POWER TAKE-OFF GP-REAR 2W4909 - Caterpillar

Starting Motor Adjustments
Pinion Clearance Adjustment
When the solenoid is installed, make an adjustment of the pinion clearance. The adjustment can be made with the starting motor removed.
Illustration 1 g00283572
Connection For Checking Pinion Clearance (1) Ground terminal. (2) SW terminal. (3) Connector.
Install the solenoid without connector (3) from the MOTOR connections (terminal) on the solenoid to the motor.
Connect a battery, that has the same voltage as the solenoid, to the "SW" terminal (2) .
Connect the other side of the battery to connector (3) .
For a moment, connect a wire from the solenoid connection (terminal), which is marked "MOTOR", to the ground connection (terminal). The pinion will shift to the crank position and the pinion will stay there until the battery is disconnected.
Illustration 2 g00283574
Pinion Clearance Adjustment (4) Shaft nut. (5) Pinion. (6) Pinion Clearance.
Push the pinion toward the end with the commutator in order to remove free movement.
Pinion clearance (6) must be 8.3 to 9.9 mm (0.33 to 0.39 inch).
In order to adjust the pinion clearance, remove the plug and turn the shaft nut (4) .Solenoid Position Adjustment
The solenoid position on the starting motor controls the pinion clearance. If the solenoid position's dimension is correct, the pinion clearance is correct. The adjustment can be made with the starting motor removed. Follow this procedure for the solenoid position adjustment.
Check the distance between the intermediate housing and the solenoid bracket.
If the distance is not correct, loosen the bolts and move the solenoid until the distance is correct. The bracket has elongated holes.
After the adjustment is correct, tighten the bolts to a torque of 7 10 N m (5 7 lb ft).Armature End Plate Adjustment
The armature end plate adjustment is made during assembly of the starting motor.
Illustration 3 g00322864
Starting Motor End Cover (1) Plug. (2) Spacer. (X) Distance between armature and face of end cover. (Y) Length of plug threads.
Remove center plug (1) and spacer (2) from the end cover.
Force the armature assembly into the drive housing up to the spacer.
Measure distance (X) from the end cover to the armature assembly.
Measure length of threads (Y) of plug (1) .
Subtract measurement (Y) from measurement (X) .This difference is the armature end play. The allowable end play is 0.004 0.12 mm (0.0002 0.0047 inch). The end play can be adjusted with different spacers (2). A list of the spacers' thicknesses follows: 1.5 mm (0.059 inch)1.7 mm (0.067 inch )1.9 mm (0.075 inch)2.1 mm (0.083 inch)2.3 mm (0.090 inch)2.5 mm (1.00 inch)
Install correct spacer (2). Put 9S-3263 Thread Lock Compound onto the threads of plug (1). Install plug (1) into the end cover.