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    Failure Analysis Report EX1296 - Final Drive LH Noise

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    putri lestari
    1. The final drive of excavator Ex1296 failed after 9326.6 hours of operation due to premature wear of components caused by misalignment between the pin, bearing, and shaft splines from the previous overhaul. 2. The previous overhaul in March 2022 replaced the bearing and shafts but not the pins, which were already worn, leading to imbalance and increased wear over time. 3. Failure parts included bearings, pins, and shafts that needed replacement, and corrective actions included overhauling the final drive with a complete assembly and proper lubrication.

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    Failure Analysis Report EX1296 - Final Drive LH Noise

    Uploaded by

    putri lestari
    104 views11 pages
    1. The final drive of excavator Ex1296 failed after 9326.6 hours of operation due to premature wear of components caused by misalignment between the pin, bearing, and shaft splines from the previous overhaul. 2. The previous overhaul in March 2022 replaced the bearing and shafts but not the pins, which were already worn, leading to imbalance and increased wear over time. 3. Failure parts included bearings, pins, and shafts that needed replacement, and corrective actions included overhauling the final drive with a complete assembly and proper lubrication.

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    1. The final drive of excavator Ex1296 failed after 9326.6 hours of operation due to premature wear of components caused by misalignment between the pin, bearing, and shaft splines from the previous overhaul. 2. The previous overhaul in March 2022 replaced the bearing and shafts but not the pins, which were already worn, leading to imbalance and increased wear over time. 3. Failure parts included bearings, pins, and shafts that needed replacement, and corrective actions included overhauling the final drive with a complete assembly and proper lubrication.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    104 views11 pages

    Failure Analysis Report EX1296 - Final Drive LH Noise

    Uploaded by

    putri lestari
    1. The final drive of excavator Ex1296 failed after 9326.6 hours of operation due to premature wear of components caused by misalignment between the pin, bearing, and shaft splines from the previous overhaul. 2. The previous overhaul in March 2022 replaced the bearing and shafts but not the pins, which were already worn, leading to imbalance and increased wear over time. 3. Failure parts included bearings, pins, and shafts that needed replacement, and corrective actions included overhauling the final drive with a complete assembly and proper lubrication.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 11

    FAILURE ANALYSIS REPORT

    Owner: PT DARMA HENWA TBK Project/Site: ACP (Asam Asam Coal Project)
    Reported By Muhammad Noval Muzaqi Date: August 14th, 2022
    Equipment Number EX1296 Model: HITACHI ZAXIS370
    Serial Number Unit THEDD1L0V00000510 HM Unit: 9326

    Component Information:
    Component Description: Final Drive LH Component P/N: A810304040017

    Date Component Install March 18rh, 2022 Date Component Fail August 14th, 2022
    Mach Hrs Install 8288.3 Mach Hrs Removed 9326.6
    Component Life/Hrs 1038.3 Engine Serial Number
    WO Number - Status of Component Final Drive Failure
    Dealer/Supplier Hexindo 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 N
    5 SOS report & Action taken/Feedback Y
    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 N

    10 Warranty Claim N

    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)

    DEWA-PM-FORM-33 Halaman 1 dari 11


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT
    Background:
    On Sunday, August 14th, 2022, unit Excavator Hitachi ZAXIS370 with number Ex1296 had problem with Final Drive LH noise. After
    that, the mechanic checks and removes the final drive cover.

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


    1. Shaft spline final drive worn out
    2. Shaft spline travel motor worn out
    3. Needle bearing planatery gear failure
    4. Pin needle bearing planatery gear worn out
    5. Ring gear found misalignment marks

    Root cause of the Failure:


    Final drive LH EX1296 had failure on Bearing Planetary, Pin Bearing Planerary, Shaft Final Drive, Shaft Travel Motor, and
    Housing Final Drive. This failure happened due to misalignment between Pin, Beari ng, and Shaft. Final drive LH EX1296
    had overhauled before on “March 18rh, 2022”. Lifetime of overhauled final drive LH is 1083.3 hours only. Last overhauled
    do with non-standard overhaul part list. Only replace Bearing, Shaft Final Drive & Shaft Travel Mo tor. Pin Bearing that
    contact with Bearing not replaced. Whereas Pin condition at that time is abrasive worn out. When Bearing had replaced
    with new part and Pin Bearing still use old part, during operational unit it would be made unbalance wear both of th em.
    This condition will produce misalignment between them. It proved by there’s misalignment marks on surface of Bearing.
    Effect of misalignment also shown on Ring Gear that have misalignment marks. During operational unit, this condition
    will getting worst then will produce abrasive wear on Shaft Final Drive, Shaft Motor Travel and Housing Final Drive. This
    condition proved by there’s increasing of Aluminium & Silicon on SOS result. Source of metal wear aluminium is from
    Housing Final Drives and Silicon is from contaminant that entrance to final drives due to Housing Final Drive worn out.

    Corrective Action Required:


    1. Replace with assembly Final Drive
    2. Use oil Final Drive & replace with interval 1000 hours based on standard OMM (Spirax S2 A 80W – 90)
    3. Reduce travel distance below 10% to keep lifetime Final Dives, Travel Motor and Undercarriage componen t
    Failure Parts:
    Part Number Description Component Group Qty Remarks
    4455098 Needle Bearing Final Drive 3 Premature Failure
    4269472 Pin Final Drive 3 Worn Out
    4642993 Thrust Plate Final Drive 6 Worn Out
    2051884 Shaft Spline Final Drive 1 Worn Out
    Responsibility Job Repair by:

    OEM

     Dealer

    Darma Henwa

    Report Prepare by : Muhammad Noval Muzaqi Checked by:


    Condition Monitoring Analyst Maint. Superintendent

    ATTACHMENT
    DEWA-PM-FORM-33 Halaman 2 dari 11
    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT

    EX1296 - HITACHI ZAXIS370

    Part Book Final Drive – EX1296

    DEWA-PM-FORM-33 Halaman 3 dari 11


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT

    Part Book Final Drive – EX1296

    DEWA-PM-FORM-33 Halaman 4 dari 11


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT

    Ring Gear

    Pin

    Adhesive Worn Out

    Adhesive Worn Out


    Adhesive Worn Out
    Pin – ( Reff 39 )
    Pin bearing planetary gear have spall and adhesive worn out, due to heavy loads that are continuously received due to
    misalignment. Pin Bearing that contact with Bearing not replaced. Whereas Pin condition at that time is adhesive worn
    out.

    DEWA-PM-FORM-33 Halaman 5 dari 11


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT

    Needle Bearing

    Misalignment marks on Needle Spalling


    Bearing Planetary

    Needle bearing – Final Drive ( Reff 37 )


    These tapered of the needle bearings have spalling indicating that the bearing receives a lot of end play, which is caused by
    misalignment due to the clearance between the pins and the planatery needle bearing.

    DEWA-PM-FORM-33 Halaman 6 dari 11


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT

    Shaft Spline Final Drive

    Shaft Spline Final Drive

    Adhesive Wear

    Shaft Spline Travel Motor

    Adhesive Wear
    Shaft Spline - ( Reff 41 )
    From the results of the inspection, the condition of the final drive shaft spline and travel motor experienced adhesive wear as
    seen from the color change on the spline gear surface. From the SOS results, the oil viscosity is 100% above standard. The oil
    layer does not function optimally so that there is direct metal contact between the spline gear.

    DEWA-PM-FORM-33 Halaman 7 dari 11


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT

    Ring Gear Final Drive

    Misalignment marks on Ring Gear

    Ring Gear – ( Reff 23 )


    Misalignment marks on Ring Gear indicates that Inner parts of Final Drive got unbalance condition due to there’s clearance
    between Pin, Bearing, and shaft splines

    DEWA-PM-FORM-33 Halaman 8 dari 11


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT

    SOS Result Final Drive LH – EX1296

    Recommendation Oil Final Drive HITACHI ZAXIS370

    Oil Top Up Final Drive LH – EX1296

    DEWA-PM-FORM-33 Halaman 9 dari 11


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT

    SOS Final Drive LH – Lab Tekenomiks


    Regarding SOS result of final drive LH shown that there’s increasing of wear metal Silicon & Alumunium. Aluminium indicates
    that there’s abrasive worn out of Housing and Silicon indicates that there’s contaminant had entrance to final drive due to
    misalignment

    DEWA-PM-FORM-33 Halaman 10 dari 11


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT

    PCR Life Time Final Drive LH – EX1296

    Listing Part Last Ovehaul Final Drive LH (18 March 2022) – EX1296
    - Pin with part number 4269472 do not replacement

    DEWA-PM-FORM-33 Halaman 11 dari 11


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak

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