KIT-ENGINE OVERHAUL 20R1166 - Caterpillar

Starting Motor
Illustration 1 g00803638
Starting and charging systemTable 1 shows the maximum acceptable loss of voltage in the circuits. The battery circuit supplies high current to the starting motor. Voltage drops that are greater than the amounts in Table 1 are caused most often by the following conditions:
Loose connections
Corroded connections
Faulty switch contacts
Table 1
Maximum Acceptable Loss of Voltage    
Circuit     Current for the circuit in amperes     Maximum voltage drop in volts    
Alternator charging     50 or 90     0.5    
Starter solenoid     5     0.63    
Starting aid switch     0.2     0.5    
Glow plugs     28     0.5    
Battery circuit     1000     0.7    Procedures For Diagnosis Of The Starting Motor
The procedures for diagnosing the starting motor are intended to help the technician determine if a starting motor needs to be replaced or repaired. The procedures are not intended to cover all possible problems and conditions. The procedures serve only as a guide.
Table 2
Typical Voltage Of Electrical System During Cranking At Various Ambient Temperatures    
Temperature     12 Volt System    
-23 to -7°C (-10 to 20°F)     6 to 8 volts    
-7 to 10°C (20 to 50°F)     7 to 9 volts    
10 to 27°C (50 to 80°F)     8 to 10 volts    Diagnosis Procedure
If equipped with electric start, do not crank the engine for more than 30 seconds. Allow the starter to cool for two minutes before cranking again.Never turn the disconnect switch off while the engine is running. Serious damage to the electrical system can result.
If the starting motor does not crank or if the starting motor cranks slowly, perform the following procedure:
Measure the voltage of the battery at the battery posts with the multimeter when you are cranking the engine or when you are attempting to crank the engine. Measure the voltage across the battery posts. Do not measure the voltage across the cable post clamps.
Battery voltage
Go to Step 3 if the voltage is equal to the voltage that is given in Table 2 or if the voltage is greater than the voltage that is given in Table 2.
The battery voltage is less than the voltage in Table 2.Refer to Special Instruction, SEHS7633 in order to test the battery.A low charge in a battery can be caused by the following conditions:
Deterioration of the battery
A shorted starting motor
A faulty alternator
Loose drive belts
Current leakage in another part of the electrical system
Measure the current from the positive "+" battery terminal to the starting motor solenoid. Use the 8T-0900 Ammeter. The maximum current that is allowed for no load conditions is given in the Specifications