BATTERY- 3T5780 - Caterpillar

Illustration 2 g00820183
Illustration 3 g00810580
Remove the plug (5) and seal from the shift lever housing. Remove the nut (6) that is inside the shift lever housing. The nut holds the plunger to the shift lever.
Remove bolts (2) and solenoid (1) from the shift lever housing. Do not disassemble the solenoid. The parts inside the solenoid are not serviceable.
Illustration 4 g00810222
Illustration 5 g00810478
Mark the following components for correct assembly: rear housing (8), pinion drive, shift lever housing and starting motor housing. Remove four bolts (7) and rear housing (8). Remove washer (9) from the armature. Remove the O-ring seal from the starting motor housing, if necessary.
Illustration 6 g00810242
Remove bushing (10) from the rear housing, if necessary.
Illustration 7 g00810245
Lift each brush spring (12) and put the spring on the left side of the brush (14). Disconnect three leads (11) and remove brush holder (13) .
Remove brushes (14) from the brush holder.
Illustration 8 g00810249
Remove six bolts (16) and pinion drive housing (15) .
Illustration 9 g00810257
Remove bushing (17) from the pinion drive housing, if necessary.
Illustration 10 g00810266
Illustration 11 g00810429
Illustration 12 g00810272
Drive retainer (18) backward away from ring (20) that is below the retainer. Remove the ring and the retainer. Remove armature (19) from pinion drive (21) and the starting motor and the shift lever housing (23). Remove the washer (22) from the armature (19) .Note: The pinion drive that is on the 41-MT starting motor is not the same pinion drive that is shown. The pinion drive is similar to a 42-MT starting motor. Refer to Disassembly and Assembly, "Starting Motor - Disassemble".
Remove pinion drive (21) from the shift lever forks (25) .
Remove five bolts (26) and shift lever housing (23). Remove ring (24) with tool (A), pin (27) and shift lever (25). Remove the seals from the pin, if necessary.
Remove the O-ring seal from the shift lever housing, if necessary.
Illustration 13 g00810276
Remove seal (28) and bushing (29) from the shift lever housing, if necessary.
Illustration 14 g00810281
Remove eight screws (32), field winding coil (30), and pole shoes (31) from the starting motor housing. It may be necessary to use an impact driver to remove screws (32). One of the screws is the negative terminal.
Clean the armature, field winding coil, and pinion drive with mineral spirits and a brush.Note: If the commutator is dirty, the commutator may be cleaned with Number 00 sandpaper. Do not use emery cloth.
Inspect all parts for wear and damage.