Product Evaluation Report - AFA Bad Report {0374, 1000} Caterpillar

Product Evaluation Report - AFA Bad Report {0374, 1000}

Usage:

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

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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Table 1
Title should state "Failure Analysis Report" for consistency across dealers.

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Table 2
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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Table 3
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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Table 4
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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Table 5
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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Table 6
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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Table 7
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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Table 8
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

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Illustration 1	g06100006

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.

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Illustration 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

Table 9
This is consequential damage and is not necessary.

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.

Failure analysis performed by:

Joe Marine
Cat Dealer
Technical Communicator