genuine mega cat785d-rsp-5.pdf · 2018. 7. 19. · met(dg)-cat 785(d)-5 3 feb 2017 section 2...

MEGA WORLDWIDE 1-800-345-8889 • 505-345-2661 • www.megacorpinc.com

® MEGA Corp., Inc. All Rights Reserved

GENUINE MEGA

SCHEDULED/SPECIALINSPECTIONS & RECOMMENDED

SUPPORT PARTS

MET(DG)-CAT785(D)-INSP-RSP-5

MET(DG)-CAT 785(D)-53 Feb 2017

TABLE OF CONTENTS

A

Section 1 Definitions and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Section 2 Scheduled Maintenance Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Section 3 Special Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Section 4 Recommended Support Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1


TABLE OF CONTENTS

B (Blank)


SECTION 1Definitions and Abbreviations

ContentsManual Usage .................................................................. ....1-1 Safety Messages ..................................................................1-2

Warning, Caution And Notes ..........................................1-1Use Of Shall, Will, Should And May ...............................1-1

Abbreviations .......................................................................1-3MET DG Overview (Typical) ........................................ ....1-4

MANUAL USAGEThis technical manual contains information requiredto safely maintain a MET CAT785(D). If your system isnot covered in this manual please contact MEGACorp. Product Support Group at: US toll free: 1-800-345-8889 Direct: 1-505-345-2661 or visit our website atwww.megacorpinc.com for more detailed contactinformation.

See the CAT 785(D) Operators and MaintenanceSafety Manuals for specific vehicle systeminformation and operating procedures. The exactlocation of the hazards and description of thehazards are reviewed in this section. All personnelworking on or operating the MET must becomefamiliarized with all of the safety messages.

Due to the nature of these processes, ensure that allsafety information, warnings and instructions areread and understood before any operation or anymaintenance procedures are performed. Someprocedures take place at moderate heights, ensureproper safety procedures are maintained whenperforming these actions. Failure to use and maintainproper safety equipment and procedures will causeinjury, death or damage to equipment.

WARNING, CAUTION AND NOTESThe following definitions are found throughout themanual and apply as follows:

Operating procedures and techniques, which couldresult in personal injury and/or loss of life if notcarefully followed.

Operating procedures and techniques, which couldresult in damage to equipment if not carefullyfollowed.

Operating procedures and techniques that areconsidered essential to emphasize.

USE OF SHALL, WILL, SHOULD AND MAY

Shall and Will – Used when application of aprocedure is mandatory.

Should – Used when application of a procedure isrecommended.

May - Used to indicate an acceptable or suggestedmeans of accomplishment.

1-1

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SAFETY MESSAGESThere are several specific safety messages on thismachine. The exact location of the hazards anddescription of the hazards are reviewed in thissection. All personnel working on or operating themachine must become familiarized with all the safetymessages.

Make sure that all of the safety messages are legible.Clean the safety messages or replace the safetymessages if you cannot read the words. Replace theillustrations if the illustrations are not legible. Whenyou clean the safety messages, use a cloth, water andsoap. Do not use solvent, gasoline or other harshchemicals to clean the safety messages. Solvents,gasoline or harsh chemicals could loosen theadhesive that secures the safety messages. Looseadhesive will allow the safety messages to detach.

Replace any safety message that is damaged ormissing. If a safety message is attached to a part thatis replaced, install a new safety message on thereplacement part.

DO NOT OPERATEThis safety label is located on control & junctionboxes..

Do not open this junction box unless you read andunderstand the instructions and warnings in theOperator and Maintenance Manual. Failure tofollow instructions or heed the warnings couldresult in serious injury or death.

BACKING RUNOVER HAZARD This safety label is located on the rear of the trailer.

The vehicle is equipped with a back-up alarm.Alarm must sound when operating this vehicle inreverse. Failure to maintain a clear view in thedirection of travel could result in serious injury ordeath.

FALL HAZARD This safety label is located on either side of thegooseneck.

Do not walk on the top of decks without fall arrestPPE. Serious injury or death could occur from afall.

1-2



HIGH PRESSURE MOTOR (4)This safety label is located in the brake systemcompartment

Hydraulic motor and supply lines contain oilunder high pressure. Improper removal andrepair procedures could cause severe injury. Toremove or repair, instructions in the MaintenanceManual must be followed.

ABBREVIATIONSCW - clockwiseDG- Drop Goosenecke.g. - example given ft - feeti.e. - included exampleLT - Left (as viewed from the rear of the unit looking forward)MET - MEGA Equipment Trailerpsi - pounds square inchRT - Right (as viewed from the rear of the unit looking forward)ROPS - Rollover Protection Systemrpm - revolutions per minuteHPU- Hydraulic Power Unit

1-3



MET(DG) 180 OVERVIEW (TYPICAL)

1-4

75

1 GOOSENECK2 RAMPS3 BRAKE & TURN LIGHTS4 HITCH, SADDLE, & DECK5 FENDERS (IF EQUIPPED)

2

4

6 TIE DOWN CLEETS7 LADDERS8 WHEEL GROUP9 TRAILING AXLE ASSEMBLY

10 DECK RAISE FOOT

4

11

6

8

9

3

TOP

10

SIDE 1



1-5

1 HITCH FENDERS2 HITCH SADDLE3 MECHANICAL TURN LIMIT INDICATOR

3

4 KICKSTAND5 DECK LIFT CYLINDERS6 DECK LOCK

10

1

4

2

6

5



1-6


SECTION 2Scheduled Maintenance Inspections

ContentsChassis Tow Systems..........................................................2-1 Gooseneck.............................................................................2-2

Cab Controls & Remote.....................................................2-1Hitch, Deck, & Fender.........................................................2-2

MET Structures.....................................................................2-3Trailing Axle...........................................................................2-3

DESCRIPTIONThis section establishes scheduled maintenance inspections of the MET and associated systems at the desig-nated frequencies. Performing these inspections will identify potential system discrepancies and allow preven-tative maintenance to be performed before a component or system is rendered totally inoperative. Once again, these inspections are in addition to and do not replace existing CAT scheduled inspection requirements.

FREQUENCY

STEPCHASSIS TOW SYSTEMS BI‐WEEKLY

(250 HRS)MONTHLY (500 HRS)

QUARTERLY (1000 HRS)

SEMI‐ANNUAL (2500 HRS)

ANNUALLY (5000 HRS)

1After initial installation or system component replacement, followchassis required initial maintenance schedule for that componentor system. Service as required.

2 Hoist pump hydraulic supply connections for gooseneck, securityleaks and damage. X3 Trailer electrical harness for damage and security X4 Inspect trailer lubrication supply lines for damage, security, andleaks. X

STEPCAB CONTROLS & REMOTE BI‐WEEKLY




ANNUALLY (5000 HRS)

1 Trailer brake lever, valve and hoses for security and damage X2 Trailer control display and cabling for mounting, security anddamage. X3 Trailer camera display and cabling for mounting security anddamage. X4 Trailer remote control, cradle and cabling for security and damage. X

2-1



FREQUENCY

STEPHITCH, DECK, & FENDER BI‐WEEKLY




ANNUALLY (5000 HRS)

1 Check body position switch and cabling for damage and security X2 Check lights, backup alarms, alarm assembly, and beacon fordamage, security and proper operation. X3 Check hitch receiver and saddle assembly mounts for damage andsecurity. Inspect pivot pins and hitch clamp assemblies for security. X4 Check ball hitch skirt assembly for damage, security, cracks. X5

Check turn limit indicator for damage, security and cracks. Inspectchassis rail mount plates for cracks and all mounting hardware forsecurity. X

6Remove ball skirt and inspect upper retention plate for broken bolts andevidence of spherical ball contact with the upper retention plate. Ensureupper spherical ball shows evidence of lubrication. Damage & security toelectrical turn limit switch & cabling.

X

7Check clearance between hitch spherical ball and upper brassbushing. If gap is more than 0.010” shim upper brass bushing asdescribed in the MET180‐CAT 785(D) Field Installation Manual. X

8 Check tractor fender assemblies for damage, cracks and security. XSTEP

GOOSENECK BI‐WEEKLY (250 HRS)

MONTHLY (500 HRS)



ANNUALLY (5000 HRS)

1 Check gooseneck electrical cabling for damage and security from gooseneck to the tractor integration point. X2

Check gooseneck assembly for damage and cracks. Inspectgooseneck turn limit cheeks for evidence of turn limit indicatorcontact. Repair as required. X

3 Inspect lock & lift cylinder for leaks. Ensure grease is present atlock & lowerpin assemblies X4 Check transmitter, receiver, and antennas for damage and security X

STEPMET STRUCTURE BI‐WEEKLY




ANNUALLY (5000 HRS)

1 Check deck for security, damage and cracks. All housing & wiringfor damage & security. X2 Check deck raise cylinders & limit switch for security, damage, &leaks. X3 Check lights & ladders for damage, security and cracks. X4 Check all MET tail and clearance lights for damage, security, andproper operation X

2-2



FREQUENCY

STEPTRAILING AXLE ASSEMBLYS BI‐WEEKLY




ANNUALLY (5000 HRS)

1 Check wheel group components as defined in CAT 785D SIS.Service individual components as required.

2 Inspect wheel group sump breathers for evidence of oil leakage. X3

Inspect wheel groups for proper fluid levels. If more than 3 Quarts(2.84 liters) are added at any inspection, See CAT SIS fortroubleshooting. X

4 Inspect brake cooling components and manifolds for leaks,damage, security and leaks. X5 Inspect rear brake accumulators, brake valves, and slack adjustersfor damage, security, and leaks. X6 All brake system cooling and activation hoses for damage, securityand leaks. X7 Check MET wheel groups and upper rear deck for damage andcracks. X8

HYDRAULIC POWER UNIT (HPU) BI‐WEEKLY (250 HRS)

MONTHLY (500 HRS)



ANNUALLY (5000 HRS)

a. Engine Air Cleaner Element (Dual Element)‐Clean/Replace X

b. Engine Oil and Filter‐ChangeX

c. Alternator and Fan Belts‐ ReplaceX

d. Engine Crankcase Breather‐ReplaceX

e. Cooling System Water Temperature Regulator‐ReplaceX

f. Check fuel tank & hoses for leaks.X

g. HPU control display & cabling for security & damage.X

h. Hydraulic tank & housing for security damage & leaks.X

i. Hydraulic filters for bypass, damage & leaksX

j. Hydraulic valves. pumps & housing for security, damage,& leaks. X

k. Cooling fan for security, damage, & cleanliness.X

2-3


SECTION 3Special Inspections

ContentsDescription ............................................................................3-1 Hitch Ball Over Oscillation ............................................ ...3-1

Turn Limit Hard Contact....................................................3-1

DESCRIPTIONThis section contains special inspection requirementsfor exceeding an establish system limit. Theestablished inspections are designed to reveal anydamage sustained and determine serviceability ofthe MET system.

TURN LIMIT INDICATOR HARD CONTACTThe metal turn limit indicator is designed to provide avisual indication to the operator they have reachedthe maximum rotation of the MET. This is noted bythe gooseneck cheek contacting the turn limitindicator as shown below.

When the system experiences high impact loadsdamage may occur to both the gooseneck cheekplates and the turn limit indicator. The gooseneckcheek plates may buckle or begin to weaken andeventually cause further damage to adjoininggooseneck plate structure. The turn limit indicatormay experience excessive bending moments andbegin to tear or weaken lower mount plate andsaddle welds.

INSPECTION1. Check gooseneck cheek structure for damage.

Inspect welds for evidence of cracking and metalplates for signs of buckling.

2. Check adjoining gooseneck interior and exteriorstructure for damage. Inspect gooseneck

structure and plating for weld cracking andevidence of steel plate buckling.

3. Check turn limit indicator for damage. Inspectplates and welds for cracks and deformities.

4. Check turn limit indicator deck and saddlemounts for damage. Inspect rail mounting platesand angle brackets for cracks and loose hardware.

Contact MEGA Product Support at: 1-800- 345-8889for any major structural repair issues.

HITCH BALL OVER OSCILLATIONThe hitch ball assembly is designed to oscillate10 degrees within the lower socket assembly asshown below. This allows the MET a large range ofmotion when operating in the pit, on haul road, oncoal piles and when unloading the MET.

10Retention

Plates

Ball to Retention

Plate Contact

Ball HitchRetention

Plates

3-1



When operating the MET beyond the allowable10 degree limit, the ball will contact the upperretention plate and potentially damage severalcomponents of the system. Repeated and hardcontacts will damage upper retaining plates, upperbrass bushings, mount bolts and in severe casescause structural damage to the gooseneck, ball hitchtube, and hitch receiver upper mount plate.

INSPECTION1. Remove hitch ball skirt assembly.

2. Check for broken bolts on the upper retainingplate. If mount bolts are missing, have beensheared off or laying on the lower receiver, severecontact has occurred.

3. Check upper retaining plates and hitch ball fordamage. Inspect retaining plates and hitch ballfor evidence of hard contacts as shown below.

4. If hard contact is confirmed, remove upperretention plates and inspect the upper retentionplates, brass bushings and lower receiver asfollows:a. Inspect upper retention plates for

mushrooming of flat mating ends. Lay theretention plate on a flat surface and check forwarpage. If retention plate is mushroomed orwarped the retention plate set must bereplaced.

b. Check upper brass bushings for overoscillation ball contact as shown below. Ifcontacted and deformed replace upperbushing set.

Ball Contact

Retention Plate Contact

Mushrooming Joint

Deformed Upper Bearing

3-2



c. Inspect lower receiver assembly forelongated/pulled upper retention plate boltholes and deformation of the lower receivermount ring as shown below. If eithercondition is noted, contact Mega ProductSupport to determine if the receiver can berefurbished or if a replacement is required.

5. Check interior and exterior gooseneck structureand plating for damage. Inspect gooseneckstructure and plating for weld cracking andevidence of steel plate buckling. If eithercondition is noted contact MEGA ProductSupport at: 1-800-345-8889.

Deformed Mount Ring

Elongated/Pulled Threads

3-3



3-4 (Blank)

MET(DG)-CAT785(D)-53 Feb 2017

SECTION 4Recommended Support Parts

ContentsDescription .........................................................................4-1 Deck............................................................................................. 4-1

HPU Parts Group .........................................................................................4-1Miscellaneous Parts Group..................................................................4-1

Hitch &Kickstand Assembly Parts Group........................... 4-1Gooseneck Assembly……............................................................... 4-2

DESCRIPTIONThis section contains a listing of recommended support parts that should be available in the supplywarehouse. The tables are categorized by specific sub system of the MET. DO NOT FORGET that METs are notall configured the same and there are several variations of hydraulic systems, gooseneck configurations andturn limit indicators. Ensure MET serial numbers and actual component part numbers are checked beforeordering any parts. Once parts are issued from warehouse stock ensure depleted quantities are replenished tokeep the recommended support parts package at 100%.

Hydraulic Power Unit (HPU)PART DESCRIPTION PART NO. QTY

1. Air Filter (PERKINS 135326206) 308084 22. Engine Oil Filter Kit (CAT 220-1523) 308085 13. Engine Fuel Filter Kit (CAT 067-6987) 308086 14. Crankcase Breather (CAT 153-5939) 308087 25. Fan Belt (CAT 211-5172) 308088 16. Engine Thermostat (CAT 249-5541) 308089 17. Thermostat Gasket (CAT 439-0945) 308090 1

Miscellaneous Part GroupPART DESCRIPTION PART NO. QTY

1. Light LED clearance Red 355374 22. Light LED Clearance Amber 355375 23. Beacon Strobe Light Amber 307762 14. Light, Work 307822 25. Camera Cover 308099 26. Control Pad, Remote 308100 1

DeckPART DESCRIPTION PART NO. QTY

1. Ladder, Assy (Deck&Trailing Axle) 050352 12. Plate, Ladder, (Deck & Trailing Axle) 050352-01 13. O-Ring Kit Rebuild Deck 308079 24. Connection, Pneumatic, Service Blue 301300 15. Connection, Pneumatic, Service, Red 301301 16. Switch, Proximity (Raise Cylinders) 306742 1

4-1


SECTION 4Recommended Support Parts

Hitch & Kickstand AssemblyPART DESCRIPTION PART NO. QTY

1. Shim Pack Hitch 040539 12. Screw, Cap 1 1/8” UNC 350507 223. Washer, Flat 354576 224. Limit Switch Assy 043305 15. Arm, Turn Limit 050332 16. O-Ring, Rebuild Kit 308076 27. Coil, Valve, Kickstand and Lift 308103 28. Coil, Valve Gooseneck Lock 308104 39. Coil Valve Gooseneck Lift/Float 308105 110. Coil Valve Gooseneck Lock/Float 308106 1

Gooseneck AssemblyPART DESCRIPTION PART NO. QTY

1. Cylinder, Lock 307647 12. O-Ring kit (lock cylinder) 308077 13. O-Ring kit (Lift Cylinder) 308078 14. Plate, Wear 050048 25. Bolt, M12x1.75 X 40mm (wear Plate) 355521 166. Washer M12 (Wear Plate) 355265 167. Connection, Pneumatic, Service, Blue 301300 18. Connection, Pneumatic, Service, Red 301301 19. Switch, Proximity (Leveling Cylinders) 306742 1

Trailing Axle AssemblyPART DESCRIPTION PART NO. QTY

1. Valve, Pneumatic, RE-6 355973 12. Switch, Assembly, Brake 050731 13. Cylinder, Master, Brake 355974 24. Beacon, Strobe, Amber 307762 15. Beacon, Strobe, Red 307764 16. Switch, Assembly, Door 307940 1

4-2

MET170-290 CAT789(C-D)-5TOCMET(DG)-180 CAT785D-5 Section 01MET(DG)-180 CAT785D-5 Section 02MET(DG)-180 CAT785D-5 Section 03MET(DG)-180 CAT785D-5 Section 04

genuine mega cat785d-rsp-5.pdf · 2018. 7. 19. · met(dg)-cat 785(d)-5 3 feb 2017 section 2...

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