AVL AVL DiGas 4000 User manual

ENGINE DIAGNOSTICS
AVL LIST GMBH
Hans-List-Platz 1
A-8020 Graz / Austria
Phone: [phone]
Fax: [phone]
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

Copyright 1999 AVL List GmbH, all rights reserved.
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.

Important Notice! – Important Notice!
This manual contains important warnings and safety instructions to be observed
by the user.
The product described is intended for only one certain area of application which is
prescribed in the instructions. Furthermore, the manual explains the critical
prerequisites for application and operation as well as the safety measures to ensure
smooth operation. No warranty is granted or liability accepted if the prerequisites and
safety measures are not met.
The product is to be operated and used only by qualified personnel capable of
observing the required safety precautions. Only accessories and expendables either
supplied or approved by AVL are to be used with the product.
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 is based on the
results.
Adjustments to and maintenance of devices when open and under voltage are only
to be carried out by a professional technician who is aware of the dangers involved.
Repairs to the product are to be carried out by the manufacturer or qualified service
personnel only.
When the product is used, a technical expert must ensure that neither the test object
nor the testing equipment is operated under conditions that may lead to damage or
injury.
LIST GmbH
Important Notice! – Important Notice!

Safety Instructions for Handling O2and NO Sensors
The O2and NO sensors are supplied fully sealed and under normal circumstances do not
represent any hazard to health.
The following instructions apply in the event of a sensor developing a leak.
•Before you remove a sensor from the gas-tight original packaging, check it for leaks.
•If you detect damage caused by a leak, always avoid contact with the skin.
•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 immediately.
The O2and NO sensors contain caustic and other substances that
are hazardous to health (e.g. caustic potash solution and lead).
When replacing sensors, check both the old and the new one for
leaks.

4000 Table of Contents
Service Manual I
Table of Contents
1. Periodic Maintenance
1.1 General......................................................................................................................................................1-1
1.2 Maintenance Plan....................................................................................................................................1-2
1.3 Minor Maintenance.................................................................................................................................1-4
1.3.1 AVL DiGas 4000.............................................................................................................................1-4
1.3.2 AVL DiSmoke 4000........................................................................................................................1-5
1.3.3 AVL DiCom 4000...........................................................................................................................1-6
1.4 Major Maintenance.................................................................................................................................1-8
1.4.1 AVL DiGas 4000.............................................................................................................................1-8
1.4.2 AVL DiSmoke 4000........................................................................................................................1-9
1.4.3 AVL DiCom 4000...........................................................................................................................1-10
2. Error Messages and Troubleshooting
2.1 4-/5-Gas Measuring Instruments Unit.................................................................................................2-1
2.1.1 Gas Flow Insufficient....................................................................................................................2-1
2.1.2 System Needs Restarting..............................................................................................................2-2
2.1.3 Measuring Chamber Temperature Too High.............................................................................2-2
2.1.4 Measuring Chamber Pressure Wrong.........................................................................................2-3
2.1.5 Leak Test Failed .............................................................................................................................2-3
2.1.6 Replace O2Sensor..........................................................................................................................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................................................................................................................................4-1
4.1.1 Basic Design...................................................................................................................................4-2
4.1.2 Evaluation Unit..............................................................................................................................4-3
4.1.3 Pneumatics Rear Panel / 4-/5-Gas Measuring Instruments Unit (5-Gas Option)................4-4
4.2 Hardware Setup ......................................................................................................................................4-5
4.2.1 Main Board.....................................................................................................................................4-5
4.2.1.1 Digital System............................................................................................................................4-5
4.2.1.2 Analogue Data Acquisition......................................................................................................4-5
4.2.1.3 Remote Control Receiver..........................................................................................................4-5
4.2.1.4 Interfaces.....................................................................................................................................4-6
4.2.1.5 Display Control and Softkey Connection...............................................................................4-7
4.2.1.6 Generation of Auxiliary Voltage..............................................................................................4-7
4.2.1.7 Board Control.............................................................................................................................4-7

Table of Contents AVL 4000
II Service Manual
4.2.1.8 Printer Board (Option)..............................................................................................................4-8
4.2.1.9 Speed /Angle Board with Diagnostics Cable Concept (Option/Installation) .................4-8
4.2.1.10 Memory Adapter.......................................................................................................................4-11
4.2.1.11 ChamberAdapter (AVL DiCom 4000)....................................................................................4-11
4.2.1.12 Extension Slot.............................................................................................................................4-11
4.2.1.13 Mains Switch Assembly............................................................................................................4-11
4.2.1.14 Converting 230 V to 115 V Device...........................................................................................4-11
4.2.1.15 Power Supply Unit....................................................................................................................4-11
4.2.1.16 Fan...............................................................................................................................................4-12
4.3 Dismantling the 4-/5-Gas Measuring Instruments Unit....................................................................4-12
4.4 Housing....................................................................................................................................................4-12
4.5 Printer.......................................................................................................................................................4-13
4.5.1 Internal Printer Unit (Option/Installation)................................................................................4-13
4.5.2 External A4 Printer (Option)........................................................................................................4-14
4.6 LCD...........................................................................................................................................................4-14
4.7 Membrane Keypad .................................................................................................................................4-14
4.8 Fan.............................................................................................................................................................4-14
4.9 Main Board...............................................................................................................................................4-15
4.9.1 Components Location Diagram...................................................................................................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 Diagram.............................................................................................................................4-31
4.14 Connector Adapter .................................................................................................................................4-32
4.14.1 Components Location Diagram...................................................................................................4-32
4.14.2 Circuit Diagram.............................................................................................................................4-33
4.15 Chamber Adapter (opacity measuring chamber type A)..................................................................4-34
4.15.1 Components Location Diagram...................................................................................................4-34
4.15.2 Circuit Diagram.............................................................................................................................4-35
4.16 Receiver Board (opacity measuring chamber type A)........................................................................4-36
4.16.1 Components Location Diagram...................................................................................................4-36
4.16.2 Circuit Diagram.............................................................................................................................4-37
4.17 Selenium Board (opacity measuring chamber type A)......................................................................4-38
4.17.1 Components Location Diagram...................................................................................................4-38
4.17.2 Circuit Diagram.............................................................................................................................4-39

4000 Table of Contents
Service Manual III
4.18 Chamber Adapter (opacity measuring chamber 4000)......................................................................4-40
4.18.1 Components Location Diagram...................................................................................................4-40
4.18.2 Circuit Diagram.............................................................................................................................4-41
4.19 Transmitter Board (opacity measuring chamber 4000)......................................................................4-42
4.19.1 Components Location Diagram...................................................................................................4-42
4.19.2 Circuit Diagram.............................................................................................................................4-43
4.20 Receiver Board (opacity measuring chamber 4000) ...........................................................................4-44
4.20.1 Components Location Diagram...................................................................................................4-44
4.20.2 Circuit Diagram.............................................................................................................................4-45
4.21 Fan Board (opacity measuring chamber 4000)....................................................................................4-46
4.21.1 Components Location Diagram...................................................................................................4-46
4.21.2 Circuit Diagram.............................................................................................................................4-47
4.22 Wiring Diagrams.....................................................................................................................................4-48
4.23 Internal Cabling.......................................................................................................................................4-51
4.24 4-/5-Gas Section......................................................................................................................................4-52
4.24.1 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 O2and 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 Motor Unit......................................................................................................................................5-3
5.2.3 Measuring Cell...............................................................................................................................5-4
5.2.4 Filter/Receiver...............................................................................................................................5-4
5.2.5 Pressure Sensor..............................................................................................................................5-4
5.2.6 Main Board and Lambda Piggyback ..........................................................................................5-5
5.2.7 Causes of Error ..............................................................................................................................5-5
5.3 Layout of Pneumatics.............................................................................................................................5-5
5.3.1 Solenoid..........................................................................................................................................5-7
5.3.2 Valve Unit.......................................................................................................................................5-7
5.3.3 Particulate Filter ............................................................................................................................5-7
5.3.4 Pump...............................................................................................................................................5-8
5.3.5 Pressure Sensor..............................................................................................................................5-9
5.3.6 Pneumatics Board..........................................................................................................................5-9
5.4 Power Supply Unit for 4-/5-Gas Measuring Instruments Unit........................................................5-10
5.5 Power Supply Board...............................................................................................................................5-10

Table of Contents AVL 4000
IV Service Manual
5.6 O2Sensor and NO Sensor.......................................................................................................................5-10
5.6.1 Replacing the O2Sensor................................................................................................................5-11
5.6.2 Replacing the NO Sensor..............................................................................................................5-11
5.7 Cleaning the Condensate Part of the 4/5-Gas Bench.........................................................................5-12
5.8 Error Symptom List - Remedies............................................................................................................5-14
6. Opacity Measuring Chamber Type A
6.1 System Check with Filter........................................................................................................................6-1
6.2 Upgrading an AVL DiGas 4000 to an AVL DiCom 4000....................................................................6-3
6.3 General Configuration............................................................................................................................6-4
6.4 Dismantling the Opacity Measuring Chamber...................................................................................6-6
6.4.1 Housing Cover 1 (on Exhaust Gas Outlet Side)........................................................................6-6
6.4.2 Housing Cover 2 (on Exhaust Gas Inlet Side) ...........................................................................6-7
6.4.3 Half-shells 1 and 2.........................................................................................................................6-9
6.5 Fans...........................................................................................................................................................6-12
6.6 Heating Blocks and Orifice Plates.........................................................................................................6-13
6.7 Changeover Valve with Geared Motor.................................................................................................6-15
6.8 Temperature Sensor................................................................................................................................6-17
6.9 Lamp Module (BO1135).........................................................................................................................6-19
6.10 Detector (BO1134) ...................................................................................................................................6-21
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 Cell (BO2138)........................................................................................................7-6
7.4.2.1 Replacing the Temperature Sensor in the Heating System..................................................7-6
7.4.3 Valve Unit (BO2139)......................................................................................................................7-7
7.4.3.1 Replacing the Temperature Sensor..........................................................................................7-7
7.4.4 Transmitter and Detector Unit.....................................................................................................7-8
7.4.4.1 Checking the Light Sources (green LEDs) and the Receiver ...............................................7-8
7.4.4.2 Checking the Reference Receiver............................................................................................7-8
7.5 Assembling the Opacity Measuring Chamber....................................................................................7-10
8. Spare Parts Lists
8.1 General......................................................................................................................................................8-1
8.2 Standard List............................................................................................................................................8-2
8.3 AVL 4000 with Opacity Measuring Chamber Type A........................................................................8-6
8.4 AVL 4000 with Opacity Measuring Chamber Model AFrance.........................................................8-10
9. Tools for the Service Technician

4000 Periodic Maintenance
Service Manual 1-1
1. Periodic Maintenance
1.1 General
This Service Manual describes the following 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.

Periodic Maintenance AVL 4000
1-2 Service Manual
1.2 Maintenance Plan
To ensure that the tester always functions properly, maintenance must be carried out at
regular intervals.
Maintenance work
Daily
Weekly
Six-monthly
(minor maintenance)
One a year
(major maintenance)
Comment
Entry in main-
tenance log book
Leak test  Automatically required
by tester every day
Filter replacement
Pre-filter on probe 
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 O2sensor Replacement is
requested by tester

Replacing NO sensor Replacement is
requested by tester

Visual check of outside 
Check using software Service engineer 
Software update (as required) Service engineer 
Open tester, visual inspection
of PCBs, clean, close housing,
seal with service seal
Service engineer 

4000 Periodic Maintenance
Service Manual 1-3
Maintenance work
Daily
Weekly
Six-monthly
(minor maintenance)
One a year
(major maintenance)
Comment
Entry in main-
tenance log book
Opacity measuring chamber
type A

Visual check
(silicon seal, leaks in
housing, housing
components, closure
fittings, snap mechanism
of the optical 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 connections,
electrical cables)
Function check (fan,
heating, changeover
valve)
Cleaning of optical
elements
Linear check

Periodic Maintenance AVL 4000
1-4 Service Manual
1.3 Minor Maintenance
1.3.1 AVL DiGas 4000
•Evaluation unit
Check using software
−Raw data from 4-/5-gas measuring instruments unit OK?
−O2sensor 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)

4000 Periodic Maintenance
Service Manual 1-5
1.3.2 AVL DiSmoke 4000
•Evaluation unit
Visual inspection
Enter in maintenance log book
•Opacity measuring chamber, type 4000
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

Periodic Maintenance AVL 4000
1-6 Service Manual
1.3.3 AVL DiCom 4000
•Evaluation unit
Check using software
−Raw data from 4-gas measuring instruments unit OK?
−O2sensor is OK?
−NO sensor is OK?
Visual inspection
Enter 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
•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 function of heating
−Check changeover valve
("Calibration", "Test", "Deactivate" settings - visual check or diesel service mode)
−Clean the optical elements (by wiping)
−Linear check

4000 Periodic Maintenance
Service Manual 1-7
•Opacity measuring chamber type 4000
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
Function test
−Leak test
(see Operating Manual)
−Gas calibration
(see Operating Manual)

Periodic Maintenance AVL 4000
1-8 Service Manual
1.4 Major Maintenance
1.4.1 AVL DiGas 4000
•Evaluation Unit
Check using software
−Raw data from 4-gas measuring instruments unit OK?
−O2sensor is OK?
−NO sensor 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

4000 Periodic Maintenance
Service Manual 1-9
1.4.2 AVL DiSmoke 4000
•Evaluation unit
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
•Opacity measuring 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 elements (by wiping)
−Linear check
•Cleaning
Visual inspection probe and hose

Periodic Maintenance AVL 4000
1-10 Service Manual
1.4.3 AVL DiCom 4000
•Evaluation unit
Check using software
−Raw data from 4-gas measuring instruments unit OK?
−O2sensor is OK?
−NO sensor 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
•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 function of heating
−Check changeover valve
("Calibration", "Test", "Deactivate" settings - visual check or diesel service mode)
−Clean the optical elements (by wiping)
−Change lamps
−Linear check