FAILURE ANALYSIS REPORT

Owner: PT DARMA HENWA TBK Project/Site: ACP (Asam Asam Coal Project)
Reported By Achirul Jamhar Date: August, 12th 2023
Equipment Number GR3077 Model: GRADER STG230C-8S - SANY
Serial Number Unit PY5823CB1053 HM Unit: 3547 Hours

Component Information:
Component Description: Drawbar Component P/N: 14055949

Date Component Install New Fitted Date Component Fail August, 11th 2023
Mach Hrs Install New Fitted Mach Hrs Removed 2044 Hours
Component Life/Hrs 3547 Hours Engine Serial Number DL07016132
WO Number - Status of Component Ball Trunion Lift Cylinder RH Fractured
Dealer/Supplier Sany Makmur 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 Y
4 Repair & Maintenance History Y
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 Y

10 Warranty Claim Y

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:
On Thursday, August, 11th 2023 reported that GRADER STG230C-8S - SANY with unit numbered GR3077 had problem with
Ball Trunnion Lift Cylinder RH Fractured. Then our mechanics move the unit to workshop for perform comprehensive
inspection. Details failure will explain below.

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

Inspection result by mechanics found that :
1. Ball Trunnion Lift Cylinder had fatigue fractured
2. Ball Trunnion & Cap surfaces had inclusions
3. Cap Ball Trunnion holes not centered

Root cause of the Failure:

Ball Trunion Lift Cylinder RH of GR3077 had Fatigue fractured due to high stressed reversed bending pressure on the cylinder.
Regarding the comprehensive observation found that there’s product issues, there are Design issues of Cap Ball Trunion Lift
Cylinder. Holes of Cap Ball Trunion Lift Cylinder not centered, there’s different holes position between right and left sides. It made
misalignment between Cap, Bolts, and Ball Trunion within operating unit. This position made Ball Trunion got overload condition
on one sides during Cylinder works. This is proved by there’s adhesive wear on one sides of Ball Trunion. Within operational unit,
this condition will produce pre-crack on Ball Trunion, pre-crack will generated to Fatigue Fractured that proved by there’s beach
marks on surface area of fractured.

Corrective Action Required:

1. Replace with new Ball Trunnion.
2. Need Sany to Inspect and analyze design of Cap Ball Trunnion Lift Cylinder.

Failure Parts:
Part Number Description Component Quantity UoM Remarks
Group
14055949 Ball Trunnion Lift Drawbar Assy 1 EA
Cylinder
Responsibility Job Repair by:
√ Sany Makmur

Darma Henwa

Report Prepare by : Achirul Jamhar Checked by:

Condition Monitoring Maint. Superintendent

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 FAILURE ANALYSIS REPORT

GRADER STG230C-8S – SANY GR3077

Position of Fractured

Position of Ball Trunion Lift Cylinder RH Fractured

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 FAILURE ANALYSIS REPORT

Bolt Nut Cap Ball Trunnion

Cap Ball Trunnion

Ball Trunnion Lift Cylinder

Parts Failure

9.75 mm
8.68 mm

11.13 mm 10.60 mm

14.18 mm
12.41 mm

Hole Not Center Hole Not Center

Cap Ball Trunnion Lift Cylinder

Holes of Cap Ball Trunnion Lift Cylinder not centered. This condition made misalignment condition between Cap, Bolts, and Ball
Stud.

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 FAILURE ANALYSIS REPORT

Details measurement of Holes Cap Ball Trunnion Lift Cylinder RH

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 FAILURE ANALYSIS REPORT

Bolt Nut & Cap Trunnion

Position of Cap Trunnion

Material defect

Fracture

Ball Trunnion

Fracture position of Ball Trunion

Misalignment condition made abnormal contact between Ball and Cap Trunion. The loads that got by Ball Trunnion not distribute well,
only one sides of Ball got overload condition due to misalignment. Ball Trunion also have quality product issues, found any inclusions
on the surface of Ball Trunion.

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 FAILURE ANALYSIS REPORT

Inclusions

Details inclusions of Ball Trunion

The grain boundaries usually contain impurities such as refractory brick or trapped slag left from the refining process. There
impurities are called Inclusions and are usually small enough not to weaken the metal. in fact inclusions are seldom harmful unless
they are too large or in a high stress area.
Inclusions on Metal Structure

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 FAILURE ANALYSIS REPORT
Ball Trunnion Lift Cylinder

Ball Trunion Lift Cylinder had Fatigue Fractured

Pre-crack

Beach Marks

Final Fracture
(Brittle) Final Fracture
(Brittle)

Details of fractured

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 FAILURE ANALYSIS REPORT

Misalignment condition between Cap, Bolts, and Ball Lift Cylinder will produce pre-crack on Ball stud area. Pre-crack that shown on
Ball Stud proved by there’s overload condition on one sides of Ball Stud because its directly contacts with the Cap. Pre-crack will
getting worst within operational unit then the stress generated to fatigue fractured on Ball Stud. Fatigue fractured shown by there’s
beach marks area on surface of fracture. Ball Stud also got high load due to operational, this is indicated from brittle area on surface
of final fracture. This fracture include on high stressed reversed bending characteristics.

High stressed reversed bending

Fatigue Fractured is a type of fracture that caused by the maximum
tensile stress caused by bending force. The characteristics are :
1. There is a beach marks which indicates that there is a
large change of load (direction fatigue crack growth).
2. Surface of fracture are flat and smooth.
3. Surface of fracture more light color than Ductile Fracture.
Brittle Fractured is a type of fracture that caused by the
Shocked load or Impact force. The characteristics are:
1. Found chevron : the direction of Crack growth that leads to
point or an area.
2. Surface of fracture looks bright when expose to light.
3. Rough surface of fracture.

Fatigue & Brittle Fracture Characteristic

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