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Electrical Gremlins – Diagnosing Intermittent Power Issues

By Sammuel MacMullin | Proven Mining Solutions Inc.


⚡ Electrical Gremlins – Diagnosing Intermittent Power Issues

Few things test a mechanic’s patience like intermittent electrical problems. One moment the machine fires right up — the next it’s dead as a rock. Or maybe it works fine all week, then throws codes at the worst possible time.

We call them gremlins for a reason. They hide, they wait, and they drive techs crazy. But with the right approach, you can track them down before they derail production.


⚙️ Why Electrical Health Matters

  • Reliability. A machine with electrical issues isn’t reliable — and an unreliable fleet costs money.

  • Safety. Shorts, arcing wires, or bad grounds can lead to fires or sudden shutdowns.

  • Diagnostics. Electrical faults often masquerade as hydraulic or fuel issues, wasting time and money.


🔎 Where to Start When Hunting Gremlins

1. Battery & Cables

The starting point for every electrical problem. Check voltage under load, inspect for corroded or loose terminals, and make sure ground straps are clean and tight.

2. Wiring Harnesses

Look for rub points where harnesses contact the frame, moving parts, or sharp edges. A wire that’s “just touching” can cause intermittent shorts.

3. Connectors

Moisture, dust, and vibration wreak havoc on connectors. Loose pins, corroded plugs, or bent contacts are common culprits.

4. Switches & Relays

A failing relay or worn switch can act up sporadically, especially in cold weather. Don’t overlook the simple stuff.

5. Sensors

Intermittent sensor faults often show up as codes that clear themselves. If a code comes and goes, don’t just erase it — dig deeper.

*After*
*After*

📏 Tools That Make Life Easier

  • Multimeter. The basic must-have for every electrical diagnosis.

  • Load tester. A battery may show 12.6V until it’s under strain — then it collapses.

  • Power probe. Speeds up tracing power and grounds.

  • OEM software. Pull live data and fault histories to pinpoint problems faster.


❌ Common Mistakes

  • Parts swapping. Throwing parts at the problem without testing wastes time and money.

  • Skipping grounds. Many “mystery issues” are solved with a cleaned ground strap.

  • Ignoring connectors. A $0.50 pin can shut down a $500,000 machine.

  • Not duplicating the fault. If you can’t recreate the issue, you haven’t found the cause.

  • Overlooking operator feedback. “It only happens when…” is usually your biggest clue.

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Before
Before
🧠 Pro Tips from the Field

  • Move the harness while monitoring voltage — if it drops, you’ve found your rub.

  • Use dielectric grease on connectors after cleaning to prevent repeat failures.

  • Never underestimate the power of patience — electrical problems reward thorough techs, not fast ones.


🔧 Proven Mining Has You Covered

Whether it’s a wiring rub, a failed connector, or a faulty sensor throwing codes, Proven Mining Solutions has the tools and experience to find and fix the issue. We’ll get your fleet powered up and reliable again.

📞 587-723-8777

 
 
 

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