Disassembly, Assembly, Testing, and Salvage of Starting Motor for 3046, 3064, and 3066 Engines {1453} Caterpillar

Caterpillar Products

All 3000 Engines

Introduction

Table 1

Revision	Summary of Changes in SEBF9088
01	Added new serial number prefixes for New Product Introduction (NPI).

© 2019 Caterpillar® All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Illustration 1	g02139237

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 a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. 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, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

The following procedures provide direction to assist the technician in disassembly, inspection, salvage, assembly, testing and adjusting of certain starting motors for 3066, 3064, and 3046 engines.

Additional service literature for 3046 and 3044 starting motors can be found in references.

Service Letters and Technical Information Bulletins

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NOTICE
The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired.

References

Table 2

References
Media Number	Title
SEBD9146	"Causes And Effects Of Low Battery Voltage On Electric Starters"
SEGV3008	"Electrical System for All Caterpillar Products"
SEHS7633	"Battery Test Procedure"
SENR3828	"Systems Operation, Specifications, Testing and Adjusting, Disassembly and Assembly, RA1.2, R1.4, R2.0, R2.2, R2.5, R2.7, R3.0, R4.5 and R5.5 Series Reduction Starting Motors"
SEPD0653	"Examine Failed Starting Motors to Understand the Reason for Failure"
SEPD0804	"Starting the Engine with Jumper Cables on Machines with an Electric Starter"
-	The Disassembly and Assembly manual for your machine
-	The Operation and Maintenance Manual for your machine
-	The Specifications manual for your machine
-	The Testing and Adjusting manual for your machine

Tooling and Equipment

Table 3

Required Tooling and Equipment
Part Number	Description
1U-7234	Feeler Gauge
1U-9238	Hacksaw Blades
2S-3230	Caterpillar High-Speed Ball Bearing Grease
4C-9800	Growler, 220 Volt, 50/60 Hz (1)
6V-7030	Metric Depth Gauge
6V-7070	Digital Multimeter Note: The following part numbers can be used or an equivalent can be used. 6V-7800 or 6V-3030
6V-2012	Depth Micrometer
8T-0447	Caliper
8T-0900	Clamp-on Ammeter
8T-5096	Dial Indicator Group
9U-6182	Inspection Mirror
153-5656	12 volt battery Use this part number or an equivalent. Note: One battery can be used for a 12 volt starting motor. Note: Two battery's can be used for a 24 volt starting motor.
263-9070	Steel File
208-6183	Hacksaw
263-9072	Thin Tapered File
263-9095	Handle
303-9339	Lint Free Shop Towels
367-9109	Digital Caliper
383-8887	Dual Scale Feeler Gauge Set
386-3364	Straight Edge Ruler
-	V-Blocks
-	Spring Scale
-	Resistance Soldering Power Supply (VENSEL Enterprises Part Number L354-0631-3-220V)(2)
	Foot Control (VENSEL Enterprises Part Number L354-0811)(2)
	Hand Held Soldering and Silver Soldering Tool (VENSEL Enterprises Part Number L504-0007)(2)
-	Silver Solder (VENSEL Enterprises Part Number R059-0175)(3)

(1)	Growler, 4C-4912, 120 Volt, 50/60Hz
(2)	Use the following tools or an equivalent.
(3)	Use only silver solder

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

Measurement Requirements

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NOTICE
Precise measurements shall be made when the component and measurement equipment are at 20° (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° (68° F). This will ensure that both the surface and core of the material is at the same temperature.

Cleaning

Clean the electrical parts of the starting motor with electrical component cleaner.

Clean all the parts that are not electrical with mineral spirits or solvent. All parts must be clean and dry to ensure complete inspection and assembly.

Note: Clean the overrunning clutch with a clean towel. Using steam cleaning methods or a degreaser can remove the original lubricant.

Disassembly

Illustration 3	g06382729
Order of Disassembly

Note: Begin the disassembly procedure by removing the auxiliary switch and the two wires from the solenoid switch assembly, if equipped.

(1) Solenoid Switch Assembly

(2) Rear Housing

(3) Brush Holder Assembly

(4) Field Winding Assembly (Yoke)

(5) Armature

(6) Rear Armature Assembly

(7) Ball

Note: The ball may be stuck to the grease on the armature shaft during disassembly. Do not lose the ball.

(8) Packing Assembly

(9) Gear Assembly

(10) Lever Assembly

(11) Washer Set

(12) Shaft Assembly

(13) Internal Gear Assembly

(14) Overrunning Clutch

(15) Front Housing

(16) Front Bearing

(17) Seal

(18) Pinion Assembly

Inspection

Visual Inspection of the Armature

Visually inspect the armature:

1. Bent shaft or worn shaft.

2. Worn commutator or rough commutator.

3. Burned commutator bars.

4. Depth of mica between segments.

5. Worn teeth or damaged teeth.

6. Worn armature windings or damaged armature windings.

7. Debris between the commutator segments.

If any of the conditions are found replace the armature.

Visual Inspection of the Brush Holder

Visually inspect the brush holder:

1. Bent brush holders.

2. Bent mounting plate.

3. Threads in the mounting plate.

4. Insulation that is worn or damaged under the brush holders for the field coil.

If any of the conditions are found replace the brush holder.

Testing and Measurement Of The Armature

Note: Follow the manufacturer's instructions before testing the armature.

Use the growler to check for shorted circuits, grounded circuits, and open circuits.

Armature Short Circuit Test

Illustration 4	g00584876
Armature short circuit test (3) Armature (4) Growler

1. Place the armature on the growler. The growler needs to be turned on to the ON position.

2. Hold a hacksaw blade against the armature core. Slowly rotate the armature while the blade is against the core.

3. The blade should not vibrate or the blade should not be attracted to the armature core.

4. If the blade vibrates or the blade is attracted to the core, the armature has a short. The armature must be rebuilt or replaced.

Armature Ground Test

Illustration 5	g00584879
Armature ground test (3) Armature

1. Select the highest resistance (continuity) level on the multimeter. Touch one lead on each commutator bar and the other lead on the armature core.

2. There should be no continuity.

3. If the multimeter displays continuity replace the armature.

Armature Ground Test (Alternative)

1. Use the test light in the growler by placing one lead on each commutator bar and the other lead on the armature core.

2. The test light should not light.

3. If the test light lights the armature must be replaced.

Armature Continuity Test

Special equipment is needed to test the armature for an open. If the commutator is pitted or the bars are burned the armature has an open. Replace the armature.

Armature Runout Check

Illustration 6	g00584880
Armature runout check (5) Commutator

Support each end of the armature in the V-blocks. Use a dial indicator to measure the runout of the commutator. Machine the commutator if the measurement is higher than the standard but not higher than the service limit. Do not exceed the service limit. If the commutator surface is rough use sandpaper (300 to 500 grit). If the commutator is machined or if the commutator is sanded remove all the debris.

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NOTICE
Keep all parts clean from contaminants Contaminants may cause rapid wear and shorten component life

Table 4

Armature Runout Check
Model	Standard	Service Limit
3046 Engine	0.03 mm (0.0012 inch)	0.1 mm (0.004 inch)
3064 Engine 3066 Engine		0.05 mm (0.0020 inch)

Commutator Outside Diameter Check

Illustration 7	g00584882
Commutator outside diameter check (5) Commutator

Measure the diameter of the commutator. If the measurement is smaller than the service limit replace the armature.

Table 5

Commutator Outside Diameter Check
Model	Size	Nominal Value	Service Limit
3046 Engine	12 Volt 3 kW	38.7 mm (1.52 inch)	38.1 mm (1.50 inch)
	12 Volt 2.2 kW	32 mm (1.26 inch)	31.4 mm (1.24 inch)
3064 Engine 3066 Engine	-

Depth Of Mica Between Segments

Illustration 8	g00584885
Depth of mica between segments (X) Depth of mica between segments

Use a depth gauge to measure the depth of the mica between each segment of the commutator. If the depth is less than the standard, the mica can be undercut. Do not exceed the service limit. If the mica is undercut, remove all the shavings and particles of mica.

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NOTICE
Keep all parts clean from contaminants Contaminants may cause rapid wear and shorten component life

Table 6

Depth Of Mica Between Segments
Model	Standard	Service Limit
3046 Engine	0.4 mm to 0.6 mm (0.016 to 0.024 inch)	0.20 mm (0.008 inch or less)
3064 Engine
3066 Engine

Test The Field Winding (Yoke) For A Grounded Circuit

Illustration 9	g00584871
Testing the field winding for a grounded circuit (1) The field winding leads. (2) Motor terminal lead

1. Set the multimeter to the position of resistance (conductivity).

2. Place one lead on each field winding lead (1) and place the other lead on the starting motor case.

3. If there is continuity check the insulation and repair or replace the field winding.

Test The Field Winding (Yoke) For An Open Circuit

Illustration 10	g00584873
Testing the field winding for an open circuit (1) The field winding leads. (2) Motor terminal leads

1. Set the multimeter to the position of resistance (conductivity).

2. Place the leads between each field winding lead (1) and the lead of the starting motor (2).

3. If there is no continuity replace the field winding.

Brush Length Measurement

Illustration 11	g00584917
Brush length measurement (X) Brush length

1. Measure brush length (X). If length (X) is less than the service limit replace the brushes. If the brush contact surface is rough use sandpaper (300 to 500 grit).

Note: The brush length measurement applies to both the field winding and the brush holder assembly.

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NOTICE
Keep all parts clean from contaminants Contaminants may cause rapid wear and shorten component life

Table 7

Brush Length Measurement
Model	Size	Nominal Value	Service Limit
3046 Engine	12 Volt 3 kW	17 mm (0.67 inch)	11 mm (0.43 inch)
	12 Volt 2.2 kW	18 mm (0.71 inch)
3064 Engine 3066 Engine	-

Measuring The Force Of The Brush Spring

Illustration 12	g06382733
Measuring the force of the brush spring (3) Spring scale (4) Brush spring (5) Brush

1. Use a new spring to measure the spring force.

2. Attach the spring scale to the brush spring close to the contact area of the brush.

3. Hold the brush holder stationary and then pull on the spring scale.

4. Note the reading on the scale when the spring moves from the brush. If the force is less than the service limit replace the spring.

Table 8

Force Of The Brush Spring
Model	Size	Standard	Service Limit
3046 Engine	12 Volt 2.2 kW	30.4 to 38.2 N (6.8 to 8.6 lb)	19.6 N (4.4 lb)
	12 Volt 3 kW	33.3 to 45.1 N (7.5 to 10.1 lb)	17.7 N (4.0 lb)
3064 Engine 3066 Engine	-	29 to 39 N (6.6 to 8.8 lb)	13.7 N (3.1 lb)

Test The Insulation In The Brush Holder

Illustration 13	g06382734
Testing the insulation in the brush holder (6) Brush holder plate (7) Brush holder (8) Brush spring (9) Brush holder insulation

1. Set the multimeter to the position of resistance (conductivity).

2. Place one lead on each positive brush holder (7) and the other lead to the brush holder plate (6). The positive brush holders are insulated.

3. If there is continuity replace the brush holder assembly.

Inspection Of The Overrunning Clutch

Illustration 14	g00584919
Inspection of the overrunning clutch

(9) Housing

(10) Pinion

1. Clean the overrunning clutch with a clean towel.

   Note: Using steam cleaning methods or a degreaser can remove the original lubricant.

2. Visually inspect the overrunning clutch for damage. If damage is found replace the overrunning clutch.

3. Hold the housing (9) and turn the pinion (10) in the direction of operation. The pinion should rotate freely. Replace the overrunning clutch if the pinion does not rotate freely.

4. Hold the housing (9) and turn the pinion (10) in the opposite direction of operation. To prevent rotation, the pinion should be locked. Replace the overrunning clutch if the pinion does not lock.

Brush Replacement

Note: Do not perform the following procedures for replacing the brush assemblies until you read the manuals for the tools and instructions for the tools and you understand the manual for the tools and the instructions for the tools.

Note: Ensure that the field winding assemblies and the brush holder assemblies are clean.

Brush Holder

Parts Identification Of The Brush Holder

Illustration 15	g06382736
Parts identification of the brush holder (1) Brush holders (2) Brush spring (3) Mounting threads (4) Brush wear on the insulation (5) Orientation of the brush (6) Brush (7) Insulation of the brush holder

Brush Replacement

1. Note the orientation of the brush assemblies on the brush holder.
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   Illustration 16	g06382738
   Removed brush assembly (1) Removed brush assembly

2. Cut the brush assembly from the brush holder. The cut must be flush with the original connection between the brush assembly and the brush holder.

3. Use a fine file to remove remaining wire and solder from the original face of the connection (1). Remove all filings.

   Note: Do not damage the insulation of the brush holder.

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   Illustration 17	g06382740
   Modified new brush terminal (1) New brush terminal (2) Modified new brush terminal (Z) Cut terminal at bend

4. Cut the end of the new brush terminal at the bend in the terminal.

   Note: This provides a flat surface to solder the modified new brush terminal to the original connection on the brush holder.

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   Always wear protective gloves when handling parts that have been heated.

5. Apply an even amount of silver solder to the modified new brush terminal and to the original connection on the brush holder.

6. Place the soldered side of the modified new brush terminal on the face of the original connection on the brush holder.

7. Align the modified new brush assembly in the original position.
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   Illustration 18	g06382741
   The soldered connection of the modified new brush (1) Soldered connection

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   Always wear protective gloves when handling parts that have been heated.

8. Use the resistance soldering tool to heat the modified new brush terminal and the original connection on the brush holder until a small amount of solder flows evenly from the joint. Do not move the hot soldered connection between the modified new brush assembly and the original connection on the brush holder. Wait until the soldered connection is cool. Wipe off any remaining flux with a clean damp towel.

9. Repeat Steps 1 through 8 for replacement of the other brush assembly.

Field Winding (Yoke)

Brush Replacement

1. Note the orientation of the brush assemblies on the field winding connector ring.

2. Cut the brush assembly from the field winding. The cut must be flush with the original connection between the brush assembly and the connector ring.
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   Illustration 19	g06382742
   Removed brush from the field winding (1) Brush has been removed from the field winding.

3. Use a fine file to remove remaining wire and solder from the original face of the connection (1). Remove all filings.

   Note: Do not damage any of the surrounding field windings.

   Note: Do not remove original material from the field winding connector ring.

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   Illustration 20	g06382744
   Modified new brush terminal (1) New brush terminal (2) Modified new brush terminal (Z) Cut terminal at bend

4. Cut the end of the new brush terminal at the bend in the terminal.

   Note: This provides a flat surface to solder the modified new brush terminal to the connector ring.

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   Always wear protective gloves when handling parts that have been heated.

5. Apply an even amount of silver solder to the modified new brush wire terminal and to the inner diameter of the original joint area of the connector ring.

6. Place the soldered side of the modified new brush terminal on the inside diameter of connector ring original joint.

7. Align the modified new brush assembly in the original position.
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   Illustration 21	g06382746
   The soldered connection of the modified new brush (1) Soldered connection

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   Always wear protective gloves when handling parts that have been heated.

8. Use the resistance soldering tool to heat the modified new brush terminal and the original connection on the connector ring until a small amount of solder flows evenly from the joint. Do not move the hot soldered connection between the modified new brush assembly and the connector ring. Wait until the soldered connection is cool. Wipe off any remaining flux with a clean damp towel.

9. Repeat Steps 1 through 8 for replacement of the other brush assembly.

Assembly

Note: All parts must be clean before assembly.

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NOTICE
Keep all parts clean from contaminants Contaminants may cause rapid wear and shorten component life

Assembly Sequence

Note: Apply grease to the following parts during assembly of the starting motor: Seal lip, front bearing, shaft assembly, internal gear assembly, gear assembly, contact surface of the lever assembly, ball, and rear bearing.

(1) Front Housing

(2) Seal

(3) Front Bearing

(4) Washer Set

(5) Overrunning Clutch

(6) Shaft Assembly

(7) Internal Gear Assembly

(8) Pinion Assembly

(9) Gear Assembly

(10) Lever Assembly

(11) Packing Assembly

(12) Ball

(13) Field Winding (Yoke)

(14) Armature

(15) Rear Bearing

(16) Brush Holder Assembly

(17) Rear Housing

(18) Solenoid Switch Assembly

Note: Complete the assembly procedure by installing the auxiliary switch and the two wires from the solenoid switch assembly, if equipped.

Testing and Adjusting

Electrical Connections At The Solenoid

Note: Solenoid assembly and switch assembly are the same part.

Illustration 22	g06382747
Electrical connections at the solenoid (1) "M" terminal is the Motor terminal. (2) "S" terminal is the Start terminal. (3) "B" terminal is the Battery terminal.

Pinion Clearance Adjustment

Illustration 23	g06382749
Electrical connections for pinion adjustment

Note: Do not continue the test for more than 20 seconds to prevent the windings on the solenoid switch assembly from overheating.

1. Connect a battery that has the same voltage as the solenoid assembly to the "S" terminal. Connect a battery, that has the same voltage as the solenoid assembly to the front housing of the starting motor. This will cause the pinion to move to the cranking position and this will cause the pinion to rotate.

2. Disconnect the cable from the "M" terminal to stop the pinion from rotating. The pinion will remain in the cranking position.
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   Illustration 24	g06382750
   Adjustment of the pinion gap (Z) Pinion gap

3. Lightly push the pinion toward the armature.

4. Measure the pinion gap (Z).

5. Add the packing or remove the packing on the solenoid switch assembly to adjust the gap (Z). Adding the packing will decrease the gap.

Table 9

Pinion Gap
Engine Model	Standard
3046	0.5 to 20.0 mm (0.020 to 0.079 inch)
3046 3066

Testing No Load

Illustration 25	g00584747
No load test diagram 24 volt shown

Note: The multimeter must be set to the voltage specifications that are listed in Table 10.

Note: The ammeter must have sufficient capacity to exceed the specifications in Table 10.

Note: All connections must have sufficient capacity to exceed the specifications in Table 10. All connections must be secure and tight.

1. Use protective jaws and clamp the starting motor securely in a bench vise. Do not damage the starting motor.

2. The above illustration shows two batteries (12 volt) that are connected to a starting motor. Use one battery for a 12 volt system. Connect the positive battery cable to the Battery terminal of the starting motor solenoid. Connect the negative battery cable to the front housing of the starting motor.

3. As shown, connect an open switch between the "S" terminal and the "B" terminal of the solenoid.

4. Connect the positive lead of the multimeter to the "M" terminal on the solenoid. Connect the negative lead of the multimeter to the front housing of the starting motor.

5. Use an rpm indicator or photo tach to measure the speed of the armature.

6. Close the switch.

7. Compare the voltage, the amperage, and speed (revolutions per minute) to the specifications.

Table 10

No Load Test
Engine Model	Size	Voltage	Amperage	Speed (rpm)
3046	12 Volt 2.2 kW	11	130 or less	3800 or more
	12 Volt 3 kw	11	130 or less	3800 or more
3064 3066	-	23	85	3300

No Load Test Results

The following information provides some results of the load test that could be seen and corresponding possible problems.

1. Achieving the rated current draw at the speed of the load test indicates a normal starting motor.

2. A low free speed and a high current draw indicate:

   1. An increase in friction could be caused by tight bearings, dirty bearings, or worn bearings. A bent armature or loose field pole shoes that would allow the armature to drag are possible causes of increased friction.

   2. A shorted armature could cause a high current draw. This can be checked on a growler after disassembly.

   3. A grounded armature or a grounded field winding could cause a high current draw. Check for grounds after disassembly.

3. Failure to operate with a high current draw indicates:

   1. A direct ground is possible in the terminal or field windings.

   2. The bearings cease to operate properly. This can be seen by rotating the armature by hand.

4. Failure to operate with no current draw indicates:

   1. An open field circuit will cause a failure. The system can be checked for an open field circuit with a multimeter after disassembly.

   2. An open armature will cause a failure. Inspect the commutator for badly burned bars.

   3. Broken brush springs, worn brushes, or high insulation between the commutator bars could prevent good contact between the brushes and the commutator.

5. A low test speed and a low current draw indicate:

   1. An internal resistance that is high is possibly caused by poor connections, leads that are faulty, a commutator that is dirty, and/or causes that are listed in Step 4.

6. A high free speed and a high current draw indicate:

   1. A shorted field circuit will cause a failure. Check the field winding for shorts after disassembly.

Testing Of The Solenoid Switch Assembly

Test The Solenoid Switch Assembly For An Open Circuit

1. Set the multimeter to the position of resistance (conductivity).

2. Place one lead on the "S" terminal and the other lead on the "M" terminal.

3. If there is no continuity replace the solenoid switch assembly.

Test The Solenoid Switch Assembly For Full Battery Current

1. Set the multimeter to the position of resistance (conductivity).

2. Place one lead on the "B" terminal and the other lead on the "M" terminal.

3. If there is continuity replace the solenoid switch assembly.

Test The Solenoid Switch Assembly For Mechanical Operation

1. Push the rod of the solenoid switch toward the terminal end.

2. Maintain the rod in this position.

3. Place one lead on the "B" terminal and the other lead on the"M" terminal.

4. If the voltage drop exceeds 0.8 volts replace the solenoid switch assembly.