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:
320D2 FM Forestry Machine Machine Systems Pump and Motor (Cab Tilt) - Remove and Install
303.5E2, 304E2, 305E2 and 305.5E2 Mini Excavator Machine Systems Bucket Cylinder - Remove and Install
558 Forest Machine Machine Systems Cylinder Speed - Check
558 Forest Machine Machine Systems Cylinder Drift - Check - Loaded Bucket
558 Forest Machine Machine Systems Cylinder Drift - Check - Empty Bucket
538 LL GF Forest Machine Machine Systems Main Hydraulic Pump - Assemble
Pressure Sensor Group May Fail on Certain Excavators {1439, 1916, 1917, 1923, 1924} Pressure Sensor Group May Fail on Certain Excavators {1439, 1916, 1917, 1923, 1924}
C4.4 and C6.6 Engines Event Codes
C4.4 and C6.6 Engines Electrical Connectors
C2.4 Tier 4 Final Engines for Caterpillar Built Machines Diesel Particulate Filter Regeneration Does Not Occur
558 Forest Machine Machine Systems Swing Speed and Swing Drift on a Slope - Check
794 AC Off-Highway Truck High Voltage Components - Check
340F Ultra High Demolition (UHD) Excavator Machine Systems Position Sensor and Mounting - Remove and Install - Swing Position Sensor
340F Ultra High Demolition (UHD) Excavator Machine Systems Position Sensor and Mounting - Remove and Install - UHD Stick
340F Ultra High Demolition (UHD) Excavator Machine Systems Position Sensor and Mounting - Remove and Install - UHD Fore-Boom
340F Ultra High Demolition (UHD) Excavator Machine Systems Position Sensor and Mounting - Remove and Install - UHD Nose Boom
340F Ultra High Demolition (UHD) Excavator Machine Systems Boom - Remove and Install - UHD Stub Boom
C4.4 and C6.6 Engines Acceleration Is Poor or Throttle Response Is Poor
558 Forest Machine Machine Systems Swing Motor - Test - Measurement of Case Drain Oil
558 Forest Machine Machine Systems Relief Valve (Swing) - Test and Adjust
320D2 FM Forestry Machine Machine Systems Cab Tilt Cylinder - Remove and Install
C2.4 Tier 4 Final Engines for Caterpillar Built Machines Engine Misfires, Runs Rough or Is Unstable
558 Forest Machine Machine Systems Travel Motor - Test - Measurement of Case Drain Oil
345D, 349D and 349D2 Excavators Sound Information and Vibration Information