Component Failure Analysis Report

Dealer Name / Location Gainwell commosales pvt.ltd. / Jharsuguda

SBU Construction Solution
Reported by Soubhagya Behera /7898
Nature of Complaint DEF not Consuming

Affected Component with component Serial. Nos. DEF Pump assy

Customer’s Name / Location M/s PL Enterprises / Kammanda

Machine Serial. Number. LZ400895
Engine Model & Sl. No NGHM111030
All fields
Date of Commissioning & Hours 28/10/2022 & 4 Hours Mandatory
Failure Date /Hours 03/04/2023 & 1262 hours
Failure Component 628-0226 / 627-6887 Those not
Part Number / Group Number applicaible mark as
'NA'
Machine utilization per day/ GET Life if any 9 HRS

Attachment Type & Size

Loader bucket
(Bucket/Rock/breaker/Crusher/ Drilling, etc)
Attachment Operating Hours 1262 Hours
Machine Application Loading Operation at Iron Plant
Handling Material
(Blue metal/Soil/Clay/Lime stone/Coal/fertilizer, etc Iron
with density)

*to be in bullets/point.
1 Engine RPM not Increase
2
Customer Complaint
3
4
Attend the Machine at customer site as per complain RPM not increase and DEF
not consuming.

01 - Checked fault code through scanning tools found - P20E600 - UDS Air pressure
system(APC) - Compressed Air Piping Crack.

02- Chcek air Pressure in air tank found 0.85 Mpa . Visually checked no Leakge
found.

03 - Clean the Def tank, Replaced new Def and Def tank filter.

04 - Replaced the Def air filter.

05 - Removed all Air, Urea pipe and Nozzle .Clean all by hot water.

06 - Clean the Def pump and Air Regular assy.

07 - Checked Air Pressure sensor 1 & 3 pin found 56 Ohm.

Observations & Analysis (include media number/ SMCS code) 08 - Checked Air Pressure sensor wiring side found 1 & 3 pin 5 volt power supply.

09 - Chceked With soap water found air Leakage in Air tank adopter.So replaced
the pipe and L adopter. Add rows according
to the need
10 - Then found air Leakage in Air filter out pipe.

11 - Suspecting any restriction in Air regulator system,may be due to back pressure

air Leakage.

2
3
1. Advice the customer to do not run the machine if DEF not consuming.

Recommended Action
2
3
1. Needs replace the DEF pump assy and related hose.Taken required photos and
data for Warranty claim process.
Action Taken to resolve issue
2
3

Caterpillar: Confidential Green

#
 Previous Failure Information

Part Number Part Hours Date Of Failure Observation

Maintenance Information
Unit History
Event Commissioning PM1 PM2
Date 28-10-2022 9/1/2023
Hours 04 Hrs 500
Any Observation (leak, crack etc) NO No

Unit History
Event PM3 PM5
Date 4/3/2023
Hours 1,021
Any observation (leak, crack etc) No

Caterpillar: Confidential Green

#
 Observations from Machine Level
Machines Serial Number
Observations: Machine SL No - LZ400895

Mandatory
Image

Hour Meter
Observations: HMR - 1262 Hours and Air Pressure 0.85 Mpa

Mandatory

Entire Machine Image (to have bucket & bucket tips should be seen)
Observations: Overall Machine

Mandatory
Image

Caterpillar: Confidential Green

#
 Quarry/Mine/ Road Construction/Application Image (If Quarry capture the boulder size excavator
handles & tip life) (Loader density and type of loading-V type or long distance)
Observations: Iron Plant

Mandatory

Image

Application Image-2 (Machine Handling the material) (if machine under breakdown attach any other
machine working image)
Observations: Machine Loading Operation

Mandatory

Image

Image of the monitor- Any active events/codes (for UC travel motor hrs)
Observations: Fault Code - P20E600

Mandatory
Image

Caterpillar: Confidential Green

#
 Failure Component Part Number - SIS Image mark up
Observations: Pump Assy

Caterpillar: Confidential Green

#
 Close up image of the component from machine level
Observations: Location Of Failure Component

Mandatory
Image

Analysis of the failure: Title:

Observations: Air Leakage From Air hose/adopter

Mandatory

1.Performance
related – Provide spec
with Actual

2.Electrical related –
Explain with circuits
3. Component related
– Explain with Root
cause

Analysis of the failure: Title:

Observations: Air Pressure sensor Resistance 56 ohm

Mandatory

1.Performance
related – Provide spec
with Actual

Image
2.Electrical related –
Explain with circuits
3. Component related
– Explain with Root
cause

Caterpillar: Confidential Green

#
 Analysis of the failure: Title:
Observations: Air Sensor Wire harness Voltage 4.99 V (5 Volt)

Mandatory
1.Performance
related – Provide spec
with Actual

Image
2.Electrical related –
Explain with circuits

3. Component related
– Explain with Root
cause

Analysis of the failure: Title:

Observations: Indicating Failure Component

Mandatory
1.Performance
related – Provide spec
with Actual

Image
2.Electrical related –
Explain with circuits

3. Component related
– Explain with Root
cause

Analysis of the failure: Title:

Observations: Overall Failure Component

Mandatory
1.Performance
related – Provide spec
with Actual

Image
2.Electrical related –
Explain with circuits

3. Component related
– Explain with Root
cause

Conclusion from findings

Checked Air Leakge from Air tank Outlet,Replaced the hose and Adopter then air leakge from another adopter.
Supecting Air Regulator Valve not working so that due to back pressure air Leakage.

Customer voice
1. Replaced Required item under warranty & Onroad the machine ASAP.
2
3
4
Kind Note
Performance related problem – Provide the spec with the Actual,
Electrical related problems – Explain with the circuits,
UC failure - attach PSR report/ travel motor hours
Front linkage/ stick/ H link- Measure Clearance at all 4 PT joints
Component related failure – Explain with the Root cause,

Caterpillar: Confidential Green

#
 SLNO Part No. Qty Part Name Group No.
1 628-0226 1 PUMP AS 627-6887
2 616-6762 2 ADAPTER 627-6887
3 628-0207 1 HOSE 627-6887

# Caterpillar: Confidential Green

 Group Name Cost Price Sale Price
TANK GP - DIESEL EXHAUST FLUID 73,138.00
TANK GP - DIESEL EXHAUST FLUID 840.00
TANK GP - DIESEL EXHAUST FLUID 1,073.00

# Caterpillar: Confidential Green

# Caterpillar: Confidential Green