Solenoid (Starting Motor) − Replace{1467} Caterpillar


Solenoid (Starting Motor) − Replace{1467}

Usage:

769C 01X
Articulated Truck:
D400D (S/N: 8TF1-UP)
D44 (S/N: 2LD1-UP)
D44B (S/N: 8SD1-UP)
D550 (S/N: 4RD1-UP)
D550B (S/N: 5ND1-UP)
Cold Planer:
PR-450C (S/N: 7PJ1-UP)
Landfill Compactor:
816 (S/N: 57U1-UP)
826C (S/N: 87X1-UP)
836 (S/N: 3RL1-UP; 7FR1-UP)
Soil Compactor:
815 (S/N: 91P1-UP)
Engine:
3196 (S/N: 1DW1-UP)
3306 (S/N: 64Z1-UP)
3408C (S/N: 9XM1-UP)
3408E (S/N: 7PR1-UP)
3412 (S/N: 2WJ1-UP)
3412C (S/N: RLR1-UP; 8AR1-UP; 9BR1-UP)
3412E (S/N: 4CR1-UP; BFT1-UP)
3508 (S/N: CNE1-UP; CNF1-UP; CAW1-UP; 95Y1-UP; 96Y1-UP; 23Z1-UP; 68Z1-UP; 69Z1-UP; 70Z1-UP)
3508B (S/N: CNB1-UP; 2BM1-UP; 3DM1-UP; 7SM1-UP; 1TW1-UP; 3DW1-UP; BGX1-UP; BPX1-UP)
3512 (S/N: CMJ1-UP; CPK1-UP; CNP1-UP; FDR1-UP; 6WW1-UP; 49Y1-UP; 50Y1-UP; 51Y1-UP; 24Z1-UP; 65Z1-UP; 66Z1-UP; 67Z1-UP)
3512B (S/N: BRC1-UP; CMC1-UP; FDE1-UP; BLF1-UP; PTF1-UP; 2AF1-UP; BRK1-UP; 7HM1-UP; 8EM1-UP; 8RM1-UP; BRN1-UP; 4TN1-UP; 6WN1-UP; 1PW1-UP; 2GW1-UP; 3ZW1-UP; 4AW1-UP; 5AW1-UP; 6GW1-UP; 2EZ1-UP)
3516 (S/N: CMD1-UP; CAL1-UP; 7KM1-UP; 8TW1-UP; 25Z1-UP; 27Z1-UP; 29Z1-UP; 71Z1-UP; 72Z1-UP; 73Z1-UP)
3516B (S/N: CPA1-UP; CDE1-UP; BPJ1-UP; BCK1-UP; CAN1-UP; FDN1-UP; 6HN1-UP; 7RN1-UP; 8CN1-UP; 8KN1-UP; 9AN1-UP; 1NW1-UP; 2FW1-UP; 2JW1-UP; 3CW1-UP; 4BW1-UP; 8NW1-UP; FDX1-UP)
3606 (S/N: 8RB1-UP)
3608 (S/N: 6MC1-UP)
C-10 (S/N: BCX1-UP)
C-12 (S/N: BDL1-UP)
D342 (S/N: 31B1-UP; 32B1-UP)
D342C (S/N: 31B1-UP; 32B1-UP; 50B1-UP)
D343 (S/N: 33B1-UP; 62B1-UP)
D346 (S/N: 39J1-UP; 40J1-UP)
D348 (S/N: 36J1-UP)
D349 (S/N: 61P1-UP; 62P1-UP)
D353 (S/N: 46B1-UP)
D353C (S/N: 46B1-UP; 47B1-UP)
D353D (S/N: 46B1-UP; 47B1-UP)
D353E (S/N: 46B1-UP; 47B1-UP)
D379 (S/N: 68B1-UP; 69B1-UP)
D379B (S/N: 68B1-UP; 69B1-UP; 34Z1-UP)
D398 (S/N: 66B1-UP; 67B1-UP)
D398B (S/N: 66B1-UP; 67B1-UP; 35Z1-UP)
D399 (S/N: 35B1-UP; 91B1-UP; 36Z1-UP)
G3406 (S/N: 4FD1-UP; 1RK1-UP)
G3408 (S/N: 6NB1-UP; 6RJ1-UP)
G3408C (S/N: 8YR1-UP; 6FW1-UP; BAZ1-UP)
G3412 (S/N: R7A1-UP; 7DB1-UP; 3NK1-UP; KAP1-UP)
G3412C (S/N: 6ZM1-UP; 5KR1-UP; 9RR1-UP; 8LW1-UP)
G342 (S/N: 31B1-UP; 71B1-UP)
G343 (S/N: 97N1-UP)
G3508 (S/N: 4WD1-UP; 9TG1-UP; CPJ1-UP; CPY1-UP)
G3512 (S/N: 5JD1-UP; 7NJ1-UP; CRN1-UP; CSP1-UP; 6JW1-UP)
G3516 (S/N: 8LD1-UP; CPG1-UP; 4EK1-UP; 8PW1-UP; CSZ1-UP)
G3516B (S/N: CSC1-UP; CME1-UP; CEY1-UP; 7EZ1-UP)
G3516C (S/N: TJB1-UP; TJC1-UP)
G3516E (S/N: SLY1-UP)
G3520B (S/N: CWD1-UP; BGW1-UP)
G3520C (S/N: HEA1-UP; MAD1-UP; B9P1-UP; HAT1-UP; CWW1-UP; CWY1-UP)
G3524 (S/N: 7SZ1-UP)
G3532 (S/N: 8BZ1-UP)
G3606 (S/N: 3XF1-UP; 4ZS1-UP)
G3608 (S/N: 4WF1-UP)
G379 (S/N: 72B1-UP)
G398 (S/N: 66B1-UP; 73B1-UP)
G399 (S/N: 49C1-UP)
Generator Set:
3406 GEN SET (S/N: 75Z1-UP)
3406C GEN SET (S/N: KPS1-UP)
Industrial Engine:
3406 IND (S/N: 6TB1-UP; 90U1-UP)
3406C IND (S/N: 3ER1-UP)
3406E IND (S/N: 6BR1-UP)
3408C IND (S/N: 9ER1-UP)
3412E IND (S/N: BDT1-UP)
3456 IND (S/N: 3LW1-UP)
D342C IND (S/N: 05A1-UP; 49B1-UP)
Marine Engine:
3406 MARINE (S/N: 91U1-UP)
3408C MARINE (S/N: 1TS1-UP)
3412E MARINE (S/N: 9PW1-UP)
Excavator:
235 (S/N: 32K1-UP; 62X1-UP; 81X1-UP)
235B (S/N: 7WC1-UP; 9PC1-UP; 1FD1-UP; 4ED1-UP)
235C (S/N: 5AF1-UP; 2PG1-UP; 3WG1-UP; 4DG1-UP)
235D (S/N: 8KJ1-UP; 8TJ1-UP)
245 (S/N: 95V1-UP; 82X1-UP)
245D (S/N: 4LK1-UP)
330 (S/N: 9NG1-UP; 6WJ1-UP; 9PJ1-UP; 9WJ1-UP; 6SK1-UP; 6ZK1-UP; 8CK1-UP; 8FK1-UP; 2EL1-UP; 8RL1-UP; 2ZM1-UP; 5YM1-UP)
330B (S/N: 9HN1-UP; 2RR1-UP; 3YR1-UP; 5LR1-UP; 6DR1-UP; 8SR1-UP; 8TR1-UP; 4RS1-UP; 5LS1-UP)
330L (S/N: 9ML1-UP)
350 (S/N: 2ZL1-UP; 3ML1-UP)
365B Series II (S/N: BTH1-UP)
365B (S/N: AGD1-UP; CFJ1-UP; CTY1-UP; 4XZ1-UP; 9PZ1-UP)
365BL Series II (S/N: JMB1-UP; PEG1-UP; SDL1-UP; DER1-UP)
365BL (S/N: 9TZ1-UP)
375 (S/N: 8WJ1-UP)
375L (S/N: 1JM1-UP)
5080 (S/N: 8SL1-UP)
5110B (S/N: AAA1-UP)
5130 (S/N: 7TJ1-UP; 5ZL1-UP)
5130B (S/N: 4CS1-UP)
E300 (S/N: 2CF1-UP)
M318 (S/N: BMD1-UP)
W330B (S/N: AME1-UP)
Track Feller Buncher:
TK1161 (S/N: TKD1-UP)
TK1162 (S/N: TKE1-UP)
Integrated Toolcarrier:
IT12 (S/N: 1LJ1-UP)
Motor Grader:
16H (S/N: 6ZJ1-UP)
24H (S/N: 7KK1-UP)
Off-Highway Truck/Tractor:
768C (S/N: 02X1-UP)
769 (S/N: 99F1-UP; 35W1-UP)
769B (S/N: 99F1-UP)
769C (S/N: 01X1-UP)
772 (S/N: 11S1-UP; 80S1-UP)
772B (S/N: 64W1-UP)
773 (S/N: 63G1-UP)
773B (S/N: 63W1-UP)
773D (S/N: 7ER1-UP; 7CS1-UP)
773E (S/N: BDA1-UP)
776B (S/N: 6JC1-UP)
776C (S/N: 2TK1-UP)
776D (S/N: 5ER1-UP; AFS1-UP)
777B (S/N: 4YC1-UP)
777C (S/N: 4XJ1-UP)
777D (S/N: AGC1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)
784B (S/N: 5RK1-UP)
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
Quarry Truck:
771C (S/N: 3BJ1-UP)
775B (S/N: 7XJ1-UP)
775D (S/N: 6KR1-UP; 8AS1-UP)
775E (S/N: BEC1-UP)
Pipelayer:
571G (S/N: 5ZD1-UP)
572F (S/N: 96N1-UP)
572G (S/N: 8PC1-UP; 40U1-UP)
589 (S/N: 31Z1-UP)
Power Module:
PMG3516 (S/N: CFD1-UP)
Track-Type Loader:
973C (S/N: BCP1-UP)
977L (S/N: 14X1-UP)
Track-Type Tractor:
D10 (S/N: 84W1-UP; 76X1-UP)
D10N (S/N: 2YD1-UP)
D10R (S/N: 3KR1-UP; AKT1-UP)
D10T (S/N: RJG1-UP)
D11N (S/N: 4HK1-UP; 74Z1-UP)
D11R (S/N: AAF1-UP; 8ZR1-UP; 9TR1-UP; 9XR1-UP; 7PZ1-UP)
D5B (S/N: 24X1-UP; 25X1-UP; 44X1-UP; 48X1-UP)
D6C (S/N: 17R1-UP)
D6D (S/N: 04X1-UP; 06X1-UP; 20X1-UP; 31X1-UP)
D6H Series II (S/N: 4RC1-UP; 6FC1-UP; 8FC1-UP; 1KD1-UP; 2KD1-UP; 3ZF1-UP; 4YF1-UP; 3YG1-UP; 4GG1-UP; 8SK1-UP; 2TL1-UP)
D6H (S/N: 8KB1-UP; 7PC1-UP; 8YC1-UP; 7ZK1-UP)
D7F (S/N: 61G1-UP)
D7G Series 2 (S/N: 3ZD1-UP; 35N1-UP; 65V1-UP; 91V1-UP; 92V1-UP)
D7R Series II (S/N: AEC1-UP; AFG1-UP; ABJ1-UP; AGN1-UP; ACS1-UP; ADW1-UP)
D7R (S/N: CBZ1-UP)
D8L (S/N: 7YB1-UP; 53Y1-UP)
D8N (S/N: 9TC1-UP)
D8R Series II (S/N: AKA1-UP; 6YZ1-UP)
D8R (S/N: 7XM1-UP; 9EM1-UP)
D9L (S/N: 14Y1-UP)
D9N (S/N: 1JD1-UP; 5FJ1-UP; 6XJ1-UP)
D9R (S/N: JJB1-UP; ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP)
D9T (S/N: RJS1-UP)
Wheel Dozer:
814 (S/N: 90P1-UP)
824C (S/N: 85X1-UP)
834B (S/N: 7BR1-UP; 92Z1-UP)
844 (S/N: BBN1-UP; 2KZ1-UP)
844H (S/N: BTW1-UP)
854G (S/N: AMP1-UP; A4W1-UP; 1JW1-UP)
Wheel Loader:
966F Series II (S/N: 8BG1-UP)
970F (S/N: 7PL1-UP)
972G (S/N: 8TS1-UP)
980G (S/N: 9CM1-UP)
988B (S/N: 50W1-UP)
988F (S/N: 8YG1-UP)
990 Series II (S/N: BCR1-UP; 4FR1-UP)
990 (S/N: 7HK1-UP)
990H (S/N: BWX1-UP)
992 (S/N: 25K1-UP)
992B (S/N: 25K1-UP)
992C (S/N: 42X1-UP; 49Z1-UP)
992D (S/N: 7MJ1-UP)
992G (S/N: 7HR1-UP; AZX1-UP; ADZ1-UP)
994 (S/N: 9YF1-UP)
994D (S/N: 3TZ1-UP)
994G (S/N: 8FR1-UP)
Wheel Tractor-Scraper:
621 (S/N: 23H1-UP)
621F (S/N: 4SK1-UP)
623 (S/N: 52U1-UP)
623F (S/N: 6BK1-UP; 5EW1-UP)
627 (S/N: 54K1-UP)
627B (S/N: 38V1-UP)
627F (S/N: 1DL1-UP)
631E Series II (S/N: 1AB1-UP; 1NB1-UP)
637D (S/N: 4JB1-UP; 20W1-UP; 21W1-UP; 22W1-UP)
637E Series II (S/N: 1FB1-UP)
639D (S/N: 88X1-UP)
641B (S/N: 65K1-UP)
650B (S/N: 58K1-UP)
651B (S/N: 67K1-UP)
651E (S/N: 4YR1-UP; 89Z1-UP)
657B (S/N: 68K1-UP)
657E (S/N: 6MB1-UP; 5YR1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP; 86Z1-UP; 90Z1-UP; 91Z1-UP)
660B (S/N: 58K1-UP)
666B (S/N: 66K1-UP)

Introduction

This instruction describes the following procedures:

  • Removal procedure for the Conventional Solenoids for the 50MT Starting Motor

  • Removal procedure for Semi-Solid Link Solenoids for the 50MT Starting Motor

  • Installation procedure for Semi-Solid Link Solenoids for the 50MT Starting Motor

Determine the type of solenoid that needs to be replaced before you begin the following procedures. Use the number that is stamped on the mounting bracket of the solenoid in order to determine the type of solenoid and the procedure to use for the removal of the solenoid.

  • Conventional Solenoids that are marked with the number 1115662 or lower

  • Semi-Solid Link Solenoids with the number 1115714 or higher

Note: Before replacing the solenoid, remove the starting motor. Ensure that the starting motor is completely disconnected from the vehicle.




Illustration 1g01045382

Removal Instructions (Conventional Solenoid)

Note: This procedure is for the removal of Conventional Solenoids that are stamped with the number 1115662 or lower.

Note: The fasteners in this procedure are referred to by the size of the wrench that is used rather than the size of the threads.

  1. Remove 19.05 mm (3/4 inch) (1) that is located on the terminal of the solenoid that is labeled "MTR".

  1. Remove the 19.05 mm (3/4 inch) nut (2) at the frame.

  1. Remove the stamped metal connector strap (3) .

  1. Remove the 9.53 mm (3/8 inch) nut (4) from ground terminal "G".

  1. Disconnect the flexible ground cable (5) from the "G" terminal.

  1. For models with a boot clamp (8) , remove the clamp by inserting a screwdriver into the serrated portion of the clamp. Pry upward. Save the clamp in order to reuse the clamp.

  1. Remove four E8 Torx Head screws (7) that mount the solenoid to the motor frame.

  1. Remove the solenoid from the lever housing. The plunger and the boot will remain on the starter.

  1. Remove access plug (9) and gasket (10) from the front of the lever housing. Make sure that the gasket is removed.

  1. Hold the plunger securely in order to prevent rotation. Remove the 12.70 mm (1/2 inch) nut (plunger) (11) carefully so that the nut (plunger) does not drop into the motor. Dispose of the nut.

  1. Remove the plunger and the boot assembly.

Removal Instructions (Semi-Solid Link Solenoid)

Note: This procedure is for Semi-Solid Link Solenoids that are stamped with the number 1115714 or higher.

Note: The fasteners in this procedure are referred to by the size of the wrench that is used rather than the size of the threads.

  1. Remove 19.05 mm (3/4 inch) (1) on the solenoid motor terminal "MTR".

  1. Remove the 19.05 mm (3/4 inch) nut (field terminal) (2) at the frame.

  1. Remove the stamped metal connector strap (3) .

  1. Remove the 9.53 mm (3/8 inch) nut (4) from ground terminal "G".

  1. Disconnect the flexible ground cable (5) from the "G" terminal.

  1. Remove access plug (9) and gasket (10) from the front of the lever housing. Make sure that the gasket is removed.

  1. Hold the plunger securely in order to prevent rotation. Then, remove the 12.70 mm (1/2 inch) nut (plunger) (11) carefully so that the nut (plunger) does not drop into the motor. Dispose of the nut.

  1. Remove four E8 Torx Head screws (7) that mount the solenoid to the motor frame.

  1. Remove the complete solenoid and remove the plunger assembly from the lever housing.

  1. For models with a boot clamp (8), remove the clamp by inserting a screwdriver into the portion of the clamp that is serrated. Pry upward.

    Save the clamp in order to reuse the clamp.

Installation Instructions (Semi-Solid Link Solenoid)

Note: The fasteners in this procedure are referred to by the size of the wrench that is used rather than the size of the threads.

  1. For applications with a boot clamp, install the boot clamp (8). Tighten the boot clamp with a pair of pliers.

  1. Place the new solenoid onto the starting motor by sliding the plunger boot into the hole of the lever housing.

    Note: Make sure that the threaded rod (plunger) (14) goes through the hole in the shift lever.

  1. Install the new 12.70 mm (1/2 inch) nut (plunger) (11) by hand. Tighten by hand.

    Note: Use of force can rotate the plunger and cause damage to the rubber boot.

  1. Push the solenoid forward until the four solenoid bracket holes and four motor frame holes line up.

  1. Install the four E8 Torx Head mounting screws (7) and tighten the screws to a torque of 213.5 ± 44.1 N·m (157.5 ± 32.5 lb ft).

  1. Install the flexible ground cable (5) to the "G" terminal.

  1. Install 9.53 mm (3/8 inch) nut (4) for the "G" terminal. Tighten the nut to a torque of 3.1 ± 1.2 N·m (27 ± 11 lb in).

    ------ WARNING! ------

    Personal injury or death can result from improper troubleshooting and repair procedures.

    The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.

    ----------------------


    NOTICE

    For electric starting motors, do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.


  1. Check the pinion clearance. Adjust the pinion clearance.

    1. Adjust the 12.70 mm (1/2 inch) nut (plunger) (11) in order to adjust pinion clearance. The solenoid must be energized in order to prevent the plunger from rotating and to prevent damaging the rubber boot.

      • The required voltage ("12V" or "24V") is stamped on the solenoid bracket.

      • Seat the plunger by pushing on the 12.70 mm (1/2 inch) nut (plunger) (11) while you apply the appropriate power to the "S" lead terminal ("+") (6) and the "G" lead terminal ("-") (4) of the solenoid. 24 VDC can be obtained by connecting two 12 VDC batteries in series.

      • Adjust the 12.70 mm (1/2 inch) nut (plunger) (11) until the distance between the face of the pinion (13) and the inside of the machined surface of the nose housing (12) is the following distance 9.1 ± .8 mm (0.36 ± 0.03 inch). Apply a slight amount of pressure against the pinion (13) while you take a measurement in order to take out the slack. This distance must conform to specifications in order for the starter to function properly.

      • Remove the power immediately after the adjustment has been completed.

  1. Install access plug (9) and gasket (10) to the front of lever housing and tighten the access plug to a minimum torque of 8.1 N·m (72 lb in).

  1. Install the stamped metal connector strap (3) .

  1. Install the "MTR" terminal nut (19.05 mm (3/4 inch)) (1) and the nut (19.05 mm (3/4 inch)) (2) at the frame. Tighten the nuts to a torque of 30.5 ± 3.4 N·m (22.5 ± 2.5 lb ft).

  1. Check the motor for the proper function before installation.

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