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KAL EQUIP 2969 Spark Analyzer

1. FULL THREE 3 YEAR WARRANTY Actron Manufacturing Company 9999 Walford Avenue Cleveland Ohio 44102 4621 USA warrants to the user that this unit will be free of defects in materials and workmanship for a period of three 3 years from the date of original purchase Any unit that fails within this period will be repaired without charge when returned to an authorized factory repair center Actron requests that a copy of the original dated sales receipt be returned with the unit to determine if the warranty period is still in effect This warranty does not apply to damages caused by accident alterations or improper or unreasonable use ACTRON MANUFACTURING COMPANY DIS CLAIMS ANY LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY WRITTEN WARRANTY ON THE UNIT Some countries do not allow the disclaimer of liability for incidental or consequential damages so the above disclaimer may not apply to you This warranty gives you specific legal rights and you may also have rights which vary from state to state acirans ACTRON MANUFACTURING CO 1998 Actron Manufacturing Co 9999 Walford Avenue Printed in USA Cleveland Ohio 44102 2 2254 USA P B i 1 pA RESET P B T 2969 Spark Analyzer Vehicle Service Information The following is a list of publishers who have manuais containing vehicle diagnostic information Some manuals may be available at auto parts stores or your local public library For others
2. higher NOTE If distributor ignition type was selected this reading will reflect every ignition event When DIS ignition type is selected this reading will reflect only combustion ignition events no wasted spark data 3 Maximum Measurement This number is the maximum measurement for the current measurement type since last reset OVER may also appear in the max location indicating that a reading higher than the range was received NOTE If DIS ignition type was selected only the combustion event data will be used to determine the maximum 4 Minimum Measurement This number is the minimum measurement for the current measurement type since last reset NOTE If DIS ignition type was selected only the combustion event data will be used to determine the minimum 5 Low battery Indicator When the testers battery is nearly discharged the Low Battery indicator will flash in the lower left corner of the display Section 2 Testing WARNING Use caution working around the ignition coil distributor cap ignition wires and spark plugs These components have high voltage when the engine is running Electrical shock may occur if you disconnect or connect secondary wires while the engine is running 2 1 Spark Event Test Procedure Attach Pickup clamp You may want to draw a picture of the engine and spark piug wires show ing the order in which you will be testing Connect the Pickup Clamp blue to the first plug wir
3. information and replacement components can be ordered by contacting KAL Equip directly By US mait Actron Manufacturing Company 9999 Walford Avenue Cleveland OH 44102 4621 USA Phone For Technical Support call 4 800 253 9880 E Mail Actron is also available electronically for comments and ordering information Actron s E Mail address is sunpro actron com And while you re on line be sure to check out Actron s Website where you ll find equipment information new products and technical tips On the World Wide Web http www actron com 15
4. secondary ignition voltage measurement on the LCD 7 Take Firing Voltage reading Take Kv reading from the LCD real time reading 8 Take Firing Voltage Reading Under Load Place the engine under load condition while observing the Kv reading The Kv reading should increase 30 to 50 percent during increased engine load If the Kv did not increase the proper amount see Table 4 on page 12 Example An idle reading of 15 Kv 15 Kv x 1 3 30 19 5Kv 15 Kv x 1 5 60 22 5Kv The Kv reading should have in creased to about 19 5 to 22 5 Kv 13 e Misfire Check Intermittent misfires under load can be found using the Spark Analyzer To find such problems follow the directions below 1t Attach Pickup clamp Connect the Pickup Clamp biue to the first plug wire near the spark plug To ensure accurate readings keep clamp at least 1 2 inches from other ignition cables and metallic engine parts 2 Ground Tester z Connect Ground Clamp black to a good vehicle ground or the battery s negative terminal 3 Turn tester ON Press the ON OFF button If the tester does turn on make sure it has a good 9V battery 4 Select Distributor or DIS Select P DISTRIB for testing on vehicles with distributors and press T DIS for distributorless vehicles 4 Start engine Start engine and let idle Allow engine to warm up and the idle to stabilize before monitoring and recording readings 5 Set tester to Peak Kv measurements Press th
5. Fuel mixture rich Plug wire or plug voitage leakage Attach Pickup clamp Connect the Pickup Clamp blue to the first plug wire near the spark plug To ensure accurate readings keep clamp at least 1 2 Inches from other ignition cables and metallic engine parts Ground Tester Connect Ground Clamp black to a good vehicle ground or the battery s negative terminal Turn tester ON Press the ON OFF button If the tester does turn on make sure it has a good 9V battery Select Distributor or DIS Select P DISTRIB for testing on vehicles with distributors and press T DIS for distributorless vehicles Start engine Start engine and let idle Allow engine to warm up and the idle to stabilize before monitoring and recording readings Set tester to Peak Kv measurements Press the P button The tester will display peak secondary ignition voltage measurement on the LCD Take Firing Voltage reading Take Kv reading from the LCD real time reading Take Acceleration Firing Voltage reading While observing the Kv reading real time quickly increase the engine s speed snap the throttle and allow engine to return to idle The Kv reading should increase from about 30 to 50 percent during increased engine speed Hf the Kv did not increase the proper amount see the Table 4 Example An idle reading of 15Kv 15Kv x 1 3 80 19 5Kv 15Kv x 1 5 50 22 5Kv The Kv reading should have increased to about 19 5 to 22 5 Kv K
6. Ignition timing overly retard Fouled spark plug Shorted spark plug Lower secondary Kv on one or more cylinders Open plug wire s Degraded spark plug s Plug gap to big Ignition timing overly advanced Fuel mixture to lean may also cause misfires Higher secondary Kv on one or more cylinders Fuel distribution problems Vacuum leak Bent or worn out shaft bushings in the distributor Loose rotor or distributor cap Moisture inside distributor cap Multiple ignition related problems such as those listed for Low and High Kv Uneven secondary Kv on all cylinders Table 1 Burn Kv Measurements 2 2 Additional Tests The amount of voltage required to maintain spark during the combustion event is referred to as Burn Kv Differences in burn voltage can be the result of bad plug wires bad plugs bad cap or rotor or fouling If the readings vary significantly from each other check Table 2 below for possible causes ult High burn Kv on one or more cylinders Low burn Kv on one or more cylinders e Secondary Cable Check This check procedure can be used to find open shorted or high resistance secondary cabies 4 Attach Pickup clamp Connect the Pickup Ciamp blue to the first plug wire near the spark plug To ensure accurate readings keep clamp at least 1 2 inches from other ignition cables and metailic engine parts 2 Ground Tester Burn Kv OKy Open plug wire s f i Connect Ground Clamp black to
7. a good vehicle ground or the battery s Corrosion on the distributor cap negative terminal Worn spark plug s 3 Turn tester ON oe F gap eao an d to plug or coil ca Press the ON OFF button If the tester does turn on make sure it has a 9 Properly plug p good 9V battery Shorted plug wire s 4 Select Distributor or DIS Shorted coil secondary Select P DISTRIB for testing on vehicles with distributors and press Fouled spark plug s T DIS for distributorless vehicles Shorted spark plug s Spark plug s gap set to small 5 Start engine Start engine and let idle Allow engine to warm up and the idle to stabilize Table 2 before monitoring and recording readings 6 Set tester to Peak Kv measurements P Press the P button The tester wiil display peak secondary ignition voltage Burn Time Measurements measurement on the LCD xa s Burn time is the amount of time spark is maintained across the electrodes Differences in burn time can be the result of secondary Burn Time ms wires plugs plug gap cap or rotor fuel mixture ignition timing cylinder compression If the readings vary significantly from each other check Table 3 below for possible causes ng burn time on one or more cylinders Short burn time on one or more cylinders Table 3 7 Take Firing Voltage reading Take Kv reading from the LCD real time reading 8 Move Pickup Clamp Move the Pickup clamp blue up the secondary cable towards the ignition coll dist
8. ark signal or button presses occur in three minutes the tester will automatically turn off Turn the tester off when not in use to conserve battery life Button This button is used to view the triple screen The triple screen gives all three real time readings at one time RESET Button The Reset button clears the minimum and maximum values All min and max values will be cleared whether they are currently being displayed or not NOTE The RESET button does not function while the unit is in Triple Screen mode P Peak Kv Pressing the P button will display Peak Kv readings The real time minimum and maximum readings will all be displayed Peak Kv is the secondary ignition voltage it took to initiate the spark event B Burn Kv Pressing the B button will display Burn Kv readings The real time minimum and maximum readings will all be displayed Burn Kv is the secondary ignition voltage it took to maintain spark during the combustion process T Burn Time ms Pressing the T button will display Burn Time readings The real time minimum and maximum readings will all be displayed Burn time is the length of time from Peak Kv until Burn Kv ends length of spark event The Burn time is measured in milliseconds one thousandths of a second Pickup Clamp blue The Pickup Clamp connects the tester to the vehicle s spark plug wires for firing event measurements Display The display is 16 characters
9. by 2 lines and will be used to show readings and display information Ground Clamp black The ground clamp is used to supply ground for the Pickup Clamp s harness shield If this is not properly grounded misleading data may be received Battery Compartment The battery compartment located on the back of the tester is used to hold the units 9V battery 4 3 Using the Spark Analyzer Selecting Distributor or Distributorless DiS A screen asking you to choose what type of ignition system is to be tested will appear after the welcome screen The two selections are P for Distributored systems and T for DIS Distributorless systems The P DISTRIB selection will not try to filter out wasted spark data The T DIS selection will allow the tester to ignore the wasted spark events This means the real time and min max data will only be displayed for combustion firing events NOTE If P DISTRIB is chosen for a DIS system the wasted spark firing event data will be displayed Since the wasted spark event has lower readings this will cause the min values to reflect the lower wasted spark readings Also do to wasted spark readings the real time data will jump around a lot Viewing Spark event measurements To view spark event measurements press P B or T buttons P for Peak Kv measurements B for Burn Kv measurements T for Burn Time measurements Clearing min and max values If you wish to clear the values store
10. d in min and max press the RESET button The reset function clears the min and max for all spark events measurements NOTE The RESET button does not function while the unit is in Triple Screen mode Triple Screen mode View ali three spark event readings at once if you wish to view Peak Ky Burn Kv and Burn Time on the display at one time press the button This function is helpful in comparing the relationship of all three measurements at once Low Battery Indicator The low battery symbol will flash in the lower left corner of the LCD when the battery needs replacing Auto shut off feature The tester will automatically tum off if no button s are pressed and no spark data is received for about three minutes Tester will not turn on Check that a fresh battery is installed in the tester if the battery is good and the tester stiil does not power up call KAL Equip at 1 800 253 9880 4 4 Display Descriptions 4 Measurement Type This area of the display will indicate what type of measurement is being displayed There are three different measurements this tester will perform Peak Kv Burn Kv and Burn ms 2 Real Time Measurement Reading The real time measurement is displayed in this screen location When readings greater than the measurement range are received OVER will appear instead of a number For Peak Kv OVER indicates that the reading was 50Kv or higher For Burn Kv OVER indicates that the reading was 10Kv or
11. e P button The tester will display peak secondary ignition voltage measurement on the LCD 6 Reset min and max values Press the RESET button The tester will display peak secondary ignition voltage measurement on the LCD 6 Observe Reading Under Load Operate the test vehicle at the speed and load conditions where you believe the misfire is occurring Check the min and max readings If either is more than 30 to 50 percent higher or lower than the average real time reading the cylinder may be misfiring NOTE A quick check off all cylinders can be accomplished by hooking the KV Clamp blue to the ignition coil s secondary wire on distributor type vehicies 14 Section 3 Battery Installation Note If the tester will not be used for an extended amount of time remove the battery This is done to prevent battery leakage while in the tester Installation of the battery 1 Disconnect the tester from vehicle 2 Turn tester OFF 3 Hold the tester face down with both hands 4 Using both thumbs firmly press downwards and outwards on the battery compartment door at the bottom of the tester 5 Slide the battery compartment door away from the tester to remove 6 Remove old battery if necessary 7 Attach new battery to connector and install inside compartment 5 Replace battery cover door Slide door inwards until it snap closed Section 4 Call KAL Equip In addition to your local dealer product catalogs pricing
12. e near the spark plug To ensure accurate readings keep clamp at least 1 2 inches from other ignition cables and metallic engine parts See the illustration for an example Ground the tester Connect Ground Clamp black to a good vehicle ground or the battery s negative terminal A good ground is required for Pickup Clamp s harness shield If this is not properly grounded noise may cause misleading data to be received Turn tester ON Press the ON OFF button If the tester does turn on make sure it has a good 9V battery Select Distributor or DIS Select P DISTRIB for testing on vehicles with distributors or press T DIS for distributorless vehicies Start Engine Start engine and let idle Allow engine to warm up and the idle to stabilize before monitoring and recording readings Take readings Record the Peak Kv Burn Kv and Burn Time real time readings Next Cylinder Connect the Pickup Clamp blue to the next cylinder s wire to be tested Refer to the drawing you made indicating test order Remember to keep clamp at least 1 2 inches from other ignition cables and metallic engine parts to ensure accurate readings Repeat steps 5 and 6 until all cylinders have been tested Compare readings Refer to the different measurement sections for test results explanations Peak Kv Measurements Peak Kv is the secondary ignition voltage it took to initiate the spark event Because this voltage is in the thousands it is refe
13. ributor Take a Kv reading and note the difference If the Kv reading increase from little or no Kv to a significantly higher reading a short may be present in between the two points A significant increase or decrease in Kv reading indicates the secondary cable is open between the two points If you reach the coil or distributor end of the cable and the Kv reading has increased more than expected check the secondary cables resistance NOTE Most modern vehicies use resistive secondary cables for noise reduction These cables will cause a slight increase in the Kv reading from the plug to the coil or distributor This is normal Rich fuel mixture e Coil or plug wires incorrect plug gap e Ignition timing Incorrect Cylinder compression Lean fuel mixture e Coil or plug wires incorrect plug gap Ignition timing Incorrect Cylinder compression 40 11 e Acceleration Test for distributor ignition systems A quick acceleration with no load on the engine can help you find several problems in the secondary of the ignition system This test checks for the following ignition related problems worn plugs spark gap problems incorrect fuel mixture and ignition wire problems A properly functioning ignition system s firing voltage will increase about 30 to 50 percent when a no load quick acceleration is performed 1 5 Kv reading Spark plug gap to small Ceramic Insulator damaged change LOW Spark plug fouled
14. rming a road test never operate the tool alone while driving the vehicle Always have one person drive the vehicle while an assistant operates the tool Always turn ignition key OFF when connecting or disconnecting electrical components unless otherwise instructed Always follow vehicle manufacturer s warnings cautions and service procedures Section 1 The Spark Analyzer 1 1 Introduction The Spark Analyzer is used to measure secondary ignition firing events Because firing voltages are typically in the thousands voltage readings are referred to as Kv Kilovolts readings Peak firing and burn voltages are both measured by this unit The tester will also measure the length of burn time This is referred to as ms milliseconds All of the measure ments are possible on ignition system using distributors and on DIS Distributoriess or Direct Ignition System type system Measurements are not possible on coil on plug systems Much like more costly ignition oscilloscopes the Spark Analyzer allows the user to compare ignition firing events to one another These readings may be taken at idle or at higher engine speeds with the engine under load The Kal Equip Spark Analyzer will often test an ignition system in less time than required to hookup an ignition oscilloscope 1 2 The Tester Burn _ Burn Time Kv l k 7 of tester 10 ON OFF Button This button is used to turn the tester on and off If no sp
15. rred to as Kv Kilovolts Differences in Peak Kv readings can be caused by problems with the following areas plug wires amp plugs cap rotor coil s ignition timing air fuel mixture cylinder compression When testing a DIS vehicle consideration must be given to cylinder firing polarity Most DIS ignition systems use coils that connect two secondary wires and plugs This type of ignition coil setup will fire one plug conventionally negative The other plug connected to the same coil will fire inverted positive Their may be a notice able difference as much as 6 Kv in Peak Kv readings from conventional to inverted This is normal To avoid being mislead only compare similar firing types readings to each other when testing on DIS systems 0 Kv NOTE Some engine applications use two spark plugs per engine cylinder The secondary plugs may not be used at all times if voltage measurements on the same type of firing plugs varies by more than about 5Kv a problem may exist in ignition circuit or it s components See the Table 1 below for test result meanings None Functioning properly All like readings within approx 5Kv No firing voltage all cylinders No power to ignition coil s Bad ignition coil s Ignition Module Powertrain controller failure e Crank Cam sensor failure Shorted plug wire s Shorted coil secondary Cylinder compression low Plug gap to small e Fuel mixture too rich
16. s at any time to this manual or accompanying product without obligation to notify any person or organization of such changes General Safety Guidelines to Follow When Working on Vehicles To prevent accidents that could result in serious injury and or damage to your vehicle or test equipment carefully follow these safety rules and test procedures at all times when working on vehicles Always wear approved eye protection Always operate the vehicle in a well ventilated area Do not inhale exhaust gases they are very poisonous Always keep yourself tools and test equipment away from all moving or hot engine parts Always make sure the vehicle is in Park Automatic transmission or neutral manual transmission and that the parking brake is firmly set Block the drive wheels Never lay tools on vehicle battery You may short the terminals together causing harm to yourself the tools or the battery Never use tool if its internal circuitry has been exposed to any liquids Never smoke or have open flames near vehicle Vapors from gasoline and charging battery are highly flammable and explosive Never leave vehicle unattended while running tests Always keep a fire extinguisher suitable for gasoline electrical chemical fires handy Always use caution when working around the ignition coil distributor cap ignition wires and spark plugs These components have high voltage when the engine is running When perfo
17. v reading change HIGH Worn spark plug Resistor spark plug bad Wide plug gap Fuel mixture lean Misaligned or worn distributor cap Spark plug wire conductor has a break in it Table 4 12 e Load Test Observing firing voltages while the engine is under load can also help you find several problems in the secondary of the ignition system A properly functioning ignition system s firing voltage will increase about 30 to 50 percent when sufficiently loaded WARNING Observe all vehicle manufacturer s safety practices and precau tions for catalytic converter protection when testing a ignition system under load 1 Attach Pickup clamp Connect the Pickup Clamp blue to the first plug wire near the spark plug To ensure accurate readings keep clamp at least 1 2 inches from other ignition cables and metallic engine parts 2 Ground Tester Connect Ground Clamp black to a good vehicle ground or the battery s negative terminal 3 Turn tester ON Press the ON OFF button If the tester does turn on make sure it has a good 9V battery 4 Select Distributor or DiS Select P DISTRIB for testing on vehicles with distributors and press T DIS for distributorless vehicles 5 Start engine Start engine and let idle Allow engine to warm up and the idle to stabilize before monitoring and recording readings 6 Set tester to Peak Kv measurements Press the P button The tester will display peak
18. you need to write for availability and pricing specifying the make model and year of your vehicle Vehicle Service Manuals Chilton Book Company Chilton Way Radnor PA 19089 Saturn Adistra Corporation c o Saturn Publications 101 Union St Post Office Box 1000 Plymouth Mi 48170 Haynes Publications 861 Lawrence Drive Newbury Park CA 91320 Ford Lincoln amp Mercury Ford Publication Department Helm Incorporated P O Box 07150 Detroit MI 48207 Mitchell Manuals inc Post Office Box 26260 San Diego CA 92126 Motor s Auto Repair Manual Hearst Company 250 W 55th Street New York NY 10019 Chrysler Plymouth Dodge Jeep Eagle Dyment Distribution Service Service Publications 12200 Alameda Drive Strongsville OH 44136 Buick Cadillac Chevrolet GEO GMC Oldsmobile Pontiac Honda Isuzu Suzuki Kia Hyundai amp Subaru Helm Incorporated Post Office Box 07130 Detroit MI 48207 All information illustrations and specifications contained in this manual are based on the latest information available from industry sources at the time of publication No warranty expressed or implied can be made for its accuracy or completeness nor is any responsibility assumed by Actron Manufacturing Co or anyone connected with it for loss or dam ages suffered through reliance on any information contained in this manual or misuse of accompanying product Actron Manufacturing Co reserves the right to make change

KAL EQUIP 2969 Spark Analyzer

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