Procedure to Replace Commutator End (CE) Housing of Starter Motor On All Cat<SUP>&reg;</SUP> Products {1408, 1450, 1453} Caterpillar


Procedure to Replace Commutator End (CE) Housing of Starter Motor On All Cat® Products {1408, 1450, 1453}

Usage:

MT700 018


Caterpillar Products
All

Introduction

This Special Instruction provides the procedure to replace 8T-9884 Insulator Kit of starter motor on all Cat® products.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If the tools, the procedure, the work method, or your actions are not recommended by Caterpillar, ensure that the tools and your actions are safe for you and for others.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by Caterpillar. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Note: Always use proper eye protection when performing any mechanical repairs to a vehicle and any installation or repairs to starting motors. Failure to use proper eye protection can lead to serious and permanent eye damage.

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

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.


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

Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.


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

When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.


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

Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.


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

Personal injury can result from improper handling of chemicals.

Make sure you use all the necessary protective equipment required to do the job.

Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.

Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.


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

Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.


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

Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.


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

Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.


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

Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.


Machine Preparation

  1. Move the machine to a level surface.

  2. Apply parking brake. Turn engine key switch to OFF position.


    Illustration 1g00104545

  3. Perform Lockout Tag Out procedure by attaching a warning tag to the machine controls.

Replacement Procedure

Note: Always disconnect battery ground before removing or replacing cables at the starter. Failure to disconnect the battery ground cable can lead to serous injury.



Illustration 2g06421474
(A) Solenoid Lead
(B) Cup and Wick
(C) CE Frame
(D) Square Insulator
(E) Ground Terminal
(F) Nut
(G) Lock Washer
(H) Flat Washer
(J) Insulators
(K) CE Frame Attaching Screw
(L) Thermostat
(M) CE Terminal, Lead, and Thermostat assembly connected to brush plate assembly (Not shown)
(N) Retaining Ring

Disassembly

  1. Remove vehicle leads connected to the starter, noting their positions for reinstallation of starter, and remove starter.

  2. Note position of the ground stud or mark the CE housing & frame for reinstallation.

  3. Remove clip from over crank protection (OCP) connector if applicable.

  4. From the insulated/ground terminal, carefully note orientation for reinstallation, and remove all parts including the solenoid ground lead. Check the condition of insulators and sealing features and consider replacing them if they are damaged or excessively worn.

  5. Remove the four CE attaching screws and CE housing. If the armature thrust washer is stuck to the CE housing hub, remove it and place it on the armature shaft.

  6. Remove the remaining insulators from the ground stud, and carefully note the orientation for reinstallation. Check the condition of insulators and sealing features and consider replacing them if they are damaged or excessively worn.

  7. Remove all parts from the CE housing assembly. If reconditioning the CE housing, remove the bushing, cup and wick.

Assembly

Note: If reconditioning the CE housing using the service package to replace the wick, cup and bushing, follow the below procedure. If CE housing assembly is being replaced, start from Step .

  1. Soak new wick in SAE20 weight oil for several hours to allow the oil to penetrate and install into the housing.

  2. Align the cup with the wick hole, open end down, and tap it into place until it is flush with the housing. It is best to use a deep well socket or similar device about the same size as the outside diameter of the wick cap. Strike it with a hammer until the cup top is flush with the casting.

  3. Install the CE housing bushing. This requires using an arbor press or a special tool. The recommended special tool is like a large pin punch which has about the same outside diameter as the armature shaft for that end with a shoulder on it about the same size outside diameter as the bushing.

  4. Install the O-ring onto the frame groove.

  5. Install the square fiber insulator and fiber washer onto the ground stud. In some Grounded 37MT & 41NT starters it will not be necessary to install the ground terminal and fasteners.

  6. Apply bearing type grease onto inner diameter of CE housing where the frame O-ring is seated and apply a small amount of SAE20 oil into the bushing area.

  7. Install CE housing over the locator pins and install CE attaching screws, assuring the square fiber washer is properly aligned with the anti-turn feature on the CE housing.

  8. On models with OCP, assure the OCP connector is seated properly into the housing and torque the CE attaching screws to 4.5 to 6.8 N·m (39.8 to 60.1 lb in).

  9. First insert the small round fiber insulator and then the rubber bushing over the ground stud into the hole on the CE housing. Installing the rubber bushing prior to installing the CE housing can pinch the bushing and destroy its sealing capabilities.

  10. Install the large round fiber washer and the remaining hardware in the same order the parts were removed. Torque the large nut on ground stud to 27.0 to 33.8 N·m (238.9 to 299.1 lb in).

  11. Install clip on OCP connector, if applicable.

  12. Reinstall starter and connect cables and other leads, as removed.

  13. Reconnect the negative cable to the battery.

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