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


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

Usage:

D3400 01T


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.)

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

Table 2
Tech. Communicator: Joe Marine  Date: 9/15/2015  Service Job #: 123456  Segment #:
Customer Name: ABC Co.  Customer Contact: Mr. ABC  Phone #: 123-456-789  Vessel/Rig Name: M/V Majestic Cat 

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:

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:

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.
 

  1. Discovered a hole in the 7C-7910 air intake elbow that is located between the aftercooler and the # 16 cylinder head.

  2. # 16 cylinder lower intake valve has a chordal failure.

  3. # 15 & # 16 injector tips have impact damage.

  4. Turbocharger exhaust wheel has damage.

  5. Found debris damage in the # 15 & # 16 cylinder.

Engine Failure Timeline:

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.
 

  1. The engine was running.

  2. Noise and smoke and fire discovered at the aftercooler.

  3. Engine was killed.

Summary of Analysis:

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:

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.
 

  1. Adjust the valve lash per the O & M Guide.

  2. Perform a top end overhaul.

  3. Overhaul schedule attached below.

Photos



    Illustration 1g06100006

  1. Discovered a hole in the 7C-7910 air intake elbow that is located between the aftercooler and the # 16 cylinder head.

    Table 9
    This is consequential damage and is not necessary. 


    Illustration 2g06100012

  2. Looks like the # 16 lower intake valve pieces shot out of the 7C-7910 air intake elbow.


    Illustration 3g06100015

  3. # 16 cylinder head. The lower intake valve has a chordal failure.


    Illustration 4g06100023

  4. Closer view of the # 16 cylinder head. The lower intake valve has a chordal failure.

    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

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
<SUP>&reg;</SUP> 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
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