BOLT 5F3492 - Caterpillar

General Information
All electrical starting systems have four elements:
Keyswitch
Start relay
Starting motor solenoid
Starting motorThe starting motor solenoid is a switch with a capacity of about 1000 amperes. The starting motor solenoid supplies power to the starter drive. The starting motor solenoid also engages the pinion to the flywheel.The starting motor solenoid has two coils. The pull-in coil draws about 40 amperes. The hold-in coil requires about 5 amperes.When the magnetic force increases in both coils, the pinion gear moves toward the ring gear of the flywheel. Then, the solenoid contacts close in order to provide power to the starting motor. When the solenoid contacts close, the ground is temporarily removed from the pull-in coil. Battery voltage is supplied on both ends of the pull-in coil while the starting motor cranks. During this period, the pull-in coil is out of the circuit.Cranking of the engine continues until current to the solenoid is stopped by releasing the keyswitch.Power which is available during cranking varies according to the temperature and condition of the batteries. Table 1 shows the voltages which are expected from a battery at the various temperature ranges.
Table 1
Typical Voltage Of Electrical System During Cranking At Various Ambient Temperatures
Temperature 12 Volt System 24 Volt System
−23 to −7°C (−10 to 20°F) 6 to 8 volts 12 to 16 volts
−7 to 10°C (20 to 50°F) 7 to 9 volts 14 to 18 volts
10 to 27°C (50 to 80°F) 8 to 10 volts 16 to 24 volts Table 2 shows the maximum acceptable loss of voltage in the battery circuit. The battery circuit supplies high current to the starting motor. The values in the table are for engines which have service of 2000 hours or more.
Table 2
Maximum Acceptable Voltage Drop In The Starting Motor Circuit During Cranking
Circuit 12 Volt System 24 Volt System
Battery post "-" to the starting motor terminal "-" 0.7 volts 1.4 volts
Drop across the disconnect switch 0.5 volts 1.0 volts
Battery post "+" to the terminal of the starting motor solenoid "+" 0.5 volts 1.0 volts
Solenoid terminal "Bat" to the solenoid terminal "Mtr" 0.4 volts 0.8 volts Voltage drops that are greater than the amounts in table 2 are caused most often by the following conditions:
Loose connections
Corroded connections
Faulty switch contactsDiagnosis Procedure
The procedures for diagnosing the starting motor are intended to help the technician determine if a starting motor needs to be replaced or repaired. The procedures are not intended to cover all possible problems and conditions. The procedures serve only as a guide.
If equipped with electric start, do not crank the engine for more than 30 seconds. Allow the starter to cool for two minutes before cranking again.Never turn the disconnect switch off while the engine is running. Serious damage to the electrical system can result.
If the starting motor does not crank or cranks slow, perform the following procedure:
Measure the voltage of the battery. Measure the voltage across the battery posts with the multimeter when you are cranking the engine or attempting to crank the engine. Do not measure the voltage across