FACT FINDING
Ask Operator
 What is the problem?
 Who noticed the problem?
 When first noticed?
 Where was the problem first noticed?
 How much or severe is the problem?
 What could you see/ hear/ feel/ smell?
 Once, repeatedly or continuously?
 Last time machine worked normally?
 Pattern or trend?
 When does problem not occur?
 More machines with same problem?
 What job done when trouble noticed?
 Who else operated the machine?
 Is this a machine problem or is operator unhappy
with this model or machine size?
Inspect machine
 Machine model: ……………….
 Machine s/n: …………………..
 Hour meter: …………………...
 Observe general machine status
 Type of front and bucket size
 Hose Rupture Valves
 Front attachment
 Undercarriage
 Type of shoe, type of tire
 Optional parts or local modifications
 Machine history
 Signs of wear/damage/leakage
Operate the machine yourself
 What do you see/ hear/ feel/ smell?
 Can you compare with a good machine?
Hydraulic
 Speed (low/high, hesitate, shocks)
 Digging force (weak, not constant)
 Relief setting
 Sounds
Electric
 Warning signals/ lamps
 Switch/ dial malfunction
Is the observed behavior normal or abnormal
 Is this normal behavior?
 Setting (parameter or switch)?
 Is it a deviation from performance standard?
 How much is the deviation?
Prerequisites for successful troubleshooting
 Hydraulic and electric knowledge
 Operator manual
 TO & TT manual
 Hydraulic & Electrical diagram
 Let operator run machine and observe
 Any leakage around the machine?
 Who performs (daily) maintenance?
 Weather when problem noticed?
 Other machine troubles previously?
 Repair before problem first occurred?
 Repair after problem first occurred?
 How is the machine being used?
 Was machine operated correctly?
 Anything else we need to know?
 Special circumstances?
 Beware of assumptions
What-Who-When-Where-How much
 Fuel cock open/closed
 Engine stop switch
 Batteries, fuses, loose connectors
 Solenoid or sensor connectors (swapped?)
 Greasing of joints
 Engine oil level
 Coolant level
 Fuel filters & water separator
 Hydraulic oil level
 Check for machine fault codes
 Check monitoring values
 ICF data download
Mechanical
 Friction, jamming, blockage
 Noise or vibrations
Engine
 Does not start / can crank
 Does not start / cannot crank
 Shuts down unexpectedly
 Rpm (too low/ too high/ unstable)
 Exhaust gas (black/ white smoke)
 Vibrations, smell, noise, temperature
 Which test procedure was used?
 Is it the correct test procedure?
 Was it done in the correct way?
 Workshop manual
 Parts catalogue
 Engine manual
 Service Bulletins
 FACT FINDING
Ask Operator
 What is the problem?
 Who noticed the problem?
 When first noticed?
 Where was the problem first noticed?
 How much or severe is the problem?
 What could you see/ hear/ feel/ smell?
 Once, repeatedly or continuously?
 Last time machine worked normally?
 Pattern or trend?
 When does problem not occur?
 More machines with same problem?
 What job done when trouble noticed?
 Who else operated the machine?
 Is this a machine problem or is operator unhappy
with this model or machine size?
Inspect machine
 Machine model: ……………….
 Machine s/n: …………………..
 Hour meter: …………………...
 Observe general machine status
 Type of front and bucket size
 Hose Rupture Valves
 Front attachment
 Undercarriage
 Type of shoe, type of tire
 Optional parts or local modifications
 Machine history
 Signs of wear/damage/leakage
Operate the machine yourself
 What do you see/ hear/ feel/ smell?
 Can you compare with a good machine?
Hydraulic
 Speed (low/high, hesitate, shocks)
 Digging force (weak, not constant)
 Relief setting
 Sounds
Electric
 Warning signals/ lamps
 Switch/ dial malfunction
Is the observed behavior normal or abnormal
 Is this normal behavior?
 Setting (parameter or switch)?
 Is it a deviation from performance standard?
 How much is the deviation?
Prerequisites for successful troubleshooting
 Hydraulic and electric knowledge
 Operator manual
 TO & TT manual
 Hydraulic & Electrical diagram
 Let operator run machine and observe
 Any leakage around the machine?
 Who performs (daily) maintenance?
 Weather when problem noticed?
 Other machine troubles previously?
 Repair before problem first occurred?
 Repair after problem first occurred?
 How is the machine being used?
 Was machine operated correctly?
 Anything else we need to know?
 Special circumstances?
 Beware of assumptions
What-Who-When-Where-How much
 Fuel cock open/closed
 Engine stop switch
 Batteries, fuses, loose connectors
 Solenoid or sensor connectors (swapped?)
 Greasing of joints
 Engine oil level
 Coolant level
 Fuel filters & water separator
 Hydraulic oil level
 Check for machine fault codes
 Check monitoring values
 ICF data download
Mechanical
 Friction, jamming, blockage
 Noise or vibrations
Engine
 Does not start / can crank
 Does not start / cannot crank
 Shuts down unexpectedly
 Rpm (too low/ too high/ unstable)
 Exhaust gas (black/ white smoke)
 Vibrations, smell, noise, temperature
 Which test procedure was used?
 Is it the correct test procedure?
 Was it done in the correct way?
 Workshop manual
 Parts catalogue
 Engine manual
 Service Bulletins
 OVERVIEW TROUBLESHOOT PROCESS

1. FACT FINDING
Ask operator
Inspect machine
Operate the machine yourself
1. Fact Finding
Is behavior normal or abnormal?
yes QUICK FIX
Quic k fix ?
Can problem be explained simply?
no Can a simple solution be made?
2. Problem Description Is immediate action necessary?
5W method (keep asking “Why”)

3. Possible Causes TT manual 2. PROBLEM DESCRIPTION

What/Who/When/Where/How much
Be objective and specific
4. Most probable cause
3a. TT MANUAL
Search by Fault Code (part A)
5. Verify & check Search by Phenomenon (part B)

no 3b. LIST POSSIBLE CAUSES

Ro o t Caus e ? Use all information and ideas
yes Do not exclude causes beforehand
Cause/Assumption/Remark/Rank
6. Fix & Test
4. MOST PROBABLE CAUSE
no Why is this the most probable cause?
Tro uble fixe d? Why not another cause?
yes Is it a combination of causes?
7. Report 5. VERIFY & CHECK
Swap method
Pressure/flow/voltage/current
Change one thing & note result

6. FIX & TEST

Repair, replace or temporary solution
Test result within specification?
Prevent this problem in future?
Change maintenance interval?
Change lubricants?
Operator instruction needed?

7. REPORT
Make report in FIR
Can add photograph or small movie
Be clear and specific
 OVERVIEW TROUBLESHOOT PROCESS

1. FACT FINDING
Ask operator
Inspect machine
Operate the machine yourself
1. Fact Finding
Is behavior normal or abnormal?
yes QUICK FIX
Quic k fix ?
Can problem be explained simply?
no Can a simple solution be made?
2. Problem Description Is immediate action necessary?
5W method (keep asking “Why”)

3. Possible Causes TT manual 2. PROBLEM DESCRIPTION

What/Who/When/Where/How much
Be objective and specific
4. Most probable cause
3a. TT MANUAL
Search by Fault Code (part A)
5. Verify & check Search by Phenomenon (part B)

no 3b. LIST POSSIBLE CAUSES

Ro o t Caus e ? Use all information and ideas
yes Do not exclude causes beforehand
Cause/Assumption/Remark/Rank
6. Fix & Test
4. MOST PROBABLE CAUSE
no Why is this the most probable cause?
Tro uble fixe d? Why not another cause?
yes Is it a combination of causes?
7. Report 5. VERIFY & CHECK
Swap method
Pressure/flow/voltage/current
Change one thing & note result

6. FIX & TEST

Repair, replace or temporary solution
Test result within specification?
Prevent this problem in future?
Change maintenance interval?
Change lubricants?
Operator instruction needed?

7. REPORT
Make report in FIR
Can add photograph or small movie
Be clear and specific