Hitachi ZW100-5B Parts And Service Manual
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Hitachi ZW100-5B Parts And Service Manual

Hitachi ZW100-5B Parts And Service Manual

Wheel loader
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Kit Part Number: 700423
+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
HITACHI
ZW100-5B WHEEL LOADER
+ Activated Carbon
Controlled Document: M0194
Issue Date: 11/10/23
Revision: 1

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Summary of Contents for Hitachi ZW100-5B

  • Page 1 Kit Part Number: 700423 Parts and Service Manual HITACHI ZW100-5B WHEEL 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: M0194 sales@breathe-safe.com...

  • Page 2: Table Of Contents

    HITACHI ZW100-5B Wheel Loader INSTALLATION INSTALLATION OVERVIEW Manufacturer Hitachi CONTENTS Type Wheel Loader Model ZW100-5B 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

    HITACHI ZW100-5B Wheel 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

    HITACHI ZW100-5B Wheel 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: Normal Operating Condition

    HITACHI ZW100-5B Wheel 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.

  • Page 6: Specifications - Pressuriser

    HITACHI ZW100-5B Wheel 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 HITACHI ZW100-5B Wheel 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

    HITACHI ZW100-5B Wheel Loader Item No. Part No. Rev Description Colour Group PARTS LIST GA 250502 Canister MK3 316SS Stock Item 200000 HPAFU 24VDC VSD TL4 Stock Item 700423 COMPLETE ASSEMBLY No: 250505 MK3 Rain Cover Unvsl Cap SS Stock Item...
  • Page 9 HITACHI ZW100-5B Wheel Loader Item No. Part No. Rev Description Material Thickness Colour Category PARTS LIST – FRESH AIR MODULE 100440-F918 Spigot Plate Mild Steel Part 100440-F919 Locating Flange Part 100440-F920 Spacer Mild Steel Part 300388-0080 76 SS Tube @80L Stainless Steel Tube (As Req’d)
  • Page 10 HITACHI ZW100-5B Wheel Loader Item Part No. Rev Description Material Thickness Colour Category PARTS LIST – RETURN AIR MODULE 100440R02 Return Air Base Charcoal Grey MX83-682 Weld Assy 100440-R917 R.A.F. Frame Charcoal Grey MX83-682 Part 500004 HEPA Filter 200x200x50 HEPA Filter...
  • Page 11 HITACHI ZW100-5B Wheel 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 12: Wiring Diagram

    HITACHI ZW100-5B Wheel 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 13: General Guide

    HITACHI ZW100-5B Wheel 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 14: Smoke Emitter Cabin Pressure Leak Test

    HITACHI ZW100-5B Wheel 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 15: Cabin Sealing Test Pressure

    HITACHI ZW100-5B Wheel 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 16: Commissioning Procedures

    HITACHI ZW100-5B Wheel 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 17: Troubleshooting Guide

    HITACHI ZW100-5B Wheel 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...

  • Page 18: Enter Setup Mode

    HITACHI ZW100-5B Wheel 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 19 HITACHI ZW100-5B Wheel 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.

  • Page 20: Service Interval

    HITACHI ZW100-5B Wheel Loader 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 21 HITACHI ZW100-5B Wheel 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 22 HITACHI ZW100-5B Wheel 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.
  • Page 23 HITACHI ZW100-5B Wheel 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 24: Data Download

    HITACHI ZW100-5B Wheel Loader 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 Go to SETUP and click on Open up TeraTerm software.
  • Page 25 HITACHI ZW100-5B Wheel Loader DATA DOWNLOAD Data Download – Setting up RS232 Connection 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.
  • Page 26 HITACHI ZW100-5B Wheel Loader DATA DOWNLOAD Data Download – Setting up RS232 Connection 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 27: Warranty

    HITACHI ZW100-5B Wheel 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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