CASE CORPORATION 700 State Street Racine, WI 53408 USA. CASE CANADA CORPORATION 450 Sherman Avenue Hamilton, ON LON 4¢$ CANADA Section 4008 ALTERNATOR 4008 © 1998 Case Corporation Printed USA. Rac7-68501 March, 1997 (Revised October, 1998},4008-2 TABLE OF CONTENTS SPECIFICATIONS 2 SPECIAL TORQUES....... 2 SPECIAL TOOLS .... 2 ALTERNATOR TESTING a ‘Checks Prior to Testing : nee Voltage Test at the Altemator Terminals =e ‘Altemator and Voltage Regulator Test .... 4 REMOVAL AND INSTALLATION ..... DISASSEMBLY AND ASSEMBLY 6 INSPECTION ..... 7 WARNING: THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. wi718 SPECIFICATIONS Manufacturer. so ; Bosch Output Current 65 Amp MOdEl .nnsnsnseninnsn 14 Volts at 6000 rpm 95 Amp Model. : ee tee 14 Volts at 6000 rpm Resistance of Stator Winding 165 Amp Model - 1 Phase Ends “ sons “ 0.045 to 0.055 ohms a — 0.090 to 0.110 ohms 95 Amp Model -t Phase Ends _ Seance sonnnnansnonnansnn 0243 10 0.0297 OMS 2 Phase Ends sn een (0.049 to 0.0805 ohms Resistance of Rotor Winding 65 Amp Model 2.34 to 2.86 ohms 95 Amp Model 2.85 to 3.15 ohms Maximum Rotor Shaft Run Out (all). “ cere snnsnsoonnansnaenonnonn 0.05 MM (0.002 inch) SPECIAL TORQUES ‘Aerator Mounting Bots : : so 24.Nm (18 tb) Pulley Retaining Nut ——— oe “ 68 Nm (50 tb) SPECIAL TOOLS 1. CAS 1559 MULTIMETER 2, SUN ELECTRIC VAT-33 TESTER NOTE: Case Corporation reserves the ight o mato improvements design or chang in speciation at anytime withowt incuting any oigaton fo irtall them on ris previously sob Rac 7.68501 Revises 10:8 Panedin USA4008-3 ALTERNATOR TESTING Checks Prior to Testing STEP 1 Park the machine on hard level ground. Apply the parking brake and stop the engine, STEP 2 Make sure that all electrical connections are tight and tree of corrosion STEP 3 Make sure that the alternator drive belt is tight and clean Voltage Test at the Alternator Terminals NOTE: Carry our Steps 1 to 5 before proceeding with this test STEP 6 esi746 1. B+ TERMINAL 2. O= TERMINAL 2. WTERMINAL Connect the positive multimeter lead to the B+ terminal of the alternator Connect the negative multimeter lead to a good ground connection on the engine. If the multimeter indicates less than rated voltage, or indicates zeo, goto Step 7. Ifthe multimeter indicates rated voltage, goto Step 9 Rac 7-68601 STEP 4 Check the operation ofthe battery warning lamp. Step 2 and three may have corrected the fault STEP 5 Test the batteries. Each battery must be fully charged and each cell should have a speciic gravity of at least 1.265 at room temperature STEP 7 Connect the positive muitimeter lead to the battery terminal of the starter solenoid Connect the negative multimeter lead to a good ground connection on the engine. Ifthe multimeter indicates rated voltage, repair or replace the wire between the alternator and the starter solenoia. It the multimeter does not indicate rated voltage, replace the positive battery cable. STEP 8 Turn the starter key switch to the ON position. Disconnect the ‘connector from the D+ terminal ofthe altemator, Connect the positive multimeter lead to the terminal in the connector and the negative multimeter lead to a good ground connection on. the engine. If the multimeter indicates rated voltage, connect the ‘connector to the alternator and refer to the Alternator and Voltage Regulator Test in this section. See section 4001 i the multimeter does not indicate rated voltage Revised 10-96 Prntedin USA,40084 Alternator and Voltage Regulator Test ON 1. SUNELEGTAIG VAT-39 TESTER 2 12VOLT BATTERY NOTE: Refer to Steps 1 to 8 in this section before carrying out this test. Use a Sun Electric VAT-33 or other suitable equipment to carry out the following test. STEP 9 Agjust the controls on the Sun Electric VAT-33 as follows: 1. Put he load control to the OFF position 2, Select the volt range that will measure 12 volts 3. Select the ampere range that will measure 0 to 100 amperes. 4. Put the volt lead select switch to the EXT. position STEP 10 Connect the positive load lead of the tester to the positive post of one of the batteries, Connect the negative load lead of the tester to the negative post of the same battery Fac 7.48501 () VOLTVETER LEAD 44 NEGATIVE () VOLTMETER LEAD roro1ss 5, ANMETER CLAMP LEAD STEP 11 Connect the positive voltmeter lead to the tester to the B+ terminal on the alternator Connect the negative voltmeter lead of the tester to a good ‘ground connection on the engine STEP 12 Connect the ammeter clamp around the wire that fastens the + terminal on the alternator to the battery terminal of the starter. The clamp must be at least 50 mm (1.97 inch) from the alternator. The point of the arrow on the ammeter clamp ‘must be pointing away from the alternator. Revised 10:98 Pantedin USA,STEP 13 Start the engine and run at 3/4 throttle. WARNING: Never operate the engine in a A closed building. Proper ventilation is required under all circumstances. sok NOTE: Carry out Steps 14 and 15 rapidly. Do not apply @ load to the battery for more than 15 seconds at a time. Alter 15 seconds, turn the foad control to the OFF position far 60 seconds before applying the load again. STEP 14 Adjust the load control on the tester to get the maximum ammeter indication, Make a note of the ammeter and voltmeter readings. Tum the load contro to the off position 4008-5 STEP 15 Slowly decrease the engine speed and stop the engine. STEP 16 ‘The ammeter reading in Step 14 must be at least the rated ‘output (85 or 95 amperes). The voltmeter reading in Step 14 must be 13 to 15 volts. If the ammeter and voltmeter readings are correct, the alterator and voltage regulator are good. If the ammeter and voltmeter readings are not correct, replace the voltage regulator and brush holder and repeat the test If the ammeter and voltmeter readings are stil nat correct, inspect and repair the alternator. REMOVAL AND INSTALLATION STEP 17 Remove the key from the key switch. Disconnect the negative (terminal from the battery. STEP 18 Remove the rear cover from the alternator. STEP 19 Remove the tension from the tension pulley bracket and remove the drive belt, ac 7.68501 Fasten identification tags to and disconnect the wires (1) rom the alternator. Bemove the top (2) and bottom mounting bolts and remove the alternator. NOTE: For installation, follow the same procedure in reverse order. Tighten the alternator mounting bolts to a torque of 24 Nm (18 Ib f) Aevsed 1096 Printed in S.A4008-6 DISASSEMBLY AND ASSEMBLY NOTE: 95 ampere alternator is shown, 65 ampere alternator is similar, NOTE: Items are numbered in order of disassembly. Nur WASHER PULLEY RETAINER, PULLEY FAN Key ec 788501 SoREW VOLTAGE REGULATOR AND BRUSH HOLDER HARDWARE SET HARDWARE SET ‘SCREW ‘oaPACITOR SCREW CcovER SOREW FOTOR SHIELD avre%20 18, SCREW 19, RECTIFIER BRIDGE 20. STATOR: 21, HOUSING 22, INSULATOR Revises 10:98 Pantedin USA,4008-7 INSPECTION NOTE: Set the multimeter to read ohms for the following steps. STEP 21 Check the stator resistance. The resistance in each coil must be as follows: 85 Amp Model 95 Amp Model ifthe resistance ina coils not as specified, replace the stator as shown inthis section. 0.045 to 0.085 ohms 0.0243 to 0.0297 ohms 517932 Check the stator for a short circuit, Make sure the rectifier bridge does not touch the stator. Connect one lead of the multimeter to the housing of the stator. Connect the other lead of the multimeter to each of the three leads from the stator. There should be no reading on the multimeter. If there is, replace the stator as shown in this section. Fac 76850 STEP 23 Check the positive diodes in the rectfier bridge. Connect the negative lead of the multimeter to the output (B+) terminal Connect the positive lead of the multimeter to one of the leads for the positive diodes. The positive diodes are the three that are closest to the output (8+) terminal. Read the mmuttimeter Reverse the multimeter leads. Read the multimeter. There must be resistance in one direction and an open inthe other If the readings are the same, replace the rectifier bridge. Repeat this procedure forthe ather two positive diodes. STEP 24 £ oon Check the negative diodes in the rectifier bridge. Connect the negative lead of the multimeter to the surface of the diode plate that is not painted. Connect the positive lead of the ‘multimeter to one of the leads for the negative diodes. Read the multimeter. Reverse the multimeter leads. Read the multimeter, There ‘must be resistance in one direction and an open inthe other. It the readings are the same, replace the rectifier bridge. Repeat this procedure for the ather two negative diodes. Revised 10-98 Pritedin USA4008-8 STEP 25 7942 If any of the diodes are damaged or the stator winding is faulty, use a soldering iron to separate the rectifier bridge from the stator. Disconnect the wires quickly to prevent damage to the diodes. STEP 26 517902 Use the multimeter to check the resistance of the rotor winding. The resistance must be as follows: 665 Amp Model 95 Amp Model. 2.34 to 2.86 ohms 2.85 to 3.15 ohms If the resistance is not as specified, the rotor must be replaced, ae 769501 STEP 27 517904 Hold one lead ofthe multimeter on the sip ring and the other lead on the housing. If there is a reading, there is a short circuit between the housing and the rotor coil. Replace the rotor. STEP 28 517814 Check for continuity between the capacitor mounting tab and the lead. If there is continuity, the capacitor must be replaced Pevsed 1098 Prntedin USA,4008-9 STEP 29 STEP 30 Measure the length of each brush. Replace the voltage Check for continuity between each brush and the brush regulator and brush holder if brush length is less than 14 mm terminal. If thete is no continuity, replace the voltage (0.55iinch, regulator and brush holder. STEP 31 ‘Check the bearings on the rotor for wear or damage. Replace if necessary. Rac 789501 Revised 10:98 Printed nS