FAILURE ANALYSIS REPORT

Owner: PT DARMA HENWA TBK Project/Site: ACP (Asam Asam Coal Project)
Reported By Abrissal Sanusi Date: Tuesday, 22 September 2020
Equipment Number DT2368 Model: Komatsu HD785-7
Serial Number Unit 9288 HM Unit: 26,593.1 Hours

Component Information:
Component Description: Rear RH Stopper Frame Component P/N: -
Fractured
Date Component Install 15 Sept 2020  (Loosen, Date Component 22 Sept 2020
welding process) Fail/Remove
Mach Hrs Install 26,504.0 Hours Mach Hrs Removed 26,593.1 Hours
Component Life/Hrs 89.1 Hours Engine Serial Number MN-501440
WO Number - Status of Component Loosen repairable
Dealer/Supplier PT United Tractors 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 Y
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 Y

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 Monday, September 23rd, 2020 at 07:01 pm, received report from base control that frame stopper rear RH loosen & hit the
differential housing

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

After perform comprehensive check found several problem :
1. Stopper RH loosen
2. Housing differential dent & crack
3. Core suspension rear RH broken

Root cause of the Failure:

Root cause of DT2368 starts from suspension problem of DT2368 seal dust suspension front & rear has same broken
problem. This condition has high potential increase for stopper frame hit the differential even the payload is normal.
Previous case this stopper loosen 7 days before September 23 rd , 2020 was welded by welder. High potential of loose
again if there is problem with welding.
The root cause is broken seal dust suspension made even normal payload will hit the differential housing

Corrective Action Required:

1. Reseal suspension for all suspension
2. Strengthen of welding frame stopper

Failure Parts:

Part Number Description Component Group Qty Remarks

561-50-85001 Front suspension LH Front axle 1 EA Broken

Responsibility Job Repair by:

OEM

Dealer

Darma Henwa

Report Prepare by : Abrissal Sanusi Checked by:

Reliability Engineer Maint. Superintendent

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 FAILURE ANALYSIS REPORT
ATTACHMENT

Photo of unit dump truck – front view Photo of unit dump truck – rear view

Stopper frame RH loose

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 FAILURE ANALYSIS REPORT

Stopper frame LH Stopper frame RH loose

Stopper frame LH dye penetrant crack test Stopper frame RH loose, dye penetrant crack test

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 FAILURE ANALYSIS REPORT

Loosen stopper stuck between hub & frame

Crack after hit by

Previous fractured stopper

Previous welded

Fractured surface After crack hit by stopper

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 FAILURE ANALYSIS REPORT

Welding not properly fit

Welding condition after loosen

Technical drawing frame dump truck Komatsu HD785-7

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 FAILURE ANALYSIS REPORT

Stress analysis frame HD785-7 Komatsu

Safety factor = 4.13

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REVISI 02
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 FAILURE ANALYSIS REPORT

F = 100 kN
SF. Ori = 4.13 = 413 kN
SF. After welding = 1.97 = 197 kN
After not properly welding, the strength decrease 52%

Seal dust rear suspension LH & RH broken, increase potential of cylinder suspension drop

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REVISI 02
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 FAILURE ANALYSIS REPORT

Seal dust front suspension LH & RH broken, increase potential of cylinder suspension drop problems

DT2368 had problem with core suspension

Stopper frame loose by previous installation by welding

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 FAILURE ANALYSIS REPORT

Code From HM From Time To SMR To Time Count Error Message

DHP6KA 26479 12-Sep-20 26479.4 12-Sep-20 2 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26480.1 12-Sep-20 26480.1 12-Sep-20 1 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26481.5 12-Sep-20 26482 12-Sep-20 2 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26482.7 12-Sep-20 26484 12-Sep-20 7 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26485.1 12-Sep-20 26485.3 12-Sep-20 2 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26485.9 12-Sep-20 26486.6 13-Sep-20 6 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26487.2 13-Sep-20 26487.5 13-Sep-20 3 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26488 13-Sep-20 26488.9 13-Sep-20 6 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26489.5 13-Sep-20 26499.8 13-Sep-20 67 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26500.5 13-Sep-20 26502.5 14-Sep-20 17 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26503 14-Sep-20 26518.3 16-Sep-20 82 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26518.8 16-Sep-20 26531.2 17-Sep-20 74 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26532.3 17-Sep-20 26533.1 17-Sep-20 5 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26534.6 17-Sep-20 26534.8 17-Sep-20 2 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26535.4 17-Sep-20 26544.9 18-Sep-20 45 Abnormality in Suspension pressure sensor circuit (RR)
DHP6KA 26545.5 18-Sep-20 26545.7 18-Sep-20 3 Abnormality in Suspension pressure sensor circuit (RR)

Fault code download, many problem suspension pressure sensor

Payload
Date Time Tonnes
21-Sep-20 1:14 71
21-Sep-20 1:40 82
21-Sep-20 2:02 100
21-Sep-20 2:24 68
21-Sep-20 2:46 84
21-Sep-20 3:07 100
21-Sep-20 3:27 88
21-Sep-20 3:48 84
21-Sep-20 4:36 79
21-Sep-20 5:22 82
21-Sep-20 6:24 54
21-Sep-20 6:45 68
21-Sep-20 9:28 79
21-Sep-20 9:50 99
21-Sep-20 10:10 96
21-Sep-20 10:38 93
21-Sep-20 10:58 91
21-Sep-20 11:16 81
21-Sep-20 11:29 93
Payload download result not found overload value

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REVISI 02
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