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Systems Operation

Introduction
The 6V-2150 Starting/Charging Analyzer Group works like a multi-channel voltmeter and reads out (displays) with a simple GO or NO
GO indication.

It is used to troubleshoot the starting/charging system of all 24 Volt Caterpillar Earthmoving Machines under the following conditions:

* Manufactured after July 1981.

* Equipped with automotive key type start.
* Equipped with a diagnostic connector.

This new approach to troubleshooting makes it unnecessary to remove any machine sheet metal to find test points. The diagnostic
connector is connected to the major test points of the machine starting/charging system, and is in an easily accessible location.

By using the 6V-2150 Analyzer Group with the diagnostic connector, this test operation can be done by one person, with no electrical
experience.

Electrical experience may be necessary for replacement of a component.

The Analyzer can be used on ALL machines using the diagnostic connector.

Refer to the Contents section of this manual for the tool group usage.

6V-2150 Starting/Charging Analyzer Group

1. 6V-3072 Case. 2. 6V-3112 Base. 3. 6V-4174 Packing Set. 4. 6V-3178 Cable Assembly. 5. SEES5548 Instruction.
6. Typical Location for the connector for the Starting/Charging Analyzer Group.

Features of the 6V-2150 Starting/Charging Analyzer Group

Adaptability: May be used on all 24 Volt Caterpillar earthmoving machines:

* Manufactured after July 1981.

* Equipped with automotive key type start.
* Equipped with a Diagnostic Connector.

Analyzer Connection: A plug from the 6V-2150 Analyzer fits into a diagnostic connector. This diagnostic connector is normally in the
engine area, near the starter, but can also be inside the cab.

Operation: For a machine that will SELF START, less than five minutes are needed to connect the analyzer and make a complete test
of the starting and charging system. More time will be needed to test a machine if it must be BOOST STARTED.

Power supply: Power to operate the analyzer comes through the diagnostic connector, from the vehicle electrical system.

Rugged: The design of the analyzer makes it possible to have good accuracy, in field service conditions.

Convenient: Analyzer operation is made easy since it is not necessary to:

* Remove any sheet metal.

* Look for components or test points in a circuit.
* Interpret (understand) a voltmeter reading.
* Have more than one person to test a machine.

Less Downtime: There will be less downtime since troubleshooting is made easier and faster. When used as part of PM or TA
inspections, the analyzer can find marginal components (parts that have an unseen defect). Finding and correcting these defects early,
can help to prevent future unscheduled downtime.

Specifications
Channels: The analyzer has fifteen channels (or readouts) that can check fifteen major components or circuits.

Accuracy: In field service conditions, this analyzer will keep and/or have the accuracy needed for diagnosis of failed or worn parts
when used within the operating temperature range specification.

Temperature Range of Ambient Air During Analyzer Operation: Will maintain (keep) the needed accuracy from -18 to +60°C (0 to
+ 140°F). The analyzer will operate outside this temperature range, but may not have the specified accuracy.

Temperature Range of Ambient Air During Analyzer Storage: -40 to 80°C (-40 to + 176°F).

Power Required: 10 to 30 volts DC at approximately 250 mA using the 24 Volt vehicle electrical system as a source.

Cable Length: 5500 mm (217 in).

Operating Position: Any position.

Size:

Carrying Case: 394 × 311 × 102 mm (15.5 × 12.25 × 4 in)

Analyzer: 254 × 191 × 30 mm (10.0 × 7.5 × 1.19 in)

Weight:
Complete Group: 3.2 kg (7 lbs) Analyzer only: 1.8 kg (4 lbs)

Basic Operations
Sometimes the analyzer will give indication that a component, or components, has a defect, but the machine will start and seem to
operate without any problems.

This normally indicates that the component (s) (including wiring harness and/or harness connectors) are at the point of being worn, and
replacement is necessary.

Before making the component replacement, however, check for loose or corroded connectors in the circuit that shows a defect.

If replacement is still necessary, install the necessary new components to prevent any unexpected downtime for the machine.

NOTICE
Field service replacement of an original equipment wiring harness with wire of a
different gauge can cause incorrect readings from the analyzer.

The complete test is made in the following four step procedure:

* Test Setup A-Hookup

* Test Step B-Crank
* Test Step C-Start Aid
* Test Step D-Hi Idle

Refer to Analyzer Panel in this manual.

Test Setup A-Hookup

This is a test of the machine with the engine and all accessories at SHUT OFF, but with the key start switch in the ON position.

In this test step, the 6V-2150 Analyzer checks:

1. Batteries: Checks open circuit voltage as an indication of battery charge level.

2. Alternator Breaker: Checks for a tripped (activated) breaker.

3. Key Breaker: Checks for a tripped (activated) breaker.

4. Key Start Switch: Checks to find if the START half of the switch is OPEN.

5. Main Relay and/or Breaker: Checks for closed contacts on relay (if equipped) and that breaker (if equipped) is not activated.

6. Coolant Switch: Checks for a CLOSED coolant switch. [Switch will CLOSE at 27°C (80°F) during cool down. Switch will OPEN at
38°C (100°F) at warm-up.]

NOTE: It is possible that the machine does NOT have starting aid components.

7. Start Aid Switch/Solenoid: Checks to see if switch is OPEN, and/or if solenoid coil is NOT OPEN.

NOTE: For those machines that have dual (two) starter motors, Step(s) 8 and 9 that follow apply to both starter motors.

The #2 starter motor is always the attachment unless a dual starting system is standard equipment.
8. Start Relay: Checks to see if relay contacts are OPEN.

9. Starter Solenoid: Checks to see if solenoid contacts are OPEN.

NOTE: If all three lamps for #2 starter are OFF, it is an indication that the machine does NOT have a second starter motor.

Test Step B-Crank

Shut OFF the fuel supply to prevent the engine from starting during this step.

This step will activate all the cranking circuits so the 6V-2150 Analyzer can measure voltage, in relation to the components on circuits
that follow, and checks:

1. Starter Ground Circuit: Checks for excessive voltage drop (voltage loss).

2. Batteries: Checks battery voltage, to see if it is within the expected range for cranking.

3. Alternator Breaker: Checks for excessive voltage drop, or for an activated breaker.

4. Key Breaker: Checks for excessive voltage drop, or for an activated breaker.

5. Key Start Switch: Checks for excessive voltage drop, or whether the switch and/or harness is OPEN.

6. Main Relay and/or Breaker: Checks for CLOSED relay contacts (if equipped) and that breaker (if equipped) is not activated.

7. Coolant Switch: Checks for CLOSED coolant switch. [Switch will CLOSE at 27°C (80°F) at cool down. Switch will OPEN at 38°C
(100°F) at warm-up.]

NOTE: It is possible that the machine does NOT have starting aid components or may have an automatic starting aid system.

8. Start Aid Switch/Solenoid: Checks for OPEN switch and/or that solenoid coil is not an open circuit.

NOTE: If the machine has dual starter motors, Step(s) 9, 10 and 11 that follow apply to both starter motors.

9. Start Relay: Checks to see if the relay is CLOSED and if there is an excessive voltage drop across the contacts.

10. Starter Solenoid Power Circuit: Checks if there is excessive voltage drop in the solenoid power circuit.

11. Starter Solenoid: Checks to see if the solenoid contacts are CLOSED and if there is excessive voltage drop across the contacts.

Test Step C-Start Aid

NOTE: If the machine is NOT equipped with a START AID switch on the dash panel or has a 3500 Engine with an automatic ether
injection system, it is NOT necessary to do Test Step C; proceed to Test Step D-Hi Idle.

If the machine IS EQUIPPED with a Start Aid switch on the dash panel, see the procedure that follows.

All lamp indications and test procedures are exactly the same as Test Step 1, UNTIL the Start Aid switch is pushed.

Then, the Analyzer measures voltages for the following components to check.

1. Coolant Switch: Checks if switch is CLOSED and if there is excessive voltage drop across the contacts.

2. Start Aid Switch/Solenoid: Checks if switch is now CLOSED and if there is excessive voltage drop across the contacts.

Test Step D-High Idle

All lamp indications and test procedures are exactly the same as Test Setup A-Hookup except as given here.

1. Alternator: This test measures battery voltage, to see if it is within the alternator charging limits.

NOTE: Batteries sometimes need over two minutes to CHARGE up into this range, especially if the machine was jump started.

2. Main Relay and/or Breaker: If the alternator tests good, turn ON all electrical loads (lights, air conditioner, etc.). This will permit the
analyzer to test for excessive voltage drop across the relay contacts and/or breaker (if equipped).

Alternator Breaker: Tests for excessive voltage drop across the breaker, caused by alternator charging current going through a defective
breaker.

NOTE: Excessive alternator output voltage will completely SHUT OFF the analyzer. If, during Hi Idle, the alternator lamp comes ON
normally, goes OFF, and then the analyzer goes OFF (dead), alternator output is more than 30 volts, and this has put the analyzer in its
safety SHUT-OFF position.

Analyzer Panel

Troubleshooting the 6V-2150 Starting/Charging Analyzer

(During operation, if there is indication of a defect in the
Analyzer).
If there is indication that the analyzer has a defect, the procedure that follows may possibly help to locate the problem.

1. Earlier repair or rework completed on the machine, such as engine removal, wiring harness replacement, etc., may be the cause of:

* Error in connection(s) of machine wiring harness.

* Error in wiring of the diagnostic connector.

NOTE: When either of the above is thought to be the problem, use a 6V-3030 Digital Multimeter and refer to Explanation of Analyzer
Tests, in this manual, to troubleshoot the wiring from the Diagnostic Connector.

2. If it is believed that the machine is wired correctly, but the analyzer still does NOT show the expected results, use another analyzer,
one that is known to be good, and REPEAT the tests.
If the analyzer has a defect, refer to Repair Information in this manual.

Test of Machine That Cannot Self-Start

To diagnose the problem(s) on a machine that has dead batteries, use the procedure that follows.

1. Connect the batteries of the DEAD machine to the batteries of the boost start machine.

NOTE: Refer to the Boost Starting Procedure in the Operation & Maintenance Manual for the machine that is to have the boost start.

2. Connect the 6V-2150 Analyzer to the Diagnostic Connector.

3. Complete analyzer Test Setup A-Hookup, Test Step B-Crank, and Test Step C-Start Aid to obtain the necessary diagnosis.

4. Start the engine of the DEAD machine, then disconnect the boost machine batteries, according to the Boost Starting Procedure in the
Operation & Maintenance Manual for the machine that was boost started.

5. Complete Test Step D-Hi Idle to obtain the necessary diagnosis.

If the voltage of the former dead batteries starts to increase and the ALTERNATOR lamp comes ON, this indicates correct alternator
operation; STOP the engine and REPEAT steps Test Setup A-Hookup, Test Step B-Crank, Test Step C-Start Aid, and Test Step D-Hi Idle
to obtain the diagnosis of defect, according to test results.

NOTE: It is possible that the analyzer lamps for STARTER GROUND CIRCUIT, BATTERIES and ALTERNATOR will not give a
correct indication while the boost machine batteries are connected to the dead machine.

Test For Machines That are Equipped with a 3208 Engine

The fuel system on 3208 Engines (613C) does NOT have a mechanical shutoff. These engines have an electrically operated shutoff
solenoid on the fuel pump housing.

The electrically operated shutoff solenoid is AUTOMATICALLY activated for approximately 30 seconds (older models are seventy
seconds), when the key start switch is turned to the OFF position.

To keep the engine from starting during Test Step B-Crank, use the following procedure.

1. Use a piece of 14 GA, 16 GA or 18 GA electrical wire approximately 2000 mm (79 in) long (preferably fused for 10 Amps) to make a
jumper wire.

Install a #63 Mueller (or equivalent) clip on one end, and a Mueller 46-A (or equivalent) battery clip on the other end of the wire.

2. Connect the jumper wire from the MOTOR terminal of the starter solenoid, to the BATTERY terminal of the shutoff solenoid.

NOTE: The jumper wire will activate the shutoff solenoid ONLY while cranking and PREVENT the engine from starting during Test
Step B-Crank.

NOTICE
Check starter cycle: Thirty seconds of cranking requires two minutes to cool.

Do NOT connect the shutdown solenoid directly to 24 volts. Coil damage MAY result.

3. Connect the 6V-2150 Analyzer to the Diagnostic Connector, and complete steps Test Setup A-Hookup, Test Step B-Crank, and Test
Step C-Start Aid. Use the test results for diagnostics of any machine problems.

4. Disconnect the jumper wire, and complete Test Step D-Hi Idle.
Test For Machines That Are Equipped With Energize-To-Run
Fuel Shutoff Solenoids (Other Than 3208 Engines)
The fuel system on some of the later engines do NOT have a mechanical fuel shutoff. These engines have an electrically operated
energize-to-run solenoid.

To prevent the engine from starting during Test Step B-Crank, disconnect the blue wire at the fuel solenoid on the fuel pump. Insulate
the wire.

Be sure that the wire does NOT touch the chassis while performing the tests. If the solenoid connects through a 2 Pin connector,
disconnect the connector.

NOTICE
Observe starter cranking cycle: Thirty seconds cranking time requires a two minute
cool down time.

Connect the 6V-2150 Starting/Charging Analyzer to the Diagnostic Connector and complete Step(s) Test Setup A-Hookup, Test Step B-
Crank, and Test Step C-Start Aid.

Reconnect the blue wire to the solenoid or connector and complete Test Step D-Hi Idle.

Explanation of Analyzer Tests

NOTE: All voltages listed in this manual are in volts direct current (DC).

With two exceptions, the basic schematic that follows is typical of all Caterpillar machines that have a Diagnostic Connector. The two
exceptions are as follows.

1. Not all of the machines will be equipped with all of the components that are shown on the schematic (such as start aid, main relay,
two starter motors, etc.).

If any of the components shown in the schematic are on a machine, the wire connections for those components will be the same as the
wiring connections shown on this schematic.

2. Harness connectors, such as those used to connect to a cab, etc., are NOT shown on the schematic.

Although the connectors are not shown, they must be considered as a possible problem area when troubleshooting for machine defects
since, many times, the analyzer tests include these connectors.

Make a comparison of this basic schematic with the wiring diagram of the machine that is to be tested, to determine which connectors
and wiring harnesses are within the test points of the analyzer test step that is being conducted.

NOTE: All test point numbers on the schematic are the same as the numbers of the pins on the diagnostic connector. As an example,
Test Point 1 on the schematic is Pin 1 on the connector.

In the topics that follow, a basic machine shows in detail each circuit test that is made by the 6V-2150 Starting/Charging Analyzer. The
schematic with each topic shows only the circuit for that part of the test.

To see how the basic machine schematic is actually wired on the machine under test, reference must always be made to the vehicle
wiring diagram.
A. Breaker/Relay Enclosure. B. Key Breaker. C. Coolant Switch. D. Alternator Breaker. E. Main Breaker. F. Main Relay. G. Start Aid Solenoid. H.
Alternator. J. Start Relay #2. K. To Vehicle Loads. L. Starter Motor #2 (possibly an attachment). M. Start Aid Switch. N. Start Relay #1. P. Start Inhibit
Switch(s) (if equipped). Q. Key Start Switch. R. Starter Motor #1. S. Disconnect Switch (if equipped).

NOTE: Test point location numbers (1) through (14) on the schematic are the same as the numbers of the diagnostic connector pins.

Starter Ground Circuit

Specification:

This test measures the voltage drop in the ground lead of starter (R), between Test Points (7) (positive) and (3) (negative).

A voltage drop between these two test points of more than 1.30 ± 0.15 volts causes the STARTER GROUND CIRCUIT lamp to come
ON and indicate a defect.

A defect can be indicated only during Test Step B-Crank.

This condition may be caused by:

* A disconnect switch with excessive voltage drop.

* Cable to frame connections with excessive voltage drop.

If the machine being tested has a disconnect switch(s), it will also be tested as part of the starter ground circuit.

Other Circuit Information:

There are three ways that a starter ground circuit may be wired:

1. A single cable from the negative battery terminal, directly to the starter negative post. With this design, test point (3) is tied to
test point (7), and the analyzer does NOT make a check of voltage drop. (Disconnect switch is not used).
2. In the second way, a disconnect switch will be found in the ground cable between the negative battery terminal and the
negative starter terminal. The analyzer checks the disconnect switch and the disconnect switch-to-starter cable.
3. In the third way, the negative starter terminal is jumped to the frame, and the negative battery terminal is jumped to the frame,
but in a different location. This type of hookup (connection) is CHECKED by the analyzer and typically includes a disconnect
switch which the analyzer ALSO checks. Most often, cleaning cable-to-frame connections will correct this type of defect.

Batteries
Specification:

This test measures the TERMINAL voltage of the batteries, between test point (1) (positive) and test point (7) (negative).

At Test Setup A-Hookup, a voltage drop between these two test points below 23.10 ± 0.15 volts will cause the BATTERIES lamp to
come ON and indicate a low state of charge.

In this condition, the batteries will not have enough power to crank the engine. A defect can be indicated during any Test Step.

This condition may be caused by:

* No alternator output.
* Worn out batteries that will not hold a charge.
* Light or accessory was left ON, with machine shut down, and this discharged batteries.

Specification:

During engine cranking, it is normal for the battery voltage to go below 23.1 volts and so the BATTERIES lamp will come ON.

However, if the battery voltage then goes below 12.50 ± 0.15 volts, the batteries will probably have cranked the engine only
momentarily, and the BATTERIES lamp will go OFF to indicate very low voltage.

This condition may be caused by:

* Batteries (refer to Specification above).

* Starter motor (check for defect).
* Excessive engine drag or friction that will cause more power than normal to be used from the batteries.

Other Circuit Information:

To find which of the defects is the real cause of the problem, check the following:

No Alternator Output:

Boost start the machine to check alternator output.

Refer to Test Step D-Hi Idle.

If the alternator is operating correctly, check, charge and/or replace batteries as necessary.
Refer to SEHS7633 ... Battery Test Procedure and than REPEAT the test with the 6V-2150 Analyzer.

NOTE: Refer to the Boost Starting Procedure in the Operation & Maintenance Manual for the machine that is to have the boost start.

Alternator Breaker

Specification:

This test measures a voltage drop of either polarity across the alternator breaker between test point (1) and test point (9).

A voltage drop between these two test points of more than 0.45 ± 0.15 volts causes the ALTERNATOR BREAKER lamp to come ON
and indicate a defect.

A defect may be indicated during any Test Step.

This condition may be caused by:

* Activated (tripped) breaker.

* Closed breaker with excessive voltage drop.

Other Circuit Information:

In the Step(s) Test Setup A-Hookup, Test Step B-Crank, and Test Step C-Start Aid, test point (1) will be positive and test point (9) will be
negative since the battery is sourcing current through alternator breaker (D) to the cranking circuits.

During the Test Step D-Hi Idle, the voltage at Test Points (1) and (9) will have reverse polarity [test point (1) will be negative and test
point (9) will be positive] since the battery is receiving current through alternator breaker (D) from alternator (H).

The batteries CANNOT get a full charge if the charging circuit has excessive voltage drop.

High charging current may cause the ALTERNATOR BREAKER lamp to blink or stay ON for a few seconds ONLY at engine startup,
and then turn OFF before the ALTERNATOR lamp comes ON. This condition is acceptable.

Key Breaker

Specification:

This test measures the voltage drop across the key breaker between test point (1) (positive) and test point (5) (negative).

A voltage drop between these two test points of more than 0.75 ± 0.15 volts causes the KEY BREAKER lamp to come ON and indicate
a defect. A defect may be indicated during any Test Step.

This condition may be caused by:

* Activated (tripped) breaker.

* Closed breaker with excessive voltage drop.

Key Start Switch

Specification:

This test measures the voltage drop across both poles (switches) of the key start switch.

The voltage drop between Test Points (5) (positive) and (6) (negative) represents the STAR pole.

The voltage drop between test point (5) (positive) and (8) (negative) represents the RELAY pole.

A voltage drop between EITHER or BOTH of these two sets of test points more than 2.50 ± 0.15 volts causes the KEY START
SWITCH lamp to come ON and indicate a defect. A defect may be indicated during any Test Step.

This Condition May Be Caused By:

* Open switch (pole).

* Closed switches, with excessive voltage drop.
* Switch (pole) with welded contacts.

NOTE: Start position of this switch is OPEN during Test Setup A-Hookup, Test Step C-Start Aid, and Test Step D-Hi Idle so it is correct
when the KEY START SWITCH lamp is ON during these test steps.

Other Circuit Information:

On machines that fail the Key Start Switch test during Test Step B-Crank (lamp is ON), the defect may be in any Start Inhibit Switch
(such as the Neutral Start Switch on direct drive machines) instead of the Key Start Switch.

Start inhibit switches (P) are always installed between Test Points (5) and (6), and become part of the test for the Key Start Switch.

The wiring harness and the wiring harness connections are also checked in this test.

Refer to the machine's Wiring Schematic for location of these components, since an OPEN harness will show as a defect.

Main Relay and/or Breaker

Specification:

This test measures the voltage drop across the main relay and/or breaker between test point (9) (positive) and test point (12) (negative).

A voltage drop between these two test points of more than 1.30 ± 0.15 volts causes the MAIN RELAY and/or BREAKER lamp to come
ON and indicate a defect. A defect may be indicated during any Test Step.

This condition may be caused by:

* Activated (tripped) breaker.

* Closed breaker with excessive voltage drop.
* Open relay contact, caused by burned contacts/open relay coil.
* Closed relay with excessive voltage drop.
* Relay with welded contacts.

NOTE: If a machine fails this test, it will be necessary to find which of the two components has the defect.

To find the defective part, use a 6V-3030 Digital Multimeter to check for excessive voltage drop across each component [main relay (F)
and main breaker (E)].

Troubleshoot with the 6V-3030 Digital Multimeter under the exact conditions (Test Step) that caused the analyzer to show the fault.

Other Circuit Information:

It is possible that a specific machine has both of these components, or does not have either one of them.

On machines that do not have either of these components, test point (12) is tied (connected) directly to test point (9) and will never
indicate a defect on the analyzer.

On machines that do have either, or both, a MAIN RELAY and MAIN BREAKER, replace defective components as necessary.

Refer to the machine's wiring diagram to determine which components are used in the electrical system under test.

Coolant Switch
Specification:

This test measures the voltage drop across the coolant test point (11) (positive) and test point (7) (negative).

A voltage drop between these two test points of more than 1.30 ± 0.15 volts, causes the COOLANT SWITCH lamp to come ON and
indicate a defect. A defect may be indicated during any Test Step.

This condition may be caused by:

* Open switch.
* Closed switch with excessive voltage drop.
* Switch with welded contacts (indicated by COOLANT SWITCH lamp OFF when coolant is above 38°C (100°F).

Other Circuit Information:

The coolant switch will OPEN when engine coolant temperature reaches 38°C (100°F).

This switch prevents the use of a starting aid in a warm engine. Use of a starting aid in a warm engine may cause possible damage.

For this test to be valid, engine coolant must be below the 38°C (100°F) temperature.

In the case of a warm engine, it must first cool down to 27°C (80°F) to CLOSE the coolant switch.

The coolant switch will CLOSE when engine coolant temperature falls to 27°C (80°F) during engine cool down.

Start Aid Switch/Solenoid

Specification:

This test measures the:

* Voltage drop across the start aid switch between test point (8) (positive) and test point (10) (negative).

A voltage drop between these two test points of more than 2.5 ± 0.15 volts causes the START AID SWITCH/SOLENOID lamp to stay
OFF and indicate a defect. A defect may be indicated during any Test Step.

* Resistance of the solenoid coil circuit between test point (10) and test point (7).

A resistance between these two test points of less than 300 Ohms will cause the START AID SWITCH/SOLENOID lamp to stay OFF.

A resistance between these two points of more than 3600 Ohms will cause the START AID SWITCH/SOLENOID lamp to come ON
and indicate a defect. A defect may be indicated during the Test Setup A-Hookup, Test Step B-Crank, and Test Step D-Hi Idle tests.

This condition may be caused by:

Start Aid Switch:

* Open switch.
* Closed switch with excessive voltage drop.
* Switch with welded contacts.

Solenoid Coil Circuit:

* Open solenoid coil.

Other Circuit Information:

If the START AID SWITCH/SOLENOID lamp is ON and the START AID SWITCH is not activated, it is possible that the switch has a
defect (welded contacts), or the START AID SOLENOID and/or harness may be OPEN.

Disconnect the 6V-2150 Analyzer and use a 6V-3030 Digital Multimeter to check continuity from test point (10) to test point (7), or the
machine frame.
If resistance from test point (10) to test point (7) is less than approximately 8 Ohms, it is probable that the switch has a defect.

If the solenoid coil is OPEN, it is possible that switch failure (welded contacts) is the cause of solenoid coil failure.

This test includes the harness and the harness connectors. A defect in any of these parts will also cause the 6V-2150 Analyzer to indicate
a START AID SWITCH/SOLENOID defect.

Refer to the machine's wiring diagram for more information.

NOTE: Engine coolant must be below 38°C (100°F) to perform this test [or 27°C (80°F) on engine cool down].

Start Relay (Starter No. 1)

Specification:

This test measures the voltage drop across the start relay contacts between Test Points (9) (positive) and test point (4) (negative).

A voltage drop between these two test points of more than 0.45 ± 0.15 volts, causes the START RELAY lamp to come ON and indicate
a defect. A defect may be indicated during any Test Step, but most often in the Test Step B-Crank Test.

This condition may be caused by:

Open Relay Contacts:

* Caused by burned contacts/open relay coils.

Closed Relay Contact:

* With excessive voltage drop.

Starter Solenoid Power Circuit (Starter No. 1)

Specification:

This test measures the voltage drop across the starter solenoid PULL-IN coil (W) between test point (2) (positive) and test point (4)
(negative).

A voltage drop between these two test points of more than 1.00 ± 0.15 volts causes the STARTER SOLENOID POWER CIRCUIT
lamp to come ON and indicate a defect. A defect may be indicated ONLY during Test Step B-Crank test.

This condition may be caused by:

* Alternator breaker with excessive voltage drop (but may be in specification for the alternator breaker test alone).
* Start relay with excessive voltage drop (but may be in specification for the start relay test alone).

Other Circuit Information:

The starter solenoid has two coils. PULL-IN coil (W) and HOLD-IN coil (X).

The instant that start relay (N) closes, both coils (W and X) receive power.

Battery voltage is applied to the HIGH end of both coils, at test point (4).

The LOW end of the HOLD-IN coil (X) is permanently grounded to the ground post of the starter motor.

Grounding for the LOW end, test point (2), of PULL-IN coil (W) is momentary, and takes place through the DC resistance of the starter
motor.

As soon as magnetic force builds in both coils, the solenoid contacts close. This removes the temporary ground from PULL-IN coil (W),
and puts battery voltage on both ends.

The instant that START RELAY (N) closes, HOLD-IN coil (X) gives assistance to PULL-IN coil (W). Together, they pull the solenoid
switch CLOSED.

After this switch closes (during cranking), PULL-IN coil (W) is, basically, out of the circuit since battery voltage appears on both ends
of the coil. This means the voltage across the PULL-IN coil is nearly zero (0). If Test Point (4) becomes MORE negative than Test Point
(2) (By 1.0 or more volts), current will then flow BACKWARDS through the PULL-IN COIL and CAUSE the solenoid to DROP OUT
(RELEASE).
As soon as it does, test point (2) will again ground the PULL-IN coil. Unless this problem is found, it will occur several times each
second, and cause the starter solenoid contacts to burn to an OPEN condition.

Replacement of the solenoid will put the machine back to work, but the problem is NOT resolved and the machine will soon be down
again.

Resolving the Problem

The voltage drop, during cranking, is greater from test point (1) to test point (4) than the voltage drop from test point (1) to test point (2).

Even if the analyzer shows that alternator breaker (D) and start relay (N) are within specifications, replacement of one, or both
components can reduce the voltage drop enough, between test point (1) to test point (4), to be acceptable.

The harness and harness connectors can also have an effect on this circuit test.

Refer to the machine's wiring diagram for further information.

To indicate acceptable limits, the lamp for STARTER SOLENOID POWER CIRCUIT must be OFF.

Or shown another way:

The voltage at V2 is sourced through the starter solenoid contacts. The contacts of a good starter solenoid will typically produce a
voltage drop of no more than 0.6 volts.

This voltage represents V2 and assumes that no harness connections or wiring add any significant voltage drops.

When energized, if the voltage supplied the test loop [measured at test point (1)] is 24.0 volts, V2 would be 23.4 volts.

The voltage at test point (4) is sourced [from test point (1)] through the alternator breaker (D) and the start relay (N).
The contacts of a good alternator breaker, or a good start relay, will typically produce a voltage drop no more than 0.4 volts each.

When taken in combination, then the typical maximum voltage drop from test point (1) to (4) is no more than 0.80 volts:

0.4 + 0.4 = 0.8 volts

This voltage represents V4 and assumes that no harness connectors or wiring add any significant voltage drops. When energized, the
voltage then at V4 would be 23.2 volts.

For the typical system then:

Any negative result in this equation is very satisfactory and the STARTER SOLENOID POWER CIRCUIT lamp remains OFF.

If, however, the voltage drop across the alternator breaker, starter relay, and associated wiring produced a voltage drop that was greater
than 0.8 volts such that V4 was made smaller (less than 22.6 volts):

Starter Solenoid (Starter No. 1)

Specification:

This test measures the voltage drop across the starter solenoid contacts between test point (1) (positive) and test point (2) (negative).
A voltage drop between these two test points of more than 0.75 ± 0.15 volts causes the STARTER SOLENOID lamp to come ON and
indicate a defect.

A defect may be indicated during any Test Step but most often during the Test Step B-Crankin test..

This condition may be caused by:

* Open solenoid contacts, caused by burned contacts/open solenoid coil.

* Closed solenoid contacts with excessive voltage drop.

Other Circuit Information:

An open wire from test point (4) to the starter solenoid will also give an indication of a defective solenoid.

Refer to the machine's wiring diagram for further information.

Start Relay (Starter No. 2)

Specification:

This test measures the voltage drop across the starter relay contacts between test point (9) (positive) and test point (14) (negative).

A voltage drop between these two test points of more than 0.45 ± 0.15 volts causes the START RELAY lamp to come ON and indicate
a defect.

A defect may be indicated during any Test Step but most often during the Test Step B-Crank Test.

This condition may be caused by:

* Open relay contacts, caused by burned contacts/open relay coil.

* A closed relay, with excessive voltage drop.

Starter Solenoid Power Circuit (Starter No. 2)

Specification:

This test measures the voltage drop across PULL-IN Coil (W) between test point (13) (positive) and test point (14) (negative).

A voltage drop between these two test points of more than 1.00 ± 0.15 volts causes the STARTER SOLENOID POWER CIRCUIT
lamp to come ON and indicate a defect. A defect may be indicated only during the Test Step B-Crank Test.

This condition may be caused by:

* Alternator breaker with excessive voltage drop (but may be in specification for the alternator breaker test alone).
* Start relay with excessive voltage drop (but may be in specification for the start relay test alone).

Other Circuit Information:

The starter solenoid has two coils, PULL-IN coil (W) and HOLD-IN coil (X).

The instant that start relay (J) closes, both coils (W and X) receive power.

Battery voltage is applied to the HIGH end of both coils, at test point (14).

The LOW end of HOLD-IN coil (X) is permanently grounded to the ground post of the starter motor.

Grounding for the LOW end, test point (13), of PULL-IN coil (W) is momentary and takes place through the DC resistance of the starter
motor.

As soon as magnetic force builds up in both coils, the solenoid contacts close. This removes the temporary ground from PULL-IN coil
(W), and puts battery voltage on both ends.

The instant that START RELAY (J) closes, HOLD-IN coil (X) gives assistance to PULL-IN coil (W). Together they pull the solenoid
switch CLOSED.

After this switch closes (during cranking), PULL-IN coil (W) is, basically, out of the circuit since battery voltage appears on both ends
of the coil. This means the voltage across the PULL-IN coil is nearly zero (0).

IF Test Point (14) becomes MORE Negative than Test Point (13) (By 1.0 or more volts), current will then flow BACKWARD through
the PULL-IN COIL and cause the solenoid to drop OUT (RELEASE).

As soon as it does, test point (13) will again ground the PULL-IN coil. Unless this problem is located, it will continue several times each
second, and cause the starter solenoid contacts to burn to an OPEN condition.

Replacement of the solenoid will put the machine back to work, but the problem is not resolved, and the machine will soon be down
again.

Resolving the Problem

The voltage drop, during cranking, is greater from test point (1) to test point (14) than the voltage drop from test point (1) to test point
(13).

Even if the analyzer shows that alternator breaker (D) and start relay (J) are within specifications, replacement of one, or both
components may reduce the voltage drop enough, between test point (1) and test point (14), to be acceptable.

The harness and harness connectors may also have an effect on this circuit test.

Refer to the machine's wiring diagram for further information.

To indicate acceptable limits, the lamp for STARTER SOLENOID POWER CIRCUIT must be OFF.

Or shown another way:

If the result Delta V is greater than 1.0 volts (disregard any negative result), the STARTER SOLENOID POWER CIRCUIT lamp
comes ON and indicates a defect.

The voltage at V2 is sourced through the starter solenoid contacts.

The contacts of a good starter solenoid will typically produce a voltage drop of no more than 0.6 volts.

This voltage represents V2 and assumes that no harness connections or wiring add any significant voltage drops.

When energized, if the voltage supplied the test loop [measured at test point (1)] is 24.0 volts, V2 would then be 23.4 volts.

The voltage at test point (14) is sourced [from test point (1)] through the alternator breaker and the start relay (J).

The contacts of a good alternator breaker, or a good start relay, will typically produce a voltage drop no more than 0.4 volts each.
When taken in combination, then the typical maximum voltage drop from test point (1) to (14) is no more than 0.8 volts:

(0.4 + 0.4 = 0.80 volts).

This voltage represents V4 and assumes that no harness connectors or wiring add any significant voltage drops. When energized, the
voltage then at V4 would be 23.2 volts.

For the typical system then:

Any negative result in this equation is very satisfactory and the STARTER SOLENOID POWER CIRCUIT lamp remains OFF.

If, however, the voltage drop across the alternator breaker, starter relay, and associated wiring produced a voltage that was greater than
0.8 volts such that V4 was made smaller (less than 22.6 volts):

Starter Solenoid (Starter No. 2)

Specification:

This test measures the voltage drop across the starter solenoid contacts between test point (1) (positive) and test point (13) (negative).

A voltage drop between these two test points of more than 0.75 ± 0.15 volts causes the STARTER SOLENOID lamp to come ON and
indicate a defect.

A defect may be indicated during any Test Step but most often during the Test Step B-Crank Test.

This condition may be caused by:

* Open solenoid contacts, caused by burned contacts/open solenoid coil.

* Closed solenoid contacts with excessive voltage drop.

Other Circuit Information:

An open wire from test point (4) to the starter solenoid will also give an indication of a defective solenoid.

Refer to the machine's wiring diagram for further information.

Alternator

Specification:

This test measures the alternator output voltage between test point (9) (positive) and test point (7) (negative).

A voltage between these two test points of:

LESS Than 26.2 ± 0.15 volts

A voltage between these two test points of LESS than 26.2 ± .15 volts causes the ALTERNATOR lamp to stay OFF and indicate a
defect (undercharge).

Undercharge is indicated when the ALTERNATOR lamp does not come ON after a minimum wait of two minutes.

MORE Than 28.9 ± 0.15 volts

A voltage between these two test points of MORE than 28.9 ± 0.15 volts causes the ALTERNATOR lamp to be OFF (after first being
ON) and indicates a defective (overcharge).

Overcharge is indicated when the ALTERNATOR lamp comes ON shortly (less than one minute) after engine start up and then goes
back OFF (may require ten or more minutes).

Correct alternator operation causes the ALTERNATOR lamp to be ON, and stay ON, with the engine at high idle.

This condition may be caused by:

Undercharge:

* Loose fan/alternator belts.

* Starter-to-engine block ground cable damaged, loose or missing.
* Defective alternator (or regulator which is internal to alternator).
* Defective batteries (will not accept a charge).

Refer to SEHS7633 ... Battery Test Procedure.

Overcharge:

* Alternator.

Other Circuit Information:

Undercharge
A marginal alternator (or sometimes batteries) is indicated when the ALTERNATOR lamp comes ON, but when all electrical loads
(lights, heater, fans) are turned ON, the ALTERNATOR lamp goes back OFF, and stays OFF.

When such a condition exists, use a 6V-4910 AC/DC Clamp On Ammeter to verify correct alternator output amperage.

For alternator output, refer to the Service Manual for the machine under test, or REGO1174 ... Specifications Electrical Components.

Overcharge
A severe overcharge may cause an alternator output so high (over 30 volts) that the 6V-2150 Analyzer goes into its safety shut down
mode, indicated when all analyzer lamps go OFF.

Overcharge may be confirmed in two ways:

* Slowly reduce engine speed to idle.

During this process, the analyzer should, first, come back ON (with the ALTERNATOR lamp OFF), then the ALTERNATOR lamp
should also come back ON.

* Low water level in every cell of both batteries.

Repair/Replacement of 6V-3178 Cable Assembly

Repair of the connector
If it is necessary to repair the connector on the analyzer (the plug that connects to the diagnostic socket on the machine), use the 6V-
4810 VE Connector Tool Group to make the repair. Parts of the connector are as follows:

Replacement of 6V-3178 Cable

A cable that is damaged beyond repair can be replaced according to the procedure that follows:

1. Remove six panel-to-base screws (1), then remove panel (2) from base (3).
2. Use a small screwdriver as shown to carefully separate connector (4), (one-half of the cable connector for the in-line PC board
connector) from the part of the connector that is fastened to the PC board.

NOTE: Prior to disconnection of connector (4), be sure to look carefully at its installed position. When the new cable is installed, the
new connector must be installed just like the original connector.

3. Use long nose pliers as shown to compress clamp/grommet (5) and push it out the front side of the panel, then push PC board
connector (6) through the hole in the panel as shown.

4. Use the same tools to install the new cable. Be sure to install clamp/grommet (5), connector (4) etc., in the same position as they were
with the former cable.

Repair Information
If the 6V-2150 Starting/Charging Analyzer needs repair, contact the Caterpillar Service Technology Group for information on obtaining
the required service:

Telephone:

In Illinois 1-800-542-8665

Outside Illinois 1-800-541-8665

Canada 1-800-523-8665

Write:

Caterpillar Service Technology Group

600 W. Washington Street, LD-180
East Peoria, II 61630

Telex:

Number 404435

Attn: Caterpillar Service Technology Group

6V-2150 Starting/Charging Analyzers less than one year old will be repaired under warranty (except for abuse). Cost of out-of warranty
repairs will be charged to the owner.

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