3516B Locomotive Engine 6HZ00001-UP(SEBP3023 - 28) - Documentation

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Product:  LOCOMOTIVE ENGINE

Model:  3516B LOCOMOTIVE ENGINE 6HZ00272
Configuration: 3516B Locomotive Engine 6HZ00001-UP

Applied Failure Analysis

Product Evaluation Report - AFA Bad Report {0374, 1000}
Media Number -M0074192-01 Publication Date -27/07/2016 Date Updated -27/07/2016

   
i06758009

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

SMCS - 0374; 1000

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

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3516B Locomotive Engine 6HZ00001-UP(SEBP3023 - 28) - Documentation

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. 

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.

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3516B Locomotive Engine 6HZ00001-UP(SEBP3023 - 28) - Documentation

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 1 g06100006

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3516B Locomotive Engine 6HZ00001-UP(SEBP3023 - 28) - Documentation

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

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

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. 

Failure analysis performed by:

Joe Marine
Cat Dealer
Technical Communicator

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