Kamaz Generator Connection Diagram

Why is there a powerful resistor on the voltage regulator of the G273 generator?

The initial excitation, as for all car generators, comes from the battery. When you turn on the instrument switch and the starter (VP and ST), plus 24V comes to point B

voltage regulator, the regulator opens, and current flows from the battery plus to the generator plus. If 24 Volts hits the excitation winding of a 14-volt rotor, the winding will burn out almost immediately, so then the excitation current flows through a powerful 75 Ohm resistor. When the generator is running, the excitation current no longer comes from the output of the generator, where 28 Volts operate, but from the middle point of the winding, where, as already mentioned, the voltage is reduced (this current is closed through the diode bridge, and therefore is rectified).

That is, a 75 Ohm resistor during initial excitation limits the current in the rotor winding, designed for 12 V. This resistor also protects the excitation winding and voltage regulator from overheating when the ignition is on and the engine is not running.

The positive experience of using generator circuits with additional diodes determined the release of the next generation of generators for KAMAZ. The Ya120M1 voltage regulator allows you to separate the excitation current and the regulator control current. In a circuit with additional diodes, the generator is excited through a light bulb with a small initial current, and then, when the generator is running, the excitation current comes from the generator winding and is rectified by additional diodes. This creates a short excitation current path. The circuit is not afraid of battery discharge through the excitation winding when VP and ST are turned on and the engine is not running.

The use of such generators requires the use of a light bulb to limit the initial excitation current. The light is located in the instrument panel and allows you to control the operation of the generator. In this circuit, an additional wire appears from the instrument panel to the generator.

It is useful to know that such generators already use their own rotor, designed for 28 Volts, its resistance is about 8 Ohms.

Voltage regulators for KAMAZ generators

Ya120 M1, analogues 77.3702, 443.3702 412.3702

Ya120M12, analogue 77.3702-01

generator regulator G273 with a quenching resistor 75 Ohm A Y120M1 regulator is installed inside

Generator regulator with additional diodes 1312.3771. A regulator Y120M1 or Y120 M12 is installed inside

The voltage regulator is recommended Y120M12, although Y120M1 also works

On the issue of replacing voltage regulators on KAMAZ

You need to install only the voltage regulator that was installed on the generator; another will not work. That is, the regulator from 1312 generators (without a resistor) will not fit on the G273V1. On generators 1312.3771 and its single-circuit models, you cannot install a generator with a resistor, or you need to remake it, it’s easier to buy the one you need.

3112.3771 analogue 6582.3701 Large size generators, but made according to the same scheme with additional. diodes, and in extreme cases they can also be replaced with G 273V1

There is also a “Ural” generator 1702.3771

Now the main question of the topic.

KamAZ-65115 generator connection diagram

All KamAZ vehicles are equipped with an electrical circuit, which is connected according to a simplified circuit with one wire. The role of the “mass” is performed by the body of the car. The operating voltage of the machine is 24 V, which is achieved using a generator. KamAZ-65115 is equipped with generators of the Euro-2, 3 type (for example, model KAMAZ-4001.3771-53), having the following connection diagram:

This diagram shows a device that uses a relay that opens the primary excitation winding to relieve the trigger contacts of electrical appliances. The essence of the work is that when the engine starts, the generator begins to generate electrical energy, and the spark plugs fire, for which a voltage of 19 Volts is sufficient. The relay opens the battery circuit and the starter operates.

What kind of generator is installed on KAMAZ

There are 18 coils installed on the inside of the GU. The material is copper, the connection method is star. The rotor is a steel shaft, on the back surface of which magnetic circuits are pressed, between which a copper winding is installed.

Excitation winding wires and copper-graphite brushes are soldered to the shaft rings. After the ignition is activated, the current from the battery passes through the brushes and winding, forming a magnetic field.

Thus, the rotor is driven, and the alternating current is converted into direct current through the coils.

There are two positions on the brush holder body: “L” and “Z”, which indicates the transition to summer and winter. In winter, the output voltage is 3.0 V higher than in summer. This is due to temperature conditions, which is necessary to improve battery charging.

On the back side of the GU there are two terminals marked “+” and “–”. Accordingly, the terminals with the indicated polarity are connected to the battery.

To rotate the PG you need a battery. When the actual voltage during operation of the unit is higher than the battery voltage, the generator will begin to supply power to the battery consumers. Thanks to this, the on-board network current is maintained within a specified range.

Principle of operation

Operating principle of the KamAZ generator:

1. The magnetic flux is created by an excitation winding through which a direct electric current passes.
2. The magnetic field is generated by a twelve-pole magnet, which is located inside the rotor.
3. The winding of the KamAZ generator set is attached to the bushing, and its terminals are soldered to slip rings made of copper.
4. Power to the winding mechanism comes from the battery through the starter switch, voltage regulator, brushes and contact rings.
5. During the rotation of the rotor mechanism, its magnetic field crosses the winding mechanism with power lines, due to which an alternating current is induced in the conductors.
6. Current begins to flow into the three-phase silicon rectifier. After this, the current passes into the external circuit.
7. The operation of the generator is monitored using an ammeter, which is located in the driver’s cab on the dashboard.

Originals and analogues, price, articles

Generator

Modern trucks require a lot of electricity to operate. Its supply is provided by a generator. Basically, all KamAZ trucks are equipped with an on-board electrical system, which is made according to a classic single-wire circuit. This means that power to all current consumers is provided by one wire, and the role of the second is performed by the KamAZ chassis.

The main purpose of the generator is to provide energy to current consumers while the engine is running, as well as to charge the battery.

The KamAZ generator starts working when the engine crankshaft speed reaches 1000 rpm or more. It follows from this that when the engine starts, the starter and on-board electrical network are supplied with power only from the battery.

Most modern generators for KamAZ are equipped with rectifiers and voltage regulators. Therefore, the generator, in addition to its two main functions, can convert alternating current into direct current, and also maintain the minimum required voltage in the on-board electrical network, regardless of what speed the engine is currently operating at.

The number of generators that KamAZ trucks are equipped with today is quite large. Based on their design, a distinction is made between generators and generator sets. The latter is now installed many times more often. Despite the variety of models, all generators have a basic basic design and differ only in minor details.

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Typical reasons for the failure of control units at KAMAZ

The causes of breakdowns are:

• insufficient tension of the drive belt;
• contamination of contacts on rings;
• mechanical damage to the rectifier unit;
• excessive wear of brushes;
• jamming (freezing) of brushes;
• short circuit in the winding;
• power supply interruption;
• the voltage regulator is faulty;
• roller bearing wear;
• pulley fixation is loose;
• Fan blades are damaged.

Device

The generator device includes the following elements:

1. Stator with winding. Sandwiched between the front and back covers of the entire mechanism.
2. Mounting foot and tension eye.
3. Covers that are made of aluminum alloys. They are tightened together using 3-4 bolts.
4. Ventilation windows through which the air flow is blown by a fan through the generator device.
5. Brush unit. Connects to a voltage regulator and a rectifier type unit. The brushes are pressed against the ring mechanism using springs.
6. Voltage regulator and rectifier unit.
7. Rotor shafts. Made from automatic steel alloy. If roller-type bearings were used in the design, the shafts are made of alloy steel, and the shaft journal is hardened.
8. At the end of the shaft there is a hole for a key.
9. Contact rings.
10. Units that consist of roller bearings with a disposable insert.

Replacing and repairing a generator at KAMAZ

• a set of tools, keys, heads, cranks;
• “crab” to check the degree of tension of the drive belts;
• mounting blade;
• flathead and Phillips head screwdriver.

Step-by-step instructions for replacing the voltage source:

1. We fix the vehicle on a level platform.
2. Squeeze the parking brake.
3. Turn off the ignition.
4. Disconnect the terminals from the battery.
5. We tilt the cabin and secure it with clamps.
6. Disconnect “+” and “-” from the generator set.
7. We unscrew the tension bolt of the support bracket 2–3 turns.
8. We lower the power unit down and remove the drive belts from the grooves.
9. We unscrew the studs and turn out the coupling bolt.
10. We remove the GU from its regular place.

Next, we carry out comprehensive preventative maintenance of the equipment, clean the components from dirt and dust, blow them with a stream of compressed air, and dry them.

We replace worn-out elements with new ones as necessary and when defective ones are discovered. The generator assembly must be replaced if cracks, chips, or breaks are detected in its housing.

Further use of the equipment is prohibited if it is defective.

Connection diagram

DIY IT installation:

1. We fix the GU on the support brackets, put on a pin and a spring washer.
2. Place the belts in the grooves.
3. We screw in the fastening bolts, but do not tighten them all the way.
4. We move the GU body up, tighten the mounting bolts of the bar.
5. We tighten the split support.
6. We tighten the generator fasteners with a torque wrench with a force of 39.0 Nm.
7. Check the amount of belt deflection. The range should not exceed 15 – 20 mm.
8. We connect the power cables and check the connection.
9. We lower the cabin.
10. We put on the battery terminals.

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