FAILURE ANALYSIS REPORT

Owner: PT DARMA HENWA TBK Project/Site: ACP (Asam Asam Coal Project)
Reported By Putri Wahyu Lestari Date: Tuesday, 25th 2022
Equipment Number DT1346 Model: Volvo FM440
Serial Number Unit A715964 HM Unit: 49617 Hours

Component Information:
Component Description: Cylinder Hoist Loose Component P/N: 71536392
Date Component Install New Fitted Date Component Tuesday, 25th 2022
Fail/Remove
Mach Hrs Install New Fitted Mach Hrs Removed 49617 Hours
Component Life/Hrs 49617 Hours Repair Hours -
WO Number - Status of Component Loose
Dealer/Supplier PT Eka Dharma Jayasakti Component S/N -

Document Support Required:

NO DESCRIPTION Y/N COMMENTS

Component Installation/Commissioning Report
1 N
component fitted
2 Data Logging Unit (Download Data) N
3 Photo of component fail & Filter Cut Y
4 Repair & Maintenance History N
5 SOS report & Action taken/Feedback N
Initial service report after 50 hrs or 100 hrs
6 N
operation
7 Performance test Report (PM Clinic, TA2 etc) N

8 Last Component Change Out (CCO) report N

9 PCR Report N
10 Warranty Claim N

11 Payload data N

12 QA report/ pre start check report/P2H N

PM service work order sheet before component
13 N
failure (2 period before)

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 FAILURE ANALYSIS REPORT
Background:
On Tuesday, October 25th 2022 on 15:55 WITA unit Coal Hauler FM440 with number DT1346 after doing dumping coal
in hopper had problem with Hoist Cylinder loose then hit rear Cabin Glass. Then our mechanics evacuate unit to safe area for
inspection and find details failure. The details parts failure will explain below.

Description/condition of the equipment found during inspection (Facts of the Damage):

Regarding the inspection, details failure parts will explain below :
1. Hoist Cylinder Loose
2. Pin Round Head Groove Missing
3. Thread Eye Piston and Piston Cylinder Adhesive Worn Out
4. Rear Cabin Glass broken

Root cause of the Failure:

Hoist Cylinder DT1346 had loosen then hit rear cabin glass. It caused by Pin Round Head Groove of Eye Piston
Cylinder Hoist had missing, so that there’s abnormal friction between thread Eye Piston and Piston Cylinder. During
operating unit, that movement and friction is getting worst then Piston Cylinder loose from Eye Piston an hit rear Cabin
Glass.

Corrective Action Required:

1. Inspect condition of all Hoist Cylinder FM440 (Pin Round Head Groove, Spherical Bearing & Thread Head
Cylinder).
2. Inspect Hoist Cylinder every 600 hours.
3. Plan Reseal/Replace Cylinder as target lifetime 12000 hours.

Failure Parts:
Part Number Description Component Group Qty Remarks
*still progress listing parts failure

Responsibility Job Repair by:

OEM

Dealer

 Darma Henwa

Report Prepare by : Putri Wahyu Lestari Checked by:

Reliability Engineer Maint. Superintendent

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 FAILURE ANALYSIS REPORT
ATTACHMENT

Technical drawing Volvo FM440 general dimension & weight

PCR Template – Hoist Cylinder DT1346

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Details Unit – Front View

Details Failure on Cylinder Hoist – DT1346

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CYLINDER HOIST DUMP DETAILS

Technical drawing cylinder hoist dump – partbook

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Photo Cylinder Hoist Dump Loose General drawing of hyva cylinder hoist dump volvo FM440

Loose

Position of Loose Cylinder Hoist DT1346

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Piston sides

Piston Eye sides

Photos cylinder hoist dump Loose

Thread adhesive
wear

Thread adhesive
wear

Thread Piston Cylinder adhesive wear due to abnormal friction Thread Piston Eye adhesive wear due to abnormal friction
with thread Piston Eye with thread Piston Cylinder

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Lock Pin Missing

Position of Lock Pin

Eye Piston DT1346 Eye Piston another unit

Lock Pin Round Head Groove had missing, so that this condition Pin Round Head Groove is locked movement thread eye Piston
causes movement between Thread Eye Piston and Piston and Piston Cylinder
Cylinder.

Technical Drawing – Cylinder Hoist Hyva FM440

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Dust Cover
Position of Pin

Actual Position of Pin Round Head Groove (inside Dust Cover)

Displacement of Hole Pin position Holes Pin position

due to Pin missing
Condition of Hoist Cylinder DT1329
Pin Round Head Groove unit DT1329 also missing, this condition can causes displacement of holes pin then there will be
abnormal friction between thread Head Eye Piston and thread Piston Cylinder. It has high probability Hoist Cylinder will loose
then hit the cabin glass. Need to reposition Hoist Cylinder, inspect thread condition and install Pin Round Head Groove to prevent
Cylinder Hoist loose.

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