Component delivery 31-januari-2012, installed on unit in 31-juili-2012 at SMR 15,225 Hrs, and than component has a problem in '7 October 2013 at SMR 14,522Hrs, Life Time component 6,095 Hrs.
Component delivery 31-januari-2012, installed on unit in 31-juili-2012 at SMR 15,225 Hrs, and than component has a problem in '7 October 2013 at SMR 14,522Hrs, Life Time component 6,095 Hrs.
Component delivery 31-januari-2012, installed on unit in 31-juili-2012 at SMR 15,225 Hrs, and than component has a problem in '7 October 2013 at SMR 14,522Hrs, Life Time component 6,095 Hrs.
Reported by : SUYOKO Check & Approved by : EKO WIJAYANTO
1 Symptom 2 General Information : : : : : : : : : : 3 Background 4 Unit Historical 5 Finding Fact Data Installation Report dan Data-data ( ASS, etc ) Component delivery 31-Januari-2012, installed on unit in 31-Juli-2012 at SMR 15,225 Hrs, and than component has a problem in '7 October 2013 at SMR 14,522Hrs, life time component 6,095 Hrs. Information base on ETR it component happen problem Final Drive UNIT CANT MOVE FORWARD & REVERSE Service Meter Reading Customer Life Time Comp. In Date QA Officer Section Head GD825A-2 12527/GR379 Buhut Component Name Model Hrs Serial. No / Code 24-Oct-13 Hrs PAMA 6,095 Serial No. 2410003288 2410003288 12-Nov-13 FINDING ANALYSIS AND INVESTIGATION REPORT (FAIR) KRA13 - Branch / Site 20,617 UNSCHEDULE OVERHAUL UNIT CANT MOVE FORWARD & REVERSE Machine Model FINAL DRIVE 235-22-00131 KX-N211142811 Brand New Machine 1st Ovh SMR Comp. 14,522 Hrs. Life Time : 14,522 Hrs Comp In at 16-Agust- 2012 JO : 2410001173 - Schedule Ovh 2nd Ovh SMR Comp.20,617 Hrs. Ex Comp KRA JO : 2100011428 Life Time Comp. 6,095 Hrs Unscheduled Overhaul
Unit Cant Move Forward & Rivers Figure 1. SPROCKET LH P/N : 235-22-11880 was Abnormal Worn Figure 3. Shaft LH P/N : 235-22-11850 was Broken Referensi Bearing CRACK Figure 2 : Bearing P/N : 234-23-12520 was ready CRACK Base on finding fact at disassy process, we found : Figure 4. Bolt mounting holter to shaft P/N : 235-22-11840 was Broken Figure 5. Shaft P/N : 235-22-51340 was abnormal worn Example of Fatigue due to Rotating Bending Load
6 ANALYSIS Based on actual condition after disassembly, we found: Shaft P/N 235-22-11850 Broken and Sprocket P/N : 235-22-11880 abnormal worn. Unit can't move forward and reverse cause by shaft Broken. When investigation process founded abnormality at hole sprocket, conclude from these finding is the shaft broken effect from external force, possibility cause by on the left side final drive sprocket retained foreign material or happen breakage at chain final drive. Operation The power transmitted from the engine to the transmission is then transmitted by the meshing of bevel pinion and bevel gear and is sent from shaft to sprocket. Final Drive RH Final Drive LH The surface is smooth and shiny in those regions which failed during crack initiation It is rough in those regions which Break starting It is rough in those regions which Possibility Chains has Jammed
7 Suggestion Costumer & UT Responsibility : Types and Figurations of Fractures (Macroscopic observation) Based on actual condition after disassembly, we found: Shaft P/N 235-22-11850 Broken and Sprocket P/N : 235-22-11880 abnormal worn. Unit can't move forward and reverse cause by shaft Broken. When investigation process founded abnormality at hole sprocket, conclude from these finding is the shaft broken effect from external force, possibility cause by on the left side final drive sprocket retained foreign material or happen breakage at chain final drive. Operation The power transmitted from the engine to the transmission is then transmitted by the meshing of bevel pinion and bevel gear and is sent from shaft to sprocket. ! ! ! ! ! Do oil sample regulary and analyse it. Do maintenance refer to OMM ( Operation & Maintenance Manual ) . Use oil lubricate recommended by KOMATSU and change them periodically as scheduled and always add fresh oil to the spesific level. Do flushing process better when installed component. Avoid to enter foreign substance when changing oil. KRSR No. 2491/MP/KRSR/11/2013 Date. 2013-11-13 Part Number Description Quantity Failure Caused By Recommendation Part Number Description Quantity Component was received at KRA with steel stand installed. LIFE TIME 20617 OVERHAUL HISTORY Picture Item CUSTOMER PAMA PERSADA NUSANTARA PT OVERHAUL CAT SERIAL NUMBER 12527 TRANSASCTION SUYOKO UNIT MODEL GD825A-2 ACC SMR SITE Buhut COMP IN DATE PRO No. 2410003288 MACHINE MODEL COMP NAME FINAL DRIVE CODE UNIT Failure Caused By Recommendation Part Number Description Quantity Failure Caused By Recommendation Part Number Description Quantity Failure Caused By Recommendation Part Number Description Quantity Failure Caused By Recommendation Part Number : 235-22-11820 Description : .CARRIER : 1 : Crack : External Force from shaft broken Recommendation : Replace Part Part Number : 235-22-11750 Description : .GEAR SUN : 2 Component was received at KRA with steel stand installed. OVERHAUL HISTORY 1st Overhaul Item OVERHAUL CAT UNSCHEDULE TRANSASCTION Single Rate ACC SMR 6095 COMP IN DATE 2013-10-24 MACHINE MODEL 235-22-00131 CODE UNIT GR379 : Crack : external force Recommendation : Replace Part Part Number : 235-22-11851 Description : .SHAFT : 1 : Broken : Shock load Recommendation : Replace Part Part Number : 235-22-51340 Description : .SHAFT LH : 1 : Damage : Effect from shaft broken Recommendation : Replace Part Part Number : 235-22-51350 Description : .SHAFT RH : 1 : Damage : Effect from shaft broken Recommendation : Replace Part GD825A-2 12527/GR379 20,617 hrs PAMA 6,095 hrs Buhut Description SHAFT Date S M R Warranty Status Delivery Installed Failure Total Attainment of component 469 Day 6,095 Hrs Available (y/n) Yes No No Not Applicable Not Applicable Available (y/n) yes No No Int. Ext. Shaft Broken Balikpapan, 13-Nov- 2013 Incomplete Commissioning / ASS Support Distributor Improper Maintenance / Operation Customer FINAL DECISSION Based on aspect E this case can be classifed as Unclaimable category with decission " Rejected " Poorworkmanship / Material Defect Reman PI 1,2,3 & PM CLINIC PM CLINIC REPORT E. Technical Analysis Result Cused by Main Cause Factor Responsibility D. Completeness of ASS Data Description Received Date Remarks COMMISSIONING & PM ok PLM RECORD VHMS PAP REPORT Need MAINTENANCE RECORD Need C. Support Technical Data Description Received Date Remarks ETR 8-Oct-13 ok B. History of Component 30-Jun-12 5-Jul-12 14,522 17-Oct-13 20,617 A. Main Part Failure: Part Number Qty Finding Fact / Condition 235-22-11850 1 Broken SECTOR MINNING COMP IN DATE 24-Oct-13 Symptom UNSCHEDULE OVERHAUL UNIT CANT MOVE FORWARD & REVERSE BRANCH / SITE JOB ORDER NO. 2410003288 PT.KOMATSU REMANUFACTURING ASIA CLAIM ADMINISTRATION EVALUATION MACHINE MODEL COMPONENT NAME FINAL DRIVE SERIAL NO. MODEL 235-22-00131 SERVICE METER SERIAL NO. KX-N211142811 CUSTOMER LIFE TIME ( Eko Wijayanto ) ( ) QA Section Head QA&Prod Dev.Manager JO No 2410003288 Comp name FINAL DRIVE Comp In Date Report Type RTFR HM of Comp 20617 Disassy Finish ETR Reff. No Mach. Model GD825A-2 RPL Finish Report By SUYOKO Tech Date Req 0000-00-00 Report Date Tech Date Rec 0000-00-00 Part Number Description Qty PRODUCTION RESPONSE (Production Manager) QA FINAL DECISSION Decission : Rejected Date : 2013-11-13 Approved By QA & Prod. Dev Manager MAIN CAUSE - EXT - Mis-adjustment QA OFFICER DECISSION Decission : Rejected Remark : 1 Product Quality Confirmation SYMPTOM - JAMMED FAILURE - Broken MAIN PART CAUSING THE PROBLEM 235-22-11850 Shaft 24-Oct-13 30-Oct-13 30-Oct-13 13-Nov-13 Date : 2013-11-13 QA Officer Date : 2013-11-13 Decided By QA & Prod. Dev Section Head PRODUCTION RESPONSE (Production Manager) QA FINAL DECISSION MAIN CAUSE - EXT - Mis-adjustment QA OFFICER DECISSION 1 Product Quality Confirmation SYMPTOM - JAMMED FAILURE - Broken MAIN PART CAUSING THE PROBLEM 235-22-11850 Shaft
PT UNITED TRACTORS Tbk REPORT NO. COMPONENT MODEL FINAL DRIVE ( 235-22-00131) REPORT DATE 7 OKTOBER 2013 ENGINE NUMBER KX-N211142811 BRANCH SITE BUHUT SMR 20607 ( ACTUAL ) LIFETIME COMPONENT 6085 HM CUSTOMER BUSINESS MINING TROUBLE DATE 7 OKTOBER 2013 CUSTOMER NAME PT.PAMA PERSADA NUSANTARA DELIVERY DATE 5 JULI 2012 ( INSTALATION DATE ) MACHINE LOCATION BUHUT CORRECTION DATE CODE UNIT GR379 CORRECTION SMR MACHINE MODEL GD 825A-2 REPORT BY NICO FEBRI K MACHINE SERIAL NO. 12527 ID NUMBER 80106021 SYMPTOM : UNIT CAN'T MOVE FORWARD & REVERSE DATA : Saat unit dioperasikan tiba tiba unit tidak bisa digerakkan maju maupun mundur unit dilakukan evakuasi untuk dilakukan pengechekan lebih lanjut , Hasil Konfirmasi by phone dengan Bp. Eko Wijayanto KRA kami mendapat ijin untuk pengechekan inner component setelah dilakukan pembongkaran ditemukan bahwa shaft mengalami patah dan innerpart banyak yang mengalami chiping. PICTURES FINAL DRIVE ASSY ( 235-22-00131) CAUSED ANALYSIS : (Describe detail of failure, analysis the cause, operating condition & ATTACHED PHOTOGRAPHS or Drawing) CORRECTION MADE : EMERGENCY TROUBLE REPORT SYMPTOM : UNIT CANT MOVE FAILURE : Crack, Dent, Worn, Scratch, Short Circuit, Burn, Bend, Loose, Rusty, Pitting, Broken etc FINAL DRIVE PROBLEM MAIN PART CAUSING THE PROBLEM (PART NO.) NAME PLATE KRA DRAIN PLUG SHAFT BROKEN