Service Manual - Altronic, LLC
Contents
1. 165 345 7 27 0 30 8J63H 2250 CCW ESES 0 180 8L63H 1350 CCW 3 3 TIMING SPECIFICATIONS continued 550 8B35H 2700 550 8G49H 1100 X I Ss es ks 22 r r lziziziz N fei NININ lt NPSL NSO MI lt lt lt lt lt lt lt lt 00 4 lt 00 00 00 oo 00 oo SM 3 11 All rights reserved ALTRONIC LLC 2011 IC altron HOERBIGER Engine Solutions Kach MIN LO lt e N DC 092 orz oz 092 ovt ozt 0921 9292 081 928 9292 081 seg 9292 081 928 008 HEI 962 Ove 99 962 ss 0081 192 081 192 8 192 081 18 moo oost HEENMZI 992 081 992 GL 992 081 SZ moo 0922 HEI 9262 081 S762 Seil gz6z 081 sen oost HSEHZI zee 008 9 2 9212 081 9 6 GE Moo 08 HITOZI g vz 081 979 9172 081 99 9172 081 979 moo 0081 09 922 0 2 021 928 oee 9262 ost wen ooze2. 998 OVC 9006 06 9 29 008 9292 OST 0 0922 9 ost set SIE 081 Gel SIE 081 set 012 05 oogt Hezazt 008 982 991 SOT 006 292 081 292 9 oset HStGzI otz ose 012 OEE oooz Here 922 081 97 081 sv 922 Gy moo 0081 HEE8ZI moo 006 1 N m N N N F Ove O8T 081 081 GL Ove 00 Ove Ove 2744 CD 081 081 081 Ove 081 Ove STE 008 992 961 OST GET SI Foe oar oe 6 oe os o oz oer 06 o wee seve LL LE pez esr ora ost os fore oer os o wea coe Leer LEE bez esr o ost fore oar os o moo oo sve 00 Orc 081 021 09 0 00 Orc 081 OZI 09 109 0081 HIcVcI 058 008 042 Otz OTZ 081 OST 021 06 09 M 006 SXTIIVCI Gee 081 GEC 081 GEC 081 SEC 081 SEZ 081 ___ IS S se ose o 681 081 681 081 681 081 681 081 681 081 LLL ISUS S ok S ue ro 982 eve ver 66 zz zz moo 006 ve VE ve ve ve 961 081 961 081 961 081 961 081 96 081 L LER epee ree ere i Hug
3. NOILVLOY Wdu 1531 ON INITdNOD BEEN DELE METERS penunuo2 SNOILV2I3I93dS SNIIALL Alll SM 3 11 el e N el a lt E 6 gt 0 2 cm 20 E 3 3 TIMING SPECIFICATIONS continued Di H H GG c5 Lil e z H e e z nu COUPLING COUPLING TEST RPM ROTATION lt TOLERANCE 2 3 2 2 3 3 3 2 2 3 2 3 4 3 T mE mE pp __ f i 60 90 150 180 240 270 330 o 60 90 150 180 240 270 330 120 180 210 270 soo o so 120 180 210 270 300 To so 180 228 270 90 180 228 270 318 o 81 135 216 270 351 45 126 180 261 315 36 90 171 225 306 90 180 180 270 2 o 90 90 180 180 270 270 16P21H 1500 o 60 90 150 180 240 270 330 60 90 150 180 240 270 330 16P31H 2250 cw o 90 135 225 270 o 45 135 180 270 315 45 90 180 225 315 16T21H 1200 o 30 90 120 180 210 270 s00 90 120 180 210 270 300 16731 2700 o 45 135 180 270 315 45 90 180 225 315 90 135 225 270 16v43H 2000 o 1
4. 15 902520 Drive pin Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 REF NO PART NO DESCRIPTION 16 310460 Drive gear 4 1 310518 Drive gear 1 5 1 510357 Drive gear 2 1 510359 Drive gear 3 1 510447 Drive gear 2 5 1 510476 Drive gear 1 1 17 501212 Wire clamp 18 901326 Washer 8 19 310408 Wire guide 16 cyl 310473 Wire guide 2 12 cyl 20 902465 Screw 8 32 21 902500 22 900423 Lockwasher 6 23 310461 Driven gear 4 1 310519 Driven gear 1 5 1 510358 Driven gear 2 1 510360 510446 Driven gear 2 5 1 510477 Driven gear 1 1 24 See Pgs 8 10 Timer arm 25 310371 Bearing shaft 26 902448 Screw 8 32 27 302106 Timing label shaft 302127 Timing label S1 unit 302128 Timing label S2 unit 28 See Pgs 8 10 Magnet plate ass y 29 310392 Gasket 30 310378 Spacer 31 351001 Pickup coil BLACK 351002 Pickup coil WHITE 351003 Pickup coil WHITE 16 cyl Screw 6 32 Driven gear 3 1 32 900944 Lockwasher 8 33 901679 Nut 8 32 34 902472 Screw 10 24 35 302094 Timing label cover 36 310365 Cover plate 37 902064 Screw 6 32 38 350001 2 Core ass y pickup CHART CONTINUES ON NEXT PAGE 2 1 PARTS LIST continued See exploded view page 4 39 Receptacle 40 902540 Screw 1 4 20 41 Washer 42 Washer 43 Screw 8 32 47 Lockwasher 10 48 902601 Screw 10 24 50 Brace 51 Circuit board ass y 519 Socket 54 Connector ass y 3 leads Connector ass y 6 leads 55 501335 Gas
5. UNIT NO STATOR BACK COVER CIRCUIT BOARD TIMER ARM MAGNET PLATE 12A25H 371604 381804 2H 373212H 370005 360406 Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 2 4 UNIT SPECIFICATIONS continued 10 51 24 28 UNIT NO STATOR BACK COVER CIRCUIT BOARD TIMER ARM MAGNET PLATE 124315 370005 360406 12A33H 360406 12A35H 360406 Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 2 5 CIRCUIT BOARD ASSEMBLY 51 373xxxH replaces all prior types 372404 37250 372604 37266x 37270x 37277x 37280x and 3729xxH To insure use of the proper part number circuit board refer to the discontinued part no list on page 7 and then the listing of current units on pages 8 10 B It is recommended that all prior types of circuit boards be returned to the factory for exchange to type 373xxxH whenever a unit is being serviced C IMPORTANT NOTE When replacing former 12 output circuit boards with SINGLE storage capacitors with type 373212H the note regarding recalibration of ignition powered tachometers and or overspeed devices must accompany the unit to the end user If the tachometer and or overspeed device is not recalibrated the new circuit board will cause incorrect one half readings this condition could lead to improper engine operation and pose the threat of personal injury to operators or other nearby personnel 2 6 CONNECTION SPE
6. 2 through resistor R3 to the gate of 1 1 then turns on discharging capacitor C1 into the primary of the ignition coil which steps up the voltage to fire the spark plug Components Q1 and Q2 insure that TC1 turns off immediately after each discharge Capacitors C2 and C3 act as filters to prevent crossfiring between cylinders DUTPUT CONNECTOR A B C TU SPARK PLUG COIL C Components Cl Capacitor energy storage Ql Transistor isolator C2 Capacitor trigger circuit Q2 Transistor C3 Capacitor TRIAC gate R1 Resistor trigger circuit D1 Diode trigger circuit R4 Resistor SCR gate D2 Diode power SCR1 P R2 R3 Pickup coil ass y D3 Diode recirculating TC TRIAC FWR Full wave rectifier Z1 Zener diode regulating Z2 Zener diode 51V Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 4 2 TROUBLESHOOTING GUIDE A See Section 3 0 3 3 for proper electrical performance B The checks below should be made with a Simpson model 260 volt ohmmeter or equivalent A Connector pin refers to the connector into which the wiring harness is plugged Circuit board pin connection refers to the solid pins on the circuit board see page 18 B The 373xxxH 3729xxH and 37280x series circuit boards require a different test hook up for tests 1b and 2b below they will always test defective if checked in accordance with prior Troubleshoot
7. 2A29H 2 8A29 8A29H 10E56 10E55H 4 28 4A29H 8A30 8A30H 8A39H 2 10H11 10H11H 4A29 4A29H 8A33 8A33H 8A37H 10P56 10P55H 4F28 4F29H 8A35 8A35H 8A39H 12A23 12A23H 4F29 4F29H 8A38 8A39H 12A24 12A25H 1 4G28 4G29H 8A39 8A39H 12A25 12A25H 1 4G29 4G29H 8B13 8B13H 12A31H 12A33H 2 5A58 5A59H 8B20 8B25H 2 12A33 12A33H 5A59 5A59H 8B24 8B25H 12A34 12A33H 1 2 6A12XS 6A17XS 2 8B25 8B25H 12A34D 12A33H 2 6A13 6A17H 8B26 8B25H 12A35 12A33H 1 2 6 14 6 17 2 8B28 8B29H 12B11 12B11H 6A27 6A27H 6A29H 2 8B29 8B29H 12C43H 12C45H 2 6A28 6A29H 8B35 8B35H 12D34 12D35H 1 6A29 6A29H 8C24 8C25H 12D35 12D35H 1 6 325 6 375 2 8C26 8C25H 12D36H 12D35H 6A37 6A37H 6A39H 2 8bE29 8E29H 12E13 12E11H 2 6A38 6A39H 8E49 8E49H 12E23 12E23H 6A39 6A39H 8F24 8F25H 12E53 12E53H 6B38 6B39H 8F26 8F25H 12G13 12G11H 2 6B39 6B39H 8G28 8G29H 12H34 12H35H 6C38 6C39H 8G29 8G29H 12H35 12H35H 6C39 6C39H 8G49 8G49H 12H36 12H35H 6F38 6F39H 8H28 8H29H 12P23 12P21H 2 6F39 6F39H 8H29 8H29H 12P34 12P35H 6P38 6P39H 8P28 8P29H 12P35 12P35H 6P39 6P39H 8P29 8P29H 12P36 12P35H 6713 6Z13H 8P49 8P49H 12V43H 12V45H 2 7A33 7A33H 7A37H 8725 8T25H 12723 12721 2 7A35 7A35H 7A39H 9A33 9A33H 9A37H 16B23 16B21H 2 8 11 8A11H 9A35 9A35H 9A39H 16G23 16G23H 8A13 8A11H 2 10A13 10A11H 2 16T23 16T21H 2 8A228 8A278 2 10A14 10A11H 2 16T32H 16T31H 2 8A24 8A25H 10A54 10A53H 1 2 1 Unit changes to dual capacitor type 2 Replacement unit requ
8. 80 260 180 260 180 260 180 260 1ewai 2250 cw o 105 135 240 270 15 45 150 180 285 315 90 195 225 330 o 40 120 160 240 280 40 120 160 240 280 12VA5H 2000 140 240 20 120 260 o 140 240 20 120 260 12721 1800 Con 16B21H 1200 ccw 16F21H 1800 ccw 16633 1350 2700 cow 16K33H 1500 16M21H 1800 Con UNIT NO 16C33 16G23 16J31 Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions altronic HOERBIGER Engine Solutions 4 0 TROUBLESHOOTING 4 1 CIRCUIT DIAGRAM A The diagram below shows the 1 circuit for one cylinder Each component in the Timing Distribution section to the right of the dashed line Is present In a quantity equal to the number of cylinders being served each engine cylinder requires a pick up coil assembly and TRIAC TC1 B The operation is as follows The AC voltage generated by the alternator is converted to DC by the full wave rectifier FWR and stored In the energy storage capacitor C1 The DC voltage level is regulated by a zener diode regulation circuit Z1 and Q2 Capacitor C2 is charged through resistor R1 to provide the energy to trigger TC1 This occurs when the rotating distributor arm passes a pickup coil P triggering on SCR 1 and connecting capacitor C
9. B for one hour C After the one hour Operating Test check timing per section 3 3 Alll SM 3 11 All rights reserved ALTRONIC LLC 2011
10. CIFICATIONS A Wiring Color Code Connector 51c 3 to 12 Cylinders 16 Cylinders G orange G orange N black all others all others white all others all others white B Connection Sequence Pickup Coils 31 A pickup coil is indicated in RED B C D etc follow consecutively in CW direction from A 2 7 BEARING FIT TOLERANCES A Housing Bearing Front Housing 6 Intermediate Housing 13 Back Cover 58 1 5737 1 5739 1 865 1 867 1 1800 1 1803 B Shaft Bearing Diameter Drive Shaft 7 6693 6696 3 0 PERFORMANCE SPECIFICATIONS Install unit on a test stand equipped with a suitable number of 501061 coils and spark gaps Test stand wiring should conform to that shown in the Installation Instructions form II 3 1 VOLTAGE TEST A With the wiring harness unplugged measure the positive voltage at the connector G pin VOLTAGE OUTPUT 60 VDC min 200 220 VDC CIRCUIT BOARD NO Any UNIT SPEED Any 3 2 OPERATING TEST A At 70 90 RPM a 7mm gap should fire consistently B At the TEST RPM see pages 12 15 a 15mm gap should fire consistently 3 3 TIMING SPECIFICATIONS A The Altronic III units are listed on pages 12 15 Establish the indicated TEST RPM and ROTATION B Check the Firing Degree Sequence as indicated The basic tolerance Is one 1 distributor degree This must be multiplied by the internal gear ratio since the degrees
11. ILS PIN 1 C Circuit Board Pin Connections viewed from pickup coil side of board 2 12 CYL O O O O O O O O O Pickup L J H E A B D M Pickup Common Common 16 CYL O O O O O O O O O O Pickup S P M K H E A Gd B D F J L N R T Pickup Common Common NOTE Crimping tool for receptacle 39 is American Pamcor Inc Part No 90204 1 Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 5 2 PICKUP COIL 31 REPLACEMENT A To change a pickup coil 31 first remove the nuts 33 screws 26 and magnet plate 28 Mark spacers 30 so that they can be reinstalled in the same position during reassembly B Cut the red and brown or black leads at the coil to be removed Install new pickup coil with the end having the black line facing up Solder the brown wire to the common lead and splice the red wire into the original line leading to the wire guide and receptacle Use heat shrinkable tubing over the spliced red wire connection be sure that no connections touch ground NOTE Do not mix black 351001 and white 351002 pickup coils in the same back cover always replace with the same color that was removed C Reassemble spacers 30 and magnet plate 28 using hardware 26 32 and 33 BEARING 25 TOOL NO 506 101A BEARING 25 WK TOOL NO 506 101C FIG 3 Alll SM 3 11 All ri
12. JINJNDAS INIYIJ SNOILVOISIDAdS Alll SM 3 11 re e ail a lt E 6 gt 0 2 cm 20 E altronic HOERBIGER Engine Solutions TA TA 0 lt NINI DINI NPE lt lt QN 5 lt m i wed 0 5 45 D OR S E 5 lu E O 5 N CN SX 55 N NN AN N 5 e Lu 180 90 0 180 45 75 225 255 90 315 120 342 16 270 300 E 270 90 0 180 0 180 270 45 90 270 0 180 180 270 135 315 135 90 13 72 252 90 270 0 180 120 240 120 240 120 eso CCW CCW Both CCW CCW Both CCW CCW cw o 120 180 soo o 120 180 300 J o 45 135 225 315 90 180 270 2250 oz EE ae DE oo oc Te 55 Ow Or o o ojojo o 09 1200 60 90 150 180 240 270 30 1200 120 180 120 180 soo 3000 cow 2250 620 loalixs 900 cw o 36 72 108 144 180 216 252 288 324 CONECRESRESEIESESESEIESEIES ETIN INR 180 270 180 270 180 270 180 270 180 270 90 270 400 800 sian 400 cw 135 15 iss ieo ss
13. Service Manual Altronic Ignition System Units with 373XXXH Series Circuit Boards Medium Engines 2 16 Cylinders Form ALT SM 3 11 altronic HOERBIGER Engine Solutions altronic HOERBIGER Engine Solutions TABLE OF CONTENTS SEULS AT IE IMPORTANT SAFETY NOTICE 1 0 3 PROPER INSTALLATION MAINTENANCE 2 0 PARTS IDENTIFICATION AND SPECIFICATION 4 Ne 2 1 Parts List Alternator 5 6 ED PRACTICES CONTAINED HEREIN 22 Part Number Designation 6 SHOULD BE FOLLOWED WITHOUT DEVIA 2 Discontin ediPart Numbers 7 TION AN IMPROPERLY INSTALLED OR OPERATING IGNITION SYSTEM COULD 2 3B Caterpillar OEM Part Numbers 8 CAUSE PERSONAL INJURY TO OPERA 24 Unit Specifications 8 10 TORS OR OTHER NEARBY PERSONNEL 2 5 Circuit Board Assembly 11 2 6 Connector Specifications 11 2 7 Bearing Fit Tolerances 11 3 0 PERFORMANCE SPECIFICATIONS 11 3 1 Voltage Test 11 3 2 Operating Test 11 33 Timing Specifications 11 15 4 0 TROUBLESHOOTING 16 4 1 Circuit Diagram 16 4 2 Troubleshooting Guide 17 4 3 Oscilloscope Tests 18 5 0 SERVICE BACK COVER ASSEMBLY 19 5 1 Circuit Board Assembly Replacement 19 5 2 Pickup Coil Replacement 20 5 3 Bearing Timer Arm Driven Gear Replacement 21 6 0 SERVICE ALTERNATOR SECTION 22 6 1 Disassembly Coupling 22 6 2 Disassembly Flange Mount Unit 22 6 3 Disassembly Stator 22 6 4 Disassembly Bearings 22 6 5 Parts Replacement 23 6 6 Reassembly Fro
14. are read at the unit drive shaft speed C If timing is out of specification change the pickup coil 31 in question Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 IC altron HOERBIGER Engine Solutions iain N s LO EW e lt NINI AN I ER HER 042 081 06 0 012 081 06 0 109 0081 H CV ste ozz 922 081 set Sv 006 gte ozz 922 081 set Gy 0081 HIIVS 902 IS Z8c 201 YSI 0091 HGCH 90 196 201 M99 000 HZEVZ ove 091 Ov woo oost 29 28 SE H6Ed9 Co gag 081 9 98 9 98 9 98 m 1 1 MO oset 9 no f oo 60 60 o8z DCH 9990 081 0 081 0 Gell 06 0 06 0 06 0 1 o 006 sxs fost o9 o wes Unie OST 081 081 OST 081 Poet of mo os vez o mo 00 1 wo oot __ _____________ o ooz ve LIT o jost o wes oost oos foj os neve NEN NN C V NOIJVIOM 1531 ON 9NITdf02 S334930
15. ark CCW or CW on the cover just as the leading edge of the trigger arm reaches the hole in the steel plate for A red pickup coil For FLANGE MOUNT UNITS mate the back cover to the alternator with both set as shown in FIG 8 for the correct unit rotation If the back cover mark does not line up exactly with the proper rotation mark with the coupling set as shown rotate the alternator shaft 180 and try again Obtain as close of a line up as possible with the CCW or CW mark Secure the back cover assembly to the alternator section with hardware 34 and 47 CCW ROTATION CW ROTATION BACK COVER TIMING INDICATOR Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 7 0 SERVICE ASSEMBLY TOOLS A The following assembly tools are referenced in sections 5 3 6 6 and 6 9 506101A Press bearing shaft 25 into back cover 58 506101C Support back cover 58 506104D Press timer arm assembly 24 on bearing shaft 25 506104E Support bearing shaft 25 506105A Press bearing 6 into front housing 5 506105B Support front housing 5 including ring 506104A Press shaft rotor 7 into front housing 5 506104D Press gear end bearing 6 on shaft rotor 7 506104C Support front housing bearing 6 506108A Drive coupling pin 1a or 2a off and on 8 0 OPERATIONAL TEST A Perform the tests following the guidelines in sections 3 0 through 3 3 B Run the Operating Test in section 3 2
16. diate housing see steps 6 3B and 6 3C and repeat steps 6 7B and 6 7C Insert stator leads in clamp 17 NOTE If clamp 17 has pulled loose from housing 13 use silicon rubber adhesive 503151 to secure clamp to housing Install a stator seal band 10a from the coupling end The band should seat against the stator 10 between housings 5 and 13 TOOL NO 506 104D 506 104A BEARING 6 SHAFT ROTOR SPACER 8 HOUSING 5 TOOL NO TOOL NO 506 1046 506 104C HOUSING 5 Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 6 8 FLANGE MOUNT UNIT A B Replace oil seals 3a in flange bracket 3 Place new gasket 4 on housing 5 Install flange bracket 3 to housing 5 and insert four new screws 11 DO NOT REUSE OLD SCREWS Note whether nameplate on unit calls for a flange to be mounted vertically with tapped hole up A or GV or horizontally D or G Tighten screws 11 to 10 12 ft lbs Glue a new flange gasket 3b to the unit flange 6 9 COUPLING A B Install coupling 1 or 2 on shaft 7 lining up holes in coupling and shaft Use tool no 506108A to drive spring pin 1 or 2a through coupling and shaft until flush with the coupling O D 6 10 REASSEMBLY BACK COVER TO ALTERNATOR A B The timing mark on the back cover should line up with the stationary rotation m
17. e outer race of the bearing using tool 506105A Referring to FIG 7a press the shaft rotor assembly 7 into the front housing assembly 5 Use tool no 5061044 to press on the end of the shaft and tool no 506104C to support the inner race of the bearing This will insure the correct extension of the shaft through the bearing see FIG 7a Install bearing spacer 8 on shaft see FIG 7b Press gear end bearing 6 on shaft 7 until it bottoms against the bearing spacer 8 Referring to FIG 7b leave tool no 506104C step 6 6B in place to support the coupling end of the shaft Press on the inner race of the bearing for this operation using tool no 506104D Install a new rubber bearing cover 9 on gear end bearing 6 Using a new lockwasher 32 and flat washer 18 install drive gear 16 if worn use a new gear Secure with screw 20 If the 360405 housing BEL has been disassembled use a lubricating grease on the mating surfaces and reinstall the large snap ring with its gap at the 3 o clock position 90 from the base TOOL NO 506105A 6 TOOL NO 506105B FIG 6 Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 6 7 REASSEMBLY ALTERNATOR A Insert one 10 24 x 2 1 4 screw 48 through the stator hole 180 from the stator leads and plug Place stator 10 over rotor 7 so that the leads are on the same side as the flat base on housing 5 U
18. ghts reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 5 3 BEARING 25 TIMER ARM 24 DRIVEN GEAR 23 REPLACEMENT A B m The procedures of this section require the use of a small arbor press Remove timing cover 36 and driven gear 23 Referring to FIG 2 support upper pickup plate 28 on both sides of timer arm 24 and press timing mark end of distributor shaft 25 until bearing is pressed out of timing cover housing Press bearing shaft 25 out of aluminum hub of timer arm assembly 24 Replace any warn or defective parts Press a new bearing shaft 25 into the back cover housing until it bottoms Referring to FIG 3 the cover should be supported around the timing access hole using tool no 506101C Press on the outer race of the bearing with tool no 506101A Thoroughly clean all filings dirt etc from the top exposed face of magnet 28 Also clean the surface of pickup arm assembly 24 that will come in close proximity to the magnet Support the end of the shaft 25 using tool no 506104D until the gap between the pickup arm and the pickup coil cores is 010 018 see FIG 4 At this point the timer arm 24 MUST ROTATE FREELY the full 360 degrees of rotation If there is any interference the bearing shaft assembly must be removed from the cover see step 5 3C and steps 5 3D through 5 3H must be repeated until the pickup arm rotates freely with a gap not e
19. ing Guides POSITIVE NEGATIVE REMEDY FOR OHMMETER OHMMETER FAULTY PROBLEM LEAD LEAD READING READING 1 One output Check corresponding circuit Correct connection not firing board pin connection Pickup coil common s see page 20 2 8 12 cylinders No output on Connector pin of output not firing RA 10 000 Move timer arm past pickup coil corresponding to test pin Meter should flicker indicating pickup output If above checks are okay Check circuit board pin connections pickup Replace pickup coil 31 Replace circuit board ass y 51 Correct connection every other output common s OR 4 6 cylinders Pin 1 and 2 Slight flicker in meter with Replace correspond No output but G see page 20 final reading loower than ing pickup coil 31 lead has 100 500 X 10 000 5 megohm volts If above checks are okay Replace circuit board ass y 51 3 Weak or no output a Stator Across 250VAC Spin alternoator coupling Replace stator 10 2 prong stator 75 VAC plug terminals b Stator Across R X 10 000 Infinite Replace stator 10 both stator terminals C Circuit Board Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 If above checks are okay Replace circuit board ass y 51 altronic HOERBIGER Engine Solutions 4 3 OSCILLOSCOPE TESTING The system should be fully connected per section 3 0 with the Altronic unit operating at the TEST RPM given i
20. ires different stator winding Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 2 3B CATERPILLAR OEM PART NUMBERS Follow specification for equivalent value CAT OEM NO EQUIVALENT CAT OEM NO EQUIVALENT CAT OEM NO EQUIVALENT 104 4510 6A39HT A 328 8383 4A39H A 7C 0753 16B21H A 104 4511 6A29HT AO 328 8385 6A39H A 7C 8882 16V43HT J S2 104 4512 8A23HT GO 328 8386 6A39HT A 7E 6215 12V43HT J S2 104 4513 12P21HT GO 4P 8903 12P21H GO 7E 8245 6A46HT J S1 2W 3741 8T25H A 4P 8904 8A23H GO 7E 8246 8A45HT J S1 2W 3743 8A25H G 4P 8905 6A29H GO 7W 2171 12A23HT J 2W 3746 4A29H A 4W 8946 12A33H A 7W 2172 16T21HT J 2W 3749 6A39H A 61 2310 4A39H A 2 4 UNIT SPECIFICATIONS See page 6 to determine mounting gear ratio and stator winding from unit part number Check discontinued part no list on page 6 for numbers not listed ALWAYS USE THE PART LISTED DO NOT SUBSTITUTE NOTES 1 3818XX XH back cover replaces prior type 3814XX X Example 381803 1 H replaces 381403 1 2 For unit with electronic timing option add T suffix to Back Cover part number Example For 8A29HT Back Cover no Is 381803 1 HT 10 51 24 28 UNIT NO STATOR BACK COVER CIRCUIT BOARD TIMER ARM MAGNET PLATE 7A37H 371602 381810 4H 373109H 370005 360442 Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 2 4 UNIT SPECIFICATIONS continued 10 51 24 28
21. ket MOUNTING i OPTIONS STATOR WINDING 2 2 PART NO DESIGNATION 8A29HT BEL LL GEAR RATIO A Even Firing Pattern Other Letters Odd Firing Pattern FIRING PATTERN NO CYLINDERS Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 56 Screw 4 40 57 Lockwasher 4 58 Cover casting 8 12 cyl Cover casting 2 6 cyl Cover casting 8 12 cyl Cover casting 2 6 cyl Cover casting 16 cyl Cover casting 16 cyl 59 Blanking screw Binder post 902736 O ring Parts for units with electronic timing option Vertical flange 1 slot Adjustable base D Flange 3 pilot Base mount Horizontal flange 2 slots GL Horizontal flange flex coupling Horizontal flange gear flex coupling Vertical flange 2 slots Round flange 3 slots 1 High output unit S Extra high output unit T Electronic timing HH ano es or N Oo o 5 00 371602 LO JO Om G r N o P 2 3 4 5 6 7 8 9 10 12 16 altronic HOERBIGER Engine Solutions 2 3A DISCOUNTINUED PART NUMBERS Follow specification for replacement unit DISCOUNTINUED REPLACEMENT DISCOUNTINUED REPLACEMENT DISCOUNTINUED REPLACEMENT 2A10H 2A19H 2 8A25 8A25H 10A55 10A53H 1 2 2A20 2A20H 2A29H 2 8A26 8A25H 10A56 10A53H 2 3A20 3A29H 2 8A28 8A29H 10D56 10D55H 4A20
22. n section 3 2 Connect the oscilloscope probe to the G lead of the output connector Set the oscilloscope vertical calibration to 50 volts div adjust the time base to get a full cycle of firings on the screen No of discharges number of outputs for single capacitor unit half the number of outputs for dual capacitor unit A STORAGE CAPACITOR PATTERN NORMAL The normal patterns for typical single 8A29H and dual storage capacitor 12A33H units are shown below NOTE Patterns below apply to units having 373xxxH circuit board assembly 200 100 B STORAGE CAPACITOR PATTERN ABNORMAL One cylinder misfiring See troubleshooting section 4 2 no 1 200 100 OV C STORAGE CAPACITOR PATTERN NORMAL Stepped waveform See troubleshooting section 4 2 no 3 200V 200V 100V 100 OV OV Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 5 0 SERVICE BACK COVER ASSEMBLY The unit breaks down into two major parts the Alternator Section and the Back Cover Assembly Remove the four back cover attaching screws 34 and carefully pull the back co
23. ns 2 0 PARTS IDENTIFICATION AND SPECIFICATION Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 21 PARTS LIST See exploded view page 4 altronic HOERBIGER Engine Solutions Reference numbers with a letter suffix are part of an assembly of the same number without a suffix Example 1a is part of 1 REF NO PART NO DESCRIPTION 1 510454 P Coupling BLACK 510454 U Coupling YELLOW la 902478 Spring pin 2 1 8 lg 2 560002 Flex coupling w pin 2 1 560006 Gear coupling w pin 2a 902475 Spring pin 1 1 8 lg 3 310418 2 Flange GN GVN 360465 1 Flange ass y 360465 2 Flange G GV 360465 3 Flange ass y D 360465 4 Flange ass y 360465 5 Flange ass y GO 360466 Flange ass y J 3a 510463 Oil seal 3b 510560 Gasket mounting 310490 Gasket 5 360401 F Front housing flange 360401 Front housing EL 360405 Front housing BEL 5a 310414 Shield 5b 902543 Screw 5 16 18 5c 901010 Lockwasher 5 16 5d 901347 Washer 5 16 5e 902554 Washer 510452 Bearing 7 360402 Shaft rotor ass y 360404 Shaft rotor ass y X unit 8 310466 Spacer bearing 9 510459 Cover bearing 10 See Pgs 8 10 Stator 10a 310421 Seal band stator 11 902484 Screw 1 4 20 12 902541 Screw 8 32 13 310355 12 Intermediate housing 13a 510550 Ventilator screen 510550A Ventilator 6 hole 14 302093 Nameplate
24. nt Housing Assembly 23 6 7 Reassembly Alternator 24 6 8 Reassembly Flange Mount Unit 25 6 9 Reassembly Coupling 25 6 10 Reassembly Back Cover to Alternator 25 7 0 26 8 0 OPERATIONAL TEST 26 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 1 0 ALTRONIC III IGNITION SYSTEM DESCRIPTION Altronic III is an alternator powered electronic ignition system All electronic parts are mounted to the back cover which disconnects from the alternator section as a module The alternator A provides the power to charge the energy storage capacitor B A separate pickup coil C and SCR D are used for each of the system s outputs which usually correspond to each engine cylinder A rotating timer arm E driven through speed reducing gears passes over the pickup coils to trigger the SCR switches to the on state in sequence This releases the capacitor s stored energy to the ignition coils which step up the voltage to fire the spark plugs SENE o 22272 A r ci ee Ua 4 77 CR CR 85777 2772 A W CROSS SECTIONAL VIEW ALTRONIC UNIT A Alternator B Energy Storage Capacitor C Pickup Coil D SCR Electronic Switch E Timer Arm F Distribution Gears Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutio
25. ring cover 9 D Pull stator winding 10 and seal band 10a free from housing 5 taking care not to damage Teflon wrapping 6 4 DISASSEMBLY BEARINGS 6 A Remove drive gear 16 then reinstall screw 20 in shaft B Remove rubber bearing cover 9 Use small bearing puller to remove gear end bearing 6 C Referring to FIG 5 support front housing 5 on the stator end Using an arbor press press on drive end of the main shaft until shaft assembly 7 is free from the front housing 5 D Press the drive end bearing 6 from either housing 5 or shaft 7 SHAFT ROTOR e 7 SUPPORT SUPPORT BLOCK 7 BLOCK 77777777777 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 6 5 PARTS REPLACEMENT A m co ou Replace gaskets 3b and 4 Replace coupling 1 or 2 seal 3a bearings 6 and bearing cover 9 with new parts Replace any removed hardware with new parts Aluminum housings should be cleaned in carbon tetrachloride or similar cleaning solution Any metal filings should be cleaned from magnet rotor 7 before reassembly 6 6 REASSEMBLY FRONT HOUSING ASSEMBLY A gum Press new drive end bearing 6 into front housing 5 until it bottoms Referring to FIG 6 support the housing with tool 506105B use the loose ring provided EXCEPT with adjustable base housing 360405 Press on th
26. se the screw to line up the stator holes properly with the tapped holes in the housing 5 Insert stator into front housing taking care not to damage the Teflon wrapping or the windings Remove screw NOTE Stator 371604 replaces previous types 371004 and 371007 The hole in housing 13 for the stator leads must be enlarged to 750 diameter in units below S N 12 000 Apply a film of Vaseline or similar lubricant to the bearing bore in intermediate housing 13 THIS IS ESSENTIAL FOR PROPER ASSEMBLY Insert the stator plug and leads through the 750 dia hole in housing 13 and start the housing over bearing cover 9 Insert three new HEX SOCKET HEAD SCREWS 48 DO NOT REUSE THE OLD SCREWS and lockwashers 47 through housing 13 and stator 10 into the tapped holes in the front housing 5 Apply pressure evenly to bring housings 13 and 5 together over the stator Take care not to damage the Teflon wrapping on the stator core Using a torque wrench tighten the three screws 48 evenly in several steps to a final torque of 78 in Ibs 6 5 ft Ibs NOTE This torque specification applies only to the hex socket head screws part no 902601 These should be used on all overhauls replacing the former filister head slotted screw At this point the shaft should turn freely without mechanical drag If there is mechanical interference not to be confused with the magnetic drag of the 12 pole alternator remove the interme
27. ver assembly away from the the alternator housing unplug the 2 prong internal connector 5 1 CIRCUIT BOARD ASSEMBLY 51 REPLACEMENT A To remove the circuit board assembly follow the steps below 1 Remove two screws 43 washers 42 and two connector screws 40 2 Tilt board away from pickup coils and unplug all the leads from the pickup coil assembly to the circuit board connections NOTE Pull the pickup connectors 39 straight back from the board to avoid splitting the connector receptacle see FIG 1 3 Pull circuit board assembly 51 consisting of the circuit board and connector 51c from the back cover B Reverse the above steps when reinstalling the circuit board assembly to the back cover 1 Insert the connector 51c through the cover hole and secure with screws 40 Note that two washers 41 are used under the screws 40 with the 373xxxH circuit boards having 14 or 17 pin connectors no washers are used on 7 pin connectors 2 Referring to FIG 1 connect the pickup coil receptacles 39 to the circuit board push straight onto the board pin and seat completely NOTE Any receptacle that has a loose fit should be squeezed together slightly with needle nosed pliers or replaced to insure a tight fit 3 Secure the board with screws 43 and washers 42 center the plastic brace 50 between the circuit board and the upper magnet plate 28 TILT BOARD CIRCUIT AWAY FROM BOARD _ Lei PICKUP CO
28. xceeding 018 Install driven gear 23 on shaft if worn use new gear Use new lockwashers 22 and tighten four screws 21 securely With timer arm 24 centered over the core of pickup coil A red the shaft timing mark 27 should be set midway between the CCW and CW marks of the decal 35 Timing labels should be clean Replace timing cover 36 and secure with two screws 37 Install a new cover gasket 29 TOOL NO 506 104D TIMER ARM ASS Y 24 Alll SM 3 11 All rights reserved ALTRONIC LLC 2011 altronic HOERBIGER Engine Solutions 6 0 SERVICE ALTERNATOR SECTION A Replace all worn or defective parts B The procedures of this section require the use of a small arbor press 6 1 DISASSEMBLY COUPLING 1 OR 2 A Drive spring pin or 2a out of coupling 1 or 2 and shaft 7 and remove coupling from shaft 6 2 DISASSEMBLY FLANGE MOUNT UNIT A Unscrew four screws 11 and remove flange 3 from housing 5 Note the relationship of flange to housing so that it may be reinstalled in the same position 6 3 DISASSEMBLY STATOR 10 A Release the stator leads from clamp 17 B Remove three screws 48 holding the alternator assembly together C Using a plastic or rubber hammer tap intermediate housing 13 away from stator and front housing until free from bea
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