Komatsu HD785-7 Guida rapida

Parts and Service Manual

KOMATSU

Controlled Document: M0048

Issue Date: 24/07/23

Revision: 1

Kit Part Number: 700456

HD785-7 DUMP TRUCK

+61 7 3276 7833

www.breathe-safe.com.au

[email protected]

62 Mica Street, Carole Park, 4300, QLD

HEPA H14 Variable Speed Pressuriser | INPRESS TS Cabin Display with CO2 Sensor | HEPA Return Air Filter

KOMATSU

HD785-7 Dump Truck

INSTALLATION

INSTALLATION OVERVIEW

Manufacturer

KOMATSU

Type

Dump Truck

Model

HD785-7

Cabin Pressure Max

Set Auto Cabin Pressure

CONTENTS

Installation ....................................1

Safety............................................2

Critical Parts & Maintenance

Schedule........................................3

Operator Guide .............................4

Specifications - Pressuriser.............5

Parts List...................................6-12

Technical Details.....................13-14

Smoke Emitter Cabin Pressure Leak

Test.............................................15

Cabin Sealing Test Pressure..........16

Commissioning Procedures..........17

Troubleshooting Guide ................18

User Settings Instructions .......19-24

Data Download.......................25-27

Warranty.....................................28

HEPA H14 Variable Speed Pressuriser

INPRESS TS Cabin Display with Data Recorder

HEPA Return Air Filter

KOMATSU

HD785-7 Dump Truck

WARNING

THE PRESSURISATION SYSTEM DESCRIBED IN THIS MANUAL HAS THE

FOLLOWING AREAS WHICH MAY BE DANGEROUS IF NOT TREATED WITH

GREAT CARE.

QUALIFIED STAFF MUST WEAR THE CORRECT PERSONAL PROTECTIVE

EQUIPMENT WHEN CLEANING AND SERVICING THIS UNIT DUE TO DUST

AND FIBRES WHICH MAY BE CAUGHT BY THE STAGES OF AIR FILTRATION

DURING NORMAL UNIT OPERATION.

THE ELECTRICAL POWER SYSTEM IS SUPPLIED BY 12V DC OR 24V DC AND

NO WORK SHOULD BE CARRIED OUT ON THE PRESSURISER SYSTEM

WITHOUT THE CORRECT SAFE WORK PROCEDURES AND ELECTRICAL

SAFETY MEASURES BEING TAKEN, AND ALL RELEVANT CIRCUIT BREAKER

OPENED TO ISOLATE THE CIRCUIT.

THE AIR FILTRATION SYSTEM MAY HAVE SEVERAL TYPES OF HIGH-SPEED

ROTATING EQUIPMENT INSTALLED WITH VERY SHARP EDGES. ENSURE ALL

SAFETY GUARD ARE IN PLACE WHILE THE SYSTEM IS RUNNING.

Please be aware that HEPA filters cannot be cleaned and must be

replaced at the end of their lifecycle or if filter media has been damaged.

SAFETY

Particulate Behaviour

This is the length of time it takes for a particle to drop from a height

of 1.5m in STILL air.

Warehouses and workshops do not have still air, so hazardous

airborne particulates may remain in air for longer, increasing chance

for workers to breathe in dust. Ensure PPE is worn when installing

this system.

Hard Hat

Eye Protection

Dust Mask

Ear Protection

Protective

Clothing

KOMATSU

HD785-7 Dump Truck

Maintenance Schedule

Inspect every 500 Hours and replace when filter is full*

Component / System

Action Required

Turbo Pre-cleaner

Check operation of the Turbo Pre-

Cleaner.

Pressuriser Blower

Ensure blower is operational.

HEPA Primary Filter p/n: 500000

Inspect filter capacity indicator.

Replace HEPA filter when 80% or

greater. Vacuum out housing

before replacing the filter

elements.

HEPA Return Air Filter P/N:

500016

Vacuum inside cabin floor before

replacing filter.

Filter Frame Assembly, Mounts,

Seals and Filter Housing

Check door seals, all bolts, screws,

and all mounts are secure.

Check the filter canister & ensure it

is correctly fitted.

Check latches are operational and

in good order.

Replace / Re-tension fixtures and

fittings required.

15,000 Hours / 36 months*

Component / System

Action Required

500 Hour Inspection

All 500-hour inspection actions.

Pressuriser’s Blower 200002

Replace BRUSHLESS Pressuriser

blower.

CRITICAL PARTS & MAINTENANCE SCHEDULE

Critical Parts

Item

Part Number

Qty.

Description

Service Interval

500000

Fresh Air HEPA H14 Filter (Tested as per

EN1822)

1000* Hours (>80%

fan capacity)

500016

HEPA Return Air Filter

500* Hours

200002

Brushless Blower Motor –24V

15,000 Hours

200027

BreatheSafe Digital Display –Data

Recorder (INPRESS TS)

The following tables show our suggested maintenance schedule

for all units. Please note that site conditions may alter this.

Excludes high corrosion environments.

Data download is required to claim the 3-year warranty on

Brushless Blower Motor.

*Filter service hours are subject to cab sealing efficiency, site conditions and correct system

use.

Suggested Schedule Servicing*

Fan Capacity Indicator

The filter is serviceable if the motor capacity is

between 10% & 80%. We recommend that the filter is

changed if the capacity is over 80%.

*Site dependent

KOMATSU

HD785-7 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.

Ensure door(s) and windows are closed correctly.

Start engine and turn HVAC on to speed 2 (medium speed).

After fixed speed delay, the BreatheSafe display will show 50 Pascals or pre-set value.

The system is working correctly when the pascal value is green.

>> There is no further action required <<

NORMAL OPERATING CONDITION

Cab Air Conditioning

BreatheSafe recommends OEM air conditioning fan is set at mid speed or greater to circulate air around the breathing zone and

minimise CO₂.

Acceptable operating range for BreatheSafe fan 10-80%. >80% recommend maintenance.

ALERTS

Fixed Fan Start Delay

•Allows the operator to carry out pre-start checks –limiting at 30% fan speed, press the red text to disable.

CO₂Level Alert (if equipped)

•Ensure air conditioning fan is set at mid speed or greater to circulate air and minimise CO₂.

Low Pressure Alarm

•Cabin is not maintaining positive pressure –check doors and windows are closed correctly.

•Refer to maintenance department to check filters and cabin sealing. Ensure filters are serviceable.

Check Filter

•Reminder to inspect or replace filter. Service hour meter requires re-set.

•Refer to maintenance department.

KOMATSU

HD785-7 Dump Truck

Blower : Brushless Blower P/N 200002.

Protection : Locked Rotor Protection (Sub Zero Environments) Under

Voltage, Under/Over Current & Over Temperature.

Voltage : 24VDC.

Current Draw : 11 amps (peak). *Note: Motor has slow start to stop excessive

in-rush current.

Air Flow : Up to 30-300 m3/h or 50-215 CFM.

Pre-cleaner : Integrated VLR (Very Low Restriction). Turbo Pre-Cleaner.

Filter Element : BreatheSafe HEPA Primary Filter (H14=99.99% MPPS) TESTED AS

PER EN1822 –P/N 500000.

Plugs & Fittings : Mining Spec. Deutsch electrical plugs as standard.

Construction : High strength composite construction.

Serviceability : Easy access HEPA filter with twist-lock (TL) dust cap single

assembly.

Mounting : Heavy Duty adjustable mounting brackets.

Design : Fully designed in SolidWorks 3D CAD & Ansys Engineering

Simulation Software.

FEA Testing : Critical components FEA (Finite Element Analyst) tested in Solid

Works Simulation.

CFD Testing : CFD (Computational Fluid Dynamics) simulations in Flow Works

to ensure optimum air flow through the system.

SPECIFICATIONS HIGH-CAPACITY HEPA PRESSURISER

Specifications High-Capacity HEPA Pressuriser

List of Abbreviations

Dual HEPA

DHPR

Dual HEPA Powered Recirculation

DHAC

Dual HEPA Activated Carbon

DHACPR

Dual HEPA Activated Carbon Powered Recirculation

CPM

Cabin Pressure Monitor

CPU

Central Processing Unit

Decibel Sensor

DPM

Diesel Particulate Matter

GAS

Gas Sensor

HEPA

High-Efficiency Particulate Air Filter

HPAFU

High Pressure Air Filtration Unit

HRAF

HEPA Return Air Filter

HVAC

Heating Ventilation and Air Conditioning

MAF

Mass Air Flow

OEM

Original Equipment Manufacturer

Particulate Mass

Relative Humidity

TEMP

Temperature

Touch screen

User Interface

VMS

Vehicle Monitoring System

Vibration Sensor

OGSP

OnGuard Sensor Pod

CO2s

CO2 Sensor INPRESS TS

KOMATSU

HD785-7 Dump Truck

PARTS LIST –TL4 24V DC PRESSURISER UNIT

Item No.

Qty.

Description

Part No.

Pre-cleaner Hood & Rotor Assy

200004

Pre-cleaner Injector Ring

200005

TL Fan Blade (inc. in #7)

200006

TL Nose Cone / Pre-cleaner

200007

TL Motor Housing

200008

TL Filter Housing

200009

24v DC Brushless VSD Motor & TL Fan Blade

200002

O Ring Seal Kit 2 Parts

200010

Included in 8

200011

Wiring Sleeve

200012

HEPA H14 Filter

500000

M6 Nyloc Nut

300218 (M6NYL)

M6 x 55mm Hex Bolt

300982 (M655B)

M8 x 190 Hex Bolt

301136 (M8190B)

M8 x 22mm O/D HD Washer

300230 (M8222HTW)

M8 Nyloc Nut

300249 (M8NYL)

M4 x 75mm Pan Head Phillips Screw

300162 (M475PBH)

PRESSURISER ASSEMBLY No: 200000

KOMATSU

HD785-7 Dump Truck

Item No.

Part No.

Rev

Description

Qty

Colour

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