TRAINING PRESENTATION

TRUCK / PRIMEMOVER
ROLL OVER/TOPPLE Accident – FAILURE ANALYSIS
Problem Statement / Root Cause / Preventive Action
TARGET EQUIPMENT’s:

• TRUCKS
• PRIMEMOVERS
• TRUCK MOUNTED CRANES
• Concrete PUMPS
• TRUCK MIXERS
• EXCAVATORS
• WHEEL LOADERS
• FORKLIFTS
• SKID STEER LOADERS
• TELEHANDLERS
• BACKHOE LOADERS
• DOZERS
• MOTOR GRADERS
• SOIL / TANDEM COMPACTORS
• ASPHALT PAVERS
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REF No: ATG/PEL/TT/CW/2019/P15
Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH
Problem Statement – 1 of 2
Events happened during the incident (23/06/2019) 1188202 KM Vehicle Accident Report
• Vehicle Topple during unloading
operation.
• Driver escaped with minor
injuries.
• Engine was running.
• Engine oil leakage.
• Vehicle was switched off after the
incident.

Recent failure reported Prime Mover

Toppled Actual Footage
(27/10/ 2019) 1194238 KM.
• Cranks shaft near 5th Journal
cracked & Broken.
• Main bearing worn out near
5th Journal .
• Front Engine mounting found
in damaged condition.
The truck was running 6036 KM Prime Mover
Until the final incident occurred. Number plate Photo 2
Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH
Problem Statement – 2 of 2

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Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH
Root Cause – 1 of 3
THIS FAILURE WILL BE ANALYSIED ON TWO ASPECTS Before & After INCIDENT

Before incident Operational Error ( Driver )

Main causes of Rollover / Topple. Main Reasons

• Speed & Cornering

• Roundabouts & Flick flack effects
• High Center of Gravity
• Load Shift
• Road Geometry
• Overloading.
• Tyres and Suspensions
• Kerb impacts
4
Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH
Root Cause – 2 of 3
THIS FAILURE is due to Two aspects of Before & After INCIDENT

After incident Technical Error ( Service team )

• Starting the engine immediately with out analyzing the internal condition of engine
components.
• drivelines alignments & Mountings have not been checked.
• the condition of intercooler, condenser and radiator Mountings, hose and line
connections have not been checked for any damages.
• Vehicle had been started immediately after the incident occurred .
• Found Engine mountings in damaged condition especially the front one. these are the
main holding & supporting points for any vehicle or equipment.
• Detailed Inspection of the engine have not been carried out.
• Main bearing conditions and journal condition have not been checked.
• valve tappet cover , cam shaft & its bearings, rocker arm, injectors, valve tappet
clearance and its conditions have not been checked in detail.
• the propeller shaft, differential & suspensions have also not been checked..
5
Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH
Root Cause – 3 of 3
Reason for failure 1, 2 & 3 Roll over/ Topple incident (23/06/2019) 1188202 KM
• lubrication oil drained out completely during roll over incident.
• Starting the engine at Vendor site workshop (Al Yahya ) with out inspecting the internal components
1 and damage conditions.
• So the engine was running at site with internal damages of Main bearing seizure at a minimum
scale.
• Impact occurred during toppling which developing Lack of lubrication in Engine crank shaft main
bearings.

2 • Lack of lubrication to crank shaft main bearing resulting in

gradual seizure and cracking of crankshaft in the 5th Main
bearing journal.
Recent failure reported (27/10/ 2019) 1194238 KM.

3
• Engine front side mountings were completely damaged
Causing excess vibration.

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Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH
Preventive Action – 1 of 7
CHECK Power Train ( one by one ) Check the driveline alignments & mountings.

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Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH
Preventive Action – 2 of 7
CHECK ENGINE MOUNTING
Engine Mounting (Front) Engine Mounting (Rear)

Tightening Torque values

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Check the Highlighted Areas
Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH
Preventive Action – 3 of 7
CHECK ENGINE HEAD – Cam Shaft
Cheek CAM shaft bearings

CAM shaft bearings = 7 Nos

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Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH
Preventive Action – 4 of 7
CHECK ENGINE PAN / SUMP
• Check for crank shaft main bearings condition.
• Check all the bearing areas for wear conditions and lubrication.
• Check the clearance.
• Check for any damages.

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Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH
Preventive Action – 5 of 7
CHECK ENGINE - General
• Rotate the engine manually and check the condition of crank shaft component and
clearances.
• Make sure engine mountings are intact and torqued.
• Similarly check the condition of cylinder head cam shaft clearance etc.
• After ensuring smooth movement of all the mechanical components as per OEM
standards.
• start the engine and Check for engine oil pressure low idle 1 bar & high idle 4 - 6 bar.
• Test the engine condition in low idle rpm , High idle rpm and
• Test the engine condition in without load and with load.

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Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH
Preventive Action – 6 of 7

During Operation:

• Center of gravity - Make sure the Center of Gravity is appropriate.

• Load Shift – Secure the load & make sure load shift does not happen, distribute the load
evenly.
• Road Geometry – Smoothly drive and manage the vehicle as per the slopes , inclinations etc.
• Overloading – do not overload .

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Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH
Preventive Action – 7 of 7
During Roll over / Toppling incident:
• Do not Start the engine.
• Check the drivelines alignments & Mountings.
• Check the condition of intercooler, condenser and radiator Mountings, hose and line
connections for any damages.
• Toe the vehicle to the near by workshop and carry out complete inspection of external &
internal components.
• Engine mountings are the main holding & supporting points for any vehicle or
equipment so check it thoroughly .
• Open the Oil pan or sump and check the conditions of main bearing one by one and
crank shaft & journals.
• Open the valve tappet cover and check the condition of the cam shaft & its bearings,
rocker arm, injectors, valve tappet clearance and conditions.
• Check the propeller shaft, differential & suspensions.
• Check all the moving joints & components.
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Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH
Thank you

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Developed by Nandakumar / Technical Training / PEL / AL TASNIM CWS MISFAH