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Kit Part Number: 700126
+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
HD605-7 DUMP TRUCK
Controlled Document: M0120
Issue Date: 06/09/23
Revision: 1
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Summary of Contents for Komatsu HD605-7
- Page 1 Kit Part Number: 700126 Parts and Service Manual KOMATSU HD605-7 DUMP 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: M0120 sales@breathe-safe.com Issue Date: 06/09/23...
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Page 2: Table Of Contents
KOMATSU HD605-7 Dump Truck INSTALLATION INSTALLATION OVERVIEW Manufacturer KOMATSU CONTENTS Type Dump Truck Model HD605-7 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump Truck Item No. Part No. Rev Description Colour Category PARTS LIST GA 200202 TS Controller Assembly Stock Item 100113A01 High Pressure Unit Module Charcoal Grey MX83-682 Assembly COMPLETE ASSEMBLY No: 700126 100113F01 Fresh Air Module Charcoal Grey MX83-682... - Page 9 KOMATSU HD605-7 Dump Truck Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – PRESSURISER MODULE 200000 TL4 24V DC Unit Stock Item 250007 TL Mount Brkt Std Mild Steel (As Req’d) Stock Item...
- Page 10 KOMATSU HD605-7 Dump Truck Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – FRESH AIR MODULE 100113F02 Fresh Air Spigot Assy Charcoal Grey MX83-682 Weld Assy 100113F03 Clamp Assembly Charcoal Grey MX83-682 Weld Assy...
- Page 11 KOMATSU HD605-7 Dump Truck Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – PIPEWORK MODULE 200308 3” – 90deg Short Elbow Silicone Pipework 200306 3” 45deg Short Elbow [45] Silicone 300388-0200 76.3 x 1.6 @ 200mm Stainless Steel Tube 3.0”ODx1.6W/T...
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Page 12: Material Thickness
KOMATSU HD605-7 Dump Truck Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – RETURN AIR MODULE 08338 R.A.F. Assy Charcoal Grey MX83-682 Assembly... - Page 13 KOMATSU HD605-7 Dump Truck Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – MONITOR MODULE 20022 TS Controller Assembly Stock Item 16683 Custom Monitor Box Charcoal Grey MX83-682...
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Page 14: Technical Details
KOMATSU HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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 HD605-7 Dump 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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