Vehicle Health Monitoring System
PC 4000
Vehicle Health
Monitoring System
PC4000_6 VHMS.PPT/ 06.09 / 8112
Main Data | Hydraulic Mining Shovel Technology
VHMS (Vehicle Health Monitoring System)
Diesel Drive – Switch Panel and Monitor Panel
1 Emergency Shut-Down
2 Audible Alarm
3 Ignition Key Switch
4 Engine Control
(if VHMS Monitor inactive)
14 5 Engine Start / Stop
6 Lighting
2 7 Slew Brake Parking
1 3
8 Mirror Heating
4 9 Wiggins Swing Down Service Arm
5 15 10 Cab Ventilation
11 Lubrication
6 16
12 Wiper / Washer
7 8
(Front Window)
9 10
13 Truck Counter
11 13
14 VHMS Monitor
12 (Vehicle Health Monitor System)
15 Function Keys
16 Input Key Pad
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Introductio
n
VHMS – Vehicle Health Monitoring System –
provides a machine status monitor in the operators
cab, which is backed up by an PLC. This receives,
records, stores, and analyses a stream of data
from numerous sensors throughout the machine.
Constantly machine function control
Self-diagnosis of various machine functions
Reduce repair and maintenance hours
Eliminate unexpected shovel downtime
Simplified machine power test PM clinic
Event data stored with download facility
(RS 232/ORBCOMM)
Higher performance and lower operating costs
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Data flow and control of VHMS in Komatsu Mining Shovels
Modular Mining * Diagnostic Tool programs
System Controller • ComProSt (protocols and statistics)
Optional • ComEdit (setup of text display)
• ComDig (update of PLC software)
CAN-Bus #1
CAN-Bus #2
KMG Shovel
Sensoric
CENSE Celect
VHMS VHMS PLC
Engine Engine
Graphic Master KMG Shovel
Monitoring Control
Display Controller Controller
System System
ORBComm Electrical
Controller RS 232 PC plug in Components
Optional Diagnostic Tools * KMG Shovel
WebCARE
Optional
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Graphic flow chart of vehicle health monitoring system
First message after ignition key is switched on
1
4
3 1 Monitor
2 Function Key
3 Data and PIN input / Key Pad
4 Opening Message
5 Confirmation of Opening Message
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Graphic flow chart
Operator Menu Service Menu
Page No. Contents Page No. Contents
1 Opening Menu 01 Real Time Monitor
2 Engine oil pressure Enter by 02 PM Clinic
Engine oil coolant Service ID 03 Serial / GCC No. Setting
Hydraulic oil temperature 04 Memory Clear
Fuel level 05 Failure History
3 Battery board power 06 Maintenance Monitor
Voltage 07 Snapshot
Gear oil temperature 08 Settings
Engine oil temperature Remarks: Details see subsidiary pages
4 Central lube system (CLS)
Slew ring gear lube system (SLS)
Engine oil level
Hydraulic oil level
Function Keys
F1 Scroll page 2 / 3 / 4
F2 Fuel consumption measuring
F3 Failure Messages if [ ! ] is yellow
Change on main screens
F4
time > service meter > date
Maintenance Monitor
F5 colour of icon change
if service will be necessary
F6 User (Operator) Settings
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Operator graphic flow chart of vehicle health monitoring system
Truck Counter
Scroll page 1 / 2 / 3 / 4
Central Lubrication System [CLS]
Engine 1/2 oil pressure Battery board power supply
Slew ring gear lubrication system [SLS]
Engine 1/2 coolant temperature Voltage
PTO 1/2 Gear oil temperature Engine 1/2 oil level
Hydraulic oil temperature
Fuel level Engine 1/2 oil temperature Hydraulic oil level
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Operator graphic flow chart of vehicle health monitoring system
F3 = Failure Message
F2 = Fuel Consumption colour of the icon ! changes
measuring possibility to yellow as soon as a
message is indicated
F3 = Scroll down button, shifts single
messages
F4 = Scroll up button, shifts single messages
F5 = Standard monitor display button,
switches back to the Main Gauge
Screen 1.
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Operator graphic flow chart of vehicle health monitoring system
F5 = Maintenance Monitor
F4 = Change on main screen Colour of the icon above
Time changes to yellow if service
Service Meter will be necessary.
Date If time passed without service
and reset icon changes to red
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Operator graphic flow chart of vehicle health monitoring system
F6 = User (Operator) Settings
down up ok
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Graphic flow chart – Service Menu
Real Time Monitor Engine Memory Clear Input memory clear ID Abnormality record data
PTO Trend data
Hydraulic Snap shot data
Electric equipment Engine log
Emergency stops Load map data
Manual SW PM Clinic engine
Central lube system (CLS)
Failure History
Slew ring gear lube system (SLS)
Others Maintenance Monitor
Output signal
Snapshot
PM Clinic General Engine model Settings Central lube system (CLS)
S/N engine Slew ring gear lube system (SLS)
Hydraulic oil viscosity Language
Ambient temperature Operating hour
X2 pressure Date
Pre-load valve pressure Time
Power check Engine rpm Daylight saving time
X1 pressure GMT reference (+/-)
Pressure pump 1/ 2 / 3 / 4 Hydraulic oil viscosity
Average pressure Gear oil viscosity
Massage on/off
Serial / GCC No. Setting Machine model / serial no. Shut-off (gate) valve
Engine model / serial no. Monitoring engine speed
GCC (orbcom base station) Hydraulic oil temperature bucket cut off
Lube system bucket cut off
Reserve
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Service Menu will be entered from operator menu with an identification code
01 Real Time Monitor Real Time Menu Select
01 Engine 1
02 PTO 1
03 Hydraulic
04 Electrical Equipment
05 Emergency Stops
06 Manual SW
07 Central Lube System 1
08 Slew Ring Gear Lube System
09 Others
10 Output Signals
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Service Menu will be entered from operator menu with an identification code
02 PM Clinic General Engine Model
S/N Engine
Operating Hours
Oil Viscosity Hydraulic
Hydraulic Oil Temperature
Ambient Temperature
X2 Pressure
Pre-Load Valve Pressure
Power Check
Engine rpm
X1 Pressure
Pressure Pump 1
Pressure Pump 2
Pressure Pump 3
Pressure Pump 4
Average Pressure
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Graphic flow chart of vehicle health monitoring system
03 Serial / GCC No. Setting Machine Model ….. Serial No.
Engine Model ….. Serial No.
GCC
04 Memory Clear Input Memory Clear ID/Code
Memory Clear 01 Abnormality Record Data
02 Trend Data
03 Snapshot Data
04 Engine Log
05 Load Map Data
06 PM Clinic Engine
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Graphic flow chart of vehicle health monitoring system
05 Failure History
06 Maintenance
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Graphic flow chart of vehicle health monitoring system
07 Snapshot
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Graphic flow chart of vehicle health monitoring system
08 Setting Central Lubrication Systen
Slew Ring Gear Lubrication System
Language
Operating Hours
Date
Time
Daylight Saving Time
GMT Ref
Oil Viscosity Hydraulic
Oil Viscosity Gear
Messages ON/OFF
PLC-Evaluation ON/OFF
Shut-off (gate) Valve
Monitoring Engine Speed
Hydraulic Oil Level
Monitoring High Pressure Filter 1-4
Hydr. Oil Temperature (Bucket cut-off)
Lube System (Bucket cut-off)
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Communication with WebCARE
PC 4000 with VHMS / ORBCOMM / Web CARE
PC 4000 VHMS and WebCARE
PC 4000 VHMS and WebCARE
Steps Remarks Steps with automatic data transfer via Remarks
with manual data transfer
ORBCOMM
1 VHMS automatic 1 VHMS automatic
2 Data download to service laptop manual by service engineer 2 ORBCOMM controler in cab base automatic
3 E-Mail to Japan Webcare centre manual by service engineer 3 ORBCOMM antenne automatic
automatic data transfer
manual update by
4 Data input to WebCARE 4 Satelite if satelite is available
Webcare centre
(about every 10 min.)
available machine automatic data transfer
5 Data reading by internet data not online 5 ORBCOMM base station if satelite is available
only last update (about every 10 min.)
6 Data per internet to Japan WebCARE centre automatic
7 Automatic input to WebCARE automatic
available machine
8 Data reading per internet data online with
update about every 10 min.
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Data transfer to WebCARE console (manual via Internet)
WebCARE
Komatsu upload
software optional
Via Internet
(FTP-Server
upload)
VHMS Controller
(in cab base)
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
ORBCOMM data transfer to WebCARE console (automatically via Satellite)
Antenna ORBCOMM Gateway ORBCOMM
(on cab roof) Earth Satellite Arrangement
Station
VHMS Controller ORBCOMM Controller WebCARE
(in cab base) (in cab base)
PC4000_6 VHMS.PPT/ 06.09 / 8112
ORBCOMM satellite global coverage
Gateway earth station coverage
PC4000_6 VHMS.PPT/ 06.09 / 8112
PC4000_6 VHMS.PPT/ 06.09 / 8112
PC4000_6 VHMS.PPT/ 06.09 / 8112
PC4000_6 VHMS.PPT/ 06.09 / 8112
PC4000_6 VHMS.PPT/ 06.09 / 8112
VHMS (Vehicle Health Monitoring System)
Summarise
Clear overview of all shovel functions with Selection code for different operators
information of machine conditions
Selection of machine data setting via service
All important data are monitored and code
electronically stored
Easy machine power performance check (PM
Fault messages are monitored, stored and clinic)
alarmed by acoustic and/or visual alarms
Reduction of service time by easy machine
Display with choice of languages condition analysis
Static memory and trend analyses Service information
Download of memory data Real running data monitor
Selected data transfer into mine service WebCARE optional
system (e.g. MMS)
Improvement of machine information, availability and productivity
PC4000_6 VHMS.PPT/ 06.09 / 8112
