John Deere 332G Skid Steer Parts and Service Manual

Introduction and Overview

This manual provides comprehensive parts and service information for the BreatheSafe system installed on the John Deere 332G Skid Steer. It covers installation, safety, maintenance, specifications, parts lists, operational guides, technical details, commissioning, troubleshooting, data download, and warranty.

Key Components:

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

Contact Information:

• Phone: +61 7 3276 7833
• Website: www.breathe-safe.com.au
• Email: sales@breathe-safe.com
• Address: 62 Mica Street, Carole Park, 4300, QLD

Document Control: Controlled Document: M0208, Issue Date: 16/10/23, Revision: 1

Contents

The manual is structured into the following sections:

• Installation
• Safety
• Critical Parts & Maintenance Schedule
• Operator Guide
• Specifications - Pressuriser
• Parts List (Pages 6-13)
• Technical Details (Pages 14-15)
• Smoke Emitter Cabin Pressure Leak Test
• Cabin Sealing Test Pressure
• Commissioning Procedures
• Troubleshooting Guide
• User Settings Instructions (Pages 20-25)
• Data Download (Pages 26-28)
• Warranty (Page 29)

Installation Overview

The installation overview details the system components and basic setup:

System Components:

• HEPA H14 Variable Speed Pressuriser
• INPRESS TS Cabin Display with Data Recorder
• HEPA Return Air Filter

Safety

WARNING: The pressurisation system involves potentially dangerous areas requiring careful handling. Qualified staff must use appropriate Personal Protective Equipment (PPE) due to dust and fibres. The electrical system is 12V DC or 24V DC; all work requires safe procedures and circuit isolation. High-speed rotating equipment in the air filtration system has sharp edges; ensure safety guards are in place.

HEPA filters cannot be cleaned and must be replaced when at the end of their lifecycle or if damaged.

Particulate Behaviour:

This section illustrates the time it takes for particles of different sizes to settle in still air from a height of 1.5m:

• 20µm: 3.6 mins
• 10µm: 8.3 mins
• 5µm: 35.7 mins
• 2µm: 2.8 hrs
• 1µm: 12 hrs
• 0.5µm: 41.7 hrs

In warehouses and workshops, reduced air stillness means hazardous particulates can remain airborne longer, increasing inhalation risk. Always wear PPE.

Required PPE:

• [Hard Hat] Hard Hat
• [Eye Protection] Eye Protection
• [Dust Mask] Dust Mask
• [Ear Protection] Ear Protection
• [Protective Clothing] Protective Clothing

Critical Parts & Maintenance Schedule

This schedule is suggested and may be altered by site conditions. Excludes high corrosion environments. Data download is required for the 3-year warranty on the Brushless Blower Motor.

Inspection Every 500 Hours:

• Turbo Pre-cleaner: Check operation.
• Pressuriser Blower: Ensure operational.
• HEPA Primary Filter (p/n: 500000): Inspect filter capacity indicator. Replace if 80% or greater. Vacuum housing before replacement.
• HEPA Return Air Filter (p/n: 500023): Vacuum inside cabin floor before replacing filter.
• Filter Frame Assembly, Mounts, Seals and Filter Housing: Check door seals, bolts, screws, and mounts. Ensure filter canister is correctly fitted. Check latches. Replace/re-tension fixtures.

15,000 Hours / 36 Months:

• 500 Hour Inspection: Perform all 500-hour inspection actions.
• Pressuriser's Blower (200003): Replace Brushless Pressuriser blower.

Critical Parts List:

*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 motor capacity is between 10% & 80%. Recommended to change if capacity exceeds 80%. (*Site dependent)

Operator Guide

OPERATORS CHECKLIST - PRE-START:

1. Visually inspect the BreatheSafe system for damage.
2. Visually inspect the cabin for damage to doors, windows, seals.
3. Remove dust & debris from shoes and clothes before entering the cabin.
4. Ensure door(s) and windows are closed correctly.
5. Start engine and turn HVAC on to speed 2 (medium speed).
6. After a fixed speed delay, the BreatheSafe display should show 50 Pascals or the pre-set value. The system is working correctly when the pascal value is green.

NORMAL OPERATING CONDITION:

Cab Air Conditioning: BreatheSafe recommends the OEM air conditioning fan be set at mid speed or greater to circulate air and minimize CO2. Acceptable operating range for BreatheSafe fan is 10-80%; >80% recommends maintenance.

ALERTS:

• Fixed Fan Start Delay: Allows pre-start checks by limiting fan speed to 30%. Press red text to disable.
• CO2 Level Alert (if equipped): Ensure air conditioning fan is set at mid speed or greater to circulate air and minimize CO2.
• Low Pressure Alarm: Indicates the cabin is not maintaining positive pressure. Check doors and windows are closed correctly. Refer to maintenance for filter checks 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.

Specifications - Pressuriser

Specifications High-Capacity HEPA Pressuriser

• Blower: Brushless Blower P/N 200003.
• Protection: Locked Rotor Protection (Sub Zero Environments) Under Voltage, Under/Over Current & Over Temperature.
• Voltage: 12VDC.
• Current Draw: 11 amps (peak). 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.
• Construction: High strength composite construction.
• Serviceability: Easy access HEPA filter with twist-lock (TL) dust cap.
• Mounting: Heavy Duty adjustable mounting brackets.
• Design: Fully designed in SolidWorks 3D CAD & Ansys Engineering Simulation Software.
• FEA Testing: Critical components FEA tested in SolidWorks Simulation.
• CFD Testing: CFD simulations in Flow Works for optimum air flow.

List of Abbreviations:

Parts List - 12V DC Pressuriser Unit

Pressuriser Assembly No: 200001

Parts List GA

Complete Assembly No: 700327

Parts List - Pressuriser Module

Parts List - Fresh Air Module

Parts List - Monitor Module

Parts List - Pipework Module

Parts List - Return Air Module

Parts List - Cab Sealing Module

Technical Details

Display Key Features:

• Digital cabin pressure monitoring system
• Automatic cabin pressure control
• Intelligent fan speed output
• Data logger
• Alarm for low-pressure (RS20)
• Light sensor for automatic dimming of the screen

CO2 Sensor:

• CO2 Sensor Type: NDIR (Non-Dispersive Infrared)
• Sample Rate: Every 2 seconds
• Operating Voltage: 12-30V DC
• Automatic Altitude Compensation
• Alarm Set points are adjustable
• No setup required

Dimensions: Display unit approximately 184.5mm x 61.8mm x 54.6mm. CO2 Sensor approximately 65mm x 120mm x 27mm.

Connections and Wiring Diagram

Connections: 200027

Wiring Details:

The wiring diagram shows connections to the INPRESS User Interface (UI), CO2 Sensor, and TL4 Pressuriser, including power supply and various signal lines.

Smoke Emitter Cabin Pressure Leak Test

WARNING: Read MSDS and safety precautions. Use appropriate PPE. Do not ignite near flammable materials. Use in well-ventilated areas. Concentrated smoke can cause burns and respiratory irritation. Harmful if swallowed.

DANGER: Use only as directed. Contains hexachloroethane. Wear protective clothing. Store securely. Keep out of reach of children.

Directions (Smoke Bomb):

1. Inform nearby workers. Place on a non-combustible container away from flammable materials.
2. Place at blower intake or upwind of target area.
3. Orient "Smoke Issues Here" towards air stream, away from surfaces. Use a heat-resistant plate if necessary.
4. Ensure smoke does not create a hazard.
5. Ignite emitter inside the cabin using a site-approved device (e.g., solder torch, lighter).
6. Do not touch or hold the smoke generator after ignition as it becomes very hot.

Smoke Emitter Cabin Pressure Leak Test Procedure:

1. Pressuriser system must be ON (TEST MODE).
2. Hold emitter angled down.
3. Ignite emitter with approved ignitor.
4. Remove ignitor when product ignites.
5. If product flames, blow out the flame.
6. Place emitter in a non-flammable container inside the cabin at floor level, close doors/windows.
7. Observe smoke leaks to identify seal locations. Check leakage points outside the cabin.
8. Do not come into contact with or inhale smoke haze.
9. Wait for smoke to disperse completely before re-entering. Open door to ventilate smoke before entering.

Potential Hazards: Falls, Fumes, Fire. Fumes may cause cancer (exposure unlikely when used as directed). Fire hazard is minimal.

Don'ts: Do not use if open flame is forbidden. Never leave the emitter unattended.

Cabin Sealing Efficiency Test Procedure

1. Start Engine - Pressuriser System is ON.
2. Ensure all windows & door(s) are CLOSED correctly (no cabin pressure leaks).
3. Note: For new cabins with effective seals, slightly open a window before closing the door to bleed static cabin air pressure outwards. Once the door is fully closed, then close windows to begin testing.
4. Enter the Settings menu via the touch screen.
5. Select and press the System Check button to go to System Test – Max Fan.
6. Record / photograph the maximum cabin pressure achieved.

The minimum BreatheSafe requirement for cabin sealing efficiency is 250 pascals.

Commissioning Procedures

Follow the installation guide for the BreatheSafe kit. Cabin sealing is critical for maintaining positive pressure as per RS20 & ISO 23875. Ensure operator enclosure seals (doors, windows) are in good working order or replaced before installation.

Touch-screen cabin pressure display/controller Part# 200027:

System Check Function: Navigate to Settings > System Check > Set Max. If the result is below 250 pascals, re-examine and fix leaks.

Submission for commissioning:

The process involves installing the kit, performing the "System Check", and if the enclosure exceeds 250 Pa, recording and photographing the results. If not, further enclosure sealing is required. Online commissioning is available at breathe-safe.com.au.

Required Commissioning Images:

• ID plate / Machine Serial Number / Asset Number or Call Sign
• INPRESS TL Pressuriser location
• HEPA Return Air Filter Location
• Cabin Pressure Display Location (including "System Check" max cabin pressure result and motor output capacity %)

BreatheSafe Service Tag Details:

• Machine Serial Number and Installer's details
• Date installed and System Check result (max cabin pressure)
• Set cabin pressure, actual pressure, and motor percentage output
• Verification of 250-pascal threshold (pass/fail)

Upload machine and installation details with required images. A Commissioning Certificate will be issued. Extended warranty requires meeting the 250-pascal requirement.

Troubleshooting Guide

BREATHESAFE SYSTEM TROUBLE SHOOTING GUIDE *TOUCH CONTROL

Access Codes: Site Access: 7597, Factory Setup: 6759

User Settings Instructions

ENTER SET UP MODE:

Start-Up Screen > Main Screen > Settings Button > Settings Screen > Site Access Button > Insert Pin > Site Menu.

To enter Setup mode, press the SETTING button, then enter the SITE ACCESS MENU by typing the 4-number pin (7597) and pressing ENTER.

SET UP PARAMETERS:

The BreatheSafe 200027 unit allows adjustment of the following parameters:

• Time (hours/minutes/seconds)
• Date (day/month/year)
• Pressure alarm setpoint
• Preferred cabin pressure
• Alarm delay/intervals
• Calibration and system settings
• Data logging reset
• Service reminders interval gap
• Current runtime reset
• CO2 settings and alarms

Pressure Setpoint: Changes the cabin pressure maintained by the INPRESS TS. Enter Setup mode, select ADJUST SETPOINT, then use UP/DOWN buttons to adjust fields.

Pressure Alarm Setting: Benchmark is 50 pascals, low-pressure alarm at 20 pascals. Alarm activates if cabin pressure drops below the pre-set value after a delay. Adjust setpoints using UP/DOWN buttons.

Service Interval: Use UP/DOWN buttons to change the service interval setpoint. Reset current runtime to zero by pressing RESET CURRENT RUNTIME and entering the site access pin.

Date & Time Settings: Change the recorded date and time displayed by the INPRESS TS.

Pressure Alarm Buzzer Setting: Toggle between ENABLED and DISABLED for pressure alarms.

Calibrate Zero Sensor: Recalibrate sensor if more than 5 Pascals out. Open windows/doors, turn off AC. Press AUTO ZERO SENSOR. Leave cabin while measuring. This resets Zero Pressure.

CO2 Module Enable/Disable: Enable or disable the CO2 module for measuring cabin CO2 levels.

CO2 Primary Alarm Point: Sets the threshold for the first CO2 alarm.

CO2 Alarm Delay: Adjusts the time between CO2 measurement and alarm sounding (Disabled / 1-10 minutes).

CO2 Critical Alarm Mute Reset: Critical alarm is set at 2500 PPM and cannot be changed. Mute delay can be configured.

Data Download

Setting up RS232 Connection:

1. Plug the RS232/USB adaptor into a free USB port.
2. Open TeraTerm software (easily accessible via online search).
3. In TeraTerm, go to Serial > Port and select the correct COM port (e.g., COM21: USB Serial Port).
4. Click OK to confirm the communication port.
5. Go to SETUP > Serial Port.
6. Configure COM ports: Baud Rate: 57600, Data: 8 bit, Parity: EVEN, Stop: 2 bit, Flow Control: NONE.
7. Optionally, save the COM port settings via Settings > Save setup. Name and save the file.
8. To restore setup, use the saved file to load COM PORT settings for data download.

Excel Data Instructions - Unformatted:

1. Open an Excel sheet, select cell A-1. Press CTRL+V to paste copied data.
2. The data will paste onto the sheet. Click 'DATA' > 'Text to Columns'.
3. Select 'Delimited', click Next.
4. Select 'Comma' in the next window, click 'Finish'.
5. Excel fields will update to place data in correct columns. Data is ready for archiving.

Data Logging Formats:

• BU No: xxxxxx (unique device number)
• Time: [HH:MM]
• Date: [DD/MM/YY]
• Pressure: Example value (e.g., 32 Pascals)
• Fields include: Date, time, motor (volts) output, cabin pressure (Pa), cabin pressure pre-set (Pa), low cabin pressure alarm (Pa).
• Alarm Type: 0 = No alarm, 1 = Low-pressure alarm, 2 = Window open, 3 = Door open.

Warranty

Express Warranty:

BreatheSafe products are warranted against defects in materials or workmanship, excluding factors outside BreatheSafe's control (neglect, lack of maintenance, improper installation/operation, unauthorized repair). BreatheSafe will replace defective goods at their Queensland factory or designated branch. All failed parts must be returned for evaluation.

Note: Systems must be installed and commissioned per BreatheSafe instructions. Online commissioning extends warranty. Systems must be serviced by trained personnel (BreatheSafe technicians, qualified automotive air-conditioning technicians, or qualified auto electricians).

Warranty Period - Standard:

• 1 year or 10,000 hours (whichever occurs first).
• Controllers: 1 year (no extended warranty option).
• Warranty Period Extension: Registered online within 28 days of installation.
• Extended warranty requires commissioning maximum pressure test of at least 250Pa.
• Brushless motor (fixed speed): 2 years or 10,000 hours.
• Variable speed brushless motor: 15,000 hours or 3 years (with data download for 3-year option).

Link for Commissioning and Extended Warranty Registration: https://www.breathe-safe.com.au/commission/

What is not covered under Express Warranty:

• Failures due to incorrect application.
• Damage from neglect, misuse, lack of maintenance, improper installation/operation, abnormal use, accidental/unauthorized servicing.
• Failures due to non-BreatheSafe approved parts.
• Failures not directly related to defects in material or workmanship.
• Product altered, modified, used not as designed, unauthorized repairs, or non-BreatheSafe parts.

BreatheSafe Responsibilities: BreatheSafe will replace defective goods or provide new replacement parts. They may offer a refund. Products are sent freight prepaid or available for pickup.

Users Responsibilities: Ensure system maintenance according to BreatheSafe requirements using authorized parts. Contact BreatheSafe for warranty claims. Claims should be made within one week of repair.

Exclusion and Limitations on Damages and Remedies: This warranty is in lieu of all other warranties. BreatheSafe's liability is limited to the original purchase price. Excludes damage from interference, abuse, or operation outside specified conditions. Consequential damages are excluded.

Australian Consumer Law: Consumers are entitled to refunds or replacements for major failures, and rectification for minor failures. Compensation for other foreseeable loss or damage is also available.

*This express warranty grants specific legal rights, and other rights may vary by country.