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    Failure Analysis Report DT2377 Engine Damper

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    Eng PLM ACP
    1) A Komatsu HD465-7 dump truck experienced engine damper noise issues and was inspected, finding several defects including a broken and fractured engine damper body assembly. 2) The root cause was determined to be a low quality non-genuine cushion damper that failed to properly dampen vibrations, leading to increased forces and the fracturing of the body. 3) Corrective actions included replacing the cushion damper with a genuine part and instituting inspections of the damper and couplings at scheduled maintenance.

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    Failure Analysis Report DT2377 Engine Damper

    Uploaded by

    Eng PLM ACP
    133 views14 pages
    1) A Komatsu HD465-7 dump truck experienced engine damper noise issues and was inspected, finding several defects including a broken and fractured engine damper body assembly. 2) The root cause was determined to be a low quality non-genuine cushion damper that failed to properly dampen vibrations, leading to increased forces and the fracturing of the body. 3) Corrective actions included replacing the cushion damper with a genuine part and instituting inspections of the damper and couplings at scheduled maintenance.

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    1) A Komatsu HD465-7 dump truck experienced engine damper noise issues and was inspected, finding several defects including a broken and fractured engine damper body assembly. 2) The root cause was determined to be a low quality non-genuine cushion damper that failed to properly dampen vibrations, leading to increased forces and the fracturing of the body. 3) Corrective actions included replacing the cushion damper with a genuine part and instituting inspections of the damper and couplings at scheduled maintenance.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    133 views14 pages

    Failure Analysis Report DT2377 Engine Damper

    Uploaded by

    Eng PLM ACP
    1) A Komatsu HD465-7 dump truck experienced engine damper noise issues and was inspected, finding several defects including a broken and fractured engine damper body assembly. 2) The root cause was determined to be a low quality non-genuine cushion damper that failed to properly dampen vibrations, leading to increased forces and the fracturing of the body. 3) Corrective actions included replacing the cushion damper with a genuine part and instituting inspections of the damper and couplings at scheduled maintenance.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 14

    FAILURE ANALYSIS REPORT

    Owner: PT DARMA HENWA TBK Project/Site: ACP (Asam Asam Coal Project)
    Reported By Abrissal Sanusi Date: Thursday, 12 November 2020
    Equipment Number DT2377 Model: Komatsu HD465-7
    Serial Number Unit 15764 HM Unit: 25,599.0 Hours

    Component Information:
    Component Description: Body Assy with Damper Component P/N: 569-01-62650, 285-01-12411
    Engine
    Date Component Install 31 August 2020 Date Component 7 November 2020
    Fail/Remove
    Mach Hrs Install 29,112.0 Hours Mach Hrs Removed 25,599.0 Hours
    Component Life/Hrs 487 Hours Engine Serial Number 611929
    WO Number 00002365 Status of Component Body fractured & damper broken
    failure
    Dealer/Supplier PT Diesel Utama Indonesia Component S/N 611929

    Document Support Required:

    NO DESCRIPTION Y/N COMMENTS


    Component Installation/Commissioning Report
    1 Y Update at component PCR replacement
    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 N
    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 14


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT
    Background:
    On November 7th, 2020 at 11:04 pm reported that Dump Truck Komatsu HD465-7 number DT2377 had problem with engine
    damper noise. Then unit parked up for further inspection by Mechanics, continue progress inspect inner part.

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


    Based on inspection from mechanics & inner part inspection found several defects :
    1. Engine damper major noise
    2. Shaft coupling to transmission had over end play effected by failure engine damper
    3. Cushion damper failure broken
    4. Rubber damper minor failure broken
    5. Body of body asse fractured
    6. Bearing shaft damper failure over end play

    Root cause of the Failure:


    Engine damper noise failure starts from very low quality of cushion damper engine. Damper system requires perfect
    cushion damper quality to optimize vibration damper. Low quality of cushion damper made vibration damper system
    not working properly & made vibration frequency still out of tolerance range then made weak cushion damper broken.
    Broken cushion damper reduces average vibration damper quality & increase possibility direct contact between body
    metal with housing metal. Direct contact between two metals produces noise, frictions & adhesive wear that
    produces micro-welding at metal surfaces. The cushion damper failed, the torque & forces applied increase up to 4 times to
    16 kN and make the body crack & fracture. The crack & fracture fragments of body, will multiple more increase the forces on to
    remains body then made the body of body assy completely fractured.

    Corrective Action Required:


    1. Cushion rubber damper engine replacement need use best quality of cushion rubber damper, requires
    genuine part
    2. Inspect engine damper noise & actual condition at PM 1200
    3. Inspect coupling & shaft bearing end-play at PM 1200

    Failure Parts:

    Part Number Description Component Group Qty Remarks


    285-01-12411 Cushion Engine damper 1 EA Broken
    569-01-62650 Body Engine damper 1 EA Fractured
    06340-06217 Bearing Engine damper 1 EA Over end play
    569-01-62410 Rubber Engine damper 1 EA Minor failure

    Responsibility Job Repair by:

    OEM

     Dealer

    Darma Henwa

    Report Prepare by : Abrissal Sanusi Checked by:


    Reliability Engineer Maint. Superintendent

    DEWA-PM-FORM-33 Halaman 2 dari 14


    FAILURE ANALYSIS REPORT
    ATTACHMENT

    DT2377 - Komatsu HD465-7 photo

    ed condition before being installed at Aug 31st, 2020 (HM : 29,112.0 Hours)
    Cushion rubber damper engine purchased

    DEWA-PM-FORM-33 Halaman 3 dari 14


    FAILURE ANALYSIS REPORT

    Reff. Order of cushion engine damper

    Body assembly with cushion rubber damper engine technical drawing from LinkOne Application (Komatsu Application)

    DEWA-PM-FORM-33 Halaman 4 dari 14


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT

    Cushion (285-01-12411) Rubber (569-01-62410)


    Non-Genuine Part Genuine Part

    Body (569-01-62650)
    Genuine Part

    Damper assembly condition after dismantle. Cushion condition broken, rubber condition remains good & body fractured

    DEWA-PM-FORM-33 Halaman 5 dari 14


    FAILURE ANALYSIS REPORT

    Rubber (569-01-62410)
    Genuine Part

    Body (569-01-62650)
    Genuine Part
    Cushion (285-01-12411)
    Non-Genuine Part

    Failure parts Rubber, Cushion & Body

    DEWA-PM-FORM-33 Halaman 6 dari 14


    FAILURE ANALYSIS REPORT

    Rubber, minor failure


    only

    Cushion, poor material


    quality and strength

    The rubber condition (Genuine parts) still remains in a better condition than the cushion (Non Genuine parts). The cushion
    remains only 1 EA from total 4 EA installed, the rest of the cushion is broken.

    Body, Brittle fracture due to


    premature failure of engine damper
    system

    The body condition found has 4 fracture area produces 4 ea fracture fragments

    DEWA-PM-FORM-33 Halaman 7 dari 14


    FAILURE ANALYSIS REPORT

    Body, Brittle fracture due


    to premature failure of
    engine damper system
    Body, Adhesive wear due
    to direct contact
    between body metal and
    housing (body)

    Body Assy (569-01-72600)

    Failure details of the body assy

    Body, Brittle Fracture,


    first fracture phase
    Body, Brittle Fracture,
    second fracture phase

    Brittle fracture phases of body

    DEWA-PM-FORM-33 Halaman 8 dari 14


    FAILURE ANALYSIS REPORT

    Brittle Fracture

    Adhesive wear after fracture

    Brittle fracture details

    Brittle Fracture

    Brittle fracture details

    DEWA-PM-FORM-33 Halaman 9 dari 14


    FAILURE ANALYSIS REPORT

    Body, Adhesive wear due


    to direct contact
    between body metal and
    housing (body)

    Body Assy (569-01-72600)

    DEWA-PM-FORM-33 Halaman 10 dari 14


    FAILURE ANALYSIS REPORT

    Body Assy (569-01-72600) technical drawing for stress analysis

    Body (569-01-62650)

    Shaft (569-01-72610)

    Body Assy (569-01-72600)

    Body assy nomenclature

    DEWA-PM-FORM-33 Halaman 11 dari 14


    FAILURE ANALYSIS REPORT

    Stress analysis of rotation with 3,256 N.m engine torque produce highest stress 13.02 MPa. The critical point of stress shared at
    the body indicated similar actual fractured area

    Engine Komatsu SAA6D170E-3 maximum torque spesifications

    DEWA-PM-FORM-33 Halaman 12 dari 14


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT

    Max. Torque (Ƭ) : 3256000 Nmm


    Dimension Square Plate (r): 80 mm
    Actual force Applied Plate* (F) : 162800 N
    *On failure rubber damper

    Actual forces applied on the body assy. Original engine torque of Komatsu HD465-7 is 3,256 Nm, produces 40 kN in normal
    condition with engine damper (rubber cushion) in a perfectly condition. When the cushion-rubber damper failed, the torque &
    forces applied increase up to 4 times to 16 kN and make the body crack & fracture. The crack & fracture fragments of body, will
    multiple more increase the forces on to remains body.

    Stress analysis of body assy with 160 kN forces applied on each body

    DEWA-PM-FORM-33 Halaman 13 dari 14


    REVISI 02
    Dokumen Tidak Terkendali Jika Dicetak
    FAILURE ANALYSIS REPORT

    Stress analysis of body assy with 160 kN forces applied on each body produced 1.09 safety factor

    Cover (569-01-72111) Bearing (06340-06217)

    Cover details conditions remains good Bearing condition misalignment


    Engine damper operated in a failed damper & fracture body, produced unbalance rotation that effected to failure bearing

    DEWA-PM-FORM-33 Halaman 14 dari 14

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