COMPONENT FAILURE ANALYSIS REPORT

CUSTOMER PT. INCO LOCATION SOROWAKO DATE 23 May 2003

MACHINE MODEL 777D SERIAL NO 03PR00284 UNIT NO 4203

ENGINE MODEL 3508 SERIAL NO SMUs 13,746 hrs

DEALER PTTU CODE J201 LOCATION SOROWAKO

WORK ORDER NO 4830423 INCO WO NO -

COMPONENT Transmission

COMPONENT LIFE 14,688 Hrs. INSTALL DATE 15 March 2001 SMUs 22,328 hrs

COMPONENT LIFE 26.2 mths FAILURE DATE 21 May 2003 SMUs 37,016 hrs

GROUP NO: 0R4005 DESCRIPTION Planetary Transmission GP (REMAN)

PART NO: 9W8442 DESCRIPTION Planetary Carrier

REPORTED BY Ali Basuki SALARY NO: 4786

APPROVED BY Peter Dale

1. HISTORY:
SMUs Part Date Work Description
No. Order
37016 0R4005 22-Mei-03 4830423 Continue Replace transmission Gp.
37016 0R4005 21-Mei-03 4830423 Replace transmission Gp.
36997 PM1000 20-Mei-03 4829578 XMSN magnetic screen fond to much material.still monitoring.
34589 6T8500 15-Jan-03 4825482 Repair connector harness lockup solenoid due to loose. Sent unit to
tyre shop
34589 N/A 14-Jan-03 4825482 Inspect transmission always neutral position. Sent to the shop for
repair tyre
32037 8E9035 ###### 4820878 Transmission performance test. Carry out during PM Check 4000
Hours.
29995 8E9035 06-Mei-02 4818115 Transmission performance test. Carry out during PM Check 2000
Hours.
29084 6I8073 21-Mar-02 4817323 Replace filter transmission gp from unit 4210 to damage of housing.
28289 8E9035 07-Feb-02 4816361 Transmission performance tes pressure – carry Out during PM service.
28088 N/A 28-Jan-02 4816437 Adjust shim for pressure primary for speed 4,5,7 position before 54 psi
after 86
28088 N/A 28-Jan-02 4816437 Inspect transmission magnetic screen and testing adjusting
transmission.
28088 9P9650 28-Jan-02 4816437 Replace pin dowel for shaft Trans switch due to broken (cannibal
4217)
28032 PM4000 24-Jan-02 4815861 Change transmission oil carry out durring 4000 hrs PM Service
26477 N/A 03-Nop-01 4814738 Inspect transmission screen = after check no found materials. Carry
out during PM service.
24773 8E9035 ###### 4813422 Refer SOS, Transmission Oil abnormal. Transmission Performance
Test. Carry out during PM 250 hrs.
23439 8E9035 29-Mei-01 4812147 Day#12; After testing found transmission can’t forward and reverse
but test manual shifting, ok. After check, plug 6J4994 and Valve
9W6964 for Switch Actuator not available after recondition by Rebuilt
component. Install Plug and valve, completed transmis
23439 8E9035 28-Mei-01 4812147 Day#11; testing & Adjusting Transmission as persheet.
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 23439 28-Mei-01 4812539 Day#11; Refill oil all compartment.
SMUs Part Date Work Description
No. Order
23439 8E9035 27-Mei-01 4812147 Day#10; Install Transmission GP. Completed Hose lines and electric
system.
23439 8E9035 26-Mei-01 4812147 Day#9; continue recondition transmission and Connect Differential to
transmission after recondition by rebuild component. Prepared install
to machine.
23439 8E9035 25-Mei-01 4812372 Day#8; Waiting Transmission from rebuild component.
23439 8E9035 24-Mei-01 4812372 Day#7; Waiting Transmission from rebuild component.
23439 8E9035 20-Mei-01 4812400 Day#3; Remove Hydraulic Tank GP.
23439 8E9035 20-Mei-01 4812372 Day#3; Remove Transmission GP and send to Rebuild Component.
Part life: 1111 hrs.
23439 N/A 19-Mei-01 4812372 Day#2; Transmission Oil any particle found. Remove Transmission GP.

2. SYMPTOMS:

During PM 1000 it was found foreign particle at magnetic screen.

3. PROBLEM/DIAGNOSIS:

It was suspected that the transmission experienced internal failure. It need further investigation.

4. OBSERVATIONS (Result and Damage):

1. Planetary carrier 9W8442 was worn at one of the planet gears.

2. 1 ea. Gear 3T2507 was worn at edge of teeth.

3. 1 ea. 7G0897 was worn away.

5. CONCLUSIONS (Root cause of failure):

Having removed and dismantled the transmission group was found that planetary carrier of #7
clutch p/n 9W8442 was worn at one of the planetary gears. The most probable of root cause was
disc thrust 7G0897 broken causing planetary gear 3T2505 scored the planetary carrier.

6. REPAIR/CONTAINMENT PLAN:

Repaired the damaged transmission gp by replacing the planetary carrier and other related
damaged parts.

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7. ADDITIONAL COMMENTS:

The REMAN transmission GP was installed on 15 March 2001. Having operated for 2 months, the
transmission failed on disc clutch #03, then installed to unit having repaired.

The ECM recorded 109 events of abuse operation.

8. COMPONENT REPLACEMENT HISTORY (Component Supplier)

CAT REMAN YES

CAT New NO

NRC REMAN NO

Site Rebuild NO

JKT Rebuild NO

CRC Rebuild NO

Other NO

9. COMMERCIAL IMPACT:

• Work Order Overview:

LABOUR HRS LABOUR COST PARTS MISC. TOTAL

• Responsibility of Cost (including Cost Split Details):

PT. Trakindo Utama (MARC) was responsible of the repair cost due to beyond part warranty
period.

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10. SUPPORTING DATA REQUIREMENT

Service Report Y N
Photos Y N
SOS Reports Y N
Magnetic Plug Inspection Results Y N
Filter Inspection Results Y N
Trenz Reports Y N
Contamination Control Report Y N
Caterpillar Correspondence Y N
Machine History Records Y N
Analyzer Actual Vs Budget Report Y N

Picture #01: Planetary carrier of #7 clutch was scratch at Picture #02: Planetary carrier of #07 clutch was deeply
one end of the planetary gear. scored.

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