FAILURE REPORT OF L2350 END CAP CRACK

Machine Model : L2350

Cumulative HMR: 26564
Life On Parts: 26564
Date of Failure : 01-Nov-2021
Complaint: Lift arm LHS Ball Cap top (RHS) corner 4 bolts got broken
Observation :
1. LHS liftarm ball cap´s top (RHS) corner 4 bolts found
broken.
2. Excess lift arm ball play. Ball end play was found at
3.048mm with comparison to standard maximum limit
1.42mm.
3. Removed the Ball cap of RHS lift arm and found that One
crack has been developed on ball cap LHS bottom corner
side
4. Ball liners found worn out.
5. 02 Types of cap screws found fitted in the machine. Some
Bolts found DB type and others FC type.
6. Shop Manual has suggested using FC bolts.

FC Bolts

DB Bolts
Torque Value:
FC Bolt Torque value: 2584 NM
DB Bolt Torque Value: 2584 NM

As Pitch and Bolt length are same torque values are same.

Broken bolts history :

i) 1st bolt broke at 4591 HMR on 05.08.2021

ii) 2nd bolt broke at 4906 HMR on 02.09.2021
iii) 3rd bolt broke at 5457 HMR on 29.10.2021
iv) 4th bolt got loose at 5500 HMR on 31.10.2021 , then next day on 01.11.2021 machine was stopped for play
adjustment job.

Recommended period for play checking / replacement :

As per manual every 500 hours - visual inspection to be done . If visually there is no play , then every 2000 hours -
need to do dial indicator play inspection .
Action Taken:-
1) Replaced Ball cap.
2) Replaced new ball cap liners.
3) Replaced broken bolts with new bolts.
4) Measured end play after fitment. End play
adjusted to 0.533 mm as per standard minimum
limit.
Possible reason of failure: It seems ball cap top (RHS) corner bolts broke first, hence
operational load (Axial load and transverse load) does not share properly among all bolts and ball cap
got cracked on opposite corner due to additional load on nearby bolts.

Possible reasons for broken bolts

1) Excessive play on ball cap joint : Excess lift arm ball play. Ball end play was found at 3.048mm
with comparison to standard maximum limit 1.42mm.
2) Over torquing on bolts : Due to multiple times tightening of bolts.
3) Fatigue of bolts : Due to ageing (26000 hrs of life) and multiple times removal and fitment, bolts
got fatigued and sheared off.
4) Excessive digging force during operation :- As noticed multiple times operation face condition
was not appropriate for operation. This caused excess force on life arm joints and caused
breakage of bolts.
5) Use of Inappropriate bolts. DB bolts in place of FC bolts.
Preventive actions need to be taken:-
1) Need to be maintained proper play as per shop Manual
2) Proper tightening of mounting bolts.
3) Use of recommended fasteners.
4) Proper face and material condition.