Caterpillar Applied Failure Analysis 1
COURSE PURPOSE:
The course is structured in modular format with
the first five (5) modules providing an in-depth
coverage of “key analysis disciplines” and “how
components fail”. The following seven modules
cover the specific components such as pistons,
valves, turbochargers, etc., applying the
knowledge learned in the early modules in
classroom and “actual iron” training.
PREREQUISITES:
Service personnel attending this course must
possess a sound understanding of Caterpillar
engine/transmission systems operations and
“hands-on” experience in product repairs. It is
suggested that students successfully complete the
multimedia module Cat Basic – Fundamentals of
Applied Failure Analysis.
COURSE OBJECTIVES:
At the completion of this course, participants
should be able to:
 identify several materials and processing
flaws that might be found in Caterpillar
parts including inclusions, casting
shrinkage, forging laps, quench cracks and
straightening cracks
 identify road signs for different types of
fractures and explain the root cause for
each type of fracture
 identify road signs for wear failures and
explain the root cause for each type of
wear
 provide accurate and complete failure
analysis determination and reports,
particularly in warranty/policy settlements,
on a broad range of components
 provide appropriate and professional
operation and preventative maintenance
advice to customers; and
 apply knowledge learned to improving
service repair methodology, efficiency
practices and overall service quality
 COURSE OUTLINE:
1. Welcome and Course - Course description
Introduction - Course materials
- Timings
- Class introductions
- Site specifics
2. AFA1 - Day 1 - Failure Analysis Management
- Basic metallurgy
- Fractures
- Wear
- Visual Examination and Reporting
- Practical Exercise on the above
3. AFA1 - Day 2 - Engine Bearings
- Practical Exercise on Engine Bearings
- Crankshaft
- Practical Exercise on Crankshafts
4. AFA1 – Day 3 - Engine Valves
- Practical Exercise on Valves
- Pistons, Rings and Liners
- Practical exercise on Pistons, Rings and
Liners
- Fasteners
5. AFA1 – Day 4 - Practical Exercise on Fasteners
- Con Rods
- Practical Exercise on Con Rods
- Turbochargers
- Practical Exercises on Turbochargers
6. AFA1 – Day 5 - Two case studies where the student applies
the skills and knowledge taught in the
previous four days. Students are required to
analyse multiple failed components and
determine the root cause, then complete the
failure analysis report document for one of
these, presenting their findings.

Course Duration: 5 Days Cost: $500 per person per day

Venue: WesTrac Institute

Enquiries and Enrolment

NSW
WesTrac Institute
1 WesTrac Drive
Tomago NSW 2322

PH: (02) 49645200

InstituteNSWACT@westrac.com.au

GENINSDOC075 Jun 2013