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12B30

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Mechanical Engineering

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Feb 20, 2024

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Running head: TROUBLESHOOTING PROCESS 1 Troubleshooting Process Danial P. Flynn ALC Class 001-19
TROUBLESHOOTING PROCESS 2 Troubleshooting Process Troubleshooting plays a vital role in any successful solution to a problem. It can serve as a solution form technical to tactical, and anything in between. As Prime Power Soldiers, it is our duty to become proficient in the process of troubleshooting. Troubleshooting is done on a daily basis, whether we notice it or not. Troubleshooting is one of the main fundamentals that a Prime Power Soldier should know as part of their skillset. There are four major steps in the troubleshooting process. Each of the steps should be conducted in order to find a suitable resolution for any given problem. Troubleshooting is defined as an organized activity aimed at identifying and rectifying an incidental defect (12P3E04, pg. 30). There are four phases that are included in the troubleshooting process. The phases are symptom recognition and elaboration, identification of the probable causes, repairing the defect and reporting the outcome. Each of these phases serves as valuable pieces in effectively identifying a problem and finding a solution. All of the phases must be conducted in sequence to find a solution to any given problem efficiently. The first phase in the troubleshooting process is symptom recognition and elaboration. As a Prime Power Soldier, having sufficient knowledge of our mechanical, electrical and instrumentation systems are immensely important. Knowing the system and being able to identify any abnormalities are critical aspects in the first phase of the troubleshooting process. For example, one day while performing proper preventative maintenance checks and service, you start the generator set. Thick black smoke is billowing out of the exhaust stack. This is an abnormality, and being a subject matter expert, you immediately know that it is an air to fuel ratio. You also notice excessive oil leakage coming out of the oil pan. You see there is a tear in the oil pan gasket. These examples are all part of system recognition.
TROUBLESHOOTING PROCESS 3 The second phase in the troubleshooting process is identifying a probable cause to an abnormality. For example, while trying to start the generator set, you hear it crank, but it fails to start. The first step of this phase is to consult the proper technical manual. For this example, TM 9-6115-746-13-3 has multiple possible probable causes for this malfunction. The different possible probable causes for this malfunction include fuel, incorrect engine timing, intake air or a possible faulty engine fuel pump. The procedures to effectively troubleshoot the probable causes are located in (Table 1. Basic Engine Troubleshooting Procedures) in TM 9-6115-746-13-3, pg. 1-4. The third phase in the troubleshooting process is to repair the defect. When a probable cause is correctly identified, corrective actions are listed in the troubleshooting tables in TM 9- 6115-746-13-3. For this example, you notice excessively black exhaust coming out of the exhaust stack. You consult the technical manual and see that the probable causes listed are a faulty turbocharger, incorrect engine timing, intake air, or engine overloading. Step one is to check the turbocharger in accordance with WP 0013 00, in TM 9-6115-746-13-3. It states to check and ensure the turbocharger freely spins and is not visibly damaged. If free movement is not observed, the replacement of the turbocharger is recommended. For all the other probable causes all have corrective actions for either repairing or replacing in their respective WP. If the problem still exists after corrective actions have been made, returning to phase 2 (isolation) is recommended. The fourth and final phase is reporting the outcome. This includes an after-action report, documenting corrective actions and probable causes in the maintenance logs and having proper caution and clearances logs. Having adequate documentation of any incident is an excellent way to keep track of a fault and have historical records in case the fault occurs again. There might be
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TROUBLESHOOTING PROCESS 4 a different fault that is supplementing the corrected deficiency. Faults and deficiencies should be annotated inside the maintenance logs while conducting operations and also annotated on the specific piece of equipment’s 5988E (Equipment and Maintenance Inspection Worksheet). Reporting of the fault or discrepancy should be reported to a supervisor. Having a proper troubleshooting process and knowing your equipment is crucial as being a Prime Power Soldier. Being able to properly troubleshoot and having good knowledge of the equipment and their respective manuals play a vital role in our organization. It is important to always refer to the proper manuals when conducting troubleshooting procedures and not just guess what a problem might be. Not using the correct manual or manufacturer's literature can have adverse negative effects on personnel or the equipment.
TROUBLESHOOTING PROCESS 5 References LSA 2 12P3E04. (2019). Fort Leonard Wood. Troubleshooting Procedures TM 9-6115-746-13-3. (2009). Herndon: DRS TSI.