Jeep Wagoneer/Commando/Cherokee 1957-1983 Repair Information

Regulator

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Regulators used with alternators are transistorized and cannot be serviced. If one of these units proves defective, it must be replaced.

Regulators used with generators are both adjustable and serviceable. These regulators have three operating units: the circuit breaker, the voltage regulator and the current-limiting regulator. Each has a separate function.

The voltage regulator unit holds the generated voltage at a predetermined value as long as the circuit values allow the voltage to build up to operating load.

The current-limiting regulator limits the output of the generator to its maximum, safe output level.

The circuit breaker is a protective unit designed to open and prevent burnout of the generator.

TESTING AND ADJUSTMENTS Circuit Breaker



The circuit breaker is the unit with the heaviest wire windings, located at one end of the regulator.

  1. Connect an ammeter in series with terminal B of the regulator and the lead removed from that terminal.
  2.  
  3. Connect a voltmeter from the A terminal of the regulator to the regulator base.
  4.  
  5. Disconnect the field lead from the regulator F terminal and insert a variable resistor between the lead and the regulator terminal.
  6.  
  7. Run the engine so that the generator is turning at about 1,000 rpm.
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  9. Load all of the resistance into the field circuit.
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  11. Slowly reduce the resistance, noting the voltage reading just before the change caused by the closing of the circuit breaker.
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  13. Increase the charging rate to the figure shown in the Generator and Regulator Specifications Chart, for your regulator, then, reduce the charging rate by inserting resistance into the field circuit. Note the charging rate just before the circuit breaker opens and the ammeter drops to zero. The closing voltage and the opening voltage or current should be within specified limits.
  14.  
  15. To adjust the closing voltage, change the armature spring tension by bending the hanger at the lower end of the spring. Increasing spring tension raises voltage; decreasing tension lowers voltage.
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  17. To adjust opening voltage, raise or lower the stationary contact, keeping the points aligned. Increasing the gap lowers the voltage; decreasing the gap raises the voltage. The gap is changed by expanding or contracting the contact bracket.
  18.  

Voltage Regulator

The voltage regulator is the unit with the finest wire windings.

  1. Connect an ammeter in series with terminal B of the regulator and the lead removed from that terminal.
  2.  
  3. Connect a voltmeter from the A terminal of the regulator to the regulator base.
  4.  
  5. Run the engine to provide about 1 / 2 generator maximum output for about 15 minutes. This will bring the regulator to normal operating temperature. Make sure that the regulator cover is in place during these tests.
  6.  
  7. Shut off the engine, then restart it and bring it up to 2500 generator rpm.
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  9. Turn on the lights and accessories until the amperage output is about 1 / 2 maximum. Note the volt reading. The voltage should be within the limits specified in the chart.
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  11. To adjust the operating voltage, change the armature spring tension by bending the hanger at the lower end of the armature spring. After each adjustment, stop the engine, restart it and repeat the test. The opening and closing clicks of the contacts should be regular and without interruption. If the clicks are not clear and regular, remove the regulator cover and inspect the contact points. The contacts should be flat and not burned, and should be squarely aligned. If not, see the section below on cleaning the contacts.
  12.  

Current-Limiting Regulator

This unit is the one in the middle.

  1. Connect an ammeter in series with terminal B of the regulator and the lead removed from that terminal.
  2.  

  1. Connect a voltmeter from the A terminal of the regulator to the regulator base.
  2.  
  3. Run the engine to about 3000 generator rpm.
  4.  
  5. Turn on the lights and accessories until the charging rate reaches maximum.
  6.  
  7. To adjust the opening amperage, change the armature spring tension by bending the hanger at the lower end of the armature spring. After each adjustment, stop the engine, restart it and repeat the test. The opening and closing clicks of the contacts should be regular and without interruption. If the clicks are not clear and regular, remove the regulator cover and inspect the contact points. The contacts should be flat and not burned, and should be squarely aligned. If not, see the section below on cleaning the contacts.
  8.  

CLEANING THE CONTACTS



Contacts should be inspected on all three regulator units whenever trouble is suspected. During normal use, contacts will become greyed and slightly worn. If the contacts are burned, dirty or misaligned, they should be cleaned and adjusted.

Contacts should be cleaned with a safe solvent, then inspected. Pitting and burning should be removed by filing squarely with a fine point file. After filing, the contacts should be cleaned again to remove any abrasives. Drying should be done with compressed air and/or a clean, lint-free cloth. Pull the cloth between closed contacts for a final cleaning.

After filing, regap the contacts and make the necessary current adjustments.

REMOVAL & INSTALLATION



The following procedure applies to generator type systems, only.

  1. Disconnect the battery ground.
  2.  
  3. Remove all wires from the regulator and tag them for installation.
  4.  
  5. Remove the attaching screws and lift the unit from the vehicle.
  6.  
  7. Install the new unit and connect the armature and battery leads.
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  9. Connect the battery ground cable.
  10.  
  11. Momentarily touch the field lead to the battery terminal of the regulator. This will polarize the generator and regulator to make them compatible with the electrical system. This polarization should be done every time all of the leads are removed from the regulator.
  12.  
  13. Connect the field lead to its terminal.
  14.  

 
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