HD785-7

UNIT

2007-04

MONTH

7050

SN UNIT

1112

HM UNIT

6-Feb-07

DELEVERY

20-Apr-07

TROUBLE

A Frame bengkok

DESCRIPTION

PAMA

CUST

ADR

COMP
P/N
FRAME/DUMP
BODY
561-40-81121

HD785-7

2007-11

7225

164

11/28/07

12/10/07

AC HOT

PAMA

BTG

AC

561-07-81141

HD785-7

2007-12

7163

166

09/24/07

AC HOT/ BLOWER MOTOR SHORT

PTI

SGT

AC

ANTKS-B210A0

HD785-7

2007-12

7171

344

09/24/07

10/29/07

AC HOT/ BLOWER MOTOR SHORT

PTI

SGT

AC

561-07-81121

HD785-7

2007-02

7032

306

4-Jan-07

5-Feb-07

ASR malfunction

PAMA

Bkj

Final Drive

HD785-7

2007-02

7007

455

4-Dec-06

20-Jan-07

ASR malfunction

PAMA

BKJ

Final Drive

HD785-7

2007-02

7033

325

4-Jan-07

7-Feb-07

ASR malfunction

PAMA

BKJ

Final Drive

HD785-7

2007-02

7007

1005

4-Dec-06

14-Feb-07

ASR malfunction

PAMA

BKJ

Final Drive

HD785-7

2007-02

7007

1044

4-Dec-06

12-Feb-07

ASR malfunction

BKJ

Final Drive

HD785-7

2007-02

7006

1032

4-Dec-06

12-Feb-07

ASR malfunction

PAMA

BKJ

Final Drive

HD785-7

2007-04

7085

486

20-Mar-07

20-Apr-07

ASR PROBLEM 3 UNIT

PAMA

KCMB

Final Drive

HD785-7

2007-07

7031

2764

07/04/07

B@BAZG ENGINE OIL PRESSURE DROP

pAMA

HD785-7

2007-10

7059

3875

10/15/07

B@BAZG ENGINE OIL PRESSURE DROP

pAMA

HD785-7

2007-11

7058

4350

02/10/07

11/12/07

B@BAZG ENGINE OIL PRESSURE DROP

PAMA

BTG

ENGINE

HD785-7

2007-04

7055

26-Apr-07

Blow by high

PAMA

BTG

ENGINE

HD785-7

2007-04

7022

26-Apr-07

26-Apr-07

Blow by high

PAMA

BTG

ENGINE

HD785-7

2007-04

7023

26-Apr-07

Blow by high

PAMA

BTG

ENGINE

HD785-7

2007-04

7054

26-Apr-07

HD785-7

2007-02

7032

HD785-7

2007-02

7018

602

16-Dec-06

12-Feb-07

Brake oil leak fr fill switc

PAMA

JMBY

Brake

HD785-7

2007-11

7008

5533

12/04/06

11/24/07

BUSHING IDLER GEAR BROKEN

PAMA

BKJ

ENGINE

HD785-7

2007-11

7034

3721

11/16/07

BUSHING IDLER GEAR BROKEN

PAMA

RANTAU

ENGINE

6212-31-6130

HD785-7

2007-01

7002

2376

16-Aug-06

6-Jan-07

Busser on DX11MA BK

SIMS

ADR

Brake

Rear brake sel propotional

HD785-7

2007-11

7114

05/21/07

05/21/07

11/07/07

CHARGING SYSTEM ABNORMAL

PAMA

BTG

ENGINE

600-825-9330

HD785-7

2007-04

7019

Coolanr radiator crack by core

PAMA

BTG

ENGINE

HD785-7

2007-04

7019

Coolanr radiator crack by core

PAMA

BTG

ENGINE

HD785-7

2007-04

7008

1751

4-Dec-06

4-Apr-06

Coolanr radiator crack by core

PAMA

BKJ

ENGINE

561-03-81630

HD785-7

2007-08

7105

1011

05/21/07

07/29/07

Coolant leak by gasket

PAMA

BKJ

ENGINE

426-03-37380

HD785-7

2007-11

7021

5126

01/02/07

11/13/07

COOLANT LEVEL LOW

PAMA

BTG

ENGINE

HD785-7

2007-03

7062

COOLANT LOW LEVEL

PAMA

ADARO

ENGINE

HD785-7

2007-07

7007

3358

4-Dec-06

1-Jul-07

COOLANT LOW LEVEL BY CORE

PAMA

BKJ

ENGINE

HD785-7

2007-08

7003

4215

12/04/06

08/22/07

COOLANT LOW LEVEL BY CORE

pAMA

BKJ

ENGINE

561-03-81650

HD785-7

2007-08

7101

1737

04/17/07

08/12/07

COOLANT MIX OIL ENGINE

PAMA

BTG

ENGINE

6211-22-2220

HD785-7

2007-02

7006

810

4-Dec-06

28-Jan-07

HD785-7

2007-02

7008

1047

4-Dec-06

11-Feb-07

HD785-7

2007-04

7019

2600

HD785-7

2007-05

7008

HD785-7

2007-05

7007

2687

4-Dec-06

24-May-07

HD785-7

2007-02

7007

455

4-Dec-06

20-Jan-07

HD785-7

2007-05

7038

1752

6-Feb-07

HD785-7

2007-07

7102

497

HD785-7

2000-07

7076

2063

21-Feb-07

HD785-7

2007-06

7127

177

15-May-07

HD785-7

2000-07

7031

2709

4-Jan-07

HD785-7

2007-01

7008

455

4-Dec-06

HD785-7

2007-02

7030

HD785-7

2007-06

VARIOUS 1900

HD785-7

2007-01

7018

HD785-7

2007-04

7033

HD785-7

2007-04

7031

1428

4-Jan-07

HD785-7

2007-04

7030

997

4-Jan-07

HD785-7

2007-02

7033

HD785-7

2007-07

7103

1070

HD785-7

2007-11

7062

4263

HD785-7

2007-08

7101

1737

HD785-7

2007-12

7127

3105

HD785-7

2007-12

7127

3105

HD785-7

2007-07

7103

511

HD785-7

2007-07

7103

HD785-7

2007-04

HD785-7

2007-06

PAMA

BRANCH

ENGINE

Blow by high

PAMA

BTG

ENGINE

PAMA

BKJ

Brake

6-Dec-06

Premature failure yang diakibatkan rusaknya resistor sehingga motor blower short / switch rusak

6219-51-1000

Ditemukan problem oil pressure droop yang disebabkan oil pump problem, dari komatsu kemudian
mengeluarkan FC7064 untuk penggantian oil pump pada semua unit
Pada unit ini pembacaan hasil VHMS untuk blow by engine tidak sama jika dibandingkan dengan
check measurement manual, dari VHMS system pembacaan /konfersinya belum akurat

6212-13-6130

561-03-81630
561-03-81630

Terdapat problem pada brake system sehingga oil final drive bercampur dengan oil brake
Terdapat problem pada spool brake karena oil brake kotor sehingga spool jamed
Pada saat pelaksanaan penggantian oil pump engine ( membuka front cover engine) bushing idler
gear diketahui sudah patah
Terdapat problem pada brake system sehinnga spool jamed
Alternator tidak recharger karena kerusakan pada dioda

Fenomena awal pada HD785-7 adalah sering terjadi kebocoran pada core radiator, dari hasil
analisa KOMATSU-bahwa terjadi kesalahan pada penggunaan coolant di beberapa site.Kemudian
Komatsu mengeluarkan /jualan coolant untuk HD785-7 dengan model radiator yang berbeda
dengan HD785-5 .Untuk core radiator pada HD785-7 menggunakan bahan alluminium jika
diguinakan coolant yang tidak spec akan berakibat capitasi pada alluminium tersebut, dengan
digunakannya SUPER COOLANT AF-NAC sudah dipastikan akan memperpanjang umur core
radiator yang saat ini akan di promosikan untuk penggunaan 5000 jam operasi .Karena informasi
untuk SUPERCOOLANT AF-NAC akan bertahan sampai 4000 jam operasi tanpa penambahan
coolant jenis lain. (sesuai informasi yang sudah ada bahwa supercoolant ini sudah dimix oleh
factory jepang di Indonesia tinggal pakai saja sehingga mengenai harga cukup mahal )

BKJ

ENGINE

Coolant radiator leak by core

PAMA

BKJ

ENGINE

Coolant radiator leak by core

PAMA

BTG

ENGINE

Coolant radiator leak by core

PAMA

BKJ

ENGINE

Cover cyl head leak

PAMA

BKJ

ENGINE

26-May-07

COVER SPINDLE / FRONT AXLE LEAK

PAMA

ADR

Axle

5-Jun-07

DiFF CHIPING

PAMA

BKJ

DIFFERENTIAL

3-Jul-07

DIFF CHIPING

PAMA

ADR

6-Jul-07

DiFF CHIPING

BUMA

JMBY

DIFFERENTIAL
DIFFERENTIA
L
07012-50150

27-Jun-07

DiFF CHIPING

PAMA

BKJ

DIFFERENTIAL561-22-71222

9-Jan-07

Drop coolant

SIMS

BKJ

Dump body crack

PAMA

BKJ

ENGINE
Dump body &
frame

13-Jul-07

Dump body / VESSEL CRACK

PAMA

KCMB

Dump body & frame

7034,7078,7085,7086,70.87,7090,7091,7092,7093.7095

20-Dec-06

Dump body cannot rise

SIMS

JMBY

Dump body crac

PAMA

BKJ

14-Apr-07

Dump body crac

PAMA

BKJ

18-Mar-07

Dump body crac

PAMA

BKJ

PAMA

BKJ

Hydroulik
Dump body &
frame
Dump body &
frame
Dump body &
frame
Dump body &
frame

Coolant radiator leak by core

PAMA

ENGINE

Coolant radiator leak by core

28

Salah penempatam jack/alat angkat

Error pada ASR system yang diakibatkan karena sensor pada speed sensor untuk ASR
adjustingnya berubah posisi ( keasundul gear), tetapi setelah reposisi dengan membuka tyre
terlebih dahulu dan dilakukan adjusting sampai saat ini tidak ada timbul error lagi

ENGINE

Brake applied at ASR switch ON

Remarks

Dump body crack

561-03-81630

Cylinder crack karena proses pembuatan cyl head by factory

Cover spindle leak oleh karena oring -seal yang rusak
Dari bebrapa site sudah ada yang dilakukan penggantian differential news,seperti pada HD785-5
ditemukan chiping pada saat pengambilan oil sample, gram merekat pada drain plug, untuk
penyebabnya masih dalam proses investigasi factory
Coolant leak from gasket

Nut lock lever missing

4-Jan-07

7-Feb-07
17-Jul-07

Engie low power

PAMA

ADR

ENGINE

03/04/07

11/28/07

ENGINE ABNORMAL NOISE

PAMA

ADARO

ENGINE

08/12/07

ENGINE BLOW BY HIGH

PAMA

BTG

ENGINE

05/24/07

12/18/07

ENGINE CANNOT RUNNING

PAMA

JMBY

ENGINE

600-464-1270

05/24/07

12/18/07

ENGINE CANNOT START

PAMA

JMBY

ENGINE

600-464-1270

7-May-07

5-Jun-07

ENGINE LOW POWER

PAMA

ADR

ENGINE

6219-11-3100

730

7-May-07

24-Jun-07

ENGINE LOW POWER

PAMA

ADR

ENGINE

6219-11-3100

7036

9050

6-Feb-07

14-Apr-07

Engine low power by

PAMA

ADR

ENGINE

561-02-82151

7102

497

5-Jul-07

6-May-07

Engine low power, staal speed not std

BUMA

ADR

ENGINE

6219-11-3100

6210-41-5620

Pada dump body/ vessel terdapat banyak crack dari hasil analisa team UTE terjadi error proses
welded sehingga hasil welded tidak sempurna. Dimungkinkan karena proses orderan vessel /
dump body yang banyak dan factor manpower yang kecapaian.Tema UTE juga sudah
melaksankan improoved pada unit unit yang crack

HD785-7

2007-07

7031

HD785-7

2007-12

7063

HD785-7

2007-03

7009

HD785-7

2007-12

HD785-7

Engine oil pressure drop

PAMA

BKJ

What

Engine vibration bolt damper broken

PAMA

ADARO

ENGINE

Error 01 (DHT5KX)T/C lock up

PAMA

JMBY

tRANSMISSI

Exhaust manifold crack

PAMA

BKJ

ENGINE

6215-11-5181

11/29/07

Exhaust manifold crack

PAMA

BKJ

ENGINE

6215-11-5181

12/04/06

11/25/07

Exhaust manifold crack

PAMA

BKJ

ENGINE

6215-11-5181

12/04/06

11/24/07

Exhaust manifold crack

PAMA

BKJ

ENGINE

4523

03/04/07

12/06/07

7007

5996

12/04/06

12/14/07

2007-11

7006

5515

12/04/06

HD785-7

2007-11

7008

5533

HD785-7

2007-11

7033

5288

Exhust muffler leak by cyl head crak

PAMA

BTG

ENGINE

FOUND MATERIAL ON FILTER

PAMA

BKJ

ENGINE

HD785-7

2007-04

7020

HD785-7

2007-12

7029

5515

01/04/06

HD785-7

2007-06

7005

2423

11-Jan-06

16-Nov-06

Front suspensi leak

BUMA

JMBY

suspensi

HD785-7

2007-11

7007

5549

12/04/06

11/04/07

FUEL SUPPLY PUMP PROBLEM

PAMA

BKJ

ENGINE

HD785-7

2007-10

7095

2771

09/28/07

Fuel tank menggelembung

PAMA

RANTAU

Ffuel tank

12/15/07

6162-33-5321

6215-11-5181
6219-71-1120
6219-71-1120

HD785-7

2007-02

7008

1025

4-Dec-06

9-Feb-07

Hoist dump problem

PAMA

BKJ

hydroulik

HD785-7

2007-09

7006

4488

12/04/06

09/09/07

HUB DRUM FOR STUD TYRE WORN OUT

PAMA

ADR

TYre

HD785-7

2007-02

7032

415

4-Jan-07

14-Feb-07

Hydroulik tanl leak/crack

PAMA

BKJ

HYdroulik

HD785-7

2007-04

7025

Injector replaced

PAMA

BTG

ENGINE

HD785-7

2007-12

7076

4718

Lever combination switch broken

PAMA

ADARO

Cabin

56B-06-16710

HD785-7

2007-01

7010

78

13-Dec-06

25-Dec-06

Monitor panel prob

SIMS

JMBY

Cabin

Settingan

HD785-7

2007-02

7017

583

16-Dec-06

13-Feb-07

Oil leak from hoist cyl

PAMA

JMBY

hydroulik

HD785-7

2007-02

7017

583

16-Dec-06

13-Feb-07

Oil leak from hoist cyl

PAMA

JMBY

hydroulik

HD785-7

2007-08

7031

3232

01/04/07

08/12/07

OIL LEAK FROM LINE FILTER

PAMA

BKJ

Hydroulik

07001-02090

HD785-7

2000-07

7029

2803

4-Jan-07

2-Jul-07

OPERATOR SEAT MALFUNCTION

PAMA

BKJ

Cabin

AS160438

ADR

Brake

12/05/07

HD785-7

2007-03

7062

HD785-7

2007-11

7032

5046

12/04/06

11/22/07

PARTICAL MATERIAL FOUND ON FILTER ENG PAMA

BKJ

ENGINE

HD785-7

2007-11

7006

5515

12/04/06

11/29/07

PRESSURE SWITCH EMERGENCY STEERING PAMA

BKJ

Steering

HD785-7

2007-10

7180

62

09/29/07

Sensor intake temperature

PAMA

Bendili

ENGINE

HD785-7

2007-12

7114

Park brake on at travel

3285

05/21/06

HD785-7

2007-009 7173

19

09/24/07

HD785-7

2007-12

DT3204

4008

HD785-7

2007-05

HD785-7

2007-12

HD785-7
HD785-7
HD785-7

12/03/07

PAMA

ENGINE

421-06-35111

SENSOR TEMP SHORT

PAMA

09/11/07

SHORT CIRCUIT ENGINE RH BANK

PTI

BALIKPAPAN

HARNESS ENGINE
6219-81-8820

12/16/07

STEERING CYL LEAK

PAMA

RANTAU

Steering

VARIOUS 351

15-May-07

STEERING CYL LEAK

PAMA

BTG

Steering

DT3198

4271

12/16/07

STEERING CYL LEAK

PAMA

RANTAU

Steering

2007-07

7100

339

STEERING CYL LEAK

PAMA

BTG

Steering

2007-12

DT3203

3899

12/16/07

STEERING CYL LEAK

PAMA

RANTAU

Steering

2007-09

7092

2307

03/26/07

09/12/07

STEERING CYL LEAK

PAMA

RANTAU

Steering

HD785-7

2007-09

7078

2761

03/26/07

09/12/07

STEERING CYL LEAK

PAMA

RANTAU

Steering

HD785-7

2007-12

DT3168

4293

12/16/07

STEERING CYL LEAK

PAMA

RANTAU

Steering

HD785-7

2007-09

7086

2767

03/26/07

09/12/07

STEERING CYL LEAK

PAMA

RANTAU

Steering

HD785-7

2007-09

7093

2777

03/26/07

09/06/07

STEERING CYL LEAK

PAMA

RANTAU

HD785-7

2007-09

7095

2464

03/26/07

09/12/07

STEERING CYL LEAK

PAMA

RANTAU

Steering

HD785-7

2007-12

DT3197

4308

12/16/07

STEERING CYL LEAK

PAMA

RANTAU

Steering

HD785-7

2007-03

7002

HD785-7

2007-03

7063

7861-93-3320

HD985-5

2007-08

1084

7980

04/12/07

HD785-7

2007-12

7186

1073

09/21/07

HD785-7

2007-11

7085

4004

HD785-7

2007-10

7055

4207

HD785-7

2007-01

7028

32

2-Jan-07

9-Jan-07

Tie rod terlalu panjang

SIMS

BTG

HD785-7

2007-04

7086

331

16-Mar-07

17-Apr-07

Torqconverter leak

PAMA

KCMB

HD785-7

2007-01

7007

35

9-Dec-06

12-Dec-06

TRANS ERROR 03

BKJ

DIFFERENTIA
L

Banyak ditemukan nya leakage pada steering cylinder RH ataupun LH posisi, dan sudah dilakukan
investigataed oleh komatsu yang hasilnya adalah akan dilakukan improved pada seal kitnya.
Karena dari beberapa steering cylindernya mengalami leakage pada hm yang rendah ( sekitar
4000 an)

Steering

Steering valve leak

PAMA

ADARO

Steering

Steering valve leak

PAMA

ADR

Steering

08/01/07

SUSPENSI TIDAK SMOOTH / KERAS

INCO

SRK

Suspensi

12/06/07

AC switc malfunction

PAMA

Jembayan

AC

561-07-81141

11/26/07

THRUST WASHER IDLER GEAR WORN OUT

PAMA

RANTAU

ENGINE

6215-31-6131

10/31/07

THRUST WASHER IDLER GEAR WORN OUT

ENGINE

6215-31-6131

Steering

Tie rod

tRANSMISSI

07012-50125

16-Aug-06

02/10/07

BKJ

561-22-72713

PAMA

SIMS

BTG

HD785-7

2007-04

7092

10

24-Mar-07

24-Mar-07

Transmissi shift lever balik sendiri

PAMA

KCMB

tRANSMISSI

714-23-15620

HD785-7

2007-11

7031

4784

01/04/07

11/21/07

TRUNION ABNORMAL WORN OUT

PAMA

BKJ

TRANSMISSI

561-16-82111

HD785-7

2007-12

7224

56

11/12/07

12/15/07

TUBE CRACK

SIS

ADARO

HYdroulik

561-61-81130

HD785-7

2007-12

7007

5996

12/04/06

12/14/07

TUBE CYLINDER HEAD CRACK

PAMA

BKJ

ENGINE

6219-61-6580

HD785-7

2007-11

7029

5031

01/04/07

11/14/07

TURBOcharger CRACK

PAMA

BKJ

ENGINE

6505-67-5040

HD785-7

2000-07

7104

536

21-May-07

2-Jul-07

WATER LEAK FROM GASKET

PAMA

BKJ

ENGINE

426-03-37380

HD785-7

2007-02

7003

1266

4-Dec-06

21-Feb-07

Water pump leak

PAMA

BKJ

ENGINE

HD785-7

2007-02

7031

5026

4-Jan-07

Water pump leak

PAMA

BKJ

ENGINE

HD785-7

2000-07

7029

3035

4-Jan-07

17-Jul-07

WATER PUMP LEAK COOLANT

PAMA

BKJ

ENGINE

6150-61-1510

HD785-7

2000-07

7003

3284

4-Dec-06

28-Jun-07

WATER PUMP LEAK COOLANT

PAMA

BKJ

ENGINE

6162-63-1515

HD785-7

2007-07

7105

532

21-May-07

1-Jul-07

WATER PUMP LEAK COOLANT

PAMA

BKJ

ENGINE

6162-63-1515

HD785-7

2007-08

7031

3185

01/04/07

08/08/07

Water pump leak oil

PAMA

BKJ

ENGINE

6162-63-1515

HD785-7

2000-07

7031

2981

4-Jan-07

24-Jul-07

PAMA

BKJ

ENGINE

6150-61-1510

HD785-7

2007-03

7033

Water pump oil leak

PAMA

BKJ

HD785-7

2007-07

7102

What

PAMA

18-Feb-07

Water pump leak oil

ENGINE
What

Pada kasus ini ditrmukannya problem adalah saat dilakukan proses replacement oi pimp,saat
dibuka front cover serta oil pan ditemukan pecahan material. Dari hasil analisa pecahan tersebut
adalah pecahan thrust washer idle gear Dari hasil penemuan ini setiap penggantian oli pump
dilakukan juga pngecekan trhust washer pada idler gearnya
Salah assembly factory
Seal torq converter leak

Fenomena yan ada adalah terjadi kerusakan pada bearing water pump