Maintenance Guide CCP800 series

Emissions Tester
CCP800 series

Maintenance Guide
I324565 Issue B

Crypton - A Brand of the Continental Corporation

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 Maintenance Guide CCP800 series Maintenance Guide CCP800 series

1 Vehicle Exhaust Gas Analyser (VEGA) Maintenance

1.1 Water Trap 1.4 O2 Sensor
Daily
Do not use any chemical based products to Check pipe and probe tip for damage.
clean the water trap. Soapy water and gently Gently with an airline blow down the
airline. probe to remove any blockages or
moisture. Don’t leave the sample hoses
on the workshop floor when not in use,
always return them to the trolley. I f
unmaintained this may cause low flow
errors, leak test failures and/or terminal
gas bench errors.

1.3 Filter Bowls

Do not use any Chemical based products to
clean the water trap. Soapy water and gently Annually
airline. O2 sensor will need to be checked and/or
replaced every 6 - 12 months depending
on your usage. It is recommended that
you keep a spare available on site.

Daily
2 Diesel Smoke Meter (DSM) Maintenance
Remove any moisture from the water trap
and check that the ‘o’ rings are not
damaged or pinched. 2.1 Clean Optics 2.3 Clean Charging Pins
Add a small amount of inert silicone Do not use chemical based cleaning products (Bluetooth Version)
petroleum jelly around the top of the on the optics Always return to the cradle when not in use.
water trap where the o ring sits. This may
cause terminal gas bench failure and Weekly
possible low flow issues if maintenance is Weekly Clean the charging pins at least once a
not carried out correctly. Remove excess moisture from all filter week to avoid corrosion. If unmaintained
bowls (Replace filter weekly if required) you may have communication issues
and check that the o rings are not and/or early life battery failure.
1.2 Sample Probe damaged or pinched. Add a small amount
Do not use any chemical based products to of inert silicone petroleum jelly around the
clean the water trap. Soapy water and gently top of the water trap where the o ring sits 2.4 Sample Pipe
airline. to help create a seal. This may cause
terminal gas bench failure and possible
low flow or contamination issues if As required
maintenance is not carried out correctly. Under normal circumstances the sampling
head does not require cleaning. If a
Monthly sampling pipe becomes restricted with
Remove dirt from the lens with a clean deposits, the test results can be affected.
cloth or alcohol wipe. If unmaintained this To clean a sampling pipe, remove the
may cause zero drift issues. More detail sample probe from the smoke head. Blow
available in the operators manual. through the sample pipe only, using
compressed air.

2.2 Smoke Head Cable (cable DO NOT BLOW THROUGH THE

version) SMOKEHEAD.
Always return to the cradle when not in use.
Daily
Ensure cable is kept clean and unkinked.
Failure to maintain may cause
communication problems.

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 Maintenance Guide CCP800 series Maintenance Guide CCP800 series

3 CCP800 series Trolley & Ancillaries Maintenance 4 Vehicle Exhaust Gas Analyser (VEGA) Fault Finding
3.1 Trolley Power 3.4 RPM Device (Battery Tach) 4.1 Leak Test Failure
The system is drawing in air, possible causes of a leak test failure are faulty joints, particularly in
sample probe/hose assembly and between the two filter bowls. Damaged 'O' ring seals of filter
Daily bowls, particularly if filters have just been changed.
At the end of the day shut down the PC
and then turn the power off using the 4.2 Checks
switch on the side of the trolley leaving ■ Pump operation - Is the pump running?
the unit plugged in and switched on at the ■ Disconnect sample hose from the gas analyser
mains. Failure to follow this process may ■ Block the sample inlet and re-test
lead to poor charge in the batteries and ■ If problem cured, inspect joints for leaks/damage
not enough to complete a test. ■ Ensure flexible probe is not damaged
To minimise the risk of unstable readings ■ In cases of extreme exhaust gas temperature the PTFE liner may melt and cause leak test
load the battery by turning on headlights, failure
fog lights etc. Keep the cabin fan off as this
3.2 Bluetooth Oil Temp Probe may introduce interference. Some modern
vehicles may not be detected due to “smart 4.3 Sample probe/hose assembly
charging systems” cutting the charge when
the battery does not require it. This is not a
fault with the equipment.

Always return the probe back to the holster Check flexible P.T.F.E liner
when not in use. Failure to follow this inside braiding. Replace the
process may lead to poor charge in the flexible probe end if
necessary.
batteries and not enough to complete a test.

3.3 Oil Temp Probe Length Check joints

■ If the test still fails, ‘pinch off’ the pipe immediately after the gas filter bowl (see Fig 3.
overleaf) and retest.
■ If problem cured, check all joints on sample inlet and filter bowl assembly, particularly the
Always adjust the probe to the correct length
prior to starting a test, it should be 10mm bowl to bowl adapter.
shorter than the dipstick. ■ Unscrew filter bowls and ensure the 'O' rings are in good condition and have not been
Failure to follow this process may cause not 'pinched' during assembly.
only probe but engine damage.
Fig. 3

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Maintenance Guide CCP800 series Maintenance Guide CCP800 series

5 Battery Smoke Meter

(DSM) Fault Finding
4.4 Gas Analyser not 5.1 Battery Charging Smoke head returned to Charging Cradle: To check the charging voltage at the
communicating ■ FAST CHARGE (2.5 flashes per charging cradle:
The DX260-1BT wireless Smoke head contains second): The Smoke head is in ‘Fast ■ Connect a digital multi-meter set to
■ Check mains supply OK and the analyser a Multi-Cell Rechargeable Battery designed to Charge’ Mode. The battery should fully measure up to 30V DC to the two
module is switched on give a maximum of 1.5 hours endurance from charge within 1.5 hours charging
■ Check communication cable a full charge. ■ Connectors on the charging cradle and
■ Check platform Config for conflicts ■ TOP-UP CHARGE (1 flash per second): depress the central charging switch
The smoke head must always be replaced The Fast Charge cycle has completed and ■ A voltage of 28V to 30V DC should
on the charging cradle in between tests. the battery is being brought to full charge register on the multi-meter display
4.5 LHC Residue Test Failure
It is also strongly recommended that the ■ SLOW CHARGE (1 flash every 2
■ Check sample probe in free air, blow out batteries be completely discharged on a 5.5 Battery Replacement
sample probe & pipe assembly if required seconds): The Smoke head battery is in
monthly basis by setting the program to ‘Slow Charge’ mode, the charging rate
■ Change gas filters if heavily contaminated Live Readings with the smoke head off the
and wash filter bowls with warm soapy determined by either terminal voltage or,
charger. battery cell temperature
water
Please note that rechargeable batteries have a
finite lifespan, therefore the battery pack will
4.6 Low Gas Flow need to be replaced periodically if the smoke 5.3 Battery Charging cont.
head is no longer sustaining sufficient charge
Ensure that the filters have been removed and for correct operation. ■ TRICKLE CHARGE (1 flash every 3
cleaned or replaced, sample probe has been seconds): LED Flashing ON/OFF shows
checked for damage and blockages. the smoke head battery is in ‘Trickle-
5.2 LED Indication
Charge’ mode indicating that the batteries
Smoke head removed from charging are fully charged.
4.7 High Lambda Readings
cradle:
The system is drawing in air, please ensure the 5.4 Fault Diagnosis:
following – All filter bowls are undamaged and ■ LED ‘On’ continuously: Smoke head is
sealed (hand tight and a little bit, do not over running on internal battery
■ FAST FLICKER (8 flashes per second or
tighten or you will damage the o ring). Sample more): The smoke head has detected
probe and pipe are undamaged and ■ LED pulsing ‘ON’ for 2 seconds, ‘OFF’ poor charging contacts. Clean the
connections are tight. for 0.5 seconds: Smoke head battery contacts on both the cradle and the
has reached a Low Voltage condition, and smoke head feet and replace on charger
has less than 10 minutes life left before
4.8 Remove Probe from Exhaust auto-shutdown. ■ LED NOT ILLUMINATED: Return the
message (at beginning of an MOT Smoke head to Charging Cradle. LED
test) ■ LED ‘OFF’: Low Voltage condition. should display according to Charging level
Smoke head will auto shut down. No more required.
Check the O2 sensor two pin connector is still testing possible until smoke head battery
connected and the millivolt reading is no less has been recharged. ■ LED NOT ILLUMINATED WHEN
than 7 millivolts. SMOKEHEAD IS ON CHARGING
If the smoke head has received no CRADLE: Check that the smoke head is
communication from host computer for over correctly seated on the charging cradle.
6 minutes it will go into ‘Sleep’ mode. Return The smoke head has twin connectors on
the smoke head to the charging unit to invoke each insulated foot, and may be
a response. connected either way round.

If the smoke head is taken outside its Check the charging cradle is connected to the
maximum operating range of about 100 240V AC mains
metres, and wireless communication is no
longer possible, after 6 minutes the smoke Check that the sprung connectors that
head will go into ‘Sleep’ mode. transmit the charging current on the
charging cradle are clean and not stuck in
a depressed condition.
To recover from ‘Sleep’ mode, the smoke head
should be put back in its charging cradle, and Check that the charging connectors on the
the LED function observed. insulated mounts on underside of the
smoke head are clean and free of dirt and
obstructions.

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Maintenance Guide CCP800 series Maintenance Guide CCP800 series

Removal:- Replacement: ■ Refit the lens housing with the arrow

■ Unscrew the knurled knob (1) and open ■ Your new battery pack is supplied with the pointing upwards (a little silicon grease on
up both end caps. activation link in the ‘transit’ position the 'O' ring will assist fitment – but do not
■ Remove the four pan head screws (2) & (marked ‘X’) see Fig. 1. This must be get on lens!)
(3) securing both end plates and carefully moved to the ‘Live’ position (Marked ‘√’) ■ Refit the end cap and tighten the knurled
ease the plates clear of the housing to activate the battery before it is installed knob
■ At the fan end, disconnect the 2-pin into your smoke head, see Fig. 2
battery plug (4a) and the 2-pin fan plug ■ Slide the new battery pack into position NOTE:
(4b) (note orientation) Ensure the end cap locates fully against
■ At the probe end, disconnect the 3-pin ■ Re-connect the 2-pin plug (4a), the 2-pin the body of the sampling head before
plug (5) plug (4b), and the 3-pin plug (5) tightening the knob. If not correctly
■ Depending on which version you have ■ Relocate the end plates to the smoke located, the lens housing is probably not
either - loosen the two screws (6a) or head and loosely secure with 4 pan head fully home.
remove the plastic spacer (6b) securing screws (7)
the battery pack ■ Check that the lens housings are fully 1. Clean the lens at the other end of the
■ Discard the two securing screws or the located, then fit the end caps and secure smoke head in the same way.
plastic spacer– they are no longer with the knurled knob. Fully tighten the
required knurled knob then slacken half a turn (8) NOTE:
■ Push the end plate upwards as far as it will The end cap for the sampling pipe must
Note: go, and then fully tighten the 4 pan head be fitted at the end away from the
screws. sampling head cable.
The orientation and remove the battery ■ Fully tighten the knurled knob on the end
pack. Do not remove by pulling the caps
cables, and ensure the connectors do not
foul any components during removal of 5.8 Cable & Fan Removal
the board. 5.6 Lens Cleaning

Move the activation link from the transit Two lenses are fitted in the smoke head, one
position Fig. 1 to the live position Fig. 2. at either end. The smoke meter checks the
cleanliness of the lenses at the start of each
test, and the PC will provide a warning when
cleaning is required.

Should the cable become damaged and

require renewal, the procedure is as
follows:
■ Unscrew the knurled knob (1) and remove
the end cap
■ Remove the four countersunk screws (2)
Fig. 1 - Activation link - Transit position which secure the internal fan and grille to
the smoke head end plate
■ Remove the four pan head screws (3)
securing the end plate and carefully ease
the plate clear of the housing
■ Disconnect the 4-pin multi-plug (4a). If
New orientation of lens housing (arrow up) carrying out a fan replacement disconnect
the 2-pin plug (4b) and replace the fan.
Carefully fit the fan and fan grille to the
5.7 Accessing a lens end plate (4 countersunk screws)
■ Remove the 4 wires from the 4-way plug.
■ If fitted, remove the sampling pipe Undo the metal cable clamp from the end
Fig. 2 – Activation link – Live position ■ Unscrew the knurled knob at the sampling
pipe end of the sampling head and plate. Loosen the cable gland strain relief
remove the end cap. and remove the cable from the end plate
■ Carefully pull out the lens housing and ■ Re-fit the new cable through the cable
wipe the lens with a soft cloth (if required, gland strain relief and secure to the end
a little methylated spirit will assist plate with the metal clamp (Important:
cleaning) secure the clamp on the earth braid of the
cable). Re-fit the 4-way plug. Ensure the

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Maintenance Guide CCP800 series Maintenance Guide CCP800 series

6 Vehicle Exhaust Gas Analyser (VEGA)

Consumables
cable gland strain relief is tightened
■ Connect the 4-pin multi-plug (4a) and the
2-pin plug (4b)
■ Locate the end plate to the smoke head
(cable on left hand side) and loosely A2C88837300
secure with the four pan head screws Primary Filter
■ Check that the lens housing is fully in,
then fit the end cap and secure with the 680EN1
knurled knob. Fully tighten the knurled
knob then slacken half a turn
■ Push the end plate upwards as far as it will
go, and then fully tighten the 4 pan head
screws A2C87827300
■ Fully tighten the knurled knob on the end Gas Filter
cap 680EN1

5.9 Adjusting Oil Temperature

Probe Length
Before testing, the probe must be adjusted A2C1839470000
to the correct length as follows: Gas Filter
Lay it alongside the vehicle dipstick (see 682EN1
illustration) and adjust the position of the
depth stop until the effective length of the
probe is approximately 10mm shorter than
the dipstick.
A2C1839450000
Water Filter
682EN1

A2C88114200
Pre-Filter
680EN1 & 682EN1

A2C88660300
Sample Probe End
WARNING: 680EN1 & 682EN1
ENSURE THAT THE OIL
TEMPERATURE PROBE IS SET TO
THE CORRECT DIPSTICK LENGTH
AND THAT IT IS CLEAN FROM A2C87844900
DEBRIS BEFORE INSERTING INTO Sample Probe (Complete)
THE ENGINE. FAILURE TO DO SO 680EN1 & 682EN1
MAY RESULT IN SERIOUS DAMAGE
TO THE PROBE AND/OR ENGINE.

A2C88396300
Oxygen Sensor aka O2 Cell
680EN1 & 682EN1

A2C88028300
Filter Bowl O Rings
680EN1

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 Maintenance Guide CCP800 series Maintenance Guide CCP800 series

7 Diesel Smoke Meter (DSM) Consumables 8 Product Support 9 Contact

Apart from the routine maintenance and Sales
adjustments stipulated in this manual the +44 121 725 1400
Sample Hose equipment must not be tampered with in any salesorders@continental-
A2C88171800 way. All further servicing must be carried out corporation.com
DX.260/270 Sample Hose only by an engineer from our Authorised
Agents. Failure to observe these conditions Support
will invalidate the Guarantee. +44 121 725 1366
uksupport@continental-
10.1 UK Customers corporation.com
Battery Tacho Power/Sensing cable If you require a Service Engineer to attend ON
A2C87921500 SITE within the UK, for any of the following Continental Automotive Trading UK
CDSS3/4/6 Battery Tach reasons: Ltd
■ An equipment fault 36 Gravelly Industrial Park
■ For machine calibration Birmingham
■ You need spare parts B24 8TA
■ Equipment covered by this manual United Kingdom
Tacho Comms Cable requires returning for factory overhaul.
A2C89483300
CDSS6 COMMS CABLE 2M 10.2 Overseas Customers
Service and spare parts cover outside the UK
is provided by the agent from whom your
equipment was purchased.

Battery Tacho Power/Sensing Cable

A2C89024000
CDSS6 Vehicle Socket Cable

Cable – Smokehead Cable Assembly

A2C89189200
DX.260 Fixed Outlet Cable 10M
Disposal of equipment

Battery Pack ■ Do not dispose of this equipment as miscellaneous solid municipal waste
A2C88489000 but arrange to have it collected separately.
DX.260BT Battery Pack
■ The re-use or correct recycling of electronic equipment (EEE) is important
in order to protect the environment and the wellbeing of humans.

■ In accordance with European Directive WEEE 2002/96/EC, special

Fan Kit collection points are available for the delivery of waste electrical and
electronic equipment.
A2C88247300
DX.260 Fan Kit ■ The public administration and producers of electrical and electronic
equipment are involved in facilitating the processes of the re-use and
recovery of waste electrical and electronic equipment through the
Oil Temperature Probes organisation of collection activities and the use of appropriate planning
A2C89335700 arrangements.
Oil Temperature Probe 0.75M
A2C89424100 ■ Unauthorised disposal of waste electrical and electronic equipment is
punishable by law with appropriate penalties.
Oil Temperature Probe 2.5M
Temperature Probe Adapters
A2C88830200
Wireless Probe Adapter
A2C88694100
5m cabled Adapter

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 Maintenance Guide CCP800 series
Continental Automotive Trading UK Ltd, 36 Gravelly Industrial Park, B24 8TA
Tel: 0121 725 1366 | Email: support@cryptontechnology.com | Web: www.cryptontechnology.com
Crypton - A Brand of the Continental Corporation

Legal notice
Errors and omissions excepted. The Company reserves the right to introduce
improvements in design or specification without prior notice. The sale of this product
is subject to our standard terms, conditions and relevant product warranty.

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