ALTRONIC I IGNITION SYSTEM SERVICE MANUAL …

1 ALTRONIC I IGNITION SYSTEMSERVICE MANUALIN-LINE ENGINES, 1-6 CYLINDERSFORM AI SM 3-02 ALTRONIC , TRUMBULL , OHIO 44420 ALTRONIC I IGNITION SYSTEM5000 SERIES S/N 5000 & UPIMPORTANT SAFETY NOTICEPROPER INSTALLATION, MAINTENANCE, REPAIR AND OPERATION OF THISEQUIPMENT IS ESSENTIAL. THE RECOMMENDED PRACTICES CONTAINEDHEREIN SHOULD BE FOLLOWED WITHOUT DEVIATION. AN IMPROPERLYINSTALLED OR OPERATING IGNITION SYSTEM COULD CAUSE PERSONALINJURY TO OPERATORS OR OTHER NEARBY OF CONTENTSALTRONIC I SERVICE DESCRIPTION IDENTIFICATION AND SPECIFICATION List - ALTRONIC I Unit Identification Specifications AND TEST SPECIFICATIONS Test - ALTRONIC I - ALTRONIC I Box - ALTRONIC I Coil - ALTRONIC I Test - ALTRONIC I-6 - ALTRONIC I-6 Box - ALTRONIC Coil - ALTRONIC - ALTRONIC I - - Front Housing - Front Housing - - Electronic Box to TEST12-- 2 I IGNITION SYSTEM - DESCRIPTIONThe ALTRONIC I 1-cylinder IGNITION SYSTEM is depicted below; the principle of operation is the same for allAltronic I alternator (A) provides the power for the electronic box (B) mounted to it.

2 The electronic box (B)rectifies the alternator s AC output to DC, stores the energy in a storage capacitor and contains an SCRswitching device. W hen the external pick-up coil (C) is triggered by the rotating magnet (D) (either discor flywheel mounted), the SCR in the electronic box is activated thus releasing the energy in the storagecapacitor to the IGNITION coil (E) which steps-up the voltage to fire the spark - Coil-- 3 IDENTIFICATION AND LIST - ALTRONIC I UNIT - Reference the exploded view on page 11510454-UCoupling - yellow 1a1902478 Spring pin 2-1/8" lg. 21 See below and page 6 Bearing-shaft 31 See page 6 Housing 3a1510541 Ventilator 41102103 Nameplate 51102106 Part no. decal 61160001 Magnet-rotor assembly 71171001 Stator - red leads171003 Stator - blue leads 7a1110447 Grommet 81110453 Spacer 91510462O-ring101110452 Cover111110474 Gasket kit11a2901317 Washer124902480 Screw 10-24 X 1/2"131 See page 6 Electronic box13a2503105 Tubing, plastic141410045 Sleeve151902503 Washer161902487 Snap ringNOTE:Reference numbers with a letter suffix are part of the assembly of the same number without thesuffix.

3 Example: (1a) is part of (1). IDENTIFICATIONBEARING-SHAFT PART NO. (2)BEARING EXTENSION " " " " "-- 5 indicates the alternator model and the number of SYSTEM outputs. Example: G1 is ModelG, 1 output. This is also the first two digits of the kit number using this model unit (G1-X-1).(12)(7)(3)(2)VENTUNIT BOXALTERNATORSTATORHOUSINGBRG. & 2190007F1181001-X180007-1171001110464110 4661190008C3181006 180005-21710031104621104672190011G318100 6 180003-21710031104621104591190017C118100 4 180005-21710031104621104671190022W318100 6 180008-21710031104621104711190023G318100 6-X180003-11710011104621104591190026D318 1006 180009 POS. in the chart above determines the orientation of the electronic box when mounted tothe alternator (see below).ELECTRONIC BOXPART NO. 181 001 ALTRONIC , , OHIOO rient the alternator housing andelectronic box to obtain the vent holeposition indicated in the chart 6 AND TEST TEST - ALTRONIC the complete SYSTEM as shown below.

4 Turn the alternator shaft one or more revolutionsby hand; then push the pick-up coil down squarely against the flush magnet of the magnet bar. Aspark should jump a 7 mm gap as shown. If the performance test is failed, proceed to step the voltmeter to the electronic box as indicated below; turn the alternator shaft one ormore revolutions by hand:POSITIVENEGATIVEMETERMETER LEADMETER LEADSCALEREADINGC enter terminalGround250 VDC101074 Box- 105-126 VDCof Elec. Box101077 Box- 105-126 VDC181001 Box- 143-157 VDC181001-X Box- 170-190 VDC181002 Box- 143-157 VDC181002-X Box- 170-190 VDC181004 Box- 130-157 tests and are passed, the ALTRONIC I unit is either or is failed, the problem may be in the alternator stator (7) or electronic box(13). Remove the two screws (12) holding box (13) to the alternator. Check the connectionsbetween the box and alternator. If OK, unplug the stator leads from the electronic - ALTRONIC stator winding (7) with ohmmeter as follows:POSITIVENEGATIVEMETERMETER LEADMETER LEADSCALEREADINGS tator leadStator leadR X 10,000171001 - 4,300-5,300 ohms171003 - 980-1,220 ohmsStator leadAlt.

5 CaseR X 10,000171001 - Infinite171003 - InfiniteNOTE:The 171001 stator has RED leads; 171003 has BLUE leads. Replace stator if 7 --MAGNET BARFLUSH MAGNETALTERNATORIGNITIONCOIL7mmCABLE7mm BOX 101074, 101077, 181001, 181001-X, 181002, 181002-X, the stator checks OK (section ) but the SYSTEM fails either test or , replace theelectronic box (13). tests below apply to types 101074, 101077, 181001, 181001-X, 181002, 181002-X and NOT short connector pins to case with the box mounted on the the box from the alternator for all tests; short center terminal to case before commencing thetests LEADMETER LEADSCALEREADINGS hutdownCaseR X 10,000 Infinite or charging to finalterminalinfinite forOtherMeter should show capacitorstator leadsocketR X 10,000charging (about 5 secs.) tofinal infinite X 10,000 Meter should give slight deflectionpin "A"R X 10,000tion with final infinite X 100101074, 101077- 430-510 ohmspin "B"pin "C"181001, 181002- 430-510 ohms181001-X, 181002-X- 430-510 ohms181004- 750-1,100 COIL AND CABLE ASSEMBLY - ALTRONIC at pick-up coil connector with ohmmeter as follows:POSITIVENEGATIVEMETERMETER LEADMETER LEADSCALEREADINGC onnectorConnectorR X 100800-1,700 ohmspin "B"pin "C"Connector pinConnectorR X 10,000 Infinite"B" or "C"pin "A"Connector pinConnectorR X 10,000 Infinite"A", "B", "C" wiring and assembly should be as indicated 8 TEST - ALTRONIC the complete SYSTEM as shown below.

6 Turn the alternator shaft one or more revolutionsby hand; then push the magnet bar down squarely against the "A" pick-up of the pick-up spark should jump a 7 mm gap as shown. Repeat the sequence above using "B" and then "C"pick-up. If the performance test is failed, proceed to step the voltmeter to the electronic box as indicated below; turn the alternator shaft one ormore revolutions by hand:POSITIVENEGATIVEMETERMETER LEADMETER LEADSCALEREADINGW hite lead ofGround250 VDC181003 Box - 105-126 VDC5-pin plug181003-X Box - 130-158 VDC181006 Box - 142-158 VDC181006-X Box - 170-190 tests and are passed, the ALTRONIC I-6 unit is either or is failed, the problem may be in the alternator stator (7) or electronic box(13). Remove the two screws (12) holding box (13) to the alternator. Check the connectionsbetween the box and alternator. If OK, unplug the stator leads from the electronic - ALTRONIC stator winding (7) with ohmmeter as follows:POSITIVENEGATIVEMETERMETER LEADMETER LEADSCALEREADINGS tator leadStator leadR X 10,000171001 - 4,300-5,300 ohms171003 - 980-1,220 ohmsStator leadAlt.

7 CaseR X 10,000171001 - Infinite171003 - InfiniteNOTE:The 171001 stator has RED leads; 171003 has BLUE leads. Replace stator if 9 --MAGNET BARFLUSH MAGNETIGNITIONCOIL7mmCABLE7mm BOX 181003, 181003-X, 181006, the stator checks OK (section ) but the SYSTEM fails either test or , replace the electronic box(13). tests below apply to types 181003, 181003-X, 181006, NOT short connector pins to case with the box mounted on the the box from the alternator for all tests; short terminal "E" of the 5-pin plug to casebefore commencing the tests LEADMETER LEADSCALEREADINGS hutdownCaseR X 10,000 Infinite or charging to finalterminalinfinite forOtherMeter should show capacitorstator leadsocketR X 10,000charging (about 5 secs.) tofinal infinite connectorR X 10,000 Meter should give slight deflectionpin "A","B","C"with final infinite connector3-pin ConnectorR X 100180-200 ohms - OKpin "A",pin "A",0-150 ohms - faultythen "B",then "B",then "C",then "C", COIL AND CABLE ASSEMBLY - ALTRONIC at pick-up module connector with ohmmeter as follows:POSITIVENEGATIVEMETERMETER LEADMETER LEADSCALEREADINGC onnectorConnector pinR X 10,000 Infinitepin "D"pin "A","B","C"ConnectorConnectorR X 10,000 Infinitepin "E"shell-- 10 - ALTRONIC I ALTRONIC I unit breaks down into two major parts: alternator and electronic box.

8 Remove thetwo screws (12) holding the electronic box (13) to the alternator. Unplug the two alternator leadsfrom the electronic box and separate the box from the procedures of this section require the use of an arbor - the two remaining screws (12) holding the cover plate (10) to the alternator. LoosenO-ring (9) from housing (3). the assembly with the flange end up, remove stator (7), spacer (8), O-ring (9) and cover(10) as a group; a vertical shaking motion will help to accomplish the stator leads and grommet (7a) from the cover (10). - FRONT HOUSING UNIT ONLY: Remove hardware (15), (16) and sleeve (14) from the unit spring pin (1a) out of coupling (1) and shaft (2) and remove it is necessary to replace bearing-shaft (2), support housing on the coupling end and press shaftout of the magnet-rotor assembly (6) and housing (3). magnet-rotor (6) in a cloth or paper to keep it - FRONT HOUSING a new bearing-shaft (2) into housing (3) until it bottoms against the shoulder.

9 Housing (3)should be supported behind the internal shoulder (tool no. 506101B). Press on the outer race ofthe bearing using tool no. all debris from magnet-rotor assembly (6). magnet-rotor assembly (6) over shaft with its plate facing inward as shown below. Supportthe shaft on the coupling end (tool no. 506102B) and press magnet-rotor assembly on shaft .650"from the housing surface - see :If the fit is loose, apply epoxy glue to the bore of the coupling (1) on the shaft and secure with spring pin (1a). Use tool no. 506108A for UNIT ONLY: Install sleeve (14) and engine gear. Secure with hardware (15) and (16).BEARING-SHAFT (2)HOUSING (3)MAGNET-ROTOR (6)COUPLING (1)SPRING PIN (1a).650"-- 11 - stator (7) so that the leads will pass directly up through the cover hole without crossing overthe shaft. See page 6 for the correct orientation of the housing ventilator spacer (8) and a new O-ring (9). stator leads and grommet (7a) throught the hole in cover (10).

10 Cover so that the four screw holes line up with the alternator; install and tighten the twoscrews (12) that do not secure the electronic that the O-ring (9) is not caught between the cover (10) and the mounting surface of housing(3). - ELECTRONIC BOX TO sure the alternator assembly has the correct ventilator orientation with respect to the statorlead position - see page without attached gasket: position a new gasket (11) and washers (11a). with attached gasket: glue on a new gasket (11) in the case of a previously used box; theloose washers (11a) are not the electronic box (13) positioned as shown below, connect the stator leads to the electronicbox sockets. Slide tubing (13a) over the two mating pieces. Position the electronic box leads flatagainst the epoxy compound in the box as shown below. Carefully lay the box in position on thealternator making sure the leads stay in the position the box to the alternator with two screws (12); be sure all four screws (12) are BOX DESIGNNEW BOX DESIGNGASKET (11)ATTACHEDWASHERTUBING (13a)GASKET (11)WASHER (11a)TUBING (13a) - ASSEMBLY assembly tools referred to in section are available from for correct operation per the test of section or 12.