Product Evaluation Report - AFA Bad Report {0374, 1000}
- Engine
- 3054 and 3056
- 3200
- 3300
- 3400
- 3400 All, 3300 All, 3200 All, 3100 All, 3000 All, and D-series All
- 3500 and G3500 Engines
- All 3600 Engines
- All C280 Engines
- All Marine Propulsion, Marine Auxiliary, and Marine Generator Sets
- C-10 All
- C-9 and C9 All
- C11 All
- C12 and C-12 All
- C13 and C-13 All
- C15 and C-15 All
- C16 and C-16 All
- C175 Engines
- C18 and C-18 Engines
- C27 Engines
- C32 Engines
- C4.4 Engines
- C6.6
- C7 All
- C7.1
- 3200
Introduction
This is an example of a bad AFA report. Pleasereview the notes that explain what is wrong with each section of this report, and what could be improved to better communicate the information necessary for a proper failure analysis. (Notes are indicated by a box with bolded text at the beginning of each section.)
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Title should state "Failure Analysis Report" for consistency across dealers. |
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Tech. Communicator: Joe Marine | Date: 9/15/2015 | Service Job #: 123456 | Segment #: 1 |
Customer Name: ABC Co. | Customer Contact: Mr. ABC | Phone #: 123-456-789 | Vessel/Rig Name: M/V Majestic Cat |
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Engine Mod. #: 3516 | Serial #: TKT00001 | Arrangement #: 395-1200 |
Delivery Date: 6/21/14 | Hrs. / Miles: 8268 | Perf. Spec.: 418-2907 |
Rating: 3000 HP at 1800 rpm | Application: Marine Prop | Eng. Loc.: SME |
Description of Complaint:
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This does not include a description of the failure mode. |
Check engine for noise at the upper rear of the engine.
Facts Observed:
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a. This is a summary of which components were damaged; this does not meet the intent of Section #2 of the Failure Analysis Report process which includes observations of the failed components and supporting data such as ECM Downloads, SOS, operator interviews, etc. b. There is no reference to valve lash measurements or records. |
- Discovered a hole in the 7C-7910 air intake elbow that is located between the aftercooler and the # 16 cylinder head.
- # 16 cylinder lower intake valve has a chordal failure.
- # 15 & # 16 injector tips have impact damage.
- Turbocharger exhaust wheel has damage.
- Found debris damage in the # 15 & # 16 cylinder.
Engine Failure Timeline:
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a. The timeline does not provide how the engine was being operated prior to the failure. b. The timeline does not indicate what failed first. |
- The engine was running.
- Noise and smoke and fire discovered at the aftercooler.
- Engine was killed.
Summary of Analysis:
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a. There is no list of possible root causes. b. There is no evaluation of the facts to eliminate possible root causes. c. There is no determination of what additional steps may be needed to confirm a root cause. |
It is XXXXXXX’s opinion that the intake valve has a chordal failure.
Recommendation:
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a. There is no statement of the root cause of the chordal fracture. b. There are no facts provided that support lack of proper valve adjustment as a contributing factor. c. There is no summary of the repair steps that were taken. d. There was no recommendation to ensure that a repeat failure of sister cylinder heads can be avoided. |
- Adjust the valve lash per the O & M Guide.
- Perform a top end overhaul.
- Overhaul schedule attached below.
Photos
- Discovered a hole in the 7C-7910 air intake elbow that is located between the aftercooler and the # 16 cylinder head.
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Table 9 This is consequential damage and is not necessary. Show/hide tableIllustration 2 g06100012 - Looks like the # 16 lower intake valve pieces shot out of the 7C-7910 air intake elbow.
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Illustration 3 g06100015 - # 16 cylinder head. The lower intake valve has a chordal failure.
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Illustration 4 g06100023 - Closer view of the # 16 cylinder head. The lower intake valve has a chordal failure.
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Table 10 a. The failed intake valve was not removed and evaluated.
b. The non-failed intake valve was not removed and evaluated.
c. There is no reference to any supporting documentation such as ECM downloads or Product Status reports.
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Illustration 1 | g06100006 |
Failure analysis performed by:
Joe Marine
Cat Dealer
Technical Communicator
Caterpillar Information System:
C4.4 and C6.6 Engines Event Codes
C4.4 and C6.6 Engines Electrical Connectors
A New Alternator Guard Is Used on Certain G3500 Engines {7174} A New Alternator Guard Is Used on Certain G3500 Engines {7174}
C2.4 Tier 4 Final Engines for Caterpillar Built Machines Diesel Particulate Filter Regeneration Does Not Occur
794 AC Off-Highway Truck High Voltage Components - Check
New Solenoid Valve for Certain Gas Engines {5479} New Solenoid Valve for Certain Gas Engines {5479}
C175 Tier 4 Final Engines for Off-Highway Trucks DEF Pressure Is High
C7.1 Marine Propulsion Engine Belts - Inspect/Adjust/Replace
794 AC Off-Highway Truck Rear Wheel Spindle Fasteners - Replace
794 AC Off-Highway Truck Rear Wheel Spindle Fasteners - Inspect
® Marine Display Display
Reference Guide for a Proper Failure Analysis by CAT Dealer {0374, 1000} Reference Guide for a Proper Failure Analysis by CAT Dealer {0374, 1000}
C4.4 and C6.6 Engines Acceleration Is Poor or Throttle Response Is Poor
DE Series Generator Set with Cat C1.1, C1.5, and C2.2 Engines Safety Messages
C7.1 Marine Engine Engine Oil Pressure Sensor - Remove and Install
C175 Tier 4 Final Engines for Off-Highway Trucks DEF Pump Motor - Test
C2.4 Tier 4 Final Engines for Caterpillar Built Machines Engine Misfires, Runs Rough or Is Unstable
HPU300 Hydraulic Power Pack Power Pack Connection and Coupling
C4.4 and C6.6 Engines Alternator Problem
C7.1 Marine Engine Fuel Pressure Sensor - Remove and Install
C9.3 Marine Propulsion Engine Electronic Modular Control Panel 4 (EMCP 4) - EMCP 4.1/4.2 If equipped
C7.1 Marine Engine Coolant Temperature Sensor - Remove and Install
G3606 and G3608 Engines Maintenance Interval Schedule - Natural Gas Engines That Have a Compression Ratio of 10.5:1 or 11:1
G3606 and G3608 Engines Maintenance Interval Schedule - Engines That Use Bio-Gas