RESPA -SD INSTALLATION KIT FOR KOMATSU SERIES 8 EXCAVATOR CABS

Transcription

1 RESPA -SD INSTALLATION KIT FOR KOMATSU SERIES 8 EXCAVATOR CABS For model numbers: PC130-8 PC160LC-8 PC 190LC-8 PC200LC-8 PC200LC-8 Super Long Front PC 210LC-8 PC 230LC-8 PC 240LC-8 PC270LC-8 PC270LC-8 Super Long Front PC 290LC-8 PC300LC-8 PC350LC-8 PC350LC-8 Super Long Front PC350HD-8 PC350HD-8 Super Long Front PC450LC-8 PC450LC-8 Super Long Front Installation time: 3 to 4 hours RESPA-SD Purpose: When properly installed, this unit's powered precleaner will eject most particulate before it reaches the integrated filter, increase filter life, pressurize the cabin, and maximize HVAC performance. Pressure sensor will alert operator to loss of cabin pressure and when air filter should be replaced. Filtration Options: This unit comes equipped with the recommended MERV 16 (EU P2) filter option. When reordering, you have a choice of the following filter options: FEFF005 - MERV 16 (EU P2) System Rated Filter* Recommended for human respiratory environments, especially where airborne particulate places operator at risk. FEFF004 - HEPA-level (EU P3) System Rated Filter* Recommended when very highest level of filtration is needed or where required by regulation. * SYSTEM RATING: RESPA system with specified filter produces air of rated quality with airflow 100 cfm (2.832 m3/m). Technical Support: Replacement Fresh Air Inlet Door Fresh Air Inlet Hood Roof Bracket US Phone - (904) ext support@sy-klone.com PAGE 1

2 Parts included in Kit Yellow Metal Parts Electrical Connector Clip M6 Bolts, Lockwashers and Washers (8 of each) XAD0029 Fresh Air Door adaptor M10 Bolts, Lockwashers and Washers (4 of each) XAD0028 Roof Bracket XAD0030 Fresh Air Inlet Hood RTV Silicone Sealant T-Bolt Clamp (2) XAD0031 Male-Female Threaded Spacer (3) XAD0027 Clamp Bracket (2) X inch x 50-inch Pipe Cab Pressure Monitor System Airline KT-CABPRES-EL1-ENG Electronic Pressure Monitor System Instructions IN THIS MANUAL: IN THE BOX: Features - page 1 Support - page 1 Changing the Settings - page 2 DIP Switch Settings Charts - page 3 Technical Specifications - page 3 Installing the Pressure Monitor System - page 4 FEATURES: The unit operates when the power is switched on. LED Alarm: The lighted indicator illuminates whenever the cab pressure drops below the preset minimum threshold for more that 10 seconds. This feature cannot be disabled. The 10 second delay allows for normal door opening and closing without setting off the alarm. Electronic Pressure Monitor System INSTALLATION GUIDELINES Numeric Display: This indicates the realtime pressure in the cab. Electronic Pressure Monitor Attached Wiring (6 feet, meters) Black Nylon Air Line (6 feet, meters) Small Plastic Screwdriver Low Pressure Signal Alarm: This feature is internal in all units. It can be activated or deactivated during set up. If this feature is activated, the alarm will sound when the cab pressure drops below the set pressure level for 10 seconds. It selfresets when the cab pressure returns to normal or when an off/on power cycle is completed. Silence Alarm Button: Sometimes it is necessary to open a window or door for more than 10 seconds. This will set off the alarm. The alarm signal can be silenced by pushing the silence button. (Note: the light will remain on until pressure is restored). The alarm mode is self-resetting when the cab pressure normalizes or with an off/on power cycle. The alarm is again armed and will sound after a 10 second pressure drop. Pressure Monitor Power Line Quick Connect Fitting: The included air line Electrical Wiring: attaches here. Connects to any convenient DC voltage connection between Low Voltage Pressure Signal Port: The unit includes a 0 to 5 volt 9VDC and 36 VDC, so this unit output signal that can stream realtime pressure information to an on-board can be installed on a 12V or 24V computer. The 1/8 mono plug signal port puts out a low power voltage signal system. that varies with the pressure reading (see technical specifications for details). TROUBLESHOOTING / FREQUENTLY ASKED QUESTIONS Please visit for additional support information on the Sy-Klone Electronic Pressure Monitor System, part number KT-CABPRES-EL1-ENG. TECHNICAL SUPPORT For assistance, contact the dealer from whom you purchased the Pressure Monitor System. SYKLITKTCABPRESEL1ENG A PAGE 1 Sy-Klone Cab Pressure Monitor System Installation Guidelines PAGE 2

3 Parts included in Kit, continued RESPA-SD and Plumbing Connectors XAD0033 Extended Striker XAD0032 Latch Cover Gasket M10 Bolts, Lockwashers and Washers (4 of each) XRE0004-ADF RESPA-SD Mounting Plate RE F-03-SYK-005 RESPA-SD S300x300 Rubber Sleeve M8 Bolts (5) X inch x 3-inch Pipe 91475W Worm Gear Clamp (6) Electrical Wiring Parts GK008 Wiring Kit Wiring Harness with Conduit XE0003 Insulation clips (3) and XD51 #12 x 1-inch self drilling screws (3) Spade Fuse Holder 5/16 Ring Terminals (2) Crimp-On Butt Splice 7.5 amp Fuse Heat Shrink Grommet Large Zip Ties Small Zip Ties PAGE 3

4 Install Cab Pressure Monitor System IN THIS MANUAL: IN THE BOX: Electronic Pressure Monitor System INSTALLATION GUIDELINES Features - page 1 Support - page 1 Changing the Settings - page 2 DIP Switch Settings Charts - page 3 Technical Specifications - page 3 Installing the Pressure Monitor System - page 4 FEATURES: The unit operates when the power is switched on. LED Alarm: The lighted indicator illuminates whenever the cab pressure drops below the preset minimum threshold for more that 10 seconds. This feature cannot be disabled. The 10 second delay allows for normal door opening and closing without setting off the alarm. Electronic Pressure Monitor Attached Wiring (6 feet, meters) Black Nylon Air Line (6 feet, meters) Small Plastic Screwdriver Low Pressure Signal Alarm: This feature is internal in all units. It can be activated or deactivated during set up. If this feature is activated, Numeric Display: the alarm will sound when the cab pressure drops This indicates the realtime below the set pressure level for 10 seconds. It selfresets when the cab pressure returns to normal or pressure in the cab. when an off/on power cycle is completed. Silence Alarm Button: Sometimes it is necessary to open a window or door for more than 10 seconds. This will set off the alarm. The alarm signal can be silenced by pushing the silence button. (Note: the light will remain on until pressure is restored). The alarm mode is self-resetting when the cab pressure normalizes or with an off/on power cycle. The alarm is again armed and will sound after a 10 second pressure drop. Low Voltage Pressure Signal Port: The unit includes a 0 to 5 volt output signal that can stream realtime pressure information to an on-board computer. The 1/8 mono plug signal port puts out a low power voltage signal that varies with the pressure reading (see technical specifications for details). Electrical Wiring: Connects to any convenient DC voltage connection between 9VDC and 36 VDC, so this unit can be installed on a 12V or 24V system. Quick Connect Fitting: The included air line attaches here. TROUBLESHOOTING / FREQUENTLY ASKED QUESTIONS Please visit for additional support information on the Sy-Klone Electronic Pressure Monitor System, part number KT-CABPRES-EL1-ENG. TECHNICAL SUPPORT For assistance, contact the dealer from whom you purchased the Pressure Monitor System. SYKLITKTCABPRESEL1ENG A PAGE 1 Sy-Klone Cab Pressure Monitor System Installation Guidelines Follow the directions supplied with the Sy-Klone cab pressure monitor system. Mounting the Pressure Monitor: The cab pressure monitor should be mounted in a location visible to the operator. Routing the External Air Tube: The supplied airline is to be connected to the pressure monitor and lead to outside air without causing a break in the cab s seal. The external air tube can be routed through grommets in the cab. The air tube should extend at least 2 inches (50 mm) outside of the cab. Choose a location where the air tube will not get clogged by dirt. 1. Remove the exterior access panel under the cab, below the operator's seat, to gain external access to the cab floor. NOTE: Existing grommets in the cab can also provide a route for the airline. As shown looking up from underside of cab, a large grommet supplied adequate room to pass the airline. Airline Existing Grommet PAGE 4

5 Verify Pressure Sensor System Installation: 1. Enter the cab. 2. Close all doors and windows. 3. Turn the key to the ON position. 4. Set the fan speed to the OFF position. The cab Pressure Monitor alarm light should be ON. NOTE: If display light is OFF, check that the Monitor has power. 5. Start the machine. 6. The recirculation feature must be turned off. Increase the fan speed through each setting allowing the fan to run in each setting for approximately 30 seconds. FRESH AIR INLET ASSEMBLY Replace Fresh Air Filter Door with Door Adapter: Note at which fan speed setting the indicator display light turns off. 7. Turn machine off. ATTENTION: This initial test of the cab pressure monitor can assess the ability of the cab to hold pressure. If the alarm light goes off at fan speed of 2 or 3, proceed to next section. If the light does not go off at these speeds, perform Cab Sealing procedures on page 10 prior to RESPA-SD installation as cab is not holding enough pressure. 1. Open the fresh air filter door on the outside of the cab and remove the four bolts that secure the door to the hinges. Discard the door but SAVE the four bolts Remove the fresh air filter. (You will be using RESPA filter instead.) 3. Enter the cab and turn the key to the ON position. 4. Set the air conditioning system to the recirculation position, then turn the machine OFF. Exit the cab. 5. The recirculation door will be visible behind the 5. fresh-air filter mounting cavity. A 3" diameter hole, or hole of equivalent area, must be drilled in the recirculation door. 6. Install the fresh air door adapter to the hinges with the bolts saved from step 1. For now, only finger tighten the hinge bolts. 7. Close the door adapter to check the alignment. 8. Adjust the door adapter as necessary and tighten hinge bolts. 9. Close the door adapter. 10. Use the three through-holes on the right side of the door to mark the location for three holes on the cab sheet metal. 11. Drill 5/16-inch holes through the outer sheet metal only and install the clip-on nuts in the holes. 12. Apply a bead of silicone approximately 1/4-inch thick to the fresh air filter mating surface and corresponding mating flange of the door adapter. 13. Close the fresh air door adapter and secure with three M6 bolts and lock washers PAGE 5

6 FRESH AIR INLET ASSEMBLY, CONTINUED Install Fresh Air Inlet Hood: 1. Apply a 1/4-inch wide bead of silicone to the mating surface of the fresh air inlet hood. 2. Secure to the fresh air adapter door with five M6 bolts and lock washers. Restrict Cab Door Swing and Replace Door Striker Hardware: 2. The door swing needs to be restricted so it won't contact the fresh air inlet hood. The door striker will be replaced with an extended door striker. 1. Remove the two exterior door bump stops from the cab (one at top and one at bottom). 2. Install the supplied M10 malefemale threaded spacers and washers. 3. Reinstall factory bump stops, finger tightening only on the factory jam nut. 4. Remove the factory exterior striker hardware cover on the inside of the door to access the two M10 nuts securing the striker. 5. Remove the two M10 nuts and save. 6. From outside, remove the striker and cover plate. 7. Remove the threaded spacers from the striker and install them on the new (supplied) extended striker. 8. Reinstall the striker cover plate. 9. From inside, reinsert striker through door and 7 & 8 secure with two M10 nuts saved from step Reinstall the hardware cover (from step 4). 11. With cab door latched open, adjust (extend) the bump stops to securely rest against the door. 12. Tighten the factory jam nuts. 11 & 12 PAGE 6

7 SEALING THE CAB Cab penetrations must be sealed or reduced in size to allow the cab to hold pressure, which will enable the RESPA to work as designed. Reduce Size of Cab Drain Holes: Along the bottom of the door, underneath the door seal, are three drain holes. Insert a grommet into each drain hole to reduce its size. Before After Seal Door Latch - Striker Receiver Slot: You are going to make a door latch gasket to reduce air leakage around the striker receiver slot. Steps 1-6 are to determine where to cut an H pattern in the latch cover gasket. 1. Close the cab door and place a length of tape on the sheet metal along the length above the raised portion. 2. Open the cab door and mark the tape along the outer edges of the striker where it enters the cab opening (see figure 1). NOTE: Opening the door window will provide greater access to the striker area. 3. Align edges of provided latch cover gasket with raised sheet metal edges and tape in place. 4. Open the door until it makes contact with the latch cover gasket. Mark center line of striker on gasket as shown. 4. Door Gasket Mark striker centerline on gasket for horizontal cut. 5. Cut a horizontal line along the centerline from the previous step. The horizontal cut should be the width that you marked in step 2 with an additional quarter inch at each end. Then make a vertical cut 1/2 inch long at each end of the horizontal cut, vertically centered on the horizontal cut. 3-6 Figure 1 Make a ½ inch vertical cut at each end of the centerline cut. Cab Top View Cut gasket width of striker plus ¼ at either end. Door in open position Cut gasket along striker centerline: width of striker plus ¼ inch at either end. Striker width Mark tape at outer edge of striker. ¼ ¼ Striker 6. Open the door and check the fit of the striker as it slides through the latch cover gasket. Adjust cut as necessary. 7. Close the door and remove all tape from the latch cover gasket and cab sheet metal. 8. Clean the latch cover gasket and the cab sheet metal around the latch opening. 9. Adhere the latch cover gasket by applying a bead of Loctite 380 to the cab mating surface of the latch cover gasket. 10. Carefully align latch cover gasket and hold in place with tape or magnets (see figure 2) until Loctite cures, approximately 15 minutes. Figure 2 PAGE 7

8 MOUNTING THE RESPA-SD Roof Mounting the RESPA-SD: Attach the black metal mounting plate to the bottom of the RESPA-SD with five M8 bolts. 2. Bolt the RESPA assembly to the yellow metal roof bracket using four M10 bolts, lock washers, and washers. 3. Bolt electrical connector clip to roof bracket with one M10 bolt, lock washer, and washer. 4. Slide grooves on the RESPA's electrical connector into the clip until it locks. 5. Remove the four plugs from the cab roof that correspond with the mounting locations of the roof bracket. 6. Place roof bracket on cab roof and attach using four M12 bolts, lock washers and washers. NOTE: The angle of the roof-mounted antennae may need to be adjusted to clear the RESPA installation. PLUMBING THE RESPA-SD Install Air Inlet Tube 1. Install clamp bracket on air inlet hood with a M10 bolt, lock washer, and washer. Leave loose. 2. Slide the rubber sleeve over air inlet hood tube until it clears the clamp bracket. 3. Place one worm gear clamp over the rubber sleeve and tighten just above the base of 1,2,3 the sleeve. NOTE: Due to the clearance of the door, it may be necessary to rotate the worm gear assembly to the front, back, or side of the rubber sleeve. 4. Slide a second worm gear clamp over the sleeve and leave it loose. 5. Remove and save nut from T-bolt clamp and slide clamp over rubber sleeve and leave loose. 6. Install M10 male-female threaded spacer onto the yellow metal roof bracket using one M10 bolt, lock washer, and washer. PAGE ,4 7. Install clamp bracket using one M10 nut, lock washer, and washer, leave loose. 8. Install long yellow air inlet tube into previously installed rubber sleeve. NOTE: Leave a gap of 1/4 to 1/2 inch between the air inlet tube and the inlet hood. 7,8 9. Slide up the second worm gear clamp, positioning it just below the top of the black rubber sleeve and tighten clamp. 10. Attach foam rubber strip around air inlet tube, in line with clamp bracket. (2 places) 11. Place T-bolt clamp around air inlet tube and upper clamp bracket; leave loose. 11.

9 PLUMBING THE RESPA-SD, CONTINUED Plumb from RESPA-SD to Air Inlet Tube ,9 8,9 NOTE: Leave all clamps and brackets loose until you are specifically instructed to tighten them. 1. Place a worm-gear clamp over rubber elbow. 2. Install rubber elbow on RESPA-SD outlet tube. 3. Insert 3-inch union piece approximately halfway into rubber elbow. 4. Place two worm gear clamps onto rubber elbow. 5. Place a worm-gear clamp over air inlet tube. 6. Place second rubber elbow over exposed half of 3-inch union. 7. Place other end of rubber elbow over upper end of air inlet tube. 8. Tighten the T-bolt clamps around the clamp brackets at the top and bottom of the air inlet tube. 9. Align the air inlet tube as desired and tighten the clamp brackets at top and bottom of air inlet tube. 10. Position the worm-gear clamps so there is one at each end of both rubber elbows and tighten. 10. PAGE 9

10 WIRING THE RESPA-SD 2,3 Routing the Conduit 1. Remove the rear interior speaker panel. NOTE: The wiring for the RESPA-SD will be routed behind the pillar panel. A visible screw in the lower portion of the panel will need to be removed. Connector Clip 2. Connect the 20-foot (6 meter) wiring harness to the connector on the RESPA-SD. 3. Use two insulation clips and two #12 x 1-inch self drilling screws to route and secure the wire harness along the back side of the roof bracket. NOTE: Starter holes are provided for the insulation clips. 4. Ensure that the slit in the conduit is pointing down, otherwise water may pool in conduit and enter cab. 5. Route the wiring into the cab through the round rubber plug by cutting or drilling a small hole. NOTE: Once wiring is through, make the hole water-tight by sealing with silicone supplied in kit. 6. Route the wire harness behind the pillar panel down to the fuse panel area Connecting to Fuse Box 1. Without removing or disconnecting the Pressure Monitor, open the rear A/C vent panel (behind operator's seat) to make connection in fuse box. 2. Connect the red wire to an ignition (+) positive and the (-) black wire to system ground. NOTE: The wire can be shortened as necessary by the installer. 3. Check that the system powers on and off properly. Turn the key to the ON position and the RESPA-SD should turn on. Turn key off and RESPA-SD should turn off. 4. Reinstall all interior panels. IMPORTANT: The RESPA-SD must receive constant nonvariable power when the ignition key is in the ON position and power must be terminated when the key is in the OFF position. The RESPA-SD must be fused minimally to 7.5 amps for 24 VDC. PAGE 10

11 SYSTEM CHECK Is the RESPA system functioning properly? 1. Enter cab and turn key to ON position. 2. Close all windows and door. While RESPA-SD is running, check the installation and the cab for leaks and seal where necessary. 3. Airflow from both ejection ports on RESPA-SD should be strong. 4. Re-enter cab, close all windows and door. 5. Start the machine. 6. With the key still in the ON position and HVAC fan in the OFF position, the cab pressure monitor alarm light should be off. 7. Check the cab pressure. The cab pressure monitor readings should fall within 10% of these readings: Fan Speed Units Off Before Installation (or with RESPA-SD unplugged*) WC pascal With RESPA-SD WC pascal * Unplug power to RESPA-SD at the Deutsch connector coming out of the unit. 8. If the alarm light is still on, check that the air tube isn't pinched or kinked, and check for additional leaks in the cab. 9. Turn machine off. Is the cab holding pressure? Correct and permanent sealing of the cab in preparation for installation of a RESPA SD or RESPA SDX System is critical to the success of the systems. The air conditioning system must be cleaned and the warm air side of the mixing plenum MUST be sealed. A common cab seal issue is the AC box itself. Start with the obvious: Check all glass of cracks and breaks. Replace if necessary. Check all window seals. Replace if necessary. Check all window latches. Repair or replace if necessary. Check door seals. Repair or replace if necessary. Check the door for proper fit to door jam. Repair if necessary. Check door latch. Repair or replace if necessary. Check the dash (instrument panel) for holes cracks or other air leak. Repair and or seal all leaks. If necessary continue with the less obvious: Using a smoke pen wave pen slowly over all seams and suspect areas. The smoke pen allow you to identify specific leak areas without smoking up the whole cab. Check weeps holes in cab doors. Fill with grommet but do not completely seal or the door will fill with water. (See photo on page 6.) Window seals may appear sealed but may not be. It may be necessary to seal the windows with clear silicone. Lift cab flooring and search floor for leaks such as holes, cracked welds or other potential leaks. From the outside of the cab look for break downs in seal around wiring harness, antenna s etc. The not so obvious: Where the wiring harness enters the cab may need to be sealed. Where hydraulic control lines enter the cab may need to be sealed. Where AC line enters and exits the cab may need to be sealed. In some instances the exterior cab shielding may need to be removed for visual inspection to fine a leak. Recommendations: When in the cab with the air conditioner on high use blue painters tape and start covering the leaks until the pressure in the cab is between 0.4 to 0.5 inches of water (96 to 125 pascal). PAGE 11