Komatsu Excavator BreatheSafe Pressuriser System

Parts and Service Manual

KOMATSU PC35MR-5 / PC45MR-5 / PC55MR-5 EXCAVATOR

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

Contents

• Installation: Page 1
• Safety: Page 2
• Critical Parts & Maintenance Schedule: Page 3
• Operator Guide: Page 4
• Specifications - Pressuriser: Page 5
• Parts List: Pages 6-13
• Technical Details: Pages 14-15
• Smoke Emitter Cabin Pressure Leak Test: Page 16
• Cabin Sealing Test Pressure: Page 17
• Commissioning Procedures: Page 18
• Troubleshooting Guide: Page 19
• User Settings Instructions: Pages 20-25
• Data Download: Pages 26-29
• Warranty: Page 30

Installation Overview

Image: A Komatsu excavator is shown.

Products shown: HEPA H14 Variable Speed Pressuriser, INPRESS TS Cabin Display with Data Recorder, HEPA Return Air Filter.

Safety

WARNING

The pressurisation system described in this manual has areas that may be dangerous if not treated with great care.

• Qualified staff must wear correct Personal Protective Equipment (PPE) when cleaning and servicing due to dust and fibres that may be caught by air filtration stages during operation.
• The electrical power system is supplied by 12V DC or 24V DC. Work on the pressuriser system requires correct safe work procedures and electrical safety measures, including opening relevant circuit breakers to isolate the circuit.
• The air filtration system may contain high-speed rotating equipment with sharp edges. Ensure all safety guards are in place while the system is running.

Note: HEPA filters cannot be cleaned and must be replaced at the end of their lifecycle or if filter media is damaged.

Particulate Behaviour

This section describes the time it takes for particles of various sizes to drop from a height of 1.5m in still air. For example, a 20µm particle takes 3.6 minutes, while a 0.5µm particle takes 41.7 hours.

Warehouses and workshops often have moving air, meaning hazardous airborne particulates may remain suspended longer, increasing the risk to workers. Ensure PPE is worn when installing this system.

Required PPE: Hard Hat, Eye Protection, Dust Mask, Ear Protection, Protective Clothing.

Maintenance Schedule

The following tables provide suggested maintenance schedules. Site conditions may alter these recommendations. Excludes high corrosion environments.

Data download is required to claim the 3-year warranty on the Brushless Blower Motor.

Inspect every 500 Hours and replace when filter is full*

15,000 Hours / 36 months*

Critical Parts & Maintenance Schedule

*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%. It is recommended to change the filter if capacity exceeds 80%. *Site dependent.

Operator Guide

Operators Checklist - Pre-Start

1. Visually inspect the BreatheSafe system for any damage.
2. Visually inspect the cabin for any 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 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 the OEM air conditioning fan is set at mid speed or greater to circulate air around the breathing zone and minimise CO2. An acceptable operating range for the BreatheSafe fan is 10-80%. Operation above 80% recommends maintenance.

Alerts

• Fixed Fan Start Delay: Allows operator pre-start checks by limiting fan speed to 30%. Press the red text to disable.
• CO2 Level Alert (if equipped): Ensure air conditioning fan is set at mid speed or greater to circulate air and minimise CO2.
• Low Pressure Alarm: Indicates the cabin is not maintaining positive pressure. Check doors and windows are closed correctly. Refer to the maintenance department to check filters and cabin sealing. Ensure filters are serviceable.
• Check Filter: Reminder to inspect or replace the filter. The service hour meter requires re-setting. Refer to the 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). *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.

List of Abbreviations

Parts List - TL2 12V DC Pressuriser Unit

Pressuriser Assembly No: 200001

Image: Diagram showing the components of the TL2 12V DC Pressuriser Unit.

Parts List GA - Complete Assembly No: 700525

Image: Diagram showing the overall assembly of the BreatheSafe system for Komatsu excavators.

Parts List - Pressuriser Module

Image: Diagram showing components of the Pressuriser Module.

Parts List - Fresh Air Module

Image: Diagram showing the Fresh Air Assy.

Parts List - Pipework Module

Image: Diagram showing components of the Pipework Module.

Parts List - Monitor Module

Image: Diagram showing components of the Monitor Module.

Parts List - Return Air Module

Image: Diagram showing components of the Return Air 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 is NDIR (Non-Dispersive Infrared)
• Sample Rate is every 2 seconds
• 12-30V DC Operating Voltage
• Automatic Altitude Compensation
• Alarm Set points are adjustable
• No setup required

Image: Illustration of the INPRESS TS display unit with dimensions and a screenshot of the main screen.

Image: Illustration of the CO2 sensor with dimensions.

Technical Details

Wiring Diagram

Connections: 200027

Connection Points:

• Item 1: PIPE A - AMBIENT PRESSURE - OUTSIDE
• Item 2: PIPE P - POSITIVE PRESSURE - INSIDE
• Item 3: RJ45 CONNECTOR - CO2 SENSOR
• Item 4: OVERRIDE TOGGLE SW = MAX SPEED

Wiring Harness Details:

• Item 1: 12/24 VOLT POSITIVE SUPPLY
• Item 2: CAN H OPTION
• Item 3: CAN L OPTION
• Item 4: SERIAL TRANSMIT RS232
• Item 5: MOTOR CONTROL VOLTS OUT
• Item 6: ALARM + OUTPUT
• Item 7: TEMP SENSOR
• Item 8: NO CONNECTION
• Item 9: SERIAL RECEIVE RS232
• Item 10: DOOR INPUT (+)
• Item 11: WINDOW INPUT (+)
• Item 12: 0V NEGATIVE GROUND

Image: Wiring diagram showing connections between the INPRESS User Interface (UI), CO2 Sensor, and TL4 Pressuriser, including power supply and Deutsch plug.

Smoke Emitter Cabin Pressure Leak Test

WARNING

For Professional Use Only. Keep out of reach of children. Do not ignite near or around flammable materials. Use only in well-ventilated areas, outdoors, and/or with proper respiratory protection. Persons with respiratory sensitivity should avoid exposure to any smoke. Concentrated smoke may cause severe burns to the skin, eyes, or respiratory system. Improper use may result in sufficient inhalation of smoke to cause respiratory tract irritation and lung damage. Harmful if swallowed.

DANGER

Use only as directed. Do not handle until all safety precautions, including Safety Data Sheet, have been read and understood. The product contains hexachloroethane. Wear protective clothing. If exposed or concerned, get medical advice. Store in a cool, dry, secure location. KEEP OUT OF REACH OF CHILDREN. Dispose of contents/container per location regulations. When used as directed, exposure should be limited and usually poses no hazard because the hexachloroethane is consumed inside the tube as smoke is produced.

Directions: (Smoke Bomb)

1. Ensure other workers in close proximity are informed of use. Place on a non-combustible container, away from flammable materials.
2. Place at Blower intake, or upwind of target area, or near centre of space.
3. Orient "Smoke Issues Here" toward air stream, away from surfaces. Place candle on a flame / heat resistance plate - if not it will melt into the plastic surface.
4. Ensure smoke will not create any hazard where it is anticipated to go.
5. Ignite emitter inside the cabin using site approved device (e.g., solder torch or 'lighter') and conduct smoke test.
6. Do not touch or hold smoke generator after ignition - item becomes very hot & remains hot after use.

Smoke Emitter Cabin Pressure Leak Test Procedure

1. The pressuriser system is switched on (TEST MODE).
2. Hold the smoke emitter angled down.
3. Ignite emitter using site approved ignitor (e.g., solder torch or 'lighter').
4. When the product ignites, remove the lighter.
5. If the product flames up, blow out the flame.
6. Place the emitter in a non-flammable container and place it inside the cabin at floor level and close the door/windows.
7. Observe smoke leaks to indicate worn-out or broken seal locations. Check leakage points outside the cabin.
8. Do not come into contact with or inhale smoke haze.
9. Wait until the smoke haze completely disperses before re-entering the cabin. Open door to allow sufficient ventilation of smoke prior to entering cabin.

Personal Protective Equipment (PPE)

• Safety glasses must be worn at all times.
• Sturdy footwear with rubber soles must be worn.
• Respiratory protection devices may be required.
• Gloves may be worn.

Pre-operational Safety Checks

• Locate and ensure you are familiar with all machine operations and controls.
• Check work area and walkways to ensure no slip/trip hazards are present.
• Ensure the work area is clean and clear of any flammable material & fire extinguish device is present.

Operational Safety Checks

• Ensure the machine is correctly isolated / immobilized.
• Ensure other persons do not inhale smoke haze.
• Take care and do not place a lit emitter close to a flammable surface.

Ending Operations and Cleaning Up

• Leave the work area in a safe, clean, and tidy state.

Potential Hazards

• Falls
• Fumes (May cause cancer - exposure highly unlikely when used as directed)
• Fire

Don't

• Do not use if an open flame is forbidden.
• Never leave the emitter [cabin test] unattended.

*This SWP does not necessarily cover all possible hazards associated with this equipment and should be used in conjunction with other references. It is designed as a guide to compliment training and as a reminder to users prior to equipment use.

Cabin Sealing Test Procedure

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). 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. Once door is fully closed then close windows to begin testing.
3. Enter the Settings menu via the touch screen button.
4. Select and press the System Check button to go to System Test – Max Fan.
5. Record / photograph the maximum cabin pressure achieved.

Image: Screenshots showing the INPRESS TS display during the cabin sealing test procedure, including settings, system check, and results.

Commissioning Procedures

COMMISSIONING PROCEDURES – CABIN PRESSURISER

Follow each step of the installation guide supplied with the BreatheSafe kit. Cabin sealing is integral to RS20 & ISO 23875; ensure cabin seals are adequate for maintaining positive pressure. The end-user must have correct procedures for servicing operator enclosure seals proactively rather than reactively. Door and window seals must be in good working order or new seals fitted before system installation.

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

• System Check Function: Enter the Settings menu, select "System Check - Set Max." The minimum BreatheSafe requirement for cabin sealing efficiency is 250 pascals. If this is not met, re-examine and find pressure leaks and apply new sealing measures.

Submission for commissioning procedure:

Image: Flowchart illustrating the commissioning submission process: Kit Installed → Cabin Display Enter: "System Check" → Does enclosure exceed 250? (Yes/No) → Record & photograph results. If No, further enclosure sealing required.

Proceed to online commissioning: Commissioning - BreatheSafe

The commissioning images required are:

• ID plate / Machine Serial Number / Asset Number or Call Sign
• INPRESS TL Pressuriser location
• HEPA Return Air Filter Location Option: Powered Return Air Filter
• Cabin Pressure Display Location - Including the "System Check" maximum cabin pressure result with motor output capacity %

Fill in the BreatheSafe Service Tag with the following details:

• Machine Serial Number and Installers details
• Date installed and System Check result (max cabin pressure)
• The set cabin pressure with actual pressure and motor percentage output
• Verify the 250-pascal threshold was achieved = pass OR not achieved = fail**

Please upload machine and installation details with the required images. A Commissioning Certificate will be sent to the nominated email address. **Extended warranty for (RS20 & ISO 23875) BreatheSafe Systems is applicable only to operator enclosures meeting this requirement.

Image: BreatheSafe Service Tag with fields for machine details, warranty period, and contact information.

Troubleshooting Guide

BREATHESAFE SYSTEM TROUBLE SHOOTING GUIDE *TOUCH CONTROL

Access Codes: Site Access: 7597 | Contact Support for Factory Setup Pin

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. Type the 4-number pin and press ENTER.

Insert Pin: 7597

Image: Screenshots showing the INPRESS TS interface navigation for entering setup mode, including the pin entry screen.

Set Up Parameters

Accessing Setup mode allows adjustment of the following parameters:

• Time (hours/minutes/seconds)
• Date (day/month/year)
• Pressure alarm setpoint
• Preferred cabin pressure
• Alarm delay/intervals of alarm
• Calibration and system settings
• Resetting of the data logging
• Service reminders interval gap
• Reset current runtime between services
• CO2 settings and alarms

Image: Screenshots showing the INPRESS TS "Settings Page 1" and "Settings Page 2" menus.

Pressure Setpoint

The pressure setpoint determines the cabin pressure to be maintained. INPRESS TS maintains the pre-set pressure within the cabin compared to outside. Enter Setup mode, select ADJUST SETPOINT, then use the onscreen UP and DOWN buttons to change fields.

Image: Screenshots illustrating the process of setting the pressure, showing the main display, settings menu, pin entry, and the pressure settings screen with options for setpoint and alarm delay.

Pressure Alarm Setting

The industry benchmark for cabin pressure is 50 pascals, with a low-pressure setpoint of 20 pascals. After a delay, an alarm activates if cabin pressure remains below the pre-set value. Enter Setup mode, select ADJUST SETPOINT, then use the onscreen UP and DOWN buttons to change fields.

Image: Screenshots illustrating the process of setting pressure alarms, showing the main display, settings menu, pin entry, and the pressure settings screen.

Service Interval

Use the onscreen UP and DOWN buttons to change the service interval setpoint. To reset the current runtime to zero, press the RESET CURRENT RUNTIME button and enter the site access pin.

Image: Screenshots showing the INPRESS TS interface for setting service intervals and resetting runtime.

Date & Time Settings

Change the recorded date displayed and measured by the INPRESS TS.

Image: Screenshots showing the INPRESS TS interface for setting date and time.

Pressure Alarm Buzzer Setting

To disable the buzzer, toggle through ENABLED and DISABLED buttons.

Image: Screenshots showing the INPRESS TS interface for setting the pressure alarm buzzer.

Calibrate Zero Sensor

Over long runtime, the 200027 may need recalibration. This screen allows sensor recalibration if it is more than 5 Pascals out. To recalibrate, open windows and doors, turn off air conditioning, and any other device that may alter cabin pressure. Then, press the AUTO ZERO SENSOR button and leave the cabin while measuring. This process will reset the Zero Pressure.

Image: Screenshots showing the INPRESS TS interface for calibrating the zero sensor and adjusting the zero pressure.

CO2 Module Enable/Disable

Enable or disable the CO2 module used for measuring CO2 levels within the cabin.

Image: Screenshots showing the INPRESS TS interface for enabling/disabling the CO2 module.

CO2 Primary Alarm Point

The first alarm will sound when CO2 levels inside the enclosure reach this point.

Image: Screenshots showing the INPRESS TS interface for setting the CO2 primary alarm point.

CO2 Alarm Delay

After CO2 (concentration in ppm) within the cabin reaches the 1000 ppm setpoint, the alarm will sound after a designated time. The Alarm Delay adjusts the time between the INPRESS TS measuring CO2 concentration and sounding the alarm. Use the onscreen ADJUST buttons to change fields, e.g., toggle through Disabled / 1 - 10 minutes.

Image: Screenshots showing the INPRESS TS interface for setting the CO2 alarm delay.

CO2 Critical Alarm Mute Reset

The critical alarm is set at 2500 PPM and cannot be changed. The mute delay, however, can be configured.

Image: Screenshots showing the INPRESS TS interface for critical alarm mute timeout adjustment.

Data Download

Setting up RS232 Connection

1. Plug the RS232/USB adaptor into a free USB port on your computer.
2. Open up TeraTerm software. (TeraTerm is an open-source software tool, accessible via online search).
3. Use the following settings in TeraTerm: Serial and choose the correct port connection. Hint: Click on the COMxx Port with the "USB serial Port" connection from the drop-down menu. Example: COM 4. This connection may be different on your computer.
4. Click OK once the correct communication port has been identified.
5. Go to SETUP and click on Serial Port.
6. Change the COM ports to the following configuration: Baud Rate: 57600 Data: 8 bit Parity: EVEN Stop: 2 bit Flow Control: NONE
7. If required, save the COM port settings. Go to Settings and click save the setup. Hint: From the drop-down menu, click on the Save Setup. Name the file and save it.
8. The next time a download is required, restore the setup; the COM PORT settings will be loaded, ready to download the data file from the 200027 unit.
9. From the drop-down menu, click on Restore setup.
10. Choose the file name you have already saved.

Image: Screenshots illustrating the TeraTerm setup process for serial connection, including port selection, configuration, saving, and restoring setups.

INPRESS Controller Set Up

1. Press 'SITE ACCESS MENU'.
2. Enter the access pin '7597'.
3. Press 'NEXT'.
4. Press 'LOG SETTINGS'.
5. Press 'DOWNLOAD LOG FILE'.
6. Data is now downloading from the controller to the terminal open on the computer (TeraTerm in this example).

Image: Screenshots showing the INPRESS TS controller setup navigation for downloading log files.

Copying Contents from Terminal to Spreadsheet

1. From the drop-down menu, click on the Edit menu function.
2. Press "Select All".
3. Select "Copy table".
4. Open a blank Excel document and click on the page. Then, right-click to paste the copied table.
5. Fields are: Date, time, motor (volts) output (e.g. 5.5 = 55%), cabin pressure (Pa), cabin pressure pre-set (Pa), CO2 sensor.

Excel Data Instructions – Unformatted

Open an Excel sheet and select the first cell A-1. Press and hold CTRL, then press V. This pastes the copied data. On the Excel sheet, click 'DATA' on the pull-down menu, then 'Text to Columns'. Select 'Delimited', click Next. Select the 'Comma' button, then click 'Finish'. Excel fields will update, placing data in correct columns. Data is now ready for archiving.

Data Logging Formats

• BU No: xxxxxx (device number unique to each unit, format = 000000)
• Time: [09:25]
• Date: [25/07/12]
• Pressure: 32 (Pascals) as an example.

Alarm Type:

• 0 = No alarm
• 1 = Low-pressure alarm
• 2 = Window open
• 3 = Door open

Image: Screenshots showing the process of copying data from TeraTerm to Excel, including the Edit menu, Select All, Copy Table, and Excel data formatting steps.

Warranty

Express Warranty

All BreatheSafe products carry a warranty against defects in materials or workmanship, provided defects are not from factors outside BreatheSafe's control (including neglect, lack of maintenance, improper installation or operation, unauthorized servicing repair, etc.). BreatheSafe will replace defective goods at their Queensland factory or designated branch*. All parts deemed failed or faulty must be returned to BreatheSafe for evaluation unless otherwise stated in writing.

Note: Systems must be installed and commissioned as per BreatheSafe installation and commissioning instructions. Once commissioned, the online commissioning sheet must be filled in to extend component warranty. The system must be serviced and maintained correctly by trained and qualified personnel, including 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: when commissioning documents are registered online within 28 days of installation.
• Extended warranty** only offered if commissioning maximum pressure test reaches at least 250Pa.
• Brushless motor (fixed speed): two years, or 10,000 hours (whichever occurs first).
• Variable speed brushless motor: 15,000 hours, or 3 years** (whichever occurs first).

Must be supplied with a variable speed pressure controller; data download required for 3-year warranty option. Link to online Commissioning and Extended Warranty Registration form: https://www.breathe-safe.com.au/commission/

What is not covered under Express Warranty?

• Failures due to incorrect application.
• Damage resulting from neglect, misuse, lack of maintenance, improper installation or operation, inappropriate or abnormal use, accidental or unauthorized servicing repair.
• Failures due to parts not being sold or approved by BreatheSafe.
• Failures arising from any other cause not directly related to a defect in material or workmanship.

This Express Warranty is VOID if the product is altered, modified, or used in a manner it was not designed for, including unauthorized repairs, or using maintenance and repair parts other than those supplied by BreatheSafe.

BreatheSafe Responsibilities

If there is a defect in material or workmanship not caused by excluded failures during the warranty period, BreatheSafe will either replace defective goods at their Queensland factory or designated branch*. Alternatively, BreatheSafe may elect to provide new replacement parts, BreatheSafe approved repair parts, or assembled components needed to repair the defect. BreatheSafe reserves the right to provide a refund of the purchase price in lieu of replacement or repair at BreatheSafe's discretion. The replacement or repaired product will be sent freight prepaid by the customer or made available for pick-up on site.

Users Responsibilities

The customer must ensure the system is maintained according to BreatheSafe service requirements and only authorized parts are used. In case of a suspected warranty claim, contact BreatheSafe first to arrange repair or assist with diagnosis. Claims should be made within one week of the repair.

After contacting BreatheSafe, you may be required to deliver or send parts to BreatheSafe's Queensland factory or designated branch*. Link to online Warranty claim form: https://www.breathe-safe.com.au/warranty/

Exclusion and Limitations on Damages and Remedies

This warranty is provided in lieu of all other warranties, written or oral. To the extent allowed by law, all other warranties, express or implied, including implied warranties of fitness for a particular purpose, are disclaimed. BreatheSafe's maximum liability shall not exceed the original purchase price of the product. Interference with the equipment, abuse, or operating outside specified ambient temperatures or electrical power characteristics are excluded, as are consequential damages.

Excluded from any express warranty are costs incurred for service outside BreatheSafe's factory or designated service branch, including travel time, waiting time, transport costs, and mechanical/overtime payments.

As per Australian Consumer Law: You are entitled to a refund or replacement for major failures. For non-major failures, you are entitled to have the failure rectified in a reasonable time, or obtain a refund and cancel the contract for service. You are also entitled to compensation for any other reasonably foreseeable loss or damage.

*This express warranty gives you specific legal rights, and you may also have other rights that vary from country to country.