Ural (Урал) - Dnepr (Днепр) Russian Motorcycle Generators ... III-3 - Ural and Dnepr... · Ural (Урал) - Dnepr (Днепр)Russian Motorcycle Generators and Alternators

Ural (Урал) - Dnepr (Днепр)Russian Motorcycle

Generators and AlternatorsPart III-3: Г-424 (G-424) Alternator

Ernie [email protected]

02 / 2018

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

Generator/Alternator

Type Vintage NominalVoltage

Current NominalPower

Motorcycles

Ural(IMZ) Dnepr (KMZ)

Г-11(G-11)

(P/N: 72181)

DCGenerator

1941-1951

6-Volt(7-Volt) 7-Amp 45-Watts M-72 Not Used

Г-11A(G-11A)

(P/N: 72181-A)

DC Generator

1952-1957

6-Volt(7-Volt)

7-Amp 45-Watts 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 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-in

Rectifier)

1974-1998 12-Volt

(14-Volt)14-Amp 150-Watts

M-67, M-67.36, IMZ 8.103 Series

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

MT-11, MT-16

Hitachi(Limited

Appearance)

Starter / Generator

1998-1998.5 12-Volt


IMZ 8.103 and8.107

“650” SeriesNot Used

14.3771(RPOC)

(P/N: 14.3771-010)

Alternator(Built-in

Rectifier &Regulator)

1998.5-2004

12-Volt(14-Volt)

35-Amp 500-WattsIMZ 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


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 the same part.2. Cannot use Г-424 Alternator with discharged battery or without battery.3. MB-750 = MW-750, MB-750M = MB-750M4. The frame (case) of the Г-11/Г-11A generator is positive (positive-ground).5. Γ-414 Generator: P/N: 750181 6-Volt (negative ground), whereas P/N: 750181-A (positive-ground) for

fitting Г-11A’s into early K-750’s.

2

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

[email protected]

time

195019801960 197019651955 1975

2010200520001990 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,MB-750)

Г-414(M-66,MT-9)

Г-424(M-67, MT-10, MT-

12, MB-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 6V/65 W in 1957, the Г-424 of 12V/150W in 1974, the 14.3771 of 12V/500W in 1998.5,

to the present-day Nippon-Denso alternator of 12-V/770W.

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

(MB-650)Г-11A(early K-750)

Nippon-Denso(IMZ 8.103,

8.123,“750”)

3

Г-424 (G-424) 12-Volt Alternator (1974-1998)•12-Volt / 11-Ampere avg. 14-Ampere max. / 150-Watt Alternator•First Used on Ural M-67 and Dnepr MT-10•Total Capacity Doubled Improved Lighting•Maximum Short-Term Overload: 200 W•Rotor Speed: –Begins to Produce Voltage (no load) at Speed of 1000-1100 rpm, corresponding to 750-850 rpm Engine Crankshaft Speed–1,300 rpm (14-V, 0-A), 2,400 rpm (11-A), 5,000 rpm (Max)

•Used on;–Ural: M-67, M-67.36, IMZ 8.103 Series–Dnepr: MB-650, MB-650M, MT-10, MT-10.36, MT-11, MT-16

•Used in Conjunction with Mechanical PP-330 & Solid-State 33.3702 Regulators•3-Ø (three-phase) Generation, 12-Pole Construction•Built-in Rectifier: MSF-2A (ВБГ-2А)

Г-424 Terminals

Ш

+

~

The higher-output capability of the Г-424 alternator was needed to provide a migratory path for electric-start.

4

Г-424 (G-424) Alternator and Terminal Identification

This diagram is handy because the terminals are unlabelled.

1- ~ 2- + 3- ш

•Polarity: Negative Ground•Direction of Rotation (drive side): Right (clockwise)•Weight: 3.8 kg

5

650 cm Engine with 14-Amp Г-424 Alternator

The 14-Amp Г-424 alternator has a thin pressed sheet-metal shroud covering the rear half, while the later 35-Amp

14.3771 alternator has a thicker cast aluminum housing.6

Γ-424 Alternator on 650cc Engine (1989)

7

Γ-424 Alternator on Dnepr MT-16 650cc (1985)

8

Γ-424

Γ-424 Alternator on Dnepr MB-650M (www.oldtimergarage.eu)

Γ-424

Γ-424 Alternator on Ural M-67.36 Engine

1. Γ-424 Alternator

Alternator G-424 (ГЕНЕРАТОР Г-424)

1 - End Shield

2 - Rubber Collar

3 - Rotor

4 - Stator Winding

5 - Terminal Block

6 - Back Cover

7 - Brush Holder

8 - Rectifying Block

9 - Axial Fan

10 - Protective Cover

11 - Bearing

The Г-424 alternator has an in-built rectifier unit, ВБΓ-2A.11

Construction of Г-424 Alternator (uraldnepr.ru/publ/5-1-0-150)Slip-Rings

Rotor(exciter magnetic field)

PP-330Regulator

12-Volt Battery Full-Wave 3Ø Rectifier

Dash “Fault” Indicator

Stator(field output winding)

12

Alternator Parts•Alternator Consists of Three Main Parts; Stator, Rotor and Covers

–Stator Pack (8):

•Sheet Electrical Steel, Thickness 1 mm, with 18 Teeth

•Three-Phase Winding, Wye-Connected

•Each of 18 Coils: Wound Wire TCPI-2, Diameter 1.08 mm

–12-Pole Rotor

•Maximum Excitation Current at 14-Volts: 1.2-Amperes

•Rotor Shaft (6) and Slip Rings (10)

–Cast Aluminum Alloy Covers (4 and 11) Enclose;

•Rectifier Unit: MSF-2A

•Non-Conductive Holder and Clamps with Three Labels

•Cover (4) and Gasket Set (5) Protect Cavity from Crankcase Oil

13

Г-424 Alternator

Terminal Block

Rotor (Anchor)

Carbon Brush SetBrush Holder

Rectifier Unit

Stator

14

Pinion Gear

Rotor

Brushes

Rectifier

Terminal Block

PlasticEnd-Cap

Stator

Г-424 Alternator Parts Breakdown (Ural 650)

15

Г-424 AlternatorPart # Description Quantity

Г424-3701006 Casing 1

Г424-3701007 Clamp 2

Г424-3701008 Fan 1

Г424-3701011 Bushing 1

Г424-3701015 Brush Holder 1

Г424-3701020 Brush 1

Г424-3701030 Brush 1

Г424-3701090 Terminal block 1

Г424-3701100 Stator with Windings 1

Г424-3701200 Rotor 1

Г424-3701300 Cover 1

Г424-3701400 Cover 1

ВБГ-2A Unit 1

1-22x40-1 Gland 1

180503K1 Bearing 2

201419 Bolt M6x18 1

222747 Screw M4x8 2

222815 Screw M6x50 3

250464 Nut M5 3

250959 Nut M12 1

252003 Washer 5 3

252004 Washer 6 3

252132 Washer 4H 2

252133 Washer 5Л 3

252134 Washer 6Л 4

16

Г-424 Alternator 12-Volts/11-Amp/150-Watt

The concentrically-located rotor shaft is madefor the newly-designed engine case.

Note: Unused “~” Terminal

17

Г-424 (G-424) Alternator (cont.)

Rubber Cover for 3-Terminal Connection

18


19

Model 424, 12-Volt, 150-Watt

List Price: $75.00 New

(www.ebay.com)

Generator 12V DNEPR

Fits: Dnepr MT-11/16, MB-650


(www.ebay.com)


20

Application of Г-424 with PP-330 RegulatorRegulator(PP-330)

Rotor(Rotating

Magnetic Field)

Red“Alternator Fault”

Indicator Lamp

IgnitionSwitch

Rectifier

Stator(3-Ø)

The 3-Ø (three-phase) winding produces three waves, 120° apart, for a more continuous supply of current.

Battery

2. TerminalBlock

CarbonBrushes

21

MT-11 and MT-16 Alternator/Regulator Circuitry

+ Ш~

+-

~ +

PP-330(RR-330)

ЛК(LC)

33.3702Ш

(W)

+ Ш~

+-

MasterSwitch

(deleted for electric-start)

AlternatorFault

Indicator(Dash)

AlternatorFault

Indicator(Dash)

'+' (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

Ш

+~

22

Alternator Rotor for G424-3701200

Fits: Dnepr MT-11/16, MT-10.36, Ural

List Price: $65.95

(www.ebay.ie)

Alternator Rotor for G-424

23

Alternator Г-424 Rotor

Exciter Slip-Rings

24

Exciter Slip-Rings

Alternator Г-424 Rotor and Stator

25

Γ-424 Diode Pack Mounted on Diode Bridge(If battery wires have been connected the wrong way, even for a second, you’ll

need new diodes in the back of the alternator.)

Pair of Brushes and Rotor for Γ-424 Alternator

Carbon Brusheson Exciter Slip-Rings

When validating a generator (as in its operation), it must be remembered that a no-load may destroy the rectifier.

26

Pinion Gears for Alternator Г-424

Alternator Gear IMZ for Ural


(www.ebay.com)

Г-424 Alternator Gear

List Price: EUR 14.00

(www.ebay.com)

27

Checking the Alternator Performance• Checking the Performance of the Alternator on a Stand

–Check Performance at No-Load and Under a Load

– In All Tests, Strictly Observe Polarity

–When Testing the Alternator Excitation, Connect the Battery Terminal

“+” to the Ш Terminal of the Alternator

• Checking the Performance of the Alternator with Motorcycle on a Stand

–Check Performance with Engine Running

–Add Voltmeter (30-volt range) and Ammeter (15-amp range)

–Add Loading Rheostat (2-ohms with current up to 15-amps)

–In Fourth Gear, Speedometer Should Read 18 kph at 1,300 rpm; 35 kph

at 2,400 rpm

28

Structure and Features of the Г-424 Alternator•Front Cover (1), from Drive Side, Has Adjustable Eccentric Cylindrical Rotor Axis•Drive-Side Has Rubber Gasket (2) for Environmental Protection• Internal Bearings Lubricated with Single- and Double-Sided Seals•Rotor (3) Rotates with Windings Excitation Powered Via Slip Rings•Three-Phase (4) Stator Winding Connected into a Star with Insulated Neutral•All Phases Soldered to Head Bolts Fastening Rectifier Unit (8)•Two Covers, End Shield (6) and Stator Fastened with Three Screws MB•Brush with Wire Attached to Plate and Holder (7) with Six Captive Screws• Integrated Semiconductor (8) Rectifier Unit type MSF-2A•Rectifier Unit (8) Consists of Three Mono-Blocks, Cast Aluminum Heat Sink Fins•Axial Fan (9), Under Protective Cover (10) on Rotor Shaft (3), Cools Rectifier•Terminal Block (5) for Connection to Alternator

29

Disassembling and Reassembling the Alternator

•To Disassemble Alternator

–Remove Two Screws and Take Off the Guard (10)

–Remove Screw and Fan (9)

–Remove Respective Nuts and Bolt to Remove Rectifier Unit(8), Terminal

Block (5) and Brush Holder (7)

–Mark the Ends of Connected Wire

–Push the Stator Slightly, Extending Bolts Inside End Shield (6)

–Undo Coupling Screws and Remove End Shield (6) by Striking

Uniformly with a Wooden Hammer on the Bosses for Coupling screws

–Take Stator (4) Out of End Shield (1)

• To Replace Bearings–Remove Bearing from Shaft Using a Pulley-Puller from Slip-Ring End

–Fit New Bearing on the Shaft

–Uncotter and Unscrew Slotted Nut from Drive End

–Remove the Gear and Key

–Scrape Metal from Splines of Screws Fastening the End Shield

–Remove the Screws and the End Shields

–Remove Shaft from the Bearing Using a Pulley-Puller by Resting It

Against the Shaft Center-Hole and the Flange of End Shield (1)30

Disassembling and Reassembling the Alternator (cont.)

–Press the Bearing Out of Its Seat in the End Shield by Resting the Tool

Against the Bearing Inner Ring

–Fit New Bearing and Reassemble End Shield (1) in Reverse Order

–After Replacing the Screws That Fasten the End Shield, Punch Its Metal

in the Screw Splines

•To Reassemble Alternator

–Observe the Reverse Order

–Locks on Alternator End Shields and Stator Should Form a Straight

Line

–Before Assembling the End Shield (6), Insert Extending Bolts in Stator

Holes So That Insulating Bushing Fitted Are Sunk in Respective

Recesses of the End Shield, While the Bolt Heads Are Placed in

Respective Recesses of These Bushings

–To Fit the Gear on the Generator Shaft, It Will Be Necessary to Remove

the Generator Guard So That the Shaft End Is Rested on a Rigid

Support

31

HornButton

(Later Up-graded with 33.3702 Solid-State

Regulator)Regulator(PP-330)

Alternator(Г-424)

32

1. Left indicator lamp 2. Right direction indicator 3. Lamp indicators A12-21-3 6. Regulator7. The switch controls the lamp Neutral 8. Switch "day-night" with the ignition safety switch 9. Switch signal inhibition handbrake 10. Relay turns 11. Lamp control indicators A12-1 12. Farah 13. Lamp control inclusion of neutral 14. Lamp driving-beam headlights 15. Speedometer 16. Lamp illuminated 17. Fuse Block 18. Horn

Ural 8.103-10 (40), 8.123-10

Flasher

Horn

HornButton

Battery

TurnSignal

IgnitionSwitch

Hi/Lo BeamSwitch

26. Alternator(Г-424)

6. Regulator(PP-330) (Later Up-graded with

33.3702 Solid-State Regulator)

Foot-BrakeSignal Switch

Spark Plug

Master Battery Switch

19. Ignition coil 20. Switch signal braking foot brake 21. Rear 22. Lamp braking signal A12-21-3 23. Lamp marker light and license plate illumination A12-5 24. Rechargeable Battery 25. Switch mass 26. Generator G-424 27. Lamp control of the generator A12-1 28. Lamp marker and parking light in the headlamp A12-4 29. Lamp control beam headlights A12-1 31. Ignition 32. Switch light and direction indicators, horn button 33. Breaker 34. Sparkplug

33

Dnepr (Днепр) MT-10 and MT-10.36(www.shematic.net/images/pages/MOTO/MT10.jpg)

31. Ignition Coil

Breaker

Horn

Neutral Transmission Indicator

Left Turn

FuseBlock

BrakeLight

Foot Brake-Light

Switch

Right Turn

Left Turn

Right Turn

Spark-plugs

Speedometer

Generator

Indicator

Oil-Pressure

SensorCentral

Switch

High-beam Headlight Indicator

Turn-signal

Indicator

26. Voltage Regulator(PP-330)

Battery(2X 3MT-6)

Flasher

TurnSignal


34

Dnepr (Днепр) MT-10 (1974)

22. Voltage Regulator(PP-330)

Alternator(Г-424)

Breaker(PM-302/PM-302A)

21. Ignition Coil(B204)

Battery(2X 3MT-6)

Foot Brake-Light

Switch

Horn

Neutral Switch

Oil-PressureSwitch

MasterSwitch

Flasher

HornButton

TurnSignal

35

Dnepr (Днепр) MT-10.36

Voltage Regulator(PP-330)

Breaker(PM-302/PM-302A)

Ignition Coil(B204)

Battery(6MTS-9 or2X 3MT-6)

Foot Brake-Light

SwitchNeutral SwitchOil-Pressure

Switch

Flasher

Horn

HornButton

TurnSignal

Alternator(Г-424) 36

Dnepr (Днепр) MT-10 and MT-10.36

22. Regulator(33.3702)

Brake

MasterSwitch

Neutral Switch

Horn

21. Ignition Coil (B204)

FootBrake-Light

SwitchOil-PressureSwitch

Breaker(PM-302A)

Battery(2X 3MT-6)

HornButton

TurnSignal

Flasher

23. Alternator

(Г-424)

37

Dnepr (Днепр) MT-11 / 16 (1992)

7-Oil Pressure Sensor (MM126)8-Foot Brake-Light Switch (BK854B)14-Flasher Unit (PC427)16-Voltage Regulator: 33.370219-Battery: 6MTS-9 (12V/9A-hr)21-Alternator: Г-424 (150W)33-Horn (C205B)35-Ignition Coil (B204)36-Spark plug (A14B)37-Breaker (PM-302A (with automatic spark timer))42-Master Switch (46.3710)

Battery

16. Regulator

Brake

MasterSwitch

Neutral Switch

35. Ignition Coil

Breaker points

FootBrake Light

Switch

Horn

HornButton

Flasher

TurnSignal 21. Alternator

(Г-424)

38

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

Older Models:PP-330

Battery

21. Regulator(33.3702)

BrakeMasterSwitch

NeutralSwitch

26. Ignition Coil(B204)

Breaker points

Horn


Oil-PressureSwitch

Flasher

HornButton

TurnSignal

39

Documents

Ural (Урал) - Dnepr (Днепр) Russian Motorcycle Generators ... III-3 - Ural and Dnepr... · Ural (Урал) - Dnepr (Днепр)Russian Motorcycle Generators and Alternators