K omatsu omatsu Under Carriage arriage Inspection Inspection Service (KUC) Reporting Program Operation Manual
Version 2.00 April , 2002
SELA195001
Forward This Undercarriage Inspection Reporting Program is developed to create the KUC report with automate wear percent calculation and graphical function. You are advised to utilize this program to boost undercarriage parts sales in your territory.
FEATURE OF THE PROGRAM 1. Inspection report creation
2. Standard value & criteria
3. Automatic calculation of the % wear life
4. Automate graph creation
5. Summary reports
6. Inspection data storage
KUC report form is being installed into the program already, and input the wear measuring result the % wear life is calculated automatically.
The standard value and also wear criteria database of the undercarriage components of all the crawler type machines are being incorporated and even the addition, elimination are possible. It is also possible even the searching easily. Just input the measurement value in the form, the % wear life is is able to be calculated automatically. Also, the numerical value cell changes color to 3 stages which are lemon yellow(normal), dark yellow(caution) and pink(critical)
The input data can be saved and accumulated so the graph display of the wear trend able to do easily. easily. It is able to print the graph as well.
Summary report (the maximum % wear life display of the individual undercarriage parts for each machine) for the fleet machine customer can be created. Even the whole summary report in terms of the machine type is able to make it also. The all input data can be saved every time.
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Page
Contents Forward The feature of KUC inspection reporting program
……. 1
1. Installation of the program 1) System Specification requirements
……. 3
2) Installing the KUC program
……. 3 ……. 3
2. Operation of the program 1) Start and close the program
……. 4
2) Registration of Customer Machine data base
……. 5
3) Create new Report
……. 6
4) Edit section
……. 10
5) View section
……. 11
(1) Library
……. 11
(2) Standard Value
……. 12 ……. 13
6) Report section (1) Create wear trend graph
……. 13
(2) KUC Report for Customer
……. 15
(3) KUC Wear Summary Report
……. 16
7) Edit and add standard value ( KUC : Undercarriage wear criteria )
……. 17
section 8) Edit and delete data in library section.
……. 19
(1) Edit data in library
……. 19
(2) Delete data in library
……. 20 ……. 21
3. Special feature 1) 2nd life calculation after bushing turn
……. 21
2) Wear life %
……. 23
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1. Installation of the program 1) System Specification requirements; To use Komatsu Undercarriage Inspection service program , you need; (1). PC with Pentium 133 MHz or higher processor (2). Microsoft Windows® 95 , 98 or later operating system, Microsoft Windows NT® Workstation operating system version 4.0 service pack 3 or later (3). Microsoft Excel® 97 or later Microsoft Excel® (4). 32 MB of ram or more (5). 100MB of available hard-disk space (6). VGA or higher-resolution monitor, Super VGA recommended
2) Installing the KUC program (1). There are two holders ``kuc1`` and ``kucsnc1`` titled ``KUC Inspection Reporting Program` form No. SELA195001, which are for usual measurement and ultra sonic measurement. (2). Copy two holders ``kuc1`` and ``kucsnc1`` to C-Drive. Program is activated under C-Drive only. Each holder ``kuc1`` and ``kucsnc1`` are consist of ``KUC.xls`` and a holder ``data``. The holder ``data`` is consist of four files as shown in the below. Switch the all copied file condition from ``Read only`` to ``Archive`` to activate the program. (KUC program consist of 5 files which are, *KUC.xls”
:Menu worksheet
*KUCMST.xls” :Master data file *KUCREG.xls” :Inspection data registration worksheet *KUCRPT.xls” :Create customer report worksheet *KUCPRNT.xls” :Create graph worksheet.)
Fig. 1
(3). Click ``KUC.xls`` for start KUC Undercarriage Inspection Service Reporting Program
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2. Operation of the Program 1) Start and close the program (1) Start the program Click holder “kuc” installed in C-Drive, and double click the file “KUC.xls” so EXCEL primary screen is displayed.
Fig. 2
Click the button “Enable Macros” in the small window in the center of screen and enable the program macros. All 5 files in the program are linked otherwise the program is not activate properly.
Fig. 3
EXCEL menu screen of the program is appeared.
(2) Close the program When you close the program, click menu bar “Exit_ KUC(X)” and “Exit(X)”.
Fig. 4
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2) Registration (Input) of the customer machine database. This is for easy customer and machine data input to new data entry sheet after undercarriage inspection is completed . This customer and machine registration must be done before start new inspection data entry. (1). Click the File(F) in the menu bar and select the 2. Add Machine_New_Data then click it. (Fig. 5) (2). Type in the all new customer & machine information data to new row with KUC standards value. (Fig. 6) In the case of registration of new machine for registered customer, customer name can be copied from the list.
Fig. 5
Fig. 7
Fig. 6
Double click this area
Fig. 8
(3). How to select the KUC standard value. 1). Double click on any cell from J to M at new row for registration. (Fig. 7) 2). Select the standard value which you need followed by message with selection the grouser type and load condition. (Fig. 8) (4). After input the all data to new row, click the Save button which is located on top of screen. (5). If you finished to input new data, click the View(V) on the menu bar and click the 4. Go to menu or sheet MENU on the bottom to return main menu screen. Before exit this screen, please save all data using SAVE button for saving the new information to your hard disk. Otherwise searching of newly input customer and machine will not be possible for new report creation.
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3) Create New Report When it create new inspection report with undercarriage wear measurement data for customer, go back to the main menu screen. 1) Click menu bar ``File(F)`` and and click ``1.Create_New_Report(N)`` on it. (Fig. 9) 2) Click menu bar `` Report(R)`` and click ``0_Import_Customer_Model(0) `` and click customer name. (Fig.10) 3) Select the machine you want, which was registered in advance. (Fig. 11)
Customer selection Fig. 9
Fig. 10
Machine selection
Fig. 11
4) All registered general information will be automatically loaded in the inspection report. (Fig. 12) 5) Enter the all items which you need for undercarriage inspection. Then click ``Print`` button indicated top
of the screen for inspection sheet. 6) After inspected undercarriage wear, enter the all
measurement data. When installed new parts or rebuild parts, enter the each Service Meter Reading which is parts installed. Specially, SMR at bushing turned is very important for calculate wear percents after turned bushing when it’s measured mechanically. Fig. 12
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Bushing diameter. When bushing and pin are turned, the start number of criteria will be able to changed to actual inspection data of turned. However, you should input turned Service Meter Reading when pin and bushing turned. In this case, measurement data at bushing and pin turn need to be registered in a same manner before. SMR at bushing turn need to be correctly input in the cell of “Turned” at each registration of the report after turn bushing and pin.
Fig. 13
Note :
Fig. 14
Bushing turned
(1). You must input following items for save data and calculate wear %. a. Serial Number
b. SMR(Service Meter Reading of machine)
(2). Inspection Date(YYYY/MM/DD) : 2000/12/25 (3). SMR of parts installed : When installed or changed parts ( New or Rebuild one ) input Service Meter Reading. If input New and Rebuild SMR, you can make wear % graph start from 0%. (4). Comments/Observation Space ; Input your recommendation. (5).Wear %
When input measured data, Wear % cell and character will be changed following color.
Character : Black
0% to 79.99%
Cell : Light Yellow(No changed)
79.99%
Character : Pink
80.00% to 99.99%
Cell : Yellow
99.99%
Character : Red
Over 100%
101%
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Cell : Pink
7) Click ``Report(R)`` and ``3. Save_A_New_Record(3)`` on the top of menu bar for saving new data.
When you want save data to other diskette or directory, click ``Report(R)`` and ``Save As(A)`` on the top of menu bar after saving in the program mentioned in the above.
Fig. 15
Fig. 16
8) Click ``Print`` button which is indicated on the top of this screen for report printing. Check printing image, and click ``Print`` for printing the reports.
Fig. 17
Fig. 18
9) When finished all job of this section, click ``Close_Entry_Sheet(X)`` and `` Close(X)`` for close this section.
Fig. 19
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Confirming of the last inspection data. W hen the last inspection report need to be referred to create new report, click menu bar ``Report(R)`` and ``2_Read_Previous_Record (2)`` so the last input data are loaded in the sheet after select Customer and machine as described in section 1) to 4).
Click ``Read Previous Record(1)``
Click ``OK`` if model is all right.
Fig. 20
Fig. 21
Click `` 1_Clear measured value only(1) `` of menu bar `` Clear Data on sheet(C) `` if measured value are not required.
All data are automatically loaded.
Fig. 22
Fig. 23
Click `` Clear All Data(2) ``of menu bar ``Clear Data On Sheet(C)`` if all data are not required.
Fig. 24
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4) Edit section This section can edit inspection data which was input formerly. 1) Click ``Edit`` and ``Edit Library`` on the top of menu bar.(Fig. 25) 2) Select the machine size then click button on the machine size illustration. (Fig. 26)
Fig. 25
Fig. 26
3) Double click on the row of machine and serial number which you want edit. (Fig. 27) 4) Double click on the row of each inspection data. (Fig. 28)
Fig. 27
Fig. 28
5) Edit data. 6) Click ``Double Click here to Edit`` button on the top of this view and ``OK`` or ``Cancel`` for change (save ) data. Do not forget this job before close library. (Fig. 29) 7) Click ``Close_Library(x)`` on the menu bar for finish edit job.
Fig. 29
Fig. 30
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5) View section This section can see Library ( inspection data ) and Standard Value ( KUC criteria ). This section is only can see view. It can not edit or add the data.
(1) Library For indicate Library.
(1). Click ``View(V)`` and ``1.Library`` on the top of the menu bar. (Fig. 31) (2). Select machine size and double click on the illustration. (Fig. 32)
Fig. 31
Fig. 32
(3). Double click the row of machine and serial number which you want see. (Fig. 33) (4). Double click the row of row of the each inspection data which you want see. (Fig. 34)
Fig. 33
Fig. 34
For close Library.
(5). Click ``Close_Library(X)`` and ``Close(X)`` for close this screen. (Fig. 35)
Fig. 35
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(2) Standard Value. For indicate the Standard Value.
(1). Click ``View(V)`` and ``2.Standard_Value`` on the top of the menu bar. (Fig. 36) (2). Select machine size and double click on the machine illustration. (Fig. 37)
Fig. 36
Fig. 37
For return to main menu.
(3). Click ``MENU`` on the sheet name at bottom or Click ``View(V)`` and ``4.Go to top menu``. (Fig. 39)
Fig. 38
Fig. 39
Menu
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6) Report Section. This section has tow function for report the inspection reports to customer. One is chart ( trend graph of each U/C components, and the other is monthly summary reports of all of the machines of customer.
(1) Chart (Graph). (1). Click ``Report(R)`` and “Chart” on the top of menu bar. (Fig. 40) (2). Select machine size and click on the machine size illustration. (Fig. 41)
Fig. 40
Fig. 41
(3). Click the row of machine and serial number which you want make graph. (Fig. 42) (4). Click ``Chart(G)`` and ``Create Chart`` then click ``OK`` for create graph or ``Cancel`` for return to main menu. Await a few minute! (Fig. 43)
Fig. 42
Fig. 43
(5). When you want select start and end of data for draw graph, double click on the column A or input ``Y``. If double click here or input ``Y``, it can draw graph of each data. If input space, it can not draw graph of each data.
Fig. 44
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(6). Draw each undercarriage components graph. a. Click ``Create Graph(G)`` and ``0. All items(1)`` for draw all undercarriage components items. You must do this job on first step.
b. Click ``Create Graph(G)`` and ``1. Link Pitch(1) to 9.Sprocket(9)`` for draw graph each undercarriage components . (Fig. 45) Note : When you want change graph like a legend, font and location etc., double click on the graph then edit each graph. If click these sheet buttons, it can go to each U/C components graph and base data. From top, (1). Link Pitch (2). Link Height (3). Bushing O.D. (4). Grouser Height (5). Carrier Roller dia. (6). Idler Top Height (7). Track Roller(L.H.) (8). Track Roller(R.H.) (9). Sprocket
2) Print Graph.
Fig. 45
(1). Click ``Print`` button on top left corner. (Fig. 46) (2). Print pre-view is appeared automatically. (3). Check the printing image then click ``Print`` for printing graph. (Fig. 47)
Fig. 46 Fig. 47
(4). Click ``Close_Chart(X)`` and ``Close`` on the top of menu bar for close job. - 14 -
This section will be print out the KUC report for customer (2) and KUC Wear Summary report (3).
(2) KUC Report for Customer(2). This report is print out all customers machine KUC data which are latest one every month. (1). Click the ``Report`` which is mentioned top of menu bar (2). Select and click the ``KUC Report for Customer(2)`` which is mentioned top of menu bar. (Fig. 48) (3). Select and double click on the ``Customers Name`` which is you want print out for report. (Fig. 49)
Fig. 48
Fig. 49
(4). Confirm the customer name and click ``OK`` if correct customer name which is you want to print out. (Fig. 50)
Comment portion.(Top row) Comment portion.(Bottom row) Fig. 50
Fig.51
(5). Check the all data and comment portion. You can correct it by manually if required. (Fig. 51) (6). If you corrected all mistake, click ``Print_KUC_Report(P)`` then select “Print Monthly Report(1). (Fig. 52) (7). If finished print out, click the ``Close report(X)`` and ``Close(X)`` for finish this section job. (Fig. 53)
Fig. 52
Fig. 53
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(3) KUC Wear Summary Report(3). KUC Wear Summary Report by each machine (Model) can be provided and printed out. (1). Click menu bar ``Report`` on top of the screen. (2). Select and click the ``KUC Wear Summary Report (3)`` . (Fig. 54) (3). Select ``Machine (model)`` group in the window and double click. (Fig. 55 )
Double click Fig. 55
Fig. 54
( 4). Confirm the machine model and click ``OK`` if it is what you want to print out. (Fig. 53)
Fig. 56
Fig. 57
( 5). Check the all data and comment portion. If you found any mistake in the sheet, correct it manually. (Fig. 57) 6). If you corrected all mistake, click ``Print_KUC_Report(P)`` then select ``Print Summery Report(1)``. (Fig. 58) 7). If finished print out, click the ``Close report(X)`` and ``Close(X)`` for finish this section job. (Fig. 59)
Fig. 59
Fig. 58
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7) Edit and add Standard value( KUC : Undercarriage wear criteria ) section. This section shows how to edit and add KUC standard value (Wear Criteria ) by manual. (Usually, it is not required.)
1. Open ``KUC.xls`` file under EXCEL or EXPLOLER with non activate macro. (Fig. 60 & 61) 2. Click ``Format(O)``, ``Sheet(H)`` and ``Indicate(I)`` for indicate hidden worksheet. (Fig. 62) 3. Click “Tool(T)”, ``Protection(P)`` and ``non-protection Sheet(P)`` for non-protect sheet. (Fig. 64) 4. Edit or add criteria using all of function of EXCEL97. Key point. : (1). Column C and D are key points. Do not type same spelling.
(2). Example: Do not type like a D65A, E, P-6 xxxxxx - xxxxxx. Input each madel like a D65A-6 xxxxxx - xxxxxx or D65E-6 xxxxxx - xxxxxx. (3). Do not insert and delete column because of the column is controlled by macro. (4). Column A = Column C + Column D. (5). Column B is automatically loaded to model name cell of report sheet when entered standard value.
Fig. 61
Fig. 60
Fig. 63
Fig. 62
Fig. 64
Fig. 65
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Save edited and added data to program. 1. Click ``Tool(T)``, ``Protection(P)`` and ``Protection Sheet(P) `` for protect sheet.And click OK without password. (Fig. 66 & 67) 2. Click ``Format(O)``, ``Sheet(H)`` and ``Hidden(H)`` for worksheet hide. (Fig. 68) 3. Click ``File(F)`` and ``Save(S)`` or ICON for save data. (Fig. 69)
Fig. 66
Fig. 67
Fig. 69
Fig. 68
Do not forget to do above steps before close EXCEL because of the if you forgot to do these steps, the program will not able to work completely.
4. Click ``File`` and ``Close`` to exit Excel 97.
Fig. 70
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8) Edit and delete data in library section. (1) Edit data in library It is able to edit individual KUC Inspection Service Report, but we can edit and delete data in library as well. 1. Click menu bar “Edit(E)” and “Edit_Library”. Model selection window is appeared.
2. Select Model group bottom in the window and click it.
Fig. 71
Fig. 72
4. Edit the the cell of History Record Table as required. The data edited in Model Record Table must be edited in this table as well at the same time.
3. Edit the the cell of Model Record T able as required. Note: Only white fill cell can be edited.
Fig. 73
Fig. 74
5.Click menu bar “Close Library(X)” and “Close(X)” after finish the edit. The menu screen appear and it is automatically saved.
Fig. 75
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(2) Delete data in library It is able to delete data in Library as same as usual EXCEL sheet. 1. Click menu bar “Edit(E)” and “Edit_Library”. Model selection window is appeared.
2. Select Model group bottom in the window and click it.
Fig. 77
Fig. 76
3. Select specific Model & S/No. which you want to delete and double click at Model or S/No. cell.
4. Select specific row of History record table and delete as usual EXCEL function.
Fig. 78
Fig. 79
5. When you deleted all history record, return Model Record Table by click sheet “ModelRecord” on the bottom and need to delete the specific row.
6.Click menu bar “Close Library(X)” and “Close(X)” after finish the edit. The menu screen appear and it is automatically saved.
Fig. 81
Fig. 80
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3.Special feature of the program 1) 2nd life calculation after bushing turn
When bushings are turned, necessary measurement must be done with its service meter, SMR. SMR is an important key to retrieve the data and calculate 2 nd life wear %.
90% L
(1st life)
d1
d2 Fig. 82
95% (2nd life)
d
Wear % calculation formula d1=d2 +
2nd %=
d d
d1= 1st Life Measurement
d2= 2nd Life Measurement
L The above example is shown that bushings turn was done at 90% wear on the 1st surface and d1 is the measured value.After bushing turn use, d2 is now measured. L is 100% wear span. The 2nd life wear % is calculated as shown above theory. On the next page an example is explained. At 3500 hours bushings were turned and then at 4000 and 5000 hours bushing O.D were measured. - 21 -
At 3010 H bushings were turned and the O.D. were measured.
Fig. 83
Fig. 84
The value of measured O.D. at 3010 H are retrieved and stored below the original criteria. A new criteria to 100 % wear of 2nd life is set and then wear % of 2nd life are calculated. In order to do this correctly, it is very important to input the SMR 3010 in the column “Turned”. - 22 -
2. WearWear 2) % %
The calculated Wear % is not a simple one like linearly calculated by dimension. Each k
component has different curve of " y = a X " basing on the accumulated data.
y=aX y
k
y : wear life %
life
a : abrasive factor X : dimension (=measured value ) k : component factor
100%
50%
Fig. 85
B
A
X
dimension
(= measured value) Undercarriage parts are hardened by heat treatment from surface and the hardness becomes softer from the surfa ce to inside. The above graph is an image that initial 50% ate dimension B and 100 % life ate dimension A. The dimension after initial 50 % ( A - B ) is bigger than the B , initial 50 %.
K
K
Criteria table consists of K column and the formula is built-in. Wear % is calculated automatically basing on each different factor K.
-- 23 22 --
Fig. 86
