ENGINE ELECTRICAL SYSTEM

SECTION EE
CONTENTS
ADJUSTMENT VALUE ........................................EE-2 Overhaul ..........................................................EE-6
TROUBLE DIAGNOSIS .......................................EE-3 Assembly Inspection........................................EE-8
STARTER MOTOR...............................................EE-4 ALTERNATOR .....................................................EE-9
Specifications...................................................EE-4 Components of Alternator ................................EE-9
Components.....................................................EE-4 Disassembly ..................................................EE-10
Component Parts Location ..............................EE-5 Inspection ......................................................EE-12

EE

199
 ADJUSTMENT VALUE

ADJUSTMENT VALUE
Component Items Description

Starter motor • Brush dimensions 10.0 - 18.0 mm (0.394 - 0.709 in)

(Wear margin 8 mm (0.31 in))
• Brush spring pressure 13.7 - 17.7 N (1.4 - 1.8 kg) [3.1 - 4.9 lb]
Alternator • Stator Resistance between respective lead wires: 1  or less
Resistance between stator core and lead wire: 
• Rotor coil Standard resistance between slip rings: 2.9 
Standard resistance between slip ring and rotor core: 
• Snap ring Snap ring outer diameter: Standard: 14.4 mm (0.567 in)
Repair limit: 14.0 mm (0.551 in)
• Brush Projected length from holder:
Standard: 10.0 mm (0.394 in)
Repair limit: 2.0 mm (0.079 in)

200 EE-2
 TROUBLE DIAGNOSIS

TROUBLE DIAGNOSIS
Condition Possible causes Action

No or slow cranking • Battery is discharged Check and repair the charging system, check and adjust the fan belt for
tension, or replace the battery
• Incident in starter system wiring Check and repair or replace the starter switch.
• Starter motor malfunction Repair or replace.
(Starter circuit diagnosis procedure)
If the light turns off or dims when the starter switch is turned to “ON” with the
headlights on:
a: Check the battery.
b: Check the electric connections and wiring.
c: Check the starter motor.
If the light remains bright when the starter switch is turned to “ON” with the
headlights on:
a: Check the wiring between battery and starter motor.
b: Check the starter switch.
c: Check the starter motor.
Engine is cranked but • Incident in ignition system (Ignition system diagnosis procedure)
not started. (Another possible cause is an Inspect the spark plug following the steps below
incident in the fuel system. Refer to Disconnect the IGN/coil from the No. 1 plug and keep the cord 10 mm (0.394
the section about the fuel system) in) away from the engine metal portions. Then crank the engine. If there is
difficulty in identifying a spark, use the following approach: connect the IGN/
coil to a new spark plug that is separately prepared, contact the thread of the
plug to the engine metal and check for a spark by activating the starter.
If a good spark is available:
a: Check the spark plug.
b: Check the ignition timing.
c: Check the fuel system.
d: Check the cylinder compression.
If no spark is available:
a: Check the primary coil current.
b: If the current is too large, a short circuit may be present, replace.
c: Check coil malfunction, replace.
d: If the IGN/coil has an open circuit, replace.

EE-3 201
 STARTER MOTOR

STARTER MOTOR CAUTION:

Before starting any electrical system service, make sure to turn
off the key switch and disconnect the battery cable.

Specifications
Item Specifications

Part type M000T65381/M000T65585

Type Built in reduction gear
Output (kW) 1.2

Components

202 EE-4
STARTER MOTOR

Component Parts Location

Major components of starter motor
Symbol Description

(1) Front bracket

(2) Overrunning clutch
(3) Lever
(4) Internal gear
(5) Packing
(6) Shaft gear
(7) Gear assembly
(8) Packing
(9) Armature
(10) Yoke assembly
(11) Connector brush holder assembly
(12) Rear bracket
(13) Switch assembly
(14) Hexagon head bolt
(15) Flange screw

EE-5 203
 STARTER MOTOR

Overhaul
RELATED TO MAGNET SWITCH
• Plunger sliding face (rust, contamination, deformation)
• Broken or worn return spring
• Rough surface of main contact (burnout)
• Operation check of magnet switch
(Proper performance of magnet coil)
1. Plunger’s drawing operation (Pull-in coil operation)
Wire the plunger as shown in the figure on the left. The plunger
should be drawn strongly by the pull-in coil and holding coil.
2. Plunger’s holding operation (Holding coil operation)
EEM0124 In the above circuit, disconnect the wiring from the terminal M.
If the holding coil is normal, the plunger should be held in
place.

EEM0125

PINION MECHANISM
• Damage or wear of pinion gear tooth tops
Visually check for damage or wear. Replace the gear if the
damage/wear is excessive.
• Pinion gear sliding face (rust, contamination, damage on spline)
Check the pinion gear sliding motion. Replace the gear(s), if the
gear(s) drag excessively.
• Broken or worn pinion spring
• Check the pinion spring(s) and replace them if excessive
damage is present.
• Pinion spring (lever fulcrum) sliding motion
• Check the pinion spring(s) and replace them if excessive
damage is present.
• Overrunning clutch operation (slippage, seizure)
Turn the pinion gear by hand. If it turns freely in both directions
or will not turn in either direction, the overrunning clutch has
lost its proper functionality. Replace it.

FIELD COIL
Check the field coil for continuity.

Judgement
If there is continuity, the field coil is normal.
If there is no continuity, the field coil has an open circuit.
Replace it.

EEM0126

204 EE-6
 STARTER MOTOR

Overhaul (Cont’d)
• Check for continuity between the field coil and a ground.

Judgement
If continuity is present, the field coil is shorted. Replace it.
If there is no continuity, the coil is normal.

CAUTION:
Note that, however, a compound-wound motor structurally
grounds the field coil. This means that the tester will show
continuity between the field coil and a ground.
EEM0127

ARMATURE COIL
• Check the continuity between the commutators.

Judgement
If there is continuity, the armature coil is normal.
If there is no continuity, the coil has an open circuit.
Replace it.

EEM0128

• Check for continuity between the armature coil and a ground.

Judgement
If continuity is present, the field coil is shorted. Replace it.
If there is no continuity, the coil is normal.

EEM0129

BRUSH COMMUTATOR RELATED

5.5 - 12.3 (0.217 - 0.484)
Brush wear: mm (in)
(Wear margin: 6.8 (0.27) max.)

Brush spring pressure N (kg, lb) 15.0 - 20.4 (1.53 - 2.08, 3.4 - 4.59)

• If the commutator has a rough surface, grind it using sandpaper

of #500 or #600.
• If the insulator (high mica) of the commutator is 0.2 mm (0.0079
in) or less in thickness, replace the commutator.

EE-7 205
 STARTER MOTOR

Assembly Inspection
• Inspection for abrasion between the armature core and the ball
core.
• Starter motor inspection (performance with no load)

EEM0131

PROCEDURE
• Connect an ammeter to the battery positive terminal and the B
terminal.
• Connect a test wire to the B terminal and S terminal.
• Connect a voltmeter to the B terminal and the starter motor
body.
• Connect a test wire to the battery negative terminal and the
starter motor body.

JUDGEMENT
• The pinion gear should pop out and the starter motor should
rotate.

206 EE-8
 ALTERNATOR

ALTERNATOR Components of Alternator

C144F038

EE-9 207
 ALTERNATOR

Disassembly
PULLEY
• Secure shaft hexagonal part with a box wrench, loosen pulley
nut, and remove pulley.

CAUTION:
Hexagonal box wrench must be used. Twelve-fold box wrench
may crush shaft head and slip.

C144F030

REAR END COVER

• Remove screw and terminal B nut, and then remove rear end
cover.

C144F031

BRUSH HOLDER
• Remove screw, and then remove brush holder.

C144F032

IC REGULATOR
• Remove screw, and then remove IC regulator.

CAUTION:
Lengths of screws are different. Arrange removed screws, and
securely install them in the original position.

C144F033

208 EE-10
 ALTERNATOR

Disassembly (Cont’d)
RECTIFIER
• Remove screws securing wires of rectifier and stator, and
remove rectifier.

C144F034

REAR END FRAME

• Remove bolts and nuts, and then remove rear end frame.

C144F035

ROTOR
• Keep drive end frame level using blocks, and then press out
rotor.

C095F148

RETAINER PLATE
• Remove screws, and remove retainer plate.

C144F036

EE-11 209
 ALTERNATOR

Disassembly (Cont’d)
BEARING
Drive end side
Keep drive end frame level using blocks, and then press out bearing
using a jig.

Slip ring side

Pull out bearing using a puller.

CAUTION:
C095F149
Bearing for high speed is specified to be used. Always use it
when replacing, and do not impact it.

C095F150

Inspection
BEARING
• Rotate bearing by hand.
• Check for noise or binding.
• Replace if necessary.

C095F151

STATOR
• Measure resistance between each lead wire using a circuit
tester.
Standard: 1  or less
• Measure resistance between stator core and lead wire.
Standard: 
• Replace if necessary.

CAUTION:
Opening of stator coil itself is not considerable. Check the
O109F317 connection part of wires if continuity should not exist.

210 EE-12
 ALTERNATOR

Inspection (Cont’d)
ROTOR COIL
• Measure resistance between each slip ring using a circuit tester.
Standard: 2.9 
• Measure resistance between slip ring and rotor core using a
circuit tester.
Standard: 
• Replace if necessary.

C095F153

SLIP RING
• Check slip ring for dirt and damage.
• Wipe it clean with a cloth that has been dipped in alcohol if dirty.
• Polish with sandpaper (#500 to 600) if there is slight damage.
• Measure slip ring outer diameter.
Slip ring outer diameter: Standard 14.4 mm (0.567 in)
Repair limit 14.0 mm (0.551 in)
• Replace if outside the repair limit.

C095F154

BRUSH
• Measure excessive brush length from brush holder.
Excessive length of brush: Standard 10.0 mm (0.394 in)
Repair limit 2.0 mm (0.079 in)
• Replace if outside the repair limit.
• Make sure that brush is slightly moving in brush holder.

C095F155

RECTIFIER
• Check continuity between each rectifier diode with circuit tester
in k range.
• It is normal that continuity should exit in one side of diode and
continuity should not exist in another side of diode.

CAUTION:
Do not use 500V mega tester that breaks rectifier.

C144F037

EE-13 211
 ALTERNATOR

Inspection (Cont’d)
NOTE:
Rectifier condition cannot be judged by forward resistance. One of
the characteristics of a diode is that forward current is greatly
changed by battery voltage. Indication of tester changes with
differences of tester type and resistance range. Rectifier condition is
judged by resistance differences between forward and reverse
currents.

O109F322

IC REGULATOR
Check continuity between IC regulator terminal B and F with circuit
tester in k range.
• It is normal that continuity should exit in one side and continuity
should not exist in another side.

CAUTION:
Do not use 500V mega tester that breaks IC regulator.
NOTE:
O109F323
IC regulator can be checked with the following procedure if there is
constant voltage power supply that can change voltage between 10
to 20V range.

CAUTION:
Regulator may be destroyed if IC regulator misconnects only
for a moment. Perform inspection after checking wiring.
• Connect IC regulator unit with constant voltage power supply,
circuit tester, and lamps.
• (SW1 and SW2 must remain OFF.)
• Set a power supply voltage to 12V.
• Set SW1 setting to ON. Make sure that L1 turns ON brightly,
and L2 turns ON dimly at this time.
• Next, turn SW2 to NO while leaving SW1 at ON. Make sure that
L1 turns OFF, and L2 turns ON brightly at this time.
• Raise battery voltage from 12V gradually. Make sure that L2
may turn OFF when battery voltage is approximately 14.5±0.6V.
C095F158

212 EE-14
Cat Lift Trucks Service Manual K21,K25 Gasoline Engine 99789-80110
 Mitsubishi Caterpillar Forklift America Inc.
2121 W. Sam Houston Parkway N.
Houston, TX 77043-2305

© 2014. All rights reserved. CAT, CATERPILLAR, their respective logos,

"Caterpillar Yellow", the "Power Edge" trade dress as well as corporate and
product identity used herein are trademarks of Caterpillar and may not be
used without permission. All registered trademarks are the property of their
respective owners. Some products may be shown with optional equipment.
99789-80110 7/14