PLUG 0531637 - Caterpillar

Test Steps for a Machine That Cannot Start
To diagnose the problem(s) on a machine that has dead batteries, use the following procedure.
Connect the batteries of the machine that does not start to the batteries of the booster. Note: See the section on jumping the engine with starter cables in the OMM for the correct machine.
Connect the 6V-2150 Starting/Charging Analyzer to the diagnostic connector.
Complete the first three test steps for the analyzer in order to obtain the necessary diagnosis. The following test steps should be performed:
"Test Setup A, Hookup"
"Test Step B, Crank"
"Test Step C, Start Aid"
Start the engine of the machine that did not start. Disconnect the booster from the machine. See the section on jumping the engine with starter cables in the OMM for the correct machine.
Perform "Test Step D" in order to obtain the necessary diagnosis. The voltage of the former dead batteries should start to increase and the indicator lamp for the alternator should illuminate. The lamp indicates proper operation of the alternator. Stop the engine. Perform test step A through D in order to obtain the diagnosis of the defect according to the test results.Note: The lamps for the analyzer may not give a correct indication while the booster is connected to the dead batteries.Test Steps for Machines That are Equipped with a 3208 Engine
The fuel system on a 3208 Engine does not have a mechanical shutoff. The 3208 engines have an electrically operated shutoff solenoid that is located on the fuel pump housing.The electrically operated shutoff solenoid is automatically activated for approximately thirty seconds when the key start switch is turned OFF. Older models activate the shutoff solenoid for approximately seventy seconds.Use the following procedure in order to keep the engine from starting during "Test Step B, Crank".
Use a piece of 14 GA, 16 GA, or 18 GA wire that is approximately 2000 mm (79 in) in length to make a jumper wire. Install a #63 clip or an equivalent clip to one end of the wire. Install a 46-A clip for a battery or an equivalent clip to the other end of the wire.
Connect the jumper wire to the "MOTOR" terminal of the starter solenoid and to "BATTERY" terminal of the shutoff solenoid. Note: The jumper wire will activate the shutoff solenoid when the engine is cranking. The jumper wire will prevent the engine from starting during "Test Step B, Crank".
Check starter cycle: Thirty seconds of cranking requries two mintues of cool down.Do NOT connect the shutdown solenoid directly to 24 volts. This could damage the coil.
Connect the 6V-2150 Starting/Charging Analyzer to the diagnostic connector. Complete the first three test steps for the analyzer in order to obtain the necessary diagnosis for any machine. The following test steps should be performed:
"Test Setup A, Hookup"
"Test Step B, Crank"
"Test Step C, Start Aid"
Disconnect the jumper wire. Complete "Test Step D, High Idle.". Test Steps for Machines That are Equipped with Energize-to-Run Fuel Shutoff Solenoids
Note: This test does not apply to 3208 Engines.The fuel