FAILURE REPORT

SERVICE ORDER 1001008

CUSTOMER Cerrejon
REPORT DATE 12/09/17
CONTACT Rafael Mendoza
FAILURE Internal leakage
COMPONENT Stick Cylinder LH, PC8000-6
SERIAL NUMBER 11090901
PART NUMBER 91588040
HOROMETER 1221
PREVIUS ORDER N/A

Customer claim:

The cylinder shows internal leakage after 408 h of operation. It was removed
after 1221 h from shovel K01(S/N 12041).

Conclusion:

According to the evidences found during this analysis, there is not technical
merit to this claim, the component failed as result of a condition present in
the shovel, external to the cylinder.
Immediate cause:
Wear in piston seals.
Basal cause:
External factor to KOMATSU, not attributable to defects in material nor
workmanship.

Possible causes:

 Cylinder misalignment (side load).

 Excessive play in the rod side connection.

Background
Brand new cylinder from factory (not previously repaired), installed on March
15th and removed on 24th August of the present year.
Observations:

1. There is evidence of metal particles in the barrel and in the piston

caused by abrasive wear.

2. In the thermography taked on July 21th is observed high temperature

in the articulation point, possible caused by high friction or poor
lubrication.

Fig. 1
Corrective actions:

1. Bore repair of the connection plate (Boom) and pin replacement.

2. To make sure the grease system is feeding lubrication points.

Failure analysis:

Fig. 2

After the disassembly and components analysis, we have the followings

findings:

Fork joint with internal wear. Worn

plate/pin

Fig. 3

Destroyed seal

Wear rings show material

delamination

Fig. 4
 Scratches on the outside circumference of
the rod. Foreign material /

Fig. 5

Fig. 6

Scratches outside the circumference Fig. 7

bitting the seal. Foreign material /
Piston seal cut in one side. Extreme load
dirt oil.
side

Marked scuffing inside wall of the

cylinder.

Fig. 8
e Fig. 9
Foreign material caught between piston and cylinder barrel.

Bushing (Cylinder head) worn on one side.

Fig. 10
Fault tree analysis:

Internal
leakage

piston seals
failure

wear

Excessive
Abrasion lateral load

piston seals cylinder

damaged misalignment

worn bore

P.E. Selwins Maturana D.

KOMATSU EMS Workshop