Fitting instructions for automatic alternator controller for Moto Guzzi with Bosch alternator 1. alternator modification - 2. Fitting - 3. adjustment (ignition only) First remove the connector block of the alterator stator coils and the Y- connection. Don't cut the wires at the connector block, only unsolder them! With the Y-connection also the screw must be removed. Also unscrew the terminal lugs at D- and DF. To avoid a short cut please file off the right half of the Y-hole flange. Then put the printed circuit board onto the alternator and fix it with two nuts and toothed lock washers at D- and DF. At the ground connection put a 6mm nut as a spacer between the printed circuit board and the alternator housing. Secure the all srews and nuts with toothed lock washers and coat all contact areas and screws (also the 6mm nut) with battery pole fat!
Finally solder the stator wires to the terminal pins very accurately (which wire on which pin doesn't matter), fasten the Y- connection to the corresponding terminal with the 5mm screw.
Fitting instructions for automatic alternator controller for Moto Guzzi with Bosch alternator 1. alternator modification - 2. Fitting - 3. adjustment (ignition only) The instructions for the version with ignition are marked blue. First unscrew the middle screw of the rotor. If it is necessary block the gear rim by a big screwdriver through the ignition controlling opening in the gear case. Then tighten again the screw (without washer) together with the disk driver, also put the provided seal under the driver. First tie out the brusher spring and clamp it above the brusher guiding (right photo). The brusher now must be pulled upward and does't bother anymore. The push the rear brusher with a screwdriver upward and push the stator as far as shown on the left picture. After fastening the stator the magnet disk is pushed onto the driver. The electrical connection consists only of two wires: 1) a 2,5qmm wire directly to the positive terminal of the battery (right screw connection, seen on the printed circuit board), and 2) a 0.5-1qmm wire to the generator control lamp (left screw connection under the small heatsink). If no control light or a LED is used, a resistor of 60 Ohms/2W must be used instead of the lamp! Don't connect the terminal directly to the supply voltage! Do not forget to bring the front coal back into the working position! The electrical connection of the ignition (if present) occurred after the instruction manual for Moto Guzzi. If no digital ignition (and no magnetic disk) is used, the stator can be fitted in the normal way.
At last still check the charging voltage. The voltage at the battery should be between 13.5-14 Volts at approx. 3000 rpm, otherwise correct the charging voltage by the small trimmer (a suitable screwdriver is provided). Beside the right brushholder nut there is a small LED which is switched in parallel with the rotor. At normal working this should light almost constantly in lower rpm and flicker a little bit with increasing rpm. This shows that the current through the rotor is switched on and off, the regulator works. If a light-emitting diode is used as a charge control light, it is necessary to connect a resistor of 68 or 82 ohms in parallel to the LED. The generator needs a starting current that is normally supplied through the charge control lamp. The current through a light emitting diode is to low. If the LED lights already by turning on the ignition, either the brushes have no contact or the rotor is broken. The resistance, measured between both brushholder nuts, should be between 4-and 8 Ohms.
ELEKTRONIK SACHSE Elektronik Sachse GmbH & Co. KG Installation Manual Digital Ignition ZDG 3.23 (Moto Guzzi Bosch Alternator) Item: Z01-B Contents 1 Function................................................................ 1 2 Scope of Delivery........................................................ 2 3 Mounting............................................................... 2 4 Electrical Connections.................................................... 5 5 Settings................................................................. 6 6 General Notes / Troubleshooting.......................................... 9 1 Function The digital ignition kit ZDG3 replaces original electronic ignition units as well as old points including the weights advancer or manual advance wires. Function: Starting from TDC the momentary peripheral speed is determined and by this means, the time up to ignition is calculated per crank turn. Because the peripheral speed varies substantially during acceleration, this long measurement is selected in order to determine a relatively exact measurement. The computation of ignition timing is divided into 4 ranges: Range Function 0 400 rpm Starting range, ignition always at TDC 400 1000 rpm Idling range, 2 to 8 advanced ignition, depending on curve selection 1000 6200 rpm Partial load range, the spark advance adjustment occurs here 6200 12000 rpm Maximum load range, constant maximum advanced ignition, depending on curve selection 1
2 Scope of Delivery 3 Mounting INFO: This image might be different to your existing alternator installation. Some alternators are turned around. First, remove the alternator cover, then unscrew the two stator screws right and left of the Y-connector. Screw the M5 screws with washers into the threaded bolt from one side and from the other the threaded rods. In this way, bolts and rods can be mounted safely. After tightening the bolts, remove the M5 screws. Next, remove the centre screw of the rotor. If necessary, block the crankshaft by placing a large screwdriver through the ignition inspection opening of the gearbox. Tighten the screw again with the driver. Then push the sector disc onto the driver, but don t tighten the set screws. With a little patience and talcum powder, the pickup cable can be pushed through the rubber grommet. Otherwise an additional groove for the pickup lead (+ provided grommet) must be made into the generator to cover next to the existing grommet. 2
Finally, fit the pickup PCB (Printed Circuit Board) to the threaded bolts with the two M5 screws. Ensure that the sector disk is the centre of the light-barrier. Alignment of sector disk and light- Figure 1 barrier. When fitting the generator cover, two 6 mm washers must be placed on each of the four screws between the cover and ring as a spacer to ensure that the sector disk does not scrape the cover. Usually only one is necessary, but this should be checked in each individual case. Tip: This distance can be tested by placing plasticine or putty on the pulse disk. 3
Connecting pickups M8 centre screw Mounted drive sleeve hu Threaded rods with spacer Mounted spacer on the rods Installed pickup and sector Wiring 4
Figure 2 Ignition circuit diagram (with Motoplat replacement) Figure 3 Ignition circuit diagram (with breaker points replacement) 4 Electrical Connections The wire cross section of the ground cable should not be below 1.5 mm 2 and should be kept as short as possible. The wire cross-section of the other cables should not be below 0.5 mm 2. Attention: Please do not shorten the pickup lead and use insulated wire end ferrules on the other cables! 5
Connector Function 1 Ignition coil cylinder left 2 Ground 3 Pickup lead, brown 4 Pickup lead, green 5 Pickup lead, yellow 6 Pickup lead, white 7 Output for electronic tachometer 8 +12 supply voltage, switched 9 Ground (same as #2) 10 Ignition coil cylinder right 5 Settings Note: Avoid solar radiation or bright daylight during the adjustment and in driving mode. Otherwise it might affect the light barriers. Attention: Remove the spark plug caps before adjusting the sector disk! Bring the right piston to TDC (D marking on the flywheel). Rotate the pulse disk precisely into the position as shown in the picture. The position is correct if the LED (yellow circle) toggles. Figure 4 Adjusting the sector disk so that the LED toggles 6
Tighten the grub screws evenly. Ensure that the pulse disk is in the centre of the light-barrier! Reconnect the spark plug caps. The bike is ready to start. If possible check the ignition timing with a timing light and if necessary, correct the position of the sector disk. Make sure the rotor set screws with a little bit of medium strength thread is locking compound. The DIP switches are on the left side of the ignition box. DIP switch No. 1 controls the rev limiter. It has two settings: up and down: Figure 5 Ensure correct alignment of sector disk and lightbarrier DIP switch 1 up down Rev limiter setting 8600 rpm 7800 rpm The rev limiter DIP switch No. 2 is next to DIP switch No. 1 and adjusts the frequency of the electronic tachometer that can be connected to #7. If no electronic tachometer is connected this switch can be ignored. DIP switch No. 2 should be in the up position for crankshaft frequency selection and down position for camshaft frequency selection: Figure 6 DIP switches and rotary switch. DIP switch 2 up down Frequency setting crankshaft camshaft The ignition curves can be set using the rotary dial on the left side of the box, right of the DIP switches. Curve No. 0 is a test mode in which the box continually fires without the engine running. This tests the installation of the units and coils. But it doesn t test the pickup. Rotary switch settings 1 9 are the different ignition curves. 7
50 40 30 20 10 0 Standard Curve Number 1 2 3 4 5 6 7 8 9 0 400 1000 2000 3000 4000 5000 6000 7000 8000 RPM Advance/ Figure 7 Selectable ignition curves. 8
6 General Notes / Troubleshooting Only use interference-free caps for the spark plugs! Recommended are NGK caps with 5 kω internal resistance. Doesn t start: If the engine should not start, or the engine kicks back, then the ignition coils are mixed up. If so, swap the ignition cables which lead to the spark plugs or reconnect the external ignition coils. As a general rule: each time when a piston reaches TDC also the corresponding plug must have a spark. To check the cable connecting and the supply voltage turn the rotary switch to 0. Now the spark plugs must fire continually. If now the rotary switch is turned again on a level you can easily check the timing with a strobe only by activating the starter (without plugs in the cylinders). If the engine should not start with slowly turning starter, probably the battery voltage falls under the minimum supply voltage of the ignition (approx. 7 V). Irregular engine cutouts: If sometimes the engine suspends while driving for 2-3 seconds and keeps running thereafter normally. That means that the ignition has been reset. The cause for it can be a defective cap or a loose ignition cable in the coil or cap. But in most cases a bad contact in the operating voltage supply (kill switch, starter lock, fuse holder, terminals etc.) causes this effect. For a test you can connect a cable directly from the ignition coils and the ignition box to the positive terminal of the battery. Also put a second cable from the negative terminal of the battery to the ignition box (secure ground connection). If the engine is running well now you can assume an error in the wiring harness. With contact breakers such a bad contact is not noticeable, because a short break for a few milliseconds of the supply voltage doesn t matter, electronics in contrast are more sensitively. Elektronik Sachse GmbH & Co. KG Busestraße 26a 28213 Bremen Germany phone: +49 (0) 5409 9069826 email: info@elektronik-sachse.de 9