These instructions cover the removal and installation of the 102200 voltage regulator, which is used on the 12 volt "JC" alternators.
The 102200 regulator has an "AC/DC" circuit built in which will allow it to be used on 12 volt "JB" and "JC" style alternators equipped with or without a diode trio. For alternators without a diode trio install a jumper wire from the regulator terminal on the alternator to one of the "AC" terminals (this will excite the alternator), the use of an ignition wire is no longer necessary. On alternators with a diode trio the regulator may be installed in the normal fashion.
1. Disconnect battery ground cable.
2. Remove four screws from regulator cover. Remove the two #10 nuts from the terminal located on the regulator holder to disconnect the diode trio lead (if alternator is equipped with a diode trio), or the jumper wire connected to the A/C tap. Tilt regulator up and remove the 10-32 square head screw to disconnect regulator blue lead (also white with blue tracer) (Figure 1).
3. Remove the brushes and visually inspect them. If brushes appear burned, cracked, or damaged, then brushes must be replaced. Inspect the springs and the shunt lead within the spring for damage. Replace brushes if necessary. Check brush length. If brush is less than half its original length (or about 3/8"), then replace brush.
4. Inspect the Red, Black, and White leads which were disconnected from the regulator. If insulation is damaged so bare wire is noticed, then alternator should be disassembled and the leads replaced.
1. Clean each of the two brushes with a spray electrical contact cleaner of the type that does not contain silicone. Silicone attacks brushes and will cause short brush life. Clean brush contact caps with #600 grade (or finer) sand paper.
2. Insert a brush in each of the two brush openings. Compress the springs and retain with a pin inserted through the access hole in the regulator holder. A suitable pin can be made of a 1/16" drill or brazing wire (Figure 2).
If the original brushes are being reused, then the wear pattern of each brush must be matched with the radius of the slip rings (Figure 3).
3. Insure that regulator gasket is in good condition and in position around the regulator circuit board. Align regulator with the holder so when installed the words "Leece-Neville" on the cover face away from the alternator.
Regulator Voltage Adjustment
NOTE: Before any adjustments are made insure that the batteries, terminal, wiring, and alternator drive belt(s) are in good working condition, and are properly tightened. Batteries must be at least 95-100% charged.
1. "Flash" field as follows:
With the engine off, connect a short jumper to the alternator NEGATIVE output terminal and to a piece of stiff wire or 1/16" drill. Insert the drill in the "full field access hole" as far as it will go for 1-2 seconds. This will restore the residual magnetism in the rotor (Figure 4).
2. Run engine at 1000-1200 rpm with an accurate voltmeter connected across the battery terminals and make a note of the voltmeter reading. Compare to vehicle manufacturer's voltage setting specification. If voltage is outside values specified, the continue with instructions listed below for adjusting regulator.
1. Stop engine and disconnect battery ground cable.
2. Remove #10-32 nuts and lockwasher from regulator terminal and disconnect diode trio lead (if alternator is equipped with a diode trio), or the jumper wire connected to the A/C tap.
3. Remove the four screws from the regulator cover. Lift regulator out of housing and move it out of the way as far as the leads will permit. Inspect the two regulator brush contact pads. If dirt or corrosion is noticed then clean pads with #600 sand paper (or finer) (Figure 5).
NOTE: In some cases dirty or corroded pads can cause a low charge condition, and voltage adjustment may not be necessary.
4. Inspect and reinstall brushes as described in "Regulator Removal" and "Regulator Installation" sections in this instruction sheet.
5. To adjust voltage remove and reinstall voltage adjustment strap in any of the three positions available: A & B (High), A & C (Medium), or C & B (Low).
Each change in position of adjustment strap will result in an INCREASE or DECREASE in voltage of approximately .4 volts.
a) Voltage at battery with
engine at 1000-1200 rpm 13.6 Volts
b) Vehicle manufacturer spec.
for voltage setting 14.0+ .1 Volt
c) Voltage adjustment strap position A & C
Necessary Adjustment: Voltage adjustment strap should be changed to "C & B" position to increase voltage by (approximately) .4 volts to 14.0 volts.
Regulator Static Test Values
For static (bench) test purposes the regulators are factory set at the following: Low 13.60 + .15, Med 14.00 + .10, High 14.40 + .15. These values should not be confused with voltages above which are taken at the battery and will vary due to voltage drops.
CAUTION: Recommended torque for the #4 cross head screws used for securing voltage adjustment strap is 4-5 in. lbs. Overtightening these screws may cause them to break and the regulator would become unusable.
6. Complete regulator installation as described in "Regulator Installation" section.
7. Reinstall battery ground cable and repeat Steps 1 and 2 in "Regulator Voltage Adjustment" section to insure proper voltage.
8. Place regulator in holder. Apply a small amount of downward pressure on the regulator and REMOVE PIN from access hole to release brush springs. Hold down regulator and secure it with four #8-32 x 7/16" long screws (Figure 6).
CAUTION: The pin used to retain the brushes during regulator assembly MUST BE REMOVED BEFORE the regulator is secured to avoid regulator damage. WARRANTY IS VOID ON ANY REGULATOR RETURNED WITH "PIN" DAMAGE!
9. Reconnect ground cable to battery.