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Sagem Ultima 600 Maintenance Manual

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S
Ref.: 21821085-0/A
S
ULTIMA 600
MAINTENANCE MANUAL
AFTER SALES DEPARTMENT
ZI Route de MAMERS
72405 LA FERTE-BERNARD - France
Tel.: 02 43 60 43 60 - Fax: 02 43 60 43 61
Printed in France; total or partial reproduction prohibited without prior written authorization. The information contained in this
document is subject to change without prior notice and cannot be understood under any circumstances as contractually binding.
.
Issue 02/99
1-1

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Summary of Contents for Sagem Ultima 600

  • Page 1 Ref.: 21821085-0/A ULTIMA 600 MAINTENANCE MANUAL AFTER SALES DEPARTMENT ZI Route de MAMERS 72405 LA FERTE-BERNARD - France Tel.: 02 43 60 43 60 - Fax: 02 43 60 43 61 Printed in France; total or partial reproduction prohibited without prior written authorization. The information contained in this document is subject to change without prior notice and cannot be understood under any circumstances as contractually binding.

  • Page 2: Table Of Contents

    Ref.: 21821085-0/A SECTION 1 – PRELIMINARY PAGES TABLE OF CONTENTS SECTION 2 UNPACKAING / COMMISSIONING..........2-1 2.1 - UNPACKAGING THE UNIT ..................2-1 2.1.1 - Opening the cardboard boxes................... 2-1 2.1.2 - Setting up the unit ......................2-2 2.1.3 - Installing the printer paper....................2-3 2.1.4 - Installing the tubes ......................
  • Page 3 Ref.: 21821085-0/A 5.2 - HARDWARE ......................5-18 5.2.1 - Replacing fuses....................... 5-18 5.2.2 - Replacing filters....................... 5-18 5.2.3 - Disassembly of rear cover....................5-20 5.2.4 - Disassembly of equipped unit ..................5-21 5.2.5 - Disassembly of pump...................... 5-22 5.3 - EXTENDED ACCESS .....................5-23 5.3.1 - Reading indicators ......................
  • Page 4 Ref.: 21821085-0/A REVISION INDEX PAGE No. DATE OF PAGE No. DATE OF PAGE No. DATE OF ISSUE ISSUE ISSUE 02/99 1-2 to 1-5 05/99 02/99 2-1 to 2-4 02/99 05/99 02/99 3-1 to 3-10 02/99 4-1 to 4-13 05/99 5-1 à 5-22 02/99 5-23 à...
  • Page 5 Ref.: 21821085-0/A UPDATE RECORD REFERENCE REMARKS UPDATE Opacimeter modifications MAY 12, 1999 Édition 05/99...
  • Page 6 FIGURES AND DRAWINGS SECTION 2 Figure 2.1 - ULTIMA 600 in its package Figure 2.2 - ULTIMA 600 with cardboard box removed Figure 2.3 – Accessory box Figure 2.4 – Storage compartment for documents supplied with unit Figure 2.5 – Installing the printer paper Figure 2.6 - ULTIMA 600 / Rear panel...
  • Page 7 Ref.: 21821085-0/A Édition 05/99...

  • Page 9: Section 2 Unpackaing / Commissioning

    Lock Plastic envelope Accessory box ULTIMA 600 Figure 2-1 - ULTIMA 600 in its package 5. Open the accessory box on the top (Cut the adhesive paper using a cutter). 6. Open the plastic bag containing the accessories using a pair of scissors.

  • Page 10: Setting Up The Unit

    - the metrology book. 2.1.2 - Setting up the unit Work area: The ULTIMA 600 must be placed: - near a 230 volts / 50 Hertz / + ground power outlet. - in a clean, non-corrosive atmosphere; avoid: . body work preparation areas (sanding, paint), .

  • Page 11: Installing The Printer Paper

    (5) - Gasoline (2) Mains cable engine speed sensor (3) - Pump water evacuation tube (6) – Temp. sensor Sampling sensor stow bracket Power cable stow bracket Figure 2-6 - ULTIMA 600 / REAR PANEL Issue 02/99...
  • Page 12 Ref.: 21821085-0/A The tubes are connected as shown in figure 2-6. Rilsan collars are provided on the frame to guide and keep all the tubes in place. (1) - Exhaust gas inlet (See fig. 2-7): • Connect the 80 cm tube to the outlet of the paper filter taking care to run it through the Rilsan collar on the frame.

  • Page 13: Installing The Tightness Fitting

    • Current : 0.3 Amps 2. Start up the unit (On/Off switch set to position 1): - Once started up, the SAGEM logo appears on the screen, - After a few seconds: ULTIMA600 is displayed. 3. The standby screen is displayed...
  • Page 14 Ref.: 21821085-0/A 4. Following power up, the ULTIMA 600 stays in « Preheating » mode for up to 15 minutes * during which no measurement can be performed. During the last three minutes of preheating in STANDBY mode, a time counter is displayed.

  • Page 15: Section 3 Description / Operation

    (CO), the carbon dioxide (CO2), the unburned hydrocarbons (HC) and the oxygen (O2) contained in the exhaust gases of vehicles with positive ignition engines. The ULTIMA 600 is also designed for use with an opacimeter option. 3.2 - DESCRIPTION OF FRONT PANEL (fig. 3-1)
  • Page 16 (7) and (8). Access and exit from a function is achieved using key (10). To return to the standby mode, meaning exit from the SELFTEST mode, select ULTIMA 600 Standby screen Service Checks that the values measured are...
  • Page 17 Software version, Checksum Lambda control Cell coefficient Info ← Figure 3-3 - Sequence of screens to reach selftest A complete description of the various menus and their use is given in the Ultima 600 User Manual. (Reference: 218200705) Issue 02/99...

  • Page 18: Description Of Rear Panel

    Ref.: 21821085-0/A 3.3 - DESCRIPTION OF REAR PANEL (fig. 3-4) Figure 3-4 - ULTIMA 600 / REAR PANEL On/Off switch with mains power input socket and fuse holder cover Paper filter for pump protection. Exhaust gas inlet for 4-cycle vehicles located in upper part of main filter (2).
  • Page 19 Ref.: 21821085-0/A Connector, mini DIN type, keyboard link. Connector, DIN type, temperature sensor link. 10. Connector, DB9 type, OBD vehicle link 11. Connector, DIN type, speed sensing clamp link for first cylinder of gasoline vehicles. 12. Connector, DB15 type, opacimeter cell link 13.

  • Page 20: Description Of Pneumatic Circuit

    Ref.: 21821085-0/A 3.4 - DESCRIPTION OF PNEUMATIC CIRCUIT Gas circ.drw Figure 3.5 - Pneumatic circuit Issue 02/99...
  • Page 21 Ref.: 21821085-0/A 1. Gas sampling sensor: comprises an adjustable stainless steel flexible end fitting with attachment spring. 2. Hose: 7-meters long, connects sampling sensor to analyzer gas inlet on rear panel. 3. -Line paper filter: first filter, located in gas sampling circuit, placed vertically at the rear of the analyzer.
  • Page 22 Ref.: 21821085-0/A Issue 02/99...

  • Page 23: Section 4 Preventive Maintenance

    Ref.: 21821085-0/A SECTION 4 PREVENTIVE MAINTENANCE 4.1 – "GAS" mode customer selftest Selftests accessible by customer: • Tightness test • Version, CS, FEP • Lambda control • Calibration • HC residue test • Info adjustment • IR cell status 4.1.1 – Tightness test Purpose: To check tightness of gas circuit from sampling sensor up to pump.
  • Page 24 Ref. 21821085-0/A ULTIMA 600 SELFTEST Tightness test Test étanchéité Version, CS, FEP Gas circuit tightness test: xxx hPa Lambda control Calibration 05 s HC residue test ULTIMA 600 Gas circuit tightness defect Figure 4-1 – TIGHTNESS TEST – Display screens •...

  • Page 25: Version, Cs, Fep

    Ref.: 21821085-0/A 4.1.2 - Version, CS, FEP Purpose: This function provides information on the software versions used by the gas analyzer and the value of the Propane Equivalent Factor (FEP) to be used to perform a conversion (C3H8, C6H14). SELFTEST Tightness test •...

  • Page 26: Hc Residue Test

    (See paragraphs 4.1.7 and 4.1.8). If the test is bad, no measurement is possible. Another test can then be performed (validate < Repeat>), or return to standby mode (validate <Cancel> OR PRESS KEY C). ULTIMA 600 ULTIMA 600 HC residue test Take off sampling...

  • Page 27: Adjustement Information

    Ref.: 21821085-0/A 4.1.5 Adjustment information Purpose: By selecting the "Info Adjustment" function, you can read the date and the organization to which the person who performed an adjustment belongs. 4.1.6 Cell status Purpose: By selecting the "IR Cell Status" function, you can read or print out a record of the statuses of the IR cell.
  • Page 28 Ref. 21821085-0/A #2= 1 point calibration status The following warning message is displayed when the calibration level changes by more than 5% with respect to the last calibration. 0X0001= HC Cal Warning 0X0002= CO Cal Warning 0X0004= CO Cal Warning 0X0008= HiHC Cal Warning 0X0010= Reference Cal Warning 0X0020= O...

  • Page 29: Cleaning The Unit And Its Accessoires

    Ref.: 21821085-0/A 4.1.7 – Cleaning the unit and its accessories 4.1.7.1 – Cleaning the unit • Whenever necessary, clean the unit by wiping it with a rag moistened with alcohol. 4.1.7.2 – Cleaning accessories • Using a dry rag, clean: - The first cylinder sensor clamp, - The engine oil temperature sensor, - The gas sampling sensor;...

  • Page 30: Service" Maintenance Mode

    Info Dnload Info Sofware • Adjust the hour using the s key (to increment) or the t key (to decrement) digit by digit. ULTIMA 600 SERVICE • Validate (key <> ) 12 : 27 HOUR ADJUSTMENT - Modifying the date: •...
  • Page 31 Ref.: 21821085-0/A - Downloading information Hour SERVICE • Select the "Info downloading" function date using the s or t key, Info Dnload Info Téléch. • Validate the function (key <>) Info Soft DOWNLOADING INFORMATION • Downloading information displayed • Validate (key <>) #01 DD/MM/YYYY xxxx yyy zzzzzz #02 DD/MM/YYYY xxxx yyy zzzzzz .
  • Page 32 Ref. 21821085-0/A - Customizing the unit Hour SERVICE date • Select the "Perso" function Info Dnload using the s or t key. Perso Perso. • Validate the function (key <>) GARAGE HEADING • Enter the garage details. L01 : | •...

  • Page 33: Opacity" Mode Customer Selftest

    Ref.: 21821085-0/A 4.3 – "OPACITY" MODE CUSTOMER SELFTEST ULTIMA 600 OPACITY - Select the "OPACITY" mode • Validate the function (key <>). SERVICE 600-85 • Follow the instructions on the Take off screen sampling exhaust pipe sensor • Validate the function (key <>).
  • Page 34 Ref. 21821085-0/A - Software information Température Temperature 600-85 600-85 K = 0,00 m K = 0,00 m Version, CS Version, CS • Select the "Version, CS" function using T = - - °C T = - - °C Status cellule Cell status the s or t key.
  • Page 35 Ref.: 21821085-0/A - HGV/LV configuration Temperature 600-85 • Select the "Config. HGV/LV" function Version, CS K = 0,00 m using the s or t key. Cell status T = - - °C • Validate the function (key <>). RPM = 000 rpm Conf.

  • Page 37: Section 5 Corrective Maintenance

    5.1 - SOFTWARE 5.1.1 - 1 point adjustment test: • Connect a keyboard. • Start up the ULTIMA 600 in Function mode: under code (Technician selftest – pressure upper arrow on power up). • Select the CODE function ULTIMA 600...
  • Page 38 Ref.: 21821085-0/A • The unit performs a calibration. ULTIMA 600 Calibration in progress • Standby screen displayed. Tightness test SELFTEST Version, CS,FEP Tightness test Version, CS, FEP Normal Lambda control Lambda control, Service Calibration Mode Calibration HC residue test • Select the ADJUSTMENT 1 POINT function using the s or t key.
  • Page 39 Ref.: 21821085-0/A ULTIMA 600 Calibration in progress • The unit performs a calibration (30’’). 30 s • Connect the quick coupling of the bottle Open the bottle to the plastic connector on the rear side of the unit (See fig. 3.4).
  • Page 40 Ref.: 21821085-0/A Adjustment information • The following screen appears: #01 05/12/1999 SD72 FACTORY #02 28/11/1998 SD72 FACTORY. New adjustment ← Old adjustment • Validate using <> key. Adjustm. 2 points SELFTEST Info ajustage Info adjustment • Return to standby screen. O2 installation Negative value Issue 05/99...

  • Page 41: Point Adjustement Test

    Ref.: 21821085-0/A 5.1.2 –2 point adjustment test: • Connect a keyboard. • Start up the ULTIMA 600 in Function mode: under code (Technician selftest – press upper arrow on power up). ULTIMA 600 CODE SERVICE • Validate (key <>). • Enter the secret code.
  • Page 42 Ref.: 21821085-0/A ULTIMA 600 Calibration in progress • The unit performs a calibration. • Standby screen displayed Tightness test SELFTEST Version, CS,FEP Tightness test Version, CS, FEP Normal Lambda control Lambda control, Service HC residue test Mode Calibration HC residue test SELFTEST •...
  • Page 43 Ref.: 21821085-0/A ULTIMA 600 Calibration in progress • The unit performs a calibration (30’’). 30 s • Connect the quick coupling of the bottle to the Open the bottle plastic connector at the rear of the unit (See fig. 3.4).
  • Page 44 Ref.: 21821085-0/A ULTIMA 600 Calibration in progress • The unit performs a calibration (30’’) 30 s • Validate (key <>). Adjustment 2 points: Point #2 • Enter the values of the 2nd bottle specified Target values: on the certificate joined with the bottle using...
  • Page 45 Ref.: 21821085-0/A Adjustment information • The following screen appears: #02 05/12/1999 SD72 FACTORY.. #01 05/12/1999 SD72 FACTORY... New adjustment ← Old adjustment • Validate using the <> key. Adjustm. 2 points SELFTEST Info ajustage Info adjustment • Return to standby screen. O2 installation Negative value Issue 05/99...

  • Page 46: Replacement Of O Sensor

    Ref.: 21821085-0/A 5.1.3 – Replacement of O sensor • Connect a keyboard. • Start up the ULTIMA 600 in Function mode: under code (Technician selftest – press upper arrow on power up). ULTIMA 600 CODE SERVICE • Validate (key <> ).
  • Page 47 Tightness test Negative value Version, CS, FEP Normal Lambda control, Service Measuring return HC residue test Mode ULTIMA 600 Install a O2 sensor then validate • Validate (key <>). ← <I> ULTIMA 600 O2 sensor installation • Validate (key <>).
  • Page 48 Ref.: 21821085-0/A 5.1.4 – Negative Values selftest • Connect a keyboard. • Start up the ULTIMA 600 in Function mode: under code (Technician selftest – press upper arrow on power up). ULTIMA 600 CODE SERVICE • Validate (key <>). • Enter the secret code.

  • Page 49: Negative Values Selftest

    Ref.: 21821085-0/A • Standby screen displayed Info Adjustment SELFTEST SELFTEST 02 installation Tightness test Negative value Version, CS, FEP Normal Valeur négative Lambda control Service Measuring return HC residue test Mode • Select Negative Values function NEGATIVE VALUES SELFTEST using the s or t key. •...

  • Page 50: Downloading The Software

    • Connect a microcomputer using the RS 232 link at the rear of the unit. • Connect a keyboard. • Start up the ULTIMA 600 in Function / code mode: (Technician selftest – press upper arrow on power up). • Start up the microcomputer.
  • Page 51 Send a text file Select the file to be downloaded (for example: V0200.TXT). SENT Flash erasure in progress Downloading time can be monitored on the microcomputer. ULTIMA 600 Downloading successful Program = 03CE36 Chk : F1FE Manufacturer code = 0001...

  • Page 52: Downloading A New Boot And A Provisional Application

    Ref.: 21821085-0/A Note: The memory is formed by an upper memory part and a lower memory part. Only the lower memory can be erased. The upper part is protected in order to restart in the event of a power cutout or a problem. However, this part can be accessed by a special procedure if necessary should a major change be required.
  • Page 53 • Unit waits for downloading. ← • Download application file (correct version = V02.00). V 02.00 Downloading successful Chk F1FE Start xxxxx End yyyyy BOOT 02 • Press • SAGEM logo is displayed Unit is now correctly configured. Issue 05/99 5-17...

  • Page 54: Hardware

    5.2 - HARDWARE 5.2.1 – Replacing fuses Procedure: • Disconnect the ULTIMA 600 from the power outlet. • Remove the power plug from the unit. The fuses are accessible in the access cover for the On/Off button. • Tilt down the cover.
  • Page 55 Ref.: 21821085-0/A To replace or clean the filter, proceed as follows: • Unscrew the blue ring. • Remove the bowl toward the rear (Caution with o-ring). The filter cartridge is slid on the tube with plastic seive. • Unscrew and remove the base plug. •...

  • Page 56: Disassembly Of Rear Cover

    Ref.: 21821085-0/A 5.2.3 – Disassembly of rear cover Tools: • Cutting pliers • Screwdriver Procedure: 1. Remove the lead seal at the rear of the unit (cutting pliers). 2. Unscrew the 2 x 3 screws securing the rear protective cover. 3.

  • Page 57: Disassembly Of Equipped Unit

    Ref.: 21821085-0/A Keyboard link Screen links Power supply links wire = +12V Printer control wire = +5V wire = +5V wire = GND wire = GND wire = -12V Solenoid Analysis cell valve power link supply (12V) Pump power supply (12V) Figure 5-2 –...

  • Page 58: Disassembly Of Pump

    Ref.: 21821085-0/A 5.2.5 – Disassembly of pump Tools: • 5mm open-end wrench • BTR 15mm wrench. • Cross-tip screwdriver Procedure: 1. Disassembly of pump assembly: • Remove nut (5mm open-end wrench) • Remove pump from mount. 2. Cleaning and replacement of pump seal in case of leak (See. fig. 5-3) •...

  • Page 59: Extended Access

    Ref.: 21821085-0/A 5.3 –EXTENDED ACCESS: 5.3.1 – Reading indicators • Connect a keyboard. • Start up the ULTIMA 600 in Function mode: under code (Technician selftest – press upper arrow on power up). • Select the CODE function. ULTIMA 600...

  • Page 60: Installing The Opacimeter Option

    Ref.: 21821085-0/A 5.3.2 – Installing the opacimeter option • Start up the ULTIMA 600 in Function mode: under code (Technician selftest – press upper arrow on power up). • Select the CODE function ULTIMA 600 OPACITY SERVICE • Validate (key <>).
  • Page 61 Ref.: 21821085-0/A • Select the Code2 function Software 600-0F-01.01 # SOFTWAREGAS= 02.02 # Software opacity = 01.01 # OBD software OBD = not Validate (key <>). present Code1 Code3 Code2 # software opacity • Enter the secret code (Monthly code +1) xxxxx Example (5792+1=5793) Secret code entry...

  • Page 63: Spare Parts Catalogue

    Ref.: 21821085-0/A SECTION 6 SPARE PARTS CATALOGUE Issue 02/99...
  • Page 64 Ref.: 21821085-0/A Item Description Reference Quantity cell bracket 218196365 Analysis cell 185749159 Electronic unit 218196604 Collar . Collar 11.0 3 390 611 . Collar 9.0 3 393 659 . Collar 8.3 3 390 662 185753434 Solenoid valve 3-2 NF 1/8‘’ Dia. 1.5 Coupling 3 331 371 .
  • Page 65 Ref.: 21821085-0/A Item Description Reference Quantity 2A mains filter 185327557 Polyurethane tube 185595436 Power supply unit 185737919 DUAL pump 5002F/5010V 185749138 Solenoid valve 3-2 12V 185753434 Keyboard 218200180 Analysis cell 185749159 Printer 185872242 Edition 02/99...
  • Page 66 Ref.: 21821085-0/A Item Description Reference Quantity Filter cartridge 18574898-8 Line filter 18574829-3 Cell protection filter 18545262-8 Stainless steel gas sensor 21819587-6 User manual 218200705 Measurement book 218200177 Mains power supply cable 185758893 Edition 02/99...
  • Page 67 Ref.: 21821085-0/A DETAILS Hose (gas sampling) Ref. 185595457 Adjustable stainless steel gas sensor Ref. 218195876 O2 cell Ref. 215766384 Tightness fitting Ref. 218194254 Line filter (paper) Ref. 185748293 Vyon filter cartridge Ref. 185748988 Cell protection filter Ref. 185452628 Heat-sensitive paper 57 x 38x 12 Ref.
  • Page 68 Ref.: 21821085-0/A Dual pump 5002F/5010V Ref. 185749138 Solenoid valve 3/2 NF 1/8 ‘’ dia. 1.5 Ref. 185753434 Printing unit Ref. 18587224-2 65W power supply 85-264V/5V-7A/12V-3A Ref. 185737919 Electronic unit Ref. 218196604 I.R. sensor cell Ref. 185749159 Activated charcoal filter Ref. 185327557 Edition 02/99...
  • Page 69 Ref.: 21821085-0/A ULTIMA 600 remote control Ref.218201963 ULTIMA 600 external keyboard Ref.185896466 Gasoline engine speed sensor Ref.91100002A Engine oil temperature sensor Ref. 91300004 Connecting cable for opacimeter cell Ref. 218198137 Edition 02/99...
  • Page 70 Ref.: 21821085-0/A ITEMS NOT DRAWN REFERENCE DESCRIPTION 218196386 Filter bowl, type F20 185449767 Activated charcoal filter, Dia.6 218196703 Front panel, installed 185748313 90° offset coupling 185748334 90° offset coupling for tube D6 185752474 D6/D4 splined straight adapter 185752536 Splined Tee for tube D4 185757044 Hose 4x 6 PU, transparent 132781308...

  • Page 71: Section 7 Technical Modifications Record

    Ref.: 21821085-0/A SECTION 7 TECHNICAL MODIFICATIONS RECORD Issue 02/99...
  • Page 72 Ref.: 21821085-0/A MODIFICATION DESCRIPTION NEW INDEX ORDER No. Modification of CPU board Ref. 21819276-3 Index A3 10 Nf capacitor connected between RPM+ and RPM- inputs (at base of pins 1 and 3 of J1004° and cross-over of pins 1 and 3 of connector J1003 (diesel input connector) Edition 02/99...
  • Page 73 Ref.: 21821085-0/A MODIFICATION DESCRIPTION NEW INDEX ORDER No. Modification of CPU board Ref. 21819276-3 Index A3 10 Nf capacitor connected between RPM+ and RPM- inputs (at base of pins 1 and 3 of J1004° and cross-over of pins 1 and 3 of connector J1003 (diesel input connector) Edition 02/99...
  • Page 74 Ref.: 21821085-0/A Edition 02/99...

  • Page 75: Section 8 List Of Drawings

    Ref.: 21821085-0/A SECTION 8 LIST OF DRAWINGS Drawing 21819275-5 ind. A3 - Schematic diagram of CPU board (10 sheets) Issue 02/99...
  • Page 76 Ref.: 21821085-0/A Edition 02/99...

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