the This safety label is located on the side of the
tank and inside the cab. tank and a sump drain.

The vehicle is equipped with a back-up

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

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.

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

1-3
MTT20-KOM785(7)-4
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SECTION 1
Definitions & Abbreviations
Fall Hazard (7) High Pressure Sprayheads (9)
This safety label is located at the top of the This safety label is located on the spraybar.
front and rear of the tank.

Do not operate sprayheads until all

Ensure PPE fall arrest harness is worn, personnel are a safe distance from the
adjusted properly and attached to an anchor vehicle.
point when performing maintenance on top
of the MTT or when fall hazards are
present. Failure to use PPE when fall High Pressure Monitor (10)
hazards are present may result in serious This safety label is located on top of the cab
personnel injury or death. control box.

Rotating Shaft (8)

This safety label is located on the pump.

Do not operate the monitor until all

personnel are a safe distance from the
vehicle.

Do not place your hand or tools within pump

bell while pump is rotating and/or pressure
held within the motor supply hose. Refer to
the Operator and Maintenance Manual for
the procedures to operate and maintain the
pump. Failure to follow proper procedures
could result in serious injury.

1-4
 MTT20-KOM785(7)-4
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SECTION 1
Definitions & Abbreviations
High Pressure Motor (11) ABBREVIATIONS
This safety label is located on the hydraulic
motor. cw - clockwise
ECM – Electronic Control Module
EPC – Electronic Pressure Control
ft - feet
fpm – feet per minute
gpm – gallons per minute
JIC – 37° flare seat design fitting
kg – kilograms
lbs – pounds
LH – Left Hand
lpm – liters per minute
m - meters
Hydraulic motor and supply lines contain oil mph – miles per hour
under high pressure. Improper removal and MTT – MEGA Truck Tank
repair procedures could cause severe injury. ORB – O-ring boss (STOR)
To remove or repair, instructions in the ORFS – O-ring face seal
Maintenance Manual must be followed. psi - pounds square inch
RH – Right Hand
Confided Space (12) rpm – revolutions per minute
This safety label is located near water tank vdc – volts direct current
access and fill ports.

Do not enter confined spaces without

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

1-5
MTT20-KOM785(7)-4
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SECTION 1
Definitions & Abbreviations

1-6(Blank)

SECTION 2
Support Equipment & Manhour Requirements
Contents
Description ……...…………..……….….. 2-1
Crane Requirements …………..…...…….. 2-1
Crew Members …………………….…...... 2-1
DESCRIPTION
The following information is provided to assist
in the successful installation of the MEGA
MTT 20. These guidelines are essential
planning tools for both supervision and work
crews to complete the entire installation in a
timely and safe manner.
CRANE
Use the appropriate size crane to lift the tank
onto truck chassis. Ensure the crane can lift
and move the tank to the required
dimensions/weight as shown below.
TANK WEIGHT = 41,500 LBS/18,825KG
Figure 2-1 Vehicle Dimensions and Weight
2-1
MTT20-KOM785(7)-4
5 Jan 2011
General Hand Tools & Equipment ...…... 2-1
Manhours …………………………..…... 2-1
GENERAL HAND TOOLS AND
EQUIPMENT
1. Basic hand tools for mechanical assembly
and wiring (wrenches, hammers, pliers,
wire strippers, rackets, and an assortment of
screw drivers).
2. At least a 10 lbs sledge hammer.
3. Electric drill capable of using a hole 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
hoisting process and 4 crew members for lifting
and positioning of all other assembly items.
MANHOURS
Actual installation time may vary greatly due to
location of assembly (truck shop or green
field). See figure 2-2 for typical manhour
requirements for installation in a large truck
shop facility with MEGA factory trained and
qualified personnel.
Customers performing MTT20 installations
MUST add additional manhours above and
beyond totals contained in figure 2-2.
MTT20-KOM785(7)-4
5 Jan 2011
SECTION 2
Support Equipment & Manhour Requirements

MTT20 TANK INSTALLATION

CREW TOTAL SUB
STEP OPERATION SIZE HOURS HOURS TOTAL
1 PREPERATION
A. Job Site 2 2.0 4.0
B. Unpacking 2 1.0 2.0
6.0
2 MTT PREPARATION
A. Hydraulic 3 6.0 18.0
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 1.5 1.5
29.0
3 TRUCK PREPARATION
A. Electrical 1 4.5 0.5
A. Hydraulic 3 6.0 18.0
B. Controls 1 5.0 5.0
27.5
4 MTT TO TRUCK MATING
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 4.0 8.0
F. Electrical Hook-up 2 2.0 4.0
26.0
5 FINAL ASSEMBLY
A. Mud Flaps 2 1.0 2.0
B. Rock Ejector 2 0.5 1.0
C. Ladder/Rails 1 2.5 2.5
D. Hose Reel 2 1.5 3.0
E. Spray Bar 2 2.0 4.0
F. Dump Bar 2 1.5 3.0
G. Conical Fill 1 1.0 1.0
16.5

FUNCTIONAL CHECK
6 PROCEDURES
A. Commissioning 2 3.0 6.0
6.0

Figure 2-2 Manhour Requirements (Typical)

TOTAL MANHOURS 111.0

2-2
 MTT20-KOM785(7)-4
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SECTION 3
Job Site Selection & Preparation

Contents
Job Site Selection ………………………… 3-1 Site Preparation …………………….…...... 3-1

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. 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.

1. Level ground. 3. Identify any shipping list shortages and

obtain required parts.
2. Hard packed surface able to support a
heavy equipment cranes and a 4. If possible, locate assembly parts close to
161,700lbs/73335kg assembled vehicle. their intended installation location on the
vehicle or MTT.
3. Shelter (highly recommended).

SITE PREPARATION
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.

3-1
MTT20-KOM785(7)-4
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SECTION 3
Job Site Selection & Preparation

3-2(Blank)
 MTT20-KOM785(7)-4
5 Jan 2011
SECTION 4
Unpacking & Parts Identification

Contents
Unpacking and Parts Identification ........... 4-1

UNPACKING AND PARTS

IDENTIFICATION
5. Remove all parts from the shipping crate
and discard excess packing material.

6. Identify each part, annotate packing list and

sort parts by hydraulic, electrical,
pneumatic and other.

7. Identify any shipping list shortages and

obtain required parts.

8. If possible, locate assembly parts close to

their intended installation location on the
vehicle or MTT.

4-1
MTT20-KOM785(7)-4
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SECTION 4
Unpacking & Parts Identification

4-2 (Blank)
 MTT20-KOM785(7)-4
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SECTION 5
MTT Preparation

Contents
Description ……...…………..………....... 5-1 Electrical ……………………………....... 5-2
Hydraulics ………...…………..……….... 5-1 Foam Concentrate Tank …………..…….. 5-2

DESCRIPTION
Preparation of the MTT is the first essential Hydraulic Drive Motor
Pressure & Return Hoses
element in completing a timely mating of the
tank (MTT) and truck. The time spent
preparing the MTT is essential in reducing time
delays later in the installation process due to
lost parts, support equipment requirements or
required sub-assemblies. Follow the steps
listed below to fully prepare the tank for
installation.

HYDRAULICS Drive Motor

1. (If Required) Install the front tunnel Case Drain
hydraulic manifold to the manifold base
plate as shown below.

3. (If Equipped) Connect monitor hydraulic

control manifold pressure and return
hoses at the monitor hydraulic control
manifold as shown below.
FORWARD

2. Attach the hydraulic hoses (pressure, Hydraulic manifold

return and case drain) from the water mounted to front of
tank tunnel
pump hydraulic drive motor and solenoid
box to the rear of the manifold as shown
below and in Section 10 Figure 10-4
Hydraulic System.

5-1
MTT20-KOM785(7)-4
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SECTION 5
MTT Preparation
ELECTRICAL 2. Install foam concentrate supply hose from
1. Route and connect pre-wired tail light the foam shut-off valve to the monitor as
wiring to existing tail light connectors on shown in Section 10 Figure 10-7 Fire
truck chassis. Ensure connector Suppression System.
configuration is correct for chassis model
and as contained in Section 10 Figure 10-6
Lighting. Ensure foam concentrate hose slack in kept
to a minimum to prevent hose collapse
during monitor/foam operation.

Ensure foam concentrate hose length is

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

FOAM CONCENTRATE TANK

(If Equipped)

1. If required, install foam concentrate shut-

off valve and foam supply hose as shown in
Section 10 Figure 10-7 Fire Suppression
System.

5-2
 MTT20-KOM785(7)-4
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SECTION 6
Truck Preparation

Contents
Description ……………………………...... 6-1 Case Drain …….…………………................. 6-2
Hydraulics .....……………………….......... 6-1 Controls ………………………..………........ 6-3

DESCRIPTION
Preparation of the truck is the second essential
element in completing a timely mating of the
tank and truck. The time spent preparing the
truck is essential in reducing time delays later in
the installation process due to lost parts, support
equipment requirements or required sub
assembly. Follow the steps listed below to fully
prepare the truck for installation.
MEGA kits contain bulk hose and the required
fittings to fabricate hose assemblies. Once
major components are installed on the chassis
hoses can then be routed, measured, removed,
and assembled. Not measuring and fabricating
hose on the machine will unusable assemblies.

Care must be taken when routing hoses to

Truck ECM will be damaged when arc welding prevent chaffing or rubbing on any portion of
is performed while ECMs are connected to machine.
truck systems. Ensure ECMs are disconnected
from wiring harnesses before welding begins.
1. Prepare hoist system for hook up of the
MEGA hydraulic system as described in
HYDRAULICS upcoming steps and in Section 10 Figure
Review the following definitions and notes to
10-4 Hydraulic System.
ensure hydraulic components are configured
properly.
2. Disconnect #12 ORF steering hose as
shown below and remove existing #12 ORF
Hoist Compatible – Truck lift cylinders are
from the manifold.
attached to mounting brackets on the lower
section of the MTT. When the hydraulic Steering Hose
configuration of the truck is changed by
reattaching hoses to the hoist valve and control
coils are reinstalled to the EPC, the truck will
be capable of lifting the tank just like dump
body.

Non-Hoist Compatible – Truck lift cylinders

are removed. Tank must be raised by a crane. #12 ORF 90°
Elbow

Case Drain - Free to tank, unrestricted oil

flow path directly back to hydraulic tank.

6-1
MTT20-KOM785(7)-4
5 Jan 2011
SECTION 6
Truck Preparation
3. (MEGA provide Hydraulic Tank 4. (Hydraulic Tank Tube Modification - If
Replacement Tube Assembly Only) not included in the kit)
Remove the existing hydraulic tank tube Modify hydraulic tank tube assembly to
assembly and install the MEGA provided accept a #20 ORB T-Fitting as shown
tube assembly as shown below and in below and in Section 10 Figure 10-2
Section 10 Figure 10-2 Hydraulic System. Hydraulic System. Install #20 ORB T-
Ensure the existing restrictor plate and fitting.
temperature sensor is reinstalled into the
#20 ORB T-fitting
new tube assembly.

Hydraulic Tank
Tube Assembly

Original Tube

5. Install ORFS/JIC and JIC/JIC adapters as

shown below and in Section 10 Figure 10-2
Hydraulic System.

JIC/JIC
Restrictor Adapter
Temperature Plate
Sensor

Reconfigured Tube ORFS/JIC

Adapter

6-2
 MTT20-KOM785(7)-4
5 Jan 2011
SECTION 6
Truck Preparation

6. Install kit provided steering jumper hose
(JIC/ORFS) as shown below and in Section
10 Figure 10-2 Hydraulic System.
9. (Hoist Compatible Only) Disconnect
existing hose from the hoist RAISE hard-
line located under the chassis. Install hoist
manifold block as shown below and in
Section 10 Figure 10-2 Hydraulic System.
Mount the manifold block to the hard-line
with the thru holes and reconnect hoist raise
hose to the manifold block OPEN port.

JIC/ORFS
Jumper Hose

Hoist Raise Hose

7. Install a cap on the remaining open #20

ORFS port on the T-fitting.

CASE DRAIN
8. (MEGA provided Tank Cover Only)
Remove existing hydraulic tank cover and
configure the MEGA provided tank cover
with elbow and breather as shown below
and in Section 10 Figure 10-2 Hydraulic
System. Reinstall the new tank cover and
tighten bolts to standard torque values.

Manifold Block

6-3
MTT20-KOM785(7)-4
5 Jan 2011
SECTION 6
Truck Preparation
CONTROLS
5. Connect the BLACK 14 gauge wire to a
Cab Control & Cable quality chassis ground.
1. Install cab control floor plate and pedestal
as shown below and in the Section 10. 6. Route 40 pin cable between jump seat and
shifter console. Removal of jump seat may
2. Mount cab control box on the pedestal and be required to route cable.
connect 40 pin cable as shown below.
7. Secure jump seat.

8. Route cable under jump seat base to near

the fuse panel.

9. Remove cover shield under cab to gain

access to electrical connectors and cab
entry to cab.

10. There are 2 possible locations to enter the

cab of the tractor. 1) a large rubber
grommet or 2) a plate that blanks off an
electrical connector that may be available.
3. Locate 4 wire “SPARE” connector near
Electrical Connector Cover Plate
main fuse panel behind operators seat.

4. Connect 40 pin cable 14 gauge RED (+)

wires to vehicle 24 VDC switched power.
WHITE wires in connector.

Location of Rubber
Grommet

11. Route and secure control cable from

hydraulic sprayhead control to the
appropriate opening in the cab, Cut hole in
“SPARE” grommet or drill hole in plate to route cable
Connector to the inside of the cab.

12. Install 40 pin plug on cable.

The WHITE wires are switched power the

RED wires are constant battery power.

6-4
 MTT20-KOM785(7)-4
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SECTION 6
Truck Preparation

13. Connect control cable plug to cab control
cable receptacle.
14. Secure cable and install cover shield under
cab.
15. Reinstall all remove cab components and
secure.
16. (Electric Monitor Equipped Only) Install
the logic box as follows:
a. Mount the logic box under the
passenger jump seat with Velcro or
mount bolts as shown below.
c. Connect the logic box 12 gauge
power wire to the logic box. Route
cable to vehicle 24 VDC switched
power.
a. Install the 20 amp fuse harness to
the 12 gauge WHITE (+) power
cable. Crimp on a terminal lug to
fuse harness.
b. Connect WHITE (+) to vehicle
switch power and BLACK (-) to
reliable vehicle ground post.
c. Secure all electrical compartment
cabling and secure the jump seat
access cover.

Body Position Sensor

17. Rig the body position sensor to indicate a

body down position to the vehicle
Logic Box controller. Secure bellcrank.

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
(Overview).

6-5
MTT20-KOM785(7)-4
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SECTION 6
Truck Preparation

6-6
 MTT20-KOM785(7)-4
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SECTION 7
MTT to Truck Mating

Contents
Lifting the MTT ……….………................ 7-1 Front Mounts ………..……………........... 7-2
Pinning The MTT ……….………............. 7-1 Hydraulic Hosing …….………….............. 7-4
Tank Shimming ......................................... 7-2

LIFTING THE MTT 6. Lift MTT to ensure the tank is hanging

1. Move the selected crane into position for level. Adjust harness setup as required.
the lifting of the MTT.
7. Once tank is level when lifted, raise MTT
2. Rig a 4-point lifting harness that will span to the required height to clear truck chassis.
the MTT for lifting.
8. Move MTT over the truck and lower to
3. Clean and lubricate the MTT and truck allow MTT mounting holes to align with
mounting bores. truck mounting bores.

PINNING THE MTT

1. With MTT over chassis, determine the
amount of shims required on each mount to
provide equal shimming.

4. Locate and identify the following parts as

shown in Section 10 Figure 10-1 Tank
Mounting.
a. Pivot Pins
b. Hoist Cylinder Pins
c. Pin Shims 2. Align one side of the mount, insert shims as
d. Pin Keepers previously determined and insert one pin
e. Fasteners until the pin begins to engage the vehicle
f. MTT Body Guides mounting bore.
g. Body Retaining Bolt Mounts
h. Body Pads
i. Body Shims

5. Install body pads without shims onto the

MTT mounting rails leaving retaining bolts
loose.

7-1
MTT20-KOM785(7)-4
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SECTION 7
MTT to Truck Mating
3. Align the other side of the mount, insert
shims as previously determined and insert
the other pin until fully seated.
4. Drive the right side pins until fully seated.
5. Locate hoist cylinder upper mounting pins
and retainers.
6. Install hoist cylinders to hoist brackets on
the MTT.
It may be necessary to remove hoist
cylinder block off plates located between
the hoist cylinder hoses and the hoist
cylinder in order to align the cylinder with
the mount.
TANK SHIMMING
1. After rear pins are installed, but before final
lowering and front mount is fit and welded
in place, ensure body pads are installed on
the mounting rails of the tank with no
shims, and body pad retaining bolts
installed loosely.
7-2
2. Lower tank to chassis, noting any possible
clearance issues with mufflers, hoses, pipe
work, tanks or cables. Adjust as necessary
to gain proper clearance.
3. When tank is lowered, step back and
observe the tank to chassis alignment. Make
sure the tank appearance is correct. The
tank should roughly align at the same
angles as the 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 the entire weight of the tank
evenly on the main chassis frame rails.
5. Hoist tank and torque main body pads
properly. ( 75 – 90 ft/lbs)
Locate and observe appropriate Komatsu
chassis assembly manual for truck model
being worked on.
FRONT MOUNTING
1. Refer to section on front mounting
installation.
2. Install front body mounting pad with no
shim to pedestal and set in place.
 MTT20-KOM785(7)-4
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SECTION 7
MTT to Truck Mating

3. Lower tank to note measurements and 5. Tack weld in place and confirm contact
dimensions for front mounting only on front body mounting pads.
installation. Once clearance is as desired and
dimensions are noted, hoist tank and
block.

No contact is required on front

mounting pads. 1/16” clearance
between the front guide pads and the
front mounting is necessary. If contact
is placed on front mounting, possible
tank structure damage may occur.
Adjust pedestal as required to achieve
this clearance.
Observe and adjust any object(s) that
may present a clearance problem
between tank mounting and chassis
when hoisting or lowering tank.
6. Weld as per specifications.

7. Lower body again and check for

clearance.

8. Position front body retaining bolt/spring

mounts and gussets as per section 10
figure 10-1 Tank Mounting.

4. Refer to manufactures procedure for

adjusting and modifying the front
9. Ensure 7 ½” gap between the tank
mount pedestal height.
mount and the chassis mount is
maintained.

10. Tack weld in place as per

recommendations.

7-3
MTT20-KOM785(7)-4
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SECTION 7
MTT to Truck Mating
11. Locate body retaining hardware. Do not 15. Clean and touch up areas that were
install bolts at this time. After final damaged from the welding process.
operational checks are complete will be the
time to install this hardware.

It may be necessary to remove and relocate

some weld-on items on the chassis. These
items may interfere with the body retaining
bolt mounts and/or the body guides and
shims.

12. Fit retaining bolts in place to ensure nuts

can be started and 1/4” compression of
springs can be achieved. Remove prior to
hoisting tank.
13. Lift MTT and block.
14. Weld front body retaining mounts as per
specifications in the KOMATSU 785-7
manual and in section 10 figure 10-1 Tank
Mounting.
HYDRAULICS
1. (Hoist-Compatible Units Only) Perform a
hoist system operational check using the
hoist cylinders as follows:
Preparation and hoisting tank
Place unit on solid, level work area with
proper clearance to accommodate the MTT
when hoisted.

a. Ensure unit contains no water.

b. Remove electrical and hydraulic power

from unit.

c. Remove components (e.g. drain bar,

hose reel..) bolted to the bottom of the
water pump sump that may be damaged
when tank is hoisted.

Ensure all components that may cause

interference with chassis to tank when
tank is hoisted are disconnected and/or
removed from tank or chassis. Failure to
remove components will cause damage
to MTT and/or chassis.

7-4
 MTT20-KOM785(7)-4
5 Jan 2011
SECTION 7
MTT to Truck Mating

d. Locate and secure tank lock back pins
or restraining device.
e. Ensure the 40 pin electrical cable
connector (truck to forward MTT
control box) is disconnected and
removed from the forward control box
and MTT.
i. Ensure the hoist cylinder raise supply hose
is connected to the open port of the dual
flange blanking plate on the hoist valve.
Hoist Raise
Supply to
Open Port

f. Ensure the 2 conductor hoist valve

control cable (MTT forward control box
to hoist valve) is disconnected and
Typical Hydraulic Connection
removed from the hoist valve control
and MTT.
j. Restore electrical power to chassis.
g. Ensure the OEM hoist control is
configured to hoist the tank. k. Start engine and hoist tank.

h. Ensure the MTT water pump pressure

hydraulic hose is connected to the
Ensure all proper hoisting procedures are
blank port of the dual flange blanking
followed. Failure to use a spotter to observe
plate as shown below.
and correct any clearance issues may result
in damage to MTT or truck while hoisting.

l. Raise tank slowly until tank lock back holes

Ensure all hydraulic pressure has been
align.
removed from hydraulic circuit prior to
removing hoses. Removing pressurized
m. Insert and secure lock back pins or
hoses may result in personnel injury or
restraining devices in the provided holes or
death.
fixtures.

n. Remove electrical and hydraulic power

from unit.
Use care when removing and installing
hoses. Unclean handling will induce
Lowering
dirt and debris resulting in possible
o. Restore electrical and hydraulic power to
damage to hydraulic components.
unit.
MTT
Pressure p. Raise MTT to remove lock back pins or
Hose to
Blank Port restraining devices.

Typical Hydraulic Connection

7-5
MTT20-KOM785(7)-4
5 Jan 2011

SECTION 7
MTT to Truck Mating
q. Lower MTT to chassis. 2. Install return hose from MTT torque tube
manifold to the hydraulic tank return
manifold fitting as shown below and in
Section 10 Figure 10-2 Hydraulic System.
Ensure all proper hoisting procedures are
followed. Failure to use a spotter to
observe and correct any clearance issues
FORWARD
may result in damage to MTT or truck
while hoisting.

r. When tank is lowered and resting on

chassis frame rails, remove electrical and
hydraulic power from unit.

s. Place lock back pins or restraining devices

in proper holding fixtures.

t. Reconfigure MTT for water truck

application.

1. Install case drain hose from the MTT

torque tube manifold to the hydraulic tank
cover as shown below and in Section 10
Figure 10-2 Hydraulic System.

FORWARD

Return

Case Drain Case Drain

Return

7-6
 MTT20-KOM785(7)-4
5 Jan 2011
SECTION 7
MTT to Truck Mating

3. (Hoist Compatible Only) Disconnect the

existing hoist raise hose from the lower
manifold block and reposition hose to the
blank port. Install pressure hose form the
MTT torque tube manifold to the MEGA
hoist manifold block located on the hoist
raise hard line as shown below and in
Section 10 Figure 10-2 Hydraulic System
(Hoist Compatible).
FORWARD

Pressure

Manifold
Block

Pressure

7-7
MTT20-KOM785(7)-4
5 Jan 2011

SECTION 7
MTT to Truck Mating
HYDRAULIC SPRAY HEAD
CONTROL BOX INTEGRATION Ensure hydraulic hosing and electrical
MEGA hydraulic control spray systems use the cabling fabrication is measured, fabricated,
PPC (Pilot Pressure Control) pilot pressure to routed and secured with vehicle operation
supply hydraulic pressure to control the in mind. Failure to do so will result in
sprayhead operation, hydraulic monitor and damage to hosing and cabling assemblies.
butterfly valves. The PPC supply pressure
offers a consistent hydraulic pressure source to 3. Install and secure pressure hose from the
the spray system when the engine is running. inlet side of the spray system hydraulic
By using this pressure source, the operation of filter. (refer to drawing # )
the spray head will be slowed down from
previous models offering about a 2 second
delay from the sprayhead ON to the sprayhead
OFF operation time.
PPC Supply
Pressure To
Hydraulic
Due to the nature of the sprayhead closing Filter
delay, it is important to educate the operators
about this feature. Failure to take into account
the delay in the operation of the sprayheads
will result in the discharge of water potentially
damaging objects or injuring persons with
water being sprayed from the system. 4. Install and secure adapter fitting on the
discharge fitting of the PPC pump. (refer to
1. Identify the PPC pump and adapter fittings. drawing # )

PPC Supply
Pressure Adapter
Fitting

PPC Pump

2. Measure and fabricate a hydraulic hose to 5. Route and secure the spray system supply
fit between the PPC pump and the hydraulic pressure hose to adapter fittings.
filter.

7-8
 MTT20-KOM785(7)-4
5 Jan 2011
SECTION 8
Final Assembly

Contents
Electrical/Controls ……………………... 8-1 Spray Bar ……………………………... 8-5
Forward Mounting Bolts ……………….. 8-3 Dump Bar …………………………….. 8-5
Mud Flaps ……………………………… 8-3 Conical Fill …………………………… 8-5
Decals ………………………………….. 8-4 Work Lights ………………………….. 8-5
Suction Loading Station ………………. 8-4 Ground Fill …………………………… 8-6
Ladders ………………………………... 8-4 Quick Drain …………………………… 8-6
Hose Reels ……………………………. 8-5

ELECTRICAL/CONTROLS

EPC Valve
1. (After MTT Hoisting Check) Remove the
coil from the directional control solenoid
located on the EPC valve as shown below Directional
and in Section 10 Figure 10-3 Control Control Coil
System (Hoist EPC Controls). Secure the
coil to a stand-off with a bolt and torque to
5 inch pounds. DO NOT disconnect the 3
pin Deutsch connector from the vehicle
wire harness.

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).

Directional Control Coil

Cut-off/Dump Solenoid Coil

8-1
MTT20-KOM785(7)-4
5 Jan 2011
SECTION 8
Final Assembly
3. Connect the MEGA supplied dummy coil Controls
to the vehicle 2 pin Deutsch (EPC cut-
off/dump) connector and secure the MEGA 1. Connect the 40 pin cab control cable from
dummy coil to a stand-off with a bolt. the MTT forward junction box to the
Torque bolt to 5 inch pounds. passenger side cab floor as shown below
and in Section 10 Figure 10-3 Control
System. Route and secure cable as
required.

2. Install the grounding cable between the

MTT and chassis as shown in Section 10
Figure 10-3 Control System (Cab Control
& Cabling).
2 Pin Deutsch Connector
3. (If equipped) Install the water level sensor
and cabling as shown in Section 10 Figure
10-3 Control System (Water Level).

4. (If equipped) Mount and connect the 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
MEGA Dummy Coil Lights.

4. Connect the MTT forward junction box 6. Install hoist lever lock out as shown below
PUMP cable to the EPC Cut-off/Dump and in Section 10 Figure 10-3 Bolt on.
valve solenoid as shown below and in
Section 10 Figure 10-3 Control System
(Hoist EPC Controls).

Hoist Lever Travel Limit Bracket

Cut-off/Dump Solenoid

8-2

SECTION 8
Final Assembly
Mandatory Water Pump Operational Check
after Reconfiguration
1. Startup vehicle and turn on the MTT
control system.
2. Turn ON the water pump switch.
Only operate the water pump low idle for
no longer than 2.5 minutes without water
in tank. Running the water pump longer
than 2.5 minutes without water in the MTT
will result in water pump shaft/seal
damage or complete failure.
3. Check to ensure water pump is spinning
CW and all hydraulic components are free
of oil leaks.
4. Refer to CAT Service and Maintenance
Manual for proper fluid levels and types.
Ensure hydraulic fluid level is at the
correct level.
5. Perform a full MTT operational check as
outlined in Section 9 Functional Check
Procedures before releasing and returning
the unit to service.
8-3
MTT20-KOM785(7)-4
5 Jan 2011
FORWARD MOUNTING BOLTS
Ensure all hoist cylinder and water pump
functional checks are completed and that the
hoist lever function is are completed prior to
installing body mounting bolts the hoist lever
function must be disabled or not installed
before installing and securing the MTT forward
mount bolts and springs. Failure to disable the
hoist controls will cause severe damage to the
MTT tank structure if hoist is activated with
cylinders installed. After functional checks are
preformed and all corrections are made these
bolts may be installed.
1. Install mounting bolts and springs as shown
below and in Section 10 Figure 10-1 Tank
Mounting. Torque mounting bolts until
springs are compressed 1/4” from the
relaxed length.
Tighten spring only 1/4”
from relaxed length.
MUD FLAPS
1. Remove mounting bar bracket and mount
bolts.
2. Install mud flap and mounting bar bracket
as shown in Section 10 Figure 10-3 Bolt-On
Assemblies.
MTT20-KOM785(7)-4
5 Jan 2011
SECTION 8
Final Assembly
DECALS
1. Install decals as described below and in 3. Install and secure hydraulic hosing to
Section 10 Figure 10-8 Decals. suction loading assembly and diversion
valve as shown in Section 10 Figure 10-4
a. MTT forward solenoid box. Hydraulic System.

4. Locate and secure suction hose for remote

filling

b. Cab windshield LADDERS (If Equipped)

c. Near hoist controls

d. On top of cab control near

monitor joystick

1. Locate ladders and mounting hardware.

2. Mount ladders as shown in Section 10

Figure 10-3 Bolt-On Assemblies.
SUCTION LOADING (If Equipped)

1. Locate suction loading assembly.

2. Mount and secure suction loading assembly

to MTT installed mounting as shown in
Section 10 Figure 10-3 Bolt-On
Assemblies.

8-4
 MTT20-KOM785(7)-4
5 Jan 2011
SECTION 8
Final Assembly

HOSE REELS (If Equipped) DUMP BAR (If Equipped)

1. Locate dump bar and mounting hardware.

2. Mount dump bar assembly as shown in

Section 10 Figure 10-3 Bolt-On
Assemblies.

CONICAL FILL (If Equipped)

1. Locate hose reel, mounting hardware, 1. Locate conical fill and mounting hardware.
adapters, soft hosing and clamps.
2. Mount conical fill assembly as shown in
2. Install the hose reel and route water supply Section 10 Figure 10-3 Bolt-On
as shown in Section 10 Figure 10-3 Bolt-On Assemblies.
Assemblies.
WORK LIGHTS (If Equipped)
SPRAY BAR

1. Locate spray bar, couplings and mounting

hardware.

2. Mount spray bar assembly as shown in 1. Locate work lights and wiring.
Section 10 Figure 10-3 Bolt-On
Assemblies. 2. Mount work lights to work light brackets at
rear of tank.

3. Route wiring to forward junction box.

4. Secure wiring to tank.

5. Install wiring in forward junction box as

shown in section 10 Figure 10-5 Controls.

8-5
MTT20-KOM785(7)-4
5 Jan 2011
SECTION 8
Final Assembly

GROUND FILL ANTI SIPHON PIPE

(If Equipped)

1. Locate Ground fill piping and hardware.

2. Mount ground fill piping as shown in

Section 10 Figure 10-3 Bolt On
Assemblies.

QUICK DRAIN (If Equipped)

1. Locate quick drain, mounts and hardware.

2. Install quick drain valve, piping and hosing

as shown in Section 10 Figure 10-3 Bolt On
Assemblies.

8-6

SECTION 9
Functional Check Procedures
Contents
Description ……………………………..... 9-1
Power On Engine Off Checks ...………… 9-1
Power ON Engine On Checks ……….…. 9-2
DESCRIPTION
The functional check procedures of the newly
assembled MTT 20 KOMATSU 785-7 is
designed to perform static checks of all systems
then move to dynamic checks of all systems
under loaded conditions and finally perform
required system adjustments.
Ensure MTT and truck is configured for water
truck application before proceeding with this
test. Performing these procedures with the
machine in the hoist configuration will result in
damage to the tuck and MTT structure.
1. Install hydraulic test gauges on the
hydraulic motor quick disconnect test
ports.
2. Install water pressure gauge on the spray
bar assembly ball or gate valve.
3. Fill water tank with a sufficient amount of
water to perform water pump RPM
adjustment and functional check of all
water spray systems to include the monitor
(if equipped).
Operating the water pump in a dry sump
will result in shaft seal damage.
4. Once tank is full, check pump couplings
for static leaks.
9-1
MTT20-KOM785(7)-4
5 Jan 2011
Water Pump Tuning ……..…………….. 9-3
Notes ………………………..…………. 9-5
5. Adjust all spray head adjustment rings to
full flow and maximum pattern width to
allow free flow of metal contaminants
during testing.
6. Ensure all cab control switches are in the
OFF position.
ELECTRICAL POWER ON AND ENGINE
OFF
7. Ensure vehicle battery power is connected.
8. Ensure all cab control switches are in the
OFF position.
9. Turn vehicle key switch ON (engine off).
Ensure the vehicle cycles through
recommended ECM functions per chassis
specific Operators Manual and all warning
and advisory lights extinguish.
ELECTRICAL POWER ON AND ENGINE
ON
10. Ensure the area around the vehicle is well
clear and ample space is available to
operate spray heads and monitor.
Use caution when performing this test.
Water may be discharged from any of the
available openings when performing this
test function.
11. Ensure wheels are chocked, parking brake
is set and vehicle is safe to operate.
MTT20-KOM785(7)-4
5 Jan 2011
SECTION 9
Functional Check Procedures
12. Start up the vehicle and ensure all required
warning and advisory lights extinguish per
chassis specific Operators Manual.
13. While the vehicle is running inspect all
installed water pump hydraulic
components and hoses for leaks.
14. Ensure all spray heads, dump bar, drain
valve, monitor and foam switches are in
the OFF position.
15. Turn the cab control box SYSTEM switch
ON. Turn the cab control box PUMP
switch ON. Inspect all water pump and
associated water components (torque tube
manifold, water pump hydraulic drive
motor and cross-over) connections and
hoses for leaks.
Engaging/disengaging the water pump
above LOW IDLE may result in water
pump component damage and reduced
service life.
16. Ensure water pump shaft is rotating in a
CW direction.
17. Inspect vehicle hydraulic tank to ensure
sufficient fluid level is available for
continuing test. If sufficient fluid is not
available shutdown vehicle, service
hydraulic tank and restart vehicle.
Ensure the MTT 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.
9-2
18. Increase engine RPM to normal operating
range and check all installed water pump
components and hoses for leaks.
19. Note hydraulic pressure and return
readings as well as water pump pressure at
about 2,100 engine RPM on work sheet
provide in the rear of this tech manual.
20. Reduce engine speed to LOW idle.
21. Turn water pump OFF.
Engaging/disengaging the water pump
above LOW IDLE may result in water
pump component damage and reduced
service life.
22. Turn system OFF.
Suction Loading
23. (If Equipped) Operate the suction
loading system as follows:
a. Vehicle – LOW IDLE.
b. Attach suction hose to the suction
pump assembly and immerse hose
into water source.
c. Activate suction pump diversion
valve to provide hydraulic pressure
for the suction pump drive motor.
d. Cab Control PUMP Switch – ON.
Engaging/disengaging the water
pump above LOW IDLE may result
in water pump component damage
and reduced service life.

SECTION 9
Functional Check Procedures
e. Engine RPM – As Required.
Priming of the suction loading pump
station may be required.
f. Record suction pump RPM. RPM
should be between 1900-1950.
Adjust flow control to obtain
suction pump target RPM.
g. Ensure MTT water level is
increasing with the suction loading
pump operating.
h. Vehicle- LOW IDLE.
i. Cab Control PUMP Switch – OFF.
Engaging/disengaging the water
pump above LOW IDLE may result
in water pump component damage
and reduced service life.
j. Diversion Valve – Reposition
handle to supply hydraulic pressure
to the MTT water pump drive
motor.
k. Disconnect and stow suction pump
supply hose.
24. Shutdown vehicle.
WATER PUMP TUNING
1. Clean water pump shaft and install
reflective tape just above the packing
gland.
9-3
MTT20-KOM785(7)-4
5 JAN 2011
2. Install a photo tachometer to measure
water pump shaft speed or prepare hand-
held device.
3. Ensure a water pressure gauge to the rear
spray bar ball or gate valve.
4. Start up vehicle.
5. At LOW IDLE turn the cab control
SYSTEM switch ON, then the PUMP
switch ON.
Operating the water pump in a dry sump
will result in shaft seal damage. Ensure the
MTT is filled with sufficient water to
perform operational test.
Engaging/disengaging the water pump
above LOW IDLE may result in water
pump component damage and reduced
service life.
6. Ensure the water pump is turning in a CW
rotation. Note water pump RPM and spray
bar water pressure.
Do not place your hand or tools within
pump bracket while pump is rotating
and/or pressure held within the motor
supply hose. Failure to follow proper
safety procedures could result in serious
injury
MTT20-KOM785(7)-4
5 Jan 2011
SECTION 9
Functional Check Procedures

7. Operate vehicle at HIGH IDLE. Note
water pump speed, water pressure and
hydraulic pressures. Water pump speed
should range from 1900-1950 RPM and
spar bar pressure should range from 90-
120 PSI.
11. Turn water pump OFF.
Engaging/disengaging the water pump
above LOW IDLE may result in water
pump component damage and reduced
service life.

Water pump RPM must not exceed 1,950 12. Turn system OFF.
rpm with engine at high idle. Failure to
keep water pump speed below 1,950 13. Shutdown vehicle.
RPMs will result in water pump failure
and reduced sprayhead service life. 14. Remove photo tachometer and water and
hydraulic pressure gauges.
8. 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.

Do not operate water pump at HIGH idle

for longer than 2.5 minutes without
discharging water from spray heads or
monitor. Allowing the water pump to run
longer than 2.5 minutes may cause water
pump to overheat resulting in damage to
the water pump, seals and bearings.

The flow control valve can control as much

as 35 GPM (135 lpm) or about 700 RPM.

9. Once desired RPM is obtained, tighten jam

nut on flow control valve.

10. Reduce engine speed to LOW idle.

9-4
 MTT20-KOM785(7)-4
5 Jan 2011

SECTION 9
Functional Check Procedures

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 1950 RPM, WATER PUMP

SHAFT SPEED. Failure to keep water pump shaft
speed below 1950 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 web site at www.megacorpinc.com
for more contact information.

9-5
MTT20-KOM785(7)-4
5 Jan 2011
SECTION 9
Functional Check Procedures

NOTES

9-6