Part XXVIII: Evolution of Russian Motorcycle Voltage Regulators

Russian Voltage Regulators(Реле-регулятор напряжения)

Part XXVIII: Evolution of Russian Motorcycle

Voltage Regulators

Ernie Franke

[email protected]

02 / 2018

Types of Generators/Alternators for Ural (Урал) and Dnepr (Днепр)

Generator/Alternator Type Vintage Nominal

VoltageCurrent Nominal

PowerRegulator

Motorcycles

Ural(IMZ) Dnepr (KMZ)

Г-11(G-11)

(P/N: 72181)

DCGenerator

1941-1951

6-Volt(7-Volt) 7-Amp 45-Watts PP-1

PP-31 (1950)M-72 Not Used

Г-11A(G-11A)

(P/N: 72181-A)

DC Generator

1952-1957

6-Volt(7-Volt) 7-Amp 45-Watts PP-31 (1950)

PP-31A (1956)M-72, M-72M,

M-61 M-72, M-72N,early K-750

Г-414(G-414)

(P/N: 750181)

DC Generator

1957-1974

6-Volt(7-Volt)

10-Amp 65-Watts PP-31A (1956)PP-302 (1963)

PP-302A

M-62, M-63, M-66

K-650, later K-750, K-750M, MB-750, MB-750M, MT-8,

MT-9, MT-12

Г-424(G-424)

(P/N: 3701000)

Alternator

(Built-inRectifier)

1974-1998

12-Volt(14-Volt)

11-Amp(aka 14-A)

150-WattsPP-302APP-330

33.3702 (1992)

M-67, M67.36, IMZ 8.103 Series

MB-650, MB-650M,MT-10, MT-10.36,

MT-11, MT-14, MT-16

Hitachi(Limited

Appearance)

Alternator/Starter

1998-1998.5

12-Volt(14-Volt)

18-Amp300-Watts

Internal toAlternator??

IMZ 8.103 and8.107

“650” SeriesNot Used

14.3771(P/N: 14.3771-

010)

Alternator(Built-in

Rectifier &Regulator)

1998.5-2004

12-Volt(14-Volt)

35-Amp 500-Watts

(aka 350-W)

Internal toAlternator

(YA212A11E)

IMZ 8.103, 8.103X,8.123, 8.123X

“650 & 750” Series

Not Used

NipponDenso

(P/N: IMZ-8.1037-18092)

Alternator(Built-in

Rectifier &Regulator)

2004-present

12-Volt(14-Volt)

55-Amp 770-WattsInternal toAlternator

(126000-0600)

IMZ 8.103, 8.103X,8.123, 8.123X“750” Series

Not Used

Notes:1. Nomenclature: The Cyrillic letter “Г” transliterates (Russian-to-Latin) to “G” or “L” or “T.” Thus we see

Г-414 or G-414 or L-414 or T-414, all for the same part.2. Cannot use Alternator with discharged battery or without battery.3. MB-650 = MW-650, MB-650M = MW-650M, MB-750 = MW-750, MB-750M = MB-750M

2

Ural (Урал) - Dnepr (Днепр)Generator/Alternator Time-Line

time

195019801960 197019651955 1975 200520001990 19951985

(M-72 thru M-66, MT-9) 6-Volts

Г-414(MT-8)

Г-414(M-62)

Г-11A(M-72N)

Г-414(later K-750)

Г-424(M-67.36)

Г-11A

(KMZ M-72)

Г-424(MT-11)

Г-11A

(M-72)

Г-414(M-63,

K-750M,MW-750)

Г-414(M-66,MT-9)

Г-424(M-67, MT-10, MT-

12, MW-750)

Г-424(IMZ 8.103,

8.107,“650”)

14.3771(IMZ 8.103,

8.107,“650 & 750”)

Г-424(MT-16)

12-Volts (M-67, MT-10 and beyond)

1974

Alternators have progressed in output voltage and power, from the Г-11 (G-11) generator of 6-Volts/45-Watts in 1941,

the Г-11A in 1952, the Г-414 of 6-Volts/65-Watt in 1957, the Г-424 of 12-Volts/150-Watts in 1974, the 14.3771 of 12-Volts/500-Watts in 1998.5,

to the present-day Nippon-Denso alternator of 12-Volts/770-Watts.

DC Generator Alternator (AC Generator with Built-In Rectifier)

1974

Г-414 Generator Г-424 Alternator

14.3771Alternator

Nippon-Denso

AlternatorГ-11A

Generator

Г-11Generator

1957 1998.5 20041951

Г-424(M-T-10.36)Г-424

(MW-650)Г-11A(early K-750)

Nippon-Denso(IMZ 8.103,

8.123,“750”)

1998Short Intro of Hitachi Alternator/Starter

3

6-Volt Electro-Magnetic (Relay-Type) Regulator (PP-1/-30/-31/-31A) for the Г-11/-11A 7-Amp Alternator

• Background– Voltage Regulators Paired with Specific Generators/Alternators– Time-Line for Generators/Alternators/Regulators– Specs for Compatible 6-Volt Г-11/-11A Generator– Generator Application in Ural (M-72, -72M)/ Dnepr (M-72, -72N, K-750, -750M, Late MT-9, MT-10) Wiring

• What Are the PP-1/-30/-31/-31A Regulators?– External Voltage Regulator for Г-11/-11A Generator (7-Amp/45-Watt)– Electro-Magnetic (Relay-Type) Design– Years of Regulator Application: 1941 -to- 1963– First 6-Volt Russian Motorcycle Regulators– Later Superceded by PP-302 Regulator in 1963

• How Does It Work?– Regulates Generator Output Voltage to 6-Volts– Supplies Exciter Current to Vary Stator Magnetic Field– Provides Constant Voltage Regardless of Rotor Speed and Load

• Circuit Description and Operation• Replacement

– Replace PP-1 with PP-30/ -31/ -31A, Available over Internet

The Relay-Regulator (PP-1, a.k.a RR-1) was the first 6-Volt regulator used on Russian sidecar motorcycles.

4

Ural (Урал) M-72 with PP-31 Regulator(post-1949)

Ural (Урал) M-72 with PP-1 Regulator(1941-1949)

Regulator(PP-1)

Regulator(PP-31)

Generator(Г-11A, 1950+)

1. Generator: Г-112. Regulator3. Battery4. Distributor5. Breaker Points6. Ignition Coil7. Spark Plugs8. Horn9. Headlight10. Lamp11. Parking Light12. Tail-Light13. Sidecar Tail-light14. Front Sidecar Light15. Indicator Light16. Central Switch17. Ignition Key18. Indicator19. Dimmer Switch20. Light Switch: Hi/Lo21. Horn Button22.Spark Advance

Generator(Г-11)

Regulator(PP-1)

5

. .

PP-1 Voltage Regulator Application

Г-11 Generator

.

+6-Volt

Battery

Red“Fault”

Indicator

Exciter Stator Coil

IgnitionSwitch

Russian generators differ from alternators in that the magnetic (exciter) field is stationary and the generator

windings are rotated. The output at the commutator is DC.

StationaryMagnetic

Field

-

Ш+

Regulator Switches Exciter Current to Control the

Magnetic Field

Я

PP-1(RR-1)

Regulator

ШБ

RotatingGeneratorWinding

Я

-

Slotted Commutator to

Produce DC Output

toIgnition Circuit

6

1 - base

2 - reverse circuit breaker (POT)

3 - voltage regulator (PH)

4 - static contact (stator)

5 - reverse circuit armature

6 - cover

7 - static contact of the voltage regulator

8 - voltage regulator armature

9 - voltage regulator yoke

10 - voltage regulator winding

11 - voltage regulator resistor

Voltage Regulator PP-1 for M-72 Motorcycle

The PP-1 automatic voltage regulator consists of two relays; the reverse-current switch and the voltage regulator.

7

• Electro-Magnetic (Relay) Device

– Periodically Switches Additional

Resistance into Generator Exciter Winding

• Consists of Two Relays:

– Voltage Regulator (PH)

• Automatic Voltage Control as Number of

Revolutions and/orLoad Current Changes

• Voltage Regulator Decreases

Output Voltage as Load Current Increases

– Reverse-Relay (POT)

• Switches Battery In-and-Out

• Automatic Connect/Disconnect of Generator

• Factory-Set, Lead-Sealed Housing

The Г-11 generator puts out 6.5-Volts at 1,500 rpm and 8.5-Volts at 5,000 rpm (no load). At full-load (7-Amps)

the generator produces 6.5-Volts at 2,500 rpm and remains at 7-Volts up to 6,000 rpm. The PP-1

relay-regulator keeps the output voltage between 6.5 and 7.0-Volts.

Relay-Regulator (RR) Description

8

PP-1 and PP-31 6-Volt Regulators

The PP-1 is distinguished from the PP-30/-31 series of regulators in that it has a taller cap with hold-down nuts.

Hold-Down Nuts

9

Relay-Regulator PP-1 (Реле-регулятор напряжения РР-1)

РР-1 Regulator

List Price: 378 rubles

(motofan.in.ua)

10

1 - Contact screw

2 - Reverse circuit breaker

3 - Reverse circuit breaker winding

4 - Fixed contact

5 - Reverse circuit breaker

6 - Contact screw ground connection

7 - Housing

8 - Gasket

9 - Limit bar

10 - Movable contact plate

11 - Fixed contact plate

12 - Voltage regulator armature

13 - Voltage regulator main winding

14 - Lid

15 - Coil of the voltage regulator

16 - Voltage regulator yoke

17 - Voltage regulator spring

18 - Adjusting nut

19 - Resistance wire

20 - Carbon resistor

21 - Reverse current switch spring

22 - Rubber cap

Voltage Regulator PP-31

11

PP-30: 6-Volt Regulator

PP-31/-31A 6-Volt Regulators

It is important to identify the exact component used on your Russian motorcycle, so that you can find

the correct schematic and secure exact replacement parts.12

PP-31 Voltage Regulator

Item: 000.911

List Price: 68.00€

(www.oldtimergarage.eu)

Dnepr (Днепр) Early K-750 and K-750M (with Ignition Coil B2B and Distributor PM-05 for Manual Control of Firing Angle)

Breaker/Distributor(PM-05)

Ignition Coil (B2B)

Generator(Г-11A)

HornButton

Horn

17. Regulator(PP-31A)

FootBrake-Light

Switch

Manual Spark Advance

Battery

1 – Hi/Lo beam lamp, 2 – key, 3 – fuse, 4 - lamp, 5 - central switch, 6 - wire “ground", 7 - high voltage wire, 8 – spark plugs, 9

- high voltage, 10 - ignition coil, 11 – sidecar front light, 12 – horn, 13 - wire front sidecar, 14 – tail-light sidecar, 15 – tail-

lamp of motorcycle, 16 - gauge stop-light, 17 - Relay-regulator, 18 – generator, 19 – battery, 20 - Low voltage wiring loom, 21

- the wire "battery – ground, 22 - breaker, 23 - valve, 24 - high voltage wire and 25 – horn button, 26 - wire signal, 27 -

advance ignition, 28 - cord switch driving and parking light, 29 - switch to driving and parking light, 30 - control lamp, 31 -

the parking light bulb, 32 - lamp illuminated, 33 - connecting wires, 34 - cable sidecar lamps, 35 - wire from sensor to stop-

light, 36 - wire from connector to lamp lighting plate

ШЯ

Б

13

Dnepr (Днепр) Early MT-9: Manual Control of Firing Angle(B2B Ignition Coil and PM-05 Breaker/Distributor)

Later MT-9: Automatic Spark Advance and MT-10(B201A Ignition Coil and PM-302 Breaker)

Breaker Points (PM-302/PM-302AA)

Ignition Coil(B201)

HornButton

Oil-PressureSensor

Flasher

Foot Brake-Light

Switch

Horn

TurnSignal

Battery

23. Regulator(PP-31A) 14

6-Volt Electro-Magnetic (Relay-Type) Regulator (PP-302/PP-302A) for the Г-414 10-Amp Generator

• Background– Voltage Regulators Paired with Specific Generators/Alternators– Time-Line for Generators/Alternators/Regulators– Specs for 6-Volt Г-414 Compatible Generator– Generator Application in Ural (M-62, M-63, M-66)/ Dnepr (K-650, K-

750, K-750M, MB-750, MB-750M, MT-9, and MT-12) Wiring• What Is the PP-302?

– External Voltage Regulator for Г-414 (10-Amp/65-Watt) Generator – Electro-Magnetic (Relay-Type) Design– Years of Application: 1963 -to- 1974– Upgraded from PP-31/31A (6-Volt Regulator)– Later Superceded by PP-330 Regulator in 1974

• How Does It Work?– Regulates Generator Output Voltage to 6-Volts– Supplies Exciter Current to Vary Stator Magnetic Field– Provides Constant Voltage Regardless of Rotor Speed and Load


– Replacement Purchased On-Line over Internet

The Relay-Regulator (PP-302, a.k.a. RR-302) was the final 6-Volt and the first 12-Volt regulator used on

Ural and Dnepr motorcycles. 15

ШЯБ

• Operates in Conjunction with Г-414 Generator• Current & Voltage Regulator with Two Elements:

– Reverse-Current Relay• Cut-In Voltage of Reverse-Current Relay: 6.0 to 6.6-V • Reverse Current for Cut-Off Reverse-Current Relay: 0.5 to 3.5-A

– Voltage Regulator Relay• Regulated Voltage @3,500 rpm Generator Speed

– Load Current 10-Amp: 6.5 to 7.0-Volts– Load Current 0-Amp: < 8 V

6-Volt PP-302 / -302A Regulator

The PP-302 maintains a constant supply voltage by controlling stator exciter

(magnetic field) current from terminal Ш.

1 – Cover2 – Reverse-Current Relay Armature3 – Reverse-Current Relay Yoke4 – Voltage-Regulator Relay Armature5 – Voltage-Regulator Yoke6 – Terminal: Ш (W) Exciter7 – Terminal: Я Output8 – Terminal: Б (E) Battery9 – Terminal: Ground

10-Amp

7-Volt

16

Reverse-Current Relay

(POT)

Voltage Regulator Relay

(PH)

. .


Г-414 Generator

.

+6-Volt

Battery

Red“Fault”

Indicator

Exciter Stator Coil

IgnitionSwitch

Russian generators differ from alternators in that the magnetic (exciter) field is stationary and the generator

windings are rotated. The output at the commutator is DC.

StationaryMagnetic

Field

-

Ш+

Regulator Switches Exciter Current to Control the

Magnetic Field

Я

PP-302(RR-302)

Regulator

ШБ

RotatingGeneratorWinding

Я

-


Produce DC Output

toIgnition Circuit

(Battery) (Exciter)

(Output)

17


Produce DC Output

Ural (Урал) M-52, M-61 and M-72K, M-72Mwith PP-302 Regulator

Foot Brake-Light

Switch

Ignition Coil (B2B)

Battery (3MT-6 or 3MT-7)

Breaker/Distributor PM-05

Horn

15. Generator(Г-11A)

24. Regulator

Hi/Lo BeamSwitch

HornButton

TurnSignal

ManualSpark Advance

Flasher Unit

Ш

Я

(Exciter, Ш)

(Output, Я)

(Battery, Б)

18

Dnepr (Днепр) K-750, K-750M and MT-12

Horn

Ignition Coil (B2B)

Battery (3MT-6 or 3MT-7)

Breaker/Distributor (PM-05)

HornButton

15. Generator(Г-414)

Flasher Unit FootBrake-Light

Switch

Manual Spark Advance

Hi/Lo BeamSwitch

TurnSignal

(Exciter, Ш)

(Output, Я)

(Battery, Б)

19

24. Regulator(PP-302)

Ural (Урал) M-62, M-63 (Ural-2) and M-66 (Ural-3)and Dnepr (Днепр) K-650, MT-9


Ignition Coil(B201)

Breaker Points(PM-302)

Horn

Flasher Unit

Battery(3MT-6 or 3MT-12)

15. Regulator(PP-302/PP-302A)

FootBrake-Light

Switch

Oil PressureSensor

Turn Signal & Horn Button

TurnSignal

(Exciter, Ш)

(Output, Я)

(Battery, Б)

20

10. Generator Charge Indicator

Dnepr (Днепр) К-750М, МВ-750, K-650 and МВ-750М

21

1 - passing-beam and high-light lamp А6-32 + 32; 2 - key; 3 - fuse; 4 - head of the FG-116; 5 - central switch; 6 - wire "mass";

7 - high voltage wire; 8 - the tip of the candle; 9 - ignition lights A8U; 10 - high voltage wire; 11 - ignition coil B2B; 12 -

overall lamp; 13 – sidecar front lamp PF-200; 14 - horn С-37А; 15 - a wire of a forward lantern of sidecar; 16 - wire

connector; 17 - rear lamp ФП-220; 18 - “stop" lamp А16-15 brake signal; 19 - rear lamp (A6-3); 20 - stroke lantern cable; 21 -

brake lamp switch lamp; 22 - wire to license plate illumination lamp; 23 - stop light sensor; 24 - relay controller; 25 - direct

current generator Г-414; 26 - portable lamp PLTM (only for motorcycles MB-750 and MB-750M); 27 - socket 47K (only for

MB-750 and MB-750M); 28 - wire to socket; 29 - battery "mass" wire; 30 - rechargeable battery ЗМТ-12; 31 - interrupter-

distributor PM-05; 32 - horn button; 33 - signal wire; 34 - ignition coin; 35 - speedometer illuminator; 36 - control lamp of

generator activation А6-0,25; 37 - Bowden cable for light switch; 38 - high and passing light switch; 39 - parking lamp А6-2


24. Voltage Regulator(PP-302)


Dnepr (Днепр) Early K-650 and MT-9with PM-05 Breaker/Distributor and B2B Ignition Coil


Ignition Coil(B2B)

Breaker/Distributor(PM-05)


Horn(C-37A)

HornButton

Oil-Pressure Sensor(MM-106A)

Hi/Lo BeamSwitch

Battery

Horn

(Exciter, Ш)

(Output, Я)

(Battery, Б)

22


12-Volt Electro-Magnetic (Relay-Type) Regulator (PP-330) for the Г-424 11-Amp Alternator

• Background– Voltage Regulators Paired with Specific Generators/Alternators– Time-Line for Generators/Alternators/Regulators– Г-424 Alternator Performance– Specs for the Г-424 Alternator– Alternator Application in Ural (M-67, -67.3 and “650cc” Series) /

Dnepr (MT-10, -11 and -16) Wiring• What Is the PP-330?

– External Voltage Regulator for 11-Amp Г-424 Alternator– Electro-Magnetic (Relay-Type) Design– Years of Application: 1974 -to- 1992– Upgraded to 12-Volts from 6-Volt PP-302 Regulator– Later Superceded by Solid-State (Electronic) 33.3702 Regulator in 1992

• How Does It Work?– Regulates Alternator Output Voltage to 14-Volts– Supplies Exciter Current to Vary Magnetic Field in Rotor– Provides Constant Voltage Regardless of Rotor Speed and Load


– Replacement Purchased On-Line

Relay-Regulator (PP-330, a.k.a RR-330) was the first 12-Volt regulator used on a Russian motorcycle

(Ural M-67 and Dnepr MT-10).23

Relay-Regulator PP-330 (Реле-регулятор РР-330)•Regulates Voltage of G-424 Alternator 14-Volts

and Nominal Current Value of 11-Amps

•Connected by Negative Conclusion to the

Ground "mass“

•Signal Indicator "Charging-Discharge" of

Battery

•Consists of Single-Stage Vibration Regulator of

Voltage and Control Relay of Control (Indicator)

Lamp

•PP-330 Has Five Connection Terminals:

–"B3" - Connection to Positive Terminal of

Rectifiers thru Ignition Switch Contacts

–"Ш" - Connection to Alternator's Ш terminal

–“ЛК” ("LC“) - Connection to Indicator Lamp

–"~" - Attach to Output of Alternator Phase

–"M" - On Body of Regulator to Connect Wire

from Ground "mass" of the Rectifier

•Relay-Regulator (Voltage Regulator) РР-330

Shown24

ЛК

~

Ш

ВЗPH

PBЛ

....

.


Г-424 Alternator

Regulator

..

+12-VoltBattery

Red“Fault” Light

RotorCoil

3-ØStatorCoil . Fuse

in Fuse Block

IgnitionSwitch

The PP-330 voltage regulator varies the current in the rotor coil (terminal Ш) to maintain a constant

output voltage at the “+” terminal.

Rectifier Diodes to convert generated AC

to battery DC

RotatingMagnetic

Field

-

Ш

+

~

MasterSwitch

(not usedwith

Electric-Start)

Regulator modulates exciter current to control the

magnetic field

With one end of the Г-424’s Rotor grounded,

the regulator must be connected between

the battery and the other end of the rotor.

15-Amp

~

PP-330(RR-330)

Ш(W)

ЛК(LC)

BЗ (BZ)

Slip-Ring Connections for Rotor (exciter) Coil

25

PP-330: 12-Volt / 11-Amp Voltage Regulator

ЛК (LC) ~ Ш Ш ~ ЛК (LC)

Top View Bottom View

14-V / 11-A Rлр Resistor (13Ω)

Rа Resistor(80Ω)

The PP-330 utilizes two electro-magnetic relays to maintain a constant output voltage from the alternator,

and to control a red “alternator fault” indicator light.

VibrationIsolation

83/B3/BZ

26

Bottom View

Voltage Regulator

Battery

Red “Alternator Failure”

Indicator Lamp

Ignition Switch”Run” Position

FuseBlock

Full-Wave3-PhaseRectifier

Rotor(Field)

Application of PP-330 Voltage Regulator with Г-424 Alternator

AlternatorTerminal Block

StatorExcitationTerminal

Terminal Control

Power (positive)Terminal

Г-424 Alternator

Ground

83/B3/BZ

~

ЛК

Ш

Over/Under-Voltage

Relay PH

Lamp Control

Relay PBЛLamp Control

Relay PBЛ

Over/Under-Voltage

Relay PH

27

HornButton

Regulator(PP-330)

Alternator(Г-424)

28

Dnepr (Днепр) MT-10 (1974)


23. Alternator(Г-424)

Breaker(PM-302/PM-302A)

Ignition Coil(B204)

Battery(2X 3MT-6)

Foot Brake-Light

Switch

Horn

Neutral Switch

Oil-PressureSwitch

MasterSwitch

Flasher

HornButton

TurnSignal

29

16. Charge Indicator

Dnepr (Днепр) Early MT-11 and MT-16with PP-330 Regulator, later replaced with 33.3072 (solid-state)

Battery (2X 3MT-6)

24. Regulator(PP-330)

Brake

MasterSwitch

NeutralSwitch

IgnitionCoil

Breaker

FootBrake Light

Switch

Horn

Oil-PressureSensor

Flasher

TurnSignal

31. Alternator(Г-424)

Trouble-LampSocket

30

12. Charge Indicator

Ural (Урал) M-67 and M-67.36

Regulator

Battery

Horn

Ignition Coil(B204)

Breaker Points (PM-302/PM-302AA)

Alternator (Г-424)

FootBrake-Light

Switch

Flasher Unit

TurnSignal

HornButton

IgnitionSwitch

Hi/Lo BeamSwitch

31

+ Ш~

+-

~ +

PP-330(RR-330)

ЛК(LC)

33.3702Ш

(W)

+ Ш~

+-

MasterSwitch

(deleted for electric-start)

AlternatorFault

Indicator(Dash)

AlternatorFault

Indicator(Dash)

Ш

+~

'+' (output) goes to the battery

'W' (field) goes to the regulator

'~' is not used. Used only with the old electromechanical regulators (PP-330).

MasterSwitch

(deleted for electric-start)

ЛК(LC)

Ш(W)

BЗ (BZ)

Г-424 (G-424)Alternator Г-424 (G-424)

Alternator

Г-424 Terminals

3

2

~(not used)

3

2

IgnitionSwitch

IgnitionSwitch

Fuse Block Fuse Block

toIgnition Module

thruKill

Switch

to Ignition Module

thruKill

Switch

Diagram is useful when unmarked wires are

removed from unmarked terminals!

1

2

3

4

1

2

3

4

Migration from the Mechanical (PP-330) to Electronic (33.3702) Regulator

32

12-Volt Solid-State (Electronic) Regulator (33.3072) for the Г-424 11-Amp Alternator

• Background– Voltage Regulators Paired with Specific Generators/Alternators– Time-Line for Generators/Alternators/Regulators– Specs for the Г-424 Alternator– Г-424 Alternator Performance– Alternator / Regulator Application in Ural and Dnepr Wiring

• What is the 33.3072 Regulator?– External Voltage Regulator for the Г-424 11-Amp Alternator– Completely Solid-State (Electronic, Transistorized)– Years of Application: 1992-to-1998– Replaced PP-330 Relay-Type (Mechanical) Regulator– Superceded by 35-Amp Alternator (14.3771) with Built-In Regulator

• How Does It Work?– Supplies Exciter Current to Vary Magnetic Field in Rotor Coil– Provides Constant Voltage Regardless of Rotor Speed– Regulates Alternator Output Voltage to 14-Volts

• Replacement– Widely Used in Lada (Russian) Vehicles– Replacements Purchased On-Line

The electronic regulator (33.3072) was a welcome substitute for the vibration-sensitive PP-330 (electro-magnetic)

mechanical regulator used in the Г-424 11-amp alternator.33

33.3702: Solid-State 12-Volt Regulator for the Г-424 Alternator• Rated for 1.5-Amp Current from the Rotor (Exciter) Coil• Used on Ural (Урал, IMZ): 650-cc 8.903, 8.923, 8.103• Used on Dnepr (Днепр, KMZ): MT-10, -10.36, -11,-14, -16• Standard Fitment on Last Years MT-11 Production• Main Manufacturer: АО КЗАМЭ (AO KZAME, Russia, Kaluga)• 6 Transistors• No Adjustment Possible• Board Covered with Thick Layer of Lacquer

The 33.3702 regulator is readily available from various Ural / Dnepr “parts suppliers” on the Internet.

12-Volt (14B)

34

....

.

33.3072 Voltage Regulator Application

Г-424 Alternator

Regulator

..

+12-VoltBattery


RotorCoil

3-ØStatorCoil .

IgnitionSwitch

The electronic (33.3072) regulator varies the current in the rotor coil (terminal Ш) to maintain a constant

output voltage at the “+” terminal.

Rectifier Diodes to convert generated AC

to battery DC

RotatingMagnetic

Field

+ЛК

(LC)

33.3702Ш

(W)

-

Ш

+

~ (not used with 33.3072,used with PP-330)

MasterSwitch

(not usedwith

Electric-Start)

Regulator modulates exciter current to control the

magnetic field

With one end of the Г-424’s Rotor grounded, the regulator must

be connected between the battery and the other end of the rotor.

15-Amp

Voltage Regulator has no adjustments

35

Voltage Regulator Types

•Grounded Regulator or a Grounded Field Regulator?

–Grounded Regulator Works by Controlling the Amount of

Grounding (–) the Alternator Windings Are Permitted thru

the Regulator

–Grounded Field Regulator Works by Controlling the

Amount of Battery Voltage (+) Applied to the Alternator

Windings thru the Regulator

•33.3072 Voltage Regulator Is Grounded Field Regulator

–Magnetic Field Generated by Rotating Exciter Field

–One End of Rotor Field Grounded

–Intensity of Magnetic Field Dependent on Exciter Voltage

The 33.3072 voltage regulator is a grounded-field regulator. 36

Dnepr (Днепр) MT-10 and MT-10.36 using 33.3702 Regulator

22. Regulator(33.3702)

Brake

MasterSwitch

Neutral Switch

Horn

Ignition Coil(B204)

FootBrake Light

SwitchOil-PressureSwitch

Breaker(PM-302/PM-302A)

Battery(2X 3MT-6)

HornButton

TurnSignal

Flasher

37

Dnepr (Днепр) MT-11, MT-14 and MT-16(showing replacement of PP-330 Regulator with the Solid-State 33.3702)

Older Models:PP-330

(Relay-Type)

Battery

Regulator(33.3702)

BrakeMasterSwitch

NeutralSwitch

Ignition Coil(B204)

Breaker points

Horn

Alternator(Г-424)

Oil-PressureSwitch

Flasher

HornButton

TurnSignal

38

12-Volt Regulator (Я212А11Е / YA212A11E / 36.3702)

for the Russian 14.3771 35-Amp Alternator• Background

– Voltage Regulators Paired with Specific Generators/Alternators– Time-Line for Generators/Alternators/Regulators– Comparison of Alternator Performance: Г-424 vs. 14.3771– Specs for the 14.3771 Alternator– Alternator Application in Ural Wiring

• What is it?– Internal (Built-In) Voltage Regulator for the Ural 14.3771 35-Amp Alternator– Completely Solid-State– Years of Application: 1998.5-to-2004– Replaced the Г-424 (14-Amp) Alternator in ‘98.5 with its PP-330 Mechanical

Regulator or the 33.3072 Electronic Regulator– Later Superseded by the More-Reliable Nippon-Denso 55-Amp Alternator

with Built-In Regulator• How Does It Work?

– Regulates Alternator Output Voltage to 14-Volts– Provides Constant Voltage Regardless of Rotor Speed– Supplies Exciter Current to Vary Magnetic Field in Rotor


– Widely Used in Lada (Russian) Vehicles– Replacement (with brushes) Purchased On-Line

The YA212A11E built-in, solid-state voltage regulator was a step forward in maintenance-free operation.

Unfortunately it was married to the 14.3771 alternator,which suffered from a bad-reliability reputation.

39

14.3771: 12-Volt Alternator Application(12/09)

36.3702 Regulator(Я212А11Е / YA212A11E)

YA212A11E Built-In Regulator

Rotor(Rotating

Magnetic Field)

Red“Alternator

Fault”Indicator Lamp

IgnitionSwitch

Full-WaveRectifier

(6X 20-Amp Diodes)

Stator(3-Ø)

Parallel Resistor(in case

lamp blows)

Carbon Brush

Battery

Instrument Panel & Indicator Lights

PositiveTerminal

Alternator Exciter (+Fault

Terminal)

RPMIndicator

Signal(not usedon Ural)

Unused Circuitryin Orange

(not connected)

ChassisGround Alternator/Rectifier

(not used on Ural)

Rectifiers Usedto Supply

Rotor Currentwhile Running

OutputTransistor

40

36.3702 (Я212А11Е / YA212A11E) Voltage Regulator for 14.3771 Alternator

• Built-In Brushes for Alternator Slip-Rings• Rated at 12-Volts / 5-Amps• Standard Threshold Regulators Must Be within 13.6-14.4 Volts (typ. 14-V)• Since 2002, Output Transistor Used a Powerful Field-Effect Transistor (FET)–Sharply Lowered Power Losses Given Off in the Form of Heat–Load and Current High-Speed Characteristics Improved Reliability

• Used In:–Vehicles (Russian): VAZ (Lada) -2108, -09, -10, -11, -12, -23; VAZ -21214, -15; NIVA, GAZ (Gorky Automobile Plant) - 3102, -29, 3302; & "Ural“ Motorcycle–Alternators: 372.3701; 373.3701; 9402.3701-01; 9402.3701; 412.3701-01; 9422.3701; 26.3771; 2502.3771-01; 37.3701 (VAZ-2110, 2112, 2111); 14.3771 (Ural)–Available in Russian Auto Shops (hanging on the wall) or Off the Internet

41

12-Volt Regulator (N-D Part # 126000-0600) for the Nippon-Denso 55-Amp Alternator

• Background– Voltage Regulators Paired with Specific Generators/Alternators– Time-Line for Generators/Alternators/Regulators– Performance Specs for the Nippon-Denso (N-D) Alternator– Alternator Application in Ural Wiring

• What is it?– Internal (Built-In) Voltage Regulator for the Ural Nippon-Denso (N-D)

Alternator– Completely Solid-State– Years of Application: 2004-to-Present– Replaced the 14.377 (35-Amp) Alternator in Jan. 2004– Retro-fitable to 14.377 (35-Amp) and Г-424 (11-Amp) Applications

• How Does It Work?– Regulates Alternator Output Voltage to 14.5-Volts– Provides Constant Voltage Regardless of Rotor Speed– Supplies Exciter Current to Vary Magnetic Field of Rotor


– Widely Used in Nippon-Denso (Denso), Daihatsu, Kubota and Suzuki Alternators

– Replacement Parts Readily Purchased On-Line

The Nippon-Denso 126000-0600 built-in, solid-state voltage regulator is a widely-used, reliable unit.

42

Recent Ural Starter/Generator/Alternator Time-line

EngineSize

Year

‘96 ‘07‘04‘02‘98

1998.5

2000

650 cc 750 cc Engine

New Engine Design (Alternator on top / Flywheel Starter

placed on bottom)

Gen/Alt

IgnitionType

1994

Ural imported to U.S. by CSMI (Classic Motorcycles and Sidecars, Inc.)

55 Amp Nippon Denso Alternator(770 W, metal rear cap)

Type IType II Type III Ignition

Type IVType V

(Type IV with electronics moved

into airstream)

Ducati

14 AmpRussian

Г-424 Alternator(150 W)

18 AmpHitachiStarter/

Generator(300 W)

35 AmpRussian Alternator: 14.3771

(Hand Grenade)(500 W, black-plastic rear cap) (Increased length

by 20 mm)

RoughlyWattage = 14 Volts X Amps

Factory Electric-Start (E-Start) Offered

(Starter/Alternator atTiming Gear)

Voltage Regulator internal to Alternator

Electric-Start (E-Start) Option & Retro-fit introduced by CSMI

StartRelays(RY-115)

One Relay One RelayTwo Relays

No points-ignition UralsApproved for U.S. sale

‘03 ‘05

Kick-Start Only

VoltageRegulator

Regulator Internal to Alternator33.3720200 Solid-State

New Transmission Case(Flywheel Starter Added,

New Wiring Harness)(IMZ-8.1037-18016-12)

New Wiring Harness (9238000)

‘01 ‘06‘99‘97‘95

43

Nippon-Denso Installation Wiring Diagram

B+ Battery: Main current connection - connect to the battery positive via

heavy duty wire.

IG: Ignition- connect to ignition switched +12V,

provides about 0.25-Amp to drive the regulator.

L: Lamp- connect via the warning lamp to +12v

Access Hole for Terminal “F”

of Rotor

Rear 2-pin Connector

Grounding the “F” terminal gives “full-field” for testing.

“Fault” Light is Optional on N-D Alternator

(note: light was mandatory for initial rotor

current in previous 14.3771 35-Amp

alternator (Russian hand grenade))

B+

44

Connections to the ND Voltage Regulator

(Terminal Fof Rotor)

IG

L

Regulator CaseGround

The voltage regulator is the brain of the charging system, monitoring both battery and stator voltages. Depending on the measured voltages, the regulator will adjust the

amount of rotor field current to control alternator output.

(Terminal Pof Stator)

Solid-state voltage regulator has only two external connections;

L (output to the indicator lamp) and IG (input from the ignition switch).

Heat Sink

“L” Terminal provides ground to light the

“Fault” warning indicator.

45

.

.

.

..

.

Inside the Nippon-Denso Voltage Regulator

Monolithic

Integrated

Circuit

(MIC)

Alternator

Regulator

. .

.. .....

...

.

....

B+

B+

IG

IG

E

E

P

F

L

L

Battery


RotorCoil

3-ØStatorCoil . Fuse

in Fuse Block

IgnitionSwitch

The regulator controls the amount of battery current going to the field winding in the rotor.

RectifierDiodes

ProtectionDiodes

Grounding the “F”Terminal gives “full-field”

for Testing

Sense

RotatingMagnetic

Field

46

Part XXVIII: Evolution of Russian Motorcycle Voltage Regulators

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Transcript of Part XXVIII: Evolution of Russian Motorcycle Voltage Regulators