1 The ALR Series Actuator is designed to replace the OEM equipped shut down solenoid. To properly install the ALR actuator, a precise measurement must be obtained from the removed OEM equipped shutdown solenoid. Before beginning the installation of the ALR Actuator, remove all DC battery power from the equipment being serviced. Do not attempt this installation with the engine running or serious damage may occur to the equipment or personnel. 2 INTRODUCTION APPLICATIONS - ALL MODELS ALR Series Electronic Linear Actuators ENGINE MAKE ENGINE MODEL D905 KUBOTA ACTUATOR MODEL D1005 D1105 Super 5 Series D1105-T V1305 ALR190-K04-12 or -24 V1505 V1505-T 3300 Series 3800 M03 M03 ALR190-KM03-12 or -24 V2403 V2403 ALR190-KV2403-12 or -24 V3073 V3073 ALR190-KV3073-12 or -24 V3307 V3307 ALR190-KV3307-12 or -24 V3600 V3600 ALR190-KV3600-12 or -24 Perkins PERKINS 404, 700 ALR190-P04-12 or -24 403D-15 ALR190-P403-12 or -24 L-Series S-Series C-Series L-Series MITSUBISHI L2E L3E S3L ALR190-M04-12 or -24 S3L2 S4L S4L2 ISUZU 2CA 3CA 3CB 3CD 3CDT ALR190-I03-12 or -24 3LB1 3LD1 3LD2 4LE1 4LE2 YANMAR 2TNV70 3TNV70 3TNV76 3TNV82A 3TNV84 TNV-Series 3TNV84T ALR190-Y04-12 or -24 3TNV88 4TNV84 4TNV94L 4TNV88 4TNV98 4TNV98T SHIBAURA N842-C Shibaura N844L-C ALR160-S03-12 or -24 N844LT-C FARYMANN Farymann 18 ALR190-F04-12 or -24 3 SPECIFICATIONS ELECTRICAL 190-F, 190-I, 190-K, 160-S 190-M, 190-P, 190-Y Operating Voltage 12 or 24 VDC 12 or 24 VDC Normal Operating Current Maximum Current Continuously Rated Coil Resistance (12VDC) (24VDC) 3.2A @12VDC 1.6A @24VDC 5.0A @12VDC 2.5A @24VDC 1.8 ± 0.2 ohms 7.2 ± 0.2 ohms 4.8A @12 VDC 2.4A @24 VDC 7.5A @12 VDC 3.8A @24 VDC 1.6 ± 0.2 ohms 6.4 ± 0.2 ohms Connection 16 AWG ( 0.8 mm² ) leads ( 0.8 mm² ) leads ENVIRONMENTAL Operating Temperature Range -40 F to +200 F (-40 C to 95 C) Relative Humidity up to 100% Vibration Shock All Surface Finishes Sealing Weight ± 4 G, 25 to 100 Hz 20 G Peak, 11msec Fungus Proof and Corrosion Resistant PHYSICAL Oil, Water, and Dust Resistant 1.3 lb (0.59 kg) 1 PERFORMANCE MODEL OPERATING STROKE RESPONSE TIME (1-90%) 160-S 0.51in (13.0mm) 1-12mm 35msec 190-F 0.34in (9.0mm) 1-8mm 35msec 190-I 0.55in (14.0mm) 2-12.6mm 35msec 190-K 0.49in (12.5mm) 1-12mm 35msec 190-M 0.54in (13.9mm) 1-13mm 35msec 190-P 0.42in (10.4mm) 1-9mm 35msec 190-Y 0.34in (9.0mm) 1-8mm 35msec CONNECTOR TYPE Spade Packard HARDWARE MODELS ALR190-I03 ALR160-S04, ALR190-F04, ALR190-I03, ALR190-K04, ALR190-KV2403, ALR190-KV3307, ALR190-KV3600T, ALR190-M04, ALR190-P04, ALR190-P403, ALR190-Y04
4 DIAGRAMS ALR160-S 32 1.26 26 14.7.58 33.1 1.30 103.4 4.07 90.4 3.56 40 1.57 5 M16 x 1.5 THRD 4.16 11.43 13.51 ALR190-P ø1.90 [36.2] ø1.43 [32.0] ø1.26 ø [11.8].46 [9.5].37 [70.6] 2.78 [36.7] 1.45 [44.0] ø1.73 [25.0] ø.98 [38.1] 1 ALR190-I M16 x 1.5 [22.2].88 [12.8] 6.00 ø1.90 [31.8] ø1.25 [25.0] ø.98 ø [12.7] [66.0] 2.60 6.0 [38.1] 1 M25 x 1.5 [9.5].38 [10.9].43 [24.9].98 2
Ø 1.90 ALR190-M [19.0].75 [4.0].16 [9.7].38 [71.6] 2.82 [1.8m] 72.0in Ø [42.0] Ø 1.65 M30 X 1.5 [26.1] 1.0 [40.0] 1.5 ALR190-F [152] 6.0in ALR190-Y [24.5] Ø.97 Ø 1.90 [23.8].94 [29.2] 1.15 [14.6] 2X R.57 [18.3].72 [21.8].86 42 [27.6] 1.09 64 [6.4].25 [30.1] 1.185 [21.4] 0.842 [80.3] 3.16 6.00 [15.5].61 [7.1] 2X Ø.28 [19.5].77 R [29.2] 1.15 [5.2] [32.5] 1.28 Ø [22.1].87 [11.8].46 3
[26.0] [26.0] ALR190-K04 [7.2] 2X ø.29 [24.6] ø.97 [24.1] 2X R.95 [14.1].55 [1.6].06 [15.9] ø.63 [12.7] [76.2] 3.0 6.0 [7.1] 2X R.28 [6.4].25 ALR 190-KM03, ALR 190-KV2403, ALR190-KV3307 ALR190-KV3600T L L 4
5 160-S, 190-I,190-M, 190-P InSTALLATION 6 The ALR190-M unit must be adjusted for proper operation. If the installation procedure is not followed, damage to the actuator and or injection pump is possible. INSTALLATION PROCEDURE 1. Index mark the OEM shutdown solenoid directly behind the locknut with a marker or scribe before loosening the locknut. This mark is important. A precise measurement (depth micrometer) will be taken after shutdown solenoid is removed from the injection pump housing. 2. Remove the wiring harness and the loosen solenoid locknut. Clean the area from dirt or grease. Loosen and remove solenoid from the injection pump housing using standard service cautions. 3. Move locknut on shutdown solenoid back to previously indexed mark (Step 1) and measure distance from the front side of locknut (side that was previously against injection pump housing) to the end of shutdown solenoid shaft. Record this measurement. The more precise this measurement (depth micrometer) the more precise the ALR actuator will perform. 4. Discard OEM installed shutdown solenoid and locknut. Locknut is NOT REQUIRED for the ALR installation. 5. The ALR comes with three shims (1mm, 2mm, and 4mm). Measure the distance from front of actuator (part that will be butted to injection pump housing) and end of actuator shaft. Make sure to record the measurement. The more precise this measurement (depth micrometer) is the more precise the ALR actuator will perform. Compare measurement from OEM shutdown solenoid and measurement of the ALR, the difference of the two measurements will indicate shims to use. If exact measurement is not obtainable, error to the negative side. Erring to positive side will affect positive shutdown when the ALR is de-energized. Note that different model engines will require no shims or a different combination of shims. 6. Clean threads, shims and mounting surface of the ALR actuator. Install ALR with or without shims (determined in Step 5) into injection pump housing (no sealant required) until actuator package is flush with injection pump housing. If resistance is felt, remove ALR and inspect threads for dirt or burrs. Also use a clean lint free rag to clean injection pump internal threads. A small amount of clean engine oil can be applied if desired. When actuator is flush with injection pump housing and hand tighten only. After engine has reached operating temperature recheck tightness (use caution, unit will get hot), if required re-tighten by hand only. 7. Install wiring harness, start engine, adjust governor speed controller per PIB document. If problems occur, contact your GAC distributor or GAC Customer Service: www.governors-america.com Engine should be equipped with an independent shut down device to prevent overspeed, which can cause equipment damage or personal injury. 190-F, 190-K, 190-Y INSTALLATION INSTALLATION PROCEDURE 1. The actuator is installed in place of the engine s stop solenoid. Remove the solenoid by first disconnecting the electrical leads at the connector. 2. Cover and secure the engine harness leads as they are no longer needed. 3. Remove the two screws that attach the solenoid to the pump face. Save the screws and o-ring. They will be reused when attaching the actuator. 4. Install the o-ring into the counter bore on the pump face. 5. Install the actuator using the solenoid screws. 6. Attach the actuator leads from the speed control unit. Engine should be equipped with an independent shut down device to prevent overspeed, which can cause equipment damage or personal injury. TROUBLE SHOOTING If the actuator fails to move to full fuel, make the following tests: 1. Measure battery voltage at the controller (see specification for the operating voltage). 2. Check linkage. Manually operate linkage to see that it is not sticking or binding. If the actuator fails to move, make the followoing tests: 1. Measure the coil resistance between the actuator leads (see specification for resistance). 2. Measure the resistance between one lead of the actuator and the housing of the actuator. It should be infinity. 3. Energize the actuator to full fuel by following the procedure in the control unit publication. If the actuator does not move, it is defective. 5