FAILURE ANALYSIS REPORT

Owner: PT Darma Henwa Tbk Project/Site: Asam-Asam

Reported By Ibnu Fuad Al Hanif Date: 11 Januari 2023
Equipment Number DT2368 Model: HD785
Serial Number Unit 9288 HM Unit: 34075
Component Information:
Component Description: Mounting Rear Support Component S/N: -
Axle RH
Date Component Install - Date Component 11 Januari 2023
Fail/Remove
Mach Hrs Install 0 Mach Hrs Removed 34075
Component Life/Hrs 34075 Part Number causing
Failure
WO Number Status of Component Broken
Dealer/Supplier PT. United Tractor
Document Support Required:

NO DESCRIPTION Y/N COMMENTS

1 Component Installation/Commissioning Report N
component fitted
2 Data Logging Unit (ECM Download Data) Y VHMS data download
3 Photo of component fail & Filter Cut Y
4 Repair & Maintenance History Y 1 week
5 SOS report & Action taken/Feedback N
6 Last Inspection Result Y
7 Performance test Report (PM Clinic, TA2 etc) N
8 Last Component Change Out (CCO) report N
9 PCR Report Y
10 Warranty Claim N
11 Payload data Y VHMS Data Download
12 QA report/ pre start check report N
13 PM service work order sheet before component N
failure (4 period before)
Background:

On January 11th , 2023 05:20 WITA Komatsu unit heavy dump truck HD785 with serial number 9288 and register number
DT2368 was down with RH mounting rear support axle broken (unit life 34075 hours )

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

On inspection result found :

1. Mounting pin support axle broken
2. Abrasive wear on pin surface
3. Bolt failure 1 ea
4. Spacer loose 2 ea

Root cause of the Failure:

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 FAILURE ANALYSIS REPORT

Rear axle is a component that designed to received radial movement to prevent undulation on road surface
while unit is running but at the actual operational condition rear axle is receives tangential and axial movement too.
To support those movement, rear axle need support or we can say Torque Rod. Torque rod is a component that
supported rear axle to receive tangential movement with support by eye rod on pin hold axial movement. Each pin on
torque rod must be lubricated well with grease to prevent adhesive wear on pin and bushing. Moreover, when the
payload unit is overload, bad haul road condition, and operational abuses contribute the tangential and axial load to
raise more high that impacted direct to torque rod. At January 11 th 2023 05:20 AM or 4 hour operation before failure
download data recorded average speed is 22.81 km/hours and maximum speed 67 km/hours.
the bad haul road condition with high operating speed and lack of lubrication condition increasing probability
torque rod receive tangential load exceed allowed standard. That’s condition reduce support part dimension faster
than before or normal operation. The vibration is conducted to bolt lock pin. Bolt lock pin loosed and pin unstable, 1
pin corner out of position from the mounting. RH rear axle load only hold with 1 pin corner. the mounting is broken
due to not able to support differential on those area.

Correction Action Required:

- Check greasing and lubrication on both pins
- Check and tighten bolt pin support axle if found loose or not tight
- Take slowly when unit operated on bad haul road condition to prevent shock load occurred at unit component
- Inspect all rear joint condition and found missing, worn out or damage part (bushing, spacer, boot, etc)
- Inspect suspension regularly to prevent suspension low pressure or leak (make some tool to facilitate inspect
suspension)

 Operator Training  Maintenance Training Equipment Improvement

Failure Parts:
Part Number Description Component Gp Quantity Remarks
Pin Rear Axle Support 1 Worn out
Bushing Rear Axle Support 2 Worn out
Bolt Rear Axle Support 1 Missing
Washer Rear Axle Support 1 Missing
Spacer Rear Axle Support 2 Missing
Bushing Rear Axle Support 1 Damage
Boot Rear Axle Support 2 Damage
O ring Rear Axle Support 2 Missing

Picture 1

RH Rear Axle Support Part Description :

1. Pin
2. Bushing
3. Bolt
4. Washer
5. Spacer
6. Bushing
7. Boot
8. O ring

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 FAILURE ANALYSIS REPORT

Picture 2

Deformation

Brittle

Picture 2 shown location of crack on mounting pin rear axle support. If we look closely on the failure surface, it indicates
that tensile stress has occurred. From failure surface, it shows that the surface looks like crystal and shinning under the
lights and feels rough. So we can conclude that brittle fracture is the result from tensile stress. Tensile stress occured by
the force that come from center pin to outer surface (bushing), material deformation occurred around crack surface and
shock load has occurred repetitively. Shock load obtained from abnormal operating unit on bad haul road condition and
overload hauling. Operating unit with high speed causing high movement on the eye rod rear axle support area that give
high load from shaft pin to mounting pin.

Picture 3

Abrasive wear

Fretting

Smearing

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 FAILURE ANALYSIS REPORT

Picture 3 shown us that adhesive wear has occurred on shaft pin. Adhesive wear occurred due to lack of lubrication
between two contact component (shaft pin and bushing). Adhesive wear is indicated by the presence of smearing marks
(friction) on the contact surface, in this case is shaft pin. Smearing is a discoloration (becomes darker) on the surface of
the material which is experiencing excessive temperature due to the thinness or absence of a lubricant layer, resulting
in 2 pieces of material surface making direct contact. Beside that, fretting also occurred. Fretting damage is induced
under load and in the presence of repeated relative surface motion, as induced for example by vibration.

Picture 4

At Picture 4 we see 5 last trend0 data and 8 pldcyn23 VHMS data recorded . the data shown maximum speed unit
operation start from June 8th 2017 at 1:17 PM until June 9th 2017 at 10:04 PM is 67 km/hours. And the right table we can
see 8 last cycle data before unit down, average speed empty load before unit down is higher than budget or target (20
km/hours). Operating with high speed on the bad haul road condition (report attached) can reduce component life time
due to abnormal load received on the component, in this case is frame and differential component.

Responsibility Job Repair by:

OEM

Dealer

 Darma Henwa

Report Prepare by : Checked by:

Maint. Supervisor Maint. Superintendent

ATTACHMENT DATA SUPPORT

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 FAILURE ANALYSIS REPORT

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 FAILURE ANALYSIS REPORT

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