Altronic V Service Manual
Contents
1. 1 0 ALTRONIC V IGNITION SYSTEM DESCRIPTION Altronic V is an alternator powered electronic ignition system All electronic parts are mounted to the back cover which disconnects as a module from the alternator section The alternator A provides the power to charge energv storage capacitor B A separate pickup coil C and SCR D are used for each of the svstem s outputs which correspond usually to each engine cylinder A rotating timer arm E driven through speed reducing gears F passes over the pickup coils to trigger on the SCR switches in sequence This releases the capacitor s stored energy to the ignition coils which step up the voltage to fire the spark plugs YoEZ Q E WE M A PE e l Ni NW SB j CROSS SECTIONAL VIEW ALTRONIC V UNIT A Alternator D SCR electronic switch B Energy storage capacitor E Timer arm C Pickup coil F Distribution gears agg 2 0 PARTS IDENTIFICATION AND SPECIFICATION 2 1 PARTS LIST ALTRONIC V Reference the exploded view on page 4 REF NO 1 1a ul ClhOl IN ID PART NO DESCRIPTION 570010 Plate bushing ass v 3A 570011 Fiste bushina T 2A 570 012 Plate bushing ass y 1A 570 020 Plate bushing ass v 4A 570 021 Piate bushing aay 5A 570 022 Plate bushing ass y 6A 26d 510 627 Spacer 1A 2A 3A 510 651 Spacer 4A 5A 6A 902 5742. 045 Spacer 40 902 058 Screw 6 32 19 902 541 Screw 8 32 41 901 004 Lockwasher 20 900 996 Lockwasher 4 42 902 567 Screw 10 24 X 1 25 21 570 017 1 Driven gear ass v 1 1 902 587 Screw 10 24 X 2 0 570 017 2 Driven gear ass v 2 1 43 902 064 Screw 6 32 570 017 3 Driven gear ass y 3 1 44 902 483 Screw 10 24 570 017 6 Driven m asy 1 5 1 45 902 645 Washer sealing 25 902 564 Screw 4 40 26 570 401 Pickup plate ass V 1A 570 402 Pickup plate ass v 2A 570 403 Pickup plate ass v 3A 570 404 Pickup plate ass v 4A 570 405 Pickup Dist iy 5A 570 406 Pickup plate ass y 6A 26a See pg 12 Pickup coil ass y 26b 570 008 Plate core ass y 2A 570 009 Plate core ass y 3A 570 015 Plate core ass y 1A 570 025 Plate core ass y 4A 570 026 Plate core ass y 5A 570 027 Plate core ass y 6A ES eS 47 902 579 Washer shim 4 od 900 966 902 525 562 001 Connector assembl 501 369 Gasket Lockwasher Screw 4 40 Parts for units with electronic timing option not illustrated NOTE Reference numbers with a letter suffix are part of the assembly of the same number without the suffix Example 1a is part of 1 2 2 PARTNO DESIGNATION 2A28HT A 2 3 UNIT SPECIFICATIONS IL MOUNTING VERTICAL FLANGE t OPTIONS CAPACITOR GEAR RATIO m FIRING PATTERN NO CYLINDERS 1 2 3 4 5 6 1 Slot Flange Coupling Angle 45 CW Extended Shaft 1 Slot Flange 3
3. Altronic V 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 system outputs each output requires a pick up coil assembly capacitor C3 and power SCR2 B The operation is as follows The AC voltage generated by the alternator is converted to DC by diodes D1 and stored in the energy storage capacitor C1 The DC voltage level is regulated by zener diode Z Capacitor C2 is charged through resistor R1 to provide the energy to trigger power SCR2 This occurs when the rotating distributor arm passes a pick up coil P triggering on SCR1 and connecting capacitor C2 through resistor R3 to the gate of SCR2 SCR2 then turns on discharging capacitor C1 into the primary of the ignition coil which steps up the voltage to fire the spark plug Capacitor C3 acts as a filter to prevent crossfiring between outputs C Components C1 Capacitor energy storage SCR1 P R2 R3 Pick up coil assembly C2 Capacitor trigger SCR2 Power SCR C3 Capacitor filter R1 Resistor trigger circuit D1 Diode R4 Resistor SCR gate D2 Diode dual R5 Resistor D3 Diode blocking Z Zener diode 4 2 OSCILLOSCOPE TESTING The system should be fully connected per section 3 0 with the Altronic V unit operating at the TEST RPM given in section 3 3 Connect the oscilloscope probe to the shutdown lead of the outp
4. off bearing 31a Remove cover plate 39 and timing decal 37 SNAP RING SECURED DRIVEN SHAFT Remove snap ring and pull driven shaft assembly from bearing 31a PRESS FIT SECURED DRIVEN SHAFT Press shaft 31b out of bearing 31a Press bearing 31a out of rear housing 31 G Support housing 31 with tool 506 103B slide bearing 31a over guide of tool no 506 103B and press bearing oon a into housing with tool no 506 103A until it bottoms Support bearing 31a on the inner race with tool 506 104B and press using tool 506 104A on the gear shoulder of shaft 31b until the shaft bottoms against bearing REASSEMBLY DRIVEN SHAFT ASSEMBLY Reinstall the pickup plate assembly 26 and secure with hardware 20 and 25 Plug the pickup connectors into the circuit board receptacles Slip shims 47 the same number as removed if any over the end of shaft 31b against shoulder Check that the air gap between the rotating arm and the plate 26c is 005 018 If the air gap requires adjustment first remove screw 19 holding the driven gear and pull the assembly 21 from the shaft Add or subtract a shim washer 47 to increase or decrease the air gap Reinstall assembly 21 and secure with hardware 11 12 and 19 Using a small brush apply a thin coat of silicone compound GC type 5Z Altronic part no 503 259 to the teeth of the driven gear 21 Install washer 35 t
5. pilot 2 Slot Flange 2 Slot Flange Extended Shaft High output unit Electronic timing bo b gt own ana JI SQ2yez5 ll oll G 4 8 microfarad 4 8 microfarad 8 0 microfarad 1 1 2 1 3 1 1 5 1 Even Firing Pattern NOTE It is recommended that 581 40x circuit boards be updated exchanged for the 572 61 x series UNIT NO BACK COVER 1A18 581 401 1 1A28 581 401 2 1A28H 581401 2H 2A14 581 404 1 2A18H 581 402 2H 2A25 581 404 3 2A28 581 402 1 2A28H 581 402 1H 2A64 581 404 2 3A14 581 406 2 3A25 581 406 4 3A35 581 406 3 3A64 581 406 1 4A24 581 407 1 4A34 581 407 2 5A24 581 405 1 6A24 581 408 2 6A34 581 408 1 61 2611 581 407 2 328 8382 581 407 2 9Y 6465 581 408 1 109 8912 581 408 2 Caterpillar OEM units CIRCUIT BOARD ASS Y 27 572 612 572 612 572 612H 572 613 572 612H 572 613 572 612 572 612H 572 613 572 613 572 613 572 613 572 613 572 614 572 614 572 616 572 616 572 616 572 614 Follow testinQ for 4A34 572 614 Follow testing for 4A34 572 616 Follow testing for 6A34 572 616 Follow testing for 6A24 3 0 PERFORMANCE SPECIFICATIONS A Install unit on a test stand equipped with a suitable number of 501 061 coils and spark gaps Test stand wiring should conform to that shown in the Installation Instructions form AV II for 6 cylinder engines 3 1 VOLTAGE TEST A With the wiring harness unplugged measure the positive voltage at the connector G pin UNIT SPEED CIRCUIT
6. A The following assembly tools are referred to in sections 5 3 and 6 4 506 101A 506 101B 506 102B 506 102C 506 103A 506 103B 506 104A 506 104B Press bearing shaft 3 into housing 4 Support housing 4 Support shaft 3 Press magnet rotor assembly 7 on bearing shaft 3 Press bearing 31a into cover housing 31 Support cover housing 31 and bearing 31a Press shaft 31b into bearing 31a Support bearing 31b 0 OPERATIONAL TEST A Perform the tests following the guidelines of sections 3 0 through 3 3 Uu Run the Operating Test of section 3 2B for one hour C After the one hour Operating Test check timing per section 3 3 15
7. ALTRONIC V SERVICE MANUAL SMALL ENGINES 1 6 CVLINDERS FORM AV SM 12 96 ALTRONIC INC 712 TRUMBULL AVE GIRARD OHIO 44420 ALTRONIC V IGNITION SYSTEM 4400 SERIES S N 4400 amp UP IMPORTANT SAFETY NOTICE PROPER INSTALLATION MAINTENANCE REPAIR AND OPERATION OF THIS EQUIPMENT IS ESSENTIAL THE RECOMMENDED PRACTICES CONTAINED HEREIN SHOULD BE FOLLOWED WITHOUT DEVIATION AN IMPROPERLY INSTALLED OR OPERATING IGNITION SYSTEM COULD CAUSE PERSONAL INJURY TO OPERATORS OR OTHER NEARBY PERSONNEL TABLE OF CONTENTS ALTRONIC V SERVICE MANUAL SECTION SYSTEM DESCRIPTION PARTS IDENTIFICATION AND SPECIFICATION 4 2 1 Parts List 5 Part No Designation 6 Unit Specifications 6 3 0 PERFORMANCE SPECIFICATIONS 7 3 1 Voltage Test 7 3 2 Operating Test 7 3 3 Timing Specifications 7 4 0 TROUBLESHOOTING 8 4 1 Circuit Diagram 8 4 2 Oscilloscope Testing 9 4 3 Procedure 10 4 4 One Output Does Not Fire 10 4 5 System Has Weak or No Output 10 5 0 SERVICE ALTERNATOR SECTION 10 5 1 Disassembly 10 5 2 Parts Replacement 10 5 3 Reassembly 11 6 0 SERVICE BACK COVER ASSEMBLY 12 6 1 Circuit Board Assembly Replacement 12 6 2 Pickup Coil Assembly Replacement 12 6 3 Driven Gear Magnet Arm Assembly 13 6 4 Driven Shaft Bearing 13 6 5 Reassembly Driven Shaft Assembly 13 6 6 Reassembly Back Cover to Alternator 14 SP a SE a ae ate we ea eg ee wre el a 7 0 SERVICE ASSEMBLY TOOLS 15 a ee s 8 0 OPERATIONAL TEST 15 ITEM PAGE
8. BOARD NO _ CONNECTOR PIN VOLTAGE OUTPUT 500 rpm 572 602 572 612 E 111 129 VDC 572 602H 572 612H E 140 160 VDC 572 603 572 613 140 160 VDC 572 604 572 614 140 160 VDC 572 606 572 616 140 160 VDC 3 2 OPERATING TEST A At50 rpm of the back cover a 7mm gap should fire consistently B Atthe TEST RPM a 15mm gap should fire consistently 3 3 TIMING SPECIFICATIONS A Timing should be as specified in the table below as measured on a standard ignition test stand with the degree wheel indicator rotating at the unit coupling speed B If timing is out of specification change the pick up coil 31 in question COUPLING COUPLING FIRING SEQUENCE DEGREES UNIT NO TEST RPM ROTATION A B C D E F TOLERANCE 1A18 1 300 CW o 1A28 1 300 CW o 1A28H 1 300 CW o 2M4 2000 Cw o 180 2 m 2A18H 700 CW 0 1180 2 2A25 2 400 CW 0 0 2 2A28 1 300 CW 0 0 2 2A28H 1 300 CW 0 0 2 2A64 3 000 CW o 90 3 180 270 3A14 2 000 CW 240 2 3A25 2 000 Cw 0 240 120 2 3A35 3 000 CW o o 0 3 3A64 3 000 CW 0 0 0 3 180 180 180 4A24 2 000 Cw o 180 o 180 2 4A34 3 000 CW o 270 180 90 3 5A24 2 000 Cw o 144 288 72 216 2 6A24 2 000 CW o 120 240 o 120 240 2 6A34 3 000 CCW o 180 o 11801 O 180 3 15 17 degree retard at low speed 30 34 degree retard at low speed 4 0 TROUBLESHOOTING 4 1 CIRCUIT DIAGRAM A The diagram below shows the
9. Screw 6 32 26f 610 117 Snap ring 27 See pg 6 Circuit board assembly 301 208 2 Zener diode 10M12025 301 233 3 Zener diode 10M15025 504 161 583 007 Nut 10 32 zener diode Plug assembl 501 335 Gasket 5 pin connector 501 368 Gasket 7 pin connector 30 510 597 Spacer PART NO DESCRIPTION REF NO 510 454 U Coupling yellow 26c 510 699 Coupling 109 8912 onl 902 478 Spring pin 2 1 8 Ig 410 063 Bearing shaft A AM D 510 654 Bearing shaft AW G 560 004 1 Housing A AM A 560 004 2 Housing GV G 560 004 3 Housing D 560 004 4 Housing GVC 26e 560 004 5 Housing 109 8912 510 541 Ventilator 502 134 Nameplate 2 0 X 1 9 27a 502 168 Nameplate 3 5 X 1 1 902 520 Drive pin 27b 160 001 Magnet rotor 27C 410 039 Gasket 29 571 003 Stator 310 518 Drive gear 1 5 1 510 357 Drive gear 2 1 31 510 359 Drive gear 3 1 570 005 Rear cover 5 pin conn 570 028 Rear cover 7 pin conn 510 625 Drive gear 1 1 570 029 1 Rear cover 5 pin w timing 11 901 326 Washer pin w timing 12 900 944 Lockwasher 8 31a 410 058 Bearing i 13 902 465 Screw 8 32 31b 510 660 Shaft driven 14 510 462 O ring 32 902 459 Nut 6 32 15 410 038 Spacer 33 902 602 Washer 16a 902 585 Screw 5 16 18 34 902 565 Screw 6 32 16b 901 010 Lockwasher 5 16 35 902 591 Washer 16c 902 586 Washer 37 302 106 Timing label shaft 17a 902 487 Snap ring 38 502 142 Timing label cover 17b 902 503 Washer 39 310 365 Cover plate 18 410
10. a see orientation as shown below E Toreinstall top plate 26c insert screws 26e through plate 26c and spacers 26d into the plate core assembly 26b then tighten screws 26e F Plug the pickup coil connector into the circuit board receptacle 570 401 AA 370 402 885 570 403 3A ear Bo 551 002 1 A 551 002 4 A 991 002 1 B 551 002 4 B 551 002 2 S51 008 3 570 404 44 570 406 6A 551 008 5 AEP 931 008 59 B S91 002 4 B S51 002 1 991 008 4 C osls00e e D 551 002 e D 951 002 3 6 3 6 4 O 0 B gt m DRIVEN GEAR MAGNET ARM ASSEMBLY 21 NOTE Early production assemblies having the driven gear held to the magnet arm with slotted pan head screws should be updated to the equivalent one plece driven gear magnet arm assembly 21 Remove screw 19 and pull driven gear magnet arm assembly 21 from shaft 31b DO NOT loosen the three small button head hex socket screws holding the gear assembly together Keep track of shim washers 47 DRIVEN SHAFT 31b BEARING 31a NOTE It is recommended that all units be updated to the current design press fit secured driven shaft 31b The procedures of this section require the use of a small arbor press Remove the driven gear assembly 21 per section 6 3 Unplug the pickup coil connectors see step 6 1A Remove three screws 25 and lockwashers 20 Then pull the entire pickup plate assembly 26
11. iming decal 37 lockwasher 12 and screw 19 but tighten screw so that the lockwasher just starts to compress Place the timing arm 21 centered on the red pickup coil core The red mark on decal 37 should be placed midway between the CCW and CW marks of the label Tighten screw 19 Install cover plate 39 and secure with two screws 40 13 6 6 REASSEMBLY BACK COVER TO ALTERNATOR SECTION A Set the back cover assembly with the timing mark aligned to either CCW or CW as required for the application Set the alternator coupling angle as shown in the chart below B Mate the back cover to the alternator keeping the alignment of the back cover timing mark and alternator coupling as set in step 6 6A C Secure the back cover to the alternator keeping the alignment of the back cover timing mark to the alternator with hardware 41 42 and 44 BACK COVER TIMING INDICATOR COUPLING ANGLE UNIT NO CCW CW 1A18 GV 0 g 1A28 A 70 UOS 2A14 A GV 0 70 mo COUPLING 2A14 AW GVW 70 ANGLE 2A14 D 0 E 2A18H GV f 70 2A25 A 70 2A28 A GV z 70 2A64 GVW 70 3A14 A GV 0 70 ae 3A14 D 0 7 3A25 GV 0 z 3A35 A 70 3A64 A GV 0 70 3A64 AM a 45 3A64 AW GVW 70 4A24 A GV 0 70 4A24 AW GVW 70 4A24 D 0 4A34 GVW 70 5A24 GV 0 6A24 D 0 6A34 AM 6A34 AW GVW 6A34 GVC 6l 2611 109 8912 14 7 0 SERVICE ASSEMBLY TOOLS
12. n the coupling end and press shaft out of the Ow M m O magnet rotor assembly and housing Wrap magnet rotor assembly 7 in a cloth or paper to keep it clean PARTS REPLACEMENT Replace gasket 8 Replace coupling 1 and bearings 3 and 31a with new parts Replace any removed hardware with new parts Aluminum housings should be cleaned with carbon tetrochloride or similar cleaning solution Any metal filings should be cleaned from magnet rotor 7 before reassembly 10 REASSEMBLY ALTERNATOR SECTION A Press new bearing shaft 3 into housing 4 until it bottoms against shoulder Housing 4 should be supported behind the internal shoulder with tool no 506 101B Push on the outer race of the bearing using tool 506 101A Clean all debris from the magnet rotor assembly 7 Slide magnet rotor assembly 7 over shaft with plate facing out as shown below Support the shaft on the coupling end using tool no 506 102B and using tool no 506 102C press magnet rotor assembly 7 on the shaft 0 575 past the shoulder for the drive gear D Slide coupling 1 onto the shaft and secure with spring pin 1a through the coupling and shaft AW GVW UNITS ONLY Install sleeve 18 and engine gear Secure with hardware 16a 16b 16c or 17a 17b see page 4 Inspect gear 10 replace if worn Secure with new hardware 11 12 and 13 G Reinstall stator with leads at the 6 o clock po
13. negative lead to connector pin with no output Move the timer arm 21a past the pickup coil corresponding to the test connector pin A is red B C etc follow in a CW direction from A meter should pulse indicating pickup coil output If not replace pickup coil assembly 26a see section 6 2 C If above tests are OK replace circuit board assembly 27 see section 6 1 SYSTEM HAS WEAK OR NO OUTPUT Check stator 9 resistance replace if defective see section 5 0 1 Center pin to outer pin 450 650 ohms RX100 scale 2 Center pin to other outer pin 5000 6000 ohms 3 Center pin to lamination core infinite 0 SERVICE ALTERNATOR SECTION A The unit breaks down into two major parts the Alternator Section and the Back Cover Assembly Remove the 5 1 A B four back cover attaching screws 42 44 and carefully pull the back cover assembly away from the alternator housing unplug the 3 prong internal connector The procedures of this section require the use of an arbor press DISASSEMBLY Remove the phenolic spacer 15 O ring 14 and stator 9 from the alternator housing AW GVW UNITS ONLY Remove hardware 16a 16b 16c or 17a 17b and sleeve 18 from unit shaft C Drive spring pin 1a out of coupling 1 and shaft and remove coupling D Remove screw 13 lockwasher 12 washer 11 and drive gear 10 E If it is necessary to replace bearing shaft 3 support the housing o
14. sition a new O ring 14 and spacer 15 USING 4 COUPLING CD SLEEVE 18 PIN 10 MAGNE T RUTOR C75 il 6 0 SERVICE BACK COVER ASSEMBLY A Replace only those parts requiring service 6 1 CIRCUIT BOARD ASSEMBLY 27 REPLACEMENT A Use a small screwdriver to pull the circuit board receptacle levers away from the 2 lead housing of the pickup coil connectors then unplug the pickup connectors from the circuit board 27 B Remove four screws 43 zener diode nut 27b and washer 45 screw 34 washer 33 and nut 32 The circuit board can then be removed from the cover Keep track of spacer 30 C Reverse steps 5 1A and 5 1B to reassemble NOTE Use new parts for washers 33 and 45 see page 5 6 2 PICKUP COIL ASSEMBLY 26a REPLACEMENT A Remove hardware 19 12 11 holding the driven gear magnet arm assembly Pull driven gear magnet arm assembly 21 from the driven shaft B Unplug the pickup coil connector in question see 6 1A C To replace a pickup coil 26a remove three screws 26e and plate assembly 26c On 1 cylinder units only remove the small snap ring 26f Then remove the pickup coil in question D When installing the new pickup coil the end with the marked line must face out against plate 26c Rotate the coil body so that the bulge does NOT face inside the circle of the O D of the bearing 31
15. ut connector E for the 5 pin connector or G for the 7 pin 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 the unit A STORAGE CAPACITOR PATTERN NORMAL The normal patterns for typical 3 output 3A64 and 6 output 6A34 units are shown below 3 OUTPUT UNIT 3A64 6 OUTPUT UNIT 6A34 B STORAGE CAPACITOR PATTERN ABNORMAL One cylinder misfiring See troubleshooting section 4 4 3 OUTPUT UNIT 3A64 6 OUTPUT UNIT 6A34 200V 200V 100V 100V OV OV C STORAGE CAPACITOR PATTERN ABNORMAL Irregular waveform See troubleshooting section 4 5 3 OUTPUT UNIT 3A64 6 OUTPUT UNIT 6A34 PROCEDURE A See section 3 0 3 3 for proper performance ss Use Simpson model 260 meter on RX10 000 scale unless otherwise specified C First discharge all capacitors Carefully use a screwdriver to short from the connector shell first to the E pin on 5 pin connector or G pin on Z pin connector then to all other pins ONE OUTPUT DOES NOT FIRE A Check that the 2 lead pickup coil connector is fully plugged into the circuit board receptacle Check with ohmmeter as follows Positive lead to case
Download Pdf Manuals
Related Search