jcb 409ZX Parts And Service Manual
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jcb 409ZX Parts And Service Manual

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Kit Part Number: 700075
+61 7 3276 7833
www.breathe-safe.com.au
sales@breathe-safe.com
62 Mica Street, Carole Park, 4300, QLD
Parts and Service Manual
HEPA H14 Variable Speed Pressuriser | INPRESS TS Cabin Display with CO2 Sensor | HEPA Return Air Filter
JCB
409ZX LOADER
+ Activated Carbon
Controlled Document: M0203
Issue Date: 12/10/23
Revision: 1

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  • Page 1 Kit Part Number: 700075 Parts and Service Manual 409ZX LOADER HEPA H14 Variable Speed Pressuriser | INPRESS TS Cabin Display with CO2 Sensor | HEPA Return Air Filter + Activated Carbon +61 7 3276 7833 www.breathe-safe.com.au Controlled Document: M0203 sales@breathe-safe.com...

  • Page 2: Table Of Contents

    409ZX Loader INSTALLATION INSTALLATION OVERVIEW Manufacturer CONTENTS Type Loader Model 409ZX Installation ........1 Cabin Pressure Max Safety ........... 2 Set Auto Cabin Pressure Critical Parts & Maintenance Schedule ........3 Operator Guide ......4 Specifications - Pressuriser .... 5 Parts List ........

  • Page 3: Safety

    409ZX Loader SAFETY WARNING Particulate Behaviour THE PRESSURISATION SYSTEM DESCRIBED IN THIS MANUAL HAS THE FOLLOWING AREAS WHICH MAY BE DANGEROUS IF NOT TREATED WITH This is the length of time it takes for a particle to drop from a height GREAT CARE.

  • Page 4: Critical Parts & Maintenance Schedule

    409ZX Loader CRITICAL PARTS & MAINTENANCE SCHEDULE Maintenance Schedule The following tables show our suggested maintenance schedule Critical Parts for all units. Please note that site conditions may alter this. Item Part Number Qty. Description Service Interval Excludes high corrosion environments.

  • Page 5: Operator Guide

    409ZX Loader OPERATOR GUIDE OPERATORS CHECKLIST PRE-START Visually inspect the BreatheSafe system for any damage. Visually inspect the cabin for any damage to doors, windows, seals. Please remove dust & debris from shoes and clothes before entering the cabin. Ensure door(s) and windows are closed correctly.

  • Page 6: Specifications - Pressuriser

    409ZX Loader SPECIFICATIONS HIGH-CAPACITY HEPA PRESSURISER Specifications High-Capacity HEPA Pressuriser List of Abbreviations Blower : Brushless Blower P/N 200002. Dual HEPA Protection : Locked Rotor Protection (Sub Zero Environments) Under DHPR Dual HEPA Powered Recirculation Voltage, Under/Over Current & Over Temperature.
  • Page 7 409ZX Loader Item No. Qty. Description Part No. PARTS LIST – TL4 24V DC PRESSURISER UNIT Pre-cleaner Hood & Rotor Assy 200004 Pre-cleaner Injector Ring 200005 200000 PRESSURISER ASSEMBLY No: TL Fan Blade (inc. in #7) 200006 TL Nose Cone / Pre-cleaner...

  • Page 8: Parts List

    409ZX Loader Item No. Part No. Rev Description Colour Group PARTS LIST GA 100062A01 Pressuriser Assembly (Per Assy) Assembly 100062F01 Inlet Assembly Charcoal Grey MX83-682 Weld Assy 700075 COMPLETE ASSEMBLY No: 100062F02 Fresh Air Door Plate Assembly Charcoal Grey MX83-682...
  • Page 9 409ZX Loader Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – PRESSURISER MODULE 100062A02 SO2 Assembly (Per Assy) Assembly 100062A03 Machined Spacer Charcoal Grey MX83-682 Weld Assy 100062A04 SO2 Rail Assembly Charcoal Grey MX83-682 Weld Assy...
  • Page 10 409ZX Loader Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – INLET MODULE 100062-F729 Inlet Mounting Plate (Per Assy) Part 100062-F730 Fresh Air Inlet (Per Assy) Part 300388-0400 76.3 x 1.6 @40mm Stainless Steel Ø3.0”ODx1.6W/T (Per Assy)
  • Page 11 409ZX Loader Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – FRESH AIR MODULE 100062-F738 Fresh Air Inlet Door Plate Mild Steel (Per Assy) Part 300388-0060 76.3 x 1.6 @60mm Stainless Steel Ø3.0”ODx1.6W/T (Per Assy)
  • Page 12 409ZX Loader Item No. Part No. Rev Description Qty Material Thickness Colour Category PARTS LIST – MONITOR MODULE 100062M02 Monitor Mount Assy (Prt Dwgs) (Prt Dwgs) Charcoal Grey MX83-682 Weld Assy 100062M03 Clamp Plate Assy (Prt Dwgs) (Prt Dwgs) Charcoal Grey MX83-682...
  • Page 13 409ZX Loader Item No. Part No. Rev Description Qty Material Thickness Colour Category PARTS LIST – PIPEWORK MODULE 100062-P02 Stauff Ring Clamp Assy (Per Assy) 100062-P751 Stauff Mounting Bracket Mild Steel 100062-P752 Stauff Upper Mount Bracket Mild Steel 300848 3 Inch Cobra Neck 300388-0400 76.3 x 1.6 @400mm...
  • Page 14 409ZX Loader Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – RETURN AIR MODULE 100062R02 Return Air Base Assy Charcoal Grey MX83-682 Weld Assy 100062R03 R.A.F. Frame Assy Charcoal Grey MX83-682 Weld Assy 500016 HEPA Filter 285x165x31...
  • Page 15 409ZX Loader PARTS GA Carbon Filter Service Kit Carbon Filter Carrier Removal 1. Please follow the steps shown for the Filter Media Carrier 1. Ensure all relevant circuit breakers are open and the electrical Removal, to remove the carrier from the case.

  • Page 16: Technical Details

    409ZX Loader TECHNICAL DETAILS Connections: 200027 Wiring Diagram Item Destination PIPE A – AMBIENT PRESSURE – OUTSIDE PIPE B – POSITIVE PRESSURE – INSIDE RJ45 CONNECTOR – CO2 SENSOR OVERRIDE TOGGLE SW = MAX SPEED Item Destination 12/24 VOLT POSITIVE SUPPLY...
  • Page 17 409ZX Loader GENERAL GUIDE General Guide to Cabin Sealing, Testing, and Commissioning of BreatheSafe variable speed Pressurisation Units (Clean Cabin with HEPA vacuum) Inspect the cabin and ensure all cover panels are in place and any cabin pressure leaks are sealed with grommets, sealer, fit new door seals for used equipment, etc Sitting inside the cabin with the door open, turn on the ignition to power up the unit.

  • Page 18: Smoke Emitter Cabin Pressure Leak Test

    409ZX Loader * Do not handle until MSDS & all safety precautions have been read and understood. Use personal protective equipment as required. SMOKE EMITTER CABIN PRESSURE LEAK TEST Before use, carefully read the product label. Safe work practices are advised to avoid eye or skin contact and inhalation. Observe good personal hygiene, including washing hands before eating.

  • Page 19: Cabin Sealing Test Pressure

    409ZX Loader CABIN SEALING TEST PROCEDURE Cabin Sealing Efficiency Test Procedure Start Engine – Pressuriser System is ON Ensure all windows & door(s) are CLOSED correctly (no cabin pressure leaks) NOTE: for a new cabin with effective seals, you may need to open a window slightly before closing the door to bleed the static cabin air pressure outwards.

  • Page 20: Commissioning Procedures

    409ZX Loader COMMISSIONING PROCEDURES – CABIN PRESSURISER Commissioning Procedures Follow each step of the installation guide that was supplied with the BreatheSafe kit. Cabin sealing is an integral part of RS20 & ISO 23875; you must ensure that cabin seals are adequate for maintaining positive pressure.

  • Page 21: Troubleshooting Guide

    409ZX Loader BREATHESAFE SYSTEM TROUBLE SHOOTING GUIDE *TOUCH CONTROL FAULT POSSIBLE CAUSE SOLUTION *ERR error code Poor sensor connection Remove & refit pod connection cable Corrupted coding Access factory setup - default reset - pin 6759 *Check filter alarm Service hour timeout...

  • Page 22: User Settings Instructions

    409ZX Loader USER SETTINGS INSTRUCTIONS User Settings Instructions ENTER SET UP MODE Start-Up Screen > Main Screen > Settings Button > Settings Screen > Site Access Button > Insert Pin > Site Menu BACK Enter Pin To enter the Setup mode, press the SETTING button.
  • Page 23 409ZX Loader PRESSURE ALARM SETTING USER SETTINGS INSTRUCTIONS PRESSURE SETPOINT The mining industry benchmark for cabin pressure is 50 pascals and low-pressure is The pressure setpoint changes the pressure that the cabin will be maintained. set at 20 pascals. INPRESS TS maintains the pre-set pressure within the cabin compared to outside.
  • Page 24 409ZX Loader SERVICE INTERVAL DATE & TIME SETTINGS USER SETTINGS INSTRUCTIONS Use the onscreen UP and DOWN buttons to change the service interval setpoint. Change the recorded date displayed and measured by the INPRESS TS. To reset the current runtime to zero, press the RESET CURRENT RUNTIME button and enter the site access pin.
  • Page 25 409ZX Loader ALARM BUZZER SETTINGS PRESSURE ALARM BUZZER SETTING CALIBRATE ZERO SENSOR To disable the buzzer, toggle through to the ENABLED and DISABLED buttons. Over long runtime, the 200027 may need recalibration. This screen allows the sensor to be recalibrated if more than 5 Pascals are out. To recalibrate, open windows and doors, turn off air conditioning, and any other device that may alter cabin pressure.
  • Page 26 409ZX Loader CO2 SETTINGS CO2 MODULE ENABLE/DISABLE CO2 PRIMARY ALARM POINT Enable or disable to CO2 module used for measuring CO2 levels within the cabin. The first alarm will sound when CO2 levels inside the enclosure reach this point. BACK...
  • Page 27 409ZX Loader CO2 SETTINGS CO2 ALARM DELAY CO2 CRITICAL ALARM MUTE RESET After CO2 (concentration in ppm) within the cabin reaches the 1000 ppm setpoint, the The critical alarm is set at 2500 PPM and cannot be changed. The mute delay, alarm will sound after this designated amount of time.

  • Page 28: Data Download

    409ZX Loader Data Download – Setting up RS232 Connection DATA DOWNLOAD Click OK once the correct Plug the RS232/USB adaptor communication port has into a free USB port on your been identified. computer Go to SETUP and click on Open up TeraTerm software.
  • Page 29 409ZX Loader Data Download – Setting up RS232 Connection DATA DOWNLOAD From the drop-down menu, If required, you may choose click on the Save setup. to save the COM port settings. Go to Settings and clock save the setup. Hint: From the drop-down menu, click on the Save Setup.
  • Page 30 409ZX Loader Data Download – Setting up RS232 Connection DATA DOWNLOAD Excel Data Instructions – Unformatted From the drop-down menu, Open an Excel sheet and select the first cell A-1. Next, press and hold down click on the Edit menu the CTRL button on your keyboard and then press the letter V on the function.

  • Page 31: Warranty

    409ZX Loader INPRESS TL WARRANTY BreatheSafe responsibilities Express Warranty If there is a defect in material or workmanship not caused by the excluded failures during the warranty period, All BreatheSafe products carry a warranty against defects in materials or workmanship, provided the BreatheSafe will either replace the defective goods at our Queensland factory, or designated branch.

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