Russian Regulators: Part VI

Voltage Regulator (126000-0600)

for the Nippon-Denso 770-Watt Alternator

Ernie Franke eafranke@tampabay.rr.com

 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-fittable to 14.377 (35-Amp) and -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 Circuit Description and Operation Replacement Widely Used in Nippon-Denso (Denso), Daihatsu, Kubota and Suzuki Alternators Replacement Parts Readily Purchased On-Line

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

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

Types of Generators/Alternators for Ural () and Dnepr () (01/10) (

eafranke@tampabay.rr.com
Generator/ Alternator -11 (G-11) (GType DC
Vintage Nominal Voltage Current Nominal Power 45-Watts 45-

Regulator
PP-1 PPPP-31 (1950) PPPP-31 (1950) PPPP-31A (1956) PPPP-31A (1956) PPPP-302 (1963) PPPP-302A PPPP-330 PP33.3702 (1992) Internal to Alternator?? Internal to Alternator (YA212A11E) Internal to Alternator (126000-0600) 126000- 0600)

Motorcycles Ural(IMZ)
M-72

Dnepr (KMZ)
Not Used

Generator

(P/N: 72181)

194119411951 195219521957 195719571974 197419741998 199819981998.5 1998.5 2004

present

6-Volt (7-Volt) (76-Volt (7-Volt) (76-Volt (7-Volt) (712-Volt 12(14-Volt) (14-

7-Amp

(P/N: 72181-A) 72181-

-11A 11A (G-11A) (G-414 (G-414) (G-

Generator

DC DC

7-Amp

45-Watts 45-

M-72, M-72M , MM-61 M-62, M-63, MM-66

M-72, M-72N, Mearly K-750 KK-650, later K-750, KK-750M, MW-750, MWMW-750M, MT-8, MWMTMT-9, MT-12 MT- MTMW-650, MW-650M, MWMWMT-10, MT-10.36, MTMTMT-11, MT-16 MTMTNot Used

Generator Alternator

10-Amp 10-

65-Watts 65-

(P/N: 750181)

(P/N: 3701000)

-424 (G-424) (GHitachi

(Built-in (BuiltRectifier)
Alternator/ Starter Alternator (Built-in (BuiltRectifier & Regulator) Alternator (Built-in (BuiltRectifier & Regulator)

11-Amp 11(aka 14-A) 1418-Amp 18-

150-Watts 150-

M-67, M67.36, IMZ 8.103 Series IMZ 8.103 and 8.107 650 Series 650 IMZ 8.103, 8.103X, 8.123, 8.123X 650 & 750 Series 750 IMZ 8.103, 8.103X, 8.123, 8.123X 750 Series 750

(Limited Appearance)

12-Volt 12(14-Volt) (1412-Volt 12(14-Volt) (14-

300-Watts 300-

(P/N: 14.377114.3771010)

14.3771 Nippon Denso

35-Amp 35-

500-Watts 500(aka 350-W) 350770-Watts 770-

Not Used

20042004-

12-Volt 12(14-Volt) (14-

55-Amp 55-

Not Used

(P/N: IMZ-8.1037IMZ- 8.103718092)

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

Regulators are paired with specific generators/alternators.

-11 Generator -11A Generator

Ural () - Dnepr () Generator/Alternator Time-Line (01/10)

eafranke@tampabay.rr.com
1974

-414 Generator

-424 Alternator

Nippon14.3771 Denso Alternator Alternator

1951

1957
-414 -414 (later K-750) (M-63, -11A -414 K-750M, (early K-750) (M-62) MW-750) -414 (MT-8)

-424 (M-67, MT-10, MT12, MW-750) -424 (MW-650) -424 (M-T-10.36) -424 (M-67.36) -414 (M-66, MT-9) -424 (MT-16) -424 (IMZ 8.103, 8.107, 650)

1998.5

2004

-11A (M-72)

-11A -11A (KMZ M-72) (M-72N)

-424 (MT-11)

14.3771 Nippon-Denso (IMZ 8.103, (IMZ 8.103, 8.107, 8.123, 650 & 750) 750)

1950

1955

1960

1965

1970

1975

1980

1985

1990

1995

2000

time
2005

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

1974

12-Volts (M-67, MT-10 and beyond) Alternator (AC Generator with Built-In Rectifier)

Alternators have progressed in output voltage and power, from the -11 (G-11) generator of 6-Volts/45-Watts in 1941, -11A in 1952, -414 of 6V/65W in 1957, -424 of 12V/150W in 1974, 14.3771 of 12V/500W in 1998.5, to the present-day Nippon-Denso alternator of 12-V/770W.

Recent Ural Starter/Generator/Alternator Time-line (01/10)

Roughly Wattage = 14 Volts X Amps Kick-Start Only

Gen/ Alt

14 Amp Russian -424 Alternator (150 W)

18 Amp Hitachi Starter/ Generator (300 W)

55 Amp 35 Amp Russian Alternator: 14.3771 Nippon Denso Alternator (770 W, metal rear cap) (Hand Grenade) (500 W, black-plastic rear cap) (Increased length
by 20 mm) Voltage Regulator internal to Alternator New Transmission Case (Flywheel Starter Added, New Wiring Harness)
(IMZ-8.1037-18016-12)

Engine Size Start Relays

(RY-115)

Electric-Start (E-Start) Option & Retrofit introduced by CSMI Factory Electric-Start (E-Start) Offered (Starter/Alternator at Timing Gear)

New Engine Design (Alternator on top / Flywheel Starter placed on bottom)

650 cc
Two Relays One Relay

750 cc Engine

New Wiring Harness (9238000) One Relay

Ignition Type
Voltage Regulator

No points-ignition Urals Approved for U.S. sale

Type I

Type II

Type III Ignition

Type IV

Type V

Ducati

(Type IV with electronics moved into airstream)

33.3720200 Solid-State

Regulator Internal to Alternator

1994 95

96

97

98

99 2000 01 02

03

04

05

06 07

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

1998.5

Year

 14-Volt / 55-Ampere / 770-Watt Alternator (actually rated at 43-Amp) Used on; Ural: 8.103, 8.103X, 8.123, 8.123X, 750 Series Dnepr: Not Used (retro-fittable to -424 applications) Built-In Voltage Regulator P/N for Alternator-Only (minus cushion adaptor): 100211-1680 Current Rating for 100211-1680 Alternator: 100211-1680 Alternator +
Engine (Crankshaft) Alternator (Rotor) Output Speed Speed Current 340-to-450 rpm 450-to-600 rpm Fault Light Extinguishes 30-Amp 2,025 rpm 2,700 rpm 34-Amp 2,250 rpm 3,000 rpm 3,000 rpm 4,000 rpm 40-Amp 3,750 rpm 5,000 rpm 43-Amp 5,250 rpm 7,000 rpm 46-Amp Not Much Increase above >7,000 rpm 50-Amp

Nippon-Denso 12-Volt Alternator (01/10)

Cush Adapter and Pinion Gear

Motorcycle Speed (mph / kmph) Idle 22 mph / 35 kmph 24 mph / 38 kmph 32 mph / 51 kmph 40 mph / 64 kmph 56 mph / 90 kmph >56 mph / 90 kmph

Nippon-Densos 100211-1680 alternator is nominally rated at 43-amps @ 5,000-rpm, corresponding to a motorcycle speed of 40-mph (64 km/hr).

Nippon-Denso Installation Wiring Diagram

L: Lamp- connect via the warning lamp to +12v 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+ Battery: Main current connection - connect to IG: Ignition- connect to the battery positive via ignition switched +12V, heavy duty wire. provides about 0.25-Amp to drive the regulator. Access Hole for Terminal F of Rotor B+

Rear 2-pin Connector

Grounding the F terminal gives full-field for testing.

Connections to the ND Voltage Regulator

Heat Sink Regulator Case Ground
Solid-state voltage regulator has only two external connections; L (output to the indicator lamp) and IG (input from the ignition switch). L Terminal provides ground to light the L Fault warning indicator.

IG

(Terminal P (Terminal F of Stator) of Rotor)

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.

... . . . . .. . ...
Alternator
Rectifier Diodes 3- Stator Coil
Rotating Magnetic Field

Inside the Nippon-Denso Voltage Regulator

B+ IG

Protection Diodes

Rotor Coil

. . . .

B+ IG

. .
Ignition Switch

Regulator

Sense

Red Fault Light

Fuse in Fuse Block

Monolithic Integrated Circuit (MIC)

L L

Battery

.
E

P E

. .
Grounding the F Terminal gives full-field for Testing

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

Ural 750 Starter / Alternator Circuit (2004-2005) ver. 2.0 (01/10)

(IMZ-8.103717001-13, 2004 & 2005 Owners Manuals) eafranke@tampabay.rr.com (IMZ- 8.103717001Right Handlebar
87

Notes: 1. Two Start Relays (RY-115) 2. In-Line Fuse #1 deleted mid-2005

85

Momentary Start Button

grn / red
Start 86 30

yel / red red

Run

RY-115 Electric Start Relay #1 (Normally Open)

RY-115 Electric Start Relay #2 (Normally Open)

Starter Solenoid

Rocker-Arm Run / Kill Switch Kill

pnk/ blk

Headlight Cavity Neutral Switch (on transmission)

gray

9-pin Connector

.
4

85 86 30 87 85 86 30 87

Starter Motor

Ignition Module

white

(+12V. in Run position)

red

black blue

white large black large grey

red

Green (Neutral)

+ Main Output

Red (Alternator Fault) Ignition Switch

6 5 1

.
2 Ignition Key

(face-side) red top red Brakes Headlites

3

(back-side)
In-Line Fuse #1

green red

55 Amp Nippon Denso Alternator L

L

IG

12 Volt Battery
Neg -

Pos +

3 1 2

(lamp) IG (ignition) Notes: 1. In-Line Fuse #1 (15A) for Turn Signal and Neutral Indicator Lamp. 2. Fuse Block #4 Fuse (5A) for Ignition & Electric Start Relays.

(0V.: Engine not running +12V.: Engine running and Alternator working.)

Chassis Ground Connector Pin

Run Lites bottom

(+12V. when Ignition Switch on Run)

Male

Female

Fuse Block

black

Terminal

Ural 750 Starter / Alternator Circuit (2006-2007) ver. 2.0 (01/10)

(Electrex, Inc. Rev. E, 2006 GPTT, 2006 & 2007 Owners Manuals) eafranke@tampabay.rr.com Right Handlebar Momentary Start Button Rocker-Arm Run / Kill Switch Kill Headlight Cavity 10-pin Connector
18 pnk Neutral Switch (on transmission) grn/red
Start 87 86 30 85

Notes: 1. Single Start Relay (RY-115) 2. ND Alternator added 2004 3. In-Line Fuse #1 Deleted mid-2005
RY-115 Electric Start Relay (Normally Open)

yel/red red
Run

Starter Solenoid

pnk/blk
D E F G

+ Ducati Ignition Module

18 blu/wht

Starter Motor
85 86 30 87

18 brn/red

16 red 16 wht 8 red

18 brn/red 18 brn/red

(+12V. in Run position)

+ Main Output

12 red Pos +

Green (Neutral) Red (Alternator Fault) Ignition 14 blu Switch

14 blu
5 6 1 2 3

18 blk/red

Fuse Block
18 blk/red
15A

55 Amp Nippon Denso Alternator

18 pnk/blk

IG L

12 Volt Battery
Neg 8 blk

18 pnk/blk

5A 15A 5A

(lamp) 18 blu 12 red

(ignition)
Male

IG

Chassis Ground Connector Pin Female

Note: # in front of wire color is AWG wire size.

Ignition Key

Terminal

Parts for NIPPON-DENSO Ural / Dnepr 12-V / 40-A Alternator

Regulator Stator Rectifier Front Cover Connector for IG/L

Rear Cover

Brush Box with Brushes Rotor

Slip Ring for Rotor Field Current

Parts for the Nippon-Denso 12-Volt alternator are readily available from Tiedemann Auto-Elektric (Denmark) at www.auto-elektrik.de and Metro Auto Industrial, Pomona, CA at www.metroautoinc.com.

Voltage Regulator for the Ural 100211-1680 Alternator 12-Volt Voltage Regulator Output Voltage Set Point: 14.5-Volts Repair Circuit: VR-H2005-26S; TRI254 Terminal Markings IG (ignition) and L (lamp) Low/High Speed RPM Charge Point (lamp on/off): 450/ 600 rpm Rotor Speed Ambient Operating Temperature (full load): -40C to +135C Alternator Series: IR / IF (internal Regulator / Internal Fan) Soft-Start for Field Load Control: Y and Load Response: 7 sec Principal Use: Fork-lift and Industrial N-D Alternators Shut Down for:
Over-Voltage Shorted B Lead High Field Current (over-load) Warning Light Will Illuminate (-40F to +275F)

The questionable 14.3771 alternator was replaced with a Nippon-Denso (N-D) alternator, adding to Urals reliability.

Nomenclature for Nippon-Denso (N-D) Alternator

Ural Announced: Starting January 2004, Motorcycles Equipped with DENSO 100211-1680 (Japan), with Built-In Regulator Consists of N-D 100211-680 Alternator plus Cush Adapter Unit Alternator Used In: Line of Toyota Forklift Trucks Ford, Kubota, New Holland Light Tractors Thermo King AG & Industrial Daihatsu Charadl Vehicle Chevrolet Sprint 1.0L (1988-87) Suzuki Samurai 1.3L (1995-86) and Sidekick 1.3L (1989) Alternator (pulley-version, instead of Ural adapter) Used In: Voltage Regulator OEM#s: Nippon-Denso Part# 126000-0600 Replaces: Toyota 27700-78301 Iseki 281-271-001-0 Daihatsu 27700-96301, 27700-87207 Victory A8062902 Voltage Regulator 27700-96301 Used In: Alternators: Ishikawajima 18504-6220 Mitsubishi MD604589 Nippon-Denso 100211-1550, -1670, -1680 Vehicles: Daihatsu Mitsubishi Subaru Suzuki Toyota

Parts for the Nippon-Denso 12-Volt alternator (minus the cushion adapter) are readily available.

 Regulator Maintains pre-Determined Charging Voltage Level: 14.5-V When Charging Voltage Falls below this Point, Regulator Increases Field Current, thus Strengthening the Rotating Magnetic Field, Resulting in Increased Alternator Output When Charging Voltage Rises above this Point, Regulator Decreases Field Current , thus Weakening the Magnetic Field, Resulting in Decreased Alternator Output

Voltage Regulation Process

The regulator monitors the battery voltage, controlling current flow to the rotor assembly. The rotor produces a magnetic field, which induces voltage into the stator. The rectifier bridge converts AC stator voltage to DC output for use by the motorcycle.
(Compression and enhancement of Automotive Series, Understanding the Alternator, developed by Kevin R. Sullivan, Professor of Automotive Technology, http://www.autoshop101.com/trainmodules/alternator/alt101.html)

A Peek inside the Alternator

Removing the Rear Case Reveals: Rotor Winding Assembly, which Rotates inside Stator Winding Rotor Generates a Rotating Magnetic Field Stator Winding Develops Voltage Current Begins to Flow from Induced Magnetic Field of the Rotor As the Rotor Assembly Rotates within the Stator Winding:

Alternating Magnetic Field from the Spinning Rotor Induces an Alternating Voltage into Stator Winding Strength of the Magnetic Field and Speed of the Rotor Affect the Magnitude of Voltage Induced into Stator

Removal the rear cover of the N-D alternator reveals the rotating magnetic field coil surrounded by the stationary three-phase winding.

Rotor Assembly

Basic Rotor Consists of Iron Core, Coil Winding, Two Slip-Rings, and Two, Inter-leaved, Claw-Shaped Finger Pole-Pieces Rotor Contains Field Winding Wound over Iron Core Surrounding the Field Coil are Two Claw-Type Finger-Poles Each End of Rotor Field Winding Attached to a Slip-Ring Stationary Brushes Connect Alternator to the Rotor Magnetic Field Saturates the Iron Finger-Poles One Finger-Pole becomes a North Pole and Other a South Pole Rotor Spins Creating Alternating Magnetic Field; North, South, North, South, etc.

The rotor (exciter) field winding creates the rotating magnetic field that induces voltage into the stator winding.

Stator Windings

Wye style has four stator leads. One of the leads is called the Neutral Junction, common to all the other leads.

Stator Composed of Three Sets of Windings Each Winding Placed in Different Position Compared with the Others, Staggered 120 Apart Laminated Iron Frame Concentrates the Magnetic Field Stator Lead Sends Output Current to Diode Rectifier Bridge Neutral Junction in the Wye (Y) Identified by the 6 Strands of Wire

The induced AC voltage in each lead of the stator winding is fed to the diode rectifier assembly to convert to DC.

Diode Rectifier Bridge Assembly

Two Rectifier Diodes Connected to each Stator Lead Six Diodes used to rectify the AC stator voltage to DC Output Voltage Full-Wave Rectification: Diodes Redirect both Positive and Negative Polarity AC Voltage to Produce DC Voltage

The Diode Rectifier Bridge is responsible for the rectification of AC voltage to DC voltage.

Slip-Rings and Carbon Brushes for Exciter Rotor

Two slip rings are located on one end of the rotor assembly. Each end of the rotor field winding is attached to a slip ring, allowing current to flow through the field winding.

Two stationary carbon brushes ride on the two rotating slip rings.

Power for the rotor (exciter) coil is supplied, through the carbon brushes and slip-rings, by the voltage regulator.