FAILURE ANALYSIS REPORT

Owner: PT DARMA HENWA TBK Project/Site: ACP (Asam Asam Coal Project)
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Reported By Putri Wahyu Lestari Date: Dec, 18 2020
Equipment Number DT2368 Model: Komatsu Dump truck HD785-7
Serial Number Unit 9288 HM Unit: 27301.3 Hours

Component Information:
Component Description: Final Drive RH Component P/N: 561-22-70304
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Date Component Install June, 11 2018 Date Component Fail Dec, 3 2020
Mach Hrs Install 19263.8 Mach Hrs Removed 27301.3 Hours
Component Life/Hrs 8037.5 Hours Engine Serial Number MN-501440
WO Number ‘- Status of Component Overhaul
Dealer/Supplier PT United Tractors, Tbk. 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 N
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:
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On Thursday, 3 December 2020, 8:00 WITA Komatsu Dump truck HD785-7 with unit number DT2368 had scheduled PM
Service 300 hours. When mechanics inspected Magnetic Plug Final Drive, there’s found Magnetic Plug Final Drive RH rating C.
then mechanics dismantling Final Drive RH and doing comprehensive inspection inner part Final Drive RH. Details failure
conditions Final Drive RH will explain later.

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

Inspection result of Dismantling Final Drive RH by mechanics found that,
1. Sun Gear contact stress fatigue condition.
2. Planetary Gear fatigue cracks.
3. Spindle Misalign worn out.
4. Bearing Misalign worn out & fatigue cracks.
5. Carrier abrasive wear condition.
6. Shaft good condition.
7. Hub good condition.

Root cause of the Failure:

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Final Drive RH DT2368 have been done overhaul before. That is on June, 11 2018 hour meter 19263.8 hours. When
overhaul, Sun Gear doesn’t replace, While at that moment Sun Gear component had started minor wear. Current
failure of Final Drive RH DT2368 is impact of Sun Gear doesn’t replace when overhaul before. So that, wear of Sun
Gear will increase and the new bearing just started worn out. Unbalanced wear of Bearing and Gear cause
misalignment, so that gear tooth backlash tight. Misalignment can cause overload of the tooth surface and possible
fatigue pre-crack. Others inner part component of Final Drive also get impact of that misalignment. Some of bearing
components also get misalign worn out indication. Misalign worn out prove that unit DT2368 works in normal
operational condition and sometimes works in overload condition. It means that this Final Drive had high lifetime
condition or replacement of this Final Drives must be done.

Corrective Action Required:

1. Bearing and Gear must be replaced at the same time (re-bearing). This is to minimize unbalanced wear
between Bearing and Gear that can impact to other components of Final Drives.
2. Replacement Final Drive when lifetime target had achieved.

Failure Parts:
Part Number Description Component Group Qty Remarks
Attached
Responsibility Job Repair by:

OEM

 Dealer

Darma Henwa

Report Prepare by : Putri Wahyu Lestari Checked by:

Condition Monitoring Analist Maint. Superintendent

ATTACHMENT

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Technical spare part drawing & part numbers – Final Drive RH

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Technical spare part drawing & part numbers – Final Drive RH

Contact stress
fatigue

Sun Gear had contact stress fatigue cause by misalignment Technical spare part drawing – Sun Gear
operation
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 FAILURE ANALYSIS REPORT
Contact stress fatigue on Sun Gear caused by overload on one of gear tooth surface. The overload started because misalignment
between Bearing and Gear so that gear got unbalance load and gear tooth backlash tight.

Fatigue pre-crack

Planetary Gear had fatigue pre-crack condition Technical spare part drawing – Planetary gear

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Misalign worn out

Contact stress fatigue

Beachmarks

Bearing had contact stress fatigue

Misalignment can cause overload of the tooth surface and possible fati gue pre-crack. Others inner part component of
Final Drive also get impact of that misalignment. Some of bearing components also get misalign worn out indication .

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 FAILURE ANALYSIS REPORT

Brinelling marks

Spindle shaft condition

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Discoloration Brinelling marks

Smearing

Adhesive wear

Spindle adhesive wear

Adhesive wear is worn out that occurs on metals when there is contact between metals with thin lubrication or no lubrication at
all, So that the impact of this condition is direct friction and temperature increase on contact area. This increasing temperature
called Overheat that indicated by discoloration on surface metal.

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Hub and Ring Gear condition

Abrasive wear

Adhesive wear

Hub and Ring Gear condition

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Abrasive wear

Shaft Abrasive worn out

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Latest Sample Oil Final Drive RH-DT2368, shown that Fe medium level, C & PQ increase

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Historical Magnetic Plug Rating Final Drive RH DT2368, the latest rating shown that on X rating.

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