Electrical System

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Electrical System
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AC DynamoExternal regulator
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Regulator (for dynamo)

• Regulator
• Dynamo
• Load
• Charge Lamp
• Battery
• Blue wire
• Yellow wire
• Red Wire
• Green wire
• Black wire

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AC Dynamo
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AlternatorExternal regulator

• 1 Fan
• 2 Drive end frame
• Stator core
• Stator coil
• Brush
• Brush holder
• Rectifier
• Rear end frame
• Rotor Coil
• Rotor
• Pulley

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AlternatorExternal regulator

• Alternator
• Regulator
• Main switch
• Fuse
• Charge lamp
• Load
• Battery
• Rotor coil

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AlternatorExternal regulator

• Voltage Regulator
• Voltage Relay (Charge Lamp Relay)
• Voltage Coil
• Pressure Coil

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Alternator - External regulator
Connector Voltage
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Alternator - External regulator
No Load Test Greater than 14VDC at more than
1500 rpm
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Alternator - External regulator
Regulator Relay Test
Connector Voltage Approximate battery voltage
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Alternator External regulator
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Alternator External regulator
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Alternator - External regulator
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AlternatorInternal regulator (IC) type

• Pulley
• Drive end frame
• Rear end frame
• Stator
• Terminal
• Connector
• IC regulator
• Spring
• Brush
• Rectifier
• Rear end cover
• Rotor
• Bearing

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AlternatorInternal regulator (IC) type
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AlternatorInternal regulator (IC) type
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AlternatorInternal regulator (IC) type
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Calculation of average electrical loading
Commercial Vehicle - Total driving time 10 hours
Example 1 D1105 Rated 3000rpm
Watt.Hour Sum (Capacity Estimated Usage Time)
3580 Estimated Watt Watt.Hour / Total driving
time 3580/10 358 Estimated Ampere Estimated
Watt / Voltage 358/12 29.8 Required
Alternator Capacity Estimated Ampere1.25
37.3 (A) In practice, to provide a reasonable
degree of surplus capacity , the generator
should be selected to have a rating approximately
25 in excess of this.
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Alternator Output Characteristics
Example 1D1105 rated 3000rpm
Alternator Speed Engine Speed Crank Pulley /
Alternator Pulley
3000 rpm 105mm 58.5mm 5385 rpm
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Alternatortemperature-output
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Starter Conventional type

• 1 Front Bracket
• Drive lever
• Magnetic switch
• Pinion Gear
• Overrunning Clutch
• Gear shaft
• Internal gear
• Pinion gear
• Armature (shaft)

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Starter Gear Reduction type

• Drive gear
• Armature
• Field coil
• Brush
• Idle gear
• Pinion gear
• Overrunning clutch
• Magnetic switch
• Plunger

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Starter Capacity

• Cold starting depends on
• Ambient temperature
• Parasitic Load
• Battery Capacity
• Starter Size
• Voltage drop
• Oil Viscosity

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Starter Gear Reduction type
Simple test
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Conventional Glow Plugs
Single heating element
External controller element (sized to amount
of plugs in circuit)
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Glow Plug Wiring(Pre Quick Glow)
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Quick Glow type glow plug
Quick Glow system Double-material type High
reliability
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Quick Glow Plug Wiring
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Glow Plugs
Conventional
Quick Glow
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Glow Plugs
Glow Plugs after 10seconds
Quick Glow
Conventional
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Comparison of Battery Power VS Ambient
Temperature
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BatteryTemperature rectification
Temperature compensation should be made for the
specific gravity measured by a gravimeter
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Wiring Size
Voltage drop depends on Length of cable Diameter
of cable Wiring connectors Ampere
value Temperature increase
Voltage drop in the circuit should never exceed
10 of the system voltage.
Voltage drop against each battery cable should
not exceed 0.6-0.8V DC.
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Wiring Size
Voltage drop depends on Length of cable Diameter
of cable Wiring connectors Ampere
value Temperature increase
mm²
The battery cable size largely influences the
starting performance of engine.
Voltage drop against each battery cable should
not exceed 0.6-0.8V DC.
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Electrical Grounding Why the Machine needs
to have an electrical ground?
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Typical Ground wiring between engine and machine
chassis
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Belt Drive (Rear)
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Electrical Discharge due to wrong ground
connection
Electrical Arcing of PTO drive universal joint
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Electrical Discharge due to wrong ground
connection
Crankshaft thrust bearings, pitting
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Crank Metal Discharge
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Crankshaft Discharge
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Electrical Wire SizeMetric to AWG conversion
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Super Mini (AC dynamo type)

• AC dynamo
• Glow plug
• Regulator
• Lamp
• Lamp timer
• Charge lamp
• Battery
• Starter
• Key Switch
• Timer
• Fuse
• Solenoid (opt)
• Switch
• Oil lamp
• Oil switch

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Super Mini (AC dynamo type)
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02 03 (external regulator alternator)
What type of glow plugs?
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02 03 (external regulator alternator)
What type of glow plugs?
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Super Mini IC reg. alternator(no lamp timer)
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05 Series (Energize to run System)
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05 Series (typical no lamp timer)
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05 Series (Energize to run System)
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V3300 (simple circuit stop solenoid wiring as
operators manual)
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V3300
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Stop solenoid Internally Switched type
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05 series wiring quiz
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Engine Control and shutdown system

• Engine should automatically stopped
• When the oil pressure is decreased below 7 psi.
• The Coolant water temperature is increased above
  110C (230F).

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Kubotas EG-20 Wiring Diagrams
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Stop Solenoids

• Appearance/Clues
• Burned Out Back
• Will Not Pull In

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Stop Solenoids

• Possible Causes
• Overcranking (Over-Energizing the Pull Coil)
• Pull Coil Wired to S Terminal of Starter