Recommendations And Procedures For Recharging Caterpillar Fire Suppression Agent Cylinders{7401} Caterpillar

Recommendations And Procedures For Recharging Caterpillar Fire Suppression Agent Cylinders{7401}

Usage:

All Caterpillar machines equipped with Caterpillar Fire Suppression System

The following recommendations and procedures give a Caterpillar dealer information to help a local fire suppression dealer to find the correct accessories and extra parts needed to perform service work on the fire suppression system, that is, if the fire suppression dealer already has Halon 1301 in stock and has the necessary handling equipment.

Caterpillar Fire Suppression System

The following recommendations are given for Caterpillar Halon and Dry Chemical cylinder groups (5G2800 and 5G2980). These agent cylinders are equipped with a Chemetron valve that must be serviced by a Chemetron dealer. These recommendations are given to help a Chemetron dealer who has not had training by Chemetron Fire Systems Division; or if he has training, the dealer who does the service does not often have cause to charge the cylinder group.

Necessary Service Equipment

1) Supply of Halon 1301, made by E. I. DuPont or Forex Chemical Corp. for recharging 5G2800 Cylinder Group.

2) Supply of ABC rated dry chemical (mono-ammonium phosphate) for recharging 5G2980 Cylinder Group.

3) Halon transfer pump for filling the agent cylinder.

4) Chemetron knurled nut fill adapter, Chemetron part number Y0201989.

5) Chemetron gland nut wrench, Chemetron part number Y0202952.

6) Scale: 0 to 45 kg (0 to 100 lbs.)

7) Pneumatic belt vise to hold the cylinder.

8) Torque wrench adapter to fit the valve body.

9) Halon leak detector, Caterpillar part number 6V4135.

Extra Parts Needed

1) Valve Stem Assembly, Chemetron part number 200289.

2) Valve Stem O-ring, Chemetron part number 803077.

3) Valve Body O-ring, Chemetron part number 803084.

4) Plug, Caterpillar part number 6T30.

5) Disc, Caterpillar part number 6T28.

6) Gasket, Caterpillar part number 6T27.

Service Recommendations

1 When agent cylinders are taken in for service, check for damage or missing parts. Remove the four screws and top plate assembly from the valve body.

Show/hide table

Make sure the agent cylinder is empty. Accidental discharge of the cylinder can cause personal injury.

2 Make sure the agent cylinder has a 5G3124 Safety Cap (1) installed on left hand threaded adapter (2). The adapter is on the outlet port of the valve. The adapter stops the flow of agent in case a filled cylinder is discharged when not connected to the discharge lines.

3 Make sure the agent cylinder is completely empty, then remove safety cap (1) and adapter (2) from the valve outlet port.

4 If the cylinder is empty, but the valve trip mechanism has not been released, check the valve burst disc to find if it has been damaged.

For replacement of a damaged burst disc:

5a) Remove plug (3), the damaged burst disc and copper gasket.

5b) Install new gasket (4), Caterpillar part number 6T27.

5c) Install new burst disc (5), Caterpillar part number 6T28.

5d) Install new plug (6), Caterpillar part number 6T30.

5e) Install the plug and tighten to a torque of 27 ± 7 N·m (20 ± 5 lb.ft.).

NOTE: Do not use Chemetron parts for replacement. Use only Caterpillar parts as given above.

6 Removal of the valve from the cylinder:

a) Clamp the cylinder in a belt vise.

b) With a wrench adapter, loosen the valve.

c) Remove the valve from the cylinder.

d) Check the inside of the cylinder for corrosion (rust) or pits (damage).

e) Check the cylinder hydrostatic test date. It is on the upper, curved part of the cylinder.

f) If it has been five years or more since the last hydrostatic test, or if pitting is found, again test the cylinder hydrostatically. Hydrostatic test pressure is 10335 kPa (1500 psi).

7 Valve disassembly and valve stem replacement. A used valve stem will not seal Halon and there will be leakage.

a) Remove discharge clamp screw (7) with an Allen wrench.

b) Remove trip lock lever (8) and discharge clamp (9).

c) Remove valve stem adjusting nut (10), valve spring (11), valve spring washer (12) and gland nut O-ring (13).

d) Remove gland nut (14). Use Chemetron tool, part number Y0202952.

e) Remove valve stem assembly (15). This is not needed again; a new valve stem assembly is to be installed. Number (16) is the metering stud.

NOTE: Also follow this procedure for dry chemical agent cylinders. Be sure to clean any dry chemical from the valve before assembly.

8 Valve Assembly:

a) Install new valve stem assembly (15), Chemetron part number 200289.

b) Install gland nut (14). Use Chemetron tool, part number Y0202952.

c) Install the following parts in the sequence shown:

1) gland nut O-ring (13).

2) valve spring washer (12).

3) valve spring (11).

4) valve stem adjusting nut (10).

d) Assemble discharge clamp (9) and trip lock lever (8) and install on the valve with discharge clamp screw (7).

9 Adjust valve stem adjusting nut (10) until the force needed to release trip lock lever (8) is between 89 to 178 N (20 to 40 lbs.).

NOTE: It may be necessary to adjust the height of metering stud (16) to permit the lock pin holes in trip lock lever (8) and the locking cam to align correctly during application of the correct trip force.

Recharge Procedure - 5G2800 - Halon Agent Cylinders

1 Install valve body O-ring (1) and again install the valve assembly in the agent cylinder. Tighten the valve body to a torque of 136 ± 27 N·m (100 ± 20 lb.ft.).

2 Install the knurled nut fill adapter (E) on the valve outlet opening, (Chemetron part number Y0201989).

3 To fill the cylinder with Halon, move trip lock lever (2) until the pin in the locking cam comes out of the detent. Move trip lock lever (2) just enough that lock pin (3) can be installed into the end of locking cam (4). The lock pin will be against the pressurizing notch of trip lock lever (2) as shown. This will hold the valve open just enough to fill the cylinder.

4 Connect the agent cylinder valve to a supply of Halon and nitrogen as shown above. The transfer pump can be a separate unit or it can be part of a complete Halon filling station, including valves (A) and (B) in the unit. Complete Halon filling stations are available from several suppliers.

5 Put the agent cylinder on a scale that can accurately measure weight to within .25 kg (.5 lb.). Make sure all the hoses are free so that the correct weight of Halon can be added.

6 To fill the agent cylinder with Halon 1301, set the valves as follows:

Valve (A) - ClosedValve (B) - OpenValve (C) - Closed

7 Open valve (C) and start transfer pump (H) to move Halon into agent cylinder (F) until 9.5 + .4, -0 kg (21 + 1, -0 lbs.) has been added. Close valve (B) and shut off the pump.

8 Open valve (A) until pressure in the agent cylinder is 2480 + 140 -0 kPa (360 + 20 -0 psi). Close valve (A) and (C).

NOTE: Use a good, accurate pressure gauge at a location near the agent cylinder.

9 Mix the Halon-nitrogen content in the agent cylinder by rocking (oscillation) for one minute or until the pressure decreases and is stationary. Open valves (A) and (C) and increase the pressure to 2480 kPa (360 psi). Close valves (A) and (C).

10 Close the agent cylinder valve. Install an extension (pipe, etc.) over the end of trip lock lever (2). Hold the trip lock lever while removing lock pin (3) [shown on page 6]. Move the trip lock lever until holes (F) in the trip lock lever and locking cam are in alignment. Install the lock pin.

11 Check for leaks using a Halon Leak Detector, Caterpillar part number 6V4135, or similar.

Recharge Procedure - 5G2980 - Dry Chemical Agent Cylinder

1 Fill the agent cylinder with 9.1 + 4 -0 kg (20 + 1 -0 lbs.) of ABC dry chemical (monoammonium phosphate) before installation of the valve body.

2 Install the valve body in the agent cylinder. Tighten the valve body to a torque of 136 ± 27 N·m (100 ± 20 lb.ft.).

3 Install knurled nut fill adapter (E) on the valve outlet opening, Chemetron part number Y0201989.

4 To fill the cylinder with nitrogen, move the trip lock lever until the pin in the locking cam comes out of the detent. Move the trip lock lever just enough so the lock pin can be installed into the end of the locking cam. The lock pin will be against the pressurizing notch of the trip lock lever as shown on page 6. This will hold the valve open just enough to fill the cylinder.

5 Open valve (A) until pressure in agent cylinder (D) is 2480 + 140, -0 kPa (360 + 20, -0 psi). Close valve (A).

NOTE: Use a good, accurate pressure gauge (C) installed near the agent cylinder.

6 Close the agent cylinder valve. Install an extension (pipe, etc.) over the end of the trip lock lever. Hold the trip lock lever while removing the lock pin [shown on page 6]. Move the trip lock lever until the hole in the trip lock lever is in alignment with the holes in the locking cam (shown on page 7. Install the lock pin.

7 Check all connections for nitrogen leaks with a soap and water solution or a similar solution. Check the valve-cylinder connection, the valve outlet, pressure gauge, fittings and the over pressure relief (burst disc) plug. Wash the leak check solution from all surfaces and use a cloth to make the agent cylinder and valve dry. Any local air conditioning company will have a supply of leak checking solution.

Assembly And Adjustments

1 Install left hand threaded adapter (1) on the valve output opening. Do not over tighten the adapter. Install top plate assembly (2) on the valve. Adjust adapter (1) to align with the opening in the top plate. Do not turn the adapter out more than 1/6 of a turn from full tight.

2 Remove top plate assembly (2) and check the position of adapter (1) in relation to fully tight before it is removed. Remove the adapter and put sealant on the threads of the valve opening, Caterpillar part number 9S3263 Thread Lock. Install adapter (1) and tighten as before. Align the flat area of the adapter with top plate assembly (2).

3 Again, install top plate assembly (2) with two 2A5546 Bolts (3) and two 310214 Bolts (4) with 5P4115 Washers. Tighten the bolts to a torque of 12 ± 4 N·m (9 ± 3 lb.ft.).

NOTE: Install safety cap (5) on adapter (1) immediately after installation of top plate (2). This will decrease the possibility of personal injury if the agent cylinder is discharged by accident when installed or when being moved.

4 It may be necessary to adjust the clearance between the hook assembly [part of top plate assembly (2)] and the trip lock lever. The correct clearance as shown above is 1 mm (.04") maximum.