CAT Fuel Pod Operation and Maintenance Manual A6474X459 - PDF DOWNLOAD

BI016359 A6474X459 December 2012

Operation and Maintenance Manual Fuel Pod

SAFETY.CAT.COM

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__________________________________________________________ This manual is intended to provide GENERAL product information for the Fuel Pod. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillar® reserves the right to revise models and designs without prior notice.

This Fuel Pod was manufactured under the guidelines, procedures and requirements of applicable regulatory agency standards.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Caterpillar® and these regulatory agencies, or any repair or replacement of parts contrary to the instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all Federal and State Mining laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

While this manual attempts to anticipate the most important operations and maintenance needs for this unit, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable. Distribution and access is limited only to authorized personnel. Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

© CATERPILLAR 2012 ALL RIGHTS RESERVED

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_________________________________________________ Table of contents

Table of Contents Safety Safety ........................................................................................ 1.3

Components Components .............................................................................. 2.3

Operation Operation .................................................................................. 3.3

Maintenance Maintenance ............................................................................. 4.3

Transportation Transportation ........................................................................... 5.3

Specifications Specifications ............................................................................ 6.3

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1

Safety

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__________________________________________________________ Safety

Your safety This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

The machine has been manufactured in accordance with state of the art and generally recognized safety standards and regulations. You and others can nevertheless be exposed to dangerous situations as a result of environmental influences, machine damage or operator errors.

Do not make any alterations or modifications which could impair the safety of the machine. All modifications and changes must be approved.

Use only original spare parts. Note that the use of parts from other manufacturers will void the guarantee.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.

Observe the safety and accident prevention regulations:

further operating manuals

■

of the mine,

■

of the mine inspector, and

■

of the mining supervisory authorities.

Please read the operating manuals of the components required for operation, e.g. pumps, motors, etc., carefully and thoroughly. Clarify any questions before starting work.

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Safety __________________________________________________________ Safety instructions General rules general

Always work with full concentration.

Familiarize yourself with your working environment.

personal protective equipment

safety equipment

symbol plates

Always wear your personal protective equipment.

Inform your colleagues of: ■

your exact location,

■

the work you are performing, and

■

the time that you will require.

Start the machine only when it is in a good and safe operating condition and all protective devices, cover plates, etc. are correctly installed. .

Observe the symbol plates on the machine.

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__________________________________________________________ Safety

Diesel Fuel Precautions

diesel vapors

Diesel vapors can irritate eyes, nose, throat and lungs. Excessive short term exposure can lead to dizziness, drowsiness, loss of coordination, blood pressure elevation, headaches, nausea, asphyxiation and lung damage. Breathing diesel vapors for long periods of time can cause kidney damage and reduce the clotting ability of blood.

diesel fuel

Diesel fuel can irritate the skin and aggravate any existing skin condition. A large skin exposure can lead to severe redness, pain and chemical burn blisters. If the fuel is not cleaned from the skin quickly, it is absorbed into the blood stream where it can cause symptoms identical to inhalation exposure.

minimize exposure

Wearing gloves may also help to reduce exposure. However, diesel fuel can easily penetrate most glove material. Gloves made of nitrile or viton have been shown to be the most effective barrier against penetration of diesel fuel. Neoprene gloves may also provide some limited protection. Vinyl gloves or butyl rubber gloves provide little or no protection.

Adequate first aid procedures are essential to minimize the health effects of exposure. If a worker gets diesel fuel on skin and/or clothing, he or she should flood the affected skin with water and remove and isolate all contaminated clothing (in a sealed plastic bag). The skin should be gently and thoroughly washed with soap and water. If symptoms such as redness or irritation develop, the worker should see a physician immediately.

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Safety __________________________________________________________

Diesel Fuel Precautions (con’t) If fuel is splashed into eyes, remove contact lenses. Flush eyes with water or normal saline solution for 20-30 minutes; at the same time contact the nearest hospital or poison control center.

When a worker is overexposed to the vapor, he or she should leave the contaminated area immediately and take deep breaths of fresh air. If the worker experiences symptoms such as wheezing, coughing, shortness of breath or burning in the mouth, throat or chest, the worker should immediately contact a physician and/or go to the hospital. spills

additional information

When cleaning up spills, remember to remove all sources of ignition.

Use absorbent paper to pick up the spilled fuel. Seal contaminated paper in a bag for disposal. Wash all contaminated surfaces with ethanol followed by washing with a soap and water solution.

For additional information specific to diesel fuel safety please refer to the diesel fuel MSDS sheet No.9909.

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2

Components

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____________________________________________________ Components

Components The Fuel Pod is comprised of a an Rapid Attachment System (RAS) mobile enclosure that contains a removable 450 gallon fuel cell that dispenses fuel via a pump and nozzle. It is equipped with an integrated fire suppression system and has space allowances for additional hand held fire suppression and storage. The Fuel Pod requires an external air source to actuate fuel delivery.

For component locations and descriptions throughout this manual refer to Fig.1 for location descriptions for sides and major components.

Fig.1: Fuel Pod overview Rear

Left/ Fire Suppression Side

Right / Pump Side

Placed hand held extinguisher mount

fire suppression

Placed hand held extinguisher mount

Front / Storage

The majority of the essential fire suppression equipment are located on the left side of the Fuel Pod behind the three sectioned doors. This includes the dual expellant tanks, dual nitrogen tanks, manually activated fire suppression actuator and the detection & control system. Expellant nozzles are located in each of the of the main compartments (right, left, and front) and on top of the fuel cell. (See Fig.2 & Fig.3 for layout)

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Components _____________________________________________________ Fig.2: Fire suppression component layout (left side)

E D

C

A

A

B F

A

Expellant Tanks

B

Expellant Propulsion Tanks

C

Detection & Control System

D

Manual Actuator

E

Expellant Nozzle

F

Gas Motor Assembly

Fig.3: Manual fire suppression actuator locations (top view) Right

Left

Front Note: Not shown hand held actuator located on length of hose (located on inby side for the Fuel Pod for quick actuation from the mine entry).

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____________________________________________________ Components pump components

The majority of the essential pumping components are located on the right side of the Fuel Pod behind the three sectioned doors. (See Fig.4 for layout) Fig.4 Pump components (right side)

A B

C

D

E

F

G

H

I

O

N

K L

M

J

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Components _____________________________________________________

fill area

A

Timer

B

Pilot Operated Air Valve

C

Water Trap & Lubricator

D

Emergency Stop

E

Pump Stop

F

Air Shut-Off Ball Valve

G

Y-Strainer

H

Pump

I

Hose Reel

J

Hose Reel Fitting

K

Hose Swivel

L

Nozzle

M

Nozzle Return Valve

N

Manual Actuator

O

Expellant Nozzle

The Fill Area is located on the top of the Fuel Pod under the hinged door. The level gauge, fuel cap, air filter and isolation valve are located here. The level gauge indicates how much fuel is in the fuel cell. The fuel cap is where additional fuel is added to refill the cell. The isolation valve controls the supply of fuel from the cell to the pump. The pump should not be run with the isolation valve in the off position (preventing fuel from leaving the cell). See Fig.5 for layout.

Fig.5 Fill area components

Isolation Valve

Level Gauge

Fuel Cap

Air Filter

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____________________________________________________ Components storage

The storage area is located in the front of the Fuel Pod behind the two hinged doors. Located in the front storage are fire extinguishers, a manual actuator for the fire suppression system and an expellant nozzle. There is additional space in this compartment for the storage of supplies. See Fig.6 for layout. Note: Hand held fire extinguishers are shown in the transport locations. Once placed the hand held fire extinguishers are located in provision on the outside of the pod (front right corner and rear left corner).

Fig.6 Storage (front) area

A

A C

B

A

Fire Extinguishers

B

Manual Actuator

C

Expellant Nozzle

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Components _____________________________________________________ fuel cell

Contained within the Fuel Pod is the 450 gallon (1703 L) stainless steel removable fuel cell. The Fill Area components are mounted to the top of the cell along with the vent stack, and the four lifting points. See Fig.7 for layout Fig.7 Fuel cell C

B

C

C C A

A

Fill Area Components

B

Vent Stack

C

Lifting Points

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____________________________________________________ Components drains

The Fuel Pod is equipped with 4 drains strategically placed to allow the draining of any fluids that have built up and accumulated within the pod. It should be noted that if oils or fuel is present it should be disposed of following all mine safety, state, and governing body environmental procedures for disposing of such materials. See Fig.8 for locations.

Fig.8 Drain locations

Rear

Front

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3

Operation

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_______________________________________________________ Operation

Operating Instructions fueling procedure

The diesel fuel pod is intended to dispense fuel while stationary in an installed capacity. Refer to Fig.9 - Fig.13 for specific locations. All doors should be closed when not in use. During use, only the doors over the pump should be opened. Ventilation will be thru the opened door, across the Pod, and into the return, and thru the vent stack.

1. Turn on the main air supply at the 1” ball valve. (Fig.9) 2. Check Emergency Stop is out. (Fig.9) 3. Remove dispensing nozzle from holster and take to the machine to be refueled. (Fig.10 & Fig.11) 4. Pull trigger on dispensing nozzle to start pump (Fig.12) 5. Refuel machine and return nozzle to holster. (Fig.13) 6. Turn off air at main air supply. (Fig.13) 7. If timer trips before the tank is full, return to holster and wait 10 seconds. The timer will automatically reset, then continue filling the tank. (Fig.10 - Fig.13) The pneumatic timer is preset to allow fueling of 35 gallons in one minute with a 75 PSI air supply.

Fig.9: Fueling steps 1 and 2.

2

1

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Operation _______________________________________________________ Fig.10: Nozzle location & removal

3

Fig.11 Nozzle in machine

3

Fig.12 Nozzle trigger

4

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_______________________________________________________ Operation Fig.13 Nozzle holster and pump components

5

6

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Operation _______________________________________________________ checking fuel level

The Fuel Pod has the capacity to hold up to 450 gallons (1703 L) of fuel. To check the current amount of fuel held within the pod, raise the top mounted cover in the Fill Area and examine the fuel level gauge.

Fig.14 Fill area components

Isolation Valve

Level Gauge

Air Filter Fuel Cap

refilling Fuel Pod

If the Fuel Pod requires more fuel it can be added from an outside source via the Fuel Cap located in the Fill Area.

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4

Maintenance

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_____________________________________________________Maintenance

Maintenance Pump Outlet

Valve Block

Pump Inlet

Air Inlet

Fig.15 Pump pump

The diaphragm pump (Fig.15) that powers the fuel delivery for the Fuel Pod is located on the right side of the machine. The pump is powered from an external air source, that is regulated and conditioned in the Fuel Pod before ultimately powering the pump that dispenses fuel. If any faults or problems arise with the pump is critical to determine which section of the pump is causing the problem. Service Kits are available for both the Air Section (Fig.16) and the Fluid Section (Fig.17) of the pump.

Fig. 16 Pump Air Section components

1 2

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Maintenance _____________________________________________________ air section torque values & lubrication / sealant notes

Air Section Torque Values: 1. Screws: 35-40 in. lbs (4.0 - 4.5 Nm) 2. Screws: 35-40 in. lbs (4.0 - 4.5 Nm) Lubricant / Sealants: Apply Lubriplate FML-2 grease (white food grade petroleum grease) to “O” Rings, “U” Cups and mating parts.

Apply anti-seize to threads at assembly.

2

4 1

3

2 Fig.17 Pump Fluid Section components

fluid section torque values & lubrication / sealant notes

Fluid Section Torque Values: 1. Diaphragm washer: 25-30 ft lbs. (33.9 - 40.7 Nm) 2. Screws: 10 - 12 ft lbs. (13.6 - 16.3 Nm) 3. Nuts: 10 - 12 ft lbs. (13.6 - 16.3 Nm) 4. Screws: tighten to 11-14 ft lbs. (14.9 - 19.0 Nm) Lubricant / Sealants: Apply Lubriplate FML-2 grease (white food grade petroleum grease) to “O” Rings, “U” Cups and mating parts.

Apply Loctite 242 to threads at assembly.

Apply anti-seize compound to threads, bolts, and nut flange heads which contact pump case when using stainless steel fasteners.

Apply PTFE tape to threads at assembly.

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_____________________________________________________Maintenance One of the most important areas to inspect when diagnosing a potential problem with the diaphragm pump is the seals/connections areas between sections. It is critical to maintain proper seals. Inspect all “O” rings for damage or deterioration. Check all bolts for proper tightness.

Do not over tighten bolts beyond their recommended torque values (refer to previous pages and manufacture's operating manual for torque values) . pump troubleshooting

Pump Troubleshooting Product discharged from the exhaust outlet (vent stack):  Check for diaphragm rupture.  Check tightness of (6) diaphragm washers.

Air bubbles in product discharge:  Check connections of suction plumbing (from fuel cell).  Check “O” rings between intake manifold and inlet side fluid caps.  Check tightness of (6) diaphragm washers.

Motor blows air or stalls:  Examine check valve for damage or wear [located behind valve block body, (6) M6x1 screws must be removed to remove valve block].  Check for restrictions in valve/exhaust.

Low output volume, erratic flow, or no flow:  Check air supply.  Check for plugged outlet hose.  Check for kinked (restrictive) outlet material hose.  Check for kinked (restrictive) or collapsed inlet material hose.  Check for pump cavitation - suction pipe should be sized at least as large as the inlet thread diameter of pump for proper flow if high viscosity fluids are being pumped. Suction hose must be a noncollapsing type, capable of pulling a high vacuum.  Check all joints on the inlet manifolds and suction connections.

These must be air tight.  Inspect the pump for solid objects lodged in the diaphragm chamber or the seat area.

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Maintenance _____________________________________________________

Filter/ Regulator

Gauge Location

Sight Dome

Lubricator

Lubricator Drain

Fig.18 Water trap and lubricator water trap

The left side of the water trap and lubricator house the filter/regulator assembly. The filter should be cleaned/replaced when it is visibly dirty.

Replacement or cleaning should only be carried out when the system is not pressurized (incoming air supply blocked via the air shut-off ball valve).

The filter/regulator assembly is equipped with an auto drain function that will drain excess water build up once it reaches the baffle level.

If leaks are detected in the filter/regulator side of the assembly a Service Kit is available with replacement gaskets and seals

lubricator

The right side of the water trap and lubricator houses the micro fog oil lubricator which introduces an oil lubricant into the air system to prolong the life of air system components by reducing friction and wear.

To add oil to the lubricator unscrew the clear sight dome mounted on the top of the assembly and add oil through the top. Only add oil when the system is not pressurized (incoming air supply blocked via the air shut-off ball valve).

Located on the bottom of the lubricator assembly is the petcock assembly which drains the oil from the lubricator (only drain if necessary during servicing). A quarter (1/4) turn is all that is required to actuate the drain function.

If any lubricator oil leaks are detected, determine from where oil is leaking. If leaks are coming from the main unit a Service Kit is available with replacement seals and gaskets. If the drain is the source of any leaks a replacement petcock should be installed.

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_____________________________________________________Maintenance fuel air filter

The fuel air filter located on top of the Fuel Pod under the fill area hatch should be changed every 3 to 6 months. The fuel air filter is removed by unscrewing it from the base attached to the fuel cell. A new filter is attached by screwing it onto the threads of the base that extends from the fuel cell.

Fig.19 Fuel air filter

Fuel Air Filter

Base

timer

The Fuel Pod is equipped with a fully pneumatic piloted fuel timer that is preset to allow 35 gallons of fuel in one minute. The Timer will disengage fuel delivery after one minute and must be reset by returning the nozzle to its holster for 10 seconds. The prescribed amount of fuel is set to correspond to the input pressure of 75 psi from the external source, but can be adjusted for variations in inlet pressure (via the top mounted dial).

visual inspection

Visual inspections should be carried out in regular intervals to check for any signs of abuse, wear, deterioration, or damage. Upon observation of any of the aforementioned conditions steps should be take to replace the affected parts. Items that should be regularly inspected: 1. Fuel nozzle and swivel assembly 2. Hose and reel assembly 3. Manual fire suppression actuators (4) 4. Fire suppression nozzles (4) 5. Ansul module (for error lights) 6. Removable fire extinguishers 7. Hoses and fittings If moved from an installed area to new location the exterior and interior compartments, in additional to the fuel cell, should all be examined to make sure no damage occurred during transportation.

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Maintenance _____________________________________________________ Fig.20 Air schematic

Fig.21 Hose routing

The pneumatic schematic depicts how the air is routed from the external source, through the system’s components, to achieve fuel delivery.

The hose routing diagram depicts the fuel & air hoses that plum the system. Note: Yellow = fuel line hoses, all others are air lines.

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_____________________________________________________Maintenance fire suppression

Maintenance to the fire suppression system should be carried out in semi-annual (or earlier) intervals.

1. Check to see that the hazard has not changed.

2. Remove all cartridges, install safety shipping caps, and put in a safe place for future reinstalling.

3. Note the general appearance of the system components checking for mechanical damage or corrosion, and check that the components are securely fastened and all hose fittings are tight.

4. Check nameplates to make certain they are clean, readable, and properly attached.

5. Remove tank fill caps and check that the agent tank is filled to the proper level with ANSUL FORAY dry chemical. The following table indicates the proper level for each size tank. Note: This table applies to both A-101 and LT-A-101 tanks. All measurements should be taken from the TOP of the fill opening (top of the threaded fill collar). If the depth of dry chemical exceeds the maxi-mum, do not add additional dry chemical. Tanks must be emptied and refilled with the correct amount of dry chemical as specified in the Recharge Section. Check the dry chemical for lumps. If lumps are present, drop one from a height of 4 in. (102 mm) onto a hard surface.

If the lumps do not break up completely, the dry chemical must be replaced.

Tank Size

Max. depth of dry chemical

101-10

5.25” (133 mm)

101-20

6.25” (159 mm)

101-20 Low Pro

5” (127 mm)

101-30

7.5” (191 mm)

6. Inspect threads on fill cap and on tank fill opening for nicks, burrs, or cross-threading 7. Check fill cap gasket and quad ring for elasticity, cuts, or checking, and lightly coat them with an extreme temperature silicon grease.

8. Disconnect sealed bursting disc assembly.

9. Examine the disc to ensure that it is not wrinkled, kinked, dented, or deformed in any way and then apply a thin coat of a good grade of extreme temperature silicone grease, to the male threads and reconnect the sealed burst disc assembly. Note: Before reconnecting blow all lines clear with dry air or nitrogen.

10. Check that the nozzle openings are not obstructed and that the nozzles are properly aimed and have not rotated out of position.

11. Make certain each nozzle has a blow-off cap properly installed (the opening of an F-1 /2 nozzle can be packed with an extreme temperature silicone grease, to avoid build-up of foreign material) and check that the caps are pliable and free of cuts and checks. Note: Blow-off caps must be replaced annually.

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Maintenance _____________________________________________________

actuator disassembly

12. Unscrew the pneumatic actuators from the cartridge receivers and inspect all threaded areas for nicks, burrs, and cross threads.

13. Clean actuators as follows (see Fig.22 for exploded view of actuator components) a. Using two wrenches, one positioned on the swivel nut, and one positioned on the bottom portion of the actuator, loosen the swivel nut and remove the top portion of the actuator. b. Using a wooden dowel, push the pin assembly and spring out of the actuator body. c. Remove the gasket from inside the cartridge thread port. Inspect, clean, apply a good grade of low temperature grease, and reinstall the gasket. Replace if necessary. d. Remove the 0-Rings from the pin assembly and swivel adaptor.

Inspect, clean, apply a good grade of low temperature grease, and reinstall the 0-Rings. Replace if necessary. e. Apply a small amount of grease to the puncture pin shaft. There is a U-Cup guide inside the actuator body and when the pin is reinstalled into the body, the grease on the shaft will lubricate the U-Cup. f. Clean the inner surface of the actuator body and, using a small diameter wire, clean the vent hole. Make certain not to scratch the inner surface g. To minimize the potential of moisture or dirt entering the actuator, apply a thin coat of a good grade of extreme temperature silicone grease, over the vent hole. h. Reinstall spring onto puncture pin shaft and insert into actuator body. Push pin down several times to allow grease to coat UCup. When positioned back in body, make certain the tip of the pin is above the gasket in the bottom of the actuator. i. Reinstall the actuator onto the cartridge. Hand tighten. j. Reinstall swivel adaptor in the correct position for the actuation lines and wrench tighten the swivel nut. Make certain all actuation and expellant lines are properly tightened into the actuator.

Fig.22

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_____________________________________________________Maintenance 14. Weigh the gas cartridge which was removed earlier. It must be +11/2 oz. from the weight stamped on the cartridge. Weigh cartridge with shipping cap removed.

15. Hand tighten the cartridge into the actuator.

16. Next, remove the gaskets from the manual remote actuators. Examine them for elasticity, cuts, and checking and lubricate them with a light coat of extreme temperature silicone grease.

17. Inspect the threaded areas for nicks, burrs, or cross threading and clean them with a stiff bristle brush.

18. Make certain the cartridge is removed. Pull the ring pin and operate the manual actuator to test the puncture lever for free movement.

19. Next, remove the puncture pin by disassembling the actuator and examine the pin to ensure it is sharp, straight, and free of corrosion.

20. Lubricate the puncture pin 0-ring and reassemble the actuator.

21. Insert ring pin and install visual seal to each actuator stem.

22. Weigh each actuator cartridge. Weight must be +/-1/4 oz. from weight stamped on cartridge. Weight cartridge with ship-ping cap removed.

23. Install cartridge into each remote actuator, hand tighten.

24. Refer to appropriate manual for detailed maintenance instructions if the system contains an automatic CHECKFIRE Detection System.

25. After all actuation devices are re-armed, record date of maintenance and inform personnel that the system is back in operation.

At the 12 year maintenance examination, along with completing the semi-annual maintenance requirements, some components will require hydrostatic testing.

1. Tank [600 psi (40.8 bar) hydro pressure] 2. Actuator hose [1,000 psi (69 bar) hydro pressure] 3. Cartridges - after properly discharging cartridges, return to ANSUL for hydro testing. recharging the system

The first concern in Recharge is to determine the cause of the system discharge and to have the problem corrected before rearming the fire suppression system. In the event of system discharge, the Fuel Pod must not be returned to service until he system has been recharged.

The system must be recharged immediately after use. A fire condition could cause damage to the hose and nozzles and possibly support members. Check all hose supports, hose, and all fitting connections.

Take the nozzles off, inspect for damage, corrosion, or obstructions, clean and reinstall, making certain they are aimed correctly. Blow-off caps must also be replaced.

Refer to Fig.23 for components and corresponding steps called out in the system recharge process.

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Maintenance _____________________________________________________ Fig.23 System recharge diagram

1. Pull ring on safety relief valve to relieve actuation pressure.

2. Disconnect actuation system hose at cartridge receiver/actuation assembly.

3. Open sealed burst disc assembly.

4. Remove dry chemical tank from its bracket.

5. Replace ruptured sealed burst disc assembly. Remove used sealed disc assembly from tank outlet. Clean tank threads. Apply a non·permanent thread sealant or Teflon tape to male threads on new sealed burst disc assembly. Install to tank outlet. Wrench tighten. Note: Before reconnecting, blow all lines clear with dry air or nitrogen.

6. Remove the tank fill cap, discard any remaining dry chemical, and fill each tank to its rated capacity with ANSUL FORAY dry chemical.

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_____________________________________________________Maintenance Tank Size

Amount of Recharge

101-10

8.5 lb ± 1 (3.9 kg ± .5)

101-20

17.0 lb ± 1 (7.7 kg ± .5)

101-30

25.0 lb ± 1 (11.3 kg ± .5)

7. Check inside the tank for any signs of corrosion. Check for any signs of moisture and/or chemical caking. Make certain gas tube and rubber check are securely in place.

8. Before securing the fill cap, brush the dry chemical from the threads on the fill cap and tank, and clean the gasket seating surface on the tank opening. Coat the gasket lightly with a good grade of extreme temperature silicone grease.

9. Secure the fill cap, hand tighten.

10. Loosen the bolts on the expellant gas cartridge bracket or remove the cartridge guard on the tank.

11. Unscrew and remove the empty expellant gas cartridge.

12. Disassemble and clean the cartridge actuator.

13. Install new cartridge per the following chart. Before installing, weigh cartridge to determine if it is within specifications stamped on the cartridge. Weigh cartridge with shipping cap removed.

Type of System

Cartridge P/N

A-101-10

15850 / 423439

LT-A-101-10

423429

A-101-20

423441

LT-A-101-20

423435

LT-LP-A-101-20

423435

A-101-30

423443

LT-A-101-30

423491

14. Re-install cartridge guard or retaining bolts on cartridge bracket 15. Return tanks to their brackets, reconnect sealed burst disc assembly to distribution hose, and tighten securely.

16. Pull up on the red actuator button 17. Remove spent cartridge. Weigh fully charged LT-10 cartridge.

Make certain cartridge is within ± 1/4 oz. (7.1 g) from weight stamped on cartridge. Install cartridge. Note: See page 4.18 - 4.19 for additional CHECKFIRE MP-N specific recharge instruction 18. Insert ring pin in actuator stem and seal with visual seal.

19. Reconnect actuation and, if necessary expellant gas hose. Wrench tighten.

20. Notify operating personnel that the suppression system is back in service and record date of recharge.

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Maintenance _____________________________________________________ Fig.24 CHECKFIRE MP-N module

The CHECKFIRE MP-N is an automatic detection system that is used for fire detection and suppression actuation. It can additionally be triggered manually in the instance of fire via the manual actuator mounted to the left of the control box. The system works in conjunction with the other manual actuators to provide multiple point of actuation to suppress fire.

The CHECKFIRE MP-N must be inspected visually, daily to verifying that the GREEN power LED is flashing and no other LED is illuminated.

Also, no audio alarm should be sounding. If any other conditions exist, contact the local authorized ANSUL distributor or whoever has been trained and authorized by ANSUL to perform inspection and maintenance checks.

LED Code

Trouble

Yellow Battery LED flashing

Internal battery disconnected

Yellow Release LED flashing

Release circuit is open

Yellow Release LED flashing, RED Alarm LED flashing

Release circuit has operated

Yellow Detection LED flashing

Detection circuit is open

Yellow Detection LED flashing, Red Alarm LED flashing

Initiating Input circuit No.2 is open

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_____________________________________________________Maintenance CHECKFIRE MP-N maintenance

The CHECKFIRE MP-N should have the following maintenance performed every six months (or sooner depending on operating environment).

Check all mounting bolts for tightness or corrosion.

2. Remove the LT-10R cartridge from the manual/automatic actuator, install shipping cap, and set aside in a safe location. Cartridge must be removed before continuing with the following steps or accidental system actuation will take place when gas motor is actuated.

3. Remove the connector lead from the gas motor.[Located on the Left Side wall, to the lower right hand side of the CHECKFIRE module] (See Fig.25) 1.

Fig.25 Gas motor location

4. Hand tighten the lead connector onto the test module.

5. Inspect the detection and interconnecting wiring as follows. First, check for wear due to vibration at penetrations, around corners, etc. Second, check for damage from direct impact or other abuse.

Then, check for tightness at points that are secured. Make certain fasteners have not come loose which would allow the wire to sag or shift.

6. If thermal detectors are used, check that they are securely mounted and have not corroded or been damaged.

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Maintenance _____________________________________________________ 7. Before conducting the functional test, remove the module cover and install the extender cables. Then, using a digital Ohmmeter, measure the resistance between terminals 3 and 4 with the detection wire connected. The resistance value should read approximately 4.7K ohms. This will verify the circuit is intact and the end-of -line resistor is connected 8. Check first time delay- Alarm to Shutdown- Using a short length of insulated wire stripped at both ends, hold one end of the wire to Terminal 3 and the other end to Terminal 4 on the control module.

(See Fig.26) Using a jumper wire, temporarily short Terminals 3 and 4, removing the jumper before the end of the first time delay cycle. This will test the non-latching function of the first time delay.

While the wire is being held in place, the RED Alarm LED will pulse and the sounder will operate. Remove the jumper wire. At this point, both the RED Alarm LED and the sounder will stop pulsing and the first time delay will recycle back to zero. The control module will return to normal with only the GREEN Power LED on.

Fig.26 Testing connections

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_____________________________________________________Maintenance

CHECKFIRE MP-N yearly maintenance

9. Check second time delay - Shutdown to Discharge—Once again, hold the wire on Terminals 3 and 4. The RED Alarm LED and the Audio Alarm will pulse. Hold the wire on the terminals for a period longer than what the first time delay is set up for. While holding the wire on the terminals, time the length of the first time delay to verify that it is the same as what it was set for. At the end of the first time delay cycle, the pulse rate of the Audio Alarm will change. This will start the cycle of the second time delay. At this point, the timing cycle is latched, and the wire jumper need not be held on the terminals. Also at this point, the shutdown relay will operate, sending a signal to the pump shutdown. Time the length of the second time delay to confirm that it is the same as what has been set. When the second time delay cycle is completed, the release circuit will activate causing the GREEN LED on the test module to illuminate.

10. Reset test module by pressing the reset button on the tester. Do not disconnect test module at this time.

11. After making sure that the control module is reset and operating in a normal non-alarm non-trouble mode, remove the gas motor actuator cable from the tester and connect to gas motor assembly.

Note: For proper assembly, the new gas motor must be threaded fully, 6 threads, onto the actuator body and properly secured with the allen head set screw 12. Remove control module cover screws and replace internal 3.6 VDC lithium battery. Caution: The battery is supplied with two separate plug-in connectors. One connector is used for plugging into MP-N modules and the other connector is used for plugging into SC-N modules. Do not cut off unused connector assembly. It must remain on battery module even though it is not used. Simply tuck the extra connector assembly along side the battery module when installing the cover. Record date of new battery Installation on label located near battery. Reinstall control module cover and depress "RESET" button. Note: Properly disposed of the lithium battery following all mine safety, local, and governing authorities regulations for battery disposal.

13. Reinstall LT-10-R cartridge by completing the following steps.

Make certain puncture pin is fully retracted and insert ring pin through actuator body into puncture pin shaft. Attach visual inspection seal. Remove shipping cap and weigh cartridge before installing. Replace if weight is 1/4 ounce (7.1 g) or more below weight stamped on LT-10-R cartridge. Screw cartridge into actuator body and hand tighten 14. Reset any auxiliary shutdown and alarm equipment in accordance with manufacture’s instructions 15. Record date of maintenance on an affixed tag or in a permanent record file.

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Maintenance _____________________________________________________ The CHECKFIRE MP-N must be recharged immediately after operation. The following steps should be carried out in conjunction with the previous process for recharging the system on pages 4.12 - 4.13.

CHECKFIRE MP-N recharge process

1. Loosen screw and remove cover form the control module.

2. Remove battery module from enclosure and properly discard. Battery must be replaced after each discharge of the system.

3. Remove the empty LT-10-R cartridge from the manual actuator or the automatic gas motor.

4. If system was manually actuated - skip steps 5, 6, and proceed to step 7.

5. If system was automatically actuated - remove the empty LT-10-R cartridge from the gas motor actuator. Do not install cartridge at this time. (See Fig.27) a. Loosen allen head set screw which locks the gas motor to the gas motor actuator. Use a 3/32” allen wrench. b. Unscrew discharged gas motor and discard. Note: When gas motor is removed, puncture pin may pop up or out of actuator body. c. Remove puncture pin and spring from actuator body. It may be necessary to push pin from bottom to overcome "0" ring friction. d. Clean inside of actuator with a dry, soft cloth. Also, lubricate "0" ring with a good grade of silicone grease. e. Reinstall spring and puncture pin in actuator body. Push pin down until bottom of pin is flush with bottom of actuator body. f. Thread new gas motor, unto top of actuator and secure with allen head set screw. Note: For proper assembly, the new gas motor must be threaded fully, 6 threads, onto the actuator body and properly secured with the allen head set screw . When gas motor is installed onto actuator body, bottom of puncture pin must be flush with bottom of body, ±1/16” (1.6mm). g. Reattach thread connector to gas motor thread. Hand tighten.

Fig.27 Gas motor disassembly

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_____________________________________________________Maintenance 7. Disconnect detection wire (or thermal detector leads) from the control module as follows: a. Loosen screws at terminals 1, 2, 3, and 4 of detection/output module. b. Loosen strain reliefs on detection wire. c. Slide the detection wire (or thermal detector leads) out of the control module. d. If damaged, remove entire length of detection wire (or thermal detector leads), cutting cable ties at points where secured. e. If thermal detectors are used, remove and replace any that are damaged.

8. If detection wire is used, install an entire new length.

9. If spot detectors are used, install any replacement detectors and all interconnecting wire.

10. Reset any auxiliary shutdown or alarm equipment in accordance with manufacturer’s instructions 11. Install new battery in module. Record date of installation.

12. Recharge the fire suppression system in accordance with pages 4.12 - 4.13 13. Test the system and place into service.

14. Record date or recharge on a tag or in permanent record file. Notify operating personnel that the system is back in service.

fusible links

The fusible links that are present on each door need to be checked on regular intervals to make sure they are free from corrosion and appear in working order.

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5

Transportation

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___________________________________________________ Transportation

Transportation & Installation The Fuel Pod utilizes an Rapid Attachment System (RAS) mount for attachment to any CAT® underground utility vehicle optioned with the RAS front receiver. The vehicle moving the Fuel Pod must also be rated capable of moving (approximately) an 11,000 pound load (unloaded) or 14,250+ pound load (fully loaded). The Fuel Pod is fully capable of being moved with a full load of fuel present within the cell.

The fuel cell is baffled to minimize excess sloshing of fuel during transport.

When hooking up the Fuel Pod to the RAS equipped CAT® utility vehicle be sure to follow all prescribed safety measures that are included in the utility vehicle’s operation manual.

installation requirements

The Fuel Pod should be installed in a service location such as an underground garage or other maintenance facility. Special considerations for installation include: 1. An external constant 75 PSI air source is required to operate the pump used to dispense fuel.

2. The Fuel Pod should be placed in an area that is accessible to ventilation to position the vent stack to positively remove any vapors from fuel.

3. The Fuel Pod should be placed away from any potential sources of ignition, such as welding equipment, torches, grinders, or other tools or equipment that may cause a spark or generate enough heat to cause combustion when in the presence of fuel vapors or the fuel itself.

4. The Fuel Pod should be placed as to avoid any collisions from moving machinery.

5. The gradient the Fuel Pod is installed upon should not exceed 1 in 4 or 25%.

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6

Specifications

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___________________________________________________ Specifications

Fuel Pod Specifications Stainless Steel Inner Tank Construction (removable) 450 gallon capacity fuel tank Triple wall protected structure with containment in excess of 675 gallons.

R.A.S. Attachment equipped pod A572-Gr50 Steel construction Hinged enclosure covers for access with (customer supplied) fusible links.

Hydraulic Fill Cap Vented Breather Assembly Spring retractable, open style hose reel, 304 stainless MSHA rated hose approximately 50’ with bronze nozzle Pneumatic Safety Shutdown Pneumatic programmable timer for fuel dispensing cycle.

Pneumatic powered motor powering fuel Polypropylene air motor, 1/4 NPT Polypropylene wet pump 200 L/min, 1” ANSI pipe flange 30 L Ansul automatic fire suppression system Fig.28 Fuel Pod

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Dimensions

A

C

B Fig.29 Dimensions Approximate dimensions: A. Height: 5’-5” (1 664 mm) B. Width: 8’-3” (2 527 mm) C. Length: 8’-8” (2 661 mm) Weight (approximately): Empty: 11,000 lbs. (4 989.5 kg) Full: 14,250 lbs. (6 463.7 kg)

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