Download - Motor Grader Etr
Job Order : Reported Date :
Reported by : SUYOKO Check & Approved by : EKO WIJAYANTO
1 Symptom
2 General Information
: :
: :
: :
: :
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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
HrsPAMA 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
❶ ❷ ❸
❶
❷
❸
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
❶ ❷ ❸ ❹ ❺
❶ ❷ ❸ ❺ ❹
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/11/2013Date. 2013-11-13
Part Number
DescriptionQuantityFailureCaused 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 CATSERIAL NUMBER 12527 TRANSASCTION
SUYOKO UNIT MODEL GD825A-2 ACC SMRSITE Buhut COMP IN DATE
PRO No. 2410003288 MACHINE MODELCOMP NAME FINAL DRIVE CODE UNIT
FailureCaused ByRecommendation
Part Number
Description
QuantityFailureCaused ByRecommendation
Part Number
Description
QuantityFailureCaused ByRecommendation
Part Number
Description
QuantityFailureCaused ByRecommendation
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 UNSCHEDULETRANSASCTION Single Rate
ACC SMR 6095COMP IN DATE 2013-10-24
MACHINE MODEL 235-22-00131CODE 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
DescriptionSHAFT
Date S M R Warranty StatusDeliveryInstalledFailure
Total Attainment of component 469 Day 6,095 Hrs
Available (y/n) YesNoNo
Not ApplicableNot Applicable
Available (y/n)
yes
No
No
Int. Ext.
Shaft Broken √ √
Balikpapan, 13-Nov- 2013
Incomplete Commissioning / ASS
SupportDistributor
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 DataDescription Received Date Remarks
COMMISSIONING & PM ok
PLM RECORD
VHMS
PAP REPORT NeedMAINTENANCE RECORD Need
C. Support Technical Data Description Received Date Remarks
ETR 8-Oct-13 ok
B. History of Component
30-Jun-125-Jul-12 14,522
17-Oct-13 20,617
A. Main Part Failure:Part Number Qty Finding Fact / Condition235-22-11850 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 ASIACLAIM 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 DateReport Type RTFR HM of Comp 20617 Disassy FinishETR Reff. No Mach. Model GD825A-2 RPL FinishReport By SUYOKO Tech Date Req 0000-00-00 Report Date
Tech Date Rec 0000-00-00
Part NumberDescriptionQty
PRODUCTION RESPONSE
(Production Manager)
QA FINAL DECISSION Decission : Rejected Date : 2013-11-13
Approved By
QA & Prod. DevManager
MAIN CAUSE - EXT - Mis-adjustmentQA OFFICER DECISSION Decission : Rejected
Remark :
1
Product Quality Confirmation
SYMPTOM- JAMMEDFAILURE- BrokenMAIN PART CAUSING THE PROBLEM
235-22-11850Shaft
24-Oct-1330-Oct-1330-Oct-1313-Nov-13
Date : 2013-11-13
QA Officer
Date : 2013-11-13Decided By
QA & Prod. DevSection Head
PRODUCTION RESPONSE
(Production Manager)
QA FINAL DECISSION
MAIN CAUSE - EXT - Mis-adjustmentQA OFFICER DECISSION
1
Product Quality Confirmation
SYMPTOM- JAMMEDFAILURE- BrokenMAIN PART CAUSING THE PROBLEM
235-22-11850Shaft
PT UNITED TRACTORS Tbk
REPORT NO. COMPONENT MODEL FINAL DRIVE ( 235-22-00131)REPORT DATE 7 OKTOBER 2013 ENGINE NUMBER KX-N211142811BRANCH SITE BUHUT SMR 20607 ( ACTUAL ) LIFETIME COMPONENT 6085 HMCUSTOMER BUSINESS MINING TROUBLE DATE 7 OKTOBER 2013CUSTOMER NAME PT.PAMA PERSADA NUSANTARA DELIVERY DATE 5 JULI 2012 ( INSTALATION DATE )MACHINE LOCATION BUHUT CORRECTION DATECODE UNIT GR379 CORRECTION SMRMACHINE MODEL GD 825A-2 REPORT BY NICO FEBRI KMACHINE 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