M-01-02-07 / 2005

Service LFR Service Dpt / EG

07/09/2005
Liebherr-France SAS
Mining Division

Information
2 Avenue Joseph Rey
B.P. 90287
F-68005 Colmar-Cedex
MJFCIFSS! Tel.: +33 (0) 389 21 37 72
Fax.: +33 (0) 389 21 35 45

MINIMUM REQUIREMENTS FOR FIRE FIGHTING

SYSTEMS FOR LIEBHERR HYDRAULIC MINING
EXCAVATORS & SHOVELS

Dear Sirs

Please find enclosed the minimum requirements for appropriate fire fighting systems for
Liebherr Mining Excavators and Shovels (from the R/P 984 up to the R/P 996) in order to
reduce the potential risk of damage to a machine as a result of a fire.

The document presents the results of an investigation of various fire suppression system
suppliers and their products, and is also considering many years of field experiences with our
existing mining machine fleet. A number of incidents were thoroughly investigated and based
on this, the system requirement for our machines have been defined and continuously
improved.

In the future, with all new Liebherr Mining Excavators delivered ex works, the attached
document will be supplied as part of the machine documentation package provided to our
customers. Furthermore the sales force is demanded to communicate the minimum
requirement to future potential customers in the very early stages of every project.

For all machines already in the field and that were equipped with fire fighting systems or that
will be equipped in the future, you must inform the customer officially that these systems must
meet or exceed the Liebherr minimum requirement in order to achieve maximum protection.
You must further make clear that modifications of the systems are required and need to be
carried out immediately if systems do not comply with the requirement, and document it to your
customers, in order to reduce potential risk of damages by fire.

In addition, please make sure that Liebherr cannot be held liable and does not provide
warranty for installation, operation and maintenance of fire fighting systems. This responsibility
has to remain with the fire fighting system supplier.

Best regards,

F. Gresser E.Goetschy

Service Department Mining Liebherr-France SAS

Liebherr-France SAS Page 1 of 11

Mining Division
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MINIMUM REQUIREMENTS FOR FIRE FIGHTING

SYSTEMS FOR LIEBHERR HYDRAULIC MINING
EXCAVATORS & SHOVELS

1. INTRODUCTION

This documentation is intended to help Liebherr’s customers choose appropriate fire fighting systems for
their Liebherr Mining Excavators and Shovels in order to reduce the potential risk to cause damage to a
machine as a result of a fire.

Liebherr (Liebherr-France and its parent companies, dealers and/or agents) does not design and does
not manufacture fire fighting systems installed on Liebherr Mining Excavators and Shovels.

The minimum guidelines provided herein are based on years of experience with our machines on the field
and information provided by successful fire fighting equipment businesses.
For instance, general information about fire and fire fighting agents are also dealt with this documentation
along with minimum recommended quantities of fire fighting agents and of diffuse nozzle quantity for
Liebherr Mining Excavators and Shovels.
On the other hand, optional equipment, such as extended discharge volume that might be installed upon
customer’s request will not be addressed in this documentation.

Since fire fighting equipment and businesses are continuously being developed, new fire fighting agents
and techniques will emerge while others may be prohibited because of environmental impacts and
regulations. This documentation has no intention to list all fire fighting systems that may exist worldwide.
Besides, different fire fighting systems might be available, recommended, authorized, or respectively
prohibited, in one part of the world only.

This documentation only provides general minimum guidelines in order to help Liebherr’s customers to a)
choose adequate fire fighting systems, b) decide how fire fighting systems shall be designed,
manufactured and c) installed on Liebherr Mining Excavators and Shovels by successful fire fighting
equipment businesses; thus documentation should not be considered as a comprehensive and certified
technical prescription of the fire fighting systems to be used on Liebherr Mining Excavators and Shovels.

For all these reasons, Liebherr’s customer shall always use this documentation and its minimum
guidelines as a starting point when choosing which fire fighting system shall eventually be installed on its
Liebherr Mining excavator. However, using said minimum guidelines shall neither supersede nor replace
the necessity to check and comply with the following :
• applicable national and international laws and regulations,
• applicable standards (ex: NFPA17, NFPA121) or local codes (ex: MDG13),
• Mine regulations and insurance requirements,
• Fire fighting system’s designer and OEM requirements,
• Other regulations by law, government or any official authority

If there are statements made that are contra dictionary, always the higher level of protection shall be
identified and chosen.

The designer and manufacturer of the fire fighting system’s (fire fighting system OEM) is (are) fully and
exclusively responsible for the design, manufacture and together with the appointed dealer, responsible
for installation, operation and maintenance of each and every fire fighting system.
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2. FIRE FIGHTING SYSTEM

2.1. General

Fire fighting system must be working on 24-hour protection basic. It must be operating at all time and
conditions even if the excavator is shutdown, without operator, or working. It must be self contained,
operating in complete feedback control, and self check itself.

2.2. Fire detection system

The fire detection system must be automatic. Fire detection should be installed in the engine and in the
pumps compartments. Additional detection could be installed in the valves banks compartment.

An optional monitoring system could be added to warn the operator in the cab about unusual increases in
temperature in the protected areas. Such system allows the operator to shutdown the excavator manually
prior the automatic discharge of the fire fighting system to investigate. Fire detectors for large off-highway
vehicles are described and discussed more in details in Section 3.3.

2.3. Activation

The activation of the fire fighting system must be automatic. It must be triggered by automatic fire
detection modules.
Additional manual activation through manual actuators must be installed at least in the places specified in
the following table:

R - P 984 R - P 994 R - P 9250 R - P 994B R - P 995 R - P 996

Cabin X X X X X X

Catwalks / main ladder X X X X X X

Engine+pumps compartment --- X X X X X

Service Flap / Escape ladder --- --- X X X X

The control module of the fire fighting system must be in reach of the operator. It must also be connected
to the engine and hydraulic tank venting system to shut the engine down and vent the hydraulic tank.

2.4. Operating sequence

In automatic and manual mode, the order of operation of the fire fighting system is:

• When the fire fighting system is set off, a fire alarm must sound during two to five seconds to warn
the operator to leave the cab or allow the operator to cancel and reset manually the activators’ control
system in case of false alarm.

• Immediately after, the diesel engine must be shutdown an air valve must be opened to vent the
hydraulic tank as if the excavator comes in emergency stop. The reason for it is that if the engine is not
immediately shutdown after the two to five seconds warning time, hydraulic fluid supply to the fire
continues (in case of a fire due to hydraulic hose leak) and it becomes more difficult to extinguish the fire

• Ten seconds after the shutdown of the diesel engine, fire fighting agent should be released. This
ten seconds delay is needed for fans to come to stop.

• If twin-agent fire fighting system is installed, the release of the second agent should start after a
delay from zero to twenty seconds after the release of the first agent. This zero to twenty seconds delay is
set by the fire fighting system OEMs.
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OPERATIONS SEQUENCE
Fire automatic detection
or
Manual actuating

2-5 sec 10 sec 0 - 20 sec

time

Engine shut down signal

Hydraulic tank venting
Fuel valve closing
First agent release

Second agent release

(if available)

2.5. Agent type

The fire fighting system OEM must supply the most appropriate fire fighting agent or combination of
agents and the right quantity of agent needed for a given machine. Selection of agent or combination of
agents should depend on climatic conditions all year around. A good fire fighting agent supplier should
advise their customers on different agents available and their effectiveness.

A table enclosed in at the end of this documentation lists and compares most fire fighting agents available
on the market. For instance, the use of gaseous agents are not recommended for mobile mining
equipment except in closed/sealed compartments such as electrical compartments.

Data points and specifications in this table were elaborated with the help of different fire fighting system
OEMs and information readily available on the market.

2.6. Number and position of nozzles

The quantity of nozzles required for a given fire fighting system is determined by the fire fighting system
OEM.
The nozzle quantity recommended in this documentation could be different from the one given by the fire
fighting system OEM since the one given by the fire fighting system OEM is based on the type of agent
and the size of the canisters sold, while the minimum nozzle quantity recommended by Liebherr is based
on how the excavator should properly be protected. If the quantity of nozzles given by the fire fighting
system OEM differs from more than 10% to the one recommended in this documentation, the OEM of the
fire fighting system shall expressively confirm that the quantity of nozzles is adequate.

These nozzles should be placed to fully flood the protected compartments. The area covered by a given
nozzle, when releasing fire fighting agents should overlap the one next to it. Special excavators, such as
pontoon excavator might need extra nozzles and volume of agents.
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2.7. Additional requirements

The electrical portion of the fire fighting system should have an automatic self error-check or self-
diagnostic procedure.

To ease the connection of the fire fighting system with the electrical system, all Liebherr Mining
Excavators and Shovels have built in extra relays located in their electrical compartment to connect
activation modules to shutdown the diesel engine and vent the hydraulic tank. On mining-excavators
(R 994 B, R 995 and R 996 since 2003, others excavators since July 2005) but not on pontoon machines,
a relay inhibits the re-start of the engine for one hour after the activation of the fire fighting system in order
to avoid a re-ignition of the fire. For more information on these relays or in case of retrofitting, please
contact Liebherr.
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When installing a new fire fighting system, the OEM or a company approved by the OEM, and the
customer, shall commission a test to check the functions of the fire fighting system, the shutdown of the
diesel engine and the vent of the hydraulic tank when the fire fighting system is activated.
If the fire fighting system is ordered through Liebherr, this test shall be done in presence of a
representative delegated by Liebherr.
The commissioning tests must include a written report, considered to be a hand-over-certificate signed by
both fire fighting system OEM and customer.

A maintenance contract for the fire fighting system installed should also be signed by both OEM or OEM
approved local dealer and customer. The OEM or OEM approved local dealer will be responsible for
maintaining and controlling the fire fighting system on site.

The fire fighting system installed has to be serviced and maintained according to local regulations and
maintenance instructions.

2.8. Excavators with electric engine

On electric driven excavators, the closed compartments where the high voltage transformer is located
have to be protected against electrical fire. A system based on gaseous fire extinction agent and air-
sealed compartment should be used in this case.

3. General information on fires and components of fire fighting system

3.1. Fires are classified into four types

Class A B C D
Flammable liquid
Carbonaceous fires Flammable gas fires Metal fires
fires

Fires with fluids and

Description Fires with solid glow Fires with gases
other liquefied fluids

Rubber hoses,
Fuel, oil, alcohol, Butane, propane, Sodium, potassium,
Examples wood, plastics,
grease methane, acetylene magnesium, titanium
carton, cables

There are four basic prerequisites for any combustion process:

- Heat
- Fuel
- Oxidising agent
- Suitable chemical reaction path

It is clear that an oxidising agent (Oxide) is always and everywhere present (in the air). On an excavator
there are also large amounts of fuel (fuel and oils) present which are combustible when in contact with hot
parts.

It follows that any method for inhibiting a combustion process must involve one or more of the following:

- removing heat at a faster rate than it is released

- separating the fuel and the oxidising agent
- diluting the vapour-phase concentration below that needed for combustion
- terminating the chemical chain reaction
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3.2. Fire extinguishing agents:

3.2.1. Water

Water is the most common agent used in general industrial fire fighting because of its cost, availability
and most importantly its class A effectiveness. Water has outstanding thermal properties in that
converting one kilogram of water at 0°C to steam at 100°C requires 2675 kJ of energy and in the process
a volumetric expansion of 1700 occurs. These two factors account for the extinguishing mechanism i.e.
cooling and dilution of the oxygen concentration.

3.2.2. Fire Fighting Foams

The area of foams presents an attempt to overcome some of the disadvantages of water. Fire fighting
foam is a stable mass of small bubbles lighter than oil or water. Foam is a watery suspension of gas,
usually Nitrogen or air, in the form of bubbles separated by films of solution.
Foam is produced mechanically, rather than by chemical reaction. It is created by mixing a liquid
concentrate with water and forcing the gas into this solution. This produces a watery suspension of air /
Nitrogen in the liquid solution – namely bubbles.
Current mechanical foam concentrates, based on different materials, are:
- Protein foam
- Fluorprotein foam
- High expansion foam
- Alcohol type foam
- Aqueous Film Forming Foam (AFFF)
- Wet chemical

Aqueous Film Forming Foam (AFFF) is obtained from synthetic fluorochemical surfactants. Foaming
agents, stabilisers and solvents are added to form the concentrate.
These materials differ from protein foams. In trials they form a thin film on the fuel surface, thereby
preventing evaporation of fuel and securing action for a fire once it has been extinguished.
AFFF allows a film of water to form on a hydrocarbon fuel surface. It extinguishes fire by suppressing fuel
vapour due to the presence of the aqueous film, the mechanical foam and the water content.
Wet chemical agent is a blend of inorganic salts coupled with surface-active agents. This blend provides
a strong measure of freeze protection along with the forming properties associated with conventional
foams.
Many off-road vehicles have large volumes of oils and hydraulic fluids under pressure. With the large
amount of fuels available, a variety of fires can occur, such as pressure, three dimensional, Class A and
spill. Foams and wet chemical can flow into hard-to-reach areas where flammable fuels may also have
flowed.

3.2.3. Dry chemical and powders

Dry chemical fire extinguishing agents chemically inhibit fires. There are a number of inorganic solids
used. These materials are generally in the size range of 15 – 60 micron particle size. Since most of these
materials are hydroscopic (water absorbing), various additives and surface treatments are usually
employed by the OEM.
Dry chemical extinguishing agents are comprised of a finely-divided powdered material that has been
specifically treated to be and capable of being fluidised and free-flowing when under expellant gas
pressure. There are several types of dry chemical extinguishing agents available, each having its own
distinct capabilities. Dry chemicals are available for all Class A, Class B or Class C fires.

The different dry chemicals are:

(1) Dry chemicals based on sodium bicarbonates

(2) Dry chemicals based on potassium salts
(3) Multi-purpose dry chemicals

The almost instantaneous quenching of flames by dry chemicals can only be accounted for on the basis
of chemical inhibition.
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3.2.4. Gaseous fire fighting agents

Fire fighting gases can be divided into two types:

CO2 stores as a liquefied gas and is an example of the diluting or the inerting type of agent in that it must
be applied in such concentrations (up to 50%) that it dilutes the oxygen level below that necessary to
sustain combustion. Other inerting gases such as INERGEN, ARGONITE and ARGOTEC have been
developed to meet the demand for a clean, non-toxic fire fighting system.

Another type of agent in this class are HALON alternatives which are materials that chemically inhibit the
combustion chain reaction sequence and are applied at concentrations of about 8%. These are
represented for example by FM 200. FM 200 is a gas at standard temperature and pressure and is used
generally in total flooding applications.

NOTE: HALON 1211 and 1301 installations have either never been permitted, or the sale or the
importation of the agent or the installation of new systems has been discontinued or severely restricted in
all countries that have signed the Montreal protocol.

All these agents should be used in engineered systems or environments having early detection
capabilities and rapid activation. The compartments in which these agents are used should be semi-
closed and for optimum effect they should be sealed.

3.3. Detection Systems

Three types of detectors are commonly used to sense the presence of flames, heat and smoke.
Flame detectors sense the infrared, visible or ultra-violet light emitted by the fire.
Smoke detectors sense the presence of visible or invisible combustion particles.
Heat detectors which sense abnormally high temperature or rate of temperature rise are generally
classified as fixed temperature or rate-of-rise detectors.

3.3.1. Flame Detectors (Infra-red, untra-violet…)

These units are normally designed to have a fast response time. They respond to particular wavelengths
of light to eliminate false alarms due to environmental or natural causes. This group of detectors is ideally
suited for use in the petrochemical industry and in industrial environments where rapid and early
response is required. In fact, they are also used in explosion fighting systems where ultra fast detection
and fire suppression is required in milliseconds rather than in seconds.

3.3.2. Smoke detectors

These detectors sense the presence of visible or invisible combustion particles. Again, therefore, they are
not suitable for use on most items of heavy plant where they will be prone to false alarm from exhaust
fumes from the engine and other external environmental debris. Their use is normally restricted to
industrial and commercial premises where the environment is normally clean.

3.3.3. Heat detectors

This class of detectors is most commonly used in mobile plant applications. These units can be split into a
number of groups.

1. Point or spot detectors - These are set temperature detectors or rate-of-rise sensitive detectors.
2. Linear electrical detectors - These fall into a number of subcategories namely:
a. An increase in temperature causing a decrease in resistance
b. An increase in temperature causing an increase in capacitance and a decrease in resistance.
c. An increase in temperature causing the salt filled core to conduct at a predetermined melting
point.
d. A 2-wire conductor covered with insulation that melts at predetermined value, causing the
conductors to short circuit.
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3. Linear pressure or pneumatic detectors - These also fall into sub-groupings:

a. Pressurised nylon tube type - with some form of gas supply or pressure make-up device. When
the tubing melts at a predetermined temperature the pressure is released thus activating the
extinguishing system.
b. Pressurised fire/overheat detectors - this type of unit works in two ways. Firstly an increase in
temperature on the overall length causes the averaging gas inside the detector to increase in
pressure, thus closing contacts in the responder housings. Secondly, an inner core element is in-
gassed with for instance Hydrogen gas. This is also released during the detectors’ response to
heat.

3.4. Control System

Systems are currently available that give fire warning only, therefore requiring the operator to stop and
manually operate the fire fighting system and then to evacuate the machine.
Others give fully automatic 24-hour protection to the machine, requiring the operator to do little more than
park up safely, if time is available, then evacuate the machine. These systems also have the facility to
signal engine shutdown from instantaneous to a maximum of 30 seconds.
Various optional components are available such as a high decibel output external alarm, fuel shut off,
main battery isolation, hydraulic system venting. Control modules are totally self-contained units.

Liebherr recommends as a minimum connecting the control module to the engine shutdown and to the
hydraulic tank venting. The control module should be mounted where it is visible to the operator.

3.5. Additional Safety Precautions

It is extremely important to clean the excavator regularly to avoid amounts of combustible such as
hydraulic fluids, fuel and grease on the machine. An alternative fire fighting equipment should be
available in case the system does not totally extinguish, or if there is re-ignition of a fire.

We recommend hand portable fire extinguishers are always fitted with a fire fighting system and
equipment operators made aware of their location and use.

4. Minimum quantities and nozzles for Liebherr Mining Excavators and Shovels

“D“ = nozzle for dry chemical

“W“ = nozzle for wet chemical
“LW“ = large discharge coverage nozzle (wet chemical)
“additionnal pontoon“ = additional quantity and nozzles for the area under the turning radius of the
excavator in pontoon application (elastic mount and barge)

4.1. LIEBHERR R 984

Option 1 Option 2
„dry chemical“ „wet chemical“

Quantity 50 kg 90 litre
Mini. number of nozzles 16 D 18 W
Engine cpt 5/6 D 7W
Pumps cpt 3/4 D 4W
Valve bank 3/4 D 4W
Rotary connection 1D 1W
Battery cpt 1D 1W
Swing motor 1D 1W
40kg 150 litre
Additional pontoon
12 D 36 W

Liebherr recommends the option 1 as standard fire fighting system.

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4.2. LIEBHERR R 994 - 171

Option 1 Option 2 Option 3

„dry chemical“ „wet chemical“ „dry + wet chemicals“
Quantity 100 kg 170 litre 100 kg + 120 litre
26 D
Mini. number of nozzles 26 D 34 W
20 W or 3 LW
10/12 D 12/14 W or 2
Engine cpt 10/12 D 14/16 W
LW
Pumps cpt 6/8 D 8/10 W
6/8 D 6/8W or 1 LW
Valve bank +Rot conn. 6D 8W
6D
Swing motor 2D 2W
2D
Additional pontoon 50kg 180 litre 100 kg
Typ 600 16 D 36 W 16 D

Liebherr recommends the option 3 as standard fire fighting system until -40°C.
The option 1 is recommended for extreme cold conditions from -40°C to -54°C.

4.3. LIEBHERR R 9250 - 437

Option 1 Option 2 Option 3

„dry chemical“ „wet chemical“ „dry + wet chemicals“
Quantity 120 kg 200 litre 120 kg + 150 litre
28 D
Mini. number of nozzles 28 D 34 W
24 W or 6 LW
Engine cpt 10/12 D 14/16 W 10/12 D 12/14 W or 3/4 LW
Pumps cpt 6/8 D 6/8 W 6/8 D 4/6 W or 1 LW
Valve bank 6/8 D 6/8 W 6/8 D 4/6 W or 1/2 LW
Rotary connection 1D 2W 1D
Swing motor 1D 2W 1D
50 kg 180 liter 100 kg
Additional pontoon
16 D 36 W 16 D

Liebherr recommends the option 3 as standard fire fighting system until -40°C.
The option 1 is recommended for extreme cold conditions from -40°C to -54°C.

4.4. LIEBHERR R 994 B - 411

Option 1 Option 2 Option 3

„dry chemical“ „wet chemical“ „dry + wet chemicals“
Quantity 150 kg 220 litre 150 kg + 150 litre
32 D
Mini. number of nozzles 32 D 36 W
24 W or 6 LW
Engine cpt 12/14 D 14 W 12/14 D 12/14 W or 3 LW
Pumps cpt 6/8 D 8W 6/8D 4/6 W or 1 LW
Valve bank 4/6 D 6W 4/6 D 4/6 W or 2 LW
Hydraulilc tank 2D 2W 2D
Rot. conn. + swing mot. 3D 4W 3D
Battery cpt 2D 2W 2D
Additional pontoon 50kg 180 litre 100 kg
Typ 447 16 D 36 W 16 D

Liebherr recommends the option 3 as standard fire fighting system until -40°C.
The option 1 is recommended for extreme cold conditions from -40°C to -54°C.
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4.5. LIEBHERR R 995 - 593

Option 1 Option 2 Option 3

„dry chemical“ „wet chemical“ „dry + wet chemicals“
Quantity 200 kg 350 litre 150 kg + 200 litre
32 D
Mini. number of nozzles 40 D 50 W
32 W or 6 LW
Engine cpt 16/18 D 20 W 14/16 D 16 W or 3 LW
Pumps cpt 10/12 D 16 W 8/10 D 8/10 W or 1 LW
Valve bank + rear swing motors 8D 10 W 6/8 D 6/8 W or 2 LW
Rotary connection + front swing motors 2D 4W 2D
Additional pontoon 50kg 180 litre 100 kg
Typ 627 16 D 36 W 16 D

Liebherr recommends the option 3 as standard fire fighting system until -40°C.
The option 1 is recommended for extreme cold conditions from -40°C to -54°C.

4.6. LIEBHERR R 996 - 173

Option 1 Option 2 Option 3

„dry chemical“ „wet chemical“ „dry + wet chemicals“
Quantity 300 kg 500 litre 200 kg + 450 litre
48 D
Mini. number of nozzles 60 D 72 W
54 W or 12 LW
Engine cpt 2x 16 D 2x 20 W 2 x [ 12 D 16 W or 4 LW ]
Pumps cpt 2x 8 D 2x 10 W 2 x [ 6 D 8 W or 1 LW ]
Valve bank + rear swing motors 8D 8W 8 D 6 W or 2 LW
Rotary connection 2D 2W 2D
Front swing motors 2D 2W 2D
Additional pontoon 50kg 180 litre 100 kg
Typ 602 16 D 36 D 16 D

Liebherr recommends the option 3 as standard fire fighting system until -40°C.
The option 1 is recommended for extreme cold conditions from -40°C to -54°C.

5. MINIMUM GUIDELINES – NO WARRANTY

WITH THIS DOCUMENTATION, LIEBHERR MAKES NO WARRANTY EXPRESS OR IMPLIED

INCLUDING ANY WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO
THE FIRE FIGHTING SYSTEM DESIGNED, MANUFACTURED AND INSTALLED ON THE LIEBHERR
MINING EXCAVATOR.

THE INFORMATION PROVIDED ABOVE IN THIS DOCUMENTATION ONLY DESCRIBE MINIMUM

GUIDELINES WITH RESPECT FIRE FIGHTING SYSTEMS. IN THIS SENSE THEY MAY HELP IN
RETARDING OR MINIMIZING DAMAGES TO THE LIEBHERR MINING EXCAVATOR. THEY ARE NOT
INTENDED TO WARRANT OR GUARANTEE THAT ALL FIRES WILL BE EXTINGUISHED.

IT IS EXTREMELY IMPORTANT THAT ALTERNATIVE FIREFIGHTING EQUIPMENT AND MEANS BE

QUICKLY AVAILABLE IN CASE THE FIRE FIGHTING SYSTEM DOES NOT TOTALLY EXTINGUISH A
FIRE. FAST INTERVENTION OF THE MINE FIRE FIGHTING UNIT IS ALWAYS ESSENTIAL IN ODER
TO GUARANTEE THAT THE FIRE IS SUPPRESSED AND WILL NOT REIGNITE.