SPRING AS 7C3953 - Caterpillar

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 C7.1Introduction
This is an example of a good AFA report. Please review the notes that explain how each section of this report adequately communicates 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
Contains all expected information related to customer name, vessel name, serial number, engine hours, dealer work order number.
Table 2
Customer: ABC Co.
Date: March 14th, 2013 Failure Date: February 28th, 2013
Failed Part Number: 317-1121 Lock nut, injector rocker arm. Hours in Service: 761
Engine Model: 3512C Engine Serial Number: NJT00XXX Section 1
Table 3
Contains expected summary of complaint and high-level failure description. Parts Received:Failure on Diesel Engine #1, powering ABC Co. locomotive #1359. Failed parts were removed and brought to dealer A for analysis.Condition Upon Receipt:Injector from cylinder #7 had broken into two main sections, the body and the solenoid.Section 2
Table 4
Contains reasonable pertinent history, observations, and facts, including environmental and adjustment observations, SOS report results, pertinent historic maintenance practices, and well-articulated findings of failed parts. Timeline builds story of what failed first. High-quality pictures of pertinent related components with reasonable observations included in subsequent pages. Facts:The engine cylinder #7 was not functioning. The cylinder #7 valve cover had a hole, which was punched out from the inside. There was fuel and engine oil on the floor, walls, and ceiling of the locomotive engine room. The engine oil level was overfull due to fuel contamination. An oil analysis reported 19.44% fuel dilution of the engine oil. There was a higher than average metal particle count in the oil filter media. Removal of the valve cover revealed the cylinder #7 injector was severely damaged. The injector hold-down bolt had broken, allowing the injector to lose its seating ability. Only the injector rocker arm kept the injector from escaping through the valve cover. The injector from cylinder #7 had broken into two main sections, the body and the solenoid. The injector solenoid was badly hammered and rounded from bouncing around under the valve cover. Eventually, the solenoid punched a hole in the valve cover.The valve cover was also damaged inside from the injector rocker arm adjustment screw, which had turned to reach its highest point possible. The adjustment screw locknut was found to be loose, which allowed the adjustment screw to turn freely, and slowly work its way higher and higher. As the adjustment screw was backing out, this caused more clearance between the injector rocker arm and its injector. The injector hold-down bolt could not tolerate the additional and