PT Trakindo Utama FAILURE ANALYSIS REPORT 故障分析报告

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Reported By 报
SO Number : : Ahmad Afandi
告人
Reported Date 报
SO Reference* : : November 29th 2022
告时间
Checked by
Approved by
Foreman / :
Superior 由工头 Service Head :

/主管检查 经服务主管批准

M. Dendy Chairul Suhardi

*Previous Service Order/Sales Order
SIMS Information
DEALER EQUIPMENT NUMBER CUSTOMER
CODE 经销商代码
J248 NAME 顾客 PT. CONCH
TECHNICIAN EQUIPMENT
DATE 日期 29-Nov-22 IDENTIFICATION 技术 27813 LOCATION 设备位置 Seradang
识别
CATERPILLAR CATERPILLAR INSTRUCTION 操作说明
MODEL 设备 988H SERIAL NO. 型号 A7A00272
Top Overhoul and Inspect problem coolant mix oil
HOURS 时间表 22.109 KILOMETERS 顶部检修和检查问题冷却剂混合油
PART PART NAME QTY DESC.* GROUP GROUP NAME ✓ IF MADE ✓ IF DESCRIPTIVE COMMENTS (20
NUMBER CODE NUMBER PRODUCT DURABILITY SPACES MAXIMUM PER
RESPONSIBLE 描述 CONTAINING INOPERABLE ISSUE INCIDENT) 描述性评论
代码 PART 包含零件
的组号
49 7760 INSPECTION 检修

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 PCR Schedule Comp. target hours (ex 12,000)
: Engine Gp 发动机组 :
Description 组件描述 Hours
Comp. Serial No. / ID Current hours failed (ex 8,000)
型号
: TXH04904 Component Hours :
Comp. Arr. / Group Remain of target life (4,000)
No.组号 : 384-1749 Life Remaining :
Mach. Hours - Component New
: :
Installed Price
Mach. Hours - (ex. $ 10,000)
: Cost To Repair :
Removed
Cost/Hour (10,000 / 4,000 = 2.5 $ /hr)
Date Comp. Installed : :
Remaining
Date Comp. Failed :

Supporting Documentation Required 需要的证明文件

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PT Trakindo Utama FAILURE ANALYSIS REPORT 故障分析报告

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# Description 描述 Yes Comments

1 Installation Check List ☐
2 Repair & Maintenance History ☐
3 SOS History ☐
4 Magnetic Plug Inspections ☐
5 ET/VIMS Data ☐
6 TPMS / Payload Data ☐
7 Performance Test Data ☐
8 Others ☐

Failure Outline 失败概要: Brief outline of what the Customer reported

Background / Research : Write down all the brief backgrounds of failure (includes the taken actions)
Customer report engine problem coolant mix oil and high blowby , add 3 liter engine oil every day 客户反映发动机问
题冷却液混合油和高喷，每天添加
When and on what condition customer 3 升发动机油
reported the failure :

What were the immediate actions taken :

Repair & Maintenance History : State all the previous repair and maintenance history related to the current events

LIST POSSIBLE CAUSES 列出可能的原因

Make a list of failure’s possible causes

Problem coolant mix oil: 有问题的冷却剂混合油：

1. Engine oil cooler internal leaks 发动机机油冷却器内部泄漏
2. Transmission oil cooler internal leaks 变速器油冷却器内部泄漏
3. Cartridge turbocharger internal leaks, crack 盒式涡轮增压器内部泄漏、裂缝
4. Cylinder head crack oil gallery to coolant jacket 缸盖裂缝油廊到冷却剂夹层
5. Cylinder block crack, oil gallery connected to coolant jacket 缸体裂纹，油廊与冷却剂夹层相连

Problem high blowby : 高吹气问题：

1. Worn liner 磨损的衬垫
2. Worn ring piston / piston 磨损的活塞环/活塞

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PT Trakindo Utama FAILURE ANALYSIS REPORT 故障分析报告

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OBSERVATIONS 检修的情况
Write down all the observations made during your Failure Analysis investigation including the good and bad dinding
To Help Explain Progression/Stage of Failure,
Part Number– Name– modifier Code (RH/LH/Upper/Lower Use Photos/Parts Book Illustration.
etc.) – Detail Explanation Identify Type, Amount, Location of Wear, Deposits,
零件编号-名称-修改码（RH/LH/Upper/Lower 等）-详细 Damage, Fractures etc. 为了帮助解释故障的进展/阶段，
说明 使用照片/零件书插图。确定磨损、沉积、损坏、断裂
等的类型、数量和位置。
Serial number machine
A7A00272

序列号机器
A7A00272

Hours meter machine

22.109

小时表机
22.109

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Top Engine view before remove cyl. Head Gp

在拆卸气缸盖组之前，要先确定发动机的最高状态

Top engine view after remove Cyl. Head Gp

拆除气缸盖组后的发动机顶部状况

Top engine view after remove 6x cyl.liner

拆除 6x 气缸套后的发动机顶情况

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Engine block inner side view, not found any sediment

coolant mix oil.
Inner side block clean and normal condition.

发动机缸体内侧的情况，没有发现任何沉积的冷却剂混
合油。
内侧块清洁，状态正常。

Gallery coolant at Cyl.head for regulator housing clean, and

not found any sediment coolant mix oil there.

缸盖上的冷却液为调节器外壳清洁，没有发现任何沉积
的冷却液混合油。

Output side of oil cooler , that is first way coolant to entry to

the cyl.block, found area clean from any sediment coolant
mix oil. 油冷却器的输出侧，也就是冷却剂进入气缸锁的
第一个途径，发现该区域没有任何沉积的冷却剂混合油
。

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There is no crack at cyl.head surface and oil hole

缸盖表面和油孔没有裂缝

There is no crack at top desk cyl. Block

桌子上的圆柱体没有裂缝

There is no crack at cyl.block near oil hole and coolant

area.

靠近油孔和冷却剂区域的气缸体没有裂缝。

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Pressurize engine oil cooler with 80 psi and put in boiling

water, not found any leaks

用 80psi 的压力给发动机油冷却器加压，并放入沸水，
没有发现任何泄漏。

Pressurize Transmission oil cooler with 80 psi and put in

boiling water, not found any leaks

用 80 磅/平方英寸的压力对变速器油冷却器进行加压，
并放入沸水，没有发现任何泄漏。

Found engine oil sediment at coolant gallery turbocharger .

indication leaks oil / remaining from last problem .
Already test with air pressure and there is no leaks . Also
test running with coolant lines removed, and there is no
leaks oil to coolant lines. 在冷却剂通道涡轮增压器处发现
发动机油沉积物。已经用空气压力测试，没有泄漏。 并
在拆除冷却液管线的情况下试运行，也没有出现油液 与
冷却液管线的泄漏。

Can’t perform inspection in normal operation temperature.

Recommendation to replace Cartridge to eliminated
component that not yet replaced with New / Good
component . 不能在正常工作温度下进行检查。建议更
换墨盒，以消除尚未更换为新/好的组件。

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PT Trakindo Utama FAILURE ANALYSIS REPORT 故障分析报告

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Waterpump and engine oil cooler already replaced with

Trakindo stock part . 水泵和发动机机油冷却器已经更
换为 Trakindo/k 卡特的库存部件。

In fact during inspection, coolant area at cyl,block and

cyl.head clean from sediment coolant mix oil. Indication oil
at radiator was remaining from last problem cooler fail Or
that is a leaks oil from component that not connect with
engine block area (turbocharger cooling system). Turbo
cooling system direct coolant from waterpump into radiator
tank. 事实上，在检查期间，气缸体和气缸盖的冷却液区
域已清除沉积物冷却液混合油。散热器上的指示油是 上
次冷却器故障时残留的，或者是未与发动机缸体区域
（涡轮增压器冷却系统）连接的组件漏油。涡轮冷却系
统将冷却液从水泵直接导入散热器水箱。

There are many sediment coolant mix oil at bottom tank

radiator. 底部水箱散热器有很多沉淀物冷却液混合油。

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Perform inspect component problem high blowby and top

Overhoul
执行检查组件问题高窜气和顶部大修
Measure liner bore found still in spec 5,4010 ± 0,001
inch , cross pattern in good condition , except liner no.5
has scratch at inner side . 测量衬里孔仍符合规格
5,4010 ± 0,001 英寸，交叉图案状况良好，除了 5 号
衬里在内侧有划痕。

Cyl. Measurement Inner Outer Reusibility

No result 测量结 side 内 side 外 可重用性
气缸号
果 5,4010 ± 侧 侧
0,0010”
1. 5,4015” Good Deep No 不
好 pitted
深坑
2. 5,4010” Good Deep No 不
好 pitted
深坑
3. 5,4010” Good Deep No 不
好 pitted
深坑
4. 5,4010” Good Deep No 不
好 pitted
深坑
5. 5,4010” Scratch Deep No 不
擦伤 pitted
深坑
6. 5,4015” Good Deep No 不
好 pitted
深坑

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Outer side Liner has deep pitted, and need to Replace 6x

Liner
外侧衬里有深坑，需要更换 6x 衬里

Deep pits 深坑
Do not reuse liners with deep pits.
SEBF8068-36
不要重复使用有深坑的内衬。
SEBF8068-36

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Measure Conrod bore found still in spec 4,0630 ±0,0005 inch

测量连杆孔仍符合规格 4,0630 ±0,0005 英寸

Cyl. Measuremnet result Visual Reusibility

No 测量结果 inspect 可重用性
气缸号 4,0630 ±0,0005 “ 视力检
查
1. 4,0630” Good 好 Yes 是
2. 4,0630” Good 好 Yes 是
3. 4,0630” Good 好 Yes 是
4. 4,0630” Good 好 Yes 是
5. 4,0630” Good 好 Yes 是
6. 4,0630” Good 好 Yes 是

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Measure pin bore at piston found still in spec 2,3671 ± 0,0002 inch
测量活塞处的销孔仍符合规格 2,3671 ± 0,0002 英寸

Cyl. Measuremnet result Visual Reusibility

No 测量结果 inspect 可重用性
气缸号 2,3671 ± 0,0002 “ 视力检查
1. 2,3671” Good 好 Yes 是
2. 2,3671” Good 好 Yes 是
3. 2,3671” Good 好 Yes 是
4. 2,3671” Good 好 Yes 是
5. 2,3671” Good 好 Yes 是
6. 2,3671” Good 好 Yes 是

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Visual inspect and measure pin diameter found still in spec.

目视检查并测量仍符合规格的销钉直径。

PROBABLE ROOT CAUSES 可能的根本原因

Describe the probable root causes and the sequence of events that caused it

that is turbocharger and transmission oil cooler . But in fact transmission oil cooler already test with air
cooling system direct coolant from waterpump into radiator tank.

是 2 个部件尚未更换，即涡轮增压器和变速箱油冷却器。但实际上变速器油冷却器已经在沸水中用气压测试并且状态良好。如

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体区域已清除沉积物冷却剂混合油。指示散热器上的沉积物油是上次冷却器故障时留下的，或者是未与发动
机缸体区域（涡轮增压器冷却系统）连接的组件漏油。 涡轮冷却系统将冷却液从水泵直接导入散热器水箱。
涡轮增压器已经过测试，但无法在工作温度条件下进行测试。

Recommendation to flashing radiator and bottom tank also replace turbo cartridge,
or reuse cartridge and test engine after assemble engine, if problem coolant mix oil still exist then replace cartridge.
推荐冲洗散热器和底部油箱也更换涡轮滤芯，或重新使用滤芯并在组装发动机后测试发动机，如果冷却液混
合油问题仍然存在则更换滤芯。

2. Problem high blowby and oil consumption 高窜气和油耗问题

During inspection found Cyl liner inner surface good condition except no.5 that has scratch . Piston also in good
condition. Most possible causes was from worn ring piston .
Recommendation to replace ring piston and 6x cyl liner (deep pitted)

2.高窜气和油耗问题
检查时发现缸套内表面状况良好，除了 5 号有划痕。 活塞也处于良好状态。最可能的原因是环形活塞磨损。
推荐更换活塞环和 6x 缸套（深坑）。

Solution to Prevent Reoccurrence : Write the recommendations to prevent future reoccurrence of the same failure

SUPPORTING DATA 支持数据

SOS History, Magnetic Plug Inspections, ET/VIMS Data, TPMS / Payload Data, Performance Test Data,
Service Head Decision : State the Service Head’s agreed decision on justification, whether warranty, goodwill, rework,
or event revenue SOS History 求救历史

VIMS DOWNLOAD

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Please attach maintenance history, oil sample results and supporting documents.

Bagian dari / Part of : Form Number :