BOOM OUT -1B 2036746 - Caterpillar

LOADERS
988F (8YG),
990 (7HK),
992D (7MJ) 994 (9YF)Reference: QUESTIONS AND ANSWERS ABOUT CAT ADHESIVES, SEALANTS AND MAINTENANCE PRODUCTS - FORM NO NEXG4502.DISTRIBUTION: TECHNICAL COMMUNICATORS, SERVICE/WORKSHOP MANAGERS, SERVICEMEN TRAINING DEPARTMENTSProblem:
We have received complaints about intermittent faults, excessive loop resistance and systems malfunctionning, due to corroded connections and poor grounds.DISSUSSION:Electronic control systems are based on the principle of: Inputs - Processor - Outputs. - Inputs being switches and sensors, the processor a preprogrammed mini-computer & the outputs - solenoids and warning systems . As in every system, there is a weak link. In electrical systems, it's probably the connectors, terminals, ground connections and - to a lesser degree - harnesses.WHY:Connectors of any sort, terminals and ground straps are hard to protect from corrosion, vibrations, heat, climatic conditions, pressure washers, etc. - Hence - corrosion and loose connections can finally increase the "loop resistance" above a "valid range" and cause a "fault". It is estimated, that over 80% of all "faults" in electrical systems originate in one way or another in "connections" and not in switches, sensors, processors and solenoids.HOWEVER: Even though those components are usually extremely reliable - due to thermal cycling & vibrations - they still have a "finite" life span as well. - Determining a realistic "life cycle" and changing them out on a preventive basis makes the most amount of sense to avoid unscheduled downtime.Solution:
To insure low resistant, good connections, be this battery terminals, ground straps, plugs, connectors, screw on solenoid cable shoes or whatever, first thing to do - if a fault occurs - is a thorough check up and clean up of the connectoins and NOT a swap out of switches, sensors and processors! - The system itself should indicate where to start with troubleshooting, with the help of the fault code readout on the processor.After the cleanup, and to avoid reoccurrence of excessive corrosion resistance, products like the 8T9020 Dielectric Tune up Grease can be used. - for more information, please consult the above mentioned Form No - NEXG4502.CATERPILLAR MINING BUSINESS UNIT COPYRIGHT 1994 CATERPILLAR ALL RIGHTS RESERVED