Diesel Common Rail Piezo - TDI (VW) - proline

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