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Exhaust gas analyzer

OPERATING MANUAL

Rev. 0 - 05/07

cod. 1160045

IMPORTANT !
We recommend you thoroughly read the instructions provided in this manual before
switching on the device.
This will enable you to obtain excellent performance and reliability over time.
Store this manual close to the device for quick reference by operators!
The Manufacturer shall not be liable for failures or other consequences deriving
from incorrect procedures on the part of the User.

No part of this manual may be reproduced in any form without prior written consent by the manufacturer.
CZ Srl reserves the right to make improvements or changes in its instruments at any time and without prior notice.
Other product names and companies mentioned in this document may be registered trademarks registered by the
respective owners.

Cod. 1160045
Document completed in may 2007

OPERATING MANUAL

Dear Customer,
Congratulations on purchasing our EGA 903 gas analyzer, a very modern instrument which will
help you for control and adjustment of vehicle emissions.
The technology applied and the quality achieved in years of experience in the sector, have made
EGA 903 an excellent instrument which will give you maximum satisfaction thanks to its efficiency
and reliability over time.
The device uses the latest technology for analysis emissions by an integrated display unit, build
on a powerful computer and a stable operating system (Linux), with a touch screen for easy
access to all the features directly on the colour high resolution LCD TFT.
This manual is to be considered an integral part of the instrument as it contains general
instructions for correct use of the device.
We therefore invite you to carefully read through the instructions before switching on the device,
to adequately train operators and to store the manual for future reference. These good practices
shall ensure that you obtain from the instrument top performance and reliability over time.

And now its over to you!

OPERATING MANUAL

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OPERATING MANUAL

INDEX

1 SAFETY RULES ........................................................................................................................... 9


1.1 For the device ........................................................................................................................... 9
1.2 For the use .............................................................................................................................. 10
1.3 Disposal .................................................................................................................................. 10
2 MAIN FEATURES....................................................................................................................... 11
2.1 Hardware................................................................................................................................. 11
2.2 Generals .................................................................................................................................. 12
2.3 Metrological characteristics .................................................................................................... 12
2.4 Conformity............................................................................................................................... 13
3 PREPARING FOR USE .............................................................................................................. 14
3.1 Package content ..................................................................................................................... 14
3.2 Installation ............................................................................................................................... 15
3.3 Connection.............................................................................................................................. 15
3.4 Rear view description.............................................................................................................. 16
3.5 Frontal view ............................................................................................................................. 17
3.6 Technical data plate................................................................................................................ 17
4 USE OF THE PROGRAM ........................................................................................................... 18
4.1 Description .............................................................................................................................. 18
4.1.1 Buttons description ........................................................................................................ 18
4.1.2 Alphanumeric keyboards............................................................................................... 19
4.2 Settings ................................................................................................................................... 19
4.2.1 Language ....................................................................................................................... 20
4.2.2 Workshop details ........................................................................................................... 20
4.2.3 Date and Time setting.................................................................................................... 21
4.2.4 Touch screen adjust ...................................................................................................... 21
4.2.5 Setup/Calibration Measurements ............................................................................... 22
4.2.6 Setup/Calibration - Identification ................................................................................... 23
4.2.7 Printer settings ............................................................................................................... 24
5 GAS ANALYSER ........................................................................................................................ 25
5.1 Test selection .......................................................................................................................... 25
5.2 Free test .................................................................................................................................. 26
5.2.1 Oil temperature measurement ....................................................................................... 27
5.2.2 Rpm measurement ........................................................................................................ 27
5.3 Graphic test............................................................................................................................. 28
5.3.1 Rpm measurement ........................................................................................................ 29
5.3.2 Buttons description ........................................................................................................ 30

OPERATING MANUAL

INDEX

6 AUTODIAGNOSIS ...................................................................................................................... 31
6.1 Parameters .............................................................................................................................. 31
6.2 Errors ....................................................................................................................................... 34
6.3 Actuators ................................................................................................................................. 35
6.4 States....................................................................................................................................... 36
6.5 ISO........................................................................................................................................... 36
7 MULTIMETER............................................................................................................................. 37
7.1 Description .............................................................................................................................. 37
8

LIST TEST REPORTS................................................................................................................. 40

9 MAINTENANCE.......................................................................................................................... 42
9.1 Description of the operations .................................................................................................. 42
9.2 Leak Test ................................................................................................................................. 42
9.3 Maintenance of the filters ........................................................................................................ 44
9.4 Replacement of the Oxigen and /or NOx Sensor ................................................................... 45
9.5 Periodic Inspection.................................................................................................................. 45
9.6 Extraordinary maintenance ..................................................................................................... 45
9.7 Error messagges ..................................................................................................................... 46
9.8 Replacement of the paper roll and/or ink ribbon .................................................................... 48
10

FITTINGS AND SPARE PARTS ............................................................................................... 49

INDEX

OPERATING MANUAL

Manufacturers CE Declaration of Conformity

CZ Srl
Declares under its sole responsibility that the product:

EGA 903 Exhaust gas analyzer


FULFILLS THE ESSENTIAL REQUIREMENTS OF THE DIRECTIVES:
Directive 98/37/ECC with subsequent amendments
89/336 CEE dated 3rd may 1989 with subsequent amendments
(Directive 92/31/ECC dated 28 the April 1992 and Directive 93/68/ECC dated 22nd July 1993)
SINCE DESIGNED AND MANUFACTURED IN COMPLIANCE WITH THE FOLLOWING EUROPEAN HARMONIZED STANDARDS:

UNI EN ISO 12100-1 Safety of machinery Basic concepts, general principles for design
Basic terminology, methodology.

UNI EN ISO 12100-2 Safety of machinery Basic concepts, general principles for design
Technical principles.

Parma, 02/05/2007
Sign of Legal Representative

OPERATING MANUAL

DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY

OPERATING MANUAL

SAFETY RULES

1.1

For the device

Forbid the use of this device to any non-allowed persons.

Carefully read the technical data plate to ensure that the frequency and voltage match mains
values.

Do not remove or make illegible tags or danger, obligatory or forbidden signals.

Do not connect the unit to voltage or frequency other than those indicated on the plate.

Use the device only in dry places, sufficiently light and well aired.

Do not expose the device to warm sources.

Do not bump the device.

If the gas analyzer is positioned on the special trolley during transport or handling, ensure
that there are no other objects on the instrument to prevent them from falling.

Do not move the device pulling it with the cables connected.

Do not wet the device and protect it from any direct contact with the rain.

Do not clean the device with products that may make damages on the plastic box or LCD.

Only qualified staff must do maintenance.

It is avoid the opening of the device by not authorized personals.

Do not repair blown or defective fuses but replace them with fuses having equivalent
characteristics.

Promptly disconnect the unit in case of electric power failure.

WARNING
If used correctly and in accordance with the instructions provided by Cz S.r.l. this
instrument present no hazard for operators.
The manufacturer shall not be liable for failures and other consequences deriving from
incorrect operations on the part of operators.

OPERATING MANUAL

SAFETY RULES

1.2

For the use

Carefully read though this operation manual before switching on power.

Keep protective wearing and behave properly

Avoid contact with wet hands.

Ensure that the mains outlet is properly connected to the ground.

Use only the supply cables supplied and ensure that the insulation is in good condition.

Do not touch the high-tension cables present into the engine compartment when this is
operating.

Stop the vehicle using the parking brake, (if the vehicle is equipped with), insert running idle,
(or in case of automatic gear, parking position), and lock the wheels.

Inside the exhaust gas of the vehicles, both diesel and gasoline are present many poisonous
substances dangerous for the health. It is necessary to assure a good ventilation of the room
and anyway into closed rooms it is obligatory the use of a suction system.

Pay attention to the moving devices on the vehicle. Particularly the electric fans may start
even when the vehicle is switched off.

Use proper protections in case the noise emissions are more than the prescription of the law.

Do not smoke, and do not use free flames or sparks sources near to the vehicle.

Protect the face, arms and legs to avoid contact with hot surfaces of the vehicle.

Be careful when you are operating near to the converter.

Do not unscrew the radiator cap while the engine is running or still warm.

Do not let tools near the battery to avoid accidental contacts.

1.3

Disposal

Separate electrical, electronic, plastic and ferrous parts before demolishing the instrument.

Dispose of the material in recycling bins as required by local regulations in force.

SAFETY RULES

10

OPERATING MANUAL

MAIN FEATURES

2.1

Hardware

Power Supply:
1030 Vdc (Vehicle battery).
Universal mains adapter 90260 Vac 4760 Hz input.
Display:
Back lighhted colour TFT 6.4 LCD VGA resolution 640 X 480 pixel
Keyboard:
Emulated onscreen alphanumerical keyboard directly operated from the touch
screen.
Also compatible with external keyboard.
Hardware platform:
Low-power 300 MHz personal computer.
Operating System:
Proprietary Linux embedded distribution.
Memory card :
64 Mbyte.
Printer :
Dot matrix, 24 columns.
Connection ports:
Standard PS2 external keyboard;
Standard RS 232 (DB9);
Via Bluetooth (optional)
Standard LAN IEEE 802.3 10/100Mbps, network connection;
N. 2 USB ports for software upgrades, EOBD autodiagnosis, module and/or external
serial connections via USB/serial converter (not supplied), and possible external
printer (optional);
Aux CRT video output, 640 X 480 @ 65536 colours not interlaced;
Internal RPM input (RDI). In COMBI version the Diesel pickup cable is supplied on
request;
Engine oil temperature sensor input.

OPERATING MANUAL

11

MAIN FEATURES

2.2

Generals

Dimensions:
W = 400 mm, H = 200 mm, D = 340 mm
Weight:
~7 Kg
Operating temperature:
+ 5 C + 40C
Storage temperature:
25 C + 70C
Operating Air Pressure range:
815 1060 mbar.
Clock:
Date and time on print, built-in internal lithium battery.

2.3

Metrological characteristics

Gas measurement range:


CO:
0 9.999 %
CO corrected: 0 9.999 %
CO2:
0 19.00 %
HC:
O2:

0 14000 ppm vol (hexane equivalence)


0 25.00 % vol

LAMBDA:

0.8 1.2

CO:
CO2:

0.001 %
0.01 %

HC:
O2:

1 ppm vol
0.01 % vol

LAMBDA:

0.001

Resolution:

MAIN FEATURES

12

OPERATING MANUAL

RPM counter range (Internal RDI input) with inductive clamp:


0 9990 rpm
RPM counter range (Internal RDI input) optional external ripple conversion adapter :
0 9990 rpm
Rpm resolution:
10 rpm
Oil Temperature measurement (PT 1000):
5 110 C
Nominal exhaust measuring aspiration capacity:
8 litres / minute
Flow control:
Automatic
Leak test:
Automatic and manual
Condensate drain:
Continuous
Zero:
Automatic
Periodic calibration:
With the use of sample filters and a periodic-checkup software page which is
protected by password
Lenght of the gas sample probe for car:
10 m

2.4

Conformity

General:
Directive 98/37/CEE.
Electromagnetic Compatibility (Directive 89/336 ECC)

OPERATING MANUAL

13

MAIN FEATURES

PREPARING FOR USE

3.1

Package content

The device comes in a special carton.


The total weight of the packaged unit is approx 8 Kg ca.
The package contains the following material:

Universal mains adapter

Exhaust sampling probe for cars

Picture 3.1

Picture 3.2

Oil temperature probe

Inductive clamp

Picture 3.3

Picture 3.4

NOTE
We recommend you do not dispose of the packaging, because it will provide protection
if you need to transport the device.

ATTENTION
The instrument must be kept in a close, clean and dry place, avoid that
atmospheric agents and/or other corrosive substances could be in contact with
the instrument.
Ensure that all the parts listed are contained in the case, if any parts are missing
or damaged contained your local dealer.
PREPARING FOR USE

14

OPERATING MANUAL

3.2

Installation
Remove the instrument from the package and put it on the working
surface or on the specific trolley (optional).

Follow the instructions provided below and bear in mind that all the
unions and connectors are located in the rear part of the unit.

3.3

Picture 3.5

Connection

Insert the plug of the UNIVERSAL MAINS ADAPTER (Picture 3.1) to mains power.

Connect the plug of the UNIVERSAL MAINS ADAPTER to the POWER INPUT CONNECTOR
(Ref.10 Pict.3.6).

To use the Gas analyzer using the vehicle battery:


1)

Connect the plug of the Power Supply Battery cable cod. 1060068 (optional) to the
POWER INPUT CONNECTOR (See Ref.10 Pict.3.6).

2)

Connect the power cable clamp to the car battery, making sure you maintain polarity:
the black clamp to the negative pole (-) and the red clamp to the positive pole (+).

Connect the drain pipe for condensate (optional) to the CONDENSATE OUTPUT joint
(Ref.15 Pict. 3.6).

Connect the EXHAUST SAMPLING PROBE* (Pict. 3.2) to the GAS INPUT (Ref.16 Pict. 3.6).

Connect the OIL TEMPERATURE PROBE (Picture 3.3) to the OIL TEMPERATURE PROBE INPUT
connector (See Ref.11 Pict. 3.6).
ATTENTION
Make sure gas outlets is not obstructed by foreign objects as this could prevent
correct operation.

Connect the INDUCTIVE CLAMP CABLE (Pict. 3.4) to the RPM INPUT (Ref.12 Pict. 3.6).

* Follow the specific indications given below for measuring vehicle or motorcycle exhaust
emissions.
OPERATING MANUAL

15

PREPARING FOR USE

3.4

Rear view description


1

5
6
7
8
9

16

15

13
14

13

12

11

10

Picture 3.6

Legend
1.

Active carbon filter

2.

Main filter

3.

Power swicht

4.

Fuse

5.

AUX CRT video output

6.

Keyboard connection

7.

LAN network connector

8.

USB ports

9.

RS 232 Serial port

10. Power Supply input


11. Oil temperature probe input
12. Rpm input
13. O2 and NO sensor housing
14. Gas out
15. Condensate drain
16. Gas input
PREPARING FOR USE

16

OPERATING MANUAL

3.5

Frontal view

Picture 3.7

Legend
1. Display TTF with Touch screen
2. Printer ( 24 columns)

3.6

Technical data plate

The technical data plate is affixed on the lower side of the smoke meter.

Picture 3.8

OPERATING MANUAL

17

PREPARING FOR USE

USE OF THE PROGRAM

4.1

Description

The EGA 903 gas analyzer programme can handle all measurement operations either in
conformity with specific regulations or in a casual mode for a quick diagnosis.
Are the procedures are visualised by pages with
graphic symbols (buttons, sensible areas, etc..).
To select the desired function, touch on the screen with
a finger the defined area.
For regular use, the programme does not require the
use of a keyboard.
However it is possible to connect an external keyboard in order to enter in the data fields provided
the characteristics of the vehicle being tested.
The graphic interface opens with an initial page where the various options listed below can be
selected; this page is referred to as MAIN MENU.

4.1.1 Buttons description


The button

allows the exit from the program.

The button HELP

allows to enter into pages dedicated to the description of the functions and the

buttons present on the visualised page.

The button ARCHIVES FILES

allows entering the page stored reports during the tests

(See Chapter 8).


The button BACK

USE OF THE PROGRAM

present in some displays, allows coming back to the previous page.

18

OPERATING MANUAL

4.1.2 Alphanumeric keyboards


In some operative pages, by the selection of some
dedicated areas for the insertion or the correction of
data, on the screen appears an alphanumeric
keyboard.
The keyboard on the display has the same features
and use of a normal PC keyboard:

Button CAPS: to enter small and capital


letters, the numbers on the symbols (!,,,$,%;&;/, etch.)

Button BS (Back Space): to cancel letters one by one.

Button ESC: to exit from the display without the confirmation.

Button OK: to give confirmation on the text visualised.

Space bar: to insert empty spaces.

4.2

Settings

Select SETTINGS from the Menu page to go in the


next page:
The display thus present the following functions:

LANGUAGE: to select the language used.

WORKSHOP DETAILS: to enter repair shop


data: name, address, etc. These data will be
included in the heading of the test report
printouts.

DATE AND TIME: to enter hour, minutes, seconds, day, etc. using the numerical keyboard
provided.

Touchscreen ADJUST: to adjust the position of the cursor with respect to the finger
contact position.

SYSTEM: to access the settings pages for smoke meter operation.

OPERATING MANUAL

19

USE OF THE PROGRAM

4.2.1 Language
When you select the LANGUAGE function in the
SETTINGS page the page shown here will be displayed,
indicating the languages currently available.
The item which is not highlighted is the language
currently used.

Press the button

to come back to the SETTINGS page.

4.2.2 Workshop details

Select WORKSHOP DETAILS from the SETTINGS page.


The data entered in the respective fields are shown in
the heading of the test report printouts.
To change a value use the editing panel which
contains the data (white background).
Every time you select a field for the item you want to
modify, an alphanumerical keyboard will appear.

Press OK to confirm and to save the data.


Press the button

USE OF THE PROGRAM

to come back to the SETTINGS page.

20

OPERATING MANUAL

4.2.3 Date and Time setting


By selecting DATE AND TIME SETTING from the SETTINGS page, it visualized the following
page.
Correct setting of date and time is necessary to
enable update of installed programmes (e.g. periodic
checkup) and to produce complete printouts.
Select the white background area for the value to be
modified. When the background changes (from white
to yellow) it means that the value may be reset, using
the keyboard next to it.

Press OK to confirm the insertion of data.

4.2.4 Touch screen adjust


By selecting Touchscreen ADJUST from the SETTINGS page, it visualized the following page.

The calibration procedure is guided throughout by a set of messages that indicate all the steps to
be performed.
NOTA
The gas analyzer is already configured before delivery, however if there are inaccuracies
in the use of the touch screen, we suggest you carry out the calibration procedure.
OPERATING MANUAL

21

USE OF THE PROGRAM

4.2.5 Setup/Calibration Measurements

Select SYSTEM from the SETTINGS page, to


enter the following page.
From the SYSTEM page access the submenus which
include settings that are particularly important for the
efficiency of the gas analyzer.

ATTENTION
Some settings are restricted and access to them is allowed only after entering a
password.
Select SETUP/CALIBRATION from the SYSTEM, to enter the following page.
The

system

then

displays

the

page

SETUP/CALIBRATION where you must select GAS


ANALYSER SETUP/CALIBR.

The menu GAS ANALYSER SETUP/CALIBR contains options in several pages; use the PgUP
and PgDown arrows to scroll through these pages.

Select MEASUREMENTS.

USE OF THE PROGRAM

22

OPERATING MANUAL

You then access the page shown here, which displays


the default values entered in the gas analyzer at the
factory.
On this screen, it is possible to activate or deactivate
the oxygen and NOX sensor.

It is also possible to adjust certain parameters such as the alarm value for low aspiration flow
conditions, depression threshold for activation of the leak test alarm and setting of autozero time.
NOTE
We recommend you maintain the values configured at the factory.

4.2.6 Setup/Calibration - Identification

Select IDENTIFICATION from the GAS ANALYSER SETUP/CALIBR page.


ATTENZION
Access and modification is allowed only after entering the required password.

In the IDENTIFICATION page you can check and/or


modify the identification data of the gas analyzer
(Example: Brand, Model, Approval no., etc.).

OPERATING MANUAL

23

USE OF THE PROGRAM

4.2.7 Printer settings

Select PRINTER SETTINGS from the SYSTEM page, to enter the following page.
It is possible to set up the printer that you wish to use
to print out the test reports:

INTERNAL when you use the printed supplied


with the gas analyzer;

USB: when you use another printer connected


to the USB port of the smoke meter.

ATTENTION
Printing out of graphs (see MULTIMETER chapter) is possible only with an external
printer (via USB port).

USE OF THE PROGRAM

24

OPERATING MANUAL

GAS ANALYSER

5.1

Test selection

The main menu of the GAS ANALYSERs operation


programme, includes two main tests:

- FREE TEST: used to carry out opacity tests without applying any particular regulation.
This test is ideal for an initial inspection of emissions, their consistency, their progress over time
and in relation to changes in engine conditions.
- GRAPHIC TEST: used to carry out opacity tests without applying any specific requirements in
the operating procedure.
The test results are displayed both in numerical form (digital) and in graphic form (single
parameters shown on coordinates against time).
At the end of the all test (GRAPHIC TEST excluded) you can print out all the values measured
during the tests.
With the REPORT function, present in the main menu GAS ANALISER, you can enter and save
the print report in the REPORT ARCHIVE (See chapter 8) and then print it out at a later time, or
print it out directly with the printer that you have previously set up (See paragraph 4.2.7).

OPERATING MANUAL

25

GAS ANALYSER

5.2

Free test

After performing the procedure required to connect the smoke meter to the test vehicle:
Select GAS EMISSIONS from the MAIN MENU.
Select FREE TEST from the GAS ANALYSER.
The first page relates to the characteristic data of the
vehicle being tested.
When you select one of the fields with white
background, relating to the items displayed (Make,
Model, etc.), an alphanumerical keyboard will appear
where you can enter/modify the text.
Press the

key to start the test in FREE

mode; after an auto-zero phase, the


measurement page will be displayed.
If necessary, the exhaust analyser carries out an initial WARM UP cycle.
Periodically (once a day) the exhaust analyser asks to carry out a LEAK TEST, to check for leaks
in the pneumatic circuit of the exhaust analyser (See paragraph 9.2).
The analyser then automatically carries out an AUTOZERO phase.
The

measurement

page

displays

the

following

parameters in numerical form (digital):

Emission (CO, CO2, O2, Hc, NOx);

Values calculated
(CO correct, Lambda factor );

Rpm (also in graphic form).

Engine oil temperature (OIL).

At the end of the test, based on the setting of the REPORT function in the GAS ANALYSER menu
(see paragraph 5.1) you can press PRINT to print out or save a test report.
FREE TEST

26

OPERATING MANUAL

5.2.1 Oil temperature measurement

The field OIL displays, during the test, the temperature of the

motor oil measured by a temperature probe supplied with the


gas analyzer.
The temperature probe must be inserted onto the oil level
control rod of the tested vehicle.
To enter the probe correctly, place the rubber stop (See Ref.1
- Pict.5.1) and use the length of the original rod for reference.

Picture 5.1

ATTENTION
When inserting the temperature probe in its seat, make sure you do not wind the
cable inside the motor compartment.

5.2.2

Rpm measurement

The rpm field displays the number of engine revolutions; this


measumente uses the internal rev counter and can be performed
in two different ways:
1)

Connect the inductive clamp to the first cylinder of the


engine of the tested vehicle, with the direction
indicated by the arrow on the inductive clamp
(See picture 5.2).

2)

Connect the inductive clamp to an adaptor/rev counter (type-

Picture 5.2

approved) according to the instructions provided with the


instrument.
Select the rpm field, a drop menu will appear to apply, if necessary, a
suitable division factor for the number of revolutions based on the
engines number of strokes.
OPERATING MANUAL

27

FREE TEST

5.3

Graphic test

After performing the preliminary procedure:


Select GAS EMISSIONS from the MAIN MENU.
Select GRAPHIC TEST from the GAS ANALYSER.
The first page relates to the characteristic data of the
vehicle being tested.
When you select one of the fields with white
background, relating to the items displayed (Make,
Model, etc.), an alphanumerical keyboard will appear
where you can enter/modify the text.

Press the

key to start the test in

GRAPHIC mode; the measurement page will be displayed.


If necessary, the exhaust analyser carries out an initial WARM UP cycle.
Periodically (once a day) the exhaust analyser asks to carry out a LEAK TEST, to check for leaks
in the pneumatic circuit of the exhaust analyser (See paragraph 9.2).
The analyser then automatically carries out an AUTOZERO phase.
The parameters visualized is:

Emission (CO, CO2, O2, Hc, NOx);

Values calculated
(CO correct, Lambda factor );

Rpm (also in graphic form).

The graphic representation over time is extremely useful to assess the behaviour of emissions
with the changing of engine conditions (for example with changes in rev number).
GRAPHIC TEST

28

OPERATING MANUAL

5.3.1

Rpm measurement

The rpm field displays the number of engine revolutions; this


measumente uses the internal rev counter and can be performed
in two different ways:
1)

Connect the inductive clamp to the first cylinder of the


engine of the tested vehicle, with the direction
indicated by the arrow on the unductive clamp
(See Picture 5.3).

2)

Connect the inductive clamp to an adaptor/rev counter

Picture 5.3

(type-approved) according to the instructions provided with the instrument.

Select the rpm field, a drop menu will appear to apply, if necessary,
a suitable division factor for the number of revolutions based on the
engines number of strokes.

OPERATING MANUAL

29

GRAPHIC TEST

5.3.2 Buttons description


The GRAPHIC test, through the specific buttons,
allows recording the signal of the single parameters,
for making a post analysis of its waveform.
The following keys are used for the registration and
display operation.
allows recording the displayed

The button
parameters.
Press button

to stop recording, after that press:

A) The button

to restart recording.

B) The button

To see the patterns from the moment you have stopped recording.

After that, it is possible to begin a new recording or to stop when desired the pattern of the signal
under test, pressing
C) The button

.
To clean the display from any pattern.

You have to press again


D) The button
The button

to restart the pattern visualization.

To save into RAM memory (Temporary) the recorded pattern.


may appear in two cases:

After having saved by button

, the recording of the pattern, or after having pressed

to

stop the visualization of the wave, in the instant you desired.


After having pressed button

, the back of the graphic window became grey and

consequently the following buttons are enabled: memorizing start


back

and

; memorizing end

forward of one page.Using such buttons, it is possible to examine on the

screen moment by moment the patterns of the captured signal.


Press button

GRAPHIC TEST

to come back to the visualization live of the signal of the graphic to examine.

30

OPERATING MANUAL

AUTODIAGNOSIS

The AUTODIAGNOSIS function it is able to manage


the data exchange useful for the diagnostic of the
vehicle.
This is between the electronic board (EOBD protocol)
and the EGA 903 Gas analyzer by the USB to the
Lastertool interface (See Pict. 6.1).

There are different numbers and types of data from the


electronic board, generally, they are divided in:

Parameters

Errors

Actuators

States

ISO

Picture 6.1

Select AUTODIAGNOSIS to enter the PARAMETERS display.

6.1

Parameters

To activate the communication with the electronic


board of the vehicle follow the instruction on the
display (Example: Turn the Key ON and press
ENTER).
The program enters into the diagnostic test visualizing
the Parameters at disposal.
In case these are not at disposal as first page, we will
have the one of errors or states.
OPERATING MANUAL

31

AUTODIAGNOSIS

When the communication is activated, it is possible


to see on the display the single parameters selecting
the fields beside the name of the parameter.
The electronic board gives the values given by the
different components of the engine (Example: RPM
sensor, timing sensor, temperature, etc.), in real
time.
If the parameter at disposal are more than the eight visualized into the page the user may
substitute the parameter selecting the kind and then push the button

or

to make

possible the appearing of the desiderate parameter .


To go in the previous or following pages of testing push button

or

The icon with the red arrows you see in the right up corner of the page
indicates that the communication is active. The absence of the arrows
indicates that the communication has not been activated or is lost.
The button

can be used to save in the REPORT ARCHIVE (See Chapter 8), the list of

enabled PARAMETERS with the corresponding value measured in that moment.


The software allows visualizing also the parameters in
a graphic way.
Select maximum four parameters and push
button

In this way will be visualized a page with some


patterns.
Pressing button

, you will activate a dedicated

page where it is possible to set the value of the time axle (sec/div) and min. and max values of
the examined parameters.
AUTODIAGNOSIS

32

OPERATING MANUAL

Select the field of the value to modify.


Then the alphanumeric keyboard appears and allows
entering the new value.

After that press OK to confirm settings or press


ESC to exit from the page.

The button

allows recording the displayed parameters .

Press button

to stop recording, after that press:

A) The button

to restart recording.

B) The button

To see the patterns from the moment you have stopped recording. After that, it

is possible to begin a new recording or to stop when desired the pattern of the signal under test,
Pressing
To clean the display from any pattern. You have to press again

C) The button

to

restart the pattern visualization.


D) The button
The button

to save into RAM memory (Temporary) the recorded pattern.


may appear in two cases:

After having saved by button

, the recording of the pattern, or after having pressed

to stop the visualization of the wave, in the instant you desired.

After having pressed button

, the back of the graphic window became grey and

consequently the following buttons are enabled:


Memorizing start

OPERATING MANUAL

; memorizing end

; back

33

and

forward of one page.

AUTODIAGNOSIS

Using such buttons, it is possible to examine on the


screen moment by moment the patterns of the
captured signal.
Press button

to come back to the

visualization live of the signal of the graphic to


examine.

can be used to save in the REPORT ARCHIVE (See Chapter 8), the

The button

previously saved record into RAM memory, with button

6.2

Errors

The picked errors occurred during the working of the


vehicle are stored in a permanent memory.
In this way, the user may check if the problem
verifies sometime (in some specified conditions) or if
it always present.

The

warning

signal

indicates

the

presence of still being faults (ATT) or


stored (MEM).

The ERRORS page gives information about the kind

of problem.
The user has to make the repair and then to continue
with the cancellation of the fault inside the memory of
the electronic board.
AUTODIAGNOSIS

34

OPERATING MANUAL

If making a new test the memory does not contain


more faults it means that it has been corrected.
To erase the fault it is necessary to visualize the
ACTUATORS page and select Fault Erase.

The system will then display the page shown here,


which can be used to cancel the error.

The button

can be used to save in the REPORT ARCHIVE(See Chapter 8), the list of the

all possible present errors in that moment..

6.3

Actuators

The ACTUATORS page allows to activate, for some


second, different components of the engine to test
the correct working (injectors, coils, RPM counter...).
The number and kind of the actuators depends from
the type of the electronic board.

The operator can decide the duration test, in some systems, in other case the duration is fixed by
the program installed into the electronic module under test.

OPERATING MANUAL

35

AUTODIAGNOSIS

6.4

States

The page STATES shows the state of some inputs or


outputs of the electronic module, showed as ONOFF (Start the engine, A/C Compressor, Lambda).
The number and kind of conditions depends from the
electronic board under test.

The button

key can be used to save in the REPORT ARCHIVE (See Chapter 8), the list of

enabled STATES with the corresponding condition detected in that moment.

6.5

ISO

The ISO page resumes all the information from the


electronic module under test:

ISO Code

Hardware Version

Software Version

The button

can be used to save in the REPORT ARCHIVE (See Chapter 8), the list of the

information visualized.

AUTODIAGNOSIS

36

OPERATING MANUAL

MULTIMETER

7.1

Description

The MULTIMETER function present in the diagnostic system has been designed for specific use
in the auto-diagnosis field.
The instrument makes it possible to measure electric values such as resistance and voltage.
These values can be displayed in numerical or graphic form.

Picture 7.1

Connect the Volt/Ohm cable (cod. 1090014) to LasterTool module and use the right pins (red
and black) to make measurements (See Pict.7.1).
In case of graphic display, it will be possible to record the variation of the width, according to the
time, in order to be able to check in quality and quantity the exact signal.
OPERATING MANUAL

37

MULTIMETER

The Multimeter allows recording the signal for making a post analysis of its waveform
To use such function a present standard symbolic buttons, working is the same way of the
graphic recording of the diagnostic device.

allows selecting the right measurement unit.

The button

In the proper field is displayed VOLTAGE or RESISTANCE according to the previous selection.

it is possible to change the measurement scale, this gives a more

Pressing button

precise display of the signal under test.


is used to make variation of the value in second per division, that is

The button

the modification of the time scale (from 1 sec/div. to 60 sec/div.), indicated in the up left side of
the page.
The button

allows resetting the value of the signal under test in order to make a correct

measurement.
The button

allows recording the graphic movement concerning the electric signal under test.

Press the button

A) The button
B) The button

to stop recording, after that press:

to restart recording.
to see again the graphic display from the moment the recording has been

stopped. After that, it is possible to begin again a new recording or stop, at the desired moment,
the graphic of the signal under test pressing

C) The button

to clean the display. It is necessary press

D) The button

To save in RAM memory (Temporary) the recorded graphic.

MULTIMETER

38

to restart the graphic display.

OPERATING MANUAL

The button

may appear in two cases:

After having saved by button

, the recording of the pattern, or after having pressed

to

stop the visualization of the wave, in the instant you desired.

After having pressed button

, the back of the graphic window became grey and

consequently the following buttons are enabled:


; memorizing end

Memorizing start

; back

and

forward of one page.

Using such buttons, it is possible to examine on the screen moment by moment the patterns of
the captured signal.

Press button

to come back to the visualization live of the signal of the graphic to

examine.

The button

allows to store into the report archive (See Chapter 8), the previously saved

record into RAM memory, with button

OPERATING MANUAL

39

MULTIMETER

LIST TEST REPORTS

The List Test Reports represents the archive which stores all the data saved after the gas test
reports (after pressing the PRINT key), and the graphs produced with the Multimeter
measurements.

The list indicate all the information (Description,


Date, Brand and model, license plate).

The button DISPLAY PRINTING allows seeing print


preview of the selected report.
Pressing DELETE PRINTING, it is possible to erase
the report previously selected.
This is an example of a report printout preview.

LIST TEST REPORTS

40

OPERATING MANUAL

This is an example of a graphic printout preview.

Pressing button SEQUENCE MODE you obtain a sequence of images, which correspond for
each image to a subdivision for a period of 30 sec. of the completely stored graphic.

In the area with the yellow background is indicated


the number of the visualized image and the total
number

of

images

making

the

graphic.

(Example: 1/3 = image 1 of 3).

Press

to pass images.

Press

to print.

The report will be printed out by the printer that you have previous set up in gas analyzer EGA
903 (INTERNAL or USB).
Remember that graphs can only be printed out with an external printer.

NOTE
The printer connected to the EGA 903 has to be PCL protocol compatible.

OPERATING MANUAL

41

LIST TEST REPORTS

MAINTENANCE

9.1

Description of the operations

The gas analyzer must be kept in perfect running order by means of regular maintenance
operations which the user must carry out personally.
To enable correct gas measurement, the following maintenance operation are of fundamental
importance:

Weekly: Leak Test of the pneumatic circuit and search for any blockages in the exhaust
sampling probe;

Depending on the type of filters: cleaning and/or substitution;

When indicated by the instrument: substitution of the Oxygen and/or NOx sensor;

Yearly: Periodic inspection (described in the Service Manual), performed by an Authorized


Service Centre; the due date for the periodic check in indicated in the print report;

9.2

Extraordinary maintenance.

Leak Test

The verification consists of checking the pneumatic circuit above the measuring chamber for
leaks.
The programme automatically carries out the leak test if this
has not already been carried out during the day.
Alternatively, the Leak Test verification can be carried out
from the measuring pages using the appropriate button.

Close the end of the sampling probe using the lid supplied

Pict. 9.1

(See Picture 9.1).


Keep the end of the probe closed until the programme gives permission to do otherwise.
MAINTENANCE

42

OPERATING MANUAL

The programme will automatically start the exhaust pump, aspirating air from the circuit.
During the verification, the programme analyses the depression value in the measuring chamber.
A few seconds later the pump is stopped, thereby checking for the presence of any leaks in the
circuit.
Where no leaks are detected, the programme notifies the user to remove the lid from the probe,
otherwise an error message will give a negative test result.
Please bear in mind that, in the event the test should fail, the measurements are halted.

ATTENTION
Remember that good maintenance of the filtering system is vital for ensuring that the
instrument lasts well throughout the course of time.

OPERATING MANUAL

43

MAINTENANCE

9.3

Maintenance of the filters

The analysers main filtering system is made up of two filters, one


with microfibre (white) and one with a stainless steel mesh.
Both the filters are inserted into a beaker from which the pump
automatically drains off the condensation water.
Operation to be carried out:

Switch off the device and remove the power supply wire.

Unscrew and remove the beaker (Pict. 9.2).

Remove the microfibre filtering part and unscrew the flange

Pict. 9.2

securing the steel filter (Pict. 9.3).

Clean out the steel intake filter on a monthly basis


(with water and soap, then dried with compressed air, including
the beaker).

Dry using compressed air blown from the inside towards the
outside of the filter.

Replace the microfibre filtering cartridge on a weekly basis.

Replace the cartridge in its support, and the whole set in its
original position.

Pict. 9.3

Reassemble the beaker.

With regard to the vehicle exhaust sampling probe:

Check and/or substitute the paper filter installed on the tube on a weekly basis.

With regard to the motorcycle exhaust sampling probe:

The filtering part installed in the exhaust sampling system should be checked, emptied and
washed (with water and soap, then dried with compressed air, including the beaker) on a
daily basis.

The paper filter mounted on the connecting tube between the motorcycle exhaust analyser
and exhaust sampling system should be checked and/or replaced on a daily basis.

MAINTENANCE

44

OPERATING MANUAL

9.4

Replacement of the Oxigen and /or NOx Sensor

In this case, the operation is prompted by the programme which automatically detects the
reduced remaining lifespan of the Oxygen and/or NOx sensor.
As a result, when the Oxygen and/or NOx sensor has been exhausted, the relevant error message
is displayed while the instrument is in usage, and measurements are halted.
To replace the sensor, proceed as follows:

Switch off the device and disconnect the power supply cable.

Disconnect the sensors connector.

Unscrew the sensor.

Write the replacement date on the case of the new sensor.

Install the new sensor by screwing it onto the rear block and connect the relevant connector.
NOTE
The spare parts are only available from CZ Srl and are exclusively distributed by
authorised dealers.

9.5

Periodic Inspection
NOTE
The PERIODIC INSPECTION operations are to be performed exclusively by authorized
CZ Srl Service Centres.

In case of doubts and/or malfunctions, please contact the closest authorised dealer.

9.6

Extraordinary maintenance
NOTE
The EXTRAORDINARY MAINTENANCE operations are to be performed exclusively by
authorized CZ Srl Service Centres.

In case of doubts and/or malfunctions, please contact the closest authorised dealer.

OPERATING MANUAL

45

MAINTENANCE

9.7

Error messagges

The following is a list of error messages that could appear on the screen of the gas analyzer.
ERROR
CODE

MESSAGE

DESCRIPTION

SOLUTION

F1/6

ABSOLUTE PRESSURE
SENSOR FAULTY

--

Request assistance of authorized


Technical Service Centre

F1/5

DIFFERENTIAL PRESSURE
SENSOR FAULTY

--

Request assistance of authorized


Technical Service Centre

F1/4

NO SIGNAL FROM I-RED


DETECTOR

--

Request assistance of authorized


Technical Service Centre

F1/3

O2 SENSOR AT ITS END OF


LIFE

The oxygen sensor is worn out

Replace the oxygen sensor

F1/2

NOX END OF LIFE

The NOx sensor is worn out

Replace the Nox sensor

CHAMBER GAS
TEMPERATURE TOO HIGH

The temperature of the cell


measuring tube has reached
values that are above the
metrological limits, the cell has
therefore been certified.
From the metrological point of
view, it is no longer guaranteed
that the rules of reference will be
respected.

F1/1

The message is a warning, it is not


necessarily a malfunction signal.
If, for example, the analyser has
been in a hot place for a long period
of time (e.g. in the sun) the message
may appear.
Wait for normal conditions to return.

CHAMBER GAS
TEMPERATURE TOO LOW

The temperature of the cell


measuring tube has reached
values that are above the
metrological limits, the cell has
therefore been certified.
From the metrological point of
view, it is no longer guaranteed
that the rules of reference will be
respected.

The message is a warning, it is not


necessarily a malfunction signal.
If, for example, the analyser has
remained in a cold place for a long
time, the message might appear.
Wait for normal conditions to return.

F2/6

REFERENCE VARIATION
TOO BIG

The device has been subjected to


a sudden temperature change, or
it is excessively dirty.

Wait for normal conditions to return


and perform an autozero.
If the problem persists, replace the
filtering parts, the internal tubes and
clean the cell measuring tube.

F2/5

OVERPRESSURE IN GAS
TUBE

Excessive pressure has been


detected within the measuring
tube.

The operator might have blown


compressed air into the analyser
intake.

F2/4

UNDERPRESSURE
ABSOLUTE

--

Request assistance of authorized


Technical Service Centre

F2/3

OVERPRESSURE ABSOLUTE

Excessive pressure has been


detected within the measuring
tube.

The operator might have blown


compressed air into the analyser
intake.

F1/0

MAINTENANCE

46

OPERATING MANUAL

ERROR
CODE

MESSAGE

F2/2

LOW FLOW

F2/1

CO CHANNEL TOO LOW

F2/0

CO2 CHANNEL TOO LOW

F3/6

HC CHANNEL TOO LOW

F3/5

REF CHANNEL TOO LOW

OPERATING MANUAL

DESCRIPTION

Obstruction of the exhaust


sampling line or presence of
water.

SOLUTION
Check for the presence of any
obstructions in the exhaust sampling
probe.
Empty out any condensation present
in the separator.
Clean and substitute any filtering
elements.
Perform an autozero.

The device is excessively dirty.

47

If the problem persists, replace the


filtering parts, the internal tubes and
clean the cell measuring tube.

MAINTENANCE

9.8

Replacement of the paper roll and/or ink


ribbon

To change the paper roll, proceed as follows:

Open the printer cover and press down the swinging


support of the print mechanism at thr point marked
PUSH;
Insert the end of the paper roll in the slit of the print
mechanism and position the paper roll so that it rotates
in the right direction, as shown in the figure;
Press the FEED key, a few centimetres of paper
automatically feed out of the printer;
Re-close the swinging support. Tear off the paper and reclose the cover.
PRECAUTIONS
Make sure the paper edge is straight before inseerting it in the machine.
Do not print when there is no paper and/or ribbon: this leads to rapid deterioration of
the needles.
Do not pull the printer carriage manually when the printer is ON.
Do not put objects inside the printer.
Avoid blows to any part of the printer, both during and after installation.
To replace the ink ribbon, proceed as follows:
Open the printer cover and remove the old ribbon cartridge by pressing at the point
marked PUSH;
Insert the new ribbon, making sure that it is correctly positioned;
Pull theribbon toght by turning the knurled knob and close the printer cover.
MAINTENANCE

48

OPERATING MANUAL

10

FITTINGS AND SPARE PARTS


Description

Code

Universal Mains Adapter

1030002

Inductive clamp

1610004

Oil temperature probe

2610003

Exhaust sampling probe

PFSONDA GAS EGA

Filter 27.40.7w

1240001

Single Seat trolley (Optional)

PFCARRELLO

Power supply battery cable (Optional)

1060068

NOTE
We recommend you use original spare parts and/or accessories.
To order the required part contact your closest CZ dealer.
OPERATING MANUAL

49

FITTINGS AND SPARE PARTS

Cz S.r.l.
Via Campanini, 3/a - 43100 PARMA - ITALY
Telefono: 0521 798280 Fax 0521 707654
e-mail: info@cz-dynamic.it
Internet: http://www.czdynamic.com

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