Komatsu WE1850-3 Wheel Loader Parts and Service Manual

Introduction & Overview

This document serves as the comprehensive Parts and Service Manual for the Komatsu WE1850-3 Wheel Loader, focusing on the integrated Breathe Safe air pressurisation system. It details installation, safety precautions, maintenance schedules, operator guidelines, technical specifications, parts lists, troubleshooting, user settings, data download procedures, and warranty information.

The system includes the following key components:

• HEPA H14 Variable Speed Pressuriser
• INPRESS TS Cabin Display with CO2 Sensor
• HEPA Return Air Filter with Activated Carbon

Safety Information

WARNING: The pressurisation system involves areas that can be dangerous if not handled with extreme care. Qualified staff must wear appropriate Personal Protective Equipment (PPE) when cleaning or servicing the unit due to potential dust and fibres. The electrical system operates on 12V DC or 24V DC; all work requires correct safe work procedures and electrical safety measures, including isolating relevant circuit breakers. The air filtration system may contain high-speed rotating equipment with sharp edges; ensure all safety guards are in place during operation. HEPA filters are not cleanable and must be replaced at the end of their lifecycle or if damaged.

Particulate Behaviour: Airborne particulates remain in air longer in non-still environments like warehouses and workshops, increasing the risk to workers. Ensure PPE is worn during installation.

Recommended PPE: ⛑️ Hard Hat, ? Eye Protection, ? Dust Mask, ? Ear Protection, ? Protective Clothing.

Smoke Emitter Cabin Pressure Leak Test: This procedure requires specific safety precautions, including the use of PPE, ensuring the work area is clear of flammable materials, and proper handling of the smoke emitter. Detailed instructions are provided for safe operation and testing.

Maintenance Schedule

Regular maintenance is crucial for optimal performance and longevity. Data download is required to claim the 3-year warranty on the Brushless Blower Motor.

Critical Parts & Maintenance Schedule

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

Inspection Schedule

• Every 500 Hours: Inspect Turbo Pre-cleaner operation. Ensure Pressuriser Blower is operational. Inspect HEPA Primary Filter capacity indicator; replace if 80% or greater, vacuum housing before replacement. Vacuum inside cabin floor before replacing HEPA Return Air Filter. Check filter frame assembly, mounts, seals, and housing for secure fitment, latches, and correct filter canister fit.
• 15,000 Hours / 36 months: Perform all 500-hour inspection actions. Replace BRUSHLESS Pressuriser Blower (200002).

Fan Capacity Indicator: The filter is serviceable if motor capacity is between 10% & 80%. Change filter if capacity exceeds 80%. (Site dependent).

Operator Guide

Pre-Start Checklist: Visually inspect the BreatheSafe system and cabin for damage (doors, windows, seals). Remove dust/debris from shoes and clothes. Ensure doors and windows are closed. Start the engine and set HVAC to speed 2. After a delay, the display should show 50 Pascals or the pre-set value, indicating correct operation.

Normal Operating Condition: BreatheSafe recommends setting the OEM air conditioning fan to mid speed or greater for air circulation and CO2 minimisation. Acceptable operating range for BreatheSafe fan is 10-80%; >80% suggests maintenance.

Alerts:

• Fixed Fan Start Delay: Limits fan speed to 30% for pre-start checks; can be disabled.
• CO2 Level Alert: Alerts if CO2 levels are high; ensure AC fan is set to mid speed or greater.
• Low Pressure Alarm: Indicates cabin is not maintaining positive pressure; check doors and windows. Refer to maintenance for filter and cabin sealing checks.
• Check Filter: Reminder to inspect or replace filters; service hour meter requires reset.

Specifications

High-Capacity HEPA Pressuriser

• 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). Motor has slow start to prevent 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.
• Construction: High strength composite.
• Serviceability: Easy access HEPA filter with twist-lock dust cap.
• Mounting: Heavy Duty adjustable brackets.
• Design: Fully designed in SolidWorks 3D CAD & Ansys Engineering Simulation Software.
• FEA Testing: Critical components tested in SolidWorks Simulation.
• CFD Testing: Simulations in Flow Works for optimum airflow.

List of Abbreviations

Parts Lists

Detailed parts lists are provided for various assemblies, including the TL4 24V DC Pressuriser Unit, GA Assembly, Pressuriser Module, Return Air Module, Monitor Module, and Pipework Module. Each list includes item number, part number, description, quantity, material, thickness, colour, and category.

(Detailed tables for each part list are omitted here for brevity but are present in the original document.)

Service Procedures

Carbon Filter Carrier Removal & Service Kit

Instructions are provided for removing and servicing the carbon filter carrier. This involves ensuring electrical isolation, unlocking latches, pulling the filter, cleaning the housing, and reassembling in reverse order. The service kit procedure involves unscrewing the unit, lifting out media and HEPA filters, cleaning the housing, and reassembling.

Technical Details

• Display Key Features: Digital cabin pressure monitoring, automatic pressure control, intelligent fan speed, data logger, low-pressure alarm, light sensor for screen dimming.
• CO2 Sensor: NDIR type, 2-second sample rate, 12-30V DC, automatic altitude compensation, adjustable alarm set points, no setup required.

Wiring Diagram

A wiring diagram illustrates the connections between the INPRESS User Interface (UI), CO2 Sensor, TL4 Pressuriser, and Power Supply, detailing connections for ambient pressure, positive pressure, CO2 sensor, and override toggle switch.

Cabin Sealing Efficiency Test Procedure

This procedure involves starting the engine with the pressuriser system ON, ensuring all windows and doors are closed, entering the Settings menu, selecting 'System Check - Set Max', and recording the maximum cabin pressure achieved. A minimum requirement of 250 Pascals for cabin sealing efficiency is noted.

Commissioning Procedures

Follow installation guide steps. Cabin sealing is critical for maintaining positive pressure, adhering to RS20 & ISO 23875 standards. Site users must have proactive procedures for servicing enclosure seals. The touch-screen controller (Part# 200027) requires a 'System Check - Set Max' function to verify a minimum cabin sealing efficiency of 250 Pascals. If this is not met, pressure leaks must be identified and addressed. Commissioning requires recording and submitting results, including ID plate, INPRESS TL Pressuriser location, HEPA Return Air Filter location, Cabin Pressure Display location, and the 'System Check' maximum cabin pressure result. A BreatheSafe Service Tag must be filled out with machine serial number, installation date, pressure readings, and verified thresholds. Extended warranty is applicable only if commissioning documents are registered online and meet the 250Pa requirement.

Troubleshooting Guide

A troubleshooting guide is provided to address common faults such as error codes, filter alarms, temperature/CO2 errors, noisy pressuriser operation, filter blocking, blank display, low pressure alarms, and pressuriser not working. It lists possible causes and corresponding solutions, including checking sensor connections, service hour timeouts, filter status, power supply, and earth continuity. Site access code 7597 is mentioned for specific functions.

User Settings Instructions

Detailed instructions are provided for navigating the INPRESS controller's setup mode using the touch screen. Users can adjust parameters such as Time, Date, Pressure Setpoint (benchmark 50 Pascals, low-pressure alarm at 20 Pascals), Alarm Delay/Intervals, Calibration, Data Logging, Service Reminders, and CO2 Settings (including CO2 Module Enable/Disable, Primary Alarm Point, Alarm Delay, and Critical Alarm Mute Timeout).

Data Download

Instructions cover setting up an RS232 connection using TeraTerm software. This involves plugging in the RS232/USB adaptor, configuring TeraTerm with specific serial port settings (Baud Rate: 57600, Data: 8 bit, Parity: EVEN, Stop: 2 bit, Flow Control: NONE), and saving/restoring setup configurations. Data can then be downloaded from the controller. The process for copying downloaded data from TeraTerm to an Excel spreadsheet is also detailed, including using 'Select All', 'Copy table', pasting into Excel, and using Excel's 'Text to Columns' feature with comma as the delimiter to correctly format the data for archiving.

Data Logging Formats: Include BU No, Time, Date, Pressure, and Alarm Type (0=No alarm, 1=Low-pressure alarm, 2=Window open, 3=Door open).

Warranty Information

BreatheSafe offers an express warranty against defects in materials or workmanship, excluding issues arising from neglect, improper installation, or unauthorized servicing. The standard warranty is 1 year or 10,000 hours. Controllers have a 1-year warranty. Extended warranties are available upon successful online commissioning registration (minimum 250Pa cabin pressure achieved) and adherence to maintenance requirements. Specific warranty periods apply to brushless motors (fixed speed: 2 years/10,000 hours; variable speed: 15,000 hours/3 years). The warranty is void if the product is altered, modified, or used improperly. BreatheSafe may replace defective goods, provide parts, or offer a refund. Users are responsible for maintaining the system according to BreatheSafe requirements and contacting BreatheSafe for warranty claims. Australian Consumer Law rights are also referenced.