KOMVISION-GB-0

Operation Manual

HYDRAULIC
MINING KomVision
SHOVEL

Unsafe use of this machine may cause serious

injury or death. Operators and maintenance
personnel must read this manual before
operating or maintaining this machine. This
manual should be kept near the machine for
reference and must be periodically reviewed by all
personnel who will come into contact with it.

Komatsu has Operation and Maintenance Manuals

written in other languages. If a foreign language
manual is required, contact your local distributor for
availability.

KomVision
 COPYRIGHT

This material is property of Komatsu Mining Germany GmbH and is not to be reproduced, used, or
disclosed except in accordance with the written authorization of Komatsu Mining Germany GmbH.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve
the right to make changes or add improvements at any time without incurring any obligation to
install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to
this publication. It is recommended that the customer contact their distributor for information on the
latest revision.

KomVision
 1 FOREWORD

This is the original version of the KomVision Manual, com-

piled in English,

1 -1
BEFORE READING THIS MANUAL FOREWORD

1.1 BEFORE READING THIS MANUAL

1.1.1 LEGAL NOTICE

The content of this manual is protected by international intellectual property laws.

All the intellectual property relating to this product belongs to Komatsu Ltd.

No portion of this material may be reprinted, republished, modified, reproduced, sold or distributed in any form
without the express written consent of komatsu Ltd.

KomVision®is a registered trademark and the sole and special property of Komatsu Ltd.

This manual may contain third party copyright and/or trademarked material, the use of which has not always been
specifically authorized by the intellectual property owner. All copyright and/or trademarks contained in this manual
are the sole and special property of their respective owners.

1.1.2 ABOUT THE SYSTEM

KomVision is a sight support system that uses a range of functions to assist the machine operator in making safe
and correct decisions when moving the machine. It is a visual aid which assists the operator in order that the
machine is operated in a safe manner and in order to prevent operator fatigue.

An array of cameras is placed about the machine that transmit their data to be visualized on a monitor in the oper-
ator’s cabin. A bird’s eye view of the machine is displayed with a 360° vision of the surrounding area.

1 -2 General Foreword KomVision

1 FOREWORD.............................................................................................. 1-1
1.1 BEFORE READING THIS MANUAL ................................................................................................. 1-2
1.1.1 LEGAL NOTICE..................................................................................................................... 1-2
1.1.2 ABOUT THE SYSTEM........................................................................................................... 1-2

2 SAFETY ..................................................................................................... 2-5

2.1 GENERAL SAFETY ........................................................................................................................... 2-6
2.1.1 SAFETY PRECAUTIONS ...................................................................................................... 2-6

3 MAINTENANCE ......................................................................................... 3-7

3.1 MAINTAINING THE SYSTEM............................................................................................................ 3-8
3.1.1 DAILY CHECK ....................................................................................................................... 3-8
3.1.2 SPECIFICATIONS ................................................................................................................. 3-8

4 OPERATION .............................................................................................. 4-9

4.1 CAMERA OPERATION.................................................................................................................... 4-10
4.1.1 CHECKS BEFORE OPERATION ........................................................................................ 4-10
4.2 NAME AND LOCATION OF ELEMENTS ........................................................................................ 4-11
4.2.1 AREAS COVERED .............................................................................................................. 4-11
4.2.2 THE NAMES AND LOCATIONS OF THE CAMERAS......................................................... 4-12
4.2.3 COMPONENTS IN OPERATOR’S CAB .............................................................................. 4-13
4.2.4 CONTROLLER IN CAB BASE ............................................................................................. 4-14
4.2.5 CAMERA SYSTEM DISPLAY IN OPERATOR'S CAB ........................................................ 4-15
4.2.6 MEANING OF ELEMENTS SHOWN ON THE DISPLAY .................................................... 4-17
4.2.7 TOUCH SCREEN OPERATION .......................................................................................... 4-20

5 TROUBLESHOOTING ............................................................................. 5-25

5.1 TROUBLESHOOTING TABLE ........................................................................................................ 5-26

KomVision
KomVision
2 SAFETY

2 -5
General Safety Safety

2.1 GENERAL SAFETY

WARNING
SKILLED PERSONS ONLY!
There is a danger of component failure, of electric shock to the person or of fire.
Do not attempt to disassemble or modify KomVision components without proper instruction.

WARNING
RESPONSIBILITY!
The operator is responsible for safe operation.

Never attempt to operate the machine relying on KomVision alone. KomVision is intended to assist the
operator in making decisions in order to reduce the chance of accidents or damage and lessen the burden
on the operator.

When a warning is activated, pay full attention to the surrounding area, perform the appropriate action as
necessary.

This system is not designed to support operation in poor visibility or in extreme weather conditions, or to
protect against careless machine operation. There are limits to the KomVision recognition performance.
Ensure that the instructions for the individual component use are thoroughly read before using the sys-
tem and that these instructions are strictly followed

2.1.1 SAFETY PRECAUTIONS

– Check that all cameras are correctly installed on the machine.
– Ensure that the cameras are always clean. Mud and dirt should be removed.
– Replace any damaged cameras immediately.
– Ensure that the monitor in the operator’s cab is correctly displaying the view.
– Ensure the monitor is always kept clean.
– Replace the monitor immediately if it is defective.
– The system should be maintained in such a way, and as far as possible, that the removal of components is
unnecessary. If the system is defective, do not use until repairs have been carried out.

2.1.1.1 GENERAL PRECAUTIONS

– When cleaning the monitor, please use a dry soft cloth and a neutral detergent. Never use abrasive cleaners
such as thinners, alcohol etc.
– Ensure that the surrounding area of the monitor is also kept clean.
– When a camera or it’s mounting becomes dirty during operation, please clean with a soft dry cloth.
– Do not place anything loosely around the controller which may lead to short circuiting. Any additional equip-
ment must be securely fixed (installed).

NOTICE
Failure to keep the KomVision components clean may cause the system to operate incorrectly

2 -6 KomVision Safety
3 MAINTENANCE

3 -7
MAINTAINING THE SYSTEM Maintenance

3.1 MAINTAINING THE SYSTEM

– Make sure that the area of maintenance is on level and firm ground.
– This should be an area where there is no fear of collapsing ground, falling stone or submersion.
– Make sure that there is no other structure within 25 meters circumference if possible.

NOTICE
Always ensure that only authorized personnel work on the maintenance of the system.

NOTICE
Caution should be practiced in areas of high maintenance. Equipment such as working platforms and
stairs must be used when working in high areas.
Tools suitable for the task of maintenance should always be used.

3.1.1 DAILY CHECK

Be sure to carry out the following daily checks on the KomVision system:

– Check and clean all camera mounts where necessary,

– Check the correct installation of each camera.
– Clean each camera lens with a clean and dry soft cloth.
– Replace damaged cameras immediately.
– Check if the monitor in the operator’s cabin displays correctly.
– Clean the monitors when necessary.
– Replace defective monitors immediately.

3.1.2 SPECIFICATIONS

Item Contents Component use

Functionality Camera system 7 WDR Cameras

(7835-33-4000)

Birds-eye view

Camera select switch

Display layout

Performance Indication of area 30 000mm (30m)

(Distance from the center of slew turn area)

3 -8 KomVision Maintenance
4 OPERATION

4 -9
CAMERA OPERATION Operation

4.1 CAMERA OPERATION

– Start up the KomVision system.
– Check all the camera images.
– If the image is defective in any way, check the appropriate camera and clean it.
– If there is no improvement in the image, contact Komatsu and request replacement or maintenance.
The start-up time for the KomVision system is 30 seconds after the key-ON switch is activated. Only start to oper-
ate the system when this time has passed.

NOTICE
If the KomVision system does not start after 30 seconds, contact the responsible person in charge imme-
diately

If the KomVision system shows any irregularities during operation, regular checks or maintenance, con-
tact the responsible person in charge immediately

Do not use the KomVision system until all abnormalities are removed

4.1.1 CHECKS BEFORE OPERATION

WARNING
ENSURE PROPER FUNCTION!
Not carrying out daily checks of the KomVision system may result in defects that may cause a serious
accident.
Always perform daily checks of the KomVision system

– Make sure there are no obstacles in the vicinity of the machine.

– Make sure the checking area is big enough for the purpose.
– Make sure people do not approach the machine.

4 - 10 KomVision Operation
Operation NAME AND LOCATION OF ELEMENTS

4.2 NAME AND LOCATION OF ELEMENTS

4.2.1 AREAS COVERED

This graphic shows the correspondence area of the cameras of KomVision.

Fig. 4-1

KomVision Operation 4 - 11
NAME AND LOCATION OF ELEMENTS Operation

4.2.2 THE NAMES AND LOCATIONS OF THE CAMERAS

Fig. 4-2

4 - 12 KomVision Operation
Operation NAME AND LOCATION OF ELEMENTS

Legend for Fig. 4-2

The location of the cameras on this example are shown on a machine type that may differ from
your actual machine. Please be aware that this is a generic view only.

(1) Front camera

(2) Left hand rear camera

(3) Left hand front camera

(4) Rear camera

(5) Camera under the counterweight

(6) Right hand rear camera

(7) Right hand front camera

4.2.3 COMPONENTS IN OPERATOR’S CAB

Legend to Fig. 4-3

1. KomVision display

REMARKS: After being switched on, the Komatsu logo will be

shown until the system has booted. Normal camera
images will be displayed after 30 seconds,.

Fig. 4-3

KomVision Operation 4 - 13
NAME AND LOCATION OF ELEMENTS Operation

4.2.4 CONTROLLER IN CAB BASE

Legend to Fig. 4-7

1. Position of cab base on the machine. This is the area of elec-

trical equipment is mounted.

2. KomVision controller in cab base.

Fig. 4-4

4 - 14 KomVision Operation
Operation NAME AND LOCATION OF ELEMENTS

4.2.5 CAMERA SYSTEM DISPLAY IN OPERATOR'S CAB

Fig. 4-5

KomVision Operation 4 - 15
NAME AND LOCATION OF ELEMENTS Operation

4.2.5.1 MONITOR DISPLAY

Legend for Fig. 4-5

(1) Large birds’ eye view image

(2) Medium bird’s eye view image

(3) Small bird’s eye view image

If there is no manual operation of the KomVision system during the 30 seconds booting process, the default setting
for the display view is the large bird’s eye view image (1).

This image can be altered in the settings menu, where one of the other images can be selected. Further informa-
tion can be found on page 4-21.

If a camera is broken, the area on the display which indicates that camera is blue.

4 - 16 KomVision Operation
Operation NAME AND LOCATION OF ELEMENTS

4.2.6 MEANING OF ELEMENTS SHOWN ON THE DISPLAY

Fig. 4-6

KomVision Operation 4 - 17
NAME AND LOCATION OF ELEMENTS Operation

Legend to Fig. 4-6

(1) Bird’s eye view image

(2) Image of shovel in center of view

(3) Image showing single camera

(4) Reference lines

(5) Status indicator

(6) Guidance indicator

(7) Small bird’s eye view camera indicator showing selected camera (viewed in (3), single image)

(8) Menu button that pulls out menu list options.

4.2.6.1 BIRD’S EYE VIEW

(1 in legend to fig Fig. 4-6) This is the image that is captured by the 7 camera placed around the machine (see Fig.
4-5). 6 cameras are mounted on the superstructure and 1 is mounted under the counterweight.

4.2.6.2 SHOVEL IMAGE

(2 in legend to Fig. 4-6) The image that can be seen in the center of the bird’s eye view is the top view of a
machine. It is superimposed and is not the actual machine. This image may vary, depending on the actual
machine in operation.

4.2.6.3 SINGLE CAMERA IMAGE

This single image is taken from one of the seven cameras used for the complete bird’s eye view. By touching the
area in the bird’s eye view, the image from the selected camera will be shown here. Additionally, the display mode
can also be changed when touching the single camera image.

4.2.6.4 REFERENCE LINES

Definition Color

Edge of superstructure (#1) White

Counterweight swing radius (#1) red

Counterweight swing radius +2m (#2) yellow

MAX reach of work equipment (#1) black

(#1) This distance depends on shovel model

(#2) This distance can be changed depending on administrator’s judgment at mine site but the minimum distance
is 1.5m. If this should be changed, please contact Komatsu service department.

4 - 18 KomVision Operation
Operation NAME AND LOCATION OF ELEMENTS

4.2.6.5 STATUS INDICATOR (USUALLY UNDISPLAYED)

Each button on the status indicator has the following meaning.

Legend to Fig. 4-7

1. System error

2. I/O error

3. Camera error

4. Communication error.

Fig. 4-7

4.2.6.6 GUIDANCE INDICATOR (USUALLY UNDISPLAYED)

Legend to Fig. 4-8

1. Error code display mode.

– This icon is shown when there is a breakdown, When this

icon is pushed, an error code is displayed.
2. Operation manual indicator

Fig. 4-8

4.2.6.7 SMALL BIRD'S EYE VIEW INDICATOR & MENU MODE

Legend for Fig. 4-9

1. The small bird’s eye view indicator shows which camera is

indicated on a single camera view. The outer frame blinks
during normal operation. If it does not blink, reboot the sys-
tem.

2. The menu mode can be accessed using this button

Fig. 4-9

KomVision Operation 4 - 19
NAME AND LOCATION OF ELEMENTS Operation

4.2.7 TOUCH SCREEN OPERATION

Fig. 4-10

4 - 20 KomVision Operation
Operation NAME AND LOCATION OF ELEMENTS

Legend to Fig. 4-10

(1) Front camera view selection

(2) Right hand front camera view selection

(3) Right hand rear camera view selection

(4) Rear camera view selection

(5) Left hand rear camera view selection

(6) Left hand front camera view selection

(7) Under counterweight camera view selection

(8) Displayed view of selected camera

(9) Menu icon to enter menu list

– The areas 1-7 on Fig. 4-10 show the camera views which can be manually switched by touching that area on
the screen.
– Area 8 on Fig. 4-10 shows the displayed view of the camera which is selected.
– Depending on the selection of the bird’s eye view in the center (see Fig. 4-5). this view will be shown
small, medium or large. The default setting is small (bird’s eye view large). This can be adjusted and
locked by touching the arrow icons on the display view.
Fig. 4-11

The selections are as follows:-

1. Display locked (off) - Bird’s eye view and single display - sin-
gle display - undisplay.

2. Display locked (on) - Bird’s eye view and single display - sin-
gle display - (no undisplay)

Fig. 4-11

KomVision Operation 4 - 21
NAME AND LOCATION OF ELEMENTS Operation

4.2.7.1 MENU LIST

Fig. 4-12

4 - 22 KomVision Operation
Operation NAME AND LOCATION OF ELEMENTS

Legend to Fig. 4-12

(1) The menu list displayed when menu icon is touched.

(2) Body display icon.

(2A) Machine without attachment but with counterweight

(2B) Machine with attachment and counterweight

(2C) Machine without attachment and without counterweight

(3) Guide line display icon

(4) Dimmer icon to change contrast and brightness

(5) Contrast control

(6) Brightness control

– When selecting the body display icon (2), the view of the machine’s body can be displayed differently in the
bird’s eye view. The default setting is the machine without attachment (2A).
– The guide markings (see 4 in Fig. 4-6) in the display can be toggled on and off with guide line display icon (3).
– When selecting the dimmer icon (4), the contrast and brightness can be adjusted (4 & 5) to day or night mode.

4.2.7.2 ERROR CODE INDICATION MODE

Legend to Fig. 4-13

1. Indication of error code

– If more than 5 error codes are displayed, the scroll buttons

can be used to access all codes.
2. Error scroll icon

– Scroll up or down
3. Display/undisplay error code icon

Fig. 4-13

KomVision Operation 4 - 23
NAME AND LOCATION OF ELEMENTS Operation

4.2.7.3 STAND-BY MODE

See Fig. 4-14

There are two versions of the stand-by mode.he system goes into
stand-by when the start key is switched off.

KomVision shuts down automatically after 2 hours when the

stand-by mode is active.

Stand-by mode A is shown until the machine is switched off.

Stand-by mode B is shown when the operator switches

KomVision off manually using the icon (1).

Fig. 4-14

Fig. 4-15

4 - 24 KomVision Operation
5 TROUBLESHOOTING

5 - 25
TROUBLESHOOTING TABLE TROUBLESHOOTING

5.1 TROUBLESHOOTING TABLE

NOTICE
When a camera or a controller becomes defective or fails to work properly, be sure to set up correctly.

Kltd code Sub code Action Caution Name of occurrence

Fault
level symbol

Output power supply

Camera controller output power
DBP5KP - L01 low voltage fault
supply 1 (for camera 8V)
(under 6V)

Camera controller over

DBP0NR - L01 Over temperature
temperature

DBPVKR - L01 Camera controller CAN5 communication fault

DBPUKR - L01 Camera controller CAN4 communication fault

DPQ4KB - L01 Monitor display ON/OFF short-circuit

DBP0KT CA01 L01 Camera controller inner Mainboard problems

Image processing
DBP0KT CA02 L01 Camera controller inner
board problems

DBP0KT CA03 L01 Camera controller inner Device open error

DBP0KT CA04 L01 Camera controller inner Memory error

DBP0KT CA05 L01 Camera controller inner LUT generation error

5 - 26 KomVision Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING TABLE

Kltd code Sub code Action Caution Name of occurrence

Fault
level symbol

DBP0KT CA06 L01 Camera controller inner C drive file IO error

DBP0KT CA07 L01 Camera controller inner D drive file IO error

DBP0KT CA08 L01 Camera controller inner Thread problems

Application manager
DBP0KT CA09 L01 Camera controller inner
problems

File IO error for

DBP0KT CA10 L01 Camera controller inner
communications

DBP0KT CA11 L01 Camera controller inner other errors

Calibration not carried

DBP0KM SA01 L01 Camera controller setting
out

Main setting not carried

DBP0KM SA02 L01 Camera controller setting
out

Radar set-up not

DBP0KM SA03 L01 Camera controller setting
carried out

NTSC 1 input - wire

DR10KA - L01 NTSC 1 input
break

NTSC 2 input - wire

DR20KA - L01 NTSC 2 input
break

NTSC 3 input - wire

DR30KA - L01 NTSC 3 input
break

NTSC 4 input - wire

DR40KA - L01 NTSC 4 input
break

KomVision Troubleshooting 5 - 27
TROUBLESHOOTING TABLE TROUBLESHOOTING

Kltd code Sub code Action Caution Name of occurrence

Fault
level symbol

NTSC 5 input - wire

DR50KA - L01 NTSC 5 input
break

NTSC 6 input - wire

DR60KA - L01 NTSC 6 input
break

NTSC 7 input - wire

DR90KA - L01 NTSC 7 input
break

DPQ4KT - L01 Monitor display inner fault

DBPLKA - L0a - Operator lamp open circuit open circuit

DBPLKB - L0a - Operator lamp open circuit short circuit

ETHERNET1
DBPWKR - L01 COMMUNICATION communication fault
ERROR

ETHERNET2
DBPXKR - L01 COMMUNICATION communication fault
ERROR

5 - 28 KomVision Troubleshooting