Job Order : Reported Date :

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

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