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Kit Part Number: 700795
+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
KOMATSU
HM400-5 HAUL TRUCK
Controlled Document: M0284
Issue Date: 12/12/23
Revision: 1
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Summary of Contents for Komatsu HM400-5 2023
- Page 1 Kit Part Number: 700795 Parts and Service Manual KOMATSU HM400-5 HAUL TRUCK HEPA H14 Variable Speed Pressuriser | INPRESS TS Cabin Display with CO2 Sensor | HEPA Return Air Filter +61 7 3276 7833 www.breathe-safe.com.au Controlled Document: M0284 sales@breathe-safe.com Issue Date: 12/12/23...
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Page 2: Table Of Contents
KOMATSU HM400-5 Haul Truck INSTALLATION INSTALLATION OVERVIEW Manufacturer Komatsu CONTENTS Type Haul Truck Model HM400-5 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
KOMATSU HM400-5 Haul Truck 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
KOMATSU HM400-5 Haul Truck 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: Operators Checklist
KOMATSU HM400-5 Haul Truck 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. -
Page 6: Specifications - Pressuriser
KOMATSU HM400-5 Haul Truck 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 KOMATSU HM400-5 Haul Truck 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...
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Page 8: Parts List
KOMATSU HM400-5 Haul Truck Item No. Part No. Rev Description Qty Colour Category PARTS LIST GA DP16201 TL Pressuriser Assembly Charcoal Grey MX83-682 Module DP12284 Fresh Air Assembly Charcoal Grey MX83-682 Module 700788 COMPLETE ASSEMBLY No: DP16202 Tube Arrangement Charcoal Grey MX83-682... - Page 9 KOMATSU HM400-5 Haul Truck Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – PRESSURISER MODULE 16209 TL Mount Assy (Prt Dwgs) (Prt Dwgs) Charcoal Grey MX83-682 Welded Assy 250035 TL Mount 56.5mm Ext Nuts (As Req’d)
- Page 10 KOMATSU HM400-5 Haul Truck Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – FRESH AIR MODULE 11526 Mounting Bracket Plate Charcoal Grey MX83-682 11690 Fresh Air Duct (Prt Dwgs) (Prt Dwgs) Charcoal Grey MX83-682...
- Page 11 KOMATSU HM400-5 Haul Truck Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – PIPEWORK MODULE 16213 Stauff Clamp Brkt LH Mild Steel Charcoal Grey MX83-682 Part 16216 Stauff Clamp Brkt Mild Steel Charcoal Grey MX83-682 Part...
- Page 12 KOMATSU HM400-5 Haul Truck Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – MONITOR MODULE 16484 Small Monitor Box Mount Mild Steel Charcoal Grey MX83-682 07026 Small Monitor Box (Prt Dwgs) (Per Assy) TQ218208.519 Ø19 O/D x 20L Spacer Mild Steel Ø19 O/D...
- Page 13 KOMATSU HM400-5 Haul Truck Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – RETURN AIR MODULE 11694 Clamping Assy (Prt Dwgs) (Prt Dwgs) Charcoal Grey MX83-682 11693 Outer Filter Carry Charcoal Grey MX83-682 16812 Rear Frame Assy...
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Page 14: Technical Details
KOMATSU HM400-5 Haul Truck TECHNICAL DETAILS CO2 Sensor Display Key Features • • CO2 Sensor Type is NDIR (Non-Dispersive Infrared) Digital cabin pressure monitoring system • • Sample Rate is every 2 seconds Automatic cabin pressure control • • 12-30V DC Operating Voltage Intelligent fan speed output •... -
Page 15: Wiring Diagram
KOMATSU HM400-5 Haul Truck TECHNICAL DETAILS Connections: 200027 Wiring Diagram Item Destination PIPE A – AMBIENT PRESSURE – OUTSIDE PIPE P – POSITIVE PRESSURE – INSIDE RJ45 CONNECTOR – CO2 SENSOR OVERRIDE TOGGLE SW = MAX SPEED Item Destination 12/24 VOLT POSITIVE SUPPLY... -
Page 16: Smoke Emitter Cabin Pressure Leak Test
KOMATSU HM400-5 Haul Truck * 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 17: Cabin Sealing Test Pressure
KOMATSU HM400-5 Haul Truck 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. Once door is fully closed then close windows to begin testing. -
Page 18: Commissioning Procedures
KOMATSU HM400-5 Haul Truck 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. In addition, the site (end- user) must have the correct procedure(s) for servicing OPERATOR enclosure seals in a proactive manner rather than reactive. -
Page 19: Troubleshooting Guide
KOMATSU HM400-5 Haul Truck BREATHESAFE SYSTEM TROUBLE SHOOTING GUIDE *TOUCH CONTROL FAULT POSSIBLE CAUSE SOLUTION *ERR error code Poor sensor connection Remove & refit pod connection cable Corrupted coding Contact support for default reset pin *Check filter alarm Service hour timeout... -
Page 20: Enter Setup Mode
KOMATSU HM400-5 Haul Truck 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 21 KOMATSU HM400-5 Haul Truck 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.
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Page 22: Service Interval
KOMATSU HM400-5 Haul Truck USER SETTINGS INSTRUCTIONS SERVICE INTERVAL DATE & TIME SETTINGS 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 23 KOMATSU HM400-5 Haul Truck 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 24 KOMATSU HM400-5 Haul Truck 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.
- Page 25 KOMATSU HM400-5 Haul Truck 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.
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Page 26: Data Download
KOMATSU HM400-5 Haul Truck DATA DOWNLOAD Data Download – Setting up RS232 Connection Click OK once the correct Plug the RS232/USB adaptor communication port has into a free USB port on your been identified. computer. Open up TeraTerm software. Go to SETUP and click on (TeraTerm is an open-source Serial Port. - Page 27 KOMATSU HM400-5 Haul Truck DATA DOWNLOAD Data Download – Setting up RS232 Connection If required, you may choose From the drop-down menu, to save the COM port click on Restore setup. settings. Go to Settings and click save the setup.
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Page 28: Controller Setup
KOMATSU HM400-5 Haul Truck CONTROLLER SET UP INPRESS Controller Set Up 4. Press ‘LOG SETTINGS’. 1. Press ‘SITE ACCESS MENU’. 2. Enter the access pin ‘7597’. 5. Press ‘DOWNLOAD LOG FILE’. 3. Press ‘NEXT’. 6. Data is now downloading from... - Page 29 KOMATSU HM400-5 Haul Truck DATA DOWNLOAD Data Download – Copying Contents from Terminal to Spreadsheet Excel Data Instructions – Unformatted 12 From the drop-down menu, Open an Excel sheet and select the first cell A-1. Next, press and hold down...
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Page 30: Warranty
KOMATSU HM400-5 Haul Truck 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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