955C Weak to start

How have you got it wired and what gauge wire for the battery feed?
You could wire direct to the starter and bypass the solenoid for a starter test. It's a bit sparky so protect any threads.

If you have good & correct size Battery Cables & good Battery Cable Terimals I would believe you would need your Starter checked by a local Alt. Starter Rebuilding Shop. My shop is located in Conn. & if your close by give me a call. 860-528-8174

Ken, do you happen to know what the going rate for a new starter is? Or a rebuilt starter

I believe the battery cable size is 02 and the connectors are new. Would having a failing starter cause the negative terminal to get really hot?

The negative terminal could be getting hot because it is a bad connection and causing a voltage drop and heating up the starter, check that out first, you could save some expense if it is that simple.

Are you putting correct voltage to the starter?

[quote="ShawnP"]So I've been doing some work on my Cat 955C and I'm battling a bit of an issue. The CAT doesn't have a generator so when I go use it for the day I put in fresh batteries. When I get the two batteries hooked up nice and tight and go to turn it over The ground on battery smokes, starter smells and its to weak to start. Could it be a starter solenoid causing the issue?

Thanks in advance.[/quote]

The ground smokes because for some reason it is a resistor to the circuit, whatever the cause, that needs to be fixed. The starter smells because the lower voltage to it (taken up by ground resistance) makes it use more amps to put out the power.

My idea is you need to look at the ground cable.

keep us posted

Like my dad used to say: "well it worked alright last time I used it!" Using that philosophy you need to look at the latest hookup.

Voltage drop should be minimal, like 10% or so max.
Either the starter is drawing excessive amps due to internal short to ground or the armature may be dragging on the pole shoes if the bushings/bearings are worn out.
This is not caused by the solenoid which is just an electrically operated switch.
Are the main cable terminals properly installed/swedged to the cables? No 2-bolt clamp type wire connections.