Caterpillar.Electronic. Systems: A-Basic Course Unit, 10 The Basic Steps.of Failure AnalysisContents Foreword The Basic Steps Of Failure Analysis Work Record Conclusion Mustrations Basic Troubleshooting Procedure Diagram Demonstrations Using The Basic Steps Of Failure Analysis © 1983 Caterpillar Inc. Produced By Caterpillar Service Training 6-18Unit 10 - The Basic Steps Of Failure Analysi: Foreword This unit of the course is designed to The special equipment you will need to teach the six basic steps of failure analysis, complete this unit of the course is as and to help you use these basic steps to follows, troubleshoot Caterpillar electronic control systems. 1, a Caterpillar SEKV 1500 Electronic Monitoring Demonstration System. 2. Any Caterpillar digital multimeter, Complete this unit as follows: READ THIS UNIT. COMPLETE THE DEMONSTRATIONS OF THIS UNIT.The Basic Steps Of Failure Analysis The basic steps of failure analysis are as follows. 1, Pull together the important INFORMATION about the machine and the problem. 2, ANALYZE the information gathered. 3. TEST the problem system. 4, Make a DIAGNOSIS of the probable cause of the problem. 5. REPLACE or REPAIR unacceptable parts 6. DEMONSTRATE the success of the repair. INFORMATION is available from many souces. The time given to get important information about the machine and the problem with the machine is time used to your advantage. You need to know both how the machine was designed to operate normally, and what the problem is. To make an ANALYSIS of the information is to compare the normal operation of the machine with the problem operation of the machine. There are two purposes of this step — 1) to make a temporary diagnosis as to the cause of the problem, and — 2) to see what other information is needed to be sure of the cause of the problem TESTING is the work done to check the possible truth of a temporary diagnosis Components of the system are tested either individually or in groups to see if they are good or bad. The purpose is to show which component is, or which group of components are, the most probable cause of the problem. To make a DIAGNOSIS of the probable cause is to name the component, or components, which have tested bad and offer the best possible explanation of the cause of the problem. If an accurate identification is made it will be possible to return the machine to normal with the smallest amount of work and parts repair or replacement. REPLACEMENT or REPAIR of unacceptable parts is the replacement or repair of parts which have been identified as the probable cause, To DEMONSTRATE the success of a repair is to get proof that the original problem has been corrected, and that the operation of the machine is again normal With this list of basic steps it is possible to see each step clearly. However, in the real world the action between these steps is often a backward and forward movement, Because of this these steps are sometimes not seen as clearly, or may be skipped over. It is to your advantage not to lose sight of any of these basic steps when troubleshooting any system.Basic Troubleshooting Procedure Diagram Figure 1 INFORMATION ‘BATHERINE PROBLEM AND NEED NORE NORMAL OPERATION INFORMATION INFORAATION ANALYSIS. TEMPORARY DIAGNOSIS TESTING Pip RESULTS Lr PART NAME NUNBER “SUCCESS”Work Record ‘A good record of the information gathered and used in troubleshooting can be of value both when the work is being done, and after. When the work is being done the record can be of assistance to the analysis of the information. After the work is done the record can be of assistance to you to explain the work. Informati System - Problem - Analysi Possible Cause — Tests: 4. Component Result 2. Component on Result 3. Component - Result 4. Component - Result 5. Component OC Result Probable Cause Parts Replacement/Repair: Repair Made Demonstration of System Repair: Repair Checks 1 oK Oo NOT OK Work Done by: Date: ‘An example of a work record form that can be used to record each of the six basic steps follows.To use these steps, make ready the SEKV 1500 Electronic Monitoring Demonstration System as shown below, and complete the demonstrations that follow. POSITION 115/230V SWITCH CORRECTLY WITH RESPECT TO OUTLET POWER O© NOTICE Never connect a battery or any other outside Power source directly to any component on the face of this training aid. If this is done it can damage the system. ELECTRONIC MONITORING DEMONSTRATION SYSTEM SEKV1500 / 15/230 nev ovrcer Note: Before you begin the demonstrations that follow, be sure that none of the switches across the top of the system are in the down position.Demonstration 1 (a) Read the information that follows: — A customer has reported that his 824C Tractor Electronic Monitoring System fuel level light does not work. The fuel light is always ON. The fuel tank is full ‘A check of the machine shows that the customer is correct — the fuel level light comes ON after a normal delay when the Power Switch is turned ON, and stays ON all the time (b) Push down switch button 1 at the top of the Electronic Monitoring Demonstration System and operate the system to see the problem. (c) Use the information in Unit 8 about how the fuel light was designed to operate normally, and the information above, to give a possible cause of the problem. Write your possible cause on the form on the opposite page (q) List the components you will need to test to see if the possible cause you have given is the real cause of the problem. Uist these components on the form on the opposite page, {e) Test the components you have listed and write the results on the form on the opposite page, (f) From the test results make a diagnosis of the probable cause of the problem. Write the probable cause on the form on the opposite pageInformation: system __824C ELECTRONIC _MONITORIN: Problem FUEL LEVEL LIGWT ON WITH FULL TANK Analysis: Possible Cause Tests: 4. Component - Result os 2. Component Result _ 3. Component Result 4. Component — Result - 5. Component - Result a 6 Component Result 7. Component : 8 Component Result __ 9. Component —___ Result 10. Component Result Diagnosis: Probable Cause (Requires write-in)Check the work record you have just completed with the one on the opposite page. If you find that your form does not make an acceptable comparison with this form, get assistance from your training instructor.Completed Work Record For Demonstration 1 — Information: system B24C ELECTRONIC MONITORING SYSTEM Problem. FUEL LEVEL LUIGHT ON WITH FULL TANK Analys Possible Cause _OPEN FUEL LEVEL SWITCH OR WIKING Tests: 4. Component SGI7S SWITCM a Result OPEN WITH FULL TANK (SHouLD BE CLoseD) | 2 Component Wie To Resut ____CONTINUITN, OK 3. Component __ GROUND WIRE _ a Result CONTINUITY OK 4. Component Result oo 5. Component = Result 6. Component Result 7. Component Result 8. Component Result 9. Component Result 40. Component Result Diagnosis: Probable Cause FAILED SGIN5 SwitcwDemonstration 2 (a) Read the information that follows: — A customer has reported that his 824C Tractor Electronic Monitoring System alarm does not work. A check of the machine shows that the customer is correct — the alarm does not work — including when the engine is running and the Test Switch is closed (b) Release switch button 1 and push down switch button 2 at the top of the Electronic Monitoring Demonstration System and operate the system to see the problem. Write a description of the problem on the form on the opposite page. (¢) Use the information in Unit 8 about how the alarm was designed to operate normally, and the information above, to give a possible cause of the problem. Write the possible cause on the form on the opposite page. 10 (d) List the components you will need to test to see if the possible cause you have given is the real cause of the problem List these components on the form on the opposite page. (e) Test the components you have listed and write the results on the form on the opposite page. (f) From the test results make @ diagnosis of the probable cause of the problem. Write the probable cause on the form on the opposite page.Information: system B2HC ELECTRONIC MONITORING SYSTEM Problem Oo Analysis: Possible Cause Tests: 1. Component Result 2. Component a Result _ 3. Component Result 4. Component Result 5. Component a Result 6. Component Result 7. Component Result 8. Component Result 9 Component Result 40. Component Result Diagnosis: Probable Cause (Requires write-in) WCheck the work record you have just completed with the one on the opposite page. If you find that your form does not make an acceptable comparison with this form, get assistance from your training instructor. 12Completed Work Record For Demonstration 2 — Information: systen __ B2Z4C ELECTRONIC MONITORING SYSTEN\ Problen __ ALARM DOES NoT Work Analysis: Possible Cause ALARM . FUEL PRESSURE SWITCH OK WIRING, _ Tests: 4. Component Result 2. Component Result OPEN CNo CONTINUITY) | 3. Component __8NZ3Z7 FUEL PRESSURE SWITCH Result OK 4. Component WIRE S Result INSULATION OK 5. Component Result = a 6. Component — Result 7. Component Result 8. Component Result 9. Component Result 40. Component — Result Probable-Cause __ FAILED HARNESS CWiRE PDDemonstration 3 (a) Read the information that follows: — A customer has reported that his 824C Tractor Electronic Monitoring System alarm and main warning light do not work Neither will work under any condition. (b) Release switch button 2 and push down switch button 3 at the top of the Electronic Monitoring Demonstration System and operate the system to see and test the customer's problem for yourselt Write the name of the system and a description of the problem on the form on the opposite page. (e) Use the information in Unit 8 about how the system was designed to operate normally, and your information about the problem, to give a possible cause of the problem. Write the possible cause on the form on the opposite page 14 (d) List the components you will need to test to see if the possible cause you have given is the real cause of the problem. List these components on the form on the opposite page. (e) Test the components you have listed and write the results on the form on the opposite page. (f) From the test results make a diagnosis of the probable cause of the problem. Write the probable cause on the form on the opposite page.Information: System Problem __. Analysis: Possible Cause Tests: 4. Component Result 2. Component Result _ 3. Component Result ___ 4, Component Result 5. Component Result 6. Component Result 7. Component Result 8. Component Result 9. Component Result 40. Component Result Diagnosis: Probable Cause (Requires. write-in) 15Check the work record you have just completed with the one on the opposite page. If you find that your form does not make an acceptable comparison with this form, get assistance from your training instructor. 16Completed Work Record For Demonstration 3 — system __&Z24C ELECTRONIC NONITORING SYSTEN, Problem ALARM & WARNING LIGHT po Not WoRK 7 Analysis: Possible Cause ALARM 2 LIGWT OR WIRING: Tests: 4. Component ALAM - Result OK 2 Component LIGHT Result OK 3. Component COMMON GROUND Result OPEN (No CONTINUITY ) 4, Component - Result oo 5. Component Result a 6. Component Result — 7. Component Result __ 8. Component Result _. — 9. Component Result — 10. Component Result Diagnosis: Provable Cause _ FAILED HARNESSDemonstration 4 (a) Read the information that follows. — A customer has reported that his 824C Tractor Electronic Monitoring System engine oil pressure light does not work (b) Release switch button 3 and push down switch button 4 at the top of the Electronic Monitoring Demonstration System and operate the system to see and test the customer's problem for yourselt. Write the name of the system and a description of the problem on the form on. the opposite page. (e) Use the information in Unit 8 about how the system was designed to operate normally, and your information about the problem, to give a possible cause of the problem: Write the possible cause on the form on the opposite page. 18 (4) List the components you will need to test to see if the possible cause you have given is the real cause of the problem List these components on the form on the opposite page. (e) Test the components you have listed and write the results on the form on the opposite page. (f) From the test results make a diagnosis of the probable cause of the problem. Write the probable cause on the form on the opposite page. (a) When you have made your diagnosis of the probable cause of the problem for this demonstration, get a copy of the completed form for Demonstration 4 from your training instructor and compare your for and diagnosis with the form and diagnosis obtained. If you find that your form and diagnosis do not make an acceptable comparison, get assistance from your training instructor.Information: System Problem. Analysis: Possible Cause Test: 4. Component Result 2 Component Result 3. Component Result ‘4. Component Result 5. Component Result 6. Component Result 7. Component Result 8. Component Result 9. Component Result 10. Component Result Diagnosis Probable Cause (Requires write-in) 19On the opposite page is the customer complaint for the Electronic Monitoring Demonstration System Problem (switch button 5). Use this problem for additional learning experience. Be sure to have only one problem switch button pushed down at any one time. 20Customer Report For Problem No. 5 Alternator light is ON, but machine starts OK. Intormatios system Problem. Analysis: Possible Cause Tests: 4. Component a Result 2. Component Result a 3. Component a Result 4. Component — Result 5. Component Result 6. Component Result 7. Component Result 8 Component Result 9. Component Result 10. Component Result Diagnosis: Probable Cause 24Conclusion Good use of the basic steps of failure analysis will make troubleshooting any Caterpillar electronic control system easier. CATERPILLAR” This booklet is one of fourteen. All fourteen booklets are available only as a set under FORM NO. SEBV0525. 22 PRINTED IN U.S.A