Troubleshooting is a method of finding the cause of a problem and correcting it. The ultimate goal of troubleshooting is to get the equipment back into service as quickly and as fully as possible. Time is of the essence because the entire operation depends on the troubleshooter’s ability to solve the problem efficiently and economically. Troubleshooters on most job sites are the mechanics.

Although the actual steps in troubleshooting may vary from case to case, there are a few general guidelines to follow. Sometimes it’s a familiar piece of equipment that breaks down, and the problem can be solved and rectified quickly. All too often, though, the root cause is buried deep in the equipment’s systems, and it turns into a lengthy and frustrating exercise before the machinery is dependably functional again.

The troubleshooting process doesn’t need to be complicated if a logical, step-by-step process is followed that is specific to the problem at hand. Here are the five basic steps to troubleshooting equipment breakdowns:

1. VERIFY A PROBLEM ACTUALLY EXISTS

The troubleshooting process begins with symptom recognition. That involves the equipment operator, equipment indicators, controls and the technical documentation about the equipment and its systems. Contacting the equipment operator should be the first action taken as they’re usually the most familiar with the equipment and can supply the primary details about the breakdown circumstances.

To get the most information, the troubleshooter should ask:

What are the operator’s indications of the trouble?

How did the operator discover the trouble?

What were the conditions at the time the trouble occurred?

Is the trouble constant or intermittent?

Next, the troubleshooter should observe the equipment or system to get a first-hand impression of what’s wrong. During this, the troubleshooter should note all abnormal symptoms, evaluate what’s observed and examine the equipment’s log or other documentation. Working with the operator to determine exactly what the problem is will lead into isolating the cause.

2. NARROW DOWN THE PROBLEM’S ROOT CAUSE

The second step of the troubleshooting process heavily relies on the troubleshooter’s technical skills, experience and intuition. The troubleshooter is responsible for narrowing down the root cause of the problem. This is done by using testing equipment and reading the equipment’s instruments. Disassembly may be required if nothing results from making any adjustments to the equipment’s components. It also involves mental activity such as logic, reasoning and evaluation. The troubleshooter’s specialized knowledge plays a key part of the isolation process, and they follow a safe and effective procedure. Troubleshooters isolate causes by:

Looking at low maintenance items first and examining all convenient possibilities to save time

Familiarizing themselves with any specific modes that could help in troubleshooting such as built-in self-tests and diagnostics

Complying with all field safety protocols

Making sure systems are de-energized and off-line before dismantling

Identifying obvious items but also being aware of those that are hidden

Almost all pieces of construction machinery have operation manuals and/or equipment logs. Many have troubleshooting checklists and guidelines. This should be a main source of information for the troubleshooter and can help to eliminate much of the “educated guess-work” that’s used in eliminating issues and drilling down to the cause of the problem. Once the cause is isolated to a specific component, the construction equipment repair can take place.

3. CORRECTING THE CAUSE OF THE PROBLEM

This step involves rectifying the problem by performing the construction equipment repair or activity that eliminates the issue. It can also involve calling in a temporary replacement or a backup piece of equipment such as a rental or spare machine. This should be part of the company’s overall breakdown preparedness program. Sometimes the construction equipment repair is as simple as turning a switch or adjusting a valve, but often it involves replacing a major component or occasionally the entire machine. In an attempt to fix the issue, the troubleshooter will test, analyze and retest the equipment. It’s vitally important that the cause of the problem is eliminated rather than just fixing the component that’s affected. Failing to deal with the actual cause such as adjusting another component to compensate for the problem will always lead to further complications and future breakdowns.

4. VERIFY THE PROBLEM IS CORRECTED

Testing the component to verify the cause of the breakdown is always done before the machinery is returned to active service. Typically, it will be necessary to double-check the same components that alerted the operator to the initial breakdown. The purpose here is to prove that the issue no longer exists. and must be thorough. When there are both quick and long procedures available, the longer method is preferable even if it may take more time. This helps ensure the problem is rectified and not masking another issue, which will repeat the breakdown.

During the verification process, these observations should be made:

Check all as gauges, readings and physical operation that related to the repaired item

Perform manufacture’s recommended process to verify the component’s integrity, the system or the entire piece of machinery

Using approved procedures, establish normally operating conditions and check the equipment while running

By thoroughly verifying the equipment’s proper operation, the operator and the troubleshooter are relatively assured that the problem has been correctly resolved. To help ensure the problem doesn’t reoccur, a follow-up is normally done.

5. PREVENT FUTURE ISSUES BY FOLLOWING UP

The fifth and final step in troubleshooting is the follow up that will limit and prevent future issues. Making recommendations and taking precautions will keep the piece of equipment from breaking down again. Actions may include:

Altering the preventive maintenance schedule or procedure

Recommending procedure modifications for more dependable performance

Conducting operator/maintainer awareness training

Changing suppliers of components or services

Completing proper and detailed documentation of the problem and repair in the equipment logbook to assist while troubleshooting similar problems in the future

Although the system test, retest and preventive measures may not seem as important as isolating the problem, fixing it and getting the machine back in operation, the time spent is vital to long-term productive performance.