FAILURE ANALYSIS REPORT

Trakindo WO : 3213340 Reported By : Edy Putranto

Original WO : Reported Date : 14 january 2013

Checked by
Approved by
Foreman / : Sukarno :
Service Head
Supervisor

(Name and Signature) (Name and Signature)

SIMS Information
DEALER EQUIPMENT CUSTOMER
CODE J218 NUMBER D603 NAME PT. KPUC
TECHNICIAN EQUIPMENT
01 / 10 / 13
DATE IDENTIFICATION H861 LOCATION SEPARI
Mo / da / yr
CATERPILLAR CATERPILLAR INSTRUCTION
MODEL D6R SERIAL No S6X00285
HOURS 5523 KILOMETERS FINAL DRIVE LH FAILURE
PART NUMBER PART NAME QTY DESC,* GROUP NUMBER GROUP NAME DID THIS INCIDENT DESCRIPTIVE COMMENTS (20
RESPONSIBLE CODE CONTAINING MAKE THE PRODUCT SPACES MAXIMUM PER
PART INOPERABLE INCIDENT)
343-6237 bearing 1 26 260-6650 Drive gp Yes No Lack of lubrication
V
final
Yes No
Yes No
DESCRIPTION CODES * A – Structural C – Leaks E – System Malfunction G – General Repair K - Serviceability X – Operator
(Refer SIMS Guidelines : B – Surface D – Factory Assembly F – Factory Shipping H – Adjustment N - Abuse Complaint
SEBD0850)

Component Information
Component Description : FINAL DRIVE PCR Schedule Hrs : CompTarget hrs (ex 12000)
Comp Serial No / ID : Comp Hours : 5523 Current hrs failed (ex 8000)
Comp Arr / Gp No : 260-6650 Life Remaining : Remain of target life (4000)
Mach Hrs Install : SINCE NEW Comp New Price :
Mach Hrs Removed : 5523 Cost To Repair : (ex $ 10000 )
Date Comp Installed : SINCE NEW Cost/Hr Remaining : (10000 / 4000 = 2.5 $ /hr)
Date Comp Failed : 31/12/12
Supporting Documentation Required
# Description Y/N Comments
1 Installation Check List N
2 Repair & Maintenance History N
3 SOS History N No Final drives SOS history found for this machine
4 Magnetic Plug Inspections Y Found to many metal particle on it.
5 ET/VIMS Data N
6 TPMS / Payload Data N
7 Performance Test Data N
8 Others N

Failure Outline: Brief outline of what the Customer reported.

Customer report that 260-6650 LH final drive have noisy during machine operation.
Found gears and bearing particle during cover shaft removed.

Bagian dari / Part of : TSD.TEC.SOP.001.R00 1 of 9 Form Number : PSDV.SVTC.FRM.001.R00

 FAILURE ANALYSIS REPORT

Background / Research: Include all observations made during your Failure Analysis investigation including good and bad.
D6R serial number S6X00285 was deliveried at January 11, 2012 and operated for dozing aplication at coal
stock pile on PT. KPUC separi. After operation for 5523 hrs , customer report that LH Final drive have unusual
noisy.
After inspection by technician found road sign :
- Too many metal particle on magnetig plug.
- Final drive oil were contaminated ( change in colour due to contaminant ).
- Final drive oil very low level ( oil quantity only est. 2 liter , OMM require 13,5 liter ).
- Found roller bearing and metal particle at final drive shaft cover during remove the cover.
- 3W6551 Axle shaft was broken on teeth gear.
- 9G9180 hub sprocket was heavy scratch and crack.
- 3 pcs 9G8638 gear planetary were broken in teeth.
- 1 pcs 156-4593 bearing that failure , roller and race was separated.
- 3 pcs 333-9410 shaft of planetary gears have abrasive wear.
- 9G9175 carrier have scratch at one of pin bore.
- 335-6121 ring gear broken on ring.
- 8E2748 hub – reaction broken on teeth.
- 6Y0859 duo cone seal were abrasive wear on rotating plate seal face.
- 260-6642 spindle have heavy abrasive wear on shaft bore.

OBSERVATION
Part Number -Name – Modifier Code To Help Explain Progression/Stage of Failure, Use – Notes
(RH/LH/Upper/Lower etc) /Photos/Parts Book Illustration.
Identify Type, Amount, Location of Wear, Deposits,
Damage, Fractures etc.

Shown D6R with machine code D603.

Shown machine information

Serial number : S6X00285 with 5523 hours of
operation

Bagian dari / Part of : TSD.TEC.SOP.001.R00 2 of 9 Form Number : PSDV.SVTC.FRM.001.R00

 FAILURE ANALYSIS REPORT

Shown LH final drive during inspection ,

Found too many metal particle on magnetig plug.

Shown final drive oil were contaminated ( change in

colour )

Found Very low level ( oil quantity only est. 2 liter ,

OMM require 13,5 liter )

Combination of poor quality of oil ( contaminated )

and low oil quantity can causing lack of lubrication to
the bearings and the other parts at the final drive.

Shown bearing roller that separated from race and

causing catrastopic failure to the other parts .

Just found during cover for axle shaft removed.

Shown 3W6551 axle shaft that removed from final

drive.
Found gear broken on teeth.
Result of scrushing metal particle during operation.

Bagian dari / Part of : TSD.TEC.SOP.001.R00 3 of 9 Form Number : PSDV.SVTC.FRM.001.R00

 FAILURE ANALYSIS REPORT

Shown 3 pcs 9G8638 gear planetary were broken in

teeth.
Result of crushing metal particle during operation.

This picture taken when final drive still fitted on

machine.

Shown 260-6650 final drive gp LH when receiving at

PTTU Workshop.

Shown 9G9175 carrier and planetary gear set during

dismantle.
Found 9G8638 gears were broken in teeth.

Bagian dari / Part of : TSD.TEC.SOP.001.R00 4 of 9 Form Number : PSDV.SVTC.FRM.001.R00

 FAILURE ANALYSIS REPORT

Shown 156-4593 bearing that failure , roller and race

was separated due to excessive abrasive wear

Roller bearing that have lack of lubrication will direct

metal to metal contact to the shaft .

Continous abrasive two body contact will causing

contact stress fatigue and lead to pitting and spalling
to the bearings and the shaft. Finally , bearing will
damage , roller come out from race and causing
damage to the other parts.

Shown 333-9410 shaft of planetary gears.

1 pcs have heavy abrasive wear result of contact with
metal particle / damage bearing.

Bagian dari / Part of : TSD.TEC.SOP.001.R00 5 of 9 Form Number : PSDV.SVTC.FRM.001.R00

 FAILURE ANALYSIS REPORT

Shown 9G9175 carrier after dismantle , found heavy

scratch and broken on pin bore area.
Result of abrasive friction during operation.

Shown 335-6121 gear ring during dismantle.

Found broken and too many metal particle trapped .
Also shown contaminated oil that change in colour.

Shown 335-6121 gear - ring and 8E2748 hub –

reaction after removed from hub sprocket and spindle.

Found :
335-6121 gear broken on ring and
8E2748 hub – reaction broken on teeth due to
improper contact with ring gear that broken.

Bagian dari / Part of : TSD.TEC.SOP.001.R00 6 of 9 Form Number : PSDV.SVTC.FRM.001.R00

 FAILURE ANALYSIS REPORT

Shown 9G9180 hub sprocket after dismatle , found to

many metal particle arround it.

Heavy abrasive wear result of contaminat that

entering at area between hub and ring gear.
It also causing dent until crack at hub too.

Shown 6Y0859 duo cone seal

Abrasive wear on rotating plate seal face
Caused by oil that contaminated by wear particle .

Shown 260-6642 spindle after dismantle .

Found :
269-4739 seal lip type damage due to unsteady shaft
and metal particle that entering lip seal area.
260-6642 spindle have heavy abrasive wear on shaft
bore. Its possible due to contact with unsteady shaft
and metal particle.

Bagian dari / Part of : TSD.TEC.SOP.001.R00 7 of 9 Form Number : PSDV.SVTC.FRM.001.R00

 FAILURE ANALYSIS REPORT

Conclusions (What Caused the Failure): Describe the root cause and the sequence of events that caused it.

Contaminated oil causing degradation of oil quality and viscosity that causing lubrication function are not
effective to final drive parts. These also causing shortened parts life time due to excessive wear.
Wear particle from final drive parts will more contaminated the oil and causing abrassive wears.

As the machine still continue to operation with this condition , duo cone seal become leak due to abrasive
wear . Final drive oil come out trough duo cone seal but machine still operated by operator. Operation with low
oil quantity will causing lack of lubrication to the bearings and the other parts at the final drive.

Roller bearing that have lack of lubrication will direct metal to metal contact to the shaft ( two body contact ).
Continous abrasive two body contact will causing contact stress fatigue and lead to pitting and spalling to the
bearings and the shaft. Finally , bearing will damage , roller come out from race and causing damage to the
other parts.

Metal particle also make make catastrophic failure to the other final drive parts during machine operation .
Note :
- Final Drive oil get contaminant probably come from refill oil .
- There are fender at upper of final drive and hign level final drive position that protect final drive from water or
other contaminant .

Warranty Decision or Recommendation: Please mark X in only one box below.

Not warranty : X Warranty Accepted : ASA Claim* :

Comments:
*) Application Severity Analysis
Solution to Prevent Reoccurrence:
Maintenance :
- Maintain oil on corect level before operate the machine.
- Use only recomented oil to the final drive , make sure recheck the oil are free from contaminant before fill it.
- Routine take oil sample and sent to SOS lab for monitor oil condition.
- Perform SOS lab recomendation as soon as possible when found SOS result at “ C “ rating.
- This heavy failure should not happen if continous SOS sample send and recomendation by lab performed.

Operation :
- Avoid to move transmission gear at opposite direction before machine complete stop.
( example: don’t shift trans lever to reverse when machine move forward . It will give shock load to the gears )
Bagian dari / Part of : TSD.TEC.SOP.001.R00 8 of 9 Form Number : PSDV.SVTC.FRM.001.R00
 FAILURE ANALYSIS REPORT
Check SIS for Service Letters and Service Magazines related to this failure. AMT history, MIM’s history, Oil sample results,
please attach supporting documents below.

Attachment :
SOS history – no final drive oil history record on data base.

Bagian dari / Part of : TSD.TEC.SOP.001.R00 9 of 9 Form Number : PSDV.SVTC.FRM.001.R00