phone JEEP CJ 1953 Service Manual

H

ELECTRICAL
SYSTEM
Regulator
ground screw to battery ground post
—.03-volt maximum.

Generator
frame to battery ground post—.03-volt
maximum.

H-47.
Test Procedure

a.
Circuit
Breaker—Connect
an ammeter in series between the regulator B-terminal and the lead
wire
removed from that terminal. Connect a
voltmeter between the regulator
A-terminal
and the regulator mounting base. Disconnect the field lead

from
the regulator
F-terminal
and insert a variable resistance (3 amp., 50 ohm capacity) between the

lead
and the regulator terminal. Run the generator
at about 1000 generator rpm. Insert all the re­
sistance in the field
circuit,
then slowly reduce the
resistance noting the voltage reading just before the change caused by the closing of the circuit

breaker.
Increase the charging rate to the figure
specified for the regulator being tested then reduce
the charging rate by inserting resistance in the
field
circuit.
Note
the voltmeter and ammeter

reading
just before the circuit breaker
opens
and
the ammeter reading drops to zero. The closing voltage and the opening voltage or current should
be within the limits specified. An accurate method
for noting the exact instant of the opening or closing
of the circuit breaker is to connect a headphone (2000 ohms or higher) to the battery and armature

terminals
of the regulator. When the contacts
open or close a
click
will
be
heard
in the headphones.
To
adjust the closing voltage change the armature

spring
tension by bending the hanger at the lower end of the spring. Increase the spring tension to

raise
the closing voltage or decrease the tension
to lower the closing voltage. To adjust the opening voltage raise or lower the stationary contact
keeping the contacts perfectly aligned. Increasing
the contact gap lowers the opening
'
voltage.
Change
the contact gap by expanding or contract­
ing the stationary contact bracket, keeping the
contacts aligned. Do not adjust the gap between
the contacts to less than the specified minimum.

b.
Voltage Regulator—Connect the ammeter as in

step
a. Connect the voltmeter between the regulator
B-terminal
and the regulator base. Remove the

variable
resistance from the field
circuit.
Run the
generator at
half
output for 15 minutes to bring
the regulator to normal operating temperature.

Keep
the cover on the regulator during the
warm-

up period and also when taking readings.
Stop the engine then bring it up to approximately 2500 generator rpm. Adjust the amperage to
half

maximum
output by turning on lights or accessor­
ies and then
note
the voltmeter reading.
This
read­

ing should be within the limits specified for the voltage regulator operation. To adjust the oper­
ating voltage change the
armature
spring tension by
bending the hanger at the lower end of the
arma­

ture
spring. After each adjustment
stop
the engine then restart it.
Bring
it up to speed and adjust the

current
before taking a reading. In order to obtain

an
accurate indication of the operation of the volt­
age regulator unit connect a headphone (2000 ohm

or
higher) between the
F-terminal
and ground to

pick
up the sound of the opening and closing of the
contacts. The clicks should be regular and clear without irregularities or missing. If the
tone
is not

clear
and regular remove the regulator cover and
inspect the contacts. The contacts should be flat
and
not burned excessively and should be aligned
to make
full
face contact. If the contacts need
cleaning refer to paragraph d for the method.

c.
Current
Regulator—Connect the regulator and the
test
equipment as in
step
b. Running the generator at approximately 3000 generator rpm.,

turn
on lights and accessories so that the generator must charge at maximum rate. The ammeter should give a reading within the limits specified.

To
adjust 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, then restart it.
Bring
the engine up to speed and take an ammeter reading. Keep
the cover on the regulator when taking
these

readings.

Connect
a headphone (2000 ohms or higher) be­
tween the regulator
F-terminal
and ground to pick
up the sound of opening and closing of the contacts.

Clear,
regular clicks should be heard over the
headphones; they should not be
irregular
or missing.
If
the
tone
is not clear and regular remove the
regulator cover and inspect the contacts. The
contacts should be flat and not burned excessively

and
should be aligned to make
full
face contact. If
the contacts need cleaning refer to paragraph d.
below for the method.

d.
Contacts—Inspect the contacts on all three
units.
In normal use the contacts
will
become

grayed.
If the contacts are burned or dirty or if they are not smooth, file the contacts with a #6

American,
Swiss cut, equalling file. Move the file

parallel
and lengthwise to the armature.
File
just
enough so that the contacts present a smooth
sur­

face toward each other. It is not necessary to remove every trace of pitting. After filing, dampen

a
piece of linen or lintless bond tape in refined

carbon
tetrachloride and draw the tape between
the contacts. Repeat with a dry piece of tape. Use
clean
tape for each set of contacts.
e. Recheck—Operate the unit at
half
maximum
output for five minutes with the cover on the regu­

lator.
Repeat the testing procedure for all units as described in a, b, c above. Be sure cover is on regu­

lator
when taking readings.

H-48.
Quick
Checks

H-49.
Low Charging Rate with a
Fully
Charged
Battery

A
fully charged battery and a low charging rate
indicates normal regulator operation.
A
further check of the regulator operation can be
made by using the starting motor for 5 to 10
seconds with the ignition switch in the "off" posi­ tion.
Then
start the engine and operate at a genera­
tor speed of 2500 to 3000 rpm. The charging rate should rise to its maximum value then taper off to

a
minimum charge as the battery becomes charged.

H-50.
High Charging Rate with a
Fully
Charged
Battery

This
is usually an indication that the voltage regu­

lator
is not operating correctly. The high voltage 192

'Jeep1
UNIVERSAL
SERIES SERVICE
MANUAL

H
will
cause the battery to gas excessively and
will

shorten the life of the ignition contacts and, in

general,
will
have a detrimental
effect
on all con­
nected load.

Connect
an ammeter in series with the regulator
"B"
terminal and the lead removed from the termi­

nal.
Run the generator at a medium speed and per­

form
the following operation. After each
test
is
completed reconnect whatever leads have been opened.

H-51.
Test One
Disconnect the field lead at the generator.

a.
Output drops to zero—shorted field circuit in regulator or in wiring harness. See
test
2.

b.
Output
does
not drop—shorted field circuit in
generator. Inspect generator.

H-52.
Test Two
Disconnect the field lead at the regulator.

a.
Output drops to zero—shorted field in regulator.
See
test
3.

b.
Output
does
not drop—shorted wiring harness.

Repair
or replace wiring harness.

H-53.
Test
Three

Remove the regulator cover and hold the
voltage

regulator contacts open.

a.
Output drops to zero—regulator contacts stick­

ing,
regulator out of adjustment, or regulator in­ operative.
Check
operation
(test
5), check for high
resistance
(test
4), and clean contacts per instruc­
tions in Par. H-56.

b.
Output
does
not drop—shorted field circuit in
the regulator.
Clean
the regulator contacts and in­ spect the regulator visually for incorrect wiring be­
tween units and shorted leads.

H-54.
Test
Four

Operate
the units at 10 amperes output and meas­

ure
the
voltage
drop from the regulator base to
the generator frame.

a.
Voltage reading below .03 volts—ground
cir­
cuit
is satisfactory. See
test
5.

b.
Voltage reading above .03 volts—Inspect ground

circuit
for poor connections and eliminate the high
resistance. See
test
5.

H-56.
Test
Five

Connect
a headphone from the regulator field ter­
minal
to the base and hold the current regulator
contacts closed.

a.
A steady beat is heard—voltage regulator oper­
ating.
Reset regulator as in the operation
test,

Par.
H-47.

b.
An unsteady beat is heard—dirty or sticking
contacts.
Clean
contacts per instructions in Par.

H-56.
c.
No beat is heard—inoperative
voltage
regulator
unit.
Adjust regulator operation as in the operation

test.
If the regulator cannot be adjusted within
limits,
remove for overhaul.
H-56.
Cleaning of Contacts

Clean
the
voltage
regulator contacts with a #6

American
Swiss cut equalling file.
File
lengthwise

and
parallel to the armature and then clean the
contacts with clean linen tape.
First
draw a piece
of tape that has been wet with carbon tetrachlor­
ide
between
the contacts then follow with dry tape. Reset the regulator operation as in the oper­
ation
test,
Par. H-47.

H-57.
Low Battery and a Low or No Charging Rate

Check
all wiring for
loose
connections, frayed in­
sulation and high resistance connections and cor­
rect
any fault.

Make
sure the generator operates correctly with­
out the regulator in the
circuit.
Remove the "A"

and
"B" leads from the regulator and connect an
ammeter
between
them. Remove the field lead from
the regulator and while operating at idle speed
touch the field lead to the regulator base. Increase
the speed slowly noting the charging rate. Do not

increase
the output above the rated output of the generator. If the generator output
will
not build

up,
inspect the wiring harness for shorts and
opens

and
remove the generator for an overhaul.

Connect
an ammeter
between
the battery lead and
the regulator
"B"
terminal. Connect the field lead to the regulator "F" terminal and connect the

armature
lead to the regulator
"A"
terminal.
Con­

nect a voltmeter from the regulator
"A"
terminal to
the regulator base. Operate the generator at a medium speed and perform the following
tests:

H-58.
Test Six

Read
the voltmeter.

a.
Voltage builds up—open series
circuit.
See
test
7.
b.
Voltage
does
not build up—regulator out of ad­
justment, field circuit open, grounded series
circuit.
See
test
8.

H-59.
Test Seven
Remove the regulator cover and with the generator
operating at a medium speed hold the circuit

breaker
contacts closed.

a.
Ammeter shows no charge—open
circuit
breaker
shunt winding, incorrect setting of circuit breaker,

or
dirty contacts.
Clean
contacts and reset circuit

breaker
as in
Par.
H-47d. If the circuit breaker
can­
not be set, the shunt coil is open and the regulator
should be removed for overhaul.

b.
No generator output—clean the circuit breaker
contacts and try the
test
again. If there is
still
no
charge the series windings are open and the regu­

lator
should be removed for overhaul.

H-60.
Test
Eight

Run
the generator at idle speed and momentarily
connect a jumper from the
F-terminal
to the regu­

lator
base.

a.
Voltage builds up—open field circuit or regula­
tor out of adjustment. See
test
9.
b.
Voltage
does
not build up—grounded series
cir­

cuit.
Remove regulator for overhaul. 193