Golden Rules of Troubleshooting

Jeff Liebermann <jeffl@cruzio.com> wrote:
> On Sat, 19 Dec 2015 01:55:44 -0800 (PST), jurb6006@gmail.com wrote:

[stuff cut]

- Most embarrassing moment: When the Chinese clone works better
than the original.

Anybody have good stories of this?
 
C

Cursitor Doom

Guest
Anyone care to share their experience on the correct approach to
troubleshooting? I'll kick off by suggesting:

1. Assume nothing.

Perhaps we can assemble a list of golden rules....
 
a) Assume nothing.
b) The nose knows.
c) The complexity of the problem is in inverse proportion to the symptoms displayed.
d) That one problem has been found and fixed does not imply that all problems have been either found or fixed.
f) First cause may be intermittent. What is observed may be secondary.

Peter Wieck
Melrose Park, PA
 
N_Cook <diverse@tcp.co.uk> wrote:
On 14/12/2015 14:05, Cursitor Doom wrote:
Anyone care to share their experience on the correct approach to
troubleshooting? I'll kick off by suggesting:

1. Assume nothing.

Perhaps we can assemble a list of golden rules....


First analysis instrument to use on removing the case cover - your nose

smell test is good.

check power, fuses, probe around for expected voltages. For example if
there's any sort of linear regulator check output, input, check voltages
on ICs. I deal with old stuff so there's always some 7400 series logic so
+5 is expected to be all over the place.

Look for burned parts, puffy caps, probe anything in areas with
heat-discolored circit boards, check and resolder and suspect joints by
parts that warms up. Diode check is a great feature on DMMS.

If you're dealing with suspect dried up caps, just solder a new one on
the solder side of the board and see if that helps at all. I like to add
parts on the bottom of the board, get things working then position parts
where they belong if all good.

If these things appear OK, then you have to narrow the problem down and
dig around into what the circuit should do vs. what's happening.

For intermittent problems tap the hell of boards, cable assemblies etc.
Check power supply voltages with the device cold AND after it warms up.

Just came across a machine that would crash fairly often, The problem
appears to be a mix of loose sensor and power connectors, a power supply
that drops voltage as it warms up, plus a dead cooling fan in the
electronics section. Just to keep things interesting, nothing warms up
that much with the service panels removed.
 
N_Cook <diverse@tcp.co.uk> wrote:
On 14/12/2015 18:02, Cydrome Leader wrote:
N_Cook <diverse@tcp.co.uk> wrote:
On 14/12/2015 14:05, Cursitor Doom wrote:
Anyone care to share their experience on the correct approach to
troubleshooting? I'll kick off by suggesting:

1. Assume nothing.

Perhaps we can assemble a list of golden rules....


First analysis instrument to use on removing the case cover - your nose

smell test is good.

check power, fuses, probe around for expected voltages. For example if
there's any sort of linear regulator check output, input, check voltages
on ICs. I deal with old stuff so there's always some 7400 series logic so
+5 is expected to be all over the place.

Look for burned parts, puffy caps, probe anything in areas with
heat-discolored circit boards, check and resolder and suspect joints by
parts that warms up. Diode check is a great feature on DMMS.

If you're dealing with suspect dried up caps, just solder a new one on
the solder side of the board and see if that helps at all. I like to add
parts on the bottom of the board, get things working then position parts
where they belong if all good.

If these things appear OK, then you have to narrow the problem down and
dig around into what the circuit should do vs. what's happening.

For intermittent problems tap the hell of boards, cable assemblies etc.
Check power supply voltages with the device cold AND after it warms up.

Just came across a machine that would crash fairly often, The problem
appears to be a mix of loose sensor and power connectors, a power supply
that drops voltage as it warms up, plus a dead cooling fan in the
electronics section. Just to keep things interesting, nothing warms up
that much with the service panels removed.









There is problem with "twizzling" for intermittant soder joint failure,
if it is a PbF board. Its too easy to temporarily "fix" a failed joint.
I start with light touching stuff with a bird feather, while switched
on. Then firmer twizzling.
Then hot air or freezer spray.
Then if I auapect a PbF failure ,an adapted engraver tool with a shaped
nylon bolt in place of the engraving tip, to rattle the board, listening
on headphones , if an audio amp.

I'm pleased to say I don't really deal with PbF stuff. How often do you
find bad joints that looked OK (well, as good as PbF looks) and did have
weird cracking or separating from the part lead?

Do you do repairs with real solder or that fake tin stuff?
 
On 14/12/2015 14:05, Cursitor Doom wrote:
Anyone care to share their experience on the correct approach to
troubleshooting? I'll kick off by suggesting:

1. Assume nothing.

Perhaps we can assemble a list of golden rules....

First analysis instrument to use on removing the case cover - your nose
 
On 14/12/2015 18:02, Cydrome Leader wrote:
N_Cook <diverse@tcp.co.uk> wrote:
On 14/12/2015 14:05, Cursitor Doom wrote:
Anyone care to share their experience on the correct approach to
troubleshooting? I'll kick off by suggesting:

1. Assume nothing.

Perhaps we can assemble a list of golden rules....


First analysis instrument to use on removing the case cover - your nose

smell test is good.

check power, fuses, probe around for expected voltages. For example if
there's any sort of linear regulator check output, input, check voltages
on ICs. I deal with old stuff so there's always some 7400 series logic so
+5 is expected to be all over the place.

Look for burned parts, puffy caps, probe anything in areas with
heat-discolored circit boards, check and resolder and suspect joints by
parts that warms up. Diode check is a great feature on DMMS.

If you're dealing with suspect dried up caps, just solder a new one on
the solder side of the board and see if that helps at all. I like to add
parts on the bottom of the board, get things working then position parts
where they belong if all good.

If these things appear OK, then you have to narrow the problem down and
dig around into what the circuit should do vs. what's happening.

For intermittent problems tap the hell of boards, cable assemblies etc.
Check power supply voltages with the device cold AND after it warms up.

Just came across a machine that would crash fairly often, The problem
appears to be a mix of loose sensor and power connectors, a power supply
that drops voltage as it warms up, plus a dead cooling fan in the
electronics section. Just to keep things interesting, nothing warms up
that much with the service panels removed.

There is problem with "twizzling" for intermittant soder joint failure,
if it is a PbF board. Its too easy to temporarily "fix" a failed joint.
I start with light touching stuff with a bird feather, while switched
on. Then firmer twizzling.
Then hot air or freezer spray.
Then if I auapect a PbF failure ,an adapted engraver tool with a shaped
nylon bolt in place of the engraving tip, to rattle the board, listening
on headphones , if an audio amp.
 
Cursitor Doom wrote:
Anyone care to share their experience on the correct approach to
troubleshooting? I'll kick off by suggesting:

1. Assume nothing.

Perhaps we can assemble a list of golden rules....

** Troubleshooting is like a maze, there are many starting points and blind alleys to negotiate on your the way to the goal.

Unfamiliar equipment requires a more cautious approach than familiar items.

Always observe the fault carefully *before* starting disassembly and find out what functions work and what do not.

Owner's descriptions are often misleading or fail to mention important issues, but you still need to find out what prompted that description.

Bench tests need to simulate actual use or worst case use, but beware of simulating abuse.

When stuck on a problem, take a break and start over a day or so later.




..... Phil
 
Cursitor Doom wrote:

Anyone care to share their experience on the correct approach to
troubleshooting? I'll kick off by suggesting:

1. Assume nothing.

Perhaps we can assemble a list of golden rules....
Well, usually that is a very good rule, and saves time chasing what you
THINK the problem must be, when in fact it is something novel you haven't
seen before.

But, then, I have repaired a few thing recently, where past experience told
me what the most likely failure was, and that was the correct thing to fix.

Jon
 
On Monday, December 14, 2015 at 6:07:52 AM UTC-8, Cursitor Doom wrote:
Anyone care to share their experience on the correct approach to
troubleshooting?

Make a block diagram. It may only be a mental picture, but it's an important
step toward tracking a symptom down.

I taught a class of technicians once, from a local factory... the
block-diagram-exercise got them talking amongst themselves more
productively than any other lesson.
 
Most important, assume nothing. As soon as you think you know what is wrong, it is impossible not to ignore contrary evidence.

I work with some engineers who are good designers because they keep their brain fixed on the goal and work through every obstacle. They THINK they are also good troubleshooters but they are wrong, obstinately frustratingly wrong, for the same reason. They KNOW what is wrong too early, and nothing shakes their belief.

Second. When anybody tells you the symptoms, listen. When they tell you why, STOP! Don't listen. It will probably be theoretically impossible, and then you end up doubting the symptoms. Sorry but this is especially a problem with techs and mechanics. They observe correctly but theorize contrary to the laws of physics, so you need to stop listening when they get to that point.
 
On Tuesday, December 15, 2015 at 7:37:47 AM UTC-8, John Robertson wrote:
Capacitors?

Back in the old days, McIntosh used to have clinics where owners could have their equipment restored up to specifications for free. I remember watching them start by routinely replacing all of the cathode bypass electrolytics; they would then check and replace the tubes, as neceeary. They rarely had to go farther (but would if required).
 
This thread, to me, represents the best of what newsgroups like this are
for.

1. The aforementioned "assume nothing". (probably should have been ALL CAPS)

2. Correlate stated or observed malfunction with:
a.) Visual inspection and yes, often smell checks.
b.) Power supply checks.
c.) Again, check for mechanically intermittent connections.

3. Don't assume too much from DC voltage checks with a multimeter. A 'scope
can often give you the best "eyes" into what the circuit is actually doing.

Nevertheless, a good multimeter can give really great information
interpreting voltage drops, finding leaky or shorted nodes, bias issues,
etc.

Too many people just start off re-capping for example, assuming this fixes
almost everything. I'm sick to death of hearing this from customers who have
been on the internet.

Another thread here, I see...

Mark Z.
 
Phil Allison wrote:
Cursitor Doom wrote:


Anyone care to share their experience on the correct approach to
troubleshooting? I'll kick off by suggesting:

1. Assume nothing.

Perhaps we can assemble a list of golden rules....



** Troubleshooting is like a maze, there are many starting points and
blind alleys to negotiate on your the way to the goal.

Unfamiliar equipment requires a more cautious approach than familiar
items.

Always observe the fault carefully *before* starting disassembly and
find out what functions work and what do not.

Owner's descriptions are often misleading or fail to mention
important issues, but you still need to find out what prompted that
description.

Bench tests need to simulate actual use or worst case use, but beware
of simulating abuse.

When stuck on a problem, take a break and start over a day or so
later.




.... Phil

"When stuck on a problem, take a break and start over a day or so
later." I cannot tell you how many problems I solved while doing that.
Sometimes getting just getting away from the problem allows clearer
thought.
 
On 15/12/2015 12:24, Ken wrote:
Phil Allison wrote:
Cursitor Doom wrote:


Anyone care to share their experience on the correct approach to
troubleshooting? I'll kick off by suggesting:

1. Assume nothing.

Perhaps we can assemble a list of golden rules....



** Troubleshooting is like a maze, there are many starting points and
blind alleys to negotiate on your the way to the goal.

Unfamiliar equipment requires a more cautious approach than familiar
items.

Always observe the fault carefully *before* starting disassembly and
find out what functions work and what do not.

Owner's descriptions are often misleading or fail to mention
important issues, but you still need to find out what prompted that
description.

Bench tests need to simulate actual use or worst case use, but beware
of simulating abuse.

When stuck on a problem, take a break and start over a day or so
later.




.... Phil


"When stuck on a problem, take a break and start over a day or so
later." I cannot tell you how many problems I solved while doing that.
Sometimes getting just getting away from the problem allows clearer
thought.

Posting a query to some "social media" may not ellicit the solution but
some suggesting will often set you thinking in a different train. Its so
easy to decide in your own mind that the problem must be in some
particular narrow area and you totally overlook a completely valid
alternative area.
 
On Tue, 15 Dec 2015 07:37:42 -0800, John Robertson wrote:

I must confess we do replace almost all electrolytic caps that are more
than about 30 years old in our vintage game monitors and amplifiers
(video/pinball/jukebox) as this saves a tremendous amount of
troubleshooting time.

Does it, though? I mean, you could save even more time by just running
all the caps through an ESR meter test and just replacing those that
fail. Given how fragile some of those old PCB traces can be, I'd only
want to replace the caps that really way out of spec.
 
On Tuesday, December 15, 2015 at 1:18:52 PM UTC-5, Cursitor Doom wrote:
On Tue, 15 Dec 2015 07:37:42 -0800, John Robertson wrote:

I must confess we do replace almost all electrolytic caps that are more
than about 30 years old in our vintage game monitors and amplifiers
(video/pinball/jukebox) as this saves a tremendous amount of
troubleshooting time.

Does it, though? I mean, you could save even more time by just running
all the caps through an ESR meter test and just replacing those that
fail. Given how fragile some of those old PCB traces can be, I'd only
want to replace the caps that really way out of spec.

I used to do a local vendor's arcade monitors, and I can tell you that a cap that might pass an ESR test may destroy the vertical output on power up when left to sit in an unheated warehouse a week or so during it's route rotation.

I always recapped arcade monitors because of the wild temp extremes they would often see.
 
On 12/15/2015 4:17 AM, Mark Zacharias wrote:
This thread, to me, represents the best of what newsgroups like this are
for.

1. The aforementioned "assume nothing". (probably should have been ALL
CAPS)

2. Correlate stated or observed malfunction with:
a.) Visual inspection and yes, often smell checks.
b.) Power supply checks.
c.) Again, check for mechanically intermittent connections.

3. Don't assume too much from DC voltage checks with a multimeter. A
'scope can often give you the best "eyes" into what the circuit is
actually doing.

Nevertheless, a good multimeter can give really great information
interpreting voltage drops, finding leaky or shorted nodes, bias issues,
etc.

Too many people just start off re-capping for example, assuming this
fixes almost everything. I'm sick to death of hearing this from
customers who have been on the internet.

Another thread here, I see...

Mark Z.

Capacitors?

<ducking>

I must confess we do replace almost all electrolytic caps that are more
than about 30 years old in our vintage game monitors and amplifiers
(video/pinball/jukebox) as this saves a tremendous amount of
troubleshooting time. It is true that perhaps 60% of the caps replaced
are fine, but the rest are marginal at best and make all sorts of errors
creep in that would take hours to find otherwise.

</ducking>

While we are in there we check resistors on
collectors/emitters/plates/cathodes as they often drift out of value.
However those we only change if off more than 10%

John :-#)#

--
(Please post followups or tech inquiries to the USENET newsgroup)
John's Jukes Ltd. 2343 Main St., Vancouver, BC, Canada V5T 3C9
(604)872-5757 or Fax 872-2010 (Pinballs, Jukes, Video Games)
www.flippers.com
"Old pinballers never die, they just flip out."
 
"John Robertson" <spam@flippers.com> wrote in message
news:v72dnRqUANBaru3LnZ2dnUU7-V-dnZ2d@giganews.com...
Capacitors?

ducking

I must confess we do replace almost all electrolytic caps that are more
than about 30 years old in our vintage game monitors and amplifiers
(video/pinball/jukebox) as this saves a tremendous amount of
troubleshooting time. It is true that perhaps 60% of the caps replaced are
fine, but the rest are marginal at best and make all sorts of errors creep
in that would take hours to find otherwise.

It all depends on the cost and how much later down time you want to take a
chance on.

At work we had a 200 HP motor drive control that quit and we called in a
factory repair man. He determined that 2 large diodes ( arund 600 volt and
100 amp or so) were bad. AS this was a 3 phase unit , there were 3 diodes.
I told him to replace the 3 rd one as it may have had some stress on it and
may fail later. He said he would but it was $ 50 for the diode. I told
him that at what we were paying him and the ammount of production it would
cost that $ 50 was nothing worth even thinking about.
 
"Ken" <Ken@invalid.com> wrote in message news:n4p0le$58i$1@dont-email.me...
"When stuck on a problem, take a break and start over a day or so
later." I cannot tell you how many problems I solved while doing that.
Sometimes getting just getting away from the problem allows clearer
thought.
That often works. If possiable after working on a problem for a while, as
someone else to take a look at it. Don't even tell him what you have done
or checked.

I found that it is beter for me when asked for help to not even listen to
what others have checked. It does pay to listen to see what parts they may
have changed out. Then check those parts to make sure they are good and
installed correctly.

I have done two things that rate as my worst boners. First was a problem
with a SCR temperature controler. Thought I had repaired it, but when
turning on the power it would blow a fuse. Did that 3 times and I just
could not understand it. The next fuse I installed, I checked it and it was
bad. Turned out when I checked the parts bin that half of the new ones were
bad.

Another one was when I replaced a part that came with about 20 feet of 5
wire cable of about # 20 wire. I used the old wire to pull the new wire
through the conduit. Some how I got distracted for a while and then when I
connected the wires, I had forgotten to cut off the old wire. That ment I
connected one end of the old wire back up and the other end was not
connected to anything. I asked someone else to see what it was that I had
done wrong as I knew it must be something simple that I over looked. He
took one look in the junction box and asked why there was so much wire in
it. Then found out what I had did wrong.
 

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