Explanation of Fuel Shutoff Solenoid Operation

Articulated Truck:
D20D (S/N: 9MG1-UP)
D250D (S/N: 6NG1-UP)
Backhoe Loader:
446 (S/N: 6XF1-UP)
446B (S/N: 5BL1-UP)
Excavator:
205B (S/N: 5ZF1-UP)
206B (S/N: 9BF1-UP)
211B (S/N: 6XG1-UP)
212B (S/N: 3PJ1-UP)
213B (S/N: 1EJ1-UP)
214B (S/N: 4CF1-UP)
224B (S/N: 7WF1-UP)
320 (S/N: 1TL1-UP; 3RK1-UP; 3XK1-UP; 4BK1-UP; 4ZJ1-UP; 7WK1-UP; 9WG1-UP)
320B (S/N: 1XS1-UP; 5MS1-UP; 7JR1-UP; 9WS1-UP)
320S (S/N: 6KM1-UP)
322 (S/N: 7WL1-UP)
322 L (S/N: 8CL1-UP)
322B (S/N: 1AS1-UP; 1BS1-UP; 1YS1-UP; 1ZS1-UP; 2ES1-UP; 3NR1-UP; 5CR1-UP; 8MR1-UP;
8NR1-UP)
322C (S/N: BFK1-UP; BFN1-UP; BFX1-UP; BGR1-UP; BKJ1-UP; BKM1-UP; BLP1-UP; BMX1-UP;
BNY1-UP)
322L (S/N: 4RM1-UP; 8ML1-UP; 9RL1-UP)
322N (S/N: 9JL1-UP)
325 (S/N: 2SK1-UP; 2SL1-UP; 3LL1-UP; 5WK1-UP; 6RM1-UP; 7LJ1-UP; 7TG1-UP; 8JG1-UP;
8NL1-UP; 8YK1-UP; 9SG1-UP; 9ZK1-UP)
325B (S/N: 1GS1-UP; 4DS1-UP; 5BS1-UP; 6DN1-UP; 7EN1-UP; 8FN1-UP; 8GM1-UP; 8PR1-UP;
8RR1-UP; 8WR1-UP; 8XR1-UP)
325L (S/N: 2JK1-UP; 6KK1-UP; 7CJ1-UP; 7LM1-UP; 8NK1-UP; 9KL1-UP)
E200B (S/N: 6KF1-UP)
E240B (S/N: 8SF1-UP)
EL240B (S/N: 5WG1-UP)
M318 (S/N: 6ES1-UP; 8AL1-UP; 8SS1-UP)
M320 (S/N: 6WL1-UP; 9PS1-UP)
M325B (S/N: BGN1-UP)
214B FT HC WT (S/N: 9MF1-UP)
320B N (S/N: 2AS1-UP)
325B L (S/N: 1HS1-UP; 2JR1-UP)
330 L (S/N: 2EL1-UP)
330 (S/N: 2ZM1-UP)
330 L (S/N: 6SK1-UP; 6WJ1-UP)
330 (S/N: 6ZK1-UP)
330 N (S/N: 8CK1-UP)
330 (S/N: 8FK1-UP; 8RL1-UP; 9NG1-UP; 9PJ1-UP; 9WJ1-UP)
330B L (S/N: 1JS1-UP; 1KS1-UP; 2RR1-UP; 3YR1-UP; 4RS1-UP)
330B (S/N: 5EZ1-UP)
330B LN (S/N: 5LR1-UP)
330B L (S/N: 5LS1-UP; 6DR1-UP)
330B (S/N: 8SR1-UP)
330B L (S/N: 8TR1-UP)
330B (S/N: 9HN1-UP; AME1-UP)
330L (S/N: 5YM1-UP; 9ML1-UP)
350 HC TT (S/N: 2ZL1-UP)
350 HC L TT (S/N: 3ML1-UP)
350 (S/N: 7RK1-UP; 8HK1-UP; 8KZ1-UP; 9FL1-UP)
350 L (S/N: 9DK1-UP)
320B LN (S/N: 3YZ1-UP)
Integrated Toolcarrier:
IT12B (S/N: 1KF1-UP)
IT14F (S/N: 4EL1-UP)
IT18F (S/N: 5EJ1-UP; 6ZF1-UP)
IT24F (S/N: 4NN1-UP; 6KN1-UP)
IT28F (S/N: 1JL1-UP; 3CL1-UP)
IT28G (S/N: 8CR1-UP; 9AR1-UP)
IT38F (S/N: 5DR1-UP; 6FN1-UP)
IT38G (S/N: 1CW1-UP; 7BS1-UP)
IT62G (S/N: 6PS1-UP; AKP1-UP)
Knuckleboom Loader:
539 (S/N: 1PZ1-UP)
Motor Grader:
120H (S/N: 2AN1-UP; 3GR1-UP; 4MK1-UP; 5FM1-UP; 6NM1-UP; 6TM1-UP; 9YR1-UP)
135H (S/N: 3YK1-UP; 8WN1-UP)
12H (S/N: 2GS1-UP; 2LR1-UP; 2WR1-UP; 4ER1-UP; 4XM1-UP; 5ZM1-UP; 8MN1-UP)
140H (S/N: 2ZK1-UP; 3AS1-UP; 3FR1-UP; 5HM1-UP; 8JM1-UP; 8KM1-UP; 9TN1-UP; 9ZN1-UP)
143H (S/N: 1AL1-UP)
14H (S/N: 7WJ1-UP)
160H (S/N: 2FM1-UP; 3GM1-UP; 3HR1-UP; 9EJ1-UP; 9JM1-UP)
163H (S/N: 5AK1-UP)
16H (S/N: 3JR1-UP; 6ZJ1-UP)
Paving Compactor:
CB-434 (S/N: 3TF1-UP)
CB-634C (S/N: 3BR1-UP; 5CL1-UP)
CP-533 (S/N: 3ZL1-UP; 5AL1-UP)
CP-533C (S/N: 3XN1-UP; 3YN1-UP)
CP-533D (S/N: 6AZ1-UP; AFC1-UP)
CP-563 (S/N: 1YJ1-UP; 5AJ1-UP)
CP-563C (S/N: 5JN1-UP; 5KN1-UP)
CP-563D (S/N: 5LZ1-UP; 9ZW1-UP)
CS-531 (S/N: 3WM1-UP; 4KM1-UP)
CS-531C (S/N: 5ZN1-UP; 9RN1-UP)
CS-531D (S/N: 3AZ1-UP; 4MZ1-UP; AGH1-UP)
CS-533 (S/N: 3BL1-UP)
CS-533C (S/N: 2WN1-UP; 2XN1-UP)
CS-533D (S/N: 5CZ1-UP; AET1-UP)
CS-563 (S/N: 7GG1-UP)
CS-563C (S/N: 4KN1-UP; 4LN1-UP)
CS-563D (S/N: 1SZ1-UP; 2RZ1-UP)
CS-573 (S/N: 8PK1-UP)
CS-573C (S/N: 6LN1-UP)
CS-573D (S/N: 2YZ1-UP)
CS-583 (S/N: 1EL1-UP)
CS-583C (S/N: 7MN1-UP; 7NN1-UP)
CS-583D (S/N: 2CZ1-UP; 3GZ1-UP)
CS-533 SP VIB (S/N: 4HL1-UP)
CS-563 SP VIB (S/N: 8XF1-UP)
Pipelayer:
561M (S/N: 1KW1-UP)
Track-Type Loader:
953B (S/N: 5MK1-UP)
953C (S/N: 2ZN1-UP)
963B (S/N: 9BL1-UP)
963C (S/N: 2DS1-UP)
973C HD (S/N: 3RZ1-UP)
Track-Type Tractor:
D5M (S/N: 3CR1-UP; 3DR1-UP; 4BR1-UP; 4JS1-UP; 5ES1-UP; 5FS1-UP; 6AS1-UP; 6GN1-UP;
7LR1-UP)
D6M (S/N: 2RN1-UP; 2YS1-UP; 3WN1-UP; 4GS1-UP; 4HS1-UP; 4JN1-UP; 5NR1-UP; 5WR1-UP;
6LR1-UP; 9ZM1-UP)
D6R (S/N: 9MN1-UP)
Wheel Loader:
910E (S/N: 1SF1-UP)
910F (S/N: 1YK1-UP)
918F (S/N: 2CK1-UP)
924F (S/N: 4YN1-UP; 5NN1-UP; 6MN1-UP; 7PN1-UP)
928F (S/N: 2XL1-UP; 7YM1-UP; 8AK1-UP)
928G (S/N: 6XR1-UP; 7SR1-UP)
936 (S/N: 45Z1-UP)
938F (S/N: 1KM1-UP; 2RM1-UP; 8SM1-UP)
938G (S/N: 4YS1-UP; 6WS1-UP; 8RS1-UP; 9HS1-UP)
950F Series II (S/N: 2LM1-UP; 5SK1-UP; 8TK1-UP; 4DJ1-UP)
950F (S/N: 6YG1-UP; 7ZF1-UP)
950G (S/N: 2JS1-UP; 3JW1-UP; 4BS1-UP; 5FW1-UP; 5MW1-UP; 6NS1-UP; 8JW1-UP)
960F (S/N: 1YM1-UP; 4CL1-UP; 6XL1-UP; 9ZJ1-UP)
962G (S/N: 3BS1-UP; 4PW1-UP; 5AS1-UP; 5RS1-UP; 6EW1-UP; 6HW1-UP; 7BW1-UP; BDP1-UP)
918F PS (S/N: 3TJ1-UP)
936F (S/N: 4TK1-UP; 8AJ1-UP; 9MK1-UP)
Wheel Skidder:
525B (S/N: 3KZ1-UP)
535B (S/N: AAE1-UP)
515 (S/N: 4LR1-UP)
522C PS (S/N: 2WL1-UP)
525 (S/N: 1DN1-UP)
545 (S/N: 2FZ1-UP)
Wheel Tractor-Scraper:
613C Series II (S/N: 8LJ1-UP)
613C (S/N: 92X1-UP)

"Explanation of Fuel Shutoff Solenoid Operation". Some of the information in this article is incorrect.
Disregard this article. See the following article.
The following solenoids are often wrongly replaced:

 155-4651 Solenoid (Fuel Shutoff) (12 volt)

 155-4652 Solenoid (Fuel Shutoff) (24 volt)
 155-4653 Solenoid (Fuel Shutoff) (24 volt)

The following sections explain solenoid operation and also provide troubleshooting guidance.

Construction

g00736320
Illustration 1

155-4651 Solenoid (Fuel Shutoff) and 155-4652 Solenoid (Fuel Shutoff)

(1) Start terminal - positive (No. 8-32 THD)

(2) Stop terminal - positive (No. 8-32 THD)

(3) GND terminal - negative (No. 10-32 THD)

(4) Plunger release button (manual override)

(5) Plunger - in the ON position (latched)

(6) Plunger - in the OFF position (unlatched)

(7) Plunger spring

g00765119
Illustration 2

155-4653 Solenoid (Fuel Shutoff) - flange mount

(8) GND terminal - negative (No. 10-32 THD)

(9) Start terminal - positive (No. 8-32 THD)

(10) Stop terminal - positive (No. 8-32 THD)

(11) Flange

(12) Plunger - in the ON position (latched)

(13) Plunger - in the OFF position (unlatched)

(14) Plunger spring

(15) Plunger release button (manual override)

 g00765161
Illustration 3

Schematic symbol

(16) Stop terminal

(17) Stop coil

(18) Ground terminal

(19) Internal switch

(20) Start coil

(21) Start terminal

The major parts of a solenoid are listed below:

Start Coil - The start coil (20) is energized when the key switch is in the START position.

Stop Coil - The Stop Coil (17) is energized when the key switch is in the OFF position.

Internal Switch - The internal switch (19) controls the operation of the start coil and the stop coil.

Plunger - The plunger (5,6,12,13) is retracted for engine run mode. The plunger is extended for engine stop.

Plunger Spring - The plunger spring (7,14) pushes the plunger outward to the STOP position.

Permanent Magnet - For the run mode, the permanent magnet holds the plunger inward.

Plunger Release Button - If electrical system power is not available, the plunger release button (4,15)
allows the engine to be shutdown manually.
Operation
1. When the key switch is turned to the start position, the start coil is energized. Current flows through
the start coil through the internal switch. Current exits the start coil through the ground terminal. A
magnetic field is created by the start coil. This magnetic field retracts the plunger.

2. When the plunger is in the retracted position (engine run position), the internal switch opens the start
coil circuit. When the permanent magnet holds the plunger in the engine run position, no current
flows through the solenoid.

3. When the key switch is turned to the OFF position, the stop coil is energized. After the stop coil is
energized, current will flow in the following pattern: through stop coil, through internal switch and
out ground terminal. The magnetic field that is created by the stop coil cancels the permanent
magnet's magnetic field. In order to stop the engine, the plunger spring pushes the plunger outward.
When the plunger is fully extended (stop position), the internal switch opens the stop coil circuit.

Troubleshooting
If a problem is suspected with the operation of the solenoid, perform the following checks before replacing
the solenoid. In order to perform this procedure, choose one of the multimeters from Table 1.

Table 1
TOOLS NEEDED

Tool Part Number

Caterpillar Digital Multimeter 9U-7330

Caterpillar Digital Multimeter 6V-7070

Caterpillar Digital Multimeter 146-4080

1. With the key in the START position, measure the voltage between the solenoid "START" terminal
(1,9) and the solenoid "GND" terminal (3,8). The voltage that is measured should equal system
voltage. If the voltage is below system voltage, inspect the solenoid wiring for the following
problems:
o broken wires or shorted wires
o loose connections
o blown fuse or tripped circuit breaker

2. With the key in the OFF position, measure the voltage between the solenoid "STOP" terminal (2,10)
and the solenoid "GND" terminal (3,8). The voltage that is measured should equal system voltage. If
the voltage is below system voltage, inspect the solenoid wiring for the following problems:
o broken wires or shorted wires
o loose connections
o blown fuse or tripped circuit breaker

3. If voltage measurements are OK, turn the key switch to the OFF position. Open the battery disconnect
switch. Disconnect the wires from the solenoid. Remove the solenoid from the engine.
4. Move the plunger to the START position (plunger in). The plunger should stay retracted. Measure the
stop coil resistance between the "STOP" terminal (2,10) and the GND terminal (3,8). For the 155-
4652 Solenoid (Fuel Shutoff) and the 155-4653 Solenoid (Fuel Shutoff), the correct resistance is from
8 ohms to 12 ohms. For the 155-4651 Solenoid (Fuel Shutoff), the correct resistance is from 2 ohms
to 3 ohms. If the resistance is not in the specified range, replace the solenoid. Operate the plunger
release button. The plunger should extend outward. Measure the stop coil resistance again. For all
three solenoids, the resistance should measure open circuit (OL). If the resistance is not in the
specified range, replace the solenoid.

5. Move the plunger to the OFF position (extended outward). Measure the start coil resistance between
the "START" terminal (1,9) and the "GND" terminal (3,8). For the 155-4652 Solenoid (Fuel Shutoff)
and the 155-4653 Solenoid (Fuel Shutoff), the correct resistance is from 1.2 ohms to 1.9 ohms. For
the 155-4651 Solenoid (Fuel Shutoff), the correct resistance is from 0.34 ohms to 0.45 ohms. If the
resistance is not in the specified range, replace the solenoid. Next, push the plunger inward. Measure
the start coil resistance again. For all three solenoids, the resistance should measure open circuit (OL).
If the resistance is not in the specified range, replace the solenoid.