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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
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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: Service Job #:
Date: 9/15/2015 Segment #: 1
Joe Marine 123456
Customer Name: ABC Customer Contact: Phone #: 123- Vessel/Rig Name: M/V
Co. Mr. ABC 456-789 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.
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.
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.
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.
Photos
Illustration 1 g06100006
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 2 g06100012
2. Looks like the # 16 lower intake valve pieces shot out of the 7C-7910 air intake elbow.
Illustration 3 g06100015
Illustration 4 g06100023
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.
Joe Marine
Cat Dealer
Technical Communicator
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