- Caterpillar Products: All
Introduction
This special instruction contains general information that can be referenced when a fire suppression system is installed on Caterpillar machines.
Read the entire special instruction. Understand the information before you perform any procedures.
Caterpillar products are designed to minimize ignition points that can result in a fire. Caterpillar machines are designed to meet international standards in order to minimize the risk of any fire hazard. Any change to the design of Caterpillar machines may adversely affect the following:
- Equipment operation
- System performance
- Safety of the equipment
- Serviceability
This special instruction is intended to provide basic guidelines concerning the installation of fire suppression systems. The information in this special instruction will provide important considerations in order to ensure the safety, reliability, and efficiency of Caterpillar products and the fire suppression system.
Important Safety Information
The following information is an explanation of various labels that are found in this document.
Warnings
The warning label informs the technician that an injury or death can occur as a result of a condition that may exist.
Notices
A notice informs the technician that component damage can occur as a result of a condition that exists.
Notes
A note contains general information for the technician about the operation that is being performed.
Proper repair is important to the safe operation and the reliable operation of this machine. This document outlines basic recommended procedures. Some of the procedures require special tools, devices, or work methods.
Before you perform any repairs or before you perform any maintenance, read all safety information. Understand all safety information before you perform any repairs or before you perform any maintenance.
Safety information is provided in this document and on the machine. Safety information is also provided in the Operation and Maintenance Manual for each Caterpillar machine. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
The "Safety Alert Symbol" that is followed by a "Signal Word" identifies a hazard. "DANGER", "WARNING", and "CAUTION" are "Signal Words".
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| Illustration 1 | g00008666 |
The signal word "WARNING" has the following meanings:
- Pay Attention !
- Become Alert !
- Your Safety Is Involved !
The message that appears under the safety alert symbol explains the hazard.
Operations or conditions that may cause product damage are identified by "NOTICE" labels on the machine and in the service information.
The person that services the machine may be unfamiliar with many of the systems on the machine. Use caution when you perform service work. Special knowledge of the systems and of the components is important. Before you remove any component or before you disassemble any component obtain knowledge of the system and knowledge of the component.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. You must determine that the tools, procedures, work methods, and operating techniques are safe. You must determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.
Basic Precautions
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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. |
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Always observe the list of basic precautions that follows:
Safety Signs
Safety signs include the items that follow: signs, information plates and decals. Read all "Safety" signs on the machine before operating, lubricating or repairing the machine. Understand all "Safety" signs on the machine before operating, lubricating or repairing the machine. Replace any safety signs that are in the conditions that follow: damage, unreadable and missing.
Protective Equipment
When you work around the machine, always wear protective equipment that is required by the job conditions. Protective equipment includes the items that follow: hard hat, protective glasses and protective shoes. In particular, wear protective glasses when you use a hammer or when you use a sledge hammer. When you weld use the appropriate protective equipment that is required by the job conditions. Protective equipment for welding includes the items that follow: gloves, welding hood, goggles and apron. Do not wear loose clothing or jewelry that can catch on parts of the machine.
Mounting and Dismounting
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| Illustration 2 | g00037860 |
Use steps and handholds whenever you mount the machine. Use steps and handholds whenever you dismount the machine. Before you mount the machine, clean the step and the handholds. Inspect the step and handholds. Make all necessary repairs.
Face the machine whenever you mount the machine and whenever you dismount the machine. Maintain a three-point contact with the step and with handholds.
Note: Three-point contact can be two feet and one hand. Three-point contact can also be one foot and two hands.
Do not mount a moving machine. Do not dismount a moving machine. Never jump off the machine. Do not try to mount the machine when you carry tools or supplies. Do not try to dismount the machine when you are carrying tools or supplies. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds when you enter the cab or when you exit the cab.
Hot Fluids and Parts
To avoid burns, be alert for hot parts on machines which have just been stopped and for hot fluids in lines, tubes, and compartments.
Be careful when you remove filler caps, breathers, and plugs on the machine. Hold a rag over the cap or plug in order to prevent being sprayed by pressurized liquids. When the machine has just been stopped, the danger of hot fluids is greater.
Batteries
Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Do not allow battery electrolyte to make contact with the skin or with the eyes. Battery electrolyte is an acid. In case of contact with battery electrolyte, immediately wash the skin with soap and water. For contact with the eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical attention.
Pressurized Items
- Always use a board or a piece of cardboard when you check for a leak. Leaking fluid under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.
- Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure that all raised components are blocked correctly. Be alert for possible pressure when you disconnect any device from a system that utilizes pressure.
- Fuel lines that are damaged and fuel lines that are loose can cause fires. Lubrication lines that are damaged and lubrication lines that are loose can cause fires. Hydraulic lines, tubes, and hoses that are damaged can cause fires. Hydraulic lines, tubes, and hoses that are loose can cause fires. Do not bend high pressure lines. Do not strike high pressure lines. Do not install lines which have been bent or damaged. Check lines, tubes, and hoses carefully. Do not use your bare hand to check for leaks. If fluids are injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.
- Pressurized air or pressurized water can cause personal injury. When pressurized air or pressurized water is used for cleaning, wear a protective face shield, protective clothing, and protective shoes. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). When you use a pressure washer, keep in mind that the nozzle pressures are very high. The nozzle pressures are frequently above 13790 kPa (2000 psi). Follow all of the recommended practices that are provided by the manufacturer of the pressure washer.
Welding on Caterpillar Machines
Refer to Service Welding Guide, SEPD0512 for welding information.
General Guidelines for Fire Suppression System Component Placement
Maintain Access Systems
International regulations require equipment to have access systems. The access systems must provide safe ingress and safe egress for operators and for service personnel.
Do not mount fire suppression equipment on access systems. Any obstruction on an access system may inhibit service personnel from servicing the machine. Any obstruction on an access system may restrict movement in an emergency.
- Fire suppression equipment should not be mounted in walkways.
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| Illustration 3 | g01025921 |
Chemical storage tanks are blocking an access platform. | |
- Fire suppression equipment should not block steps or platforms.
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| Illustration 4 | g01026142 |
The nozzles for the fire suppression system are mounted over a stepping platform. | |
- Do not mount fire suppression equipment in a location that will restrict access into and out of the operators compartment.
- Do not mount fire suppression equipment in a location that will restrict access to ladders.
- Do not mount fire suppression equipment in a location that will generate trip hazards.
Maintain Access Locations for Maintenance
Daily maintenance is essential for the safe and efficient operation of Caterpillar machines. Access points have been designed into the machine in order to provide service personnel with easier access to machine components. Equipment that is improperly modified can block required access points.
- Do not install components in locations that will interfere with daily walk-around inspections.
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| Illustration 5 | g01025921 |
Chemical storage tanks are blocking access for cleaning the operator compartment windows. | |
- Do not install components in locations that will interfere with service requirements for the machine.
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| Illustration 6 | g01022051 |
The mounting bracket for the chemical storage tanks is welded (1) on a removable floorplate. | |
Maintain Operator Envelope
- Any modifications to the inside of the operator station should not project into the operator envelope or passenger envelope.
- Objects must not present an impact hazard to the operator in rough terrain.
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| Illustration 7 | g01026096 |
Manual actuator is mounted in a location that could injure the operator. | |
- Objects must not present an impact hazard to the operator in the event of a rollover.
Maintain Operator Visibility
- Do not block operator visibility. Visibility is critical in order to provide safe operation of Caterpillar machines.
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| Illustration 8 | g01049365 |
Consider operator visibility when mounting chemical storage tanks. | |
- Ensure that the location of all fire suppression equipment does not block the visibility of the operator in the following directions:
- Front view
- Left side view
- Right side view
- Rear view
- Front view
Protective Structures Must Not be Modified
The ROPS/FOPS structure (if equipped) on your machine is specifically designed, tested, and certified for that machine. Any alteration or any modification to the ROPS/FOPS structure could weaken the structure. This places the operator into an unprotected environment. Modifications or attachments that cause the machine to exceed the weight that is stamped on the certification plate also place the operator into an unprotected environment. The protection that is offered by the ROPS/FOPS structure will be impaired if the ROPS/FOPS structure has structural damage. Damage to the structure can be caused by an overturn, a falling object, a collision, etc. For more information on the ROPS/FOPS structure refer to Service Magazine, SEBD1587-00, "What ROPS/FOPS Certification Means".
- Do not mount items by welding brackets to the ROPS/FOPS structure.
- Do not mount items by drilling holes in the ROPS/FOPS structure.
- Consult your Caterpillar dealer for ROPS/FOPS mounting guidelines.
Guidelines for Routing
Hose Routing
All hoses on the machine will vibrate due to normal operation. Hoses must be mounted properly in order to eliminate all contact between components. Contact and vibration between components will accelerate the wear on the components. Accelerated wear on hoses will cause the hoses to leak or fail.
- Fire suppression hose (1) must be properly clamped.
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| Illustration 9 | g01046851 |
Fire suppression hose is in contact with a hydraulic hose. | |
- A fire suppression hose that is not properly clamped will cause damage (3) to surrounding components (2) .
- Do not use factory hoses to support the fire suppression system. This practice increases the stress on the hose. This practice creates rubbing points that may lead to hose failure.
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| Illustration 10 | g01026453 |
Lubrication hose (4) is being used to support fire suppression hoses (5) to the frame. | |
- Do not use tie wrap (8) to mount fire suppression hose (7) onto hydraulic hose (6). This practice places unacceptable stress on the hydraulic hose.
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| Illustration 11 | g01026555 |
Incorrect practice for mounting fire suppression hose. | |
- Hydraulic hose (6) will expand when the hose is pressurized. Hydraulic hose (6) will stretch when the hose is pressurized. Hose (6) and hose (7) will slide against each other during machine operation. Hoses that slide against each other will create a rubbing point that will lead to hose failure.
- Use mounting clamp (9) in order to secure fire suppression hose.
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| Illustration 12 | g01038527 |
Correct practice for mounting hose. | |
- Use properly sized mounting clamps for support of hoses. Refer to Hose Product and Tooling Guide, PECP5030-03, "Hose Accessories" for information on sizing mounting clamps.
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| Illustration 13 | g01047969 |
Example of common hose mounting clamps. | |
- Use a grommet when hoses are routed through sheet metal surfaces.
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| Illustration 14 | g01047594 |
Fire suppression actuation hose is routed through a sheet metal surface (10) without a protective grommet. | |
Remove All Contact Between Components
- In locations where hoses may rub together, install a clamp (1) in order to keep hoses from contacting each other.
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| Illustration 15 | g01039558 |
Correct hose separation. | |
- Do not use tie wraps (3) to secure fire suppression hose at a mounting location (2) .
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| Illustration 16 | g01047534 |
Incorrect hose separation at mounting locations. | |
- Use mounting clamps to remove all contact between hoses at mounting locations.
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| Illustration 17 | g01032805 |
Correct hose separation at mounting location (4) . | |
- Do not tie wrap shielding (6) around hose (5) as wear protection. Secure hose in a fixed location by using mounting clamps. Mounting clamps that are used in appropriate locations will eliminate contact between hoses and other components.
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| Illustration 18 | g01026568 |
Incorrect practice for hose protection. | |
- Do not install fire suppression distribution blocks (7) in a location that will allow contact with Caterpillar machine systems.
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| Illustration 19 | g01026548 |
Incorrect contact between fire suppression components and hydraulic hoses. | |
- Fire suppression components should be mounted in a location that will not contact Caterpillar machine systems.
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| Illustration 20 | g01047579 |
Correct separation of contact between fire suppression components (8) and machine systems. | |
- Do not route hose (9) across sharp edges.
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| Illustration 21 | g01032713 |
Incorrect hose routing. | |
- Hose vibration against a sharp edge will cause hose damage (10) .
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| Illustration 22 | g01047232 |
Incorrect routing will cause hose damage. | |
- Use mounting clamps to remove the contact between hose (11) and sharp edges.
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| Illustration 23 | g01047628 |
Correct routing around a sharp edge. | |
- Caterpillar does not recommend tie wrapping fire suppression hoses together. If a fire suppression hose is replaced, a technician may not know where tie wraps need to be placed. If a fire suppression hose is replaced, a technician may not know how many tie wraps to use.
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| Illustration 24 | g01025880 |
Tie wrapping fire suppression hoses together is not a recommended practice. | |
- Caterpillar recommends using a fixed threaded boss and a hose clamp for supporting hose. If a fire suppression hose needs to be replaced, the technician will know exactly where to attach the fire suppression hose for proper support.
- Fire suppression hose must not be tie wrapped to the following locations:
- Hydraulic hoses
- Wiring Harnesses
- Battery cables
- Fuel lines
- Air conditioning lines
Electrical Routing
Electrical wiring must be protected to minimize damage that could result in shorts. Special care is needed where a wiring harness is vulnerable to the following conditions:
- Being stepped on
- Hit by rocks
- Hit by debris from the machine
- Rubbing on other components
- Routing through walls
- Fire suppression hose (1) must be properly clamped.
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| Illustration 25 | g01026310 |
Fire suppression hose is not clamped and is in contact with the battery cable. | |
- Fire suppression hose that is not properly clamped may damage surrounding components.
- Do not use fire suppression hose as a mounting location (2) for a wiring harness.
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| Illustration 26 | g01026469 |
Incorrect attachment. | |
- Vibration, excessive load and movement of the fire suppression hose could damage the wiring harness.
- A damaged electrical system may cause the following conditions:
- Electrical shorts
- Loss of machine control
- Machine down time for maintenance
- Machine down time for electrical troubleshooting
- Electrical shorts
- Do not allow fire suppression hose (3) to make contact with wire harness assemblies (4) .
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| Illustration 27 | g01046979 |
Factory wiring harness has been damaged by fire suppression hose. | |
- Do not tie wrap shielding (5) around electrical wire as a method of wear protection. Secure the wire in a fixed location by using mounting clamps. Mounting clamps that are used in appropriate locations will eliminate contact between hoses and other components.
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| Illustration 28 | g01047906 |
Incorrect practice for wire protection. | |
- Use ladder clips (6) or properly sized mounting clamps (7) in order to secure electrical wires. Refer to Pocket Reference, SEBD0402-00, "Guidelines for Routing and Installing Wire Harness Assemblies" for more information on wire harness assemblies.
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| Illustration 29 | g01035173 |
Example of common electrical wire clamps. | |
- Use a grommet (8) when electrical wires are routed through sheet metal surfaces.
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| Illustration 30 | g01047898 |
Correct practice for routing wire through sheet metal. | |
Use Proper Strain Relief
- Electrical wire needs proper strain relief near the sensor box.
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| Illustration 31 | g01038429 |
Strain relief not provided near sensor box. | |
- Strain relief (2) is necessary to ensure that movement of a wire does not cause the wire to fail at the sensor box (3). Strain relief (2) should be located near the electrical wires point of attachment.
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| Illustration 32 | g01038523 |
Correct technique for proper strain relief. | |
Weld In Appropriate Locations
- Do not weld hose clamp bosses close to weld joints for structural members.
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| Illustration 33 | g01026459 |
Improper weld location. | |
- Do not weld nozzle brackets (2) close to weld joints (3) of structural members.
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| Illustration 34 | g01039110 |
Improper weld location. | |
- Welding too close to a structural weld may create a stress riser that will propagate cracks in the structural member.
Do Not Block Factory Components from Being Removed
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| Illustration 35 | g01049506 |
Example of the amount of disassembly required for an engine removal procedure on a haul truck. | |
Many Caterpillar parts may need to be removed in order to access and remove a major component.
Engines and other major machine components are designed to be removed and replaced quickly to minimize equipment down time.
The amount of time that is required to remove major components can be affected if fire suppression components are mounted in locations that will prevent component removal. Fire suppression suppliers must consider machine component removal procedures when locations for fire suppression equipment are determined.
Do Not Mount Fire Suppression Equipment In a Location That Will Interfere With Machine Controls
Machine controls are carefully placed by design to meet ergonomic standards. Machine controls are carefully placed by design to maintain safe and efficient operation of Caterpillar machines. Fire suppression controls and fire suppression circuits should not alter Caterpillar machine controls.
In some areas, Caterpillar machines and their electrical systems are required to meet standards relative to the effects of operating in or around electromagnetic fields. Fire suppression systems installed by fire suppression suppliers should have documentation to support compliance with these standards.
Safety Signs
Safety signs and proper training in relation to fire suppression systems must be provided to personnel that may operate a machine or to personnel that work in the vicinity of a machine. Personnel that operate or work in the vicinity of a machine must understand how to properly discharge the fire suppression system.
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| Illustration 36 | g01038815 |
Safety sign has not been maintained. | |
Fire suppression safety signs that are added to Caterpillar machines by fire suppression dealers must be maintained.
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| Illustration 37 | g01038795 |
Properly maintained safety sign. | |
Safety signs should also be translated into the appropriate language based on machine location.
Engine Shutdown
It is Caterpillar's position that the engine should continue to operate until the operator chooses to shut the engine off. For engines not electronically controlled and injected, an energize-to-shut-off system should be used. Control and protection systems shall be designed to keep the engine running until the operator chooses to stop the engine, unless a thorough safety hazard analysis concludes that shut down is the only reasonable option. All logic should prolong the operation and control of the engine for as long as possible or until the operator chooses to shut the engine off.
Fire System Monitoring Information
Some fire suppression systems require fire sensing equipment to be active between shifts and overnight. Some fire suppression systems require the system to be able to discharge upon the detection of a fire between shifts and overnight. This may require the system to be armed at all times:
- Service personnel must be informed when the fire suppression system is armed.
- Service personnel must be informed if the system will discharge when the battery disconnect switch is in the off position.
- Systems, which are installed around the battery disconnect switch, should provide proper warning for the operator.
- Systems, which are installed around the battery disconnect switch, should provide proper warning for service personnel.
- Instructions should be provided in order to disarm the system.
Fire suppression systems may be equipped with a manual disarm switch in order to disarm the fire suppression system. The manual disarm switch should be mounted in a visible location near ground level. Caterpillar recommends that the manual disarm switch should be mounted near the battery disconnect switch on the machine. Mounting the manual disarm switch near the battery disconnect switch will provide the technician with a convenient location to lockout\tagout the machine.
Maintenance and Operation Information
Fire suppression system operation and maintenance information must be provided by the installer. The owner of a Caterpillar machine must provide the operation and maintenance information in relation to the fire suppression system to any personnel that work in or around a Caterpillar machine equipped with a fire suppression system. Follow the fire suppression manufacturer's instructions with regard to the following:
- Maintenance intervals
- Inspection intervals
- Fire suppression system operation instructions
Personnel that operate or maintain a Caterpillar machine must understand the following:
- How the fire suppression system is actuated on a specific machine.
- How to determine if the system is charged and ready to operate.
- How to determine if the automatic detection system is active or inactive.
- How to make the fire suppression system safe for maintenance and service of the machine.
- How to avoid accidental discharge of the fire suppression system during maintenance and service of the machine.
Record Fire System Information
Caterpillar recommends that important fire suppression information should be kept in each machine equipped with fire suppression, as well as in the machines maintenance records.
Supplier information____________________
____________________
Type of system____________________
____________________
Dealer contact____________________
____________________
Maintenance information____________________
____________________
____________________
Procedure to disarm system____________________
____________________
____________________
____________________
____________________
Procedure to arm system____________________
____________________
____________________
____________________
____________________
Contact Information
Only dealers that are factory trained and authorized by the fire suppression system manufacturer, are certified to handle fire suppression systems for mobile equipment. The following information is a list of fire suppression manufacturers that specialize in the fire protection of mobile equipment:
- AFEX Fire Suppression Systems, 5808 Lease Lane, Raleigh, NC 27617; Phone (919) 781-3915, Fax (919) 787-3915, e-mail: afex@afexsystems.com, website: www.afexsystems.com
- Ansul Incorporated, One Stanton Street, Marinette, WI 54143; 1-800-862-6785, website: www.ansul.com
- Kidde-Fenwal Incorporated, Ashland, MA; (508) 881-2000, website: www.kiddefiresystems.com