CUSHION (back) 9D6897 - Caterpillar

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 #: 1
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.
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:
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:
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.
Adjust the valve lash per the O & M Guide.
Perform a top end overhaul.
Overhaul schedule attached below.Photos
Illustration 1 g06100006
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
Looks like the # 16 lower intake valve pieces shot out of the 7C-7910 air intake elbow.
Illustration 3 g06100015
# 16 cylinder head. The lower intake valve has a chordal failure.
Illustration 4 g06100023
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