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ALTRONIC EZRAIL
INSTALLATION INSTRUCTIONS MODULAR IGNITION
RAIL SYSTEM

DEVIATION FROM THESE INSTRUCTIONS MAY LEAD TO

FORM EZRAIL II 6-08
WARNING: IMPROPER ENGINE OPERATION WHICH COULD CAUSE
PERSONAL INJURY TO OPERATORS OR OTHER NEARBY
PERSONNEL.

1.0 DESCRIPTION

1.1 EZRail is a comprehensive line of modular ignition wiring and coil-

mounting systems. EZRail systems are thoroughly tested to ensure
maximum reliability and performance. Operational and functional
benefits include:
• Extremely easy to install, just mount and connect components.
• Complete wiring and mounting system from the ignition unit
to the ignition coils. Eliminates hours of wire and conduit
cutting in the field. Guarantees against skinned insulation
due to long conduit pulls.
• Universal design takes advantage of standard cables, wiring
rails and integral/flange or off-mounted coils (shielded or
unshielded). Optional bolt-on coil mounting rails.
• Flexible and upgradeable. If coil types are changed, e.g.,
from unshielded to shielded or integral, the same wiring rail
can be used without modification. The same is true if the coil
mounting rail is added later.
• Premium construction materials include high-quality
aluminum extrusions, sealed junction boxes, military-
style connectors and harnesses and stainless
steel hardware. Connector back shells are
potted and strain-relieved, and external
surfaces are plated or anodized for corrosion
resistance.
• Standard Altronic ignition components,
including the primary and secondary cables
and leads, are incorporated into the design,
which allows for quick, cost-effective repair
and service in the field. In the unlikely event
that the rail itself requires service (or if
on-engine mechanical work is required), the EZRail
system can be easily disconnected, removed, and
re-installed.

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INSTALLATION INSTRUCTIONS

2.0 HIGH SPEED ENGINES (REFER TO DIAGRAM ON PAGE 3)

2.1 COMPONENTS NOTE: Standard rail compo-
A. EZRail (Wiring) Assembly – 593qab-xyzm – Anodized aluminum rail(s) nents are laid out for applica-
are available in custom lengths to suit specific applications; refer tions where lead “A” of the
to Form EZRail AL. Military-style connectors have potted backshells. ignition system connects to
Coil connectors are spaced to align with each engine cylinder. the first cylinder in the engine
B. Coil Mounting Assembly – 5805ab-xyz (Optional) – Anodized aluminum firing order through the rail
coil mounting rail(s) may be mounted directly to the EZRail or sepa- with the “A” suffix.
rately at the user’s option.
— If ignition lead “A” connects
C. Junction Box – 593axx-xxx, heavy-duty, corrosion resistant construc- to the first cylinder in the
tion, military-style connectors, a shutdown lead connector, and an
engine firing order, the rail
easily-accessible timing lead.
with suffix “A” mounts on that
D. Harnesses (all connectors sealed with epoxy potting)
bank of the engine.
Ignition to J-Box – 793101-L , one straight and one right-angle connector.
J-Box to Rail Assembly – 793101-L – one straight and one right-angle — If ignition lead “A” is con-
connector, or 793102-L, two right-angle connectors (use only up to 8 nected to a cylinder other
circuits per bank). than the first cylinder in the
Shutdown Lead – 593052-L, straight or 593057-L, right-angle connector. engine firing order, contact
the factory for further infor-
2.2 MOUNTING mation. A different memory
A. J-Box – Mount at either the no. 1 end or opposite end of the engine, chip for the ignition system
based on the J-Box part number that was ordered. Avoid loca-
(CPU-95) or a non-standard
tions that might cause exposure to excessive vibration or heat.
junction box may be required.
B. EZRail Assembly – Determine an appropriate mounting point. Avoid lo-
cations which might cause exposure to excessive vibration or heat.
C. Coil Mounting Assembly (Optional) – Determine appropriate mounting
point(s) and mount using included hardware. Coil rails may be NOTE: J-Box part number is
mounted directly to the EZRail Assembly.
specific to whether mounted
2.3 CONNECTIONS at the no. 1 end or the oppo-
A. J-Box to Ignition — Connect harness 793101-L to CPU-95 Ignition. site end of the engine — see
form EZRail AL.
B. J-Box to Rail
Connect harness 793101-L or 793102-L as appropriate.
C. Shutdown Lead — Connect cable 593052-L or 593057-L to the shut-
down lead connection. NOTE: Mount J-Box as close
NOTE: Pin A = Shutdown Lead, Pin B = #1 Coil Output (A), Pin C = Ground. to the appropriate end of the
D. Timing Lead — A #1 cylinder primary wire loop is accessible under engine as is practical using
the timing lead connector cover. Use with inductive timing light included or other suitable
on completely shielded systems. For timing light use on all cylin- hardware.
ders use Altronic Safe-T-Lead™.

NOTE: 19-pin connector end

of rail (for both banks of a V-
engine) must be installed at
the end of the engine clos-
est to the J-Box.

2 FORM EZRAIL II 6-08

 ALTRONIC EZRAIL MODULAR IGNITION RAIL SYSTEM

SYSTEM OVERVIEW FOR HIGH SPEED ENGINES

SHUTDOWN LEAD CABLE

HARNESS:
593052-L
593057-L
E C1 IGNITION TO J-BOX
793101-L

JUNCTION BOX
NOTE: IF THE SHUTDOWN LEAD CABLE B 593axx-xxx
IS NOT USED, ORDER A SCREW-ON CAP,
PART NUMBER 515021.

HARNESS:
J-BOX TO RAIL
HARNESS: C2 793101-L
J-BOX TO RAIL 793102-L
793101-L C2
793102-L

NOTE: MOUNT EZRAIL ASSEMBLY 593qab-xyzm

FOR BOTH BANKS WITH 19-PIN
CONNECTOR AT THE APPROPRIATE
END OF THE ENGINE.

H
COIL MOUNTING ASSEMBLY
5805ab-xyz

A
EZRAIL
ASSEMBLY
593qab-xyzm

A
EZRAIL
ASSEMBLY
593qab-xyzm

SPARK PLUG
F
COIL PRIMARY CABLE COIL
G SPARK PLUG LEAD CABLE

583017-60KT
593069-L

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INSTALLATION INSTRUCTIONS

3.0 INTEGRAL ENGINES (REFER TO DIAGRAM ON PAGE 5)

3.1 COMPONENTS
A. EZRail (Wiring) Assembly – 593qab-xyzm – Anodized aluminum rail(s)
are available in custom lengths to suit specific applications; refer
to Form EZRail AL. Military-style connectors have potted backshells.
Coil connectors are spaced to align with each engine cylinder. Due
to the length of the engine in some cases, two rails, with an inter-
NOTE: The 19-pin connector
connecting harness, are required for each bank of cylinders.
adjacent to the EZRail label
B. Coil Mounting Assembly – 5805ab-xyz (Optional) – Anodized aluminum
is the input connector. The
coil mounting rail(s) may be mounted directly to the EZRail or sepa-
rately at the user’s option. output connector is at the op-
posite end of the rail.
C. Junction Box – 593axx-xxx – The junction box features heavy-duty, cor-
rosion resistant construction, military-style connectors, a shut-
down lead connector, and an easily-accessible timing lead.
D. Harnesses (all connectors sealed with epoxy potting) NOTE: J-Box part number is
Ignition to J-Box – 793101-L, one straight and one right-angle connector. specific to whether mounted
J-Box to Rail Assembly – 793101-L, one straight and one right-angle at the no. 1 end or the oppo-
connector or 793102-L, two right-angle connectors (use only up to
site end of the engine — see
10 circuits per bank).
form EZRail AL.
Rail 1 to Rail 2 Assembly – 793102-L, two right-angle connectors.
Shutdown Lead – 593052-L, straight or 593057-L, right-angle connec-
tor or 593069-L (if the CPU-2000 Diagnostic Module is used).
NOTE: Mount J-Box as close
3.2 MOUNTING to the appropriate end of the
A. J-Box – Mount at either the no. 1 end or opposite end of the engine, engine as is practical using
based on the J-Box part number that was ordered. Avoid loca- included or other suitable
tions that might cause exposure to excessive vibration or heat.
hardware.
B. EZRail Assembly – Determine an appropriate mounting point. Avoid lo-
cations which might cause exposure to excessive vibration or heat.
C. Coil Mounting Assembly (Optional) – Determine appropriate mounting NOTE: 19-pin input connector
point(s) and mount using included hardware. Coil rails may be
mounted directly to the EZRail Assembly.
end of rail (for both banks of a
V-engine) must be installed at
3.3 CONNECTIONS the end of the engine closest
A. J-Box to Ignition — Connect harness 793101-L to CPU-2000 Ignition. to the J-Box.
B. J-Box to Rail
Connect harness 793101-L or 793102-L as appropriate.
C. Rail to Rail — Connect harness 793102-L from Rail 1 to Rail 2.
D. Shutdown Lead — Connect cable 593052-L or 593057-L to the shut-
down lead connection. If the CPU-2000 diagnostic module
291105-1 is used, connect cable 593069-L between it and the J-Box.
E. Timing Lead — A #1 cylinder primary wire loop is accessible under
the timing lead connector cover. Use with inductive timing light
on completely shielded systems. For timing light use on all cylin-
ders use Altronic Safe-T-Lead™.

4.0 HAZARDOUS AREA CERTIFICATION

CSA CERTIFIED, Class I, Div. 2, Groups C & D

4 FORM EZRAIL II 6-08

 ALTRONIC EZRAIL MODULAR IGNITION RAIL SYSTEM

SYSTEM OVERVIEW FOR INTEGRAL ENGINES

CPU-2000 CPU-2000
DIAGNOSTIC OUTPUT
MODULE MODULE

HARNESS:
C1 IGNITION TO J-BOX
793101-L

JUNCTION BOX
B 593axx-xxx
SHUTDOWN LEAD CABLE
593069-L E
Note: If Diagnostic Module is
not used, use cable 593052-L
or 593057-L

HARNESS: HARNESS:
J-BOX TO RAIL J-BOX TO RAIL
793101-L C2 C2 793101-L
793102-L 793102-L

EZRAIL EZRAIL
ASSEMBLY A A ASSEMBLY
593qab-xyzm 593qab-xyzm

HARNESS:
C3 RAIL 1 TO RAIL 2
793102-L

EZRAIL EZRAIL
ASSEMBLY A A ASSEMBLY
593qab-xyzm 593qab-xyzm

NOTE: ALL CPU-2000 RAILS HAVE NOTE: ALL CPU-2000 RAILS HAVE
A 19-PIN CONNECTOR ON A 19-PIN CONNECTOR ON
EACH END. A SCREW-ON CAP EACH END. A SCREW-ON CAP
IS REQUIRED AT THE END OF IS REQUIRED AT THE END OF
EACH BANK, PART NUMBER EACH BANK, PART NUMBER
515013. 515013.

SPARK PLUG

G
SPARK PLUG LEAD CABLE
COIL PRIMARY CABLE F F COIL PRIMARY CABLE
583017-60KT
593069-L
H 583017-60KT
593069-L
COIL MOUNTING ASSEMBLY
5805ab-xyz

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INSTALLATION INSTRUCTIONS

FIGURE 2 — DIMENSIONS: J-BOX

6 FORM EZRAIL II 6-08

 ALTRONIC EZRAIL MODULAR IGNITION RAIL SYSTEM

FIGURE 3 — DIMENSIONS: EZRAIL

FIGURE 3.5 — DIMENSIONS: EZRAIL BRACKET (515010)

1. The EZRail Bracket (515010), pictured,

includes 3 washers, 3 carriage bolts and 3
locking nuts.
2. If a coil rail is ordered, 2 carriage bolts, 2
washers and 2 locking nuts are supplied for
each of the appropriate number of coils.
3. Additional carriage bolts, washers and
locking nuts (2 of each) are avaialble by
ordering the hardware kit (515015).

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INSTALLATION INSTRUCTIONS

NUMBER OF MOUNTING KITS PER RAIL

Eng. Cylinders 2 3 4 5 6 8 10 12
1 coil per cyl. 2 2 3 3 4 5 6 6
2 coils per cyl. 3 4 5 6

LAYOUT WITH ONE COIL PER CYLINDER

1 2 3
x x

1 2 3 4
x x x

1 2 3 4 5
x x x

1 2 3 4 5 6
x x x x

1 2 3 4 5 6 7 8
x x x x x

1 2 3 4 5 6 7 8 9 10
x x x x x x

1 2 3 4 5 6 7 8 9 10 11 12
x x x x x x

LAYOUT WITH TWO COILS PER CYLINDER

1 1 2 2
x x x

1 1 2 2 3 3
x x x x

1 1 2 2 3 3 4 4
x x x x x

1 1 2 2 3 3 4 4 5 5
x x x x x x

x = Mounting bracket between Primary Wiring Rail and Coil Mounting Rail

8 FORM EZRAIL II 6-08