Component Failure Analysis Report

Dealer Name / Location GAINWELL COMMOSALES PVT. LTD.

SBU Construction

Reported by Govind Nag

Nature of Complaint Blow by & engine starting issue.

Affected Component with Engine/E7A15828
Component S. No.
Customer’s Name / Location Prem Vikash All
Work Order Number 5500010793 fields
are
Machine Serial Number LXX10475 Mand
C7.1 & E7A15828 atory
Engine Model & Sl. No
Date of Commissioning & SMU of 23.08.2019 & 16 hours.
Engine Those
Failure Date /Hours 28.02.2024 / 4609 Hours not
Failure Component Fuel pump (375-2647) & Injectors (396- applic
Part Number/ Group Number 9626)/391-4811 & 416-8908 able
Machine utilization per day/ GET NA mark
Life if any as 'NA'
Attachment Type & Size Bucket
(Bucket/ Rock breaker/ Crusher/
Drilling, etc.)
Attachment Operating Hours NA

Machine Application Description NA

Handling Material (Blue metal/ NA
Soil/ Clay/ Lime stone, etc)

* To be in bullets/ Points
Customer Complaint:
Engine starting issue & blow by with high engine oil consumption.

History: -
As per field inspection report said engine consumed 16 liters engine oil between 4102 hours to
4513 hours. The consumption of oil and fuel over a period of 51.4 engine hours is 0.18%.
During last visit at 4609 hours on 28.02.2024 it was observed that engine rpm reached to 172
& rail pressure not reached beyond 1340 PSI and engine not get start. Engine oil dropping
from breather tail pipe with engine blow by & engine oil level found low than specified level in
gauge. Removed engine from machine & installed float engine then engine send to CRC for
testing & dismantling.

Observation and Analysis: - (Include Media Number/ SMCS Code) -

Observation & Information from site: -
➢ 16 liters engine oil consumption between 4102 to 4513 hours.
➢ Engine rpm reached 172 hours, fuel rail pressure not developed beyond 1340 PSI & engine not get start.
➢ Engine oil droplet from breather tail pipe with excess engine blow by.
➢ Removed engine from machine & send CRC for further testing & inspection.
• Observation at CRC during dismantling & Inspection: -
➢ Engine rotates in both directions.
➢ Valve lash checked & found within specified limit.
➢ Not any dust or dirt found in air intake system. As per last oil sample silicon also with in
specified limit.
➢ Wet carbon accumulated on all Piston rings land & grooves. Carbon accumulated on Injector
tips.
➢ Dry carbon on all exhaust port.
➢ Mild wet carbon accumulated on inlet & exhaust valve fillet neck.
➢ Wear step at exhaust & inlet valves seating face due to excess carbon accumulation during
combustion.
➢ Piston rings end gaps measured and found top rings end gap is at higher side. Also noticed
that top ring fully mating with cylinder wall. Inter rings & Oil rings end gap found with in
lower limit range.
➢ Piston top ring groove pitted and mild wear step from excess carbon accumulation.
➢ Oil pump housing & rotor have abrasive scored marks.
➢ Sign of coolant leakage from water pump weep hole.
➢ Measured intermediate & oil rings thickness, and found with in specified limit. Top ring is
tapered rings, cannot measure the thickness.
➢ Normal wear & tear noticed in engine main & rod bearings.
➢ As per last Oil sample report viscosity dropped to 3.180 due to dilution.

Maintenance Information
* All fields are Mandatory
 Observation from Machine Level

Machine Serial Number Hour meter Reading

Observation – Serial number tag for Engine- Observation – Machine SMU

E7A15828
Quarry/Mine/ Road Construction/
Application Image (If Quarry capture the
boulder size excavator handles & tip life)
Entire Machine Image (to have bucket & (Loader density and type of loading-V type or
bucket tips should be seen) long distance)

Observation – Affected Components Photograph. Observation – Affected components serial

Model – C7.1 number
 Fix the evidences photographs

Observation – Not any dirt or dust found in Observation – Not any dirt or dust found in
turbo compressor housing out let port. turbo compressor housing.

Observation – Not any sign of dirt or dust found Observation – All valve mechanism components
in engine air intake system. found intact on their location.

Observation – Head surface of #1 & 2, mild Observation – Head surface of #3 & 4, mild
carbon accumulated. Valves are intact. carbon accumulated. Valves are intact.
Observation – Head surface of #5 & 6, mild Observation – Mild wet carbon packs on #1
carbon accumulated. Valves are intact. intake valve & dry carbon on #1 exhaust valve.

Observation – Mild wet carbon packs on #2 Observation – Mild wet carbon packs on #3
intake valve & dry carbon on #2 exhaust valve. intake valve & dry carbon on #3 exhaust valve.

Observation – Mild wet carbon packs on #4 Observation – Mild wet carbon packs on #5
intake valve & dry carbon on #4 exhaust valve. intake valve & dry carbon on #5 exhaust valve.
Observation – Mild wet carbon packs on #6 Observation – Sign of coolant leakage observed
intake valve & dry carbon on #6 exhaust valve. from water pump weep hole.

Observation – Wet carbon packs accumulated on Observation – Wet carbon packs on #1 Piston
#1- piston rings lands & grooves. rings lands & grooves.

Observation – Wet carbon packs accumulated Observation- Wet carbon packs accumulated on
on #2- piston rings lands & grooves. #2- piston rings lands & grooves.
Observation – Wet carbon packs accumulated Observation- Wet carbon packs accumulated on
on #3- piston rings lands & grooves. #3- piston rings lands & grooves.

Observation – Wet carbon packs accumulated Observation- Wet carbon packs accumulated on
on #4- piston rings lands & grooves. #4- piston rings lands & grooves.

Observation – Wet carbon packs accumulated Observation- Wet carbon packs accumulated on
on #5- piston rings lands & grooves. #5- piston rings lands & grooves.
Observation – Wet carbon packs accumulated on Observation- Wet carbon packs accumulated
#6- piston rings lands & grooves. Rusted due to on #6- piston rings lands & grooves. Rusted
water entry. due to water entry.

Observation – Hatch marks partially abolished, Observation- Hatch marks partially abolished,
mostly at top piston ring travel at top. #1 Cyl. mostly at top piston ring travel at top. #1 Cyl.

Observation – Hatch marks partially abolished, Observation- Hatch marks partially abolished,
mostly at top piston ring travel at top. #2 Cyl. mostly at top piston ring travel at top. #2 Cyl.
Observation – Hatch marks partially abolished, Observation- Hatch marks partially abolished,
mostly at top piston ring travel at top. #3 Cyl. mostly at top piston ring travel at top. #3 Cyl.

Observation – Hatch marks partially abolished, Observation- Hatch marks partially abolished,
mostly at top piston ring travel at top. #4 Cyl. mostly at top piston ring travel at top. #4 Cyl.

Observation – Hatch marks partially abolished, Observation- Hatch marks partially abolished,
mostly at top piston ring travel at top. #5 Cyl. mostly at top piston ring travel at top. #5 Cyl.
Observation – Hatch marks partially abolished, Observation- Hatch marks partially abolished,
mostly at top piston ring travel at top. #6 Cyl. mostly at top piston ring travel at top. #6 Cyl.

Observation – Carbon pack accumulated on Injector tip area.

Observation – Piston top ring groove pitted and Observation – Piston top ring groove pitted and
mild wear step due to excess carbon packs. mild wear step due to excess carbon packs.
Observation – Abrasive wear found on oil pump Observation – Abrasive wear on oil pump outer
housing. rotor.

Observation – Abrasive wear found on oil pump Observation – Abrasive wear on oil pump inner
outer rotor. rotor.

Observation – Connection as water found Observation- Due to rusting, glow plug was very
damaged & fitted with applying sealant gasket. hard to loosen & get damaged during removal.
Observation – Presence of oil at fumes disposal Observation- Presence of oil at fumes disposal
hose from valve cover to filter. hose tail end. (from filter to atmosphere)

Observation – All intermediate rings matting Observation- Scoring at top rings matting
surface contact is 50%. surface & made 100% contact with liner wall.

Observation- Light abrasive marks noticed in Observation- Light abrasive marks noticed in
main bearings. rod bearings.
Observation- Thickness measured of Oil Observation- Dip grooved formed at rear seal lip
control rings. seating area, need reworking for next reusability.

Cylinder Liner bore measurement detail: - Service limit 105.025 mm.

Position Cyl. -1 Cyl. -2 Cyl. -3 Cyl. -4 Cyl. -5 Cyl. -6
AA 125.024 125.025 125.025 125.025 125.025 125.025
BB 125.025 125.025 125.025 125.025 125.025 125.025
CC 125.024 125.025 125.025 125.025 125.025 125.025
A,A, 125.024 125.024 125.024 125.024 125.024 125.024
B,B, 125.025 125.025 125.024 125.024 125.025 125.024
C,C, 125.025 125.025 125.024 125.024 125.025 125.024

Note: - All measurement found at higher side only after running of 4.5K hours.
Recommended to sleeve fitment with standard boring. Hatch marks also partially
abolished.

Piston rings end gaps measurement: -

Specification Cyl. -1 Cyl. -2 Cyl. -3 Cyl. -4 Cyl. -5 Cyl. -6
TOP- 0.012 to 0.019 0.018 0.018 0.018 0.019 0.018
0.018 inch
IN- 0.039 to 0.043 0.042 0.042 0.043 0.043 0.042
0.049 inch
OIL- 0.012 to 0.019 0.018 0.018 0.018 0.019 0.018
0.0216 inch

Thickness of Piston rings: -

Specification Cyl. -1 Cyl. -2 Cyl. -3 Cyl. -4 Cyl. -5 Cyl. -6
TOP- Tapered NA NA NA NA NA NA
Type
IN- 2.47 to 2.49 2.48 2.48 2.49 2.49 2.49
2.495 mm
OIL- 2.97 to 2.97 2.97 2.97 2.97 2.96 2.95
2.99 mm
Last Oil sampling at 4609 hours: -

Oil viscosity 3.180

Conclusion from findings

From above observation, we observed wet carbon packs accumulated in all Pistons ring groove
and lands area, which developed during combustion process from burning of excess fuel &
engine oil. As per field observation report said engine already having starting issue due to
malfunctioning of fuel system, rail pressure not reached beyond 1340 PSI. Additionally, engine
having high blow by rate with dropping of engine oil from breather tail pipe. During inspection
the presence of engine oil found at fumes disposal hose tail end which open to atmosphere.

In intake valves stem accumulated with wet carbon packs, wear step at valve face due to excess
carbon accumulation. Exhaust valve seating face worn out due to excess carbon accumulation
during combustion process. All cylinder liner bores dimeter at higher level. Top piston rings gaps
at higher side. Deposition of wet carbon established that engine oil burnt at combustion
chamber.

As per last engine oil sampling at 4609 hours, oil viscosity shows 3.180, which one very less.
Low viscosity due to malfunctioning of fuel system & engine oil contaminated with fuel. At initial
stage suspected as engine run with low viscosity oil, which causing wear of internal components
like Liner bore & rings. Due to premature wear of those components engine blow by rate
increased and resulting high engine crankcase pressure, which allow the engine oil mist to exit
from breather tail pipe. Due to wear of those components also some amount of engine oil gets
passed and burnt inside the combustion chamber.

Suspected that the malfunctioning of fuel system primarily responsible for carbon accumulation
and at final stage engine blow by rate increased due to wear & tear of Rings & cylinder bores.