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AVL DiGas 4000 Service Manual

Engine diagnostics
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ENGINE DIAGNOSTICS
Ident. number:
AT0391E
Revision no.:
04
Edition:
January 1999
Subject to alteration
Printed in Austria by
AVL LIST GMBH Graz
Service Manual
AVL DiGas 4000
AVL DiCom 4000
AVL DiSmoke 4000
AVL LIST GMBH
Hans-List-Platz 1
A-8020 Graz / Austria
Phone: +43 316 787-0
Fax: +43 316 787-550
http://www.avl.com

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Summary of Contents for AVL AVL DiGas 4000

  • Page 1 Phone: +43 316 787-0 Fax: +43 316 787-550 http://www.avl.com ENGINE DIAGNOSTICS Ident. number: AT0391E Revision no.: Service Manual Edition: January 1999 AVL DiGas 4000 AVL DiCom 4000 AVL DiSmoke 4000 Subject to alteration Printed in Austria by AVL LIST GMBH Graz...
  • Page 2 The contents of this document may not be reproduced in any form or communicated to any third party without the prior written consent of AVL. While every effort is made to ensure correctness, AVL assumes no liability for errors and omissions.
  • Page 3 The product is to be operated and used only by qualified personnel capable of observing the required safety precautions. Only accessories and expendables either supplied or approved by AVL are to be used with the product. Due to the operating principle of this product, the accuracy of the measurement results it produces not only depends on its correct operation and function but also upon a variety of peripheral conditions beyond the control of the manufacturer.
  • Page 5 Safety Instructions for Handling O and NO Sensors The O 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. •...

  • Page 7: Table Of Contents

    Table of Contents Table of Contents 1. Periodic Maintenance 1.1 General..............................1-1 1.2 Maintenance Plan............................1-2 1.3 Minor Maintenance..........................1-4 1.3.1 AVL DiGas 4000 ..........................1-4 1.3.2 AVL DiSmoke 4000........................1-5 1.3.3 AVL DiCom 4000 ...........................1-6 1.4 Major Maintenance ..........................1-8 1.4.1 AVL DiGas 4000 ..........................1-8 1.4.2...
  • Page 8 Printer Board (Option) ......................4-8 4.2.1.9 Speed / Angle Board with Diagnostics Cable Concept (Option/Installation) ....4-8 4.2.1.10 Memory Adapter ........................4-11 4.2.1.11 Chamber Adapter (AVL DiCom 4000)..................4-11 4.2.1.12 Extension Slot..........................4-11 4.2.1.13 Mains Switch Assembly......................4-11 4.2.1.14 Converting 230 V to 115 V Device...................4-11 4.2.1.15 Power Supply Unit ........................4-11...
  • Page 9 4000 Table of Contents 4.18 Chamber Adapter (opacity measuring chamber 4000) ..............4-40 4.18.1 Components Location Diagram....................4-40 4.18.2 Circuit Diagram ..........................4-41 4.19 Transmitter Board (opacity measuring chamber 4000) ..............4-42 4.19.1 Components Location Diagram....................4-42 4.19.2 Circuit Diagram ..........................4-43 4.20 Receiver Board (opacity measuring chamber 4000) ................4-44 4.20.1 Components Location Diagram....................4-44 4.20.2 Circuit Diagram ..........................4-45 4.21 Fan Board (opacity measuring chamber 4000) ..................4-46...
  • Page 10 5.8 Error Symptom List - Remedies ......................5-14 6. Opacity Measuring Chamber Type A 6.1 System Check with Filter........................6-1 6.2 Upgrading an AVL DiGas 4000 to an AVL DiCom 4000..............6-3 6.3 General Configuration..........................6-4 6.4 Dismantling the Opacity Measuring Chamber ...................6-6 6.4.1 Housing Cover 1 (on Exhaust Gas Outlet Side) ................6-6...

  • Page 11: Periodic Maintenance

    This Service Manual describes the following instruments: − AVL DiGas 4000 (= AVL DiTest 5400) − AVL DiSmoke 4000 (= AVL DiTest 5430) − AVL DiCom 4000 (= AVL DiTest 5460) Some areas are described in detail in the respective Operating Manual and therefore not dealt with in this Service Manual.

  • Page 12: Maintenance Plan

    Periodic Maintenance AVL 4000 Maintenance Plan To ensure that the tester always functions properly, maintenance must be carried out at regular intervals. Maintenance work Comment Leak test Automatically required by tester every day Filter replacement Pre-filter on probe Particulate filter...
  • Page 13 4000 Periodic Maintenance Maintenance work Comment Opacity measuring chamber type A Visual check (silicon seal, leaks in housing, housing components, closure fittings, snap mechanism of the optical elements, electrical connections, probe connection plate O-ring, electrical cables, soiling of measuring chamber and purging air channel) Function check (fans, heating, changeover...

  • Page 14: Minor Maintenance

    Periodic Maintenance AVL 4000 Minor Maintenance 1.3.1 AVL DiGas 4000 • Evaluation unit Check using software − Raw data from 4-/5-gas measuring instruments unit OK? − sensor is OK? − NO sensor is OK? Visual check of outside Entry in maintenance log book •...

  • Page 15: Avl Dismoke 4000

    4000 Periodic Maintenance 1.3.2 AVL DiSmoke 4000 • Evaluation unit Visual inspection Enter in maintenance log book • Opacity measuring chamber, type 4000 Visual check − Silicon seal − Leaks in housing − Housing components (cracks, faults) − Closure fittings, snap mechanism of optical elements −...

  • Page 16: Avl Dicom 4000

    Periodic Maintenance AVL 4000 1.3.3 AVL DiCom 4000 • Evaluation unit Check using software − Raw data from 4-gas measuring instruments unit OK? − sensor is OK? − NO sensor is OK? Visual inspection Enter in maintenance log book •...
  • Page 17 4000 Periodic Maintenance • Opacity measuring chamber type 4000 Visual check − Silicon seal − Leaks in housing − Housing components (cracks, faults) − Closure fittings, snap mechanism of optical elements − Electrical plug connections and cables − Probe hose, probe clamp Function check (each test is described in the Operating Manual) −...

  • Page 18: Major Maintenance

    Periodic Maintenance AVL 4000 Major Maintenance 1.4.1 AVL DiGas 4000 • Evaluation Unit Check using software − Raw data from 4-gas measuring instruments unit OK? − O sensor is OK? − NO sensor is OK? Open evaluation unit (remove cover)

  • Page 19: Avl Dismoke 4000

    4000 Periodic Maintenance 1.4.2 AVL DiSmoke 4000 • Evaluation unit Open evaluation unit (remove cover) Visual inspection, clean pcb If necessary update setpoint data and software Close housing, seal with service seal Enter in maintenance log book • Opacity measuring chamber Visual check −...

  • Page 20: Avl Dicom 4000

    Periodic Maintenance AVL 4000 1.4.3 AVL DiCom 4000 • Evaluation unit Check using software − Raw data from 4-gas measuring instruments unit OK? − O sensor is OK? − NO sensor is OK? Open evaluation unit (remove cover) Visual inspection, clean pcb...
  • Page 21 4000 Periodic Maintenance • Opacity measuring chamber type 4000 Visual check − Silicon seal − Leaks in housing − Housing components (cracks, faults) − Closure fittings, snap mechanism of optical elements − Electrical plug connections and cables − Probe hose, probe clamp −...
  • Page 22 Periodic Maintenance AVL 4000 1-12 Service Manual...

  • Page 23: Error Messages And Troubleshooting

    4000 Error Messages and Troubleshooting 2. Error Messages and Troubleshooting 4-/5-Gas Measuring Instruments Unit 2.1.1 Gas Flow Insufficient Check the following: • Is the exhaust gas probe nozzle blocked? − Clean the probe out with compressed air. CAUTION - before doing so, always disconnect the probe from the tester! •...

  • Page 24: System Needs Restarting

    Error Messages and Troubleshooting AVL 4000 2.1.2 System Needs Restarting If two consecutive attempts at restarting do not return the tester to normal operating mode, the measuring instruments unit must be defective. • Remove the unit (see Dismantling the 4-/5-Gas Measuring Instruments Unit) and check the −...

  • Page 25: Measuring Chamber Pressure Wrong

    4000 Error Messages and Troubleshooting 2.1.4 Measuring Chamber Pressure Wrong • Check whether the measurement gas outlet is blocked. • If it is, remove blockage and acknowledge by pressing >>. • If you are unable to remedy the error, the measuring instruments unit must be defective.

  • Page 26: Replace O Sensor

    Error Messages and Troubleshooting AVL 4000 2.1.6 Replace O Sensor When the O sensor needs replacing, the appropriate message is output on the display. • Switch the tester off and disconnect it from the mains. • Remove the O sensor (see section 5.6.1 Replacing the O Sensor).

  • Page 27: Opacity Measuring Chamber

    4000 Error Messages and Troubleshooting Opacity Measuring Chamber 2.2.1 Measuring Chamber Too Hot/Too Cold If the error message "Measuring chamber too hot" occurs during operation, remove the probe from the exhaust pipe and wait until the temperature returns to the permitted range.

  • Page 28: Linearity / Opacity Error

    Error Messages and Troubleshooting AVL 4000 Linearity / Opacity Error, 2.3.1 Opacity Measuring Chamber, Type A If either of these messages occur, proceed as follows. • Fold the optical elements of the opacity measuring chamber to the side, out of the way;...

  • Page 29: Software

    4000 Software 3. Software General The instrument carries out an automatic self-test when it is powered up at the ON/OFF switch. The following data is displayed during the self-test: SELF TEST VERSION MEMORY/OPTIONS: CHECKSUM: PRINTER INTERN: EXTERN: KEYBOARD INTERN: EXTERN: MEAS.CHAMB.4GAS: MEAS.CHAMB.DIES: DICOM A...
  • Page 30 Software AVL 4000 − Software options The first two hexadecimal digits of the four-digit checksum indicate the software options installed (i.e. available for use). hex. digit hex. digit hex digit hex digit no significance Bit = 0: Option not available...
  • Page 31 4000 Software Troubleshooting when hardware self-test fails The error or status code is represented by a special error code. Code Problem Printer fault Keyboard fault Opacity measuring chamber not connected 4-gas measuring chamber fault rtc_bat_test Voltage test Fan control unit Pneumatics valve Serial silicon number - motherboard Serial silicon number - opacity measuring chamber...

  • Page 32: Installation Of Operating Software (Software Update)

    AVL 4000 Installation of Operating Software (Software update) The AVL 4000 has an externally accessed slot for memory cards which is compatible with the PCMCIA PC industry standard. The card has a memory of up to 56 MB. AVL identification no. EN0339 (4 MB memory) Basic functions: −...

  • Page 33: Evaluation Unit

    4000 Evaluation Unit 4. Evaluation Unit General Description Fig. 4-1 The 4000 Evaluation Unit basically consists of the following components: − housing cover − rear panel − front panel − frame − LC display − membrane keypad − printer unit −...

  • Page 34: Basic Design

    − option board (free slot) − The chamber adapter board (for the AVL DiCom 4000) is located on the main board at slots J4, J6, J10 and J14. − The printer board is also on the main board at slots J27 and J28.

  • Page 35: Evaluation Unit

    4000 Evaluation Unit 4.1.2 Evaluation Unit The evaluation unit hardware consists of: − the user interface with displays, softkeys, remote control (optional), memory card connection, strip printer (optional) − electronic circuits with main board and the option pcbs, printer board, opacity board, speed/angle board including interfaces and sensor connections.

  • Page 36: Pneumatics Rear Panel / 4-/5-Gas Measuring Instruments Unit (5-Gas Option)

    Evaluation Unit AVL 4000 4.1.3 Pneumatics Rear Panel / 4-/5-Gas Measuring Instruments Unit (5-Gas Option) The entire pneumatic unit is mounted on the rear wall. The 4-gas measuring instruments unit is screwed to the rear panel. The condensate trap, particulate filter, O (NO- 5-gas option) sensor and pump are mounted directly on the outside of the rear panel.

  • Page 37: Hardware Setup

    4000 Evaluation Unit Hardware Setup 4.2.1 Main Board The main board represents the heart of the electronics and uses predominantly SMD technology. The most important function blocks are described below. 4.2.1.1 Digital System The digital system is built around the highly integrated Intel I80C196NT controller with 20 MHz clock frequency.

  • Page 38: Interfaces

    A TRUART module serves the internal serial interface to the 4-gas measuring instruments unit in the AVL DiGas and AVL DiCom. The interface to a host computer (PC, SilverDat computer, Bilanmatik, test bed computer,…) is also via a standard 9-pin SUB-MIN-D socket and implemented by the asynchronous serial interface installed in the 196NT.

  • Page 39: Display Control And Softkey Connection

    4.2.1.7 Board Control The printer board (optional) and chamber adapter board (for AVL DiCom 4000) are plugged straight into the main board, whereas the pneumatics board, speed/angle board and free slot are connected via control or ribbon cables.

  • Page 40: Printer Board (Option)

    − optical sensor − digital pulses from engine management system − AVL clamp-on transducers (AVL DiGas 4000 and AVL DiCom 4000) − RIV sensors (AVL DiGas 4000 and AVL DiCom 4000) − needle movement sensors (AVL DiGas 4000 and AVL DiCom 4000) −...
  • Page 41 Resolution: 0.1% Accuracy: 1.0% • Oil temperature measurement The temperature is measured by inserting the AVL oil temperature sensor, available in various lengths, into the sump (or more rarely, into the cooling water). Measurement range: 0…120° C Resolution: 1 °C Accuracy: ±...
  • Page 42 Evaluation Unit AVL 4000 • Diagnostics cable concept: There are five plugs to connect the supported sensors: − clamp-on transducer/RIV plug − cyl1 plug for needle movement sensor, inductive trigger clamp and interrupter connection (black box for special signals) −...

  • Page 43: Memory Adapter

    4000 Evaluation Unit 4.2.1.10 Memory Adapter The Memory Adapter (AVL identification no. BB0730) is installed on the main board. • Insert the Memory Adapter at slots J8 and J9 on the main board • Mark the memory adapter option on the options sticker.

  • Page 44: Fan

    Evaluation Unit AVL 4000 4.2.1.16 Fan The machine is ventilated at the sides and also at the rear to keep the pneumatic pump cool. The angle of the air flow near the display has been kept as small as possible to prevent the screen from becoming dirty too quickly.

  • Page 45: Printer

    4000 Evaluation Unit Printer A hardcopy can be printed out of all the measurement results displayed. The official measurements end with an official results printout. 4.5.1 Internal Printer Unit (Option/Installation) It takes about 30 seconds to printout a hardcopy. A results printout takes ½ to 1 minute depending on how long it is.

  • Page 46: External A4 Printer (Option)

    (hardcopy, results printout) are diverted to that printer. The time required for printing depends very much on the printer’s buffer. A standard Centronics cable is used for the printer (AVL identification no. EX0308). The 320 × 240 display is controlled by a separate controller.

  • Page 47: Main Board

    4000 Evaluation Unit Main Board 4.9.1 Components Location Diagram Service Manual 4-15...

  • Page 48: Circuit Diagrams

    Evaluation Unit AVL 4000 4.9.2 Circuit Diagrams 4-16 Service Manual...
  • Page 49 4000 Evaluation Unit Service Manual 4-17...
  • Page 50 Evaluation Unit AVL 4000 4-18 Service Manual...
  • Page 51 4000 Evaluation Unit Service Manual 4-19...
  • Page 52 Evaluation Unit AVL 4000 4-20 Service Manual...

  • Page 53: Speed Angle Board

    4000 Evaluation Unit 4.10 Speed Angle Board 4.10.1 Components Location Diagram Service Manual 4-21...

  • Page 54: Circuit Diagrams

    Evaluation Unit AVL 4000 4.10.2 Circuit Diagrams 4-22 Service Manual...
  • Page 55 4000 Evaluation Unit Service Manual 4-23...
  • Page 56 Evaluation Unit AVL 4000 4-24 Service Manual...
  • Page 57 4000 Evaluation Unit Service Manual 4-25...

  • Page 58: Pneumatics Board

    Evaluation Unit AVL 4000 4.11 Pneumatics Board 4.11.1 Components Location Diagram 4-26 Service Manual...

  • Page 59: Circuit Diagram

    4000 Evaluation Unit 4.11.2 Circuit Diagram Service Manual 4-27...

  • Page 60: Printer Adapter

    Evaluation Unit AVL 4000 4.12 Printer Adapter 4.12.1 Components Location Diagram 4-28 Service Manual...

  • Page 61: Circuit Diagram

    4000 Evaluation Unit 4.12.2 Circuit Diagram Service Manual 4-29...

  • Page 62: Memory Adapter

    Evaluation Unit AVL 4000 4.13 Memory Adapter 4.13.1 Components Location Diagram 4-30 Service Manual...

  • Page 63: Circuit Diagram

    4000 Evaluation Unit 4.13.2 Circuit Diagram Service Manual 4-31...

  • Page 64: Connector Adapter

    Evaluation Unit AVL 4000 4.14 Connector Adapter 4.14.1 Components Location Diagram 4-32 Service Manual...

  • Page 65: Circuit Diagram

    4000 Evaluation Unit 4.14.2 Circuit Diagram Service Manual 4-33...

  • Page 66: Chamber Adapter (Opacity Measuring Chamber Type A)

    Evaluation Unit AVL 4000 4.15 Chamber Adapter (opacity measuring chamber type A) 4.15.1 Components Location Diagram 4-34 Service Manual...

  • Page 67: Circuit Diagram

    4000 Evaluation Unit 4.15.2 Circuit Diagram Service Manual 4-35...

  • Page 68: Receiver Board (Opacity Measuring Chamber Type A)

    Evaluation Unit AVL 4000 4.16 Receiver Board (opacity measuring chamber type A) 4.16.1 Components Location Diagram 4-36 Service Manual...

  • Page 69: Circuit Diagram

    4000 Evaluation Unit 4.16.2 Circuit Diagram Service Manual 4-37...

  • Page 70: Selenium Board (Opacity Measuring Chamber Type A)

    Evaluation Unit AVL 4000 4.17 Selenium Board (opacity measuring chamber type A) 4.17.1 Components Location Diagram 4-38 Service Manual...

  • Page 71: Circuit Diagram

    4000 Evaluation Unit 4.17.2 Circuit Diagram Service Manual 4-39...

  • Page 72: Chamber Adapter (Opacity Measuring Chamber 4000)

    Evaluation Unit AVL 4000 4.18 Chamber Adapter (opacity measuring chamber 4000) 4.18.1 Components Location Diagram 4-40 Service Manual...

  • Page 73: Circuit Diagram

    4000 Evaluation Unit 4.18.2 Circuit Diagram Service Manual 4-41...

  • Page 74: Transmitter Board (Opacity Measuring Chamber 4000)

    Evaluation Unit AVL 4000 4.19 Transmitter Board (opacity measuring chamber 4000) 4.19.1 Components Location Diagram 4-42 Service Manual...

  • Page 75: Circuit Diagram

    4000 Evaluation Unit 4.19.2 Circuit Diagram Service Manual 4-43...

  • Page 76: Receiver Board (Opacity Measuring Chamber 4000)

    Evaluation Unit AVL 4000 4.20 Receiver Board (opacity measuring chamber 4000) 4.20.1 Components Location Diagram 4-44 Service Manual...

  • Page 77: Circuit Diagram

    4000 Evaluation Unit 4.20.2 Circuit Diagram Service Manual 4-45...

  • Page 78: Fan Board (Opacity Measuring Chamber 4000)

    Evaluation Unit AVL 4000 4.21 Fan Board (opacity measuring chamber 4000) 4.21.1 Components Location Diagram 4-46 Service Manual...

  • Page 79: Circuit Diagram

    4000 Evaluation Unit 4.21.2 Circuit Diagram Service Manual 4-47...

  • Page 80: Wiring Diagrams

    Evaluation Unit AVL 4000 4.22 Wiring Diagrams 4-48 Service Manual...
  • Page 81 4000 Evaluation Unit Service Manual 4-49...
  • Page 82 Evaluation Unit AVL 4000 4-50 Service Manual...

  • Page 83: Internal Cabling

    4000 Evaluation Unit 4.23 Internal Cabling The internal cabling has been minimised by using connectors that are directly soldered into the pcbs. Most of the remaining cables in the evaluation unit therefore are the mains cables with protective earth wiring, the connection cables to the peripheral devices (power supply unit, display, softkeys, printer, fan), the ribbon cables connecting the main board to the optional pcbs and the connection lines to the 4-/5-gas section.

  • Page 84: 5-Gas Section

    AVL board. Also to be borne in mine are the automatic measuring system control routines for the pump and solenoid valve (e.g.
  • Page 85 NO board (12-pin or 6-pin + cable item 4) Supply to NO + signal Supply to pneumatics module Supply to AVL board Pressure sensor signal 0…5 V Pump control signal (TTL) Supply to/control of fan 24 V DC...

  • Page 86: Service Mode

    Evaluation Unit AVL 4000 4.25 Service Mode 4.25.1 Changing O and NO Sensor see Section 5.6 or Operating Manual 4.25.2 Gas Calibration see Operating Manual Remember that the instrument must be switched on for at least 30 minutes before the calibration.
  • Page 87 4000 Evaluation Unit Fig. 4-6 Display data Field 1 The following values are displayed: [% vol] [% vol] [ppm vol] [% vol] [Torr] [°C] [ppm vol] Data Status Mask (07 means: "ZERO necessary") measured exhaust gas HC values are always hexane If a propane mixture is used as the calibration gas, this figure must be multiplied by the PEF to determine the hexane concentration.
  • Page 88 Evaluation Unit AVL 4000 Raw data for the measuring instrument unit Field 2 ï ï 19 bit ADC values ï ï These values are recorded during calibration at the works (see "Service" printout in the Appendix to the Operating Manual).
  • Page 89 4000 Evaluation Unit Measuring instrument unit status and errors Field 4 System status Message Processor in warmup phase other messages are irrelevant Zero status This tells you which warmup phase the tester is in. Message wait for obligatory zero calibration 1 minute mode 5 minute mode 15 minute mode...
  • Page 90 Evaluation Unit AVL 4000 Pneumatic components no / yes Field 8 Low flow Zero failure Leak failure Pneumatic failure Message error in pneumatic components module error in measuring instrument unit low flow in pneumatic components module communication error Irrelevant Displays whether zero (= zero calibration) or leak test is in progress...
  • Page 91 4000 Evaluation Unit Function keys Switches pump on/off (the pump status is displayed in field 7) PUMP Used to start automatic zero calibration. ZERO To carry out a leak test: Close off the probe! (see Operating Manual) LEAK Any leak error is displayed in field 8. Current "service values"...

  • Page 92: Diesel - Opacity Measuring Chamber Type A

    Evaluation Unit AVL 4000 4.25.4 Diesel - Opacity Measuring Chamber Type A Error diagnostics menu for opacity measuring chamber Opacity signal Change the set gain (depending on lamps, with AMPL selenium cell and gain setting) Lamp status change with LAMP...
  • Page 93 4000 Evaluation Unit Valve voltage, setting The various valve positions can be set with the VALVE button (calibration, measurement, closed) – the corresponding valve voltage is displayed. • Check the valve positions. The offset of the valve vane from the inlet or outlet aperture should not be more than ±2 mm.

  • Page 94: Diesel - Opacity Measuring Chamber 4000

    Evaluation Unit AVL 4000 4.25.5 Diesel - Opacity Measuring Chamber 4000 Error diagnostics menu for opacity measuring chamber Opacity signal System voltage Gain (depending on LEDs, (4 values) factor photoelectric cell and gain setting) Change lamp status by pressing LAMP...
  • Page 95 4000 Evaluation Unit System voltage System voltages RC and RF are clocked voltages (i.e. square-wave signals). The system voltages are represented as RC HIGH / RC LOW and RF HIGH / RF LOW and are somewhere between 0 and 5 V. RC HIGH RF HIGH RC LOW...
  • Page 96 Evaluation Unit AVL 4000 Temperature Measuring chamber temperature Measuring chamber temperature display − Here you can observe the heating process and control behaviour. − If the temperature does not reach 100° C, a heating element may be faulty. − Once the heating process is complete (after approx. 15 min), the measuring chamber temperature is 100 ±...

  • Page 97: 5-Gas Measuring Instruments Unit

    4000 4-/5-Gas Measuring Instruments Unit 5. 4-/5-Gas Measuring Instruments Unit General 4-/5-gas subsystem HC, CO, CO , NO Gas analyzer subsystem Pneumatics Power supply analyzer unit unit Fig. 5-1 Apart from the activities described below, the measuring instruments unit may only be opened by the manufacturer otherwise the P.E.F.

  • Page 98: Gas Analyzer

    Filter/receiver Fig. 5-2 All work on and modifications to the Gas Analyzer and its periphery may only be carried out by trained and qualified technicians. Technicians must be able to provide proof of training by AVL or Andros. Service Manual...

  • Page 99: Light Source

    4000 4-/5-Gas Measuring Instruments Unit 5.2.1 Light Source To carry out repair work: • Disconnect the inlet and outlet hose from the measuring cell. • Remove the complete gas analyzer from the base plate (see Dismantling the 4-/5-Gas Measuring Instruments Unit). •...

  • Page 100: Measuring Cell

    The preamplifier board may only be replaced together with the EPROM on the lambda pcb because the two components are finely tuned to each other. Replacing the board is only allowed with permission by AVL List GmbH! 5.2.5 Pressure Sensor •...

  • Page 101: Main Board And Lambda Piggyback

    4000 4-/5-Gas Measuring Instruments Unit 5.2.6 Main Board and Lambda Piggyback • Replace the complete analyzer unit. 5.2.7 Causes of Error Measuring cell temperature yellow wire might be broken re-solder Gas display not stable 10-pin ribbon cable to receiver is check (channel is dead) defective...
  • Page 102 4-/5-Gas Measuring Instruments Unit AVL 4000 Pneumatics flow diagram ∆ p ∆ p Fig. 5-4 Probe Pre-filter Particulate filter Condensate trap Condensate filter Non-return valve Pump Solenoid valve Activated carbon filter Non-return valve (0.3 bar) Measuring instruments unit Throttle Service Manual...

  • Page 103: Solenoid

    4000 4-/5-Gas Measuring Instruments Unit 5.3.1 Solenoid (see Fig. 5-3) • Disconnect the hose. • Undo the hexagon screw fitting. • Disconnect the power supply cable (screw the Phillips screw out of the plug). • Remove the solenoid together with the housing. •...

  • Page 104: Pump

    4-/5-Gas Measuring Instruments Unit AVL 4000 5.3.4 Pump • Disconnect the hoses from the gas IN and condensate IN side. • Disconnect the mains plug and take it right out of the socket. • Remove the screwable, right-angle connector from the instrument’s rear panel (1 slotted screw).

  • Page 105: Pressure Sensor

    4000 4-/5-Gas Measuring Instruments Unit 5.3.5 Pressure Sensor • Undo the two screws. • Unsolder the sensor. • Disconnect the hose and replace the sensor. • Attach the hose to the new sensor at nipple B. • Screw the sensor on. •...

  • Page 106: Power Supply Unit For 4-/5-Gas Measuring Instruments Unit

    4-/5-Gas Measuring Instruments Unit AVL 4000 Power Supply Unit for 4-/5-Gas Measuring Instruments Unit • Disconnect connector P1 (3-pin) and P2 (9-pin). • Remove the entire unit by undoing the 4 screws on the carrier plate. (It is a good idea to use an offset screwdriver, Phillips screw) •...

  • Page 107: Replacing The O

    4000 4-/5-Gas Measuring Instruments Unit 5.6.1 Replacing the O Sensor • Always switch the instrument off and pull the mains plug out of the socket. • Remove the O sensor cover by unscrewing the four screws from the rear panel. •...

  • Page 108: Cleaning The Condensate Part Of The 4/5-Gas Bench

    4-/5-Gas Measuring Instruments Unit AVL 4000 Cleaning the Condensate Part of the 4/5-Gas Bench 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.
  • Page 109 4000 4-/5-Gas Measuring Instruments Unit 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).

  • Page 110: Error Symptom List - Remedies

    4-/5-Gas Measuring Instruments Unit AVL 4000 Error Symptom List - Remedies The remedies apply to the 4/5-gas bench of the AVL DiGas/DiCom 4000 and the AVL DiGas 465. Primary error symptom Primary cause Secondary cause of Possible tests/ Remedy (of error)
  • Page 111 4000 4-/5-Gas Measuring Instruments Unit Primary error symptom Primary cause Secondary cause of Possible tests/ Remedy (of error) error establishing cause RS232 cable, Andros No measurement Communication Service mode: Connect cable measuring values displayed but error pumps and valves correctly or replace instruments unit chopper is working can be switched but...
  • Page 112 4-/5-Gas Measuring Instruments Unit AVL 4000 Primary error symptom Primary cause Secondary cause of Possible tests/ Remedy (of error) error establishing cause Self-test Faulty measuring ES in service mode Replace measuring instruments unit not 000000 instruments unit Faulty pump Short circuit...
  • Page 113 4000 4-/5-Gas Measuring Instruments Unit Primary error symptom Primary cause Secondary cause of Possible tests/ Remedy (of error) error establishing cause Permanently Measurement cell Condensate end of Water, condensate Clean or replace stabilising contaminated with pump faulty escaping at oxygen measurement cell condensate sensor...
  • Page 114 4-/5-Gas Measuring Instruments Unit AVL 4000 Primary error symptom Primary cause Secondary cause of Possible tests/ Remedy (of error) error establishing cause Measurement values Warm-up error FE, SE, SZ stable at Wait until instrument fluctuating 128 ± 10? has warmed up (SS...
  • Page 115 4000 4-/5-Gas Measuring Instruments Unit Primary error symptom Primary cause Secondary cause of Possible tests/ Remedy (of error) error establishing cause Calibration not Measurement See “Measurement values fluctuating possible values fluctuate significantly” or “Zeroing not possible” significantly Pressure or temperature measurement See related pressure measurement values, value not OK temperature measurement values...
  • Page 116 4-/5-Gas Measuring Instruments Unit AVL 4000 Primary error symptom Primary cause Secondary cause of Possible tests/ Remedy (of error) error establishing cause Instrument leaking Leak in hose, pre- Damage Any damage Replace or repair filter, screwed visible? filter leaking after...
  • Page 117 4000 4-/5-Gas Measuring Instruments Unit Primary error symptom Primary cause Secondary cause of Possible tests/ Remedy (of error) error establishing cause No/low gas flow Filter soiled Pre- and paper filter Any soiling visible, Clean, replace not changed flow rate setpoint: especially after tests on 2-stroke engines at each outlet...
  • Page 118 4-/5-Gas Measuring Instruments Unit AVL 4000 Primary error symptom Primary cause Secondary cause of Possible tests/ Remedy (of error) error establishing cause No AU (Official Calibration timer Timer set to 0 days Calibrate the Measurement) possible has expired in calibration mode...
  • Page 119 4000 4-/5-Gas Measuring Instruments Unit Primary error symptom Primary cause Secondary cause of Possible tests/ Remedy (of error) error establishing cause Oxygen measurement Plug and/or cable Not connected or Check: Connect or replace value incorrect and O faulty or irreparably service mode and cable sensor faulty...
  • Page 120 4-/5-Gas Measuring Instruments Unit AVL 4000 Primary error symptom Primary cause Secondary cause of Possible tests/ Remedy (of error) error establishing cause NO measurement Measurement Exhaust gas Carry out value slow without exhaust measurement over measurements with gas (i.e. fresh air)
  • Page 121 AVL 4000 pneumatics pressure sensor Setpoint: 118…138 Replace sensor faulty with pump Replace board switched off Pressure reducer throttle in AVL 4000 Setpoint must Replace pressure pneumatics system faulty increase (128 ± 10 ) reducer throttle in when pump silicon hose...
  • Page 122 4-/5-Gas Measuring Instruments Unit AVL 4000 Primary error symptom Primary cause Secondary cause of Possible tests/ Remedy (of error) error establishing cause Pump faulty Pump does not Cable faulty (465), Service mode: test Use edge protectors switch off function (465)
  • Page 123 4000 4-/5-Gas Measuring Instruments Unit Primary error symptom Primary cause Secondary cause of Possible tests/ Remedy (of error) error establishing cause General Temperature range 5 to 40° C (465) Ensure required temperature range 5 to 45° C (4000) operating conditions exceeded or undershot Instrument place in room near door, Ensure required...
  • Page 124 4-/5-Gas Measuring Instruments Unit AVL 4000 5-28 Service Manual...

  • Page 125: Opacity Measuring Chamber Type A

    4000 Opacity Measuring Chamber Type A 6. Opacity Measuring Chamber Type A This chapter applies only to AVL DiCom 4000 instruments. Only 12 V A-type (435) opacity measuring chambers may be used with the AVL DiCom 4000! Use of 2.6 V opacity measuring chambers will damage...
  • Page 126 Opacity Measuring Chamber Type A AVL 4000 • Place transmission filter on detector (caution – receiver side only)! Place filter on detector Fig. 6-2 • Close detector • Press >>. • The measured filter absorption is displayed. • Open detector.

  • Page 127: Upgrading An Avl Digas 4000 To An Avl Dicom 4000

    • Connect the two cables to the 435 Chamber Adapter Board. • The fuses of the mains switch group must be changed - for AVL DiCom 4000, 3.15 A slow-blow fuses must be used • Change the sticker on the rear panel and enter the new fuse rating.

  • Page 128: General Configuration

    Opacity Measuring Chamber Type A AVL 4000 General Configuration The opacity measuring chamber basically consists of the following main components: − Detector (Selenium Board) − Lamp module − Half-shell 1 − Half-shell 2 − Cover 1 − Cover 2 −...
  • Page 129 4000 Opacity Measuring Chamber Type A Control cable Heating cable socket socket Detector Lamp module module Probe holder (passenger car) Rubber pads Identification plate Fig. 6-3 Cross-section A-A Half-shell 1 Half-shell 2 Cover 2 Cover 1 Sample gas and Sample gas inlet purging air outlet Changeover valve...

  • Page 130: Dismantling The Opacity Measuring Chamber

    Opacity Measuring Chamber Type A AVL 4000 Dismantling the Opacity Measuring Chamber 6.4.1 Housing Cover 1 (on Exhaust Gas Outlet Side) • Undo the screws shown in Fig. 6-5 (11 screws) and carefully lift off cover 2. Housing cover 2...

  • Page 131: Housing Cover 2 (On Exhaust Gas Inlet Side)

    4000 Opacity Measuring Chamber Type A Rubber pads Detail: You do not need to remove the rubber pads to dismantle the measuring chamber. Cross-section B-B (Fig. 6-5) DM0086 Rubber pad DF0019 Washer DZ0250 Screw DS0165 Fig. 6-7 6.4.2 Housing Cover 2 (on Exhaust Gas Inlet Side) Undo the screws shown in Fig.
  • Page 132 Opacity Measuring Chamber Type A AVL 4000 11 x DS1172 Oval-head screw M5x10 DZ0567 DZ0253 Fig. 6-9 Housing cover 2 RM0115 Label ZB1384 Silicon seal RM0121 Rubber pads Detail: You do not need to remove the rubber pads to dismantle the measuring chamber.

  • Page 133: Half-Shells 1 And 2

    4000 Opacity Measuring Chamber Type A 6.4.3 Half-shells 1 and 2 Place the measuring chamber on its side with half-shell 1 (recognisable by the control and heating cable connections) facing upwards. Fig. 6-11 • Undo stud bolts (A) shown in Fig. 6-11. 9 pcs.
  • Page 134 Opacity Measuring Chamber Type A AVL 4000 2 pcs. While undoing these bolts, apply Stud bolt C YM2681 counterpressure to the bolts underneath them (located between the two half-shells and reached via access point "X"). Fig. 6-13 • Undo the two screws on the measuring chamber handle.
  • Page 135 4000 Opacity Measuring Chamber Type A The measuring chamber should now be standing upright in front of you with the exhaust gas outlet (half-shell 1) facing you. • Fold open the optical modules. • Carefully pull the half-shells apart. • Make sure that the axles of the optical modules remain in the mounting on the gas outlet side.

  • Page 136: Fans

    Opacity Measuring Chamber Type A AVL 4000 Stud bolt C YM2681 2 pcs. Fig. 6-19 Half-shell 1 RM0113 Half-shell 2 RM0114 Silicon seal RM0120 Fans • Dismantle the opacity measuring chamber as described in section 6.4 Dismantling the Opacity Measuring Chamber.

  • Page 137: Heating Blocks And Orifice Plates

    4000 Opacity Measuring Chamber Type A Heating Blocks and Orifice Plates • Dismantle the opacity measuring chamber as described in section 6.4 Dismantling the Opacity Measuring Chamber. One heating block is mounted in half-shell 1 and the other in half-shell 2 - the two heating blocks are identical.
  • Page 138 Opacity Measuring Chamber Type A AVL 4000 − Carefully extract the heating block from the inside of the half-shell. Heating block complete BO1248 The heating block you now have in front of you consists of the following components: − 1 heating block YM2675 (incl.

  • Page 139: Changeover Valve With Geared Motor

    4000 Opacity Measuring Chamber Type A Changeover Valve with Geared Motor • Dismantle the opacity measuring chamber as described in section 6.4 Dismantling the Opacity Measuring Chamber. The changeover valve is located in half-shell 1 (exhaust gas outlet side). • Simply pull the valve out of the half-shell by its aluminium housing.
  • Page 140 Opacity Measuring Chamber Type A AVL 4000 Dismantling the valve block • The two valve bonnets are press-fitted in the valve housing. • Open the valve housing by carefully forcing open gap "X" (Fig. 6-24) applying even pressure around the circumference using a thin blade (e.g. chisel, screwdriver etc.) until the bonnet drops out of the housing.

  • Page 141: Temperature Sensor

    4000 Opacity Measuring Chamber Type A Ensure that the setscrew is screwed into the flattened side of the motor shaft. When press-fitting the valve bonnet into the housing, ensure that it goes in straight and that the housing is in the correct position (guided by straight pin).
  • Page 142 Opacity Measuring Chamber Type A AVL 4000 Positioning: Glue temperature CAUTION: sensor back into position! Half-shell 1 Heating block Temperature sensor Fig. 6-25 Temperature sensor 2 (half-shell 2, exhaust gas inlet) The sensor is located at the gas inlet and is bonded in position.

  • Page 143: Lamp Module (Bo1135)

    4000 Opacity Measuring Chamber Type A • Position the sensor so that it extends to approximately the middle of the gas inlet bore. • Glue the sensor into the groove at the gas inlet. Do not get glue on the inside surface of the bore. Lamp Module (BO1135) Seal ring...
  • Page 144 Opacity Measuring Chamber Type A AVL 4000 Seal ring YM2721 is glued on with silicon. • Before replacing the protecting glass, first remove the seal ring. • Then undo the 2 countersunk screws concealed beneath the seal ring. • The entire light unit can now be pulled out from the rear.

  • Page 145: Detector (Bo1134)

    4000 Opacity Measuring Chamber Type A 6.10 Detector (BO1134) • If the detector housing needs replacing, dismantle the measuring chamber as described in section 6.4 Dismantling the Opacity Measuring Chamber. All the other detector components can be replaced without dismantling the measuring chamber.
  • Page 146 Opacity Measuring Chamber Type A AVL 4000 The protecting glass is bonded to the selenium holder. • You can now press it off the selenium holder from the inside. • Clean any silicon residues from the selenium holder. • Replace the green filter, selenium cell and O-ring in the selenium holder.

  • Page 147: Purging Air Panels (Ym2691)

    4000 Opacity Measuring Chamber Type A 6.11 Purging Air Panels (YM2691) There are two purging air panels, one either side of the measuring chamber. Fixing bolts Fixing bolts Cross-section A-A Purging air panel Purging air panel YM2691 YM2691 2 oval-head screws M4x6 DS1041 2 contact discs DZ0549...

  • Page 148: Electrical Wiring

    Opacity Measuring Chamber Type A AVL 4000 When reassembling, note: • The panels are not screwed in place. They are automatically held in place by the two half-shells. • The protective conductor connections must face the measuring chamber. • When the two half-shells are reassembled, the panels must not slip out from the fixing bolts and get jammed.
  • Page 149 4000 Opacity Measuring Chamber Type A Fig. 6-30 Fig. 6-31 Service Manual 6-25...
  • Page 150 Opacity Measuring Chamber Type A AVL 4000 Fig. 6-32 6-26 Service Manual...
  • Page 151 4000 Opacity Measuring Chamber Type A Control cable loom (BV1605) Pos. 2 Pos. 3 Pos. 8 Pos. 7 Pos. 6 Pos. 4 Pos. 5 Pos. 1 Fig. 6-33 Service Manual 6-27...
  • Page 152 Opacity Measuring Chamber Type A AVL 4000 Spare parts list Pos. 1 Contact pin EU0661 Faston 4.8 connector EU0542 Insulating sleeve for Faston 4.8 EU0536 2-pin connector EU0945 Pin contact EU1155 6-pin connector EU1431 PT100 temperature sensor EU0116 Faston 6.3 connector EU0804 Heating cable loom (BV1620, Fig.
  • Page 153 4000 Opacity Measuring Chamber Type A Heating cable loom (BV1620) Pos. 3 Pos. 2 Pos. 4 Pos. 5 Pos. 1 Fig. 6-34 Service Manual 6-29...
  • Page 154 Opacity Measuring Chamber Type A AVL 4000 Sensor cable (BV1710) (additional cable to heating cable) Pos. 1 2x Pos. 2 Pos. 3 2x Pos. 4 bn L=400mm bn L=500mm bl L=50mm Fig. 6-35 6-30 Service Manual...
  • Page 155 4000 Opacity Measuring Chamber Type A Opacity measuring chamber type A - connection diagram Fig. 6-36 Service Manual 6-31...

  • Page 156: Reassembly Of The Opacity Measuring Chamber

    Opacity Measuring Chamber Type A AVL 4000 6.13 Reassembly of the Opacity Measuring Chamber • Check that the seal in half-shell 2 is sitting correctly. • Join the two half-shells together − Before doing so, feed the disconnected cables through the space in half-shell 2 (fan, heating block and protective conductor cables, see section 6.12 Electrical...

  • Page 157: Opacity Measuring Chamber 4000

    4000 Opacity Measuring Chamber 4000 7. Opacity Measuring Chamber 4000 System Check with Filter • Switch the instrument on ready for operation. • Select Control measurements (CONT) in the diesel engine menu and then Control measurement with filter (FLT). • Remove the lens protector from the opacity measuring chamber on the receiver side (probe connection side).

  • Page 158: Upgrading An Avl 4000 Digas To An Avl 4000 Dicom

    Opacity Measuring Chamber 4000 AVL 4000 Upgrading an AVL 4000 DiGas to an AVL 4000 DiCom A trained service technician can carry out this upgrade with the following components: Component AVL ident. number Chamber Adapter BB0776 Measuring Chamber Cable BV1982 4 metal screws 2.9 ×...
  • Page 159 4000 Opacity Measuring Chamber 4000 DS0992 BV1982 Fig. 7-3 Service Manual...

  • Page 160: Assembling And Disassembling The Opacity Measuring Chamber

    Opacity Measuring Chamber 4000 AVL 4000 Assembling and Disassembling the Opacity Measuring Chamber The measuring chamber consists of 2 symmetrical shell halves which are screwed together with M4 hexagon socket screws. • Undo the six screws on each side to open the instrument. Separate the two shell halves by inserting a screwdriver into the gap between them at the top or bottom (e.g.

  • Page 161: Design And Details Of Assemblies

    4000 Opacity Measuring Chamber 4000 Design and Details of Assemblies 7.4.1 Fan Unit (BO2189) Fan plate Oval head screw YM3207 DS1269 Spacer pin EP0329 Fan axial EI0253 Fan pcb Oval head screw Fig. 7-6 BB0807 DS0161 Service Manual...

  • Page 162: Measurement Cell (Bo2138)

    Opacity Measuring Chamber 4000 AVL 4000 7.4.2 Measurement Cell (BO2138) Heating element Temperature sensor Insulation Fig. 7-7 Heating element: ident. no. EH0845, resistance 20 Ohm Temperature sensor, heating: ident. no. EZ0161, PT 100 7.4.2.1 Replacing the Temperature Sensor in the Heating System •...

  • Page 163: Valve Unit (Bo2139)

    4000 Opacity Measuring Chamber 4000 7.4.3 Valve Unit (BO2139) Valve plunger Valve block RM0154 YM3190 Inflow tube YM3185 Drive motor including cable BV2084 Oval head screw DS1270 Fig. 7-8 The motor, ident. no. BV2084, can be dismantled by undoing the two screws. Temperature sensor PT 100: ident.

  • Page 164: Transmitter And Detector Unit

    Opacity Measuring Chamber 4000 AVL 4000 7.4.4 Transmitter and Detector Unit Transmitter unit (BO2140) Transmitter board Optical pickup Flow channel BB0777 YM3191 RM0146 Reference detector EO0148 LEDs EO0147 Fig. 7-9 Detector unit (BO2141) Flow channel Optical pickup RM0146 YM3192 Receiver board...
  • Page 165 4000 Opacity Measuring Chamber 4000 Opacity measuring chamber 4000 - connection diagram Service Manual...

  • Page 166: Assembling The Opacity Measuring Chamber

    Opacity Measuring Chamber 4000 AVL 4000 Assembling the Opacity Measuring Chamber • Insert all the units (detector, transmitter, fan…) completely into one shell half, not forgetting the seal. • Screw in the screws on one side first, then on the other. Tighten the screws on the first side.

  • Page 167: Spare Parts Lists

    8. Spare Parts Lists General Different spare parts lists apply depending on the opacity measuring chamber model used in the AVL DiSmoke 4000 and AVL DiGas 4000. The table below shows the lists relevant to the various configurations. Instrument configuration...

  • Page 168: Standard List

    Standard List This spare parts list applies to the following instruments: • AVL DiGas 4000 • AVL DiSmoke 4000 with Opacity Measuring Chamber 4000 • AVL DiCom 4000 with Opacity Measuring Chamber 4000 EVALUATION UNIT 4000 DONGLE for 4000 E321.00./B00.0...
  • Page 169 4000 Spare Parts Lists 4-GAS/5-GAS BENCH 4000 453 REAR PANEL MODULE 4530F01./B00.0 BR0273 6231 MEASURING INSTRUMENTS EN0323 UNIT for 4000 4000 REAR PANEL 4530U01./B00.0 ZG1940 02 SENSOR CABLE 4530V09./B00.0 BV2009 FAN CABLE 4530V03./B00.0 BV1987 PNEUMATICS MAINS CABLE 4530V01./B00.0 BV1985 PUMP CABLE 4530V06./B00.0 BV1990 4 GAS SERIAL CABLE...
  • Page 170 Spare Parts Lists AVL 4000 OPTIONS STANDARD ANALOGUE CABLE 4330V09./B00.0 BV2054 PRINTER CABLE 4330V05./B00.0 BV1983 SPEED/ANGLE CABLE 4330V06./B00.0 BV1984 CONNECTOR ADAPTER 4630L06./B00.0 BB0740 MEMORY ADAPTER 4630L05./B00.0 BB0730 4000 PRINTER OPTION 4330W02./B00.0 BO1720 SPEED ANGLE OPTION 4330W03./B00.0 BO1721 PAPER ROLL FOR DOT MATRIX PRINTER57X50X12...
  • Page 171 4000 Spare Parts Lists SPARE PARTS FOR 4000 MEASURING CHAMBER 4000 OPACITY MEASURING CHAMBER 4330.02./C00.0 BO2135 PROBE CLAMP 4330S07./C00.0 BO2201 PROBE TIP 10mm 4330X22./C00.0 YM3209 CONTROL CABLE 4000 6M E313.00./B00.0 BV2095 CONTROL CABLE 4000 12 M E313.01./B00.0 BV2096 CONTROL CABLE 4000 18M E313.02./B00.0 BV2097 MEASUREMENT CELL COMPLETE...

  • Page 172: Avl 4000 With Opacity Measuring Chamber Type A

    AVL 4000 with Opacity Measuring Chamber Type A This spare parts list applies to the following models: • AVL DiSmoke 4000 with Opacity Measuring Chamber Type A • AVL DiCom 4000 with Opacity Measuring Chamber Type A EVALUATION UNIT 4000 PLUG FOR 4000 E321.00./B00.0...
  • Page 173 4000 Spare Parts Lists 4-GAS/5-GAS BENCH 4000 REAR PANEL MODULE 453 4530F01./B00.0 BR0273 MEASURING INSTRUMENTS UNIT 6231 for 4000 EN0323 4000 REAR PANEL 4530U01./B00.0 ZG1940 02 SENSOR CABLE 4530V09./B00.0 BV2009 PUMP CABLE 4530V06./B00.0 BV1990 4-GAS SERIAL CABLE 4530V05./B00.0 BV1989 VALVE CABLE EX0470 ANDROS CABLE 4530V07./B00.0...
  • Page 174 Spare Parts Lists AVL 4000 OPTIONS STANDARD ANALOGUE CABLE 4330V09./B00.0 BV2054 PRINTER CABLE 4330V05./B00.0 BV1983 SPEED/ANGLE CABLE 4330V06./B00.0 BV1984 CONNECTOR ADAPTER 4630L06./B00.0 BB0740 MEMORY ADAPTER 4630L05./B00.0 BB0730 PAPER ROLL FOR DOT MATRIX PRINTER57X50X12 HP0057 PAPER HOLDER 4370U12./B00.0 ZG1132 SPEED SOCKET COVER 4330U03./B00.0...
  • Page 175 4000 Spare Parts Lists SPARE PARTS FOR 435 MEASURING CHAMBER (BO1635) SENSOR UNIT COMPLETE 4350.02I/C00.0 BO1635 DETECTOR MODULE 4350.02./R40.0 BO1134 for BO1635 PHOTOCELL 90UA BEI 150 LX A45 EO0099 LAMP HEAD MODULE 4350.02./R30.0 BO1135 for BO1635 OPACITY MEASURING RM0115 CHAMBER COVER 4350.02./R03.0 HALOGEN BULB 12V 5W EL0209...

  • Page 176: Avl 4000 With Opacity Measuring Chamber Model A France

    AVL 4000 with Opacity Measuring Chamber Model A France This spare parts list applies to the following instruments: • AVL DiSmoke 4000 with Opacity Measuring Chamber Type A/France • AVL DiCom 4000 with Opacity Measuring Chamber Type A/France SPARES CONTROL UNIT CONNECTOR SW IMPL.
  • Page 177 4000 Spare Parts Lists 4-Gas/5-Gas Bench BACK PANEL COMPLETE 4530F01./B00.0 BR0273 4-GAS BENCH 6231 for 4000 EN0323 BACK PANEL 4000 4530U01./B00.0 ZG1940 CABLE - 02 SENSOR 4530V09./B00.0 BV2009 CABLE PUMP 4530V06./B00.0 BV1990 CABLE SERIAL 4 GAS 4530V05./B00.0 BV1989 CABLE VALVE EX0470 ANDROS CABLE 4530V07./B00.0...
  • Page 178 Spare Parts Lists AVL 4000 OPTIONS STANDARD ANALOGUE CABLE 4330V09./B00.0 BV2054 PRINTER CABLE 4330V05./B00.0 BV1983 RPM CABLE 4330V06./B00.0 BV1984 CONNECTOR ADAPTER 4630L06./B00.0 BB0740 MEMORY ADAPTER 4630L05./B00.0 BB0730 RPM/TEMP OPTION 4330W03./B00.0 BO1721 PAPER ROLL / DOT MATRIX PRINTER 407/435 HP0057 PAPER SUPPORT 4370U12./B00.0...
  • Page 179 4000 Spare Parts Lists 435 OPACITY MEASURING CHAMBER (F) SENSOR UNIT COMPLETE BO1567 for the Belgium, France, the Netherlands, Norway, Austria, Spain, Sweden LAMP ELEMENT BO1593 for BO1567 COVER FOR SENSOR UNIT RM0115 HALOGEN BULB 12V 5W EL0209 HEATING BLOCK COMPLETE 4350.02./R20.0 BO2169 HEATING BLOCK COMPLETE...
  • Page 180 Spare Parts Lists AVL 4000 8-14 Service Manual...

  • Page 181: Tools For The Service Technician

    Delivers calibratable rpm signal, permits simulation of the following signals: clamp-on transducer, nozzle needle lift sensor, RIV, TDC analogue, TDC digital, oil temperature, ignition signal, λ Κprobe Together with AVL Adapter Box 803 (ident. number: GH0474) suitable for Series 400 Exhaust Gas Testers and AVL DiTime 873. Service Manual...
  • Page 182 Tools for the Service Technician AVL 4000 Service Manual...

This manual is also suitable for:

Avl dicom 4000Avl dismoke 4000

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