Altronic III Service Manual (Form ALT III SM)
Altronic III Service Manual (Form ALT III SM)
Altronic III Service Manual (Form ALT III SM)
TABLE OF CONTENTS
SECTION
ITEM
PAGE
1.0
SYSTEM DESCRIPTION
2.0
2.1
5-6
2.2
2.3A
2.3B
2.4
Unit Specifications
8-10
2.5
11
2.6
Connector Specifications
11
2.7
11
3.0
PERFORMANCE SPECIFICATIONS
11
3.1
Voltage Test
11
3.2
Operating Test
11
3.3
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
19
5.1
19
5.2
20
5.3
21
6.0
22
6.1
Disassembly Coupling
22
6.2
22
6.3
Disassembly Stator
22
6.4
Disassembly Bearings
22
6.5
Parts Replacement
23
6.6
23
6.7
Reassembly Alternator
24
6.8
25
6.9
Reassembly Coupling
25
6.10
25
7.0
26
8.0
OPERATIONAL TEST
26
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
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 systems 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 capacitors stored energy to the ignition coils, which step up the voltage to fire the spark plugs.
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
36 54
37
33
34
10
57
43
32
59
55
47
42
41
58
40
10a
31
38
39
19
32
30
20
29
6
8
28
50
26
12
51
32
27
25
6
24
48
20
23
5c
5b
5e
32
22
18
5d
5a
21
16
3
15
14
3b
2a
11
3a
13a
1a
13
2
2a
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
17
47
51d
PART NO.
DESCRIPTION
REF. NO.
PART NO.
DESCRIPTION
510454-P
Coupling - BLACK
16
310460
510454-U
Coupling - YELLOW
310518
1a
902478
510357
560002
510359
2-1
560006
510447
2a
902475
510476
310418-2
17
501212
Wire clamp
360465-1
18
901326
Washer #8
360465-2
19
310408
360465-3
310473
360465-4
20
902465
Screw 8-32
360465-5
21
902500
Screw 6-32
360466
22
900423
Lockwasher #6
3a
510463
Oil seal
23
310461
3b
510560
Gasket- mounting
310519
310490
Gasket
510358
360401-F
510360
360401
510446
360405
510477
5a
310414
Shield
24
5b
902543
Screw 5/16-18
25
310371
Bearing-shaft
5c
901010
Lockwasher 5/16
26
902448
Screw 8-32
5d
901347
Washer 5/16
27
302106
5e
902554
Washer
302127
510452
Bearing
302128
360402
Shaft-rotor assy.
28
360404
29
310392
Gasket
310466
Spacer - bearing
30
310378
Spacer
510459
Cover - bearing
31
351001
10
351002
10a
310421
351003
11
902484
Screw 1/4-20
32
900944
Lockwasher #8
12
902541
Screw 8-32
33
901679
Nut 8-32
13
310355-12
Intermediate housing
34
902472
Screw 10-24
13a
510550
Ventilator, screen
35
302094
510550A
Ventilator, 6-hole
36
310365
Cover plate
14
302093
Nameplate
37
902064
Screw 6-32
15
902520
Drive pin
38
350001-2
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
504072
Receptacle
56
902525*
Screw 4-40
40
902540
Screw 1/4-20
57
900996*
Lockwasher #4
41
902577
Washer
58
310474
42
902524
Washer
310475
43
902355
Screw 8/32
310538*
47
901004
Lockwasher #10
310539*
48
902601
Screw 10-24
310559
50
310596
Brace
310560*
51
902734
Blanking screw
51d
304102
Socket
902735
Binder post
54
362008-1*
902736
O-ring
362008-2*
501335*
Gasket
55
59
8 A 2 9 H T - BEL
MOUNTING
A
BEL
D
EL
G
GL
GN
GV
J
OPTIONS
STATOR WINDING
`
0
1
2
3
5
6
7
9
=
=
=
=
=
=
=
=
371006
371601
371600 (16 cyl.), 371601 (6, 8 cyl.)
371602
371604
371604
371602
371604
GEAR RATIO
1
2
3
4
5
6
=
=
=
=
=
=
1:1
2:1
3:1
4:1
2.5:1
1.5:1
FIRING PATTERN
2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 16
NO. CYLINDERS
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
REPLACEMENT
DISCOUNTINUED
REPLACEMENT
DISCOUNTINUED
REPLACEMENT
2A10H
2A19H (2)
8A25
8A25H
10A55
2A20, 2A20H
2A29H (2)
8A26
8A25H
10A56
10A53H (2)
3A20
3A29H (2)
8A28
8A29H
10D56
10D55H
4A20
2A29H (2)
8A29
8A29H
10E56
10E55H
4A28
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
6A12XS
6A17XS (2)
8B25
8B25H
12A34D
12A33H (2)
6A13
6A17H
8B26
8B25H
12A35
6A14F
6A17H (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)
6A32S
6A37S (2)
8C26
8C25H
12D36H
12D35H
6A37, 6A37H
6A39H (2)
8E29
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
6Z13
6Z13H
8P49
8P49H
12V43H
12V45H (2)
7A33, 7A33H
7A37H
8T25
8T25H
12Z23
12Z21H (2)
7A35, 7A35H
7A39H
9A33, 9A33H
9A37H
16B23
16B21H (2)
8A11
8A11H
9A35, 9A35H
9A39H
16G23
16G23H
8A13
8A11H (2)
10A13
10A11H (2)
16T23
16T21H (2)
8A22S
8A27S (2)
10A14
10A11H (2)
16T32H
16T31H (2)
8A24
8A25H
10A54
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
2.3B CATERPILLAR OEM PART NUMBERS Follow specification for equivalent value.
CAT OEM NO.
EQUIVALENT
EQUIVALENT
EQUIVALENT
104-4510
6A39HT-A
328-8383
4A39H-A
7C-0753
16B21H-A
104-4511
6A29HT-AO
328-8385
6A39H-A
7C-8882
16V41HT-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
6I-2310
4A39H-A
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.
UNIT NO.
(10)
STATOR
BACK COVER
(51)
CIRCUIT BOARD
(24)
TIMER ARM
(28)
MAGNET PLATE
2A19H
371604
381801-10H
373104H
370005
360418
2A29H
371604
381801-0H
373104H
370005
360418
3A29H
371604
381801-4H
373104H
370005
360407
4A29H
371604
381801-1H
373104H
370005
360418
4A39H
371604
381801-6H
373104H
370005
360418
4A49H
371604
381801-14H
373104H
370005
360418
4F29H
371604
381801-2H
373104H
370005
360408
4G29H
371604
381801-3H
373104H
370005
360429
5A59H
371604
381805-1H
373106H
370005
360424
6A17H
371602
381802-11H
373106H
370005
360407
6A17XS
371602
381802-11H
373106H
370005
360407
6A29H
371604
381802-2H
373106H
370005
360407
6A37S
371602
381802-1H
373106H
370005
360407
6A39H
371604
381802-1H
373106H
370005
360407
6A46H
371604
381807-11H
373109H
370005
360407
6A69H
371604
381802-7H
373106H
370005
360407
6B36H
371604
381807-6H
373208H
370005
360446
6B39H
371604
381802-3H
373106H
370005
360446
6C39H
371604
381802-6H
373106H
370005
360436
6F39H
371604
381802-4H
373106H
370005
360430
6F69H
371604
381802-8H
373106H
370005
360430
6P39H
371604
381802-5H
373106H
370005
360433
6Z13H
371602
381807-4H
373208H
370005
360447
7A37H
371602
381810-4H
373109H
370005
360442
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
(10)
STATOR
7A39H
371604
381810-4H
373109H
370005
360442
8A11H
371601
381803-13H
373208H
370005
360419
8A12XS
371601
381803-21H
373108H
370005
360419
8A23H
371602
381803-5H
373208H
370005
360419
8A25H
371604
381803-5H
373208H
370005
360419
8A27S
371602
381803-1H
373108H
370005
360419
8A29H
371604
381803-1H
373108H
370005
360419
8A37H
371602
381803-9H
373109H
370005
360419
8A39H
371604
381803-9H
373109H
370005
360419
8A45H
371604
381803-25H
373208H
370005
360419
8A49H
371604
381803-24H
373108H
370005
360419
8B13H
371602
381803-14H
373208H
370005
360429
8B25H
371604
381803-6H
373208H
370005
360429
8B29H
371604
381803-3H
373108H
370005
360429
8B35H
371604
381803-23H
373208H
370005
360429
8C25H
371604
381803-7H
373208H
370005
360409
8E29H
371604
381803-12H
373108H
370005
360439
8E49H
371604
381803-124H
373108H
370005
360439
8F25H
371604
381803-10H
373208H
370005
360432
8G29H
371604
381803-4H
373108H
370005
360428
8G49H
371604
381803-44H
373108H
370005
360428
8H29H
371604
381803-8H
373108H
370005
360431
8J63H
371602
381813-1H
373208H
370813-1
360455
8L63H
371602
381803-16H
373208H
370005
360449
8P29H
371604
381803-11H
373108H
370005
360434
8P49H
371604
381803-114H
373108H
370005
360434
8T25H
371604
381803-20H
373208H
370005
360429
9A37H
371602
381811-1H
373109H
370005
360450
9A39H
371604
381811-1H
373109H
370005
360450
10A11H
371601
381806-2H
373212H
370005
360424
10A11XS
371601
381806-2H
373212H
370005
360424
10A51S
371601
381806-3H
373212H
370005
360424
10A53H
371602
381806-3H
373212H
370005
360424
10D55H
371604
381814-1 H
373212H
370814-1
360462
10E55H
371604
381814-2H
373212H
370814-2
360462
10H11H
371601
381806-5H
373212H
370005
360464
10P55H
371604
381814-3H
373212H
370814-3
360462
10T53H
371602
381814-4H
373212H
370814-4
360462
12A11XS
371601
381804-21H
373212H
370005
360406
12A21H
371601
381804-2H
373212H
370005
360406
12A23H
371602
381804-2H
373212H
370005
360406
12A25H
371604
381804-2H
373212H
370005
360406
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
(51)
CIRCUIT BOARD
BACK COVER
(24)
TIMER ARM
(28)
MAGNET PLATE
BACK COVER
(51)
CIRCUIT BOARD
12A31S
371601
381804-6H
373212H
370005
360406
12A33H
371602
381804-6H
373212H
370005
360406
12A35H
371604
381804-6H
373212H
370005
360406
12B11H
371601
381812-51H
373212H
370812-51
360456
12B33H
371602
381812-5H
373212H
370812-5
360456
12C45H
371604
381804-20H
373212H
370804-20
360436
12D35H
371604
381804-7H
373212H
370005
360435
12E11H
371601
381812-11H
373212H
370812-11
360456
12E23H
371602
381812-2H
373212H
370812-2
360456
12E33H
371602
381812-1H
373212H
370812-1
360456
12E53H
371602
381812-3H
373212H
370812-3
360456
12F33H
371602
381804-18H
373212H
370005
360452
12G11H
371601
381804-12H
373212H
370005
360452
12H35H
371604
381804-9H
373212H
370005
360436
12J33H
371602
381804-8H
373212H
370005
360451
12K33H
371602
381804-14H
373212H
370005
360463
12P21H
371601
381804-11H
373212H
370005
360457
12P35H
371604
381804-10H
373212H
370005
360457
12T23H
371602
381812-9H
373212H
370812-9
360456
12T33H
371602
381812-10H
373212H
370812-10
360456
12V33H
371602
381804-19H
373212H
370005
360451
12V45H
371604
381804-16H
373212H
370005
360451
12Z21H
371601
381812-8H
373212H
370812-8
360456
16B21H
371601
381809-3H
373216H
370809-3
360458
16C33
371602
381809-9H
373216H
370809-9
360458
16F21H
371601
381809-13H
373216H
370809-13
360458
16G23
371602
381809-6H
373216H
370809-6
360458
16G33H
371602
381809-7H
373216H
370809-7
360458
16J31
371601
381809-8H
373216H
370809-8
360458
16K33H
371602
381809-10H
373216H
370809-10
360458
16M21
371601
381809-12H
373216H
370809-12
360458
16P21H
371601
381809-17H
373216H
370809-17
360458
16P31H
371601
381809-16H
373216H
370809-16
360458
16T21H
371601
381809-5H
373216H
370809-5
360458
16T31H
371601
381809-18H
373216H
370809-18
360458
16V43H
371602
381809-14H
373216H
370809-14
360458
16W31H
371601
381809-15H
373216H
370809-15
360458
UNIT NO.
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
10
(24)
TIMER ARM
(28)
MAGNET PLATE
orange
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 Bores:
1.5737"/1.5739"
1.865"/1.867"
1.1800"1.1803"
.6693"/.6696"
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 Alll II.
VOLTAGE OUTPUT
70 rpm
Any
60 VDC min.
500 rpm
Any
200-220 VDC
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
11
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
12
1600
900
550
750
2100
4A39H
4A49H
4F29H
4G29H
5A59H
6A17H
825
1350
675
800
1800
3000
1500
1800
900
1800
6F39H
6F69H
6P39H
6Z13H
7A37H
7A39H
8A11H
8A12XS
8A23H
3000
6B36H
600
450
6A69H
6C39H
2000
6A46H
6B39H
2700
6A39H
2700
2700
4A29H
6A37S
1800
3A29H
900
800
2A29H
1800
800
2A19H
6A29H
700
UNIT NO.
6A17XS
COUPLING
TEST RPM
Both
CW
Both
CCW
CCW
CCW
CW
CW
CW
CW
CW
CCW
Both
CCW
Both
CCW
Both
CW
Both
Both
CW
CW
CCW
CCW
Both
CW
CW
CW
COUPLING
ROTATION
60
90
90
45
45
154
154
40
82.5
85.5
265.5
0
180
0
171
112.5
90
90
270
240
0
180
180
180
120
60
0
180
0
180
0
120
234
270
180
240
180
90
90
309
309
120
0
180
0
180
120
240
120
120
0
180
300
180
120
180
270
135
135
103
103
160
82.5
85.5
265.5
171
112.5
90
90
90
270
180
180
180
180
0
180
180
234
90
180
180
180
257
257
240
0
180
0
180
240
120
240
240
0
180
90
225
225
51
51
280
82.5
85.5
265.5
171
112.5
90
90
90
270
120
180
180
240
300
300
180
270
270
206
206
270
315
315
1.5
1.5
2.5
TOLERANCE
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
13
1800
1800
3000
300
2000
2000
1200
1200
550
2700
1200
400
800
8A25H
8A27S
8A29H
8A37H
8A39H
8A45H
8A49H
8B13H
8B25H
8B29H
8B35H
8C25H
8E29H
8E49H
620
900
2700
2250
10A11XS
10A51S
10A53H
2250
9A39H
10A11H
3000
8P29H
9A37H
550
8L63H
1100
1350
8J63H
1200
2250
8H29H
8T25H
400
8G49H
8P49H
550
1100
8G29H
900
1800
UNIT NO.
8F25H
COUPLING
TEST RPM
CCW
CCW
CW
CCW
Both
CCW
CCW
CW
CW
CCW
CCW
CW
CW
CW
CW
CW
CW
CCW
CW
CW
CW
CW
CCW
CCW
Both
CCW
CCW
CCW
Both
COUPLING
ROTATION
90
270
90
270
0
180
0
180
36
36
120
120
60
230
115
72
252
0
180
0
30
210
0
180
240
120
54
90
45
45
180
120
120
60
180
180
135
135
90
90
90
135
0
180
0
180
72
72
240
240
180
50
205
135
315
135
315
180
60
210
180
270
135
180
270
180
180
90
270
270
180
180
180
90
270
90
270
108
108
240
230
295
207
27
165
345
315
240
300
234
90
225
225
90
300
300
150
180
180
45
45
270
270
270
0
180
0
180
144
144
120
120
50
25
270
90
270
90
60
30
270
315
180
180
180
180
90
270
90
270
180
180
240
240
60
180
90
342
162
300
120
135
180
90
54
180
90
45
120
120
240
180
180
315
315
90
90
90
0
180
0
180
216
216
180
180
45
225
45
225
180
180
180
180
180
90
180
180
270
90
90
180
180
180
90
270
90
270
252
252
120
120
240
180
270
117
297
75
255
315
180
270
234
180
270
225
270
300
300
330
180
180
225
225
270
270
270
0
180
0
180
288
288
240
240
90
270
90
270
324
324
2.5
2.5
1.5
1.5
TOLERANCE
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
14
1200
1200
2700
2700
2700
12A21H
12A23H
12A25H
12A31S
12A33H
12A35H
900
1800
2250
2250
1800
750
1500
2250
1500
1800
800
1250
12E11H
12E23H
12E33H
12E53H
12F33H
12G11H
12H35H
12J33H
12K33H
12P21H
12P35H
12T23H
1350
1800
12A11XS
12D35H
900
10T53H
2000
1500
10P55H
12C45H
650
10H11H
900
900
10E55H
1800
450
10D55H
12B33H
500
UNIT NO.
12B11H
COUPLING
TEST RPM
CW
CW
CCW
CCW
CCW
CW
CCW
CCW
CCW
CCW
CW
CW
CCW
CW
CCW
CCW
Both
Both
CCW
Both
Both
Both
CW
CW
CW
CCW
CW
CW
COUPLING
ROTATION
20
82.5
55
81
75
112.5
37.5
67.5
112.5
292.5
0
180
0
135
90
45
72
90
45
15
90
90
90
60
60
60
30
55
235
0
180
0
9
189
0
180
34
214
0
180
27
15
195
0
180
120
180
120
180
180
180
60
180
150
330
180
120
60
180
240
180
60
180
180
180
120
120
120
60
0
180
0
180
72
0
180
0
180
140
262.5
175
261
255
292.5
97.5
247.5
262.5
82.5
315
210
105
252
330
225
75
270
270
270
180
180
180
90
55
235
9
189
99
34
214
15
195
240
240
120
300
120
240
120
120
120
240
240
240
120
0
180
0
180
144
0
180
0
180
260
82.5
295
81
75
112.5
157.5
67.5
52.5
232.5
135
330
165
72
210
45
135
90
90
90
300
300
300
150
55
235
9
189
171
34
214
15
195
180
180
180
180
180
180
90
270
180
180
180
180
180
180
180
180
180
0
180
0
180
216
0
180
0
180
20
262.5
55
261
255
292.5
217.5
247.5
202.5
22.5
315
90
225
252
90
225
195
270
270
270
60
60
60
210
55
235
9
189
243
34
214
15
195
120
120
240
240
60
120
240
240
240
120
120
120
240
0
180
0
180
288
0
180
0
180
140
82.5
175
81
75
112.5
277.5
67.5
352.5
172.5
135
210
285
72
330
45
255
90
90
90
180
180
180
270
55
235
9
189
315
34
214
15
195
240
180
240
180
180
180
300
180
30
210
180
240
300
180
120
180
300
180
180
180
240
240
240
300
260
262.5
295
261
255
292.5
337.5
247.5
142.5
322.5
315
330
345
252
210
225
315
270
270
270
300
300
300
330
2.5
2.5
2.5
2.5
2.5
TOLERANCE
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
15
2250
1200
2700
2000
2250
16T31H
16V43H
16W31H
1500
16P21H
16T21H
1800
16M21H
16P31H
2700
1500
1350
16G33H
16K33H
900
16G23
16J31
2700
1800
1200
16B21H
16F21H
1800
12Z21H
16C33
2250
2000
12T33H
12V45H
1800
UNIT NO.
12V33H
COUPLING
TEST RPM
CW
CW
CW
CW
CW
CW
CCW
CCW
CCW
CCW
CCW
CCW
CCW
CCW
CCW
CW
CW
CW
COUPLING
ROTATION
105
80
45
30
90
60
81
30
72
48
30
67.5
60
40
140
105
30
135
180
135
90
135
90
90
135
135
135
90
90
135
90
120
240
180
180
240
260
180
120
225
150
90
216
165
207
138
120
202.5
150
160
20
185
210
270
270
180
270
180
180
270
270
270
180
180
270
180
240
120
15
80
315
210
240
180
351
300
342
228
210
337.5
240
280
260
105
30
45
180
45
270
45
270
270
45
45
45
270
270
45
270
180
180
150
260
90
300
135
330
270
126
75
117
318
300
112.5
330
40
140
185
210
180
180
180
180
180
180
180
120
240
285
80
225
30
270
60
261
210
252
48
30
247.5
60
160
20
105
30
315
180
315
90
315
90
90
315
315
315
90
90
315
90
240
120
180
180
60
260
120
45
150
90
36
345
27
138
120
22.5
150
280
260
185
210
90
90
180
90
180
180
90
90
90
180
180
90
180
195
80
135
210
180
240
180
171
120
162
228
210
157.5
240
225
180
225
270
225
270
270
225
225
225
270
270
225
270
330
260
270
300
315
330
270
306
255
297
318
300
292.5
330
TOLERANCE
4.0 TROUBLESHOOTING
4.1 CIRCUIT DIAGRAM
A. The diagram below shows the A1tronic III 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 C2 through resistor R3 to the gate of
TC1. TC1 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.
C. Components:
C1
Q1
Transistor, isolator
C2
Q2
Transistor
C3
R1
D1
R4
D2
Diode, power
SCR1,P,R2,R3
D3
Diode, recirculating
TC1
TRIAC
FWR
Z1
Z2
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
16
PROBLEM
1. One output
not firing
a)
b)
POSITIVE
OHMMETER
LEAD
NEGATIVE
OHMMETER
LEAD
SCALE
READING
Pickup coil
Connector pin
common(s)
of output not
(see page 20) firing
REMEDY FOR
FAULTY
READING
Correct connection
Replace pickup coil
(31)
c)
2. 8-12 cylinders:
No output on
every other output
a)
Correct connection
OR 4-6 cylinders
No output but G
lead has 100+
volts
a)
c)
Pin 1 and 2
Connector pins R X 10,000 Slight flicker in meter with
(see page 20)
final reading no loower than
500 X 10,000 (5 megohm)
3. Weak or no output
a) Stator
Across
2-prong stator
plug terminals
b) Stator
Across
both stator
terminals
c) Circuit Board
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
250VAC
Ground
R X 10,000 Infinite
17
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
18
C. Circuit Board Pin Connections (viewed from pickup coil side of board):
212 CYL:
Pickup
Common
16-CYL:
Grd
Pickup
Common
Pickup
Common
Grd
Pickup
Common
NOTE: Crimping tool for receptacle (39) is American Pamcor, Inc. Part No. 90204-1.
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
19
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
20
5.3 BEARING (25), TIMER ARM (24), DRIVEN GEAR (23) REPLACEMENT
A. The procedures of this section require the use of a small arbor press.
B. Remove timing cover (36) and driven gear (23).
C. 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.
D. Press bearing shaft (25) out of aluminum hub of timer arm assembly (24).
E. Replace any warn or defective parts.
F. 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.
G. 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.
H. 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 exceeding .018.
I. Install driven gear (23) on shaft; if worn, use new gear. Use new lockwashers (22) and tighten four screws (21) securely.
J. 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.
K. Replace timing cover (36) and secure with two screws (37).
L. Install a new cover gasket (29).
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
21
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
22
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
23
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
24
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
25
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
AIII SM 3-11
All rights reserved ALTRONIC, LLC 2011
26