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With this teaching and training rig all functions and processes, errors and measuring values can be demonstrated and examined without emissions as they are in the original engine. All original parts and required components are clearly arranged in the IPO-principle on the color printed front panel. The required power supply, wiring and component configuration are already integrated into the system and preset, ready for operation. This means the system can be put into operation immediately upon setup.
At a glance
Features
Original parts, Original injection pressures
Measuring of all relevant parts and components in the central circuit diagram measuring field
Arrangement in the IPO principle: input - processing - output
Can be diagnosed via OBD interface
Fault circuit, lockable by a lid
Connection for student circuit diagram measuring desks
Compact device build, mobile, for lab and workshop practice
Learning Objectives
TDI injection technology: Naming components of the entire engine management system and explain their interaction
Working with original schematics and specify problem-oriented connector pins on components and control unit
Determining reference values depending on operating situation
Using common OBD diagnostic tools for the workshop
Measuring and assessing sensor signals and actuator control voltages, recording CAN-bus signals with the oscilloscope and assessing signal levels
Making screen-shots of all signals, all control voltages and the CAN data-bus with a digital oscilloscope and storing them for customer-specific documentations
Examples for exercises
Verification of the power supply side plus and minus side
Verification of the sensors - with multimeter and oscilloscope: power supply, signals, component testing
Verification of the actuators - with multimeter and oscilloscope: supply voltage, control signals, duty cycle, component testing
Determining the influence of various sensors on the different actuators. Recording and evaluating the control of the actuators corresponding to the input information
Representation of the pressure conditions in relation to the sensor signals and engine speed
Recording and evaluation of the speed-dependent injection time and the regulation of the amount injected in relation to the preselected sensor signals
Practical errors: detect and evaluate cable breaks and corrosion resistances
Self-diagnosis with OBD diagnostic tool (original tester)
Equipment
Proline system cart with cabinet, construction in a closed housing
Front panel design with color digital printing, circuit diagrams, components and symbols, protective film
8 x large digital color displays
Original: Ignition start switch with transponder, instrument cluster with control unit immobilizer, engine control unit TDI, fuel pressure sensor (rail pressure) with digital display, fuel temperature sensor with switch for simulation mode and selector switch adjustable from -25 to 110°C
Simulation: Air mass meter (HFM6) continuously adjustable with digital display, boost pressure continuously adjustable with digital display, intake air temperature adjustable from -25 to 60°C with selector switch, temperature sensor coolant input and output each adjustable from -25 to 110°C with selector switch, lambda sensor value continuously adjustable
Original: Hall sensor for camshaft, position sensor for crankshaft, pedal value sensor infinitely variable, diagnostic interface, throttle valve unit with throttle valve drive and angle sensor for throttle valve position, exhaust gas recirculation valve with sensor for exhaust gas valve position, servomotor for intake manifold valve with sensor for valve position, fuel piezo injection valves cylinders 1 to 4 where the injection process is visible at cylinder 4 through sight glass - digital display of the injected fuel quantity
brake light switch, motor speed controller
Original: Fuel pressure control valve, valve for fuel dosing, glow time control unit, fuel pump relay 1 and 2 simulation: Exhaust gas pressure infinitely variable with digital display, exhaust gas temperature sensor 1 / 3 / 4, with selector switch adjustable from 200 to 800°C, control of valve boost pressure limitation, position of boost pressure regulator infinitely variable, fan control coolant, control of coolant circulation pump 2, control of switch valve for radiator exhaust gas recirculation
Activation via LED's is indicated: control valve fuel pressure, valve fuel metering, valve boost pressure limitation, radiator fan, pump 2 for coolant circulation, fuel pump relay 1 and 2, annealing time for Q1, Q2, Q3 and Q4, heating lambda sensor
Original: High pressure pump, rail, piezo injectors and high pressure lines, speed sensor wheel and original speed sensor, camshaft wheel and original camshaft sensor, second drive unit with speed sensor wheel and camshaft sensor wheel, synchronous running to the high pressure pump unit
73 x measuring sockets in 4mm safety version, Connection for error switchgear and decoupler to student measuring desks
Detailed documentation and extensive worksheets for teachers and students