AVL DiCom 4000 User Manual (English)

Questions and Answers:

S
stewartsamanthaAug 15, 2025
What to do if AVL Test Equipment leak test failed?
- R
  Robert BrewerAug 15, 2025
  If the AVL Test Equipment leak test fails, you should: * Check the entire sampling line for leaks, from the probe tip to the inlet on the rear panel. * Disconnect the probe hose and connect a leak-proof 2 m hose. * Inspect the O-rings in the filter housing and condensate trap, and check the connections for leaks on the probe hose and condensate drainage hose. * Also, check if the tester was stored with condensate at temperatures below 0° C.
L
Linda CaldwellAug 18, 2025
What to do if AVL Test Equipment measuring chamber temperature is too high?
- M
  Mary YoungAug 18, 2025
  If the measuring chamber temperature is too high on your AVL Test Equipment, you should remove the probe from the exhaust pipe. Wait at least 10 minutes, then acknowledge the error by pressing >>. If the issue persists, there may be a fault in the measuring instruments unit; remove the unit and check the cable to the receiver, replacing the unit if necessary.
T
Terry SmithAug 21, 2025
What to do if my AVL Test Equipment measuring chamber is too hot or too cold?
- D
  Dana BrennanAug 22, 2025
  If your AVL Test Equipment's measuring chamber is too hot or too cold, first remove the probe from the exhaust pipe and wait for the temperature to return to the permitted range. Then, acknowledge the message by pressing >>. If the temperature is still too low, one of the heating blocks has probably failed. If the temperature is still too high, the feedback control system is malfunctioning.
A
Anthony PhillipsAug 25, 2025
What to do if AVL Test Equipment measuring chamber pressure is wrong?
- T
  Tommy Stout MDAug 26, 2025
  If the measuring chamber pressure is wrong on your AVL Test Equipment, first check whether the measurement gas outlet is blocked. If the error persists, remove the unit and check whether the hose system is blocked. Additionally, check or replace the pressure sensor.
J
Jeanne JordanAug 28, 2025
How to fix insufficient gas flow in AVL Test Equipment?
- D
  Dustin CoxAug 28, 2025
  To fix insufficient gas flow in your AVL Test Equipment: * Clean the probe out with compressed air. * If the filter is black, replace it. * Remove the measuring instruments unit and check the hose system and pump.
R
Randall HughesAug 31, 2025
What to do with Opacity Measuring Chamber, Type A, of AVL Test Equipment?
- J
  Jeffery MillsAug 31, 2025
  For the Opacity Measuring Chamber, Type A, of your AVL Test Equipment: * Fold the optical elements to the side. * Check that both lamps are working. * Clean the glass disc in front of the optical elements. * Fold the optical elements back into place and acknowledge the message by pressing >>.
C
Curtis WebbSep 4, 2025
What to do with Opacity Measuring Chamber, Type 4000, of AVL Test Equipment?
- M
  Mary ZimmermanSep 4, 2025
  For the Opacity Measuring Chamber, Type 4000, of your AVL Test Equipment, remove the lens protector and check the windows. Then, press
M
Melissa CampbellSep 7, 2025
What causes Changeover Valve Error in AVL Test Equipment?
- A
  aballSep 7, 2025
  A Changeover Valve Error in AVL Test Equipment is caused by failure of the changeover valve in the opacity measuring chamber. The suggested solution is to replace the changeover valve.
S
Samuel HunterSep 12, 2025
What to do if AVL Test Equipment calibration fails?
- D
  Dwayne AndersonSep 12, 2025
  If the calibration fails on your AVL Test Equipment, press >> to call up the diesel service screen for further error diagnosis.

AVL DiCom 4000 Specifications

General

Category	Test Equipment
Manufacturer	AVL
Model	DiCom 4000
Communication Interface	Ethernet, Serial (RS-232), USB
Measurement Range	Consult official documentation for specific measurement ranges depending on the sensors/modules used.
Accuracy	Consult official documentation for specific accuracy depending on the sensors/modules used.
Resolution	Consult official documentation for specific resolution depending on the sensors/modules used.
Response Time	Consult official documentation for specific response time depending on the sensors/modules used.
Operating Temperature	Typically 5°C to 40°C (41°F to 104°F), consult official documentation for exact range.

Summary

Periodic Maintenance

Maintenance Plan Schedule

Schedule of daily, weekly, six-monthly, and annual maintenance tasks.

Minor Maintenance Procedures

Procedures for performing minor maintenance on the instruments.

AVL DiGas 4000 Minor Maintenance

Specific minor maintenance steps for the AVL DiGas 4000 unit.

AVL DiSmoke 4000 Minor Maintenance

Specific minor maintenance steps for the AVL DiSmoke 4000 unit.

AVL DiCom 4000 Minor Maintenance

Specific minor maintenance steps for the AVL DiCom 4000 unit.

Major Maintenance Procedures

Procedures for performing major maintenance on the instruments.

AVL DiGas 4000 Major Maintenance

Specific major maintenance steps for the AVL DiGas 4000 unit.

AVL DiSmoke 4000 Major Maintenance

Specific major maintenance steps for the AVL DiSmoke 4000 unit.

AVL DiCom 4000 Major Maintenance

Specific major maintenance steps for the AVL DiCom 4000 unit.

Error Messages and Troubleshooting

4-/5-Gas Measuring Instruments Unit Troubleshooting

Diagnosing and resolving errors for the 4-/5-gas measurement unit.

Gas Flow Insufficient Troubleshooting

Steps to troubleshoot insufficient gas flow errors in the measuring unit.

System Needs Restarting Troubleshooting

Procedures for resolving system restart errors.

Measuring Chamber Temperature Too High Troubleshooting

Steps to address overheating issues in the measuring chamber.

Measuring Chamber Pressure Wrong Troubleshooting

Troubleshooting incorrect pressure readings in the measuring chamber.

Leak Test Failed Troubleshooting

Replace O2 Sensor Procedure

Replacing the NO Sensor Procedure

Opacity Measuring Chamber Troubleshooting

Diagnosing and resolving errors related to the opacity measuring chamber.

Measuring Chamber Temperature Issues Troubleshooting

Changeover Valve Error Troubleshooting

Linearity / Opacity Error Troubleshooting

Troubleshooting linearity and opacity measurement errors.

Opacity Chamber Type A Linearity/Opacity Error

Opacity Chamber Type 4000 Linearity/Opacity Error

Software

Installation of Operating Software

Procedure for updating or installing the instrument's operating software via memory card.

Evaluation Unit

Hardware Setup and Components

Detailed information on the evaluation unit's hardware setup and component descriptions.

Main Board Components and Functionality

Interfaces and External Connections

Speed/Angle Board Installation and Function

Dismantling the 4-/5-Gas Measuring Instruments Unit

Step-by-step guide for safely dismantling the 4-/5-gas measuring instruments unit.

Printer Options and Installation

Main Board Overview

Speed Angle Board Details

Pneumatics Board Details

Printer Adapter Details

Memory Adapter Details

Chamber Adapter (Opacity Measuring Chamber Type A)

Receiver Board (Opacity Measuring Chamber Type A)

Selenium Board (Opacity Measuring Chamber Type A)

Chamber Adapter (Opacity Measuring Chamber 4000)

Transmitter Board (Opacity Measuring Chamber 4000)

Receiver Board (Opacity Measuring Chamber 4000)

Fan Board (Opacity Measuring Chamber 4000)

Wiring Diagrams

Comprehensive diagrams showing the electrical wiring connections between components.

Internal Cabling Overview

4-/5-Gas Section Technical Details

Technical information about the 4-/5-gas section, pneumatics, and multi-gas system.

Pneumatics Board Functionality

Multi-gas System General Requirements

Service Mode Operations and Diagnostics

Guide to accessing and using the service mode for diagnostics and adjustments.

Changing O2 and NO Sensors

Procedure for replacing O2 and NO sensors, referencing other sections.

Gas Calibration Procedure

Instructions for performing gas calibration, referencing the operating manual.

4-/5-Gas Diagnostics and Status Assessment

How to assess status and diagnose errors for the 4-/5-gas unit in service mode.

Diesel Opacity Chamber Type A Diagnostics

Error diagnostics menu and operational checks for the Type A opacity chamber.

Diesel Opacity Chamber 4000 Diagnostics

Error diagnostics menu and operational checks for the 4000 opacity chamber.

4-/5-Gas Measuring Instruments Unit

Gas Analyzer Components and Maintenance

Details on the gas analyzer's parts and required maintenance.

Light Source Repair Procedures

Motor Unit Replacement

Measuring Cell Replacement

Guide for safely replacing the measuring cell.

Pressure Sensor Replacement Procedure

Causes of Error in Gas Analyzer

Common causes of error and their remedies for the gas analyzer.

Layout of Pneumatics System

Diagram and description of the pneumatics system layout.

Solenoid Replacement Procedure

Valve Unit Replacement Procedure

Particulate Filter Replacement

Pump Replacement Procedure

Pressure Sensor Replacement

Pneumatics Board Replacement

Power Supply Unit for 4-/5-Gas Unit

Power Supply Board Replacement

O2 and NO Sensor Handling and Replacement

Information on the O2 and NO sensors, including replacement.

Replacing the O2 Sensor

Detailed procedure for replacing the O2 sensor.

Replacing the NO Sensor

Detailed procedure for replacing the NO sensor.

Cleaning the Condensate Part of the 4/5-Gas Bench

Error Symptom List and Remedies

Comprehensive list of primary error symptoms, causes, tests, and remedies.

Opacity Measuring Chamber Type A

Upgrading AVL DiGas 4000 to AVL DiCom 4000

Dismantling the Opacity Measuring Chamber

Step-by-step instructions for disassembling the opacity measuring chamber.

Dismantling Housing Cover 1

Dismantling Housing Cover 2

Dismantling Half-shells 1 and 2

Fan Unit Maintenance and Replacement

Heating Blocks and Orifice Plates Maintenance

Procedures for dismantling and accessing the heating blocks and orifice plates.

Changeover Valve with Geared Motor Maintenance

Steps for dismantling and servicing the changeover valve assembly.

Temperature Sensor Replacement Procedure

Lamp Module Replacement Procedure

Detector Unit Maintenance and Replacement

Procedures for maintaining and replacing detector components.

Electrical Wiring and Cable Routing

Details on the electrical wiring looms and cable routing within the chamber.

Reassembly of the Opacity Measuring Chamber

Step-by-step guide for reassembling the opacity measuring chamber.

Opacity Measuring Chamber 4000

System Check with Filter Procedure

Steps to perform a system check using a filter on the 4000 opacity chamber.

Upgrading AVL 4000 DiGas to AVL 4000 DiCom

Assembling and Disassembling the Opacity Measuring Chamber

Step-by-step instructions for assembling and disassembling the 4000 opacity chamber.

Measurement Cell Details

Valve Unit Details

Transmitter and Detector Unit Details

Checking Light Sources and Receiver

Checking the Reference Receiver

Assembling the Opacity Measuring Chamber

Instructions for reassembling the opacity measuring chamber after maintenance.

Tools for the Service Technician

Essential Tools and Software for Service Technicians

List of necessary tools, software, and diagnostic equipment for service technicians.

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