AVL DiGas 4000 AVL DiCom 4000 AVL DiSmoke 4000 ENGINE DIAGNOSTICS

DITEST FAHRZEUGDIAGNOSE GMBH Alte Poststraße 152 A-8020 Graz / Austria Phone: +43 316 787-0 Fax: +43 316 787-1460 http://www.avlditest.com ENGINE DIAGNOSTICS Ident. number: AT0480E Revision number: 03 Edition: 03/2001 Subject to alteration Printed in Austria by DITEST GMBH Graz Operating Manual AVL DiGas 4000 AVL DiCom 4000 AVL DiSmoke 4000 from software version 1.02

Copyright 2001 DITEST FAHRZEUGDIAGNOSE 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 DITEST. While every effort is made to ensure correctness, DITEST assumes no liability for errors and omissions.

Important Notice! Important Notice! This manual contains important warning and safety instructions to be observed by the user. This product is only intended for one certain area of application which is prescribed in the instructions. Furthermore the most important necessary prerequisites for application and operation as well as the safety measures are explained to ensure smooth operation. No warranty or liability will be granted if the product is applied in areas others than those described or if the necessary 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 measures. Only accessories and supplies either delivered by DITEST or approved by DITEST are to be used with the product. Due to the operating principle of this product the accuracy of measurement results which it produces does not only depend upon its correct operation and function, but also upon a variety of boundary conditions beyond the control of the manufacturer. Therefore the results obtained from this product must be subjected to careful examination by an expert (e.g. for plausibility) before action based upon the results is undertaken. Adjustment and maintenance of instruments when open and under voltage are only to be carried out by a professional technician being aware of the dangers involved. Repairs on the product are to be carried out by the manufacturer or qualified service personnel only. Upon application of the product an expert is to ensure that neither the object of examination nor the testing equipment are operated under conditions that my lead to damage or injury. DITEST FAHRZEUGDIAGNOSE GMBH Important Notice! Important Notice!

Important Notice Follow the manufacturer's instructions when holding the cut-off speed of diesel engines! All armatures used for NO calibration must be corrosion resistant and suitable for NO and NO x. Venting holes must not be blocked. Only use the supplied network cable with protective ground! Only connect the network cable to a socket with an earth contact! To prevent the tester from becoming damaged, always unplug it before cleaning with compressed air! Never allow the probe to be bent!

Connected equipment that uses voltages higher than 50 V AC or 75 V DC must comply with the Low Voltage Directive 73/23/EWG. To comply with the requirements of the 89/336/EWG Directive on electromagnetic compatibility, only shielded cables with appropriately shielded plug connections may be used. Mains connections with standard plugs and the specific cases listed as exceptions do not have to be shielded.

Safety Instructions Before using the instrument, ensure that the O 2 sensor and NO sensor outputs are open and not covered by the cap and that the discharge hose is connected. The tester can become damaged or produce errored measurement results if operated with the gas outlet closed. Before using the instrument after moving or transporting it, check that the condensate outlet hose is not obstructed in any way, otherwise condensate may flow back into the measuring cell and contaminate it. After transport or storage at low temperatures and after setting up the tester, remember that it needs at least one hour for the temperature to stabilise before being switched on (to avoid condensed water forming). A tester stored at temperatures below 0 C must be allowed to adjust to at least +2 C before being switched on. Do not allow the tester to draw in exhaust gas for an unnecessarily long time. Only insert the probe into the exhaust pipe when this is necessary for measurements. Otherwise the probe should be continuously purged with ambient air with the pump running. Never let the probe lie on the floor. Never let liquids (e.g. water) or any other impurity be drawn into the tester through the probe. The exhaust gas probe must never by bent. Never place the tester in hot sun, rain, snow, corrosive atmospheres, or atmospheres contaminated with petrol fumes. Ensure that where possible, the tester is connected to a plug socket or mains phases that are not loaded by other equipment with high starting currents (such as welding equipment, drills, compressors, extractor fans). Make sure that within a radius of about 5 m of the tester no equipment is used that causes serious electromagnetic interference (such as radio telephones, electronic welding equipment, large electric motors etc.). The opacity measuring chamber must never be placed directly behind the exhaust pipe of a vehicle (because of the danger of soiling). If the display indicates insufficient gas flow, check whether the hose or probe is kinked or blocked, or whether the filters are soiled and need cleaning or replacing. Only ever use standard DITEST exhaust probes. Only ever use standard DITEST spare parts. Regular maintenance of the filter units (replacing the pre-filter, condensate filter and filter cartridge in the filter housing) is absolutely necessary to ensure long service life and to guarantee that the instrument functions correctly. Before switching the instrument off, the 4/5-gas unit should be purged with clean ambient air with the pump running for a few minutes. The 4/5-gas measuring instrument must be calibrated every twelve months.

Important Instructions Follow the safety instructions for handling O 2 sensor and NO sensors (see section 5.5.1) for handling calibration gas containing CO (see section 5.11.2). Check whether the calibration seal is out of date (on side of evaluation unit). If it is out of date, the tester must be re-calibrated by the respective weights and measures office before the equipment is used. Should the calibration seal be broken or damaged, the tester must be re-calibrated. Remember that certain maintenance work carried out by the user (see section 5.1 Maintenance Plan) must be documented (i.e. entered in the maintenance log book).

4000 Table of Contents Table of Contents 1. Description and Start-up... 1-1 1.1 General...1-1 1.2 Front View (Controls)...1-1 1.3 Side View (Electric Connections)...1-2 1.4 Rear Panel (Probe Connection, Filters)...1-3 1.5 Opacity Measuring Chamber...1-5 1.6 Start-up...1-6 2. Petrol Measurements... 2-1 2.1 Operating the Instrument...2-2 2.2 Official Measurement...2-3 2.3 Standard Measurement (and optional NO measurement)...2-9 2.4 AVL Diagnosis Plus (Option)...2-14 2.4.1 Ignition Point Adjustment...2-15 2.4.2 Lambda Probe Curve...2-17 2.4.3 Catalytic Converter Analysis...2-19 2.4.4 Dwell Angle...2-22 2.5 Emission Expert (Option)...2-23 2.6 Speed and Angle Measurement...2-25 2.7 Editor...2-27 3. Diesel Measurements... 3-1 3.1 Operating the Instrument...3-2 3.2 Official Measurement...3-3 3.3 Standard Measurement...3-13 3.4 AVL Diagnosis Plus (Option)...3-17 3.4.1 Advance Angle Curve...3-18 3.4.2 Opacity Curve...3-19 3.5 Emission Expert (Option)...3-23 3.6 Controlling Measurement...3-25 3.6.1 Linearity Test...3-26 3.6.2 Verification Measurement With Filter...3-26 3.7 Speed and Angle Measurement...3-27 4. Error Messages... 4-1 4.1 General...4-1 4.2 Error Messages - Petrol...4-2 4.3 Error Messages - Diesel / Technical Faults...4-3 4.4 Diesel - User Errors...4-4 Operating Manual I

Table of Contents AVL 4000 5. Maintenance... 5-1 5.1 Maintenance Plan...5-1 5.2 Changing the Printing Paper and Ribbon...5-3 5.3 Cleaning the Probe...5-4 5.4 Filter Replacement...5-5 5.4.1 Particulate Filter, Pre-filter and Condensate Filter...5-5 5.4.2 Activated Carbon Filter...5-5 5.5 Changing the O 2 and NO Sensors...5-6 5.5.1 Safety Instructions for Handling O 2 and NO sensors...5-7 5.6 Condensate Trap...5-8 5.7 Cleaning the Condensate Side of the 4/5-Gas Measuring Instruments...5-9 5.8 Leak Check...5-11 5.9 System Check With Filter...5-12 5.10 Cleaning the Optical Elements of the Opacity Measuring Chamber...5-13 5.11 Service Mode...5-14 5.11.1 Gas Calibration...5-15 5.11.2 Safety Instructions for Handling Calibrating Gas Containing CO or NO x...5-20 5.11.3 Diesel 4000...5-21 5.11.4 User Data...5-22 5.11.5 Date and Time...5-23 5.12 Spare Parts List...5-24 6. Technical Data II Operating Manual

4000 Description and Start-up 1. Description and Start-up 1.1 General This manual describes how to use the AVL DiGas 4000, AVL DiSmoke 4000, and AVL DiCom 4000 Exhaust Gas Testers. The following chapters deal with the two testers as shown below: Petrol engines (Chapter 2) AVL DiGas 4000! Diesel engines (Chapter 3) AVL DiSmoke 4000! AVL DiCom 4000!! 1.2 Front View (Controls) Display Function keys Printer (option) Fig. 1-1 Operating Manual 1-1

Description and Start-up AVL 4000 1.3 Side View (Electric Connections) Some sockets are colour coded. The colour coded cables should be plugged into them accordingly. Fig. 1-2 Symbol Colour Connection *) RIV sensor; clamp-on transducer *) yellow AVL DiSpeed, TDC sensor, digital (diagnostics cable), optical pick-up; strobe; TDC sensor, inductive (diagnostics cable) % *) red Interrupter; needle movement sensor (NBG); trigger crocodile clip *) blue Lambda probe voltage; battery voltage *) white Oil temperature probe Slot for memory card (PCMCIA) Keyboard (5-pin standard PC keyboard interface) RS232 Serial port (RS232) depending on the configuration, data exchange with external equipment (details upon request) Printer (Epson-compatible, Centronics interface) *) These connections are only available with the RPM option. 1-2 Operating Manual

4000 Description and Start-up 1.4 Rear Panel (Probe Connection, Filters) AVL DiGas 4000 and AVL DiCom 4000 Connection for probe Condensate trap Particulate filter Pump Pure air inlet (no exhaust gas) Activated carbon filter O 2 sensor NO sensor (option) Inlet for calibration gas *) AVL DiCom 4000 only Fig. 1-3 Condensate filter Power supply to pump Non-return valve Connector to opacity measuring chamber *) Mains connection with mains switch and fuses Condensate outlet Analog out *) (analog signal of exhaust gas opacity 0 5 V $= 0 100 % opacity) The condensate outlet and the outlets of the O 2 sensor and NO sensor (option) must not be closed off! Make sure that the hose is connected to the condensate outlet. Connect the mains cable supplied with the tester to the mains. Connect the probe to the appropriate socket. Operating Manual 1-3

Description and Start-up AVL 4000 AVL DiSmoke 4000 Connector to opacity measuring chamber Mains connection with mains switch and fuses Fig. 1-4 Analog out (analog signal of exhaust gas opacity 0 5 V $= 0 100 % opacity) Connect the mains cable supplied with the tester to the mains. 1-4 Operating Manual

4000 Description and Start-up 1.5 Opacity Measuring Chamber (AVL DiSmoke 4000 and AVL DiCom 4000) 1 9 2 8 3 3 4 5 6 7 4 Fig. 1-5 Nr. Function 1 Handle 2 For connection cable to control unit 3 Optics protector (removable) 4 Purging air outlet 5 Sample gas outlet 6 Mounting for extraction funnel 7 Rating and nameplate 8 Sample gas input 9 Purging air inlet Operating Manual 1-5

Description and Start-up AVL 4000 1.6 Start-up Before using the tester for the first time, read the safety instructions at the beginning of this manual! Switch the tester on. The tester then carries out an initialisation procedure and a self-test, then the main menu is displayed. MAIN MENU PETR: PETROL DIES: DIESEL Now call up the measurement menu you want or the service mode. SERV: SERVICE Fig. 1-6 1-6 Operating Manual

4000 Petrol Measurements 2. Petrol Measurements Basic program structure: Petrol menu Official measurement Standard measurement Diagnosis Plus Emission Expert Fig. 2-1 Remember that the program structure may be different depending on the options used. Do not insert the probe in the exhaust pipe until the display tells you to. Operating Manual 2-1

Petrol Measurements AVL 4000 2.1 Operating the Instrument The AVL 4000 can be operated by means of the function keys on the front panel, an optional remote control, or an external, standard PC keyboard. The current function of keys F1 to F6 is displayed above the keys either as a symbol or in writing. The key LF performs a line feed on the internal printer. The following symbols may be displayed at any given time: Aborts the current measurement Rolls the measurement process back a step Continues the measurement process YES NO Select speed sensor Cursor keys Switches between propane and hexane (petrol) Freezes the current measurement values Resumes a measurement that has been halted Changes the resolution of the displayed curve Zoom toggle for resolution of graphic display of measurement data Shows detailed information about exhaust gas concentrations Shows detailed information Prints out current data or starts results printout (internal printer) Editor for text input (see section 2.7) Cancels entire entry The displays illustrated are comparative representations which may differ from what you actually see on the screen depending on your system configuration (including program options, installed hardware options). 2-2 Operating Manual

4000 Petrol Measurements 2.2 Official Measurement Mounting the Cables / Probe RPM measurement Use the trigger clamp to measure the speed. Measuring rpm on engines with ignition distributor Clip the trigger clamp onto any ignition lead between the distributor and spark plugs. Fig. 2-2 Measuring rpm on single-spark coils (DIS systems) Clip the trigger clamp onto the control cable (primary circuit cable) of any cylinder. Note: If all primary cables have to be measured, you must later specify the number of cylinders measured as pulses (see section 2.6 Speed and Angle Measurement). Fig. 2-3 Operating Manual 2-3

Petrol Measurements AVL 4000 Measuring rpm on twin-spark coils Clip the trigger clamp to the control cable (primary circuit cable) of any cylinder. You must later specify TWIN SPARK COIL as speed sensor (see section 2.6 Speed and Angle Measurement). Fig. 2-4 Exhaust gas probe Insert the probe at least 30 cm into the exhaust pipe. The exhaust system must be airtight (inleaked air will affect the measurement results). The air extraction system must not be mounted on the exhaust pipe (as this will affect the measurement values). The probe must protrude 30 cm into the exhaust pipe (otherwise the pulsation of the exhaust gases can affect the measurement values). The probe can be very hot after a measurement caution is therefore advised when handling it! Oil temperature probe (option) When working with petrol engines, make sure that the cap of the oil temperature probe fits firmly and is not leaking (inleaked air at the dip stick will affect the control loop). Before inserting the oil temperature probe, dry the rubber cone on the probe and the part it rests against on the engine. Always make sure that the oil temperature probe is the same length as the original dip stick. If the length is different, damage can occur to both the engine and the oil temperature probe! 2-4 Operating Manual

4000 Petrol Measurements Carrying Out the Official Measurement MAIN MENU PETR: PETROL DIES: DIESEL SERV: SERVICE MODE Select PETROL in the main menu Fig. 2-5 MENU PETROL OM: OFFICIAL MEAS. STD: STANDARD MEAS. DP: DIAGNOSIS PLUS EE: EMISSION EXPERT and then OFFICIAL MEASUREMENT. Fig. 2-6 Enter the required data. VEHICLE REG.NO.: MILEAGE: Finish your input with >> to automatically jump to the next screen. If possible, use an external keyboard for your input. If you use the internal editor, read section 2.7 Editor on inputting data. Fig. 2-7 VEHICLE REG.NO.: MILEAGE: Fig. 2-8 The system now asks you whether the registration number is to be searched for in the customer database. Press to search for the vehicle data in the customer database. If the data is found, it is displayed (see Fig. 2-11). If the data is not found, you will have to input it (see Fig. 2-10). Press to input the data without the customer database being searched. You can also press to call up information about the customer database (see Fig. 2-9). Operating Manual 2-5

Petrol Measurements AVL 4000 CUSTOMER MEMORY INFO 128 kbyte 1 % 0 CUSTOMERS: FREE STORED DELETED DEL deletes entries in the customer database, IMP imports customer data from an external memory card (PCMCIA), EXP exports customer data to an external memory card (PCMCIA). Press >> to return to the data input. Fig. 2-9 An external memory card (PCMCIA) must only be plugged in or removed when the equipment is turned off! Decide whether a measurement is to be carried out at increased idle: INCREASED IDLE NO / YES? If you select (YES), you have to define the upper and lower limit of the speed range. Fig. 2-10 INC.IDLE MIN: MAX: If a measurement is to be carried out at increased idle, all the input data is now displayed. displays information about the customer database (see Fig. 2-9, e.g. no. of stored and of free customer entries). Fig. 2-11 saves the displayed data in the customer memory and the measurement sequence continues automatically. Press < to correct the input data. Press to continue the measurement without saving the displayed data. 2-6 Operating Manual

4000 Petrol Measurements TESTER IS IN WARMUP PHASE WAIT 14 MINUTES MAX. The tester takes 15 min to stabilise if it has not yet been in operation long enough (the time left to wait is continuously displayed). Note: The tester goes through a warmup phase every time it is switched on. Leave your tester in stand-by mode (with main menu displayed). Here you can also select the speed sensor used (see section 2.6 Speed and Angle Measurement). Fig. 2-12 LEAK CHECK CLOSE OFF PROBE A leak check must be carried out daily. Follow the instructions on the screen. N.B. Probe and hose must be connected for the leak check! If the tester fails the leak test, see section 5.6 for further information. Fig. 2-13 TESTER IS STABILISING REMOVE PROBE The tester then needs time to stabilise and the time left to wait is displayed on the screen. WAIT 30 SECONDS MAX. Fig. 2-14 The tester automatically checks the HC residue in the sampling hose and lines. The probe must be in the fresh air and not in the exhaust pipe! HC RESIDUE 22 ppm CLEAN PROBE AND TUBE MAXIMUM VALUE ALLOWED 20 ppm If the probe is not in the exhaust gas flow and the HC concentration is greater than 20 ppm, there may be a high level of petrol residue in the air. Make sure the probe intake is fresh air - move to another location if necessary or ventilate the room. Fig. 2-15 Operating Manual 2-7

Petrol Measurements AVL 4000 Measuring Measuring at increased idle (if you have activated this measurement): CO O 2 %vol %vol CO 2 HC %vol RPM Fig. 2-16 ppm min -1 8000 λ Increase the speed until you are inside the selected speed band. Hold the speed for a few seconds until the values stabilise. If the measured values are OK, reduce the speed again. The tester automatically stores the displayed gas values and the measurement sequence is continued after a few seconds (or when you press >>). Toggles the HC value display between propane and hexane (petrol, LBG or CNG). Allows you to select the connected speed sensor (see section 2.6 Speed and Angle Measurement). N.B. If you don t want to accept the gas value, accelerate again and increase the speed to within the speed band. The measurement is repeated and the new measured values stored. CO O 2 %vol %vol HC CO COR %vol CO 2 Fig. 2-17 ppm λ %vol RPM T oil min -1 C Let the speed drop to idle. Wait until the values stabilise. Allows you to select the connected speed sensor (see section 2.6 Speed and Angle Measurement). Starts the printout of the official measurement. Freezes the current measurement values. Then press continue with the measurement. Press < to return to the measurement at increased idle (if you activated this measurement). Press << to return to the petrol engine menu. to Remove the probe from the exhaust after the measurement. It can be very hot, so be careful! Do not switch the tester off immediately after a measurement is completed but stay in the main menu Leave the tester switched on for a few minutes during which time the measuring instrument unit is purged with fresh air. Tip: During working hours, leave the tester in stand-by mode (with the main menu displayed). 2-8 Operating Manual

4000 Petrol Measurements 2.3 Standard Measurement (and optional NO measurement) Mounting the Cables / Probe Use the trigger clamp to measure the speed. RPM measurement Measuring rpm on engines with ignition distributor Clip the trigger clamp onto any ignition lead between the distributor and spark plugs. Fig. 2-18 Measuring rpm on single-spark coils (DIS systems) Clip the trigger clamp onto the control cable (primary circuit cable) of any cylinder. Note: If all primary cables have to be measured, you must later specify the number of cylinders measured as pulses (see section 2.6 Speed and Angle Measurement). Fig. 2-19 Operating Manual 2-9

Petrol Measurements AVL 4000 Measuring rpm on twin-spark coils Clip the trigger clamp to the control cable (primary circuit cable) of any cylinder. You must later specify TWIN SPARK COIL as speed sensor (see section 2.6 Speed and Angle Measurement). Fig. 2-20 Exhaust gas probe Insert the probe at least 30 cm into the exhaust pipe. The exhaust system must be airtight (inleaked air will affect the measurement results). The air extraction system must not be mounted on the exhaust pipe (as this will affect the measurement values). The probe must protrude 30 cm into the exhaust pipe (otherwise the pulsation of the exhaust gases can affect the measurement values). The probe can be very hot after a measurement caution is therefore advised when handling it! Oil temperature probe (option) When working with petrol engines, make sure that the cap of the oil temperature probe fits firmly and is not leaking (inleaked air at the dip stick will affect the control loop). Before inserting the oil temperature probe, dry the rubber cone on the probe and the part it rests against on the engine. Always make sure that the oil temperature probe is the same length as the original dip stick. If the length is different, damage can occur to both the engine and the oil temperature probe! Angle measurement Use either the trigger cable on cylinder one and a strobe, or a trigger cable on cylinder one and a TDC sensor cable. 2-10 Operating Manual

4000 Petrol Measurements Strobe Operation: Press switch 1 on the strobe to activate the flash light. Aim the beam at the mark on the engine block and change the angle value with switch 2 on the strobe (without releasing switch 1). Continue adjusting like this until the TDC mark on the flywheel corresponds with the reference mark on the engine block. Make sure that the RPM during the measurement stays at the prescribed test speed. The adjustment range is 0 to 60 CA; when 60 is reached the display stays at 60. To lower the angle value, press the bottom of switch 2. To raise it press the top. Fig. 2-21 2 1 Note The adjusting rocker switch 2 must be pressed continuously. The first 10 adjustments are made at increments of 0.1 CA and after that at increments of 1.0 CA. The moment the switch is released, the adjustment intervals return to 0.1 CA. Switch 2 can be pressed in two directions so that the angle can be adjusted up or down. As soon as you finish working with the strobe and release both switches, the measured values are frozen on the display. Dwell angle Attach clamp one of the interrupter cable to the negative terminal of the ignition coil. Operating Manual 2-11

Petrol Measurements AVL 4000 Performing standard measurement (and optional NO measurement) MAIN MENU PETR: PETROL DIES: DIESEL SERV: SERVICE MODE Select PETROL in the main menu Fig. 2-22 MENU PETROL OM: OFFICIAL MEAS. STD: STANDARD MEAS. DP: DIAGNOSIS PLUS EE: EMISSION EXPERT Fig. 2-23 and then STANDARD MEASUREMENT. N.B. If the NO option is installed on the measuring instrument, at this point you can choose between standard and NO measurement. If the NO option is not installed, the standard measurement is called up immediately. Do not connect any hose at the exhaust gas outlet of the NO sensor. If the option NO is integrated in the measuring instrument, the measuring instrument must be switched on at least once per month for one day, in order to load the lead-acid battery again. 2-12 Operating Manual

4000 Petrol Measurements λ CO CO 2 O 2 HC Fig. 2-24 RPM IGN DA T oil Immediately after calling up the standard measurement, the following values are displayed on the right: speed dwell angle ignition point oil temperature The following information is first displayed on the left: tester is in warm-up phase tester is stabilising carry out leak test HC residue test For notes on these operating steps, see section 2.2 Official Measurement. When the 4/5-gas measuring instruments have also reached a stable operating state, the following measurement values are also displayed (standard measurement): Lambda (λ) CO CO 2 O 2 HC The function keys shown below are available during the standard measurement: DP Calls up the Diagnosis Plus functions (see section 2.4). If NO measurement not present. Toggles the HC value display between propane and hexane (petrol, LBG or CNG). This allows you to select the connected speed and angle sensor (see section 2.6 Speed and Angle Measurement). Starts the printout of the measured values. The current measurement values are frozen. Press to then carry on with the measurement. << Terminates the standard measurement and returns you to the petrol engine menu. Operating Manual 2-13

Petrol Measurements AVL 4000 2.4 AVL Diagnosis Plus (Option) MAIN MENU PETR: PETROL DIES: DIESEL SERV: SERVICE MODE Select PETROL in the main menu Fig. 2-25 MENU PETROL OM: OFFICIAL MEAS. STD: STANDARD MEAS. DP: DIAGNOSIS PLUS EE: EMISSION EXPERT and then DIAGNOSIS PLUS. Fig. 2-26 AVL DIAGNOSIS PLUS IA: IGNITION ADV. PROBE: λ-probe VOLT. CAT: CC ANALYSIS DA: DWELL ANGLE In addition to the measurements shown on the display, with STD you can call the standard measurement and with DA you can start the dwell angle measurement. Fig. 2-27 2-14 Operating Manual

4000 Petrol Measurements 2.4.1 Ignition Point Adjustment (graphic and digital evaluation) Mounting the Cables RPM measurement Use the trigger clamp for measuring the rpm. Measuring rpm on engines with ignition distributor Clip the trigger clamp onto any ignition lead between the distributor and spark plugs. Fig. 2-28 Modern ignition systems with engine map control or loop control are mostly coded, i.e. to adjust the ignition point, you have to implement a measure defined by the manufacturer. For this purpose therefore, always follow the manufacturer s instructions. Angle measurement Use either the trigger cable on cylinder one and a strobe, or a trigger cable on cylinder one and a TDC sensor cable. Drawing a curve with the strobe To record the adjustment with the strobe graphically, the rpm must be increased and held in stages. At each increased rpm stage, adjust the strobe until the marks on the engine are in alignment again. This will give you a stepped representation of the adjustment curve. Drawing a curve with a TDC sensor When using a TDC sensor and trigger clamp, the signals are recorded continuously. Increase the rpm and watch the adjustment curve on the display - the data is recorded and calculated automatically. Operating Manual 2-15

Petrol Measurements AVL 4000 Strobe Operation: Press switch 1 on the strobe to activate the flash light. Aim the beam at the mark on the engine block and change the angle value with switch 2 on the strobe (without releasing switch 1). Continue adjusting like this until the TDC mark on the flywheel corresponds with the reference mark on the engine block. Make sure that the RPM during the measurement stays at the prescribed test speed. The adjustment range is 0 to 60 CA; when 60 is reached the display stays at 60. To lower the angle value, press the bottom of switch 2. To raise it press the top. Fig. 2-29 2 1 Note The adjusting rocker switch 2 must be pressed continuously. The first 10 adjustments are made at increments of 0.1 CA and after that at increments of 1.0 CA. The moment the switch is released, the adjustment intervals return to 0.1 CA. Switch 2 can be pressed in two directions so that the angle can be adjusted up or down. As soon as you finish working with the strobe and release both switches, the measured values are frozen on the display. Measurement To start the measurement, select IGNITION ADV in the AVL DIAGNOSIS PLUS menu. MIN: 60 CA 40 20 MAX: RPM IGN 0 0 2000 4000 6000 min -1 Display of angle adjustment curve Press to select the connected TDC sensor and cylinder 1 sensor (see section 2.6 Speed and Angle Measurement). Starts the printout of the curve. Freezes the current measurement values and the curve. Press Fig. 2-30 to then continue with the measurement. Press < to return to the AVL Diagnosis Plus menu. Press << to return to the petrol engine menu. 2-16 Operating Manual

4000 Petrol Measurements 2.4.2 Lambda Probe Curve (graphic and digital evaluation) Mount the cable RPM measurement Use the trigger clamp to record the rpm. Measuring rpm on engines with ignition distributor Clip the trigger clamp onto any ignition lead between the distributor and spark plugs. Fig. 2-31 Measuring rpm on single-spark coils (DIS systems) Clip the trigger clamp onto the control cable (primary circuit cable) of any cylinder. Note: If all primary cables have to be measured, you must later specify the number of cylinders measured as pulses (see section 2.6 Speed and Angle Measurement). Fig. 2-32 Operating Manual 2-17

Petrol Measurements AVL 4000 Measuring rpm on twin-spark coils Clip the trigger clamp to the control cable (primary circuit cable) of any cylinder. You must later specify TWIN SPARK COIL as speed sensor (see section 2.6 Speed and Angle Measurement). Fig. 2-33 Lambda probe cable Connect the lambda probe cable to the positive and negative terminals of the lambda probe, if you want to check the lambda probe. Fig. 2-35 Fig. 2-34 Performing the measurement To start the measurement, select LAMBDA PROBE in the AVL DIAGNOSIS PLUS menu. PROBE mv 1 FREQ Hz RPM min-1 λ Probe volt display to change the resolution at which the curve is Press displayed. 0 1 0 Fig. 2-36 2 4 6 8 s Toggles between 1 V and 5 V probes. Select speed sensor (see Section 2.6 Speed and Angle Measurement). Prints out current data or starts result printouts Freezes the current measurement values; press continue. to Press < to return to the AVL Diagnosis Plus menu. Press << to then return to the petrol engine menu. 2-18 Operating Manual

4000 Petrol Measurements 2.4.3 Catalytic Converter Analysis Mounting the Cables / Probe Exhaust gas probe Insert the probe at least 30 cm into the exhaust pipe. The exhaust system must be airtight (inleaked air will affect the measurement results). The air extraction system must not be mounted on the exhaust pipe (as this will affect the measurement values). The probe must protrude 30 cm into the exhaust pipe (otherwise the pulsation of the exhaust gases can affect the measurement values). Lambda probe cable Connect the lambda probe cable to the positive and negative terminals of the lambda probe, if you want to check the lambda probe. Fig. 2-37 Fig. 2-38 Operating Manual 2-19

Petrol Measurements AVL 4000 Measuring To start the measurement, select CC ANALYSIS in the AVL DIAGNOSIS PLUS menu. TESTER IS IN WARMUP PHASE WAIT 14 MINUTES MAX. Fig. 2-39 The tester takes 15 min to stabilise if it has not yet been in operation long enough (the time left to wait is continuously displayed). Note: The tester goes through a warmup phase every time it is switched on. Leave your tester in stand-by mode (with main menu displayed). Here you can select the rpm sensor used (see section 2.6 Speed and Angle Measurement). LEAK CHECK CLOSE OFF PROBE A leak check must be carried out daily. Follow the instructions on the screen. N.B. The probe and hose must be connected for the leak test! If the tester fails the leak test, see section 5.6 for further information. Fig. 2-40 TESTER IS STABILISING REMOVE PROBE The tester then needs time to stabilise and the time left to wait is displayed on the screen. WAIT 30 SECONDS MAX. Fig. 2-41 The tester automatically checks the HC residue in the sampling hose and lines. The probe must be in the fresh air and not in the exhaust pipe! HC RESIDUE 22 ppm CLEAN PROBE AND TUBE MAXIMUM VALUE ALLOWED 20 ppm If the probe is not in the exhaust gas flow and the HC concentration is greater than 20 ppm, there may be a high level of petrol residue in the air. Make sure the probe intake is fresh air - move to another location if necessary or ventilate the room. Fig. 2-42 2-20 Operating Manual

4000 Petrol Measurements LAMBDA PROBE λ (CALCULATED) CO Display of measurement data Toggles the HC value display between propane and hexane (petrol, LBG or CNG). Toggles between 1 V and 5 V probes. Starts the printout of the curve. Fig. 2-43 Freezes the current measurement values and the curve. Press to continue with the measurement. Press < to return to the AVL Diagnosis Plus menu. Press << to then return to the petrol engine menu. Remove the probe from the exhaust after the measurement. It can be very hot, so be careful! Do not switch the tester off immediately after a measurement is completed but stay in the main menu Leave the tester switched on for a few minutes during which time the measuring instrument unit is purged with fresh air. Tip: During working hours, leave the tester in stand-by mode (with the main menu displayed). Operating Manual 2-21

Petrol Measurements AVL 4000 2.4.4 Dwell Angle Mounting the cable Attach the clamp of the interrupter cable to the negative terminal of the ignition coil. Measuring To start the measurement, select Dwell angle (DA) in the AVL DIAGNOSIS PLUS menu. DWELL ANGLE Display of the measurement value Prints the current measurement value. Fig. 2-44 % Freezes the current measurement value. Press to continue with the measurement. Press < to return to the AVL Diagnosis Plus menu. Press << to return then to the petrol engine menu. 2-22 Operating Manual

4000 Petrol Measurements 2.5 Emission Expert (Option) Press PETROL in the main menu Fig. 2-45 and then EMISSION EXPERT. For a description of how to carry out the measurement, see section 2.4. Fig. 2-46 A checklist of the test conditions is then displayed. Press >> to start the measurement. Fig. 2-47 Display of the current measurement values. Measurement values that exceed the limit values are displayed in reverse highlighting (i.e. white value against a black background). Press to call up detailed information on λ and the separate exhaust gas values. Fig. 2-48 Operating Manual 2-23

Petrol Measurements AVL 4000 Select the relevant value, e.g. HC (F4), for more detailed information. Fig. 2-49 The current HC value is displayed top right. Basic information about the selected value. Select one of the main groups, e.g. mixture preparation, by pressing the and keys and then press >>. Fig. 2-50 Any deficients relating to the HC value are now listed. Page down with the key. The PROBE key (F2) is available if a cross-reference to the λprobe maskes sense. Fig. 2-51 When you press PROBE, the λ voltage curve is displayed. Fig. 2-52 2-24 Operating Manual

4000 Petrol Measurements 2.6 Speed and Angle Measurement You can select the rpm sensor (and a second sensor for angle measurement) using. RPM-SENSOR TRIGGER CYL 1 TWIN SPARK COIL CONTACT-BREAKER min -1 SPECIAL TIMING TDC-SENSOR INDUCTIVE TDC-SENSOR DIG. 12 V TDC-SENSOR DIGITAL IMPULS/CYCLE OPTICAL SENSOR 1 2 3 4 5 6 8 AVL DiSpeed On the left, the rpm sensor are displayed. Use and to select a sensor. On the right, additional settings can be selected using (e.g. the numbers of pulses or a special setting). Fig. 2-53 An engine speed of lower than 200 min -1 is outside of valid range - the rpm value flashes. If an error occurs during the rpm measurement, is displayed instead of the rpm. If the symbol E appears to the right of the measurement value, there are also problems with the rpm measurement. The displayed value may be invalid. Special timing This is where the Terminal W setting can be selected. Press direct (10.0 50.0). to enter here the transmission ratio value TDC sensor and optical pickup When one of these sensors is selected, you can select the pulses/revolution or enter the values direct. Then press as often as necessary until is displayed. Press to call up the editor, then enter the required value (33 255 pulses/revolution). TDC-sensor inductive On the right, the quality of the actual sensor is displayed. Press to toggle between no current supply for sensor and current supply for sensor. Use the setting that provides a good signal at low as well as at high speed. Operating Manual 2-25

Petrol Measurements AVL 4000 Angle measurement Press (if available) to select a second sensor. (If TRIGGER CYL 1 or TWIN SPARK COIL is selected as rpm sensor, an angle can always be measured using a stroboscope.) SENSORS FOR ANGLE TRIGGER CYL 1 TWIN SPARK COIL Fig. 2-54 min -1 CA TDC-SENSOR INDUCTIVE TDC-OFFSET 1 IMPULSE/REVOLUT. CA On the right, the actual rpm and angle values are displayed. Use and to select a sensor. TDC-Sensor Inductive: Press to change the automatical Pin-/Slotdetetection. Using key you can enter the TDC offset. TDC offset is the difference (in CA) between reference point and engine TDC (depending on manufacturer). Not all sensor offer the possibility to change the TDC offset. Press Use to select the digit you want to change. to change the selected digit. To change the sign, select the sign and press between + and. Press >> to return to the diagnosis mode. to toggle 2-26 Operating Manual

4000 Petrol Measurements 2.7 Editor You can use the editor to enter text (letters and numbers) in the input fields (such as vehicle registration no., rpm values) if no external keyboard is connected. Call up the editor by pressing. The editor offers you the following keys and functions: Page up and down - select numbers, letters and special characters Move cursor left or right in the selection line Transfer selected character to the input field Quit editor Example: To input the number 64 in an input field Select when the cursor is in the input field. Press or until the number 6 is highlighted. Transfer the number 6 to the input field by pressing. Press or until the number 4 is highlighted. Transfer the number 4 to the input field by pressing. Finally press >> to quit the editor. Your cursor will now be in the input field. Press >> to exit the input field and jump to the next input field or continue with the measurement. Operating Manual 2-27

Petrol Measurements AVL 4000 2-28 Operating Manual

4000 Diesel Measurements 3. Diesel Measurements Basic program structure: Diesel menu Official Measurement Controlling Measurement Standard Measurement Diagnosis Plus Emission Expert Fig. 3-1 Remember that the program structure may be different depending on the options used. Operating Manual 3-1

Diesel Measurements AVL 4000 3.1 Operating the Instrument The AVL 4000 can be operated by means of the function keys on the front panel, an optional remote control, or an external, standard PC keyboard. The current function of keys F1 to F6 is displayed above the keys either as a symbol or in writing. The key LF performs a line feed on the internal printer. The following symbols may be displayed at any given time: Aborts the current measurement Rolls the measurement process back a step Continues the measurement process YES NO Cursor keys Select speed sensor Freezes the current measurement values Resumes a measurement that has been halted Graphic display of the opacity curve Shows detailed information about exhaust gas concentrations Shows detailed information Prints out current data or starts results printout (internal printer) Editor for text input (see section 2.7) Cancels entire entry The displays illustrated are comparative representations which may differ from what you actually see on the screen depending on your system configuration (including program options, installed hardware options). 3-2 Operating Manual

4000 Diesel Measurements 3.2 Official Measurement Mounting the Cables / Probe RPM measurement (if required) You can use a clamp-on transducer for universal rpm measurement. Connect the clamp-on transducer cable to the Fig. 3-2 Fig. 3-3 20 mm straight section of pipe Clamp-on transducer socket. Decide the clamping position on the injection line: straight part of the line at least 20 mm long Clean the mounting position If the mounting position is undamaged, it is sufficient to clean it thoroughly with a cloth. If the position is damaged (i.e. scratched, scored, dented, rusty etc.), sand down the surface with a piece of emery cloth, remove all remnants of emery with a cloth. If this does not produce a smooth rounded mounting surface, the transducer must be mounted elsewhere. If the line is painted, remove the paint first (preferably with a solvent). Use the correct clamp-on transducer for the job. Now mount the transducer on the injection line. The plane of the transducer's closure should lie in the same plane as the next bend in the pipe. Never turn a transducer once clamped on! Connect the transducer cable to the transducer. Attach the ground clip of the transducer cable to the fixing nut of the injection line the transducer is clamped to. For start of delivery measurement, mount the clamp-on transducer at the outlet of the injection pump. Operating Manual 3-3

Diesel Measurements AVL 4000 Exhaust gas probe Connect the probe hose to the opacity measuring chamber at the measuring gas inlet (see section 1.5 Opacity Measuring Chamber, Fig. 1-5). Attach the probe to the exhaust pipe. The probe must be inserted at least 30 cm into the end section of the exhaust pipe. The longitudinal axis of the probe and exhaust pipe should be as far as possible parallel. Do not bend the probe hose! During calibration the opacity measuring chamber draws in air. Do not place the opacity measuring chamber in the path of the exhaust gases therefore, but at right angles to it. The probe can be very hot after a measurement caution is therefore advised when handling it! Wrong! Right! Measuring chamber draws in exhaust gas Opacity measuring chamber Measuring chamber draws in fresh air Fig. 3-4 Oil temperature probe Before inserting the oil temperature probe, dry the rubber cone on the probe and the part it rests against on the engine. Always make sure that the oil temperature probe is the same length as the original dip stick. If the length is different, damage can occur to both the engine and the oil temperature probe! 3-4 Operating Manual

4000 Diesel Measurements Carrying Out the Official Measurement MAIN MENU PETR: PETROL DIES: DIESEL SERV: SERVICE MODE Select DIESEL in the main menu Fig. 3-5 MENU DIESEL OM: OFFICIAL MEAS. STD: STANDARD MEAS. DP: DIAGNOSIS PLUS EE: EMISSION EXPERT and then OFFICIAL MEASUREMENT. Fig. 3-6 Enter the required data. VEHICLE REG.NO.: MILEAGE: Finish your input by pressing >> and the next screen is automatically displayed. Use an external keyboard if possible for the data input. If you use the internal editor, read section 2.7 Editor on inputting data. Fig. 3-7 VEHICLE REG.NO.: MILEAGE: Fig. 3-8 The system now asks you whether the registration number is to be searched for in the customer database. Press to search for the vehicle data in the customer database. If the data is found, it is displayed (see Fig. 3-12). If the data is not found, you will have to input it (see Fig. 3-11). Press to input the data without the customer database being searched. You can also press to call up information about the customer database (see Fig. 3-9). Operating Manual 3-5

Diesel Measurements AVL 4000 CUSTOMER MEMORY INFO 128 kbyte 1 % 0 CUSTOMERS: FREE STORED DELETED DEL deletes entries in the customer database, IMP imports customer data from an external memory card (PCMCIA), EXP exports customer data to an external memory card (PCMCIA). Press >> to return to the data input. Fig. 3-9 An external memory card (PCMCIA) must only be plugged in or removed when the equipment is turned off! The entered data is then displayed: VEHICLE REG NO.: MILEAGE: Press < to correct the input data. Press >> to continue the measurement. Fig. 3-10 Input of limit values INPUT OF LIMIT K-VALUE MAX.: Fig. 3-11 Now decide whether the oil temperature is to be checked. If you select an input field appears. 3-6 Operating Manual

4000 Diesel Measurements The entered data is then displayed: K-VALUE MAX: OIL TEMP MIN: Fig. 3-12 displays information about the customer database (see Fig. 3-9, e.g. no. of stored and of free customer entries). saves the displayed data in the customer memory and the measurement sequence continues automatically. Press < to correct the input data. Press to continue the measurement without saving the displayed data. You are now asked whether the user prompting is to be rpm or opacity-driven. OPERATING GUIDANCE BY: RPM: RPM TRIGGERED OPAC: OPACITY TRIGG RPM-driven measurement: see Fig. 3-14 Opacity-driven measurement: see Fig. 3-19 Fig. 3-13 You are then asked to start the engine and mount the probe on the exhaust pipe. Operating Manual 3-7

Diesel Measurements AVL 4000 RPM triggered measurement The tester then checks the idle speed. CHECK THE IDLE SPEED 10 s RPM 0 6000 Let the engine idle - the measurement sequence will continue automatically. You can press to select the connected speed sensor (see section 3.7 Speed and Angle Measurement). Fig. 3-14 The tester then checks the cut-off speed. CHECK THE CUTOFF-SPEED RPM 0 6000 Accelerate the engine to cutoff speed. Hold this speed for 1 to 2 s and then decelerate. The measurement sequence continues automatically. You can press to select the connected speed sensor (see section 3.7 Speed and Angle Measurement). Fig. 3-15 Vertical arrows on the display always indicate sudden depression (or release) of the accelerator pedal. When the instrument prompts you to do so, carry out the blow-out measurement(s) before the actual measurement. Each of the measurements has the following sequence (the idle speed always stabilises between two individual measurements): ACCELERATION REV UP ENGINE 0 6000 When you see the ACCELERATION command, depress the accelerator pedal suddenly and smoothly as far as it will go. Hold the accelerator in this position until the STOP REVVING command appears. Fig. 3-16 3-8 Operating Manual

4000 Diesel Measurements STOP REVVING Now take you foot off the accelerator pedal as quickly as possible. 0 6000 Fig. 3-17 RPM k VALUE OPAC. ACCEL. TIME TEMPERATURE The measured values are then displayed. Fig. 3-18 Carry out as many individual measurements as the instrument prompts you to. When the measurement is finished, the result is displayed (see Fig. 3-24). Operating Manual 3-9

Diesel Measurements AVL 4000 Opacity-driven measurement OFFICIAL MEASUREMENT INCL: INCLUSIVE RPM DISPLAY EXCL: EXCLUSIVE RPM DISPLAY Select whether the rpm is to be measured and displayed during the measurement (the rpm itself is not taken into account in the measurement). The sequence of the measurements is always the same illustrated in the figures below with rpm. Fig. 3-19 ENGINE CONDITIONING 59 s RPM Fig. 3-20 6000 Now carry out the engine conditioning: Accelerate the engine in stages up to cut-off speed. If the cut-off speed is OK, reduce to holding speed and hold it until the time expires. Maximum permissible weight Holding rpm 3.5 t approx. 3000 rpm > 3.5 t approx. 1500 rpm When the instrument prompts you to do so, carry out the blow-out measurement(s) before the actual measurement. Each of the measurements has the following sequence (the idle speed always stabilises between two individual measurements): REV UP ENGINE 0 6000 When you see the ACCELERATION command, depress the accelerator pedal suddenly and smoothly as far as it will go. Hold the accelerator in this position until the STOP REVVING command appears. Fig. 3-21 STOP REVVING Now take you foot off the accelerator pedal as quickly as possible. 0 6000 Fig. 3-22 3-10 Operating Manual

4000 Diesel Measurements RPM k VALUE The measured values are then displayed. Fig. 3-23 Carry out as many individual measurements as the instrument prompts you to. When the measurement is finished, the result is displayed (see Fig. 3-24). Operating Manual 3-11

Diesel Measurements AVL 4000 The measurement is complete - the results printout is started automatically. k VALUE OPAC. MEAN VALUE Starts another results printout. VAL displays the measurement values of the individual measurements. Press << to return to the diesel engine menu. Fig. 3-24 Remove the probe from the exhaust after the measurement. It can be very hot, so be careful! 3-12 Operating Manual

4000 Diesel Measurements 3.3 Standard Measurement Mounting the Cables / Probe RPM measurement (if required) You can use a clamp-on transducer for the universal rpm measurement. Connect the clamp-on transducer cable to the Fig. 3-25 Fig. 3-26 20 mm straight section of pipe Clamp-on transducer socket. Decide the clamping position on the injection line: straight part of the line at least 20 mm long Clean the mounting position If the mounting position is undamaged, it is sufficient to clean it thoroughly with a cloth. If the position is damaged (i.e. scratched, scored, dented, rusty etc.), sand down the surface with a piece of emery cloth, remove all remnants of emery with a cloth. If this does not produce a smooth rounded mounting surface, the transducer must be mounted elsewhere. If the line is painted, remove the paint first (preferably with a solvent). Use the correct clamp-on transducer for the job. Now mount the transducer on the injection line. The plane of the transducer's closure should lie in the same plane as the next bend in the pipe. Never turn a transducer once clamped on! Connect the transducer cable to the transducer. Attach the ground clip of the transducer cable to the fixing nut of the injection line the transducer is clamped to. For start of delivery measurement, mount the clamp-on transducer at the outlet of the injection pump. Operating Manual 3-13

Diesel Measurements AVL 4000 Strobe Operation: Press switch 1 on the strobe to activate the flash light. Aim the beam at the mark on the engine block and change the angle value with switch 2 on the strobe (without releasing switch 1). Continue adjusting like this until the TDC mark on the flywheel corresponds with the reference mark on the engine block. Make sure that the RPM during the measurement stays at the prescribed test speed. The adjustment range is 0 to 60 CA; when 60 is reached the display stays at 60. To lower the angle value, press the bottom of switch 2. To raise it press the top. Fig. 3-27 2 1 Note The adjusting rocker switch 2 must be pressed continuously. The first 10 adjustments are made at increments of 0.1 CA and after that at increments of 1.0 CA. The moment the switch is released, the adjustment intervals return to 0.1 CA. Switch 2 can be pressed in two directions so that the angle can be adjusted up or down. As soon as you finish working with the strobe and release both switches, the measured values are frozen on the display. 3-14 Operating Manual

4000 Diesel Measurements Exhaust gas probe Connect the probe hose to the opacity measuring chamber at the measuring gas inlet (see section 1.5 Opacity Measuring Chamber, Fig. 1-5). Attach the probe to the exhaust pipe. The probe must be inserted at lease 30 cm into the end section of the exhaust pipe. The longitudinal axis of the probe and exhaust pipe should be as far as possible parallel. Do not bend the probe hose! During calibration the opacity measuring chamber draws in air. Do not place the opacity measuring chamber in the path of the exhaust gases therefore, but at right angles to it. The probe can be very hot after a measurement caution is therefore advised when handling it! Wrong! Right! Measuring chamber draws in exhaust gas Opacity measuring chamber Measuring chamber draws in fresh air Fig. 3-28 Oil temperature probe Before inserting the oil temperature probe, dry the rubber cone on the probe and the part it rests against on the engine. Always make sure that the oil temperature probe is the same length as the original dip stick. If the length is different, damage can occur to both the engine and the oil temperature probe! Operating Manual 3-15

Diesel Measurements AVL 4000 Carrying out the standard measurement MAIN MENU PETR: PETROL DIES: DIESEL SERV: SERVICE MODE Select DIESEL in the main menu Fig. 3-29 MENU DIESEL OM: OFFICIAL MEAS. STD: STANDARD MEAS. DP: DIAGNOSIS PLUS EE: EMISSION EXPERT and then STANDARD MEASUREMENT. Fig. 3-30 Display of the measurement values RPM OPAC k VALUE CA ACT.VALUE MAX.VALUE T The opacity and the k-value are only displayed when the measuring chamber has reached the requisite operating temperature. The following function keys are available during the standard measurement: DP Calls the Diagnosis Plus functions (see section 3.4). Fig. 3-31 Allows you to select the connected speed and angle sensor (see section 3.7). Starts the printout of the measurement values The current measurement values are frozen. Press to continue with the measurement sequence. << Terminates the standard measurement and returns you to the diesel engine menu. 3-16 Operating Manual

4000 Diesel Measurements 3.4 AVL Diagnosis Plus (Option) MAIN MENU PETR: PETROL DIES: DIESEL SERV: SERVICE MODE Select DIESEL in the main menu Fig. 3-32 MENU DIESEL OM: OFFICIAL MEAS. STD: STANDARD MEAS. DP: DIAGNOSIS PLUS ED: EMISSION EXPERT and then DIAGNOSIS PLUS. Fig. 3-33 AVL DIAGNOSIS PLUS OPC: OPACITY CURVE AAC: ADV. ANGLE CURVE Fig. 3-34 Operating Manual 3-17

Diesel Measurements AVL 4000 3.4.1 Advance Angle Curve To start the measurement, select ADV. ANGLE CURVE in the AVL DIAGNOSIS PLUS menu. For instructions on mounting the cables and probes, see section 3.3 Standard Measurement. MIN: 40 CA 20 MAX: RPM min -1 CA CA Display of advance angle curve You can press to select the connected TDC and cylinder 1 sensor (see section 3.7 Speed and Angle Measurement). 0 0 1000 3000 5000 min -1 Fig. 3-35 Starts the printout of the curve. Freezes the current measurement values. Then press to continue with the measurement. Press < to return to the AVL Diagnosis Plus menu. Press << to then return to the diesel engine menu. 3-18 Operating Manual

4000 Diesel Measurements 3.4.2 Opacity Curve To start the measurement, select OPACITY CURVE in the AVL DIAGNOSIS PLUS menu. For instructions on mounting the cables and probes, see section 3.3 Standard Measurement. AVL DIAGNOSIS PLUS OPERATING GUIDANCE BY: TIME: TIME TRIGGER RPM: RPM TRIGGERED Here you can choose whether the opacity curve measurement is to be rpm triggered (Fig. 3-37) or time triggered (Fig. 3-44). Press < to return to the AVL Diagnosis Plus menu. Press << to return to the diesel engine menu. Fig. 3-36 Operating Manual 3-19

Diesel Measurements AVL 4000 RPM-triggered Opacity Measurement To start the measurement, select RPM TRIGGERED in the AVL DIAGNOSIS PLUS menu. Mount the oil temperature probe in the engine. ENGINE TEMPERATURE TEMP Display of engine temperature Press to print out the measured value, >> continues the measurement sequence. Fig. 3-37 IDLE SPEED RPM Let the engine idle. Press >> to continue the measurement. 0 6000 Fig. 3-38 CUTOFF SPEED RPM 0 6000 Rev the engine to cutoff speed. Hold cutoff speed for 1 second. Take your foot off the accelerator pedal and the measurement sequence continues automatically. Fig. 3-39 The measured idle speed and the measured cut-off speed are then displayed. 3-20 Operating Manual

4000 Diesel Measurements After about 10 seconds you will be asked to accelerate. ACCELERATE When you see the ACCELERATE command, depress the accelerator pedal suddenly and smoothly as far as it will go. Hold the accelerator in this position untils the STOP REVVING command appears. Fig. 3-40 DECELERATE Now take you foot off the accelerator pedal as quickly as possible. Fig. 3-41 RPM OPAC. k VALUE ACCEL.TIME TEMPERATURE Fig. 3-42 The result values of the measurements carried out are displayed. Displays the opacity/rpm curve (see Fig. below). Starts the printout of the measurement values. Freezes the display. continues with a new measurement in the measurement sequence. << Terminates the measurement and returns you to the diesel engine menu. OP % 100 75 50 25 0 OPACITY-RPM-CURVE 0 1 2 3 4 RPM min -1 6000 4500 3000 1500 0 Starts the printout of the curve. >> Returns to the display of the measured values. Fig. 3-43 Operating Manual 3-21

Diesel Measurements AVL 4000 Time-triggered Opacity Measurement To start the measurement, select TIME TRIGGER in the AVL DIAGNOSIS PLUS menu. Start the engine Mount the probe in the exhaust pipe, and Wait approx. 15 s. When you see the ACCELERATE command, depress the accelerator pedal suddenly and smoothly as far as it will go. Hold the accelerator pedal in this position for about 2 s and then take your foot off the pedal very quickly. Fig. 3-44 OPAC. k VALUE TEMPERATURE Fig. 3-45 The measurement results are displayed. Displays the opacity curve (see Fig. below). Starts the printout of the measured values Freezes the display. continues with a new measurement in the measurement sequence. << Terminates the measurement and returns you to the diesel engine menu. OP OPACITY CURVE % 100 75 50 25 0 0 1 2 3 4 Starts the printout of the curve. >> Returns you to the results display. Fig. 3-46 3-22 Operating Manual

4000 Diesel Measurements 3.5 Emission Expert (Option) Press DIESEL in the main menu Fig. 3-47 and then EMISSION EXPERT. For a description of how to carry out the measurement, see section 3.4. Fig. 3-48 You will see some error information about the exhaust gas diagnostics. Press >> to start the measurement. Fig. 3-49 You will see some basic information about the exhaust gas diagnostics. Press >> to start the measurement. Fig. 3-50 Operating Manual 3-23

Diesel Measurements AVL 4000 The current opacity and rpm curve are displayed. Press to call up detailed information. Fig. 3-51 Select one of the main groups, e.g. filling, by pressing the keys and then press >>. and Fig. 3-52 Select a sub-group, e.g. air feed, and press >>. Fig. 3-53 Here you will find a detailed description of the selected groups. You can page down with the key. Fig. 3-54 This is a graphic of the good curve (dotted line) and the errored curve (continuous line) relating to the selected group. Press Press to return to the measured curve. to page up. Fig. 3-55 3-24 Operating Manual

4000 Diesel Measurements 3.6 Controlling Measurement MAIN MENU PETR: PETROL DIES: DIESEL SERV: SERVICE MODE Select DIESEL in the main menu Fig. 3-56 MENU DIESEL OM: OFFICIAL MEAS. STD: STANDARD MEAS. DP: DIAGNOSIS PLUS ED: EMISSION DIAGN. and then CONTROLLING MEASUREMENT (CONTR). Fig. 3-57 CONTROLLING MEAS. LIN: LINEARITY CHECK FLT: VERIFICATION WITH FILTER Fig. 3-58 Operating Manual 3-25

Diesel Measurements AVL 4000 3.6.1 Linearity Test To start the measurement, select LINEARITY CHECK in the CONTROLLING MEASUREMENT menu. After approx. 15 s, the linearity value is displayed. LINEARITY OK Press < to return to the control measurment menu. LINEARITY: MEASURED AT K-VAL Press to printout the linearity. Fig. 3-59 3.6.2 Verification Measurement With Filter To start the measurement, select VERIFICATION WITH FILTER in the CONTROLLING MEASUREMENT menu. INSERT FILTER Place the filter in the opacity measuring chamber and press >>. Fig. 3-60 FILTER ABSORPTION The measured filter absorption is displayed. Press < to return to the control measurment menu. Press to printout the filter absorption. Fig. 3-61 3-26 Operating Manual

4000 Diesel Measurements 3.7 Speed and Angle Measurement You can select the rpm sensor (and a second sensor for angle measurement) using. RPM-SENSOR CLAMP-ON TRANSDUCER CLAMP-ON FRENCH CONTACT-BREAKER min -1 NEEDLE MOVEM.SENSOR SPECIAL TIMING TDC-SENSOR INDUCTIVE TDC-SENSOR DIG. 12 V TDC-SENSOR DIGITAL IMPULS/CYCLE OPTICAL SENSOR 1 2 3 4 5 6 8 AVL DiSpeed On the left, the rpm sensor are displayed. Use and to select a sensor. On the right, additional settings can be selected using (e.g. the numbers of pulses or a special setting). Fig. 3-62 An engine speed of lower than 200 min -1 is outside of valid range - the rpm value flashes. If an error occurs during the rpm measurement, is displayed instead of the rpm. If the symbol E appears to the right of the measurement value, there are also problems with the rpm measurement. The displayed value may be invalid. Special timing This is where the Terminal W setting can be selected. Press direct (10.0 50.0). to enter here the transmission ratio value TDC sensor and optical pickup When one of these sensors is selected, you can select the pulses/revolution or enter the values direct. Then press as often as necessary until is displayed. Press to call up the editor, then enter the required value (33 255 pulses/revolution). TDC-sensor inductive On the right, the quality of the actual sensor is displayed. Press to toggle between no current supply for sensor and current supply for sensor. Use the setting that provides a good signal at low as well as at high speed. Operating Manual 3-27

Diesel Measurements AVL 4000 Angle measurement Press (if available) to select a second sensor. (If TRIGGER CYL 1 or TWIN SPARK COIL is selected as rpm sensor, an angle can always be measured using a stroboscope.) SENSORS FOR ANGLE CLAMP-ON TRANSDUCER CLAMP-ON FRENCH RIV SENSOR min -1 NEEDLE MOVEM.SENSOR CA TDC-SENSOR INDUCTIVE TDC-OFFSET 1 IMPULSE/REVOLUT. CA Fig. 3-63 On the right, the actual rpm and angle values are displayed. Use and to select a sensor. TDC-Sensor Inductive: Press to change the automatical Pin-/Slotdetetection. Using key you can enter the TDC offset. TDC offset is the difference (in CA) between reference point and engine TDC (depending on manufacturer). Not all sensor offer the possibility to change the TDC offset. Press Use to select the digit you want to change. to change the selected digit. To change the sign, select the sign and press between + and. Press >> to return to the diagnosis mode. to toggle 3-28 Operating Manual

4000 Error Messages 4. Error Messages 4.1 General When troubleshooting, remember the warnings and safety instructions at the beginning of this manual. Error message Automatic restart Ambient temperature too high / too low Printer error Memory full Action and remedy If the program run is affected by electromagnetic interference, the tester automatically restarts itself and then displays the main menu. Are all cables connected properly? Are there any electromagnetic interference sources near the tester? Take the necessary steps to ensure that the ambient temperature returns to within the permissible range (see section 6 Technical Data - operating temperature). When the temperature has returned to within tolerance, acknowledge by pressing >> to return automatically to the main menu. Neither the internal nor any external printer is responding. Check whether the printer has paper and, if it is an external printer, that it is switched on and the printer cable is connected. If you cannot solve the problem, contact your service engineer. The customer memory may be full. Check how full the memory is. If you cannot solve the problem, contact your service engineer. Operating Manual 4-1

Error Messages AVL 4000 4.2 Error Messages - Petrol Error message Low flow Measurement chamber pressure wrong Measurement chamber temperature too high System needs restarting Action and remedy Is the probe nozzle blocked? Clean the probe out with compressed air. Is the sample gas outlet blocked? Is the flexible probe hose kinked or is the gas flow obstructed by a heavy object placed on the hose that is preventing the flow? Check the pre-filter and particulate filter. If these filters are black, replace them. After replacing filters, always carry out a leak check (see section 5.8 Leak Check). Check whether the tester has been stored at temperatures below 0 C and possibly has frozen residual condensate in it. If all the above actions do not remedy the error, contact your service engineer. Check that the sample gas outlet is not blocked. If it is, unblock it and then press >>. If this does not eliminate the error, contact your service engineer. Remove the probe from the exhaust pipe (when this error occurs, the tester switches to zero point calibration and draws in fresh air). Do not switch the tester off! Wait at least 10 min, Acknowledge the error by pressing >>, Start the measurement again. If the same error message appears again, there is a fault in the measurement chamber. Contact your service engineer. Press >> or switch the tester off at the main ON/OFF switch and then on again to restart it. If two consecutive attempts at restarting do not return the tester to normal operating mode, contact your service engineer. 4-2 Operating Manual

4000 Error Messages 4.3 Error Messages - Diesel / Technical Faults Error message Change-over Valve Fault Exhaust Temperature too High Measurement Chamber too Hot/Cold Measuring Head too Hot Linearity Error Opacity Error Light is getting in Action and remedy Contact your service engineer. If this error message occurs, the change-over valve immediately sets itself to the safety position to prevent any exhaust gas from penetrating into the opacity measurement chamber. Remove the probe from the exhaust pipe immediately whenever this error occurs. Once the exhaust gas temperature has returned to the permissible range, acknowledge by pressing >> to return to the main opacimeter menu. If the error message "Measurement chamber too hot" occurs during operation, remove the probe from the exhaust pipe and wait until the temperature has dropped to the permissible range. Then acknowledge by pressing >>. If the message "Measurement chamber too cold" appears, the chamber has been cooled by cold exhaust gas. Wait until the measurement chamber warms to at least 80 C and acknowledge by pressing >>. If the measurement chamber temperature still does not return to the permissible range after several (2 to 3) attempts, contact your service engineer. Do not expose the tester to bright sunlight. Check that the lamps are working. Clean the glass plate in front of the optical elements. See Error Message Linearity Error The opacity measuring chamber should not be subjected to any direct light from powerful light sources (torch, headlights) - if necessary, set the measuring chamber up somewhere else. Operating Manual 4-3

Error Messages AVL 4000 4.4 Diesel - User Errors Error message Acceleration too Slow Acceleration Stopped too Soon Acceleration Not Constant Action and remedy In response to the command "Accelerate", you did not depress the accelerator pedal suddenly or fast enough. Wait 10s; then the measurement is repeated automatically. You stopped accelerating too soon and didn't hold the cut-off speed long enough. Always keep your foot on the accelerator during measurements until the command "Release pedal" appears. Wait 10 s; then the measurement is automatically repeated. The tester automatically senses if the accelerator pedal is not depressed quickly and smoothly (i.e. during acceleration the speed is not increased continuously and constantly). Always depress the accelerator pedal rapidly and smoothly, without jerking. If this message is displayed, you must wait 15 s until the engine has stabilised again at idle. The measurement is then automatically repeated. 4-4 Operating Manual

4000 Maintenance 5. Maintenance 5.1 Maintenance Plan To guarantee the proper functioning of the tester, maintenance must be carried out at regular intervals. This work can be carried out by qualified personnel. Do not forget that the 4/5-gas measuring instrument must be calibrated every twelve months. The work should be carried out at the intervals shown in the table below or more frequently if necessary. Maintenance work Comment Leak check " " " " Automatically required by tester every day Filter replacement Cleaning Pre-filter on probe " " " " Particulate filter " " " " Condensate filter " " " " Activated carbon filter " Replace in good time when soiled by HC vapour (e.g. petrol vapour). Probe and hose " " see section 5.3 Condensate pump (cleaning kit) Calibration with calibrating gas " " see section 5.7 " see section 5.11.1 " Replacing O 2 sensor " Replacement is requested by tester " Operating Manual 5-1

Maintenance AVL 4000 Maintenance work Comment Replacing NO sensor Visual check of outside " " Replacement is requested by tester " Check using software " Service engineer " Software update (as required) " Service engineer " Open tester, visual inspection of PCBs, clean, close housing, seal with service seal Opacity measuring chamber Visual inspection Check that everything is functioning properly Linear check " " " " Service engineer " 5-2 Operating Manual

4000 Maintenance 5.2 Changing the Printing Paper and Ribbon Inserting the printing paper Open the front flap on the right of the front panel. Cut off any paper between the printer and the paper holder with a pair of scissors. Eject the strip of paper from the printer (by pressing the LF = Line Feed button). Remove the old paper roll from the holder. Take a new roll of printing paper making sure that the front edge of the paper is straight and not frayed. Insert the roll shaft through the paper roll and place it in the holder. Insert the paper roll in such a way that the paper rolls off towards the back and not towards the front. Feed the paper into the printer slit from above and press the LF button to draw it into the printer. Continue to press LF until the paper protrudes a few centimetres from the printer. Close the printer flap, feeding the paper through the slit as you do so. Changing the ribbon Open the front flap on the right of the front panel. Cut off any paper between the printer and the paper holder with a pair of scissors. Eject the strip of paper from the printer (by pressing the LF = Line Feed button). Press the point marked PUSH on the right-hand side of the ribbon cartridge. Remove the cartridge. Take the new cartridge and tension the ribbon if necessary by gently turning the transport wheel. Insert the new cartridge. The transport mechanism of the cartridge must be on the left-hand side and the word PUSH on the right-hand side. Tension the ribbon by turning the transport wheel. Feed the paper into the printer slit from above and press the LF button to draw it into the printer. Continue to press LF until the paper protrudes a few centimetres from the printer. Close the printer flap, feeding the paper through the slit as you do so. Operating Manual 5-3

Maintenance AVL 4000 5.3 Cleaning the Probe Disconnect probe and hose from tester. Remove pre-filter (behind probe). Loosen any residues in probes by tapping them gently. Clean out the probe and hose with compressed air. Clean the outside of probes with a cloth. Reassemble probe, pre-filter and hose and reconnect to the tester. Always disconnect probes from the tester before using compressed air in order to avoid any damage to the tester! The probes must never be bent! 5-4 Operating Manual

4000 Maintenance 5.4 Filter Replacement 5.4.1 Particulate Filter, Pre-filter and Condensate Filter Filter Particulate filter Pre-filter, condensate filter Ident. number MM0336 MF0478 Depending on the degree of soiling, these filters should be changed up to once a day or when you read the error message Exhaust gas flow insufficient as a result of soiling. Always replace a filter when it has become black. Replace the second pre-filter (if used for measurements on 2-stroke engines) at the same time as the pre-filter. For measurements on 2-stroke engines, the filters must be replaced frequently. Note Prolonging the life of the particulate filter Use a rotation system Replace the filter with a new one at the end of the day. Keep the used filter in a dry, well-ventilated place to allow all moisture to evaporate. This way you will be able to use the filter several times (depending on the number of tests carried out). 5.4.2 Activated Carbon Filter Ident. No. MM0338 This filter must be changed once a year, or more frequently if the air of the test site is often contaminated with petrol vapours. When working with petrol in the vicinity of the tester, the filter will become defective within a very short time due to vapours and this will affect the measurement accuracy for HC. Operating Manual 5-5

Maintenance AVL 4000 5.5 Changing the O 2 and NO Sensors When the O 2 sensor or the optional NO sensor needs replacing, the appropriate message is output on the display. Switch the tester off and disconnect it from the mains. Remove the cover plate on the right-hand side of the tester rear panel by undoing the four screws. Changing the O 2 sensor Note If the optional NO sensor is installed, the O 2 sensor is on the right-hand side on the mounting. Disconnect the lead from the sensor. Unscrew the sensor out of the mounting. Screw in the new O 2 sensor (ident. no. EZ0147). Reconnect the lead to the sensor. Changing the NO sensor Pull the NO sensor (located on the left-hand side on the mounting) backwards out of its mounting. Insert the new NO sensor (ident. no. EZ0206). Screw the cover plate back onto the rear panel of the tester, ensuring that the ground cable on the plate is plugged in. Observe the safety instructions for handling O 2 and NO sensors (section 5.5.1)! Old sensors must be properly disposed of (they are highly toxic waste)! O 2 and NO sensor replacement must be documented (i.e. entered in the maintenance book). After replacing a sensor, the new sensor must be re-parametrised. For calibration instructions for the NO sensor, see section 5.11.1 Gas Calibration. Parametrisation of the O 2 sensor: Reconnect the mains cable and switch the tester on. Connect the probe (including all probe filters) to the tester. Press the following keys when the main menu appears: Service mode 4/5-gas analyser O 2 sensor The tester will then draw in fresh air for 10 minutes, during which time the O 2 sensor stabilises itself (the time left to wait is continuously displayed). A new O 2 sensor must be parametrised to prevent any damage occurring to the 4/5-gas analyzer. O 2 sensor replacement must be documented (i.e. entered in the maintenance log book). 5-6 Operating Manual

4000 Maintenance 5.5.1 Safety Instructions for Handling O 2 and NO sensors The O 2 and 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. The O 2 and 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. 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. Operating Manual 5-7

Maintenance AVL 4000 5.6 Condensate Trap The condensate trap at the rear of the tester is designed to prevent water and condensate from entering the 4/5-gas measuring instruments. Empty and clean the condensate trap, when it is about 2 3 full (don t wait until it automatically disables the intake), if the measurement values for hydrocarbon (HC) are too high when air is drawn in. Cleaning Switch the tester off. If the float switch in the condensate trap has already blocked the intake, open the particulate filter housing to release the underpressure. Unscrew the collecting vessel of the condensate trap and empty if necessary. Only use warm soapy water to clean it. Rinse after with clean water. Screw the collecting vessel back on tightly (but do not force it). Close the particulate filter housing again, if applicable. Carry out a leak check (see section 5.8). When unscrewing and screwing the collecting vessel back on, be careful not to damage the float! 5-8 Operating Manual

4000 Maintenance 5.7 Cleaning the Condensate Side of the 4/5-Gas Measuring Instruments This part should be cleaned every six months or once a year, especially if the instrument is often used to test non-catalytic-converter vehicles or 2-stroke engines. It should also be cleaned if the condensate end of the pump starts to leak. Accessories: Cleaning hose with filter Length l = 0.5 1 m; diameter d i = 6 mm and hole diameter max. 1 mm (the best way to clean it is by drawing through a 50/50 % mixture of air and cleaning fluid) Connector Hose fitting for connecting 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 connected to the exhaust gas tester! Connect the probe hose and the probe to the condensate discharge hose (on the pump) using a connecting piece Now set up a rinsing fluid circuit as shown: 4 10 Hole 9 2 1 3 7 6 5 1... Cleaning hose with aperture 2... Filter 3... Check valve 4... Pump 5... Connecting piece 6... Probe hose 7... Probe 8... Cleaning fluid 9... Condensate filter 10... Condensate collector 8 Fig. 5-1 Operating Manual 5-9

Maintenance AVL 4000 N.B. Large amounts of deposits tend to be washed away when you first start cleaning. Do not therefore feed the cleaning fluid back into the circuit to start with. The length of time depends on the level of soiling; guideline ~30 s). Switch the instrument on and activate the pump. The cleaning process itself should take about 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 filter on the rear panel of the instrument. Connect the hose between the condensate filter and check valve. Replace the filter in the probe hose. After cleaning, carry out a leak check. 5-10 Operating Manual

4000 Maintenance 5.8 Leak Check The tester automatically prompts you to carry out a leak check once a day. Carry out an extra leak check when you change the filters and clean the condensate side of the 4/5-gas measuring instruments (for manual call-up of the leak check, see below). To carry out the leak check, follow the instructions on the screen. The hose and probe must be connected when a leak check is carried out! Manual call-up of the leak checks When you are in the main menu, press the following keys Service mode 4/5-gas analyser Leak check Leak check failed If the tester fails the leak check, check the entire sampling line for leaks from the tip of the probe to the inlet on the rear panel of the tester. Check whether the gas flow is insufficient (see section 3 Diesel Measurements). 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 check. If the system passes the test, the leak must be in the probe/hose assembly. If the system fails the leak check, check the O-rings in the filter housing and condensate trap and check whether the connections for the probe hose and condensate drainage hose are leaking. Replace all the tester s filters, including the probe pre-filter. If the system still fails the leak check, there must be a leak inside the system or the pump is too weak. Contact your service engineer. Also check whether the tester has been stored with condensate in it at temperatures below 0 C (leaks may be caused by ice). Operating Manual 5-11

Maintenance AVL 4000 5.9 System Check With Filter Switch the tester on. From the Diesel menu, select controlling measurement (CONTR) and then Verification with Filter (FLT). Remove the optics protector of the opacity measuring chamber on the receiver side (sample gas input side, see Fig. 1-5). Insert filterholder with filter into the optics protector. Opacity measuring chamber optics protector Filter Fig. 5-1 Filter holder Re-insert the optics protector into the opacity measuring chamber. Press >>. The measured filter absorption is displayed. Remove the filter - press upwards first (see arrow). Fig. 5-2 Re-insert the optics protector into the opacity measuring chamber. Press <. 5-12 Operating Manual

4000 Maintenance 5.10 Cleaning the Optical Elements of the Opacity Measuring Chamber Clean the glass panels when you see the linearity error or opacity error message. Procedure: Remove the optics protectors of the opacity measuring chamber on both sides, see Fig. 1-5. Clean the glass panels with a soft cloth (and window cleaning spray if necessary). Then mount them back in position. Do not scratch the glass when cleaning it! Operating Manual 5-13

Maintenance AVL 4000 5.11 Service Mode MAIN MENU PETR: PETROL DIES: DIESEL SERV: SERVICE MODE Select SERVICE in the main menu. Fig. 5-3 SERVICE MODE F2: 4/5 GAS-ANALYZER F3: DIESEL F4: USER DATA F5: DATE / TIME Fig. 5-4 5-14 Operating Manual

4000 Maintenance 5.11.1 Gas Calibration This tester must be calibrated every twelve month. Each gas calibration (using the calibrating gas certified by the gas gas supplier) must be documented (i.e. entered in the maintenance log book). The optional NO sensor should be calibrated every 1 to 3 months. All armatures used for NO calibration must be corrosion resistant and suitable for NO and NO x. The gas calibration can and may only be carried out by authorised personnel! The calibration process is for calibrating both the 4/5-gas unit and the optional NO sensor. The component that is defined by the input of the calibration values is calibrated (see below). Current meas. value Display/input of calibration values MEAS. VAL. CAL. VALUE CO 2 %vol CO %vol HC ppm NOx ppm TIMER COUNTER PEF CALIB. GAS VALUES OK? Information User prompt Fig. 5-5 Display and input of calibration values Calibration of the 4/5-gas unit: The value for NO x must be 0. For HC mixtures, the type of gas mixture used must be specified: Propane e.g. 400 ppm Vol. / P Hexane e.g. 180 ppm Vol. / H Calibration of the NO sensor: When calibrating a new NO sensor or a sensor that was not used to measure NO x for some time, the calibration has to be performed twice. Do not connect any hose at the exhaust gas outlet of the NO sensor. When a value is entered in the NO x field, the values for CO 2, CO and HC are automatically set to 0. Operating Manual 5-15

Maintenance AVL 4000 Information Date Time TIMER The first value shows the time remaining until the next required gas calibration (in days). The second value indicates how many days since the last calibration of the optional NO sensor. COUNTER Number of gas calibrations carried out (calibrations of the NO sensor are not included) PEF Propane gas equivalence factor for the 4/5-gas measuring instruments The output of the HC channel always relates to hexane. To be able to interpret the HC display of the calibration values correctly when using a propane mixture, the value must be multiplied by the PEF. e.g. PEF = 512 HC HEX = HC PROP 0.512 User prompt Here you will read user prompts relating to the gas calibration. Function keys << Return to main menu PUMP ZERO Switch pump on/off Carry out zero point calibration >> Confirmation key - continue calibration The PUMP, ZERO and LEAK keys can only be used during the warm-up (or stabilising) phase. 5-16 Operating Manual

4000 Maintenance Gas calibration - procedure Enter the calibration values indicated on your calibration gas cylinder. CALIB. GAS VALUES OK? If the values are input correctly, acknowledge this message by pressing >>. Fig. 5-6 The equipment must have stabilised for 30 minutes. It cannot be used until after the internal check (or wait) period has elapsed. WAIT 30 MIN Sometimes stability is not achieved after 30 minutes, in which case the tester continues to stabilise (although 0 MIN continues to be displayed). Fig. 5-7 Observe the safety instructions for handling calibrating gas containing CO (see section 5.11.2). The calibrating gas flowing out of the tester must be conducted as far away as possible - preferably, out of doors. Calibrating one or more testers repeatedly can cause damage to health as well as resulting in faulty calibrations. After 30 minutes (or earlier if it has already stabilised), the following message is displayed: KEEP GAS CYLINDER CLOSED Connect the calibrating gas to the CAL GAS connection and keep the cylinder valve closed. Then press >> Fig. 5-8 The system then resets for about 35 s. Operating Manual 5-17

Maintenance AVL 4000 GAS CYLINDER OPEN THEN CONFIRM Fig. 5-9 Now you must open the cylinder valve within 5 minutes. Then press >>. When calibrating the NO sensor, wait until approx. 30 50 % of the expected measurement value is displayed before pressing >>. Make sure that the pressure is set correctly (+0.4 0.6 bar). If the pressure is too high, this can damage the 4/5-gas measuring instruments! The gas calibration is now carried out (it takes about 1 minute). CALIBRATION Fig. 5-10 When the calibration has finished, the following message appears: GAS CYLINDER CLOSE Close the valve on the gas cylinder and confirm by pressing >>. THEN CONFIRM Fig. 5-11 If a new NO sensor is calibrated, INIT must be pressed after the first and the second calibration. This step is omitted if a used NO sensor is being re-calibrated. The calibration procedure is now complete. After the calibration, always remember to close the calibrating gas inlet again! 5-18 Operating Manual

4000 Maintenance Permissible calibrating gas concentrations CO 2 5 15 % CO 0.9 8.5 % Hexane *) (propane gas 140 1700 ppm Vol. 280... 3400 ppm Vol.) O 2 20 22 % (continuously calibrated during passage through zero) NO 150 4000 ppm *) Please note that the propane gas concentration is shown in the HC line (in ppm by vol. n-hexane). To obtain the correct hexane concentrations, multiply the propane gas concentration of the gas by the PEF (see page 5-16). Error message Calibration not possible Make sure that the concentration of the calibrating gas lies within the specified tolerance and that the correct calibrating gas is being used. Check the calibration values that have been input. Check the calibrating gas pressure. Switch the tester off and on again at the main switch and repeat the calibration. If the calibration is still unsuccessful, there is a fault in the 4/5-gas measuring instruments. Operating Manual 5-19

Maintenance AVL 4000 5.11.2 Safety Instructions for Handling Calibrating Gas Containing CO or NO x Carbon monoxide (CO) is a colourless and odourless gas and cannot therefore be seen or smelt! NO is a colourless gas - in air it can be recognised because of its stinging smell caused by reaction with humidity. Safety instructions When you have finished calibrating the tester with gas, always remember to close the gas cylinder containing the calibrating gas. Headaches, dizziness, buzzing in the ears and fainting (after several hours or at the end of the working day) are signs of CO poisoning. Smoking raises the CO concentration in the blood and can cause symptoms of poisoning even if there is only a low level of CO in the air. Take care that all necessary safety devices are available! First Aid in the event of poisoning Fainting or unconsciousness indicate acute danger to life! (The person affected is usually red in the face, not pale!) Close the calibrating gas cylinder immediately. Place an oxygen mask over the person s face. Call an ambulance and a doctor immediately. Thoroughly ventilate the premises. Effect of CO on human beings CO concentration in the air breathed [%] Effect on human beings up to 0.003 % No hazard to health up to 0.01 % Severe headache, dizziness, fainting 0.1 0.2 % Death within 30 minutes over 0.3 % Death within a few minutes 5-20 Operating Manual

4000 Maintenance 5.11.3 Diesel 4000 Opacity signal System voltage (4 values) Lamp status - change with LAMP (Lamp A, B, A/B, OFF) Valve position - change with VALVE Measured temperatures System info: date, time, software version, silicon serial number (main board and chamber adapter) Fig. 5-12 Display of linearity Start the linearity test with LIN White level adjustment Press to generate a printout of the displayed values. Press << to return to the main menu. Operating Manual 5-21

Maintenance AVL 4000 5.11.4 User Data To call this menu up, press Service mode in the main menu and then User data. Select one of the following menu options. Garage address GARAGE ADDRESS NAME: ADDRESS: ADDRESS: TELEPHONE: Enter here the garage address as you want it to appear on the printout. Then save the input by pressing >> or cancel the input without saving the data by pressing <<. Fig. 5-13 Configuration CONFIGURATION SERIAL NUMBER: CONTROL NUMBER: PC INTERFACE Here you can input the tester s serial number as well as the workshop control number. Fig. 5-14 Selection of Language Here you can select the language in which the user guidance will be displayed. LCD Contrast Here you can adjust the display contrast: Press F3 to make it lighter, and F4 to make it darker. Customer Memory (Option) See section 3.2, Fig. 3-9. 5-22 Operating Manual

4000 Maintenance 5.11.5 Date and Time To call this menu, press Service mode in the main menu and then Date/time. TIME DAY MONTH YEAR Enter the time and the date. For information on the editor, see section 2.7. Save your input by pressing >>. Fig. 5-15 Operating Manual 5-23

Maintenance AVL 4000 5.12 Spare Parts List Spare part Ident. number 1.6 A fuse, slow-blow EV0044 O 2 sensor NO sensor Probe filter, condensate filter Particulate filter Activated carbon filter Printer paper Printer ribbon EZ0147 EZ0206 MF0478 MM0336 MM0338 HP0057 EN0276 (Spare) O 2 sensors must be stored in the gasproof original packaging and at temperatures between 0 50 C, preferably 10 30 C. The recommended temperature range for storing NO sensors is -10 45 C, but preferably +5 20 C. 5-24 Operating Manual

4000 Technical Data 6. Technical Data Monitor LC display (quarter VGA format), with graphic capability, with high contrast and light, illuminated background Operation 6 function keys Standard PC keyboard can be connected Printer Optional integrated dot matrix printer (with graphic capability, adequate for documents) or external printer (Epson-compatible) Data carrier Memory card (PCMCIA standard) for program options, databases, software-updates and data exchange with PCs Measurement principle CO, HC, CO 2 Infrared measurement Measurement principle O 2 NO (option) Electrochemical measurement Operating temperature Storage temperature Air humidity Power supply Power draw Dimensions +5 +45 C +1 +50 C +5 +35 C -20 +60 C -20 +50 C -10 +45 C 0 +50 C 90 % max., non-condensing 195 253 V, 47 65 Hz 150 VA Keeping measurement accuracy Ready for measurement With integral NO sensor (peaks of: +40 C) With integrated O 2 sensor With integrated NO sensor With water in filter and/or pump 470 431 230 mm (length width height) Weight AVL DiSmoke 4000 11.0 kg Opacity measuring chamber Meas. chamber heating Effective length Max. exhaust gas temp. Dimensions Weight 4/5-gas measuring instruments AVL DiGas/Dicom 4000 17.7 kg 100 C 0.215 ± 0.002 m 200 C 395 285 136 mm (W H D) 3.5 kg Calibration interval Rated flow rate Minimum flow rate Total flow rate Calibration gas flow rate (at pressure of 0.4 0.6 bar) 12 month 360 l h 180 l h 180 500 l h ) 90 180 l h Operating Manual 6-1

Technical Data AVL 4000 Measurement parameters Measurement range Resolution DiGas DiSmoke DiCom Opacity 0 100 % 0.1 % " " Absorption (k-value) 0 99.99 1 / m 0.01 1 / m " " Acceleration time 0 5 s 0.1 s " " Engine speed *) 250 8000 rpm 10 rpm " " " Oil temperature 0 120 C 1 C " " " CO 0 10 % by vol. 0.01 % by vol. " " CO 2 0 20 % by vol. 0.1 % by vol. " " HC 0 20 000 ppm vol. 1 ppm vol. " " O 2 0. 4 % by vol. 4 22 % by vol. 0.01 % by vol. 0.1 % by vol. " " NO 0 4000 ppm vol. 1 ppm vol. " " Angle measurement TDC Sensor strobe -10 100 CA 0 60 CA 0.1 CA 0.1 CA " " Dwell angle 0 100 % 0.1 % " " All specification requirements as per NORM OIML R99 CLASS 1 are met. *) To obtain a valid rpm display in clamp-on transducer mode, there must be a useable engine speed signal. Conformity 89/336/ EEC Directive on Electromagnetic Compatibility Met with the following standards complied: EN 50081-1 Generic Emission Standard 1992 EN 50082-1 Generic Immunity Standard 1992 73/23/EEC Low Voltage Directive Met with the following standard complied: EN 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use 1993/95 6-2 Operating Manual

Configuration AVL DiGas / DiSmoke / DiCom 4000 AVL DiGas 4000 AVL DiSmoke 4000 AVL DiCom 4000 S/N: Opacity measuring chamber S/N: Revision Addition to AT0480E rev. 03 Entries by the service technician Changes of configuration Service printout BA No: