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Wear Evaluation

Section 3 - 3

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Wear Evaluation 2

● Purpose
● Calculate %worn
● Estimate number of hours left
● Recommendation to owner
(maintenance options)
● Undercarriage management

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 Purpose for Wear Evaluation 3

● Longer undercarriage life

● Reduced operating cost
● Planned maintenance to minimize
production time
● Owner can select best maintenance
option
● More Komatsu parts and service
sales

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Way for Wear % (Life) Calculation 4

Using :
1. Wear % and Hours Left Chart

2. KUC Program (Software)

3. Non-Linear Wear Life % table

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1. Wear % Chart & Hours Left Table

・Basic idea for calculating “Hours Left”

・This method was only available before creating

KUC Program

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%Worn Charts 6

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 Hours Left Charts 7

Chart A

Chart B

Chart C

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Example 8

1st Step: Calculate dimensional %

worn

● Bushings
● D65-12 dozer with LTS tracks
● Measurement:67.2 mm
● Assume machine operates in high
impact conditions

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● New dimension
● Wear limit
● Wear factor
● Normal vs. impact
wear
● Calculations
67.2mm⇒54 %

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Example 10

2nd Step: Estimate hours left

● Bushings
● D65-12 dozer
● 54% worn (From % Worn Chart)
● Current hours = 2500 hrs
Note: Wearing speed differs based on material hardness
(Harder material is slower to wear)

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(a) Locate % Worn 11

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(b) Locate Current Hours 12

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(c) Find Intersection at Point X 13

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(d) Draw Parallel Line to Point Y 14

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(e) Determine Total Potential Hours 15

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Determine Hours Left 16

Hours Left = total potential hours - current ours

= 3500 hours - 2500 hours
= 1000 hours

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2. KUC Program (Software Program) 17

1) Process by only clicking its

menu bar
2) Automatically calculate wear life
% with formula “Y=aX*k”

“Total potential hour

= current hour / wear life % “

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3. Non-Linear Wear Life % Table 18

1) This table is arranged

based on non-linear
curve (Same idea as
KUC Program)
2) Directly you can get wear
life % (Not wear %) from
the table

Total potential hour

= current hour / wear life %

Please refer to UCFN04-014

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Wear Evaluation

● Purpose
● Calculate %worn
● Estimate number of hours left
● Recommendation to owner (maintenance
options)
¾ Turning
¾ Rebuilding
¾ Replacing
¾ Switching
¾ Running to destruction
● Undercarriage management
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Turning 20

● LTS wet turn

● LTS dry turn
● LTS grease turn
● Dry-seal track turn
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 Turning (Cont’d) 21

Turning Bushing video

Turning Bushing

Let’s have a look “How to turn bushing , and rotation “

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Rebuilding 22

● Track links

● Track rollers

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 Rebuilding (Cont’d) 23

• Front idlers

• Grousers

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Replacing 24

● Pins and bushings

● Track links

● Sprockets

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Replacing (Cont’d) 25

● Carrier rollers

● Track shoes

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Switching 26

● Track rollers

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Running to Destruction 27

Potential hours = Total hours x 1.3

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Wear Evaluation 28

● Purpose
● Calculate %worn
● Estimate number of hours left
● Recommendation to owner
(maintenance options)
● Undercarriage management

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Undercarriage Management 29

● Maximize undercarriage life

● Minimize operating costs and down-
time
● Strategy #1:
¾ Maximize service life from the link
● Strategy #2:
¾ Get as close to 100% bushing life as
possible

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Example 30

Scenario
Total hours of link = 4000 hours
Total hours of pins/bushings = 2500 hours

Recommendation
Turn pins/bushings after 2000 hours

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