AVL AVL DiCom 4000 Service Manual Download Page 181

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4000

Tools for the Service Technician

Service Manual

9-1

9. Tools for the Service Technician

−

Memory card with current operating software

−

Installation adapter for software update (ident. number: BV2150)

−

PC keyboard
(German [ident. number: GY0369] or English (ident. number: GY0413)]

−

3-component calibrating gas mixture (CO, HC, CO

) with fine-adjustment

pressure regulator

−

Special spanner for undoing speed angle board socket

−

AVL DiTest 803 diagnostics simulator (ident. number: GH0465)

Delivers calibratable rpm signal, permits simulation of the following signals:
clamp-on transducer, nozzle needle lift sensor, RIV, TDC analogue, TDC digital,
oil temperature, ignition signal,

probe

Together with AVL Adapter Box 803 (ident. number: GH0474) suitable for Series
400 Exhaust Gas Testers and AVL DiTime 873.

Summary of Contents for AVL DiCom 4000

Page 1: ...8020 Graz Austria Phone 43 316 787 0 Fax 43 316 787 550 http www avl com Ident number AT0391E Revision no 04 Edition January 1999 Subject to alteration Printed in Austria by AVL LIST GMBH Graz Service Manual AVL DiGas 4000 AVL DiCom 4000 AVL DiSmoke 4000 ...

Page 2: ...erved The contents of this document may not be reproduced in any form or communicated to any third party without the prior written consent of AVL While every effort is made to ensure correctness AVL assumes no liability for errors and omissions ...

Page 3: ...t Due to the operating principle of this product the accuracy of the measurement results it produces not only depends on its correct operation and function but also upon a variety of peripheral conditions beyond the control of the manufacturer The results obtained from this product must therefore be subjected to careful examination by an expert e g for plausibility before any action is taken that ...

Page 4: ......

Page 5: ... In this event use rubber gloves and goggles First Aid Contact with the eyes Rinse eyes with water for at least 15 minutes consult a doctor immediately Contact with the skin Remove contaminated clothing immediately Wash the affected part of the body thoroughly with water If a burning sensation is felt on the skin consult a doctor immediately Swallowing Drink a lot of cold water Consult a doctor im...

Page 6: ......

Page 7: ...2 4 2 1 7 Replacing the NO Sensor 2 4 2 2 Opacity Measuring Chamber 2 5 2 2 1 Measuring Chamber Too Hot Too Cold 2 5 2 2 2 Changeover Valve Error 2 5 2 3 Linearity Opacity Error 2 6 2 3 1 Opacity Measuring Chamber Type A 2 6 2 3 2 Opacity Measuring Chamber Type 4000 2 6 3 Software 3 1 General 3 1 3 2 Installation of Operating Software Software update 3 4 4 Evaluation Unit 4 1 General Description 4...

Page 8: ...4 15 4 9 2 Circuit Diagrams 4 16 4 10 Speed Angle Board 4 21 4 10 1 Components Location Diagram 4 21 4 10 2 Circuit Diagrams 4 22 4 11 Pneumatics Board 4 26 4 11 1 Components Location Diagram 4 26 4 11 2 Circuit Diagram 4 27 4 12 Printer Adapter 4 28 4 12 1 Components Location Diagram 4 28 4 12 2 Circuit Diagram 4 29 4 13 Memory Adapter 4 30 4 13 1 Components Location Diagram 4 30 4 13 2 Circuit D...

Page 9: ...24 1 Pneumatics Board 4 52 4 24 2 Multi gas Measuring System General Requirements 4 52 4 25 Service Mode 4 54 4 25 1 Changing O2 and NO Sensor 4 54 4 25 2 Gas Calibration 4 54 4 25 3 4 5 Gas 4 54 4 25 4 Diesel Opacity Measuring Chamber Type A 4 60 4 25 5 Diesel Opacity Measuring Chamber 4000 4 62 5 4 5 Gas Measuring Instruments Unit 5 1 General 5 1 5 2 Gas Analyzer 5 2 5 2 1 Light Source 5 3 5 2 2...

Page 10: ... 21 6 11 Purging Air Panels YM2691 6 23 6 12 Electrical Wiring 6 24 6 13 Reassembly of the Opacity Measuring Chamber 6 32 7 Opacity Measuring Chamber 4000 7 1 System Check with Filter 7 1 7 2 Upgrading an AVL 4000 DiGas to an AVL 4000 DiCom 7 2 7 3 Assembling and Disassembling the Opacity Measuring Chamber 7 4 7 4 Design and Details of Assemblies 7 5 7 4 1 Fan Unit BO2189 7 5 7 4 2 Measurement Cel...

Page 11: ...instruments AVL DiGas 4000 AVL DiTest 5400 AVL DiSmoke 4000 AVL DiTest 5430 AVL DiCom 4000 AVL DiTest 5460 Some areas are described in detail in the respective Operating Manual and therefore not dealt with in this Service Manual We therefore advise always using the Service Manual together with the respective Operating Manual ...

Page 12: ...Particulate filter Condensate filter Activated carbon filter Replace in good time when soiled by HC vapour e g petrol vapour Cleaning Probe and hose see Operating Manual Condensate pump cleaning kit see Operating Manual Calibration with calibrating gas as per statutory requirements Replacing O2 sensor Replacement is requested by tester Replacing NO sensor Replacement is requested by tester Visual ...

Page 13: ...l elements electrical connections probe connection plate O ring electrical cables soiling of measuring chamber and purging air channel Function check fans heating changeover valve Cleaning of optical elements Linear check Change lamps Opacity measuring chamber type 4000 Visual check silicon seal leaks in housing housing components closure fittings snap mechanism of the optical elements electrical ...

Page 14: ...m 4 5 gas measuring instruments unit OK O2 sensor is OK NO sensor is OK Visual check of outside Entry in maintenance log book Cleaning Replace particulate filter see section 5 3 3 Particulate Filter Check O ring paper filter Visual inspection of probe and hose Function check Leak test see Operating Manual Gas calibration see Operating Manual ...

Page 15: ...Visual check Silicon seal Leaks in housing Housing components cracks faults Closure fittings snap mechanism of optical elements Electrical plug connections and cables Probe hose probe clamp Function check each test is described in the Operating Manual Test function of fan Test function of heating Check changeover valve Clean the optical elements by wiping Linear check ...

Page 16: ...and hose Opacity measuring chamber type A Visual check Silicon seal Leaks in housing Housing components cracks faults Closure fittings snap mechanism of optical elements Electrical plug connections and cables Probe connection plate O ring Probe hose probe clamp Soiling of measuring chamber purging air channel Function check each test is described in the Operating Manual Test function of fans Test ...

Page 17: ...ittings snap mechanism of optical elements Electrical plug connections and cables Probe hose probe clamp Function check each test is described in the Operating Manual Test function of fan Test function of heating Check changeover valve Clean the optical elements by wiping Linear check Function test Leak test see Operating Manual Gas calibration see Operating Manual ...

Page 18: ...ensor is OK Open evaluation unit remove cover Visual inspection clean pcb If necessary update setpoint data and software Close housing seal with service seal Enter in maintenance log book Cleaning Replace particulate filter see section 5 3 3 Particulate Filter Check O ring paper filter Visual inspection probe and hose Clean condensate pump using cleaning kit Function test Leak test Gas calibration...

Page 19: ...ring chamber Visual check Silicon seal Leaks in housing Housing components cracks faults Closure fittings snap mechanism of optical elements Electrical plug connections and cables Probe hose probe clamp Soiling of measuring chamber purging air channel Function check each test is described in the Operating Manual Test function of fan Test function of heating Check changeover valve Clean the optical...

Page 20: ...pacity measuring chamber type A Visual check Silicon seal Leaks in housing Housing components cracks faults Closure fittings snap mechanism of optical elements Electrical plug connections and cables Probe connection plate O ring Probe hose probe clamp Soiling of measuring chamber purging air channel Function check each test is described in the Operating Manual Test function of fans Test function o...

Page 21: ...se probe clamp Soiling of measuring chamber purging air channel Function check each test is described in the Operating Manual Test function of fans Test function of heating Check changeover valve Clean the optical elements by wiping Linear check Cleaning Replace particulate filter see section 5 3 3 Particulate Filter Check O ring paper filter Visual inspection probe and hose Clean condensate pump ...

Page 22: ...Periodic Maintenance AVL 4000 1 12 Service Manual ...

Page 23: ... hose kinked or is there a heavy object on the hose that is stopping the gas flow Check the paper filter in the filter housing If the filter is black replace it Always carry out a leak test after replacing a filter If the above measures do not solve the problem the hose system must be blocked in the measuring instruments unit or the pump is defective Remove the measuring instruments unit see Disma...

Page 24: ...in board and the measuring instruments unit 2 1 3 Measuring Chamber Temperature Too High Remove the probe from the exhaust pipe because when this error occurs the tester switches to zero calibration mode and needs to draw in fresh air Do not switch the tester off Wait at least 10 min Acknowledge the error by pressing Select Measurement again If the same error message appears again there is a fault...

Page 25: ...leaks from the tip of the probe to the inlet on the rear panel of the tester If you find no leaks disconnect the probe hose from the tester Connect a 2 m hose that is guaranteed leakproof to the inlet port of the tester close it off and carry out another leak test If the system passes the test the leak must be in the probe hose assembly If the system fails the leak test check the O rings in the fi...

Page 26: ...sor needs replacing Switch the instrument off and disconnect the mains cable Remove the NO sensor see section 5 6 2 Replacing the NO Sensor Observe the safety instructions for handling O2 sensors at the front of this manual Old sensors must be properly disposed of they are highly toxic special waste Every time the O2 sensor is replaced this must be recorded i e entered in the maintenance book Obse...

Page 27: ...ssage by pressing If the measuring chamber temperature does not return to the permitted range after several attempts 2 to 3 times there must be a fault If the temperature is still too low one of the heating blocks has probably failed see Operating Manual Heating Function Test or section 6 6 Heating Blocks and Orifice Plates or a temperature sensor has failed see section 6 8 Temperature Sensor If t...

Page 28: ... elements see Operating Manual Cleaning the Optical Elements of the Opacity Measuring Chamber Fold the optical elements back into place and acknowledge the message by pressing you will then see the main opacimeter menu 2 3 2 Opacity Measuring Chamber Type 4000 Remove the lens protector from the opacity measuring chamber and check the windows clean if necessary Press to start an automatic calibrati...

Page 29: ...1 1 Installed software version 2 Checksums depending on the country specific software allows the calibrating authorities to monitor The following checksums are displayed memory checksums for petrol and diesel Customer memory Checksum Not available 0002 500 KB 0036 1 MB 00F6 SELF TEST VERSION MEMORY OPTIONS CHECKSUM PRINTER INTERN EXTERN KEYBOARD INTERN EXTERN MEAS CHAMB 4GAS MEAS CHAMB DIES DICOM ...

Page 30: ...ption BMW option bit 0 option available bit 1 option not available The Speed Angle Board is absolutely necessary for the software options e g all options installed 01xx no options installed The following checksums are also displayed checksum for sections of the petrol program that are relevant to the measurement technology checksum for sections of the diesel program that are relevant to the measur...

Page 31: ...7 Fan control unit 8 Pneumatics valve 9 Serial silicon number motherboard 10 Serial silicon number opacity measuring chamber 11 Fan opacity measuring chamber 4000 12 Fan opacity measuring chamber 435 opacity measuring ï chamber 17 Communication 18 19 20 ü ý Power supply 21 Breaker channel 22 TDC channel 23 TDCANA channel 24 Peak meter TDC 25 Peak meter 26 Integrator 27 TDCANA channel filtering 28 ...

Page 32: ... PCMCIA slot Switch the tester on The software on the memory card is then installed automatically During installation the installation adapter will output short beeps On completion of the software installation the tester will output a long beep A continuous sound indicates that the software cannot be installed If the installation fails you will hear an intermittent signal A brief pause between the...

Page 33: ...it basically consists of the following components housing cover rear panel front panel frame LC display membrane keypad printer unit power supply board main board speed angle board measuring instruments block 4 5 gas measuring instruments unit O2 sensor fan rating label rubber feet memory extension memory adapter ...

Page 34: ...r measurement and condensate pump various filters and non return valve are accommodated on the rear panel The cover closes the entire housing and has built in finger grips to make it easier to carry The screws are situated in the cover in such a way as to permit the housing to be sealed for official calibration and subsequent sealing purposes The four gas tester can be upgraded to a combination te...

Page 35: ...eys remote control optional memory card connection strip printer optional electronic circuits with main board and the option pcbs printer board opacity board speed angle board including interfaces and sensor connections free slot for future expansions and the power supply assembly with mains switch components power supply unit fan and wiring ...

Page 36: ... rear panel Fig 4 2 Inlet for calibration gas O2 sensor NO sensor option Zero gas inlet pure air Control cable connect to opacity measuring chamber type A only Particulate filter Connection for probe Activated carbon filter Pump Condensate trap Analog output analog signal of exhaust opacity 0 5 V 0 100 opacity Condensate outlet Heating cable connection opacity measuring chamber type A or control c...

Page 37: ... by programmable logic The RTC real time clock has a ten year function guarantee on the lithium cell The main board and therefore the evaluation unit is unambiguously identified by a silicone serial number which carries an individual 48 bit code The internal temperature of the instrument is monitored by an NTC 4 2 1 2 Analogue Data Acquisition The necessary analogue values are measured by the 10 b...

Page 38: ...uch as baud rate parity check Interface socket 9 pin D sub socket Interface RS232 serial Data transfer format 8 bit 1 stop bit no parity Data transfer rate 9600 bit s Transfer code ASCII Pin assignment 1 2 3 4 5 PRG TxD RxD DTR GND Connected to GND Transmit data output Receive data input Not used Ground 6 7 8 9 DSR RTS CTS RI Not used Provided the instrument has the requisite software installed me...

Page 39: ...ddressed by ESD protected drivers 4 2 1 6 Generation of Auxiliary Voltage Various voltages are generated from the 4 power supply unit voltages 5 V 15 V 24 V 15 V analogue filtered voltages for powering the analogue circuits Vpp 12 V switchable programming voltage for flash eproms 5 12 V analogue precision reference voltage for ADC channels in the 196NT 5 V analogue negative supply for low cast mul...

Page 40: ...evaluated by the 196NT on the main board Measurements RPM measurements Supported sensors inductive sensors e g TDC sensors with different timings incl Motronic flywheel optical sensor digital pulses from engine management system AVL clamp on transducers AVL DiGas 4000 and AVL DiCom 4000 RIV sensors AVL DiGas 4000 and AVL DiCom 4000 needle movement sensors AVL DiGas 4000 and AVL DiCom 4000 inductiv...

Page 41: ...nt range 0 0 99 9 Resolution 0 1 Accuracy 1 0 Oil temperature measurement The temperature is measured by inserting the AVL oil temperature sensor available in various lengths into the sump or more rarely into the cooling water Measurement range 0 120 C Resolution 1 C Accuracy 4 C Lambda probe voltage and voltage of vehicle electric system A voltage can be measured lambda probe voltage or the volta...

Page 42: ...nnection cable can be used without an extension lead The speed angle board option ident number BO1721 consists of the following components speed angle board ribbon cable Installation Switch the instrument off and disconnect from the mains Open the instrument Remove the side housing sections undo 4 Phillips screws on the outside one hexagon nut on the inside Remove the GND connector Insert the spee...

Page 43: ...externally accessed mains fuse and a filter required by the statutory provisions for mains pollution 4 2 1 14 Converting 230 V to 115 V Device Replace 230 V pump on the real panel with 115 V pump The hose lengths must not be changed Both fuses in the mains switch group must be replaced by 3 15 A slow blow fuses The modification from 230 V to 115 V must be indicated clearly on the rating plate with...

Page 44: ... ignition board to the rear panel Remove the 4 fixing screws on the rear panel Remove the 3 fixing screws on the base plate Remove the solenoid valve from the rear panel Disconnect the hoses to the pneumatics module Remove the rear panel pulling towards the back Remove the activated carbon filter from the rear panel Disconnect the mains wiring to the power supply unit of the measuring instruments ...

Page 45: ...typical service life of long life ribbon 1 million characters violet 600 000 characters black The printer option ident number BO1720 consists of the following components printer adapter BB0279 printer cable for printers with connection cable BV1983 paper shaft YM3388 paper roll for dot matrix printer HP0057 3 metal screws DS1101 Instructions for conversion Switch off the instrument and disconnect ...

Page 46: ...variants the external PC keyboard option should be used The software supports an external PC keyboard connected to the 5 pin standard PC keyboard interface Function keys F1 to F6 have a parallel function with the softkeys When the instrument is powered up the external keyboard is initialised during the self test In the Service menu User data Languages it is possible depending on the software versi...

Page 47: ...4000 Evaluation Unit Service Manual 4 15 4 9 Main Board 4 9 1 Components Location Diagram ...

Page 48: ...Evaluation Unit AVL 4000 4 16 Service Manual 4 9 2 Circuit Diagrams ...

Page 49: ...4000 Evaluation Unit Service Manual 4 17 ...

Page 50: ...Evaluation Unit AVL 4000 4 18 Service Manual ...

Page 51: ...4000 Evaluation Unit Service Manual 4 19 ...

Page 52: ...Evaluation Unit AVL 4000 4 20 Service Manual ...

Page 53: ...4000 Evaluation Unit Service Manual 4 21 4 10 Speed Angle Board 4 10 1 Components Location Diagram ...

Page 54: ...Evaluation Unit AVL 4000 4 22 Service Manual 4 10 2 Circuit Diagrams ...

Page 55: ...4000 Evaluation Unit Service Manual 4 23 ...

Page 56: ...Evaluation Unit AVL 4000 4 24 Service Manual ...

Page 57: ...4000 Evaluation Unit Service Manual 4 25 ...

Page 58: ...Evaluation Unit AVL 4000 4 26 Service Manual 4 11 Pneumatics Board 4 11 1 Components Location Diagram ...

Page 59: ...4000 Evaluation Unit Service Manual 4 27 4 11 2 Circuit Diagram ...

Page 60: ...Evaluation Unit AVL 4000 4 28 Service Manual 4 12 Printer Adapter 4 12 1 Components Location Diagram ...

Page 61: ...4000 Evaluation Unit Service Manual 4 29 4 12 2 Circuit Diagram ...

Page 62: ...Evaluation Unit AVL 4000 4 30 Service Manual 4 13 Memory Adapter 4 13 1 Components Location Diagram ...

Page 63: ...4000 Evaluation Unit Service Manual 4 31 4 13 2 Circuit Diagram ...

Page 64: ...Evaluation Unit AVL 4000 4 32 Service Manual 4 14 Connector Adapter 4 14 1 Components Location Diagram ...

Page 65: ...4000 Evaluation Unit Service Manual 4 33 4 14 2 Circuit Diagram ...

Page 66: ...Evaluation Unit AVL 4000 4 34 Service Manual 4 15 Chamber Adapter opacity measuring chamber type A 4 15 1 Components Location Diagram ...

Page 67: ...4000 Evaluation Unit Service Manual 4 35 4 15 2 Circuit Diagram ...

Page 68: ...Evaluation Unit AVL 4000 4 36 Service Manual 4 16 Receiver Board opacity measuring chamber type A 4 16 1 Components Location Diagram ...

Page 69: ...4000 Evaluation Unit Service Manual 4 37 4 16 2 Circuit Diagram ...

Page 70: ...Evaluation Unit AVL 4000 4 38 Service Manual 4 17 Selenium Board opacity measuring chamber type A 4 17 1 Components Location Diagram ...

Page 71: ...4000 Evaluation Unit Service Manual 4 39 4 17 2 Circuit Diagram ...

Page 72: ...Evaluation Unit AVL 4000 4 40 Service Manual 4 18 Chamber Adapter opacity measuring chamber 4000 4 18 1 Components Location Diagram ...

Page 73: ...4000 Evaluation Unit Service Manual 4 41 4 18 2 Circuit Diagram ...

Page 74: ...Evaluation Unit AVL 4000 4 42 Service Manual 4 19 Transmitter Board opacity measuring chamber 4000 4 19 1 Components Location Diagram ...

Page 75: ...4000 Evaluation Unit Service Manual 4 43 4 19 2 Circuit Diagram ...

Page 76: ...Evaluation Unit AVL 4000 4 44 Service Manual 4 20 Receiver Board opacity measuring chamber 4000 4 20 1 Components Location Diagram ...

Page 77: ...4000 Evaluation Unit Service Manual 4 45 4 20 2 Circuit Diagram ...

Page 78: ...Evaluation Unit AVL 4000 4 46 Service Manual 4 21 Fan Board opacity measuring chamber 4000 4 21 1 Components Location Diagram ...

Page 79: ...4000 Evaluation Unit Service Manual 4 47 4 21 2 Circuit Diagram ...

Page 80: ...V ANLG GND ANLG 15V ANLG JA GND P3 1 2 3 4 5 6 7 8 9 O2 OUT GND ANLG GND ANLG 1 2 3 H COPYRIGHT 1994 AVL LIST GMBH ALL RIGHTS RESERVED THIS DRAWING IS THE PROPERTY OF AVL LIST GMBH AND MAY NOT BE REPRODUCED IN ANY FORM EITHER IN WHOLE OR IN PART OR MADE AVAILABLE TO ANY THIRD PARTY OR USED FOR MANUFACTURING OR ANY OTHER PURPOSE WITHOUT THE PRIOR WRITTEN PERMISSION OF AVL LIST GMBH c AGND VCC GND G...

Page 81: ...SERVED THIS DRAWING IS THE PROPERTY OF AVL LIST GMBH AND MAY NOT BE REPRODUCED IN ANY FORM EITHER IN WHOLE OR IN PART OR MADE AVAILABLE TO ANY THIRD PARTY OR USED FOR MANUFACTURING OR ANY OTHER PURPOSE WITHOUT THE PRIOR WRITTEN PERMISSION OF AVL LIST GMBH c H1 12V H2 12V FAN 15V TEMP CHMB PT 100 HEAT PT 100 IN AGND VALVE MOT A OPAC DIFF 15V PRESSURE H1 SENSE H2 DENSE GND NC H2 GND SENS H1 GND SENS...

Page 82: ...TY OF AVL LIST GMBH AND MAY NOT BE REPRODUCED IN ANY FORM EITHER IN WHOLE OR IN PART OR MADE AVAILABLE TO ANY THIRD PARTY OR USED FOR MANUFACTURING OR ANY OTHER PURPOSE WITHOUT THE PRIOR WRITTEN PERMISSION OF AVL LIST GMBH E D 1 2 3 PE c NULL PHASE PE 2 1 PHASE OUT 4 braun Buchse ERDE NULL PHASE 1 2 3 1 2 3 GND NULL PHASE GND 3P UNML BV2123 HEATING PLUG Option Sensor Unit 4350 3P UNML PHASE IN N C...

Page 83: ...ys printer fan the ribbon cables connecting the main board to the optional pcbs and the connection lines to the 4 5 gas section The figure below shows the wiring of the 4 gas section i e how the 4 gas measuring instruments unit pneumatics modules O2 sensor and pneumatics board are connected to each other and to the evaluation unit Fig 4 4 X8 Mains 230V 50 Hz pressure RS232 direct voltage X3 X6 X5 ...

Page 84: ...of an electro chemical oxygen sensor to the measuring instruments unit and evaluation of the signal at the multi gas measuring system Power supply to multi gas measuring system overall approx 30 W output Power is supplied via the Andros power supply unit 15 V 12 V 5 V Power supply to the pneumatic components Pump 220 230 Volt 50 60 Hz controlled by AVL board NO sensor supplied via measuring system...

Page 85: ... cable for NO board 12 pin or 6 pin cable item 4 Supply to NO signal 6 Supply to pneumatics module 7 Supply to AVL board 8 Pressure sensor signal 0 5 V 9 Pump control signal TTL 10 Supply to control of fan 24 V DC 11 Control signal 24 V DC zero solenoid valve 12 Supply to pump 230 V AC control 13 Control signal 24 V DC backflush Sensor NM Zero solenoid valve O2 NO Pump Fan Measuring system Rear pa...

Page 86: ...t raw data with that from the last service service printout Error messages in fields 3 and 4 suggest a fault in the hardware Check the pneumatic components unit cables etc before sending the measuring instrument unit back to the works Observe the initial response of the gain factors field 9 If the target values are not reached this suggests a fault in the hardware Remember that the instrument must...

Page 87: ...ure must be multiplied by the PEF to determine the hexane concentration The PEF can be found in field 9 or on the rear panel of the evaluation unit e g PEF 0 503 HC concentration hexane concentration propane 0 503 P Measuring chamber pressure P should correspond approximately to the ambient air pressure If there is significant deviation 50 Torr there is something wrong with the measuring instrumen...

Page 88: ...is recorded during calibration at the works see Service printout in the Appendix to the Operating Manual Enter the value in the maintenance manual at every service Check the drop in voltage from one service to the next If the O2 sensor looks likely to show a voltage of less than 5 mV by the next routine service the O2 sensor needs replacing see Operating Manual P T Raw values for pressure and temp...

Page 89: ...prox 7min the display should read 00 Field 5 Depending on the software version not all of the following values may be displayed 1st line date 2nd line time 3rd and 4th line software version 5th and 6th line silicon serial no of mainboard 7th line serial no of measuring instrument unit not including pneumatic components module Field 6 Software version installed in the measuring instrument unit Vers...

Page 90: ...s Field 9 Display field for gain factors Setpoint values SE 128 FE 128 OE 0 or NO sensor temperature SZ 128 O2 239 PEF 490 540 The factors fluctuate violently when the tester is switched on but should settle down to the following values once the measuring instrument unit has stabilised approx 15min SE FE SZ 128 10 OE 0 O2 239 10 PEF must be stable and lie in the range specified above If the values...

Page 91: ...ing Manual Any leak error is displayed in field 8 Current service values are printed out SOL Operates the valves The two valves are selected in sequence The valve status is displayed in field 7 Quit the 4 gas menu and return to service menu If the measuring instrument unit develops a fault and has to be returned to the works always include a service printout to assist the error diagnosis SOL 1 ON ...

Page 92: ...ium voltage lamps OFF 0 2 V there must either be a fault in the selenium cell or selenium board or the photo element is not closing properly causing incidence of ambient light SIGNAL OPACITY GAIN LAMP 2 685 V LOW A VALVE VOLTAGE POSITION 1 86 V CALIBRATION TEMPERATURE MEAS CHAMBER INLET MEAS HEAD SYSTEM 101 C 85 C 20 C 25 C LINEARITY DATE TIME 0 5 30 01 99 16 30 Opacity signal depending on lamps s...

Page 93: ...y soiling of the valve Temperature Measuring chamber temperature The measuring chamber temperature is displayed You can observe the heating process and control behaviour If 100 C is not reached the heating element may be defective Once the heating system has stabilised after approx 15 min the measuring chamber temperature should be 100 10 C Inlet temperature Displays the exhaust gas temperature PT...

Page 94: ...r and dictates the LED intensity gain 0 5 1 8 OPACITY SIGNAL SYSTEM VOLTAGE LAMP 2 685 V 1 2 A VALVE SWITCH TIME POSITION 1 7 s CALIBRATION TEMPERATURE MEAS CHAMB INLET MEAS HEAD SYSTEM 101 C 85 C 20 C 25 C LINEARITY DATE TIME SW version 0 5 30 01 99 16 30 Opacity signal depending on LEDs photoelectric cell and gain setting System voltage 4 values Change lamp status by pressing LAMP Lamp A B A B O...

Page 95: ...the reference signal photocell Since the light radiated from the back of the LEDs is proportional to the light radiated to the front and since the light sources i e LEDs are clocked i e switched on and off it is possible to correct a measurement signal RC that is affected by external influences e g temperature outside light even during a measurement The measurement accuracy of a system is no longe...

Page 96: ...perature or slightly above it System Temperature inside the instrument Linearity You can carry out a linearity check by pressing the LIN key The tolerance limits are prescribed by law normally 1 or 2 System info Date Time Software version SSN_M silicon serial number main board SSN_C silicon serial number opacity measuring chamber Re initialisation of the opacity measuring system The opacity measur...

Page 97: ...asurement cell Hoses Pressure sensors Pump Valve units Power supply unit Cable repair or replacement Gas analyzer subsystem Power supply unit Pneumatics unit Gas analyzer Apart from the activities described below the measuring instruments unit may only be opened by the manufacturer otherwise the P E F propane gas equivalent factor may be affected and that automatically necessitates official recali...

Page 98: ...ng cell Measuring cell Analyzer board Lambda pcb Pressure sensor Light source Filter receiver Retaining brackets Stepping motor All work on and modifications to the Gas Analyzer and its periphery may only be carried out by trained and qualified technicians Technicians must be able to provide proof of training by AVL or Andros ...

Page 99: ...rn the analyzer back to its proper position and screw it to the base plate Connect the inlet hose to the IR side of the measuring cell Connect the outlet hose to the detector side of the measuring cell 5 2 2 Motor Unit Disconnect the inlet and outlet hoses from the measuring cell Remove the complete gas analyzer from the base plate see Dismantling the 4 5 Gas Measuring Instruments Unit Disconnect ...

Page 100: ...s Unit Undo the 4 screws Replace the components 5 2 5 Pressure Sensor Unsolder the sensor Disconnect the hose Attach the hose to the new pressure sensor Solder the new sensor into position The sensor s zero point is set by means of potentiometer R124 adjustment instructions required Never touch the glass tube of the measuring cell light cell or receiver with your bare fingers Always use gloves The...

Page 101: ...nit 5 2 7 Causes of Error Measuring cell temperature yellow wire might be broken re solder Gas display not stable channel is dead 10 pin ribbon cable to receiver is defective check 5 3 Layout of Pneumatics Fig 5 3 Activated carbon filter Solenoid valve Valve unit Particulate filter Condensate trap Pump Measuring instruments unit ...

Page 102: ...w diagram 1 2 3 4 5 6 7 8 9 10 11 12 12 p p NO O2 6 Fig 5 4 1 2 3 4 5 6 7 8 9 10 11 12 Probe Pre filter Particulate filter Condensate trap Condensate filter Non return valve Pump Solenoid valve Activated carbon filter Non return valve 0 3 bar Measuring instruments unit Throttle ...

Page 103: ...ert the new solenoid Reassemble in reverse order 5 3 2 Valve Unit see Fig 5 3 Remove the solenoid as described in section 5 3 1 above Disconnect the hose Remove the activated carbon filter at the zero gas input Undo the hexagon nut on the valve unit at the rear Replace the unit Reassemble in reverse order 5 3 3 Particulate Filter Fig 5 5 Never use adhesive type sealing material Remove the filter h...

Page 104: ...ct the mains plug and take it right out of the socket Remove the screwable right angle connector from the instrument s rear panel 1 slotted screw Unscrew the 4 Phillips screws on the pump unit from the rear panel The four rubber vibration pads remain attached Replace the pump unit Reassemble in reverse order Fig 5 6 Rear view View from above ...

Page 105: ...he sensor Disconnect the hose and replace the sensor Attach the hose to the new sensor at nipple B Screw the sensor on Solder the pins 5 3 6 Pneumatics Board Remove the connector Disconnect the hose Remove the rear panel Undo the four screws that hold the pneumatics board in place Mount the new pneumatics board ...

Page 106: ...truments unit Unscrew the 4 Phillips screws from the base plate Disconnect the mains power supply and the connection cable to the main board Install the new power supply board Reconnect the plugs 5 6 O2 Sensor and NO Sensor Fig 5 7 The O2 sensor is mounted on the rear panel and is easily accessible It is protected by a metal cover which is secured to the rear panel by 4 Phillips screws For connect...

Page 107: ...Pull the NO sensor backwards out of its mounting it is on the left Insert the new NO sensor ident number EZ0206 Screw the cover panel back onto the rear panel of the instrument making sure that the ground cable is connected Whenever a new O2 sensor is installed it must be reparametrised see O2 sensor Follow the safety instructions for handling O2 sensors Do not throw the old O2 sensor away Return ...

Page 108: ...onnecting the condensate discharge hose and the probe hose Cleaning fluid approx 2 5 l water with non foaming detergent Procedure Switch the instrument off Open the hose connection between the condensate filter and check valve Connect the cleaning hose with filter straight to the check valve Clean the probe hose and probe with clean oil free compressed air Caution the probe hose must not be connec...

Page 109: ...out half an hour When cleaning is completed rinse the system in the same way with cold water Remove the cleaning hose from the check valve and let the pump run on for 30 s Switch the pump off Remove the cleaning hose and the probe hose Clean the probe hose and probe with clean oil free compressed air Caution the probe hose must not be connected to the exhaust gas tester Replace the condensate filt...

Page 110: ...ell burning Replace transformer 465 Transformer bar burned out Faulty contact Smell of burning Replace transformer or transformer bar 465 Faulty cable connection in transformer Crimp plug has bad contact Check cable connections and crimp plug Connect cable or repair crimp lug 465 Chopper faulty Chopper vane loose or motor faulty Chopper vane is catching clicking sound can often always be heard Err...

Page 111: ...ight source faulty power supply unit faulty UC raw values in service mode lower than 10000 ES not zero Light source does not light up Replace light source Replace measuring instruments unit No measurement values displayed but chopper is working Faulty detector UC raw values in service mode lower than 10000 ES not zero Replace detector Replace measuring instruments unit Faulty transformer Faulty fu...

Page 112: ...ate cable Use edge protectors Electrical interference EMC Faulty vehicle ignition cable Faulty ignition Software error Radio or telephone interference Are there sparks Ignition interference in vehicle Very damp atmosphere Radioing equipment in the vicinity Try placing the instrument somewhere else Mains voltage fluctuation Less than 180 greater than 265 V Mains too weak Other equipment being opera...

Page 113: ...et up out of doors Place instrument somewhere else Ambient temperature fluctuates significantly more than 15 C Instrument set up near garage doors Place instrument somewhere else Low flow occurred Probe hose kinked did someone tread on hose Zeroing occurs after Low Flow error Lay the hose without kinks Replace filter Clean metal filter 465 Error occurred during zeroing Hose kinked blocked O2 signa...

Page 114: ...ents unit Hoses inside are disconnected or faulty Test flow rates Replace hoses Measurement values fluctuating significantly after zeroing or calibration Exhaust gas petrol or other gases in the air Can you smell anything Air the room or connect hose on carbon filter to fresh air supply Substantial fluctuations in measurement values See Measurement values fluctuating significantly Ambient air heav...

Page 115: ...ions are too large Check calibration values and gas values propane hexane ok Carry out power reset then CALIBRATION Instrument not in 30 minute calibration mode Error in warm up phase or significant fluctuations in ambient temperature Check zero status in service mode must be 1E DSM must be 00 Place instrument somewhere else Wait another 15 min Calibration not possible Calibration error Check stat...

Page 116: ...en ice in pump Pump heavily soiled Pump connection fitting leaking Is soiling visible Stored at below 0 Celsius Gas flow too low Change filter regularly clean pump condensate in the instrument do not store at below 0 C Leak test carried out incorrectly Probe hose only bent Viton hose becomes leaky when kinked or bent at temperatures below 10 C Use original silicon cap Check valve is faulty Soiling...

Page 117: ...st valve and flow rate in service mode flow rate set point greater than 2 min l at each outlet Replace solenoid valve Hose leaking or disconnected Hose kinked inside Check hoses Carry out leak test Check flow rate Replace or connect hose No low gas flow Pump faulty or leaking Pump connection fitting broken off Check flow rate carry out leak test Replace or clean pump or pump head Measurement disto...

Page 118: ...Exhaust gas petrol or other gas in the air Negative measurement values HC Can you smell anything Air the room or connect hose from the carbon filter to the fresh air supply Carbon filter faulty soiled HC Hydrocarbon content i e petrol in the air too high Service mode zeroing If HC 0 is then displayed carbon filter faulty Replace carbon filter Connect hose from carbon filter to fresh air supply Mea...

Page 119: ... too much Condensate in hose Ambient operating conditions Sensor is too old sensor voltage must be between 5 and 14 mV see raw values Replace sensor ensure required operating conditions Leak in exhaust pipe Applies to 4 stroke engines only and lambda setpoint value 1 CO CO2 measurement value less than 15 by volume O2 0 Repair leak in exhaust Leak in instrument Applies to 4 stroke engines only and ...

Page 120: ... filter is full Replace NO sensor Leak in exhaust pipe O2 measurement value too high only applies to 4 stroke engines and lambda setpoint 1 Lambda value setpoint generally applies CO CO2 measurement value less than 15 by vol If less than 14 probably a leak in exhaust pipe or probe for 4 stroke only lambda 1 Repair leak in exhaust Caution some engines add fresh air externally to the exhaust In such...

Page 121: ... 4000 pneumatics pressure sensor faulty Setpoint 118 138 with pump switched off Replace sensor Replace board Pressure reducer throttle in AVL 4000 pneumatics system faulty Setpoint must increase 128 10 when pump switched on and inlet is closed off Replace pressure reducer throttle in silicon hose Pressure measurement value incorrect Pressure reducer throttle in the Andros measuring instruments uni...

Page 122: ...nd vibrations Tighten screws and secure with Loctite Pump faulty Pump cable worn through 465 See Self test and stabilisation Use edge protectors 465 Insulation Pump very noisy Screws loose Check Tighten screws and secure with Loctite Software error Communication Test pump in service mode and let it run Replace pneumatics board 465 Replace measuring instruments unit Pump faulty Internal short circu...

Page 123: ...strument placed near radiator Ensure required operating conditions Instrument place in hot sunshine Ensure required operating conditions Petrol or solvent in the ambient air Air the room Mains interference due to powerful power consuming equipment Use a different plug socket EMC interference due to drills welding apparatus radio equipment Clear or suppress interference General EMC interference due...

Page 124: ...4 5 Gas Measuring Instruments Unit AVL 4000 5 28 Service Manual ...

Page 125: ...with Filter Switch the instrument on ready for operation Select Control measurements CONT in the diesel engine menu and the Control measurement with filter FLT Open the detector cover Fig 6 1 Only 12 V A type 435 opacity measuring chambers may be used with the AVL DiCom 4000 Use of 2 6 V opacity measuring chambers will damage the AVL DiCom 4000 Open detector cover ...

Page 126: ...L 4000 6 2 Service Manual Place transmission filter on detector caution receiver side only Fig 6 2 Close detector Press The measured filter absorption is displayed Open detector Remove filter Close detector Press Place filter on detector ...

Page 127: ... control cable and heating cable you will need the ZG1940 rear panel These cutouts have already been prepared in most rear panels and simply need to be pushed out of the panel Conversion instructions Open the instrument completely Remove speed angle board 4 Phillips screws on the outside one hexagon nut on the inside Insert 435 Chamber Adapter Board at slots J4 J6 J10 and J14 of the main board Pus...

Page 128: ...r Selenium Board Lamp module Half shell 1 Half shell 2 Cover 1 Cover 2 Changeover valve with geared motor 2 fans Heating blocks 2 in measuring chamber Orifice plates in measuring chamber 3 gaskets Ports for connection cables to evaluation unit control cable and heating cable Sample gas inlet Sample gas and purging air outlet Rubber pads Rating plate Probe holder passenger car ...

Page 129: ...trol cable socket Fan Heating cable socket Lamp module Probe holder passenger car Identification plate Rubber pads Cover 2 Cover 1 Half shell 1 Half shell 2 Sample gas and purging air outlet Sample gas inlet Changeover valve and geared motor Heating blocks Gaskets Orifice plates Cross section A A ...

Page 130: ...hown in Fig 6 5 11 screws and carefully lift off cover 2 Fig 6 5 These two screws have a different head from the others 2 countersunk slotted head screws 9 Phillips screws DS1172 DZ0567 DZ0253 DS0467 YM2727 9 x 2 x Countersunk screw M5x16 Fig 6 6 Probe holder YM2722 Housing cover 2 RM0115 Label ZB1384 Silicon seal RM0121 Housing cover 2 Label Holder for passenger car probe ...

Page 131: ...emove the rubber pads to dismantle the measuring chamber Cross section B B Fig 6 5 Fig 6 7 6 4 2 Housing Cover 2 on Exhaust Gas Inlet Side Undo the screws shown in Fig 6 8 11 screws and carefully lift off cover 1 Fig 6 8 Nut DM0086 Rubber pad DF0019 Washer DZ0250 Screw DS0165 Housing cover 1 Label ...

Page 132: ...ads to dismantle the measuring chamber Detail Probe connection plate You do not need to remove the probe connection plate to dismantle the measuring chamber Cross section A A Fig 6 8 Fig 6 10 DS1172 Oval head screw M5x10 DZ0567 DZ0253 Hexagonal nut DM0089 3 pcs Oval head screw M5x16 DS0947 3 pcs Washers DZ0253 3 pcs Spring washer DZ0567 3 pcs O ring DA0288 Probe connection plate YM2761 ...

Page 133: ...s S t u d b o l t A S t u d b o l t C S t u d b o l t C S t u d b o l t A S t u d b o l t A S t u d b o l t A S t u d b o l t A S t u d b o l t A Stud bolt A Stud bolt A Acces point X Fig 6 11 Undo stud bolts A shown in Fig 6 11 80 5 Fig 6 12 Stud bolt A YM2679 9 pcs As you undo each bolt apply counterpressure to the bolt at the other end Unscrew bolt A while applying counterpressure to bolt B at ...

Page 134: ...and the measuring chamber upright It should now be possible to undo 9 stud bolts B by hand on the exhaust gas inlet side half shell 2 80 5 Fig 6 16 2 pcs While undoing these bolts apply counterpressure to the bolts underneath them located between the two half shells and reached via access point X Stud bolt C YM2681 Spacer pin Stud bolt B YM2680 9 pcs DS1172 Oval head screw M5x10 DZ0567 DZ0253 Oval...

Page 135: ...ain in the mounting on the gas outlet side When you have completely separated the two half shells you can let half shell 1 lie horizontally Fig 6 17 If you want to separate the two half shells completely disconnect the following cables from half shell 2 protective conductor Faston connector on the purging air and heating block fan cable heating cable The remaining 4 bolts do not need to be removed...

Page 136: ...hell 1 and the other in half shell 2 the two fans are identical To dismantle them undo the two screws on the back of the fans Fig 6 20 Fans EI0188 12 VDC incl connection cable and connector Stud bolt C YM2681 2 pcs Oval head screw M3x6 DS0160 Spring washer DZ0526 Washer DZ0245 Draw the connection cable through the hole in the half shell when reassembling Reconnect the cables when re mounting the f...

Page 137: ...ntle them Disconnect the Faston connector of the protective conductor Disconnect the power cable connector to the heating block Undo the screws shown in Fig 6 21 on the outside of each half shell DS0162 DZ0558 DZ0251 Fig 6 21 In the heating block of half shell 1 exhaust gas outlet is a temperature sensor which is bonded to the half shell Remove the sensor by gently pulling it away before you disma...

Page 138: ... heating element 230 V 500 W ZH0061 2 oval head screws M4x6 for fastening the face plate to the heating block Fig 6 22 Fig 6 23 After re installing the heating block Glue the temperature sensor back into position see Section 6 8 Temperature Sensor Re connect the power cable Re connect the protective conductor DS1041 DZ0558 DZ0251 After working on the heating blocks always carry out a function chec...

Page 139: ...by its aluminium housing Disconnect the cable to the geared motor The connector is held in place by barbs on the side of the plug socket to prevent it from being pulled out inadvertently Release the barbs by pressing inwards with a small screwdriver Valve block BO1136 Fig 6 24 Valve housing YM2685 Sliding disc DL0092 Valve bonnet 2 YM2687 Liner DL0091 Valve vane YM2688 Setscrew DS0988 3 countersun...

Page 140: ...M3x16 countersunk screws During reassembly the straight pin ensures that the valve housing is correctly positioned Reassembling the valve block Fix the three M3x16 countersunk screws with Loctite 242 after assembly Fix the setscrew DS0988 with Loctite 242 Always open valve bonnet 2 first With a waterproof marker mark the position of valve bonnet 1 and valve housing in relation to each other Not al...

Page 141: ...16 are fitted in the measuring chamber Temperature sensor 1 half shell 1 heating block The sensor is bonded in position and can be removed by carefully pulling it away Remove any remains of glue before reassembling Ensure that the setscrew is screwed into the flattened side of the motor shaft When press fitting the valve bonnet into the housing ensure that it goes in straight and that the housing ...

Page 142: ...Fig 6 25 Temperature sensor 2 half shell 2 exhaust gas inlet The sensor is located at the gas inlet and is bonded in position Positioning Fig 6 26 CAUTION Glue temperature sensor back into position Half shell 1 Heating block Temperature sensor Half shell 2 Temperature sensor ...

Page 143: ...6 27 Undo the 4 PT screws The entire cover plate can now be removed from the module housing Disconnect the 4 plugs at the rear of the light source Unscrew the lamp socket to change the lamps Halogen lamp 12 V 5 W EL0209 Do not get glue on the inside surface of the bore Seal ring YM2721 Protective glass MO0046 Spacing ring RM0123 Mounting bracket YM2806 4 self tapping screws DS1009 2 lamp sockets B...

Page 144: ...can then press the protecting glass off the spacing ring glued with silicon adhesive Clean any remains of silicon adhesive from the spacing ring Replace the light unit in the cover plate Bond the protecting glass to the spacing ring from the outside Bond the seal ring back into place with silicon adhesive Connecting the lines Connect the two plastic plugs to the lamp socket Connect the two metal p...

Page 145: ...Disconnect the cable on the selenium board Before replacing the protecting glass first remove the seal ring Then undo the two 2 countersunk screws concealed beneath it apply counterpressure to the hexagon nuts on the selenium board The entire receiver can now be pulled out of the cover plate the selenium board is released first Remove the retaining ring with saw tooth round nose pliers Then remove...

Page 146: ...older back onto the cover plate Bond the protecting glass to the selenium holder from the outside with silicon adhesive Bond the seal ring back into position also with silicon adhesive Soldering the selenium cell After replacing the selenium cell it must be soldered back onto the selenium board black wire to soldering terminal SELEN HI red wire to soldering terminal SELEN LO Reconnect the cable to...

Page 147: ...rging air panels one either side of the measuring chamber Fig 6 29 The purging air panels are connected to the protective conductor Purging air panel YM2691 Fixing bolts Fixing bolts Purging air panel YM2691 Cross section A A 2 oval head screws M4x6 DS1041 2 contact discs DZ0549 2 Faston connectors EU0520 ...

Page 148: ...12 Electrical Wiring The wiring basically comprises 2 looms of cables Control cable BV1605 The connector is fastened to the half shell by 4 snap rivets MK0219 Heating cable BV1620 The connector is fastened to the half shell by the following elements 2 oval head screws M3x12 DS0157 2 washers DZ0245 2 hexagon nuts M3 DM0085 The cable routing is as shown in Fig 6 30 Fig 6 32 An additional cable BV171...

Page 149: ...4000 Opacity Measuring Chamber Type A Service Manual 6 25 Fig 6 30 Fig 6 31 ...

Page 150: ...Opacity Measuring Chamber Type A AVL 4000 6 26 Service Manual Fig 6 32 ...

Page 151: ... cable loom BV1605 bl ye or rd wh bl br gn Pos 2 Pos 3 Pos 8 wh bl bk ye or br 1 1 1 2 3 5 wh bk or gr Pos 4 Pos 5 2x Pos 6 bl ye or rd br gn wh bk 5 3 10 7 8 11 6 4 bl ye or wh br bk shield 15 25 17 14 18 26 16 13 12 33 32 1 27 22 2 19 20 21 30 Pos 1 Pos 7 Fig 6 33 ...

Page 152: ... temperature sensor EU0116 8 Faston 6 3 connector EU0804 Heating cable loom BV1620 Fig 6 34 Spare parts list Pos 1 3 pin installed plug EU0013 2 Faston 6 3 connector EU0673 3 Faston 6 3 0 8 connector EU0804 4 3 pin connector housing EU1081 5 Pin contact EU0947 Sensor cable BV1710 Fig 6 35 additional cable in heating cable Spare parts list Pos 1 3 pin connector housing EU1081 2 Pin contact EU0947 3...

Page 153: ...ity Measuring Chamber Type A Service Manual 6 29 Heating cable loom BV1620 AMPHENOL Pos 1 Pos 2 Pos 3 Pos 4 Pos 5 2x 1 bl br 1 bl br 3P UNMNL 1 3 bl br bl br 3P UNMNL 1 3 ye gn ye gn ye gn 3 E 1 2 ye gn Fig 6 34 ...

Page 154: ...ity Measuring Chamber Type A AVL 4000 6 30 Service Manual Sensor cable BV1710 additional cable to heating cable 1 bl L 50mm bn L 500mm bn L 400mm 1 Pos 1 2x Pos 2 Pos 3 2x Pos 4 1 2 3 1 2 3 1 2 3 1 Fig 6 35 ...

Page 155: ...OCK OUTLET SENSOR UNIT 37P CPC gn 3 H1 2 6V ye ye 4 gr 5 pi 6 H1 GND bk H1 SENSE bl H1 GND SEN wh bl 7 rd 8 bk 10 pu 11 H2 GND SEN gn H2 SENSE or H2 GND br H2 2 6V rd SHIELD 16 SHIELD wh gn 14 br gn 15 br rd 26 12V wh 12V bl AGND bk wh rd 25 wh ye 17 ye br 18 NTC CHMB ye SELEN HI or SELEN LO br gr pi 12 bl rd 13 FAN GND bk FAN 12V rd rd 32 bl 33 FAN GND bk FAN 12V rd wh gr 19 gr br 20 PT100 AGND w...

Page 156: ...o the mounting The purging air panels must be correctly mounted No cables should be caught or pinched Screw the half shells back together with the stud bolts including the handle Fit the housing cover and probe holder Make sure not to confuse the housing covers when reassembling they are not interchangeable Tighten the stud bolts gently so as not to damage the half shells If you use a torque wrenc...

Page 157: ... from the opacity measuring chamber on the receiver side probe connection side Insert the filter holder with filter into the protector Fig 7 1 Insert the lens protector back into the opacity measuring chamber Press The measured filter absorption is then displayed Then remove the filter again after first pushing upwards on the spot indicated Fig 7 2 Slide the lens protector back into the opacity me...

Page 158: ...G1940 Most rear panel have these socket holes stamped in them the centres just need to be pushed out Instructions for conversion Open the instrument completely Remove speed angle board undo 4 Phillips screws on the outside one hexagon nut inside Insert chamber adapter in slots J4 J6 J10 and J14 on the main board Push out the stamped socket centres on the rear panel If the rear panel has no stamped...

Page 159: ...4000 Opacity Measuring Chamber 4000 Service Manual 7 3 Mainboard Chamber Adapter BB0814776 DS0992 BV1982 Fig 7 3 ...

Page 160: ...rewdriver into the gap between them at the top or bottom e g at the handle and prising them apart Then lift the top shell half as shown in Fig 7 4 off the bottom one All integrated assemblies Fig 7 5 except the changeover valve unit are simply inserted into this shell half and can therefore easily be removed Only the changeover valve unit is fixed to the shell by a self tapping screw See next sect...

Page 161: ...suring Chamber 4000 Service Manual 7 5 7 4 Design and Details of Assemblies 7 4 1 Fan Unit BO2189 Fig 7 6 Fan plate YM3207 Fan axial EI0253 Oval head screw DS1269 Spacer pin EP0329 Oval head screw DS0161 Fan pcb BB0807 ...

Page 162: ...e defective sensor out of the measurement cell insulation and remove it by pinching off the litz wire Solder on the new sensor insulate the solder points and insert the sensor through the measurement cell insulation into the hole in the aluminium measuring cell tube using three pin pliers for example to hold open the hole in the insulation The PT 100 is held in place by the insulation when you rel...

Page 163: ...ature sensor PT 100 ident no EZ0180 for measuring the gas temperature 7 4 3 1 Replacing the Temperature Sensor Pull the PT 100 out and pinch off the litz wire Solder on a new sensor Insulate soldering points and insert the sensor in the bore again Valve plunger RM0154 Valve block YM3190 Inflow tube YM3185 Drive motor including cable BV2084 Oval head screw DS1270 ...

Page 164: ...en LEDs and the Receiver See service screen The light source voltage must be between 3 5 and 4 5 V 7 4 4 2 Checking the Reference Receiver See service screen The voltage must be between 2 5 and 4 5 V Reference detector EO0148 LEDs EO0147 Transmitter board BB0777 Optical pickup YM3191 Flow channel RM0146 Flow channel RM0146 Optical pickup YM3192 Receiver board BB0778 Detector EO0148 Lens MO0102 ...

Page 165: ...SN 18 CONTROL CABLE 9 AGND HEATING 16 6 24V 12 GND 19 AGND 1 TEMP CHMB 2 OPAC DIFF 3 OPAC DIFF 4 LAMP B 5 LAMP A 7 LAMP INTENSITY 8 LAMP INTENSITY 9 15V 10 AGND 11 PT100 HEATING 13 PT100 INLET 14 VALVE MOT B 15 VALVE MOT A 16 HEATING 17 FAN CHMB 18 SSN J1 J2 J8 24V 1 GND 2 AGND 3 TEMP CHMB 1 OPAC DIFF 2 OPAC DIFF 3 LAMP B 4 LAMP A 5 LAMP INTENSITY 6 LAMP INTENSITY 7 15V 8 AGND 9 PT100 HEATING 1 PT...

Page 166: ...or transmitter fan completely into one shell half not forgetting the seal Screw in the screws on one side first then on the other Tighten the screws on the first side Tighten the screws gently so as not to damage the shell Always carry out a full function test after any maintenance work involving dismantling of the measuring chamber ...

Page 167: ...ts list AVL DiGas 4000 Section 8 2 Opacity Measuring Chamber 4000 Section 8 2 Opacity Measuring Chamber Type A Section 8 3 AVL DiSmoke 4000 with Opacity Measuring Chamber Type A France Section 8 4 Opacity Measuring Chamber 4000 Section 8 2 Opacity Measuring Chamber Type A Section 8 3 AVL DiCom 4000 with Opacity Measuring Chamber Type A France Section 8 4 The opacity measuring chambers are describe...

Page 168: ...40 DOT HOSIDEN EL0277 DISPLAY LCD 320X240 DOT HITACHI EL0285 SPACER M3 L 50mm INSIDE WIDTH 8 EP0321 SPACER PIN V5737A EP0052 HOUSING COVER 4330U01 B00 0 ZG1923 MEMBRANE KEYPAD 4000L 4330K05A B00 0 ZI0053 FOOT PAD ORDER NO 921 1024 000 DF0034 LOCK 4330U10 B00 0 ZG1929 4000 MAIN BOARD CONSISTING OF 1 MAIN BOARD 4630A01 B00 0 TD4000MBA 01 BA0885 PCMCIA CARD 4MB EN0339 PLUG PANEL 4330U02 B00 0 ZG1924 ...

Page 169: ...0415 FLOAT COMPLETE 4530X00 B00 0 BO1916 FLOAT TUBE 4530X07 B00 0 YM3090 FUSE 1 25A SLOW BLOW EV0082 SOLENOID VALVE 3 2 W R1 4 DN 2 5 7BAR 24V MM0495 POWER SUPPLY UNIT MODEL 1103 MULTIGAS MEASING INSTRUMENTS UNIT EN0280 O2 COVER 4530U03 B00 0 ZG1928 PARTICULATE FILTER COVER 4530X03 B00 0 RM0138 PARTICULATE FILTER HOUSING 4530X04 B00 0 RM0139 PNEUMATICS BOARD 4630L03 B00 0 BB0728 PUMP 453 CONVERSIO...

Page 170: ... PRINTER ADAPTER 4630L04 B00 0 BB0729 SPEED ANGLE BOARD 4630L02 B00 0 BB0727 STICKER RING BLUE 4330U17 B00 0 ZB1787 STICKER RING RED 4330U15 B00 0 ZB1785 STICKER RING WHITE 4330U18 B00 0 ZB1788 STICKER RING YELLOW 4330U16 B00 0 ZB1786 ELECTRICAL PARTS FOR SAMPLING PETROL PETROL SAMPLING PU 4530 09D C00 0 Standard for DiGas 4000 DiCom 4000 BO2341 PETROL SAMPLING VIT VAR 4530 09A C00 0 BO2144 PETROL...

Page 171: ...12 M E313 01 B00 0 BV2096 CONTROL CABLE 4000 18M E313 02 B00 0 BV2097 MEASUREMENT CELL COMPLETE 4330S01 C00 0 BO2138 PT 100 CABLE 4330V12 B00 0 BV2060 CALIBRATION VALVE 4330S02 C00 0 BO2139 TRANSMITTER UNIT 4330S03 C00 0 BO2140 DETECTOR UNIT 4330S04 C00 0 BO2141 GATE VALVE COMPLETE 4330S05 C00 0 BO2142 VALVE UNIT 4330S06 C00 0 BO2189 CABLE S B 4330V15 B00 0 BV2063 SHELL HALF 4330X01 C00 0 RM0145 F...

Page 172: ...277 DISPLAY LCD 320X240 DOT HITACHI EL0285 SPACER M3 L 50mm INSIDE WIDTH 8 EP0321 SPACER PIN V5737A EP0052 HOUSING COVER 4330U01 B00 0 ZG1923 MEMBRANE KEYPAD 4000L 4330K05A B00 0 ZI0053 FOOT PAD ORDER NO 921 1024 000 DF0034 LOCK 4330U10 B00 0 ZG1929 MAIN BOARD 4000 CONSISTING OF 1 MAIN BOARD 4630A01 B00 0 TD4000MBA 01 BA0885 435 CHAMBER ADAPTER 4630L12 B00 0 BB0814 RAPIT CONNECTOR FITTING Type B R...

Page 173: ...1 25A SLOW BLOW EV0082 SOLENOID VALVE 3 2 W R1 4 DN 2 5 7BAR 24V MM0495 POWER SUPPLY UNIT MODEL 1103 MULTIGAS MEASURING INSTRUMENTS UNIT EN0280 O2 COVER 4530U03 B00 0 ZG1928 PARTICULATE FILTER COVER 4530X03 B00 0 RM0138 PARTICULATE FILTER HOUSING 4530X04 B00 0 RM0139 PNEUMATICS BOARD 4630L03 B00 0 BB0728 PUMP 453 CONVERSION 4530W03 B00 0 BO1813 CHECK VALVE 3 GRAM APERTURE 3 16 MM0492 CHECK VALVE 0...

Page 174: ...PEED ANGLE BOARD 4630L02 B00 0 BB0727 STICKER DISPEED NL 0490U05 B00 0 ZB1985 STICKER RING WHITE 4330U18 B00 0 ZB1788 ELECTRICAL PARTS FOR SAMPLING PETROL PETROL SAMPLING PU 4530 09D C00 0 Standard for DiGas 4000 DiCom 4000 BO2341 PETROL SAMPLING VIT VAR 4530 09A C00 0 BO2144 PETROL SAMPLING PU VAR 4530 09B C00 0 variable sampling for DiGas 4000 DiCom 4000 BO2293 PETROL SAMPLING VITON 4530 09 C00 ...

Page 175: ...ATING BLOCK COMPLETE PREASSEMBLED 4350 02 R20 0 BO1248 HEATING BLOCK COMPLETE PREASSEMBLED 4350 02 R20 0 BO2169 O RING 30 OX3 00 DA0288 SILICON SEAL COVER 4350 02 R05 0 RM0121 SILICON SEAL SHELL HALF 4350 02 R04 0 RM0120 PROBE CONNECTOR PLATE 4350 02 R23 0 YM2761 1st SHELL HALF SENSOR UNIT 4350 02 R01 0 for BO1635 RM0113 2nd SHELL HALF SENSOR UNIT 4350 02 R02 0 for BO1635 RM0114 CHANGEOVER VALVE W...

Page 176: ...HUSIDEN 4330U09 B00 0 ZG1931 SPACER M3 L 50mm INSIDE WIDTH 8 EP0321 SPACING PIN V5737A EP0052 HOUSING COVER 4330U01 B00 0 ZG1923 KEYPAD SW BL 4000L 4330K05A B00 0 ZI0053 FOOT PAD 435 465 DF0034 LOCK 4330U10 B00 0 ZG1929 MAINBOARD 4000 CONSISTING OF 1 MAIN BOARD 4630A01 B00 0 TD4000MBA 01 BA0885 435 CHAMBER ADAPTER 4630L12 B00 0 BB0814 RAPIT CONNECTOR FITTING Type B R8540 MR0498 FLASH MEMORY CARD 4...

Page 177: ...0X07 B00 0 YM3090 FUSE 1 25A SLOW BLOW EV0082 SOLENOID VALVE 3 2 WEGE R1 4 DN 2 5 MM0495 POWER SUPPLY UNIT 1103 FOR BENCH EN0280 O2 COVER 4530U03 B00 0 ZG1928 PARTICULATE FILTER COVER 4530X03 B00 0 RM0138 PARTICULATE FILTER HOUSING 4530X04 B00 0 RM0139 PNEUMATICS BOARD 4630L03 B00 0 BB0728 PUMP FOR 4 GAS BENCH 4530W03 B00 0 BO1813 CHECK VALVE 3 16 MM0492 CHECK VALVE 4000 MM0494 SET OF GROUND CABLE...

Page 178: ...0L04 B00 0 BB0729 SPEED ANGLE BOARD 4630L02 B00 0 BB0727 STICKER RING RED 4330U15 B00 0 ZB1785 STICKER RING WHITE 4330U18 B00 0 ZB1788 EXHAUST PROBE PETROL EXHAUST PROBE PETROL PU 4530 09D C00 0 standard for DiGas 4000 DiCom 4000 DiGas 4000 Light BO2341 EXHAUST PROBE PETROL VIT VAR 4530 09A COO 0 BO2144 EXHAUST PROBE PETROL VITON 530 09 C00 0 BO2143 EXHAUST PROBE PU VAR 4530 09B C00 0 specially ad...

Page 179: ...OR TUBE CONNECTION 30 OX3 00 DA0288 RACK COVER 4350 02 R31 0 RM0116 CHANGEOVER VALVE WITH MOTOR BO1136 CHANGEOVER VALVE WITH MOTOR BO1136 SENSOR CONNECTING BOARD 4350 02 R23 0 YM2761 SILICON GASKET HALF RM0120 LIFT UP LID COATED ON PHOTO ELEMENT SIDE for BO1567 RM0131 2nd HALF OF OPACITY SENSOR for BO1567 RM0134 PT100 TEMP SENSOR SHORT AS OF SN 511 EZ0161 PT100 TEMP SENSOR SHORT AS OF SN 511 EZ016...

Page 180: ...Spare Parts Lists AVL 4000 8 14 Service Manual ...

Page 181: ...ating gas mixture CO HC CO2 with fine adjustment pressure regulator Special spanner for undoing speed angle board socket AVL DiTest 803 diagnostics simulator ident number GH0465 Delivers calibratable rpm signal permits simulation of the following signals clamp on transducer nozzle needle lift sensor RIV TDC analogue TDC digital oil temperature ignition signal λΚprobe Together with AVL Adapter Box ...

Page 182: ...Tools for the Service Technician AVL 4000 9 2 Service Manual ...

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