GUIDLINE FOR FIXING PROBLEM ON DISTRIBUTORLESS IGNITION SYSTEM

Problem:
ES-DIS-3: Distributorless Ignition System Trainer-The Spark Plug No. 1 emits a spark of low
intensity.

Solution:
This kind of problem is a common problem that can be caused by several factors such as; a
bad spark plug, bad Ignition coil, problem on power transistor circuit or it also can be caused
be the problem on ECU board.
As you have been troubleshooting the unit by changing the spark plug position, we assume
that possible problem is caused by the Power transistor board or ECU board. In order to solve
the problem we recommend you to replace both of the boards

REPLACEMENT PROCEDURE OF PCB POWER TRASNISTOR AND DISTIBU-

TOR LESS IGNITION ELECTRONIC CONTROL UNIT

Make sure you have already received the parts below:

1. PCB Electronic Control Unit (Picture 1)
2. PCB Power Transistor (Picture 2)
3. Electronic Choke noise filter (Picture 2)

Figure 1. Part replacement of Distributor less ignition system trainer

Tool Requirement :
1. Screwdriver +
2. Wrench size 6mm
3. Solder Iron
4. Solder Pasta (if necessary)
5. Multimeter
6. Oscilloscope

Replacement Procedure
First step, please study carefully the electrical wiring (real wiring connection) of
distributorless ignition system trainer as shown in Figure 2 and make sure you understand the
wiring connection.

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Follow procedure below to replace the Distributor Less Ignition Electronic Control Unit PCB
(DAQ-DIECU7160-V1.0), Labtech Power Transistor PCB and assemble the Electronic Choke
(noise filter) :

1. Place the Distributor ignition system trainer (ES-DIS-3) in a proper place.

2. Make sure the power input of the trainer is disconnected from the power source.
3. Use screwdriver (+) to open the back cover of the trainer.
4. Observe and find both of the PCBs. The PCB of Distributor Less Ignition Electronic
Control unit is located on the top left side in front of you and Power transistor PCB is
located at bottom side of the trainer. See Figure 3 as reference.

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 Figure 2. Wiring connection of distributor less ignition system trainer

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Figure 3. Back side of the distributor less ignition system trainer. Position of both PCBs need
to be replaced.

5. Open 4 bolts on PCB holder by using wrench size 6 mm or pliers. Observe that PCB
and find the wiring connection, there are 4 wiring connection group (1. input from
crankshaft sensor, 2. input from camshaft sensor, 3. DC power supply and 4. output
into PCB Labtech power transistor and (TP) test points). For more detail see Figure 4
below.

Figure 4. PCB of distributor less ignition electronic control unit

6. Please take good pictures of all wiring connections before replacing the boards. This
will be very important for your reference.
7. Please replace carefully the wiring from the old PCB Distributor less ignition
electronic control board with the new PCB. Use Figure 4 above as a reference.
Note : Please remove and re-connect the wire one by one to avoid any mistake or
incorrect connection during the exchanging process. Use color codes for your

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 reference.
8. Make sure all wire connections (terminal screw) are tightened properly.

Replacement of Labtech Power Transistor PCB

9. Find the Labtech Power Transistor PCB that is located at the bottom of the trainer.
Open 4 bolts on PCB holder by using wrench size 6 mm or pliers.
10. Labtech power transistor PCB has 4 terminal screws. One is 12DC power supply (red
cable with 703 cable mark), and the other terminal screws are input from Distributor
less ignition electronic control unit PCB. The output of this PCB is connected to the
ignition coil in front of the trainer as the trigger to the spark plug according to the
firing order. Cable mark 01 (blue wire) is connected to the coil on plug ignition coil
No.1 as the trigger for the tachometer (green wire).

Figure 5. Wiring connection of Labtech power transistor PCB

11. Replace carefully the wiring from the old PCB Labtech power transistor ignition coil
(old version) with the new version PCB.
12. Make sure the all the wire connection are tightened properly.

Assembling the electronic choke (noise filter)

13. Prepare your solder iron to assemble the electronic choke (noise filter).
14. Find the wire as shown in Figure 6 below.

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 Figure 6. Electronic choke (noise filter) assembly

15. The electronic choke is assembled on the 12DC power coil of plug ignition coil No. 1
to reduce noise when observing the ignition timing advance.
16. After completing the procedure above, please make sure that the connection is correct
and tightened properly before connecting the power supply of the trainer.
17. Double check your wiring connection with the wiring diagram.

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