Caterpillar 796AC Electrical Cabinet Parts and Service Manual

Introduction

This manual provides detailed information for the installation, operation, and maintenance of the Volt Aire by BreatheSafe pressurization system for the Caterpillar 796AC EHVC Haul Truck's electrical cabinet. It includes safety guidelines, critical parts, operator instructions, technical specifications, and commissioning procedures.

Contents

• Installation
• Safety
• Critical Parts & Maintenance Schedule
• Operator Guide
• Specifications - Pressuriser
• Parts List
• Technical Details
• Looms
• Commissioning Procedures
• Warranty

Installation Overview

The installation of the Volt Aire system involves integrating the EPA E11 Variable Speed Pressuriser and the OnGuard Air Quality Monitoring & Control system into the Caterpillar 796AC truck.

Safety Precautions

WARNING: The pressurization system contains areas that can be dangerous if not handled with care. Qualified staff must wear appropriate Personal Protective Equipment (PPE) when cleaning or servicing the unit due to potential dust and fibers. The electrical system operates on 12V DC or 24V DC; always follow correct safe work procedures and ensure all circuit breakers are opened before commencing work. The air filtration system may contain high-speed rotating equipment; ensure all safety guards are in place during operation.

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

Particulate Behaviour: The document illustrates the time it takes for particles of various sizes (0.5µm to 20µm) to drop from a height of 1.5m in still air, highlighting the effectiveness of filtration.

Safety Icons: [Safety Goggles Icon], [Gloves Icon], [Ear Protection Icon], [Respirator Icon], [Hard Hat Icon], [Safety Shoes Icon]

Critical Parts & Maintenance Schedule

This section outlines the suggested maintenance schedule, excluding high corrosion environments. Data download is required for the 3-year warranty on the Brushless Blower Motor.

Inspection Every 1000 - 2000 Hours

• Turbo Pre-cleaner: Check operation.
• Pressuriser Blower: Ensure operational.
• EPA E11 Primary Filter (p/n: 510095): Inspect filter capacity indicator. Replace when 80% or greater. Clean housing before replacement.
• Filter Frame Assembly, Mounts, Seals and Filter Housing: Check door seals, bolts, screws, and mounts. Ensure filter canister is correctly fitted and latches are operational. Replace/re-tension fixtures.

Suggested Schedule Servicing

The filter is serviceable if the motor capacity is between 10% and 80%. Replacement is recommended if capacity exceeds 80%.

15,000 Hours / 36 Months

• 500 Hour Inspection: Perform all 500-hour inspection actions.
• Pressuriser's Blower (200002): Replace Brushless Pressuriser Blower.

Critical Parts List

Operator Guide

Pre-Start Checklist

1. Visually inspect the BreatheSafe system for any damage.
2. Visually inspect the cabinet for damage to doors and seals.
3. Ensure doors are closed correctly.
4. System will activate with ignition.
5. Startup system and check screen for alarms or alerts.
6. Check pressure reading corresponds to the value on the commissioning sticker.

The system is working correctly when the pascal value is green. ▶️ There is no further action required

Normal Operating Condition

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

Specifications High-Capacity EPA 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 a 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 EPA E11 Primary Filter TESTED AS PER EN1822 – P/N 510095.
• Plugs & Fittings: Mining Spec. Deutsch electrical plugs.
• Construction: High strength composite construction.
• Serviceability: Easy access EPA filter with twist-lock dust cap.
• Mounting: Heavy Duty adjustable mounting 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 List – 24V DC Pressuriser Unit

Pressuriser Assembly No: 210000

Filter Information: EPA E11 Grade Filter, Test Method: EN1822, Efficiency: 95% @ 0.3 Microns, PN: 510095. Handle with care. Do NOT touch filter media. EPA filters cannot be cleaned.

Parts List – General Assembly

Complete Assembly No: 720007

Parts List – Pressuriser Module

Parts List – Sealing Module

Parts List – Controller Module

Technical Details - Wiring Diagram

The wiring diagram illustrates the connections between the Low Voltage Cabinet, Controller, OnGuard system, and the Inverter Cabinet. Key components include:

Parts List – Master Controller Loom

Wiring Loom No: 400009

Wiring Details:

• 14AWG RED/WHITE, 14AWG BLACK (4 Pin Deutsch Male)
• 14AWG RED, 14AWG Black (3 Pin Deutsch Male)
• 14AWG RED/BLUE, 14AWG BLACK, 14AWG YELLOW (2 Pin Deutsch Female)

Loom Setback from Plug: 75.0 mm to solder joint, 100.0 mm to solder joint, 150.0 mm to solder joint.

Parts List – Pin Looms & Air Pressure Pipe

Wiring Assembly No: 400001

Wiring Details:

• Loom A: 2 Pin Deutsch Male, 14AWG RED, 14AWG Black. Part Number: 400002 (L100002), Dimension A: 5000.0 mm.
• Loom B: 3 Pin Deutsch Male, 14AWG RED/BLUE, 14AWG BLACK, 14AWG YELLOW. Part Number: 400003 (L100003), Dimension B: 5000.0 mm.
• Pipe C: Nylon Pressure Pipe. Part Number: 400004 (L100004), Dimension B: 5000.0 mm.

Commissioning Procedures

Follow these steps for the commissioning of the cabin pressuriser system:

Step One: Access Commissioning Form

Access the commissioning form via the following link or scan the QR code: https://three.breathe-safe.com/coregform

Step Two: Carry out Commissioning

• System Check Guide: Start engine (pressuriser ON), ensure all windows & door(s) are CLOSED correctly (no cabin pressure leaks).
• Take a photograph of the pressure reading on the UI while the Full-Speed Test is running.
• Press settings and "Cancel System Check" to end the test.

Cabin Sealing: Cabin sealing is crucial for maintaining positive pressure as per RS20 & ISO 23875. Ensure seals are adequate. The minimum BreatheSafe requirement for cabin sealing efficiency is 250 pascals. If this is not met, investigate and fix pressure leaks.

Step Three: Fill out Commissioning Form

Complete the commissioning form on the BreatheSafe website.

Step Four: Upload Commissioning Images

Upload the following required commissioning images:

• Whole Machine (Showing Pressuriser)
• Mounted Pressuriser
• Return Air Filter Label
• Return Air Filter Installation
• Pressure Test Result
• Actual Pressure and Motor Load
• Commissioning Sticker
• Machine S/N Plate
• Engine Hours / Odometer
• Pressuriser Serial No

Step Five: Fill in BreatheSafe Service Tag

Fill in the BreatheSafe service tag with the following details:

• Machine serial number and installer's details
• Date installed and "Full-Speed Test" result (max cabin pressure)
• The set cabin pressure with actual pressure and motor percentage output
• Verify the 250 pascal threshold was achieved (pass or fail).

Note: Extended warranty for BreatheSafe systems is only applicable to operator enclosures meeting the 250 pascal requirement.

Warranty: 3 years or 15,000 hours.

Important: Ensure doors are securely latched and sealed at all times, except during maintenance. Do not blow air into the pressure sensor tube.

Contact Information

US: +1 800 359 1704 | AU: +61 7 3276 7833

Email: sales@breathe-safe.com | Website: breathe-safe.com