Cutaway Battery EC-520_52945 Rev. 2026/01 consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product EC-520 Cutaway battery PRODUCT SPECIFICATIONS The EC-520 Cutaway Battery is the ideal aid for teaching battery principles and allows visualisation of the inner parts. Designed to work in lawn mowers, lawn and garden tractors, small tractors, loaders, backhoes, 4-wheelers, gen- erators, and motorcycles. No electrolyte for educational purposes. • Battery Type : Lead Acid (without electrolyte) • BCI Group Size : U1 • Cold Cranking Amps : 300 amps • Cranking Amps : 375 amps • Deep Cycle/Starting : Starting • Height : 7 5/16 in (18 cm) • Lenght : 7 3/4 in (19 cm) • Width : 5 13/16 in (15.5 cm) • Maintenance Free : Yes • Terminal type : Top Terminal • Voltage : 12 Vdc • Weight : 17 lbs (7.75 kg)

Instructors Manual for EM-123-2_053251 Two wheel hydraulic brake system EM-123-2-96_V2024-1 © ConsuLab Educatech Inc, 2024. All rights reserved. EM-123-2_053251-96 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 © ConsuLab Educatech Inc, 2024. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. The content of this manual is applicable to models 053251 and above. Table of Contents Introduction 4 Application 4 Features 4 Student assignments Answers SA1 — Master Cylinder Inspection Service Answers 6 SA1-A — Master Cylinder Remove/Replace Answers 7 SA2 — Brake Pad Replacement Answers 10 SA2-A — Front Brake Disc Inspection Answers 15 SA3-A — Rear Brake Drum Inspection and Service Answers 17 consulab.com info@consulab.com 4 EM-123-2_053251-96 Introduction Introduction The ConsuLab EM-123-2_053251 is a two-wheel hydraulic brake system with disc and drum that can be used to see the functionality of a typical non-ABS braking system as it operates on a real vehicle. The trainer is built with OEM compo- nents and is based on the Honda Civic platform. The trainer can be used in the classroom environment for demonstra- tions to students. It provides a safe and effective method of learning the principles of hydraulic braking systems used on today’s vehicles. Application Non-ABS Honda Civic Features • Real OEM automotive components with fully functional disc/drum hydraulic braking system including : - All OEM hydraulic components - OEM Brake pedal and parking brake pedal - OEM Power brake booster - OEM Parking brake components • Fully functional parking brake system • Fits through a standard 30” door opening • Heavy duty metal stand with casters for easy transport (two fixed and two swivel w/locks) • All routine brake service procedures can be performed on this trainer including : - Master cylinder service - Brake pad/shoe replacement - Disc/Drum service - Wheel bearing service - Caliper/Wheel cylinder service - Brake hose/line service - Parking brake service - Brake inspection - Lug nut torque - Tire isentification and inspection consulab.com info@consulab.com 5 EM-123-2_053251-96 Student assignments Answers Student assignments Answers consulab.com info@consulab.com 6 EM-123-2_053251-96 SA1 — Master Cylinder Inspection Service Answers SA1 — Master Cylinder Inspection Service Answers 1. Look up related service information first. 2. Inspect and note these items : 3. Check that all parts are free of dirt and other foreign particles. Why ? So no dirt falls into the brake fluid upon inspection. 4. Do not allow dirt or foreign matter to contaminate the brake fluid. Why ? Because it’s brake fluid! We don’t want dirt to contaminate a safety systems operation. 5. Clean up work area and return tools to the proper place, hand in worksheet. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 7 EM-123-2_053251-96 SA1-A — Master Cylinder Remove/Replace Answers SA1-A — Master Cylinder Remove/Replace Answers (3 pages) 1. Look up related service information first. 2. Special tools required ? Fluid removal syringe, line wrenches, rags. 3. Be careful not to damage or bend the brake lines during removal and installation. 4. After removal, plug the ends of the hoses and the joints to prevent spilling brake fluid. Why ? Avoiding contamination, brake fluid is hygroscopic, and to prevent damage. 5. Remove the reservoir cap and brake fluid from the master cylinder reservoir with a syringe. 6. Disconnect the brake fluid level switch connector (A). 7. Remove the reservoir tank mounting bolt (B). consulab.com info@consulab.com 8 EM-123-2_053251-96 SA1-A — Master Cylinder Remove/Replace Answers 8. Disconnect the brake lines (A) from the master cylinder (B). To prevent spills, cover the hose joints with clean rags or shop towels. To prevent spills, cover the hose joints with clean rags or shop towels. * Learning moment here ! 9. Remove the master cylinder mounting nuts (C) and washers (D). 10. Remove the master cylinder from the brake booster (E). Be careful not to bend or damage the brake lines when removing the master cylinder. If new master is installed, compare rod length! (see below). 11. Remove the rod seal (F) from the master cylinder. NOTE : During installation, set the new rod seal onto the master cylinder with its grooved side (G) toward the master cylinder. 12. Do not try to disassemble the master cylinder assembly. 13. Honda recommends replacing the master cylinder assembly with a new part if necessary. Why ? Most modern cylinders are made from aluminum and rebuilding requires a process called honing, which removes some metal from the inside of the cylinder, making it bigger and less likely to seal as well. consulab.com info@consulab.com 9 EM-123-2_053251-96 SA1-A — Master Cylinder Remove/Replace Answers 14. Reinstall the master cylinder with a new rod seal in the reverse order of removal, and note these items : • Coat the inner bore lip and outer circumference of the new rod seal with the Shin-Etsu silicone grease (P/N 08798- 9013). • Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves. • Check the brake pedal height and free play after installing the master cylinder, and adjust if necessary. • If the reservoir tank hose was disconnected, install the reservoir tank (A) and the reservoir tank hose (B) to the sub-reservoir (C). - NOTE : Align the ‘‘Δ ‘’ marks (D) on the reservoir tank and sub-reservoir with the paint marks (E) on the hose. Posi- tion the direction of the clamp (F). 15. Bleed the brake system (See SA-4 worksheet). 16. Spin the wheels to check for brake drag. Why ? Always verify repairs, but any time a master cylinder to booster is disturbed, the relationship between the master cylinder piston and push rod could have changed. This could result in the hydraulics being applied slightly even when the pedal is not being depressed, causing the wheels to drag. Left unattended, this will cause the brakes to heat up and lock up even more, possibly damaging brake linings. 17. Clean up work area and return tools to the proper place, hand in worksheet. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 10 EM-123-2_053251-96 SA2 — Brake Pad Replacement Answers SA2 — Brake Pad Replacement Answers (5 pages) 1. Look up related service information first. 2. Special tools required ? Caliper piston compressor, slide lube, vernier caliper 3. Any safety cautions to be observed ? • Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. • Avoid breathing dust particles. • Never use an air hose or brush to clean brake assemblies. • Use an OSHA-approved vacuum cleaner. 4. Check the thickness (A) of the inner pad (B) and the outer pad (C). Do not include the thickness of the backing plate. Brake pad thickness : Standard specifications : 9.6 - 10.2 mm (0.378 - 0.402 in) Service Limit specifications : 1.6 mm (0.063 in) Inner pad Outer pad 5. If any part of the brake pad thickness is less than the service limit, replace the brake pads as a set. consulab.com info@consulab.com 11 EM-123-2_053251-96 SA2 — Brake Pad Replacement Answers Replacement of pads 6. Remove some brake fluid from the master cylinder. Why ? Because in a disc brake system, the fluid takes up the space for pad wear and so when compressing piston back into caliper the fluid will push back into the master cylinder reservoir and overflow if full to start. 7. Remove the flange bolt (A), and pivot the caliper body (B) up out of the way. 8. Secure caliper up with a tie strap. Why ? We don’t want the weight of the caliper to be hanging with the bake hose – it could damage hose. 9. Check the hose and pin boots for damage and deterioration. 10. Remove the pad shims (A) and the brake pads (B). 11. Remove the pad retainers (A). consulab.com info@consulab.com 12 EM-123-2_053251-96 SA2 — Brake Pad Replacement Answers 12. Clean the caliper bracket (B) thoroughly; remove any rust, and check for grooves and cracks. Verify that the caliper pins (C) move in and out smoothly. Clean and lube if needed. 13. Inspect the brake disc for runout, thickness, parallelism, and check for damage and cracks. *** See Student Activity SA2-A. 14. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the retainer mating surface of the caliper bracket (indicated by the arrows). 15. Install the pad retainers. Wipe off the excess assembly paste from the retainers. Keep the assembly paste away from the brake disc and the brake pads. 16. Install the brake caliper piston compressor tool (A) on the caliper body (B). 17. Press in the piston with the brake caliper piston compressor tool so the caliper body will fit over the brake pads. 18. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper body down. consulab.com info@consulab.com 13 EM-123-2_053251-96 SA2 — Brake Pad Replacement Answers 19. NOTE : Be careful when pressing in the piston; brake fluid might overflow from the master cylinder’s reservoir. Why ? See above 20. If brake fluid gets on any painted surface, wash it off immediately with water. 21. Remove the brake caliper piston compressor tool. 22. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the pad side of the shims (A), the back of the brake pads (B) and the other areas indicated by the arrows. 23. Wipe off the excess assembly paste from the pad shims and the brake pads friction material. 24. Keep grease and assembly paste away from the brake disc and the brake pads. Contaminated brake disc or brake pads reduce stopping ability. 25. Install the brake pads and the pad shims correctly. 26. Why are shims needed ? Noise reduction, anti-squeal 27. Install the brake pad with the wear indicator (C) on the upper inside position. 28. NOTE : If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a temporary loss of braking efficiency. consulab.com info@consulab.com 14 EM-123-2_053251-96 SA2 — Brake Pad Replacement Answers 29. Pivot the caliper body down into position. Install the flange bolt (A), and tighten it to the specified torque. 30. Press the brake pedal several times to make sure the brakes work. 31. NOTE : Engagement may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. Why ? Pumping the pedal moves the caliper piston back into contact with the pad where is stays for correct brake applica- tion. 32. Add brake fluid as needed. 33. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Test-drive the vehicle, then recheck for leaks. 34. Clean up work area and return tools to the proper place, hand in worksheet. 35. Have instructor check work Name : Group : Date : Instructor : Grade : Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 15 EM-123-2_053251-96 SA2-A — Front Brake Disc Inspection Answers SA2-A — Front Brake Disc Inspection Answers (2 pages) 1. Look up related service information first. Thickness and Parallelism 2. Remove the brake pads. 3. Using a micrometer (A), measure the brake disc thickness at eight points, about 45 ° apart and 10 mm (0.39 in) in from the outer edge of the brake disc. 4. Replace the brake disc if the smallest measurement is less than the maximum refinishing limit. 5. Brake disc thickness : Standard specifications : 20.9 - 21.1 mm (0.823 - 0.831 in) Maximum refinishing limit specifications : 19.0 mm (0.748 in) Brake disc parallelism* specifications : 0.015 mm (0.00059 in) max. * This is the maximum allowable difference between the thickness measurements. 6. Is this rotor within spec’s ? Runout 7. Inspect the brake disc to wheel surface for damage and cracks. Clean the brake disc thoroughly, and remove all rust. 8. Install suitable flat washers (A) and wheel nuts (B), and tighten the wheel nuts to the specified torque to hold the brake disc securely against the hub. 9. Set up the dial gauge (C) against the brake disc as shown, and measure the runout at 10 mm (0.39 in) from the outer edge of the brake disc. consulab.com info@consulab.com 16 EM-123-2_053251-96 SA2-A — Front Brake Disc Inspection Answers 10. Brake disc runout specifications : Service limit : 0.04 mm (0.0016 in) If the brake disc is beyond the service limit, refinish the brake disc with a Honda-approved commercially available on-car brake lathe. Maximum refinishing limit : 19.0 mm (0.748 in) Actual runout measured : NOTE : If the brake disc is beyond the service limit for refinishing, replace it. If the brake disc is replaced with a new one, check the new disc for runout. If the new disc is out of specification, refinish the disc. 11. Clean up work area and return tools to the proper place, hand in worksheet. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 17 EM-123-2_053251-96 SA3-A — Rear Brake Drum Inspection and Service Answers SA3-A — Rear Brake Drum Inspection and Service Answers (2 pages) 1. Look up related service information first. 2. Release the parking brake, and remove the brake drum. 3. Check the wheel cylinder (A) for leakage (See SA3-B). 4. Check the brake linings (B) for cracking, glazing, wear, and contamination. NOTE : Contaminated brake linings or drums reduce stopping ability. 5. Measure the brake lining thickness (C). Measurement does not include the metal brake shoe thickness. 6. Brake lining thickness specifications : Standard specifications : 4.0 mm (0.157 in) Service limit specifications : 2.0 mm (0.079 in) Actual measurement : 7. If any part of the brake lining thickness is less than the service limit, replace the brake shoes as a set. 8. Check the hub bearing unit (D) for smooth operation. If it requires servicing, replace the hub bearing unit. consulab.com info@consulab.com 18 EM-123-2_053251-96 SA3-A — Rear Brake Drum Inspection and Service Answers 9. Measure the inside diameter of the brake drum with inside vernier caliper. 10. Drum inside diameter specifications : Standard specifications : 199.9 200.0 mm (7.870 7.874 in) Service limit specifications : 201 mm (7.91 in) Actual measurement : 11. If the inside diameter of the brake drum is more than the service limit, replace the brake drum. 12. Check the brake drum for scoring, grooves, corrosion, and cracks. 13. Install the brake drum. 14. Clean up work area and return tools to the proper place, hand in worksheet. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2024. All rights reserved. Introduction Application Features Student assignments Answers SA1 — Master Cylinder Inspection Service Answers SA1-A — Master Cylinder Remove/Replace Answers SA2 — Brake Pad Replacement Answers SA2-A — Front Brake Disc Inspection Answers SA3-A — Rear Brake Drum Inspection and Service Answers

Operation manual for EM-123-2_053251 Two wheel hydraulic brake system EM-123-2-93_V2024-1 © ConsuLab Educatech Inc, 2024. All rights reserved. Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space https://www.consulab.com/customer-space EM-123-2_053251-93 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 © ConsuLab Educatech Inc, 2024. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. The content of this manual is applicable to models 053251 and above. Table of Contents Product Description 5 Application 5 Features 5 Technical Information 5 Component Identification 6 Operating Instruction 7 consulab.com info@consulab.com 4 EM-123-2_053251-93 Teachers Resources EM-123-2-95 Student Assignments Table of Contents EM-123-2_053251-95 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 © ConsuLab Educatech Inc, 2024. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. The content of this manual is applicable to models 053251 and above. Table of Contents Introduction 4 Application 4 Features 4 Student assignments SA1 — Master Cylinder Inspection Service 6 SA1-A — Master Cylinder Remove/Replace 7 SA2 — Brake Pad Replacement 10 SA2-A — Front Brake Disc Inspection 15 SA2-B — Front Brake Disc Refinishing 17 SA2-C — Front Brake Caliper Inspection 18 SA3 — Rear Brake Shoe Inspection and Replacement 19 SA3-A — Rear Brake Drum Inspection and Service 24 SA3-B — Wheel Cylinder Inspection and Service 26 SA4 — Bleeding Brake Service 27 SA5 — Wheel Lug Torque 29 EM-123-2-96 Instructors Manual Table of Contents EM-123-2_053251-96 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 © ConsuLab Educatech Inc, 2024. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. The content of this manual is applicable to models 053251 and above. Table of Contents Introduction 4 Application 4 Features 4 Student assignments Answers SA1 — Master Cylinder Inspection Service Answers 6 SA1-A — Master Cylinder Remove/Replace Answers 7 SA2 — Brake Pad Replacement Answers 10 SA2-A — Front Brake Disc Inspection Answers 15 SA3-A — Rear Brake Drum Inspection and Service Answers 17 consulab.com info@consulab.com 5 EM-123-2_053251-93 Product Description Product Description The ConsuLab EM-123-2_053251 is a two-wheel hydraulic brake system with disc and drum that can be used to see the functionality of a typical non-ABS braking system as it operates on a real vehicle. The trainer is built with OEM compo- nents and is based on the Honda Civic platform. The trainer can be used in the classroom environment for demonstra- tions to students. It provides a safe and effective method of learning the principles of hydraulic braking systems used on today’s vehicles. Application Non-ABS Honda Civic Features • Real OEM automotive components with fully functional disc/drum hydraulic braking system including: - All OEM hydraulic components - OEM Brake pedal and parking brake pedal - OEM Power brake booster - OEM Parking brake components • Fully functional parking brake system • Fits through a standard 30” door opening • Heavy duty metal stand with casters for easy transport (two fixed and two swivel w/locks) • All routine brake service procedures can be performed on this trainer including: - Master cylinder service - Brake pad/shoe replacement - Disc/Drum service - Wheel bearing service - Caliper/Wheel cylinder service - Brake hose/line service - Parking brake service - Wheel lug torque and tire specification identification Technical Information • Sturdy powder coated metal stand with two locking swivel and two fixed casters • Dimensions: H 54” x W 25” x D 64” (137.1 x 63.5 x 162.5 cm) H 60” x W 29” x D 68” (152.4 x 73.7 x 172.7 cm) with packaging • Weight: 320 lb (145 kg) / 360 lb (163.2 kg) ) with packaging consulab.com info@consulab.com 6 EM-123-2_053251-93 Component Identification Component Identification 5 6 1 3 2 4 1. Hydraulic Unit 2. Power Brake Booster 3. Brake Pedal 4. Emergency Brake 5. Drum Assembly 6. Disc assembly consulab.com info@consulab.com 7 EM-123-2_053251-93 Operating Instruction Operating Instruction 1. Make sure that the brake fluid reservoir level is adequate. 2. Pump the brakes with the brake pedal until pressure is correct to operate the hydraulic braking system. 3. Use the emergency brake to show how the wiring cable operates to actuate the braking mechanism. 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2024. All rights reserved. Product Description Application Features Technical Information Component Identification Operating Instruction

Student Assignments for EM-123-2_053251 Two wheel hydraulic brake system EM-123-2-95_V2024-1 © ConsuLab Educatech Inc, 2024. All rights reserved. EM-123-2_053251-95 Table of Contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 3 © ConsuLab Educatech Inc, 2024. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. The content of this manual is applicable to models 053251 and above. Table of Contents Introduction 4 Application 4 Features 4 Student assignments SA1 — Master Cylinder Inspection Service 6 SA1-A — Master Cylinder Remove/Replace 7 SA2 — Brake Pad Replacement 10 SA2-A — Front Brake Disc Inspection 15 SA2-B — Front Brake Disc Refinishing 17 SA2-C — Front Brake Caliper Inspection 18 SA3 — Rear Brake Shoe Inspection and Replacement 19 SA3-A — Rear Brake Drum Inspection and Service 24 SA3-B — Wheel Cylinder Inspection and Service 26 SA4 — Bleeding Brake Service 27 SA5 — Wheel Lug Torque 29 consulab.com info@consulab.com 4 EM-123-2_053251-95 Introduction Introduction The ConsuLab EM-123-2_053251 is a two-wheel hydraulic brake system with disc and drum that can be used to see the functionality of a typical non-ABS braking system as it operates on a real vehicle. The trainer is built with OEM compo- nents and is based on the Honda Civic platform. The trainer can be used in the classroom environment for demonstra- tions to students. It provides a safe and effective method of learning the principles of hydraulic braking systems used on today’s vehicles. Application Non-ABS Honda Civic Features • Real OEM automotive components with fully functional disc/drum hydraulic braking system including : - All OEM hydraulic components - OEM Brake pedal and parking brake pedal - OEM Power brake booster - OEM Parking brake components • Fully functional parking brake system • Fits through a standard 30” door opening • Heavy duty metal stand with casters for easy transport (two fixed and two swivel w/locks) • All routine brake service procedures can be performed on this trainer including : - Master cylinder service - Brake pad/shoe replacement - Disc/Drum service - Wheel bearing service - Caliper/Wheel cylinder service - Brake hose/line service - Parking brake service - Brake inspection - Lug nut torque - Tire isentification and inspection consulab.com info@consulab.com 5 EM-123-2_053251-95 Student assignments Student assignments consulab.com info@consulab.com 6 EM-123-2_053251-95 SA1 — Master Cylinder Inspection Service SA1 — Master Cylinder Inspection Service 1. Look up related service information first. 2. Inspect and note these items : 3. Check that all parts are free of dirt and other foreign particles. Why ? 4. Do not allow dirt or foreign matter to contaminate the brake fluid. Why ? 5. Clean up work area and return tools to the proper place, hand in worksheet. Name : Group : Date : Instructor : Grade : Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 7 EM-123-2_053251-95 SA1-A — Master Cylinder Remove/Replace SA1-A — Master Cylinder Remove/Replace (3 pages) 1. Look up related service information first. 2. Special tools required ? 3. Be careful not to damage or bend the brake lines during removal and installation. 4. After removal, plug the ends of the hoses and the joints to prevent spilling brake fluid. Why ? 5. Remove the reservoir cap and brake fluid from the master cylinder reservoir with a syringe. 6. Disconnect the brake fluid level switch connector (A). 7. Remove the reservoir tank mounting bolt (B). consulab.com info@consulab.com 8 EM-123-2_053251-95 SA1-A — Master Cylinder Remove/Replace 8. Disconnect the brake lines (A) from the master cylinder (B). To prevent spills, cover the hose joints with clean rags or shop towels. 9. Remove the master cylinder mounting nuts (C) and washers (D). 10. Remove the master cylinder from the brake booster (E). Be careful not to bend or damage the brake lines when removing the master cylinder. 11. Remove the rod seal (F) from the master cylinder. NOTE : During installation, set the new rod seal onto the master cylinder with its grooved side (G) toward the master cylinder. 12. Do not try to disassemble the master cylinder assembly. 13. Honda recommends replacing the master cylinder assembly with a new part if necessary. Why ? consulab.com info@consulab.com 9 EM-123-2_053251-95 SA1-A — Master Cylinder Remove/Replace 14. Reinstall the master cylinder with a new rod seal in the reverse order of removal, and note these items : • Coat the inner bore lip and outer circumference of the new rod seal with the Shin-Etsu silicone grease (P/N 08798- 9013). • Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves. • Check the brake pedal height and free play after installing the master cylinder, and adjust if necessary. • If the reservoir tank hose was disconnected, install the reservoir tank (A) and the reservoir tank hose (B) to the sub-reservoir (C). - NOTE : Align the ‘‘Δ ‘’ marks (D) on the reservoir tank and sub-reservoir with the paint marks (E) on the hose. Posi- tion the direction of the clamp (F). 15. Bleed the brake system (See SA-4 worksheet). 16. Spin the wheels to check for brake drag. Why ? 17. Clean up work area and return tools to the proper place, hand in worksheet. Name : Group : Date : Instructor : Grade : Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 10 EM-123-2_053251-95 SA2 — Brake Pad Replacement SA2 — Brake Pad Replacement (5 pages) 1. Look up related service information first. 2. Special tools required ? 3. Any safety cautions to be observed ? • • • • 4. Check the thickness (A) of the inner pad (B) and the outer pad (C). Do not include the thickness of the backing plate. Brake pad thickness : Standard specifications : Service Limit specifications : Inner pad Outer pad 5. If any part of the brake pad thickness is less than the service limit, replace the brake pads as a set. consulab.com info@consulab.com 11 EM-123-2_053251-95 SA2 — Brake Pad Replacement Replacement of pads 6. Remove some brake fluid from the master cylinder. Why ? 7. Remove the flange bolt (A), and pivot the caliper body (B) up out of the way. 8. Secure caliper up with a tie strap. Why ? 9. Check the hose and pin boots for damage and deterioration. 10. Remove the pad shims (A) and the brake pads (B). 11. Remove the pad retainers (A). consulab.com info@consulab.com 12 EM-123-2_053251-95 SA2 — Brake Pad Replacement 12. Clean the caliper bracket (B) thoroughly; remove any rust, and check for grooves and cracks. Verify that the caliper pins (C) move in and out smoothly. Clean and lube if needed. 13. Inspect the brake disc for runout, thickness, parallelism, and check for damage and cracks. *** See Student Activity SA2-A. 14. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the retainer mating surface of the caliper bracket (indicated by the arrows). 15. Install the pad retainers. Wipe off the excess assembly paste from the retainers. Keep the assembly paste away from the brake disc and the brake pads. 16. Install the brake caliper piston compressor tool (A) on the caliper body (B). 17. Press in the piston with the brake caliper piston compressor tool so the caliper body will fit over the brake pads. 18. Make sure the piston boot is in position to prevent damaging it when pivoting the caliper body down. consulab.com info@consulab.com 13 EM-123-2_053251-95 SA2 — Brake Pad Replacement 19. NOTE : Be careful when pressing in the piston; brake fluid might overflow from the master cylinder’s reservoir. Why ? 20. If brake fluid gets on any painted surface, wash it off immediately with water. 21. Remove the brake caliper piston compressor tool. 22. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the pad side of the shims (A), the back of the brake pads (B) and the other areas indicated by the arrows. 23. Wipe off the excess assembly paste from the pad shims and the brake pads friction material. 24. Keep grease and assembly paste away from the brake disc and the brake pads. Contaminated brake disc or brake pads reduce stopping ability. 25. Install the brake pads and the pad shims correctly. 26. Why are shims needed ? 27. Install the brake pad with the wear indicator (C) on the upper inside position. 28. NOTE : If you are reusing the brake pads, always reinstall the brake pads in their original positions to prevent a temporary loss of braking efficiency. consulab.com info@consulab.com 14 EM-123-2_053251-95 SA2 — Brake Pad Replacement 29. Pivot the caliper body down into position. Install the flange bolt (A), and tighten it to the specified torque. 30. Press the brake pedal several times to make sure the brakes work. 31. NOTE : Engagement may require a greater pedal stroke immediately after the brake pads have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. Why ? 32. Add brake fluid as needed. 33. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. Test-drive the vehicle, then recheck for leaks. 34. Clean up work area and return tools to the proper place, hand in worksheet. 35. Have instructor check work Name : Group : Date : Instructor : Grade : Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 15 EM-123-2_053251-95 SA2-A — Front Brake Disc Inspection SA2-A — Front Brake Disc Inspection (2 pages) 1. Look up related service information first. Thickness and Parallelism 2. Remove the brake pads. 3. Using a micrometer (A), measure the brake disc thickness at eight points, about 45 ° apart and 10 mm (0.39 in) in from the outer edge of the brake disc. 4. Replace the brake disc if the smallest measurement is less than the maximum refinishing limit. 5. Brake disc thickness : Standard specifications : Maximum refinishing limit specifications : Brake disc parallelism* specifications : * This is the maximum allowable difference between the thickness measurements. 6. Is this rotor within spec’s ? Runout 7. Inspect the brake disc to wheel surface for damage and cracks. Clean the brake disc thoroughly, and remove all rust. 8. Install suitable flat washers (A) and wheel nuts (B), and tighten the wheel nuts to the specified torque to hold the brake disc securely against the hub. 9. Set up the dial gauge (C) against the brake disc as shown, and measure the runout at 10 mm (0.39 in) from the outer edge of the brake disc. consulab.com info@consulab.com 16 EM-123-2_053251-95 SA2-A — Front Brake Disc Inspection 10. Brake disc runout specifications : Service limit : If the brake disc is beyond the service limit, refinish the brake disc with a Honda-approved commercially available on-car brake lathe. Maximum refinishing limit : Actual runout measured : NOTE : If the brake disc is beyond the service limit for refinishing, replace it. If the brake disc is replaced with a new one, check the new disc for runout. If the new disc is out of specification, refinish the disc. 11. Clean up work area and return tools to the proper place, hand in worksheet. Name : Group : Date : Instructor : Grade : Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 17 EM-123-2_053251-95 SA2-B — Front Brake Disc Refinishing Year and Model: VIN: Rotor Location: LF RF RR LR Rotor thickness before refinishing Rotor run-out before refinishing Rotor thickness variation (measure in 8 places): 1. 2. 3. 4. 5. 6. 7. 8. Attach to R.O. # Disc Brake Rotor Refinishing Worksheet © 2002 American Honda Motor Co., Inc. - All Rights Reserved GJA 24213 (0212) Date: Rotor Location: LF RF RR LR Rotor thickness before refinishing Rotor run-out before refinishing Rotor thickness variation (measure in 8 places): 1. 2. 3. 4. 5. 6. 7. 8. Thickest part Thinnest part Maximum variation Refinishing time overall min. Rough-cut time min. Fine-cut time min. – = Technician Signature Technician Number Rotor thickness after refinishing Rotor run-out after refinishing Thickest part Thinnest part Maximum variation Refinishing time overall min. Rough-cut time min. Fine-cut time min. – = Rotor thickness after refinishing Rotor run-out after refinishing Copyright 2009 - 2013 Service Repair Solutions, Inc. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. SA2-B — Front Brake Disc Refinishing consulab.com info@consulab.com 18 EM-123-2_053251-95 SA2-C — Front Brake Caliper Inspection SA2-C — Front Brake Caliper Inspection 1. Look up related service information first. 2. Remove, inspect, reassemble, and install the caliper, and note these items : • Make sure that the caliper pins are installed correctly. Upper caliper pin and lower caliper pin are different. - If these caliper pins are installed in the wrong location, it will cause vibration, uneven or rapid brake pad wear, and possibly uneven tire wear. • To prevent dripping brake fluid, cover disconnected hose joints with clean rags or shop towels. • Before reassembling, check that all parts are free of dirt and other foreign particles. - Make sure no dirt or other foreign matter gets in the brake fluid. • Make sure no grease or oil gets on the brake discs or pads. • When reusing brake pads, always reinstall them in their original.positions to prevent loss of braking efficiency. • Do not reuse drained brake fluid. Use only new Honda DOT 3 Brake Fluid from an unopened container. - Using a non-Honda brake fluid can cause corrosion and shorten the life of the system. • Use recommended greases in the front caliper set. 3. After installing the caliper, check the brake hose and line for leaks, interference, and twisting. 4. Clean up work area and return tools to the proper place, hand in worksheet Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 19 EM-123-2_053251-95 SA3 — Rear Brake Shoe Inspection and Replacement SA3 — Rear Brake Shoe Inspection and Replacement (5 pages) 1. Look up related service information first. CAUTION : Frequent inhalation of brake shoe dust, regardless of material composition, could be hazardous to your health. AVOID BREATHING DUST PARTICLES. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. 2. Release the parking brake, and remove the breake drum. 3. Check the wheel cylinder for leakage (See SA3-B). consulab.com info@consulab.com 20 EM-123-2_053251-95 SA3 — Rear Brake Shoe Inspection and Replacement 4. Remove the tension pins (A) by pushing the respective retainer springs (B), and turning the pin. 5. Remove the lower return spring (A), and remove the brake shoe assembly over the hub. 6. Remove the forward brake shoe (B) by removing the upper return spring (C), and disassemble the brake shoe assembly. 7. Remove the rearward brake shoe (D) by disconnecting the parking brake cable from the parking brake lever (E). consulab.com info@consulab.com 21 EM-123-2_053251-95 SA3 — Rear Brake Shoe Inspection and Replacement 8. Remove the U-clip (A), the wave washer (B), and the pivot pin (C), and separate the parking brake lever (D) from the brake shoe (E). Reassembly 9. Install the parking brake lever (C) and the wave washer (D) on the pivot pin, and secure the pin with a new U-clip (E). 10. Apply Molykote 44MA grease to the sliding surface of the pivot pin (A) for the rearward brake shoe (B). 11. Connect the parking brake cable to the parking brake lever. NOTE : Pinch the U-clip securely to prevent the parking brake lever from coming out of the brake shoe 12. Apply a thin coat of Molykote 44MA grease to the connecting rod ends (A), and the sliding surfaces (B) as shown consulab.com info@consulab.com 22 EM-123-2_053251-95 SA3 — Rear Brake Shoe Inspection and Replacement 13. Wipe off any excess. Keep grease away from the brake linings. 14. Install connecting rods A and B on the adjuster bolt (C). NOTE : Clean the threaded portions of connecting rod A and the sliding surface of connecting rod B, then coat them with Molykote 44MA grease. 15. Shorten connecting rod A by fully turning in the adjuster bolt. 16. Assemble the brake shoes with the upper return spring (D), with the connecting rods and the adjuster bolt onto the backing plate. 17. Reconnect the parking brake cable to the parking brake lever (E), then install the self-adjuster lever (F) and the self- adjuster spring (G) on the forward brake shoe (H). 18. Install the tension pins (A) and the retainer springs (B) by pushing in the respective spring and turning each pin. consulab.com info@consulab.com 23 EM-123-2_053251-95 SA3 — Rear Brake Shoe Inspection and Replacement 19. Install the lower return spring. NOTE : Make sure the brake shoes are positioned on the brake shoe bosses on the backing plate, and the fitting on the top of the brake shoes are fitted into the wheel cylinder pistons. 20. Install the brake drum. NOTE : Before installing the brake drum, clean the mating surfaces between the hub bearing unit and the inside of the brake drum. 21. Press the brake pedal several times to make sure the brakes work and to set the self-adjusting brake. NOTE : Engagement of the brakes may require a greater pedal stroke immediately after the brake shoes have been replaced as a set. Several applications of the brake pedal will restore the normal pedal stroke. 22. Adjust the parking brake. 23. Clean up work area and return tools to the proper place, hand in worksheet. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 24 EM-123-2_053251-95 SA3-A — Rear Brake Drum Inspection and Service SA3-A — Rear Brake Drum Inspection and Service (2 pages) 1. Look up related service information first. 2. Release the parking brake, and remove the brake drum. 3. Check the wheel cylinder (A) for leakage (See SA3-B). 4. Check the brake linings (B) for cracking, glazing, wear, and contamination. NOTE : Contaminated brake linings or drums reduce stopping ability. 5. Measure the brake lining thickness (C). Measurement does not include the metal brake shoe thickness. 6. Brake lining thickness specifications : Standard specifications : Service limit specifications : Actual measurement : 7. If any part of the brake lining thickness is less than the service limit, replace the brake shoes as a set. 8. Check the hub bearing unit (D) for smooth operation. If it requires servicing, replace the hub bearing unit. consulab.com info@consulab.com 25 EM-123-2_053251-95 SA3-A — Rear Brake Drum Inspection and Service 9. Measure the inside diameter of the brake drum with inside vernier caliper. 10. Drum inside diameter specifications : Standard specifications : Service limit specifications : Actual measurement : 11. If the inside diameter of the brake drum is more than the service limit, replace the brake drum. 12. Check the brake drum for scoring, grooves, corrosion, and cracks. 13. Install the brake drum. 14. Clean up work area and return tools to the proper place, hand in worksheet. Name : Group : Date : Instructor : Grade : Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 26 EM-123-2_053251-95 SA3-B — Wheel Cylinder Inspection and Service SA3-B — Wheel Cylinder Inspection and Service 1. Look up related service information first. 2. Remove the brake shoes (see Student Activity SA3). 3. Disconnect the brake line (A) from the wheel cylinder (B). 4. Remove the bolts (C) and the wheel cylinder from the backing plate. NOTE : Use the special bolts on reassembly. 5. Apply Cemedine 366E sealant or equivalent between the wheel cylinder and backing plate (D), and install the wheel cylinder, then connect the brake line. 6. Install the brake shoes. Bleed the brake system. 7. Inspect and adjust the parking brake. 8. Spin the wheels to check for brake drag. 9. After installation, check for leaks at hose and line joints or connections, and retighten if necessary. 10. Clean up work area and return tools to the proper place, hand in worksheet. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 27 EM-123-2_053251-95 SA4 — Bleeding Brake Service SA4 — Bleeding Brake Service (2 pages) 1. Look up related service information first. 2. Do not reuse the drained fluid. Use only new Honda DOT 3 Brake Fluid from an unopened container. Using a non- Honda brake fluid can cause corrosion and shorten the life of the system. 3. Make sure no dirt or other foreign matter gets in the brake fluid. The reservoir connected to the master cylinder must be at the MAX (upper) level mark at the start of the bleeding procedure, and checked after bleeding each wheel location. Add fluid as required. 4. Make sure the brake fluid level in the reservoir (A) is at the MAX (upper) level line (B). 5. Have someone slowly pump the brake pedal several times, then apply steady pressure. 6. Start the bleeding at the driver’s side of the front brake system. NOTE : Bleed the calipers or the wheel cylinders in the sequence shown. consulab.com info@consulab.com 28 EM-123-2_053251-95 SA4 — Bleeding Brake Service 7. Attach a length of clear drain tube (A) to the bleed screw (B), then loosen the bleed screw to allow air to escape from the system. 8. Then tighten the bleed screw securely. 9. Refill the master cylinder reservoir to the MAX (upper) level line. 10. Repeat the procedure for each brake circuit until there are no air bubbles in the fluid. 11. Clean up work area and return tools to the proper place, hand in worksheet. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. consulab.com info@consulab.com 29 EM-123-2_053251-95 SA5 — Wheel Lug Torque SA5 — Wheel Lug Torque 1. Look up related service information first. 2. Remove and inspect tire the and wheel assembly. Be sure to inspect the mating surfaces of the wheel and the hub for rust or corrosion; clean as needed, at the direction of your instructor. 3. After inspection re-install the tire and wheel assembly. 4. Torque the wheel (lug) nuts, installed dry, to the specification listed in service information. 5. Tighten in a star or crisscross pattern using a torque wrench with a current calibration certification. 6. Clean up work area and return tools to the proper place, hand in worksheet. WHEEL NUT TORQUE SPECIFICATION : 1 4 2 3 5 Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 30 EM-123-2_053251-95 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2024. All rights reserved. Introduction Application Features Student assignments SA1 — Master Cylinder Inspection Service SA1-A — Master Cylinder Remove/Replace SA2 — Brake Pad Replacement SA2-A — Front Brake Disc Inspection SA2-B — Front Brake Disc Refinishing SA2-C — Front Brake Caliper Inspection SA3 — Rear Brake Shoe Inspection and Replacement SA3-A — Rear Brake Drum Inspection and Service SA3-B — Wheel Cylinder Inspection and Service SA4 — Bleeding Brake Service SA5 — Wheel Lug Torque

Disc & drum brake trainer + faults EM-123-4HN02_052746 Rev. 2023/12 EM-123-4HN02_052746 Disc & drum brake trainer + faults consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product EDUCATIONAL ADVANTAGES FEATURES APPLICATION TECHNICAL INFORMATION The EM-123-4HN02_052746 Disc & drum brake trainer + faults is used to demonstrate the functionalitiy of a modern automotive hydraulic braking system as it functions on vehicle. The inclusion of four permanent, mechan- ical, real-world faults captures students attention and proves their learning. The product is built using recycled OEM components for the platform and all wear items are brand new (discs, pads, drums, shoes, etc.). The product has an extremely small footprint and can fit into any classroom, even your office! It fits through a 30” door. • Demonstrates full functionality of a 4-wheel hydraulic brake system • Provides easy access to all brake components without the confinements of a vehicle • Pressure gauges show actual braking pressure at each wheel circuit • Trainer includes all OEM ABS components and hydraulic plumbing (non-functional) for student learning and awareness • Many ASE Education Foundation (NATEF) and Red Seal tasks can be accomplished using this trainer • All brake system components are accessible for complete mechanical and hydraulic repair and service • Real OEM automotive components with fully functional disc/ drum hydraulic braking system including : - All OEM hydraulic components - OEM Brake pedal and parking brake pedal - OEM Power brake booster - OEM ABS components and hydraulic plumbing (nonfunctional) - OEM Parking brake components • Hydraulic pressure gauges at each wheel (4) • Components with mechanical faults (4) • Fully functional parking brake system • Fits through a standard 30” door opening • Heavy duty metal stand with casters for easy transport (two fixed and two swivel w/ locks) • All routine brake service procedures can be performed on this trainer including : - Master cylinder service - Power brake booster service - Brake pad/shoe replacement - Disc/Drum service - Wheel bearing service - Caliper/Wheel cylinder service - Brake hose/line service - Parking brake service • Curriculum provided Non-ABS 2006-2010 Honda Civic • Dimensions : 44 x 28 x 42 inch (110 x 70 x 105 cm) / 48 x 40 x 48 inch (120 x 100 x 120 cm) with packaging • Weight : 230 lb (104 kg) / 300 lb (136 kg) with packaging

EM-130_specsheet_EN.indd Suspension & steering system trainer EM-130_052793 Rev. 2024/06 EM-130_052793 Suspension & steering system trainer consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 EDUCATIONAL ADVANTAGES APPLICATION The ConsuLab EM-130 Suspension and Steering trainer is designed to as- sist instructors in teaching basic alignment geometry and the function of a MacPherson strut suspension system with rack & pinion steering. The trainer is extremely versatile in that students can easily visualize all component op- eration as well as practice adjusting the various alignment angles. The EM-130 trainer can be used to provide students with the following educational outcomes: • Provides full accessibility of vehicle components without access limitations of a real vehicle • Alignment demonstrations, measurement and adjustments can be accomplished with clear viewing by students • Component identification of a typical MacPherson strut suspension system • Component identification of a typical rack & pinion steering system • Component identification of a typical sway & stabilizer bar • Front bearing hub and wheel bearing service • Make, measure and observe changes of Caster, Camber and Toe The EM-130 trainer can be used for student identification of a typical disc brake system. Stu- dents can practice the following brake tasks: • Wheel & tire service • Brake caliper and rotor service • Rotor (T.I.R.) runout and thickness measurements • Brake condition inspection The EM-130 trainer can be used for the instruction and practice of common MacPherson strut and rack & pinion steering service procedures including: • Rack removal and reinstallation • Inner & outer tie rod service • Strut and ball joint service The trainer allows superior component visualization and allows actual measurement of cam- ber, caster and SAI using the included magnetic gauge. Students can easily make adjustments and view the results of the changes. Students can also view the following alignment concepts on the trainer: • SAI (STEERING AXIS INCLINATION) • TOTAL INCLUDED ANGLE • SIDE-TO-SIDE DIFFERENCES IN CASTER, CAMBER AND TOE. 2012-2018 Hyundai Accent EM-130_052793 Suspension & steering system trainer consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product • Equipped with two movable turntables and a magnetic alignment measuring gauge to assist students in observing actual measurement and changes in alignment angles. • Students can visualize and learn common braking system components. • The trainer consists of a typical front wheel drive vehicle having MacPherson strut sus- pension, rack & pinion steering and front disc brakes. • The components necessary for correct operation and service of alignment angle adjust- ments and component identification are included. • The potential danger of the MacPherson spring pressures have been eliminated by re- placing the stock coil spring with a custom plastic coil spring that does not support any of the weight of the suspension system. • The lower control arm and support bushings are OEM. • The sway bar has been designed with a quick disconnect feature that allows students to disconnect it for easy and precise alignment adjustment procedures. • The rack and pinion steering linkage is connected to a steering wheel identical to actual vehicle configuration. • The tie-rod ends are equipped with typical adjustment methods for the adjustment of toe specifications. • The frame has three manual adjustment features that allow students to create abnormal vehicle conditions such as uneven front or rear loading, worn springs, etc. • Features adjustment plates at the top of both MacPherson strut assemblies which allow easy adjustment of caster and camber. • The tires sit on movable plates for ease of movement during adjustments. • Can be used for student learning of front wheel bearing and hub construction as well as the disc brake system based on a 2012-2018 Hyundai Accent. • Dimensions : 30 x 77 x 65 inch (76.2 x 195.6 x 165.1 cm) / 36 x 82 x 65 inch (91.4 x 208.3 x 165.1 cm) with packaging • Weight : 545 lbs (247.2 kg) / 645 lbs (292.6 kg) with packaging FEATURES TECHNICAL INFORMATIONS

Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space Operation manual for EM-130_052793 Suspension & steering system trainer 93-EM-130_REVA © ConsuLab Educatech Inc, 2023. All rights reserved. https://www.consulab.com/customer-space 93-EM-130 Table of contents 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 © ConsuLab Educatech Inc, 2023. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. The content of this manual is applicable to models 052793 and above. Table of Contents General Description 3 Features and Explanation 3 NATEF Tasks for the EM-130 Suspension & Steering trainer 4 MLR — Maintenance & Light Repair 4 AST — Automotive Service Technician 5 Alignment Theory and Understanding 6 Vehicle Riding Height 7 Symptoms Of Worn Suspension Springs And Unequal Vehicle Loading 7 Suspension and Steering Understanding 8 Brake System Understanding 8 Component identification 9 consulab.com info@consulab.com 3 93-EM-130 General Description General Description The ConsuLab EM-130 Suspension and Steering trainer is designed to assist instructors in teaching basic alignment ge- ometry and the function of a MacPherson strut suspension system with rack & pinion steering. The trainer is extremely versatile in that students can easily visualize all component operation as well as practice adjusting the various alignment angles. Students can also visualize and learn common braking system components. Features and Explanation The EM-130 trainer consists of a typical front wheel drive vehicle having MacPherson strut suspension, rack & pinion steering and front disc brakes. The components necessary for correct operation and service of alignment angle adjust- ments and component identification are included. The potential danger of the MacPherson spring pressures have been eliminated by replacing the stock coil spring with a custom plastic coil spring that does not support any of the weight of the suspension system. The lower control arm and support bushings are OEM. The sway bar has been designed with a quick disconnect feature that allows students to disconnect it for precision alignment adjustment procedures. The rack and pinion steering linkage is connected to a steering wheel identical to actual vehicle configuration. The tie-rod ends are equipped with typical adjustment methods for the adjustment of toe specifications. The trainers frame has three manual adjustment features that allow students to create abnormal vehicle conditions such as uneven front or rear loading, worn springs, etc. The trainer also features adjustment plates at the top of both MacPherson strut assemblies which allow easy adjustment of caster and camber. The tires sit on movable plates for ease of movement during adjust- ments. The trainer can also be used for student learning of front wheel bearing and hub construction as well as the disc brake system. consulab.com info@consulab.com 4 93-EM-130 NATEF Tasks for the EM-130 Suspension & Steering trainer NATEF Tasks for the EM-130 Suspension & Steering trainer MLR — Maintenance & Light Repair MANUAL DRIVE TRAIN & AXLES NO DESCRIPTION PRIORITY LEVEL III-D-1 Inspect, remove, and replace front wheel drive (FWD) bearings, hubs, and seals. P-2 STEERING & SUSPENSION NO DESCRIPTION PRIORITY LEVEL IV-B-1 Inspect rack and pinion steering gear inner tie rod ends (sockets) and bellows boots. P-1 IV-B-8 Inspect tie rod ends (sockets), tie rod sleeves, and clamps. P-1 IV-B-15 Inspect and replace front stabilizer bar (sway bar) bushings, brackets, and links. P-1 IV-B-16 Inspect strut cartridge or assembly. P-1 IV-B-17 Inspect front strut bearing and mount. P-1 IV-C-1 Perform prealignment inspection and measure vehicle ride height; determine necessary action. P-1 IV-D-1 Inspect tire condition; identify tire wear patterns; check for correct size and application (load and speed ratings) and adjust air pressure; determine necessary action. P-1 IV-D-2 Rotate tires according to manufacturer’s recommendations. P-1 IV-D-5 Inspect tire and wheel assembly for air loss; perform necessary action. P-1 BRAKES NO DESCRIPTION PRIORITY LEVEL V-A- 3 Install wheel and torque lug nuts. P-1 V-D-1 Remove and clean caliper assembly; inspect for leaks and damage/wear to caliper hous- ing; determine necessary action. P-1 V-D-2 Clean and inspect caliper mounting and slides/pins for proper operation, wear, and dam- age; determine necessary action. P-1 V-D-3 Remove, inspect, and replace pads and retaining hardware; determine necessary action. P-1 V-D-4 Lubricate and reinstall caliper, pads, and related hardware; seat pads and inspect for leaks. P-1 V-D-5 Clean and inspect rotor, measure rotor thickness, thickness variation, and lateral runout; determine necessary action. P-1 V-D-6 Remove and reinstall rotor. P-1 consulab.com info@consulab.com 5 93-EM-130 NATEF Tasks for the EM-130 Suspension & Steering trainer AST — Automotive Service Technician MANUAL DRIVE TRAIN & AXLES NO DESCRIPTION PRIORITY LEVEL III-D-1 Inspect, remove, and replace front wheel drive (FWD) bearings, hubs, and seals. P-2 STEERING & SUSPENSION NO DESCRIPTION PRIORITY LEVEL IV-B-1 Inspect rack and pinion steering gear inner tie rod ends (sockets) and bellows boots. P-1 IV-B-7 Remove and replace rack and pinion steering gear; inspect mounting bushings and brackets. P-2 IV-B-8 Inspect tie rod ends (sockets), tie rod sleeves, and clamps. P-1 Inspect rack and pinion steering gear inner tie rod ends (sockets) and bellows boots; replace as needed. P-2 IV-B-15 Inspect and replace front stabilizer bar (sway bar) bushings, brackets, and links. P-1 IV-B-16 Inspect strut cartridge or assembly. P-1 IV-B-17 Inspect front strut bearing and mount. P-1 IV-C-1 Perform prealignment inspection and measure vehicle ride height; determine necessary action. P-1 IV-C-2 Diagnose strut suspension system noises, body sway, and uneven ride height concerns; determine neces- sary action. P-1 IV-C-6 Inspect, remove and install steering knuckle assemblies. P-3 IV-C-9 Inspect, remove and install front stabilizer bar (sway bar) bushings, brackets, and links. P-3 IV-C-10 Inspect, remove and install strut cartridge or assembly, strut coil spring, insulators (silencers), and upper strut bearing mount. P-3 IV-D-1 Inspect tire condition; identify tire wear patterns; check for correct size and application (load and speed ratings) and adjust air pressure; determine necessary action. P-1 IV-D-2 Rotate tires according to manufacturer’s recommendations. P-1 IV-D-5 Inspect tire and wheel assembly for air loss; perform necessary action. P-1 IV-E-1 Diagnose vehicle wander, drift, pull, hard steering, bump steer, memory steer, torque steer, and steering return concerns; determine necessary action. P-1 BRAKES NO DESCRIPTION PRIORITY LEVEL V-A- 3 Install wheel and torque lug nuts. P-1 V-D-1 Remove and clean caliper assembly; inspect for leaks and damage/wear to caliper housing; determine necessary action. P-1 V-D-2 Clean and inspect caliper mounting and slides/pins for proper operation, wear, and damage; determine necessary action. P-1 V-D-3 Remove, inspect, and replace pads and retaining hardware; determine necessary action. P-1 V-D-4 Lubricate and reinstall caliper, pads, and related hardware; seat pads and inspect for leaks. P-1 V-D-5 Clean and inspect rotor, measure rotor thickness, thickness variation, and lateral runout; determine nec- essary action. P-1 V-D-6 Remove and reinstall rotor. P-1 consulab.com info@consulab.com 6 93-EM-130 Alignment Theory and Understanding Alignment Theory and Understanding The trainer allows superior component visualization and students can easily make adjustments and view the results of the following alignment angles: • CAMBER • CASTER • TOE The trainer is equipped with CASTER and CAMBER scales identifying the correct direction for both positive and negative alignment angle changes as adjustments are made. Caster and camber adjustments are made simply by moving upper strut mount in the provided adjustment slots and lock knobs. TOE can be adjusted with the tie-rod adjusting nuts and threaded tie-rods identical to OEM vehicle design. CASTER & CAMBER ADJUSTMENT SCALES TIE-ROD ADJUSTING NUT AND TIE-ROD THREADSCASTER & CAMBER ADJUSTMENT LOCK KNOBS (4) consulab.com info@consulab.com 7 93-EM-130 Vehicle Riding Height Vehicle Riding Height Symptoms Of Worn Suspension Springs And Unequal Vehicle Loading Three adjustment wheels are provided by which the trainer can be tilted, lowered and raised to demonstrate different abnormal conditions regarding vehicle riding height. NOTE: The adjustment wheels can also be used to raise the trainer off the mounting platform high enough to remove the tire/wheel assembly, thus providing lifting capability with the need of a floor jack. This feature allows visual demonstrations of the negative performance results of lowering and raising a vehicle riding height which is often a common procedure among students. Extreme negative and positive camber adjustments can also be demonstrated. RIDING HEIGHT ADJUSTMENT HANDWHEELS WARNING: Do not attempt to move the trainer frame around the shop area with one or both of the tire/wheel assem- blies removed. Students can also view the following alignment concepts on the trainer: • SAI (STEERING AXIS INCLINATION) • TOTAL INCLUDED ANGLE • SIDE-TO-SIDE DIFFERENCES IN CASTER, CAMBER AND TOE consulab.com info@consulab.com 8 93-EM-130 Suspension and Steering Understanding & Brake System Understanding Suspension and Steering Understanding The EM-130 trainer can be used to provide students with the following educational outcomes: • Component identification of a typical MacPherson strut suspension system • Component identification of a typical rack & pinion steering system • Component identification of a typical sway & stabilizer bar • Front bearing hub and wheel bearing service Brake System Understanding The EM-130 trainer can be used for student identification of a typical disc brake system. Students can practice the following brake tasks: • Wheel & tire service • Brake caliper and rotor service • Rotor (T.I.R.) runout and thickness measurements • Brake condition inspection SWAY BAR DISCONNECT NOTE: Both wheels are lock to prevent them from rotating during the alignment tasks. consulab.com info@consulab.com 9 93-EM-130 Component identification Component identification MACPHERSON STRUT ASSEMBLY SHOWING CASTER ADJUSTMENT PLATE (SIDE VIEW) MACPHERSON STRUT ASSEMBLY SHOWING CAMBER ADJUSTMENT PLATE (FRONT VIEW) 2 3 4 1 1 1. CASTER/CAMBER ADJUSTMENT LOCK KNOBS 2. HEIGHT ADJUSTMENT WHEELS 3. LEVEL INDICATOR 4. TURNTABLE consulab.com info@consulab.com 10 93-EM-130 Component identification GRADUATED TURNTABLE WITH LOCKING PINS OPTIONAL MAGNETIC CAMBER/CASTER GAUGE WITH STORAGE CASE 400-6330, rue Zéphirin-Paquet Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2023. Tous droits réservés. General Description Features and Explanation NATEF Tasks for the EM-130 Suspension & Steering trainer MLR — Maintenance & Light Repair AST — Automotive Service Technician Alignment Theory and Understanding Vehicle Riding Height Symptoms Of Worn Suspension Springs And Unequal Vehicle Loading Suspension and Steering Understanding Brake System Understanding Component identification

96-EC-520_REVA © ConsuLab Educatech Inc, 2026. All rights reserved. Cutaway Battery Trainer Instructors manual for EC-520-052945 Teacher Only 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada consulab.com info@consulab.com Toll-free: +1 (800) 567-0791 USA: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 2 © ConsuLab Educatech Inc, 2026. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. The content of this manual is applicable to models 052945 and above. 96-EC-520 Table of Contents Table of Contents What is a battery ? 3 SA1 - Student assignement 4 SA1 - Student assignement - Answers 5 SA2 - Student assignement 6 SA2 - Student assignement - Answers 7 consulab.com info@consulab.com 3 96-EC-520 What is a battery ? What is a battery ? Electrical energy comes in many forms. Two common forms of electricity are alternating current and direct current. Alternating current (AC) is generated by power plants to be used on demand in homes and businesses but it cannot be stored for future use. Direct current (DC) is also generated but has the ability to be stored. The simple definition of a lead-acid battery is that it is a storage device for DC electrical energy. This energy can then be used to power electrical circuits within a car. Batteries used in cars are lead-acid batteries. This means they produce DC voltage by having plates of metal (made of leadbased alloys) immersed in an electrolyte solution (a mix of 65% water and 35% sulphuric acid) in a six-cell configu- ration. A chemical reaction between the plates produces a voltage of approximately 2.1 volts per cell, so multiply by 6 cells to achieve a total of 12.6 volts There are two main things to consider when looking at a car battery: voltage and current. The voltage should typically be around 12.6 volts when the battery is fully charged and refers to how much energy is stored in the battery. This is often referred to as the batteries state of charge. At 12.4 volts a battery is considered only 75% charged, and at this point the battery might not be able to power systems that require a lot of current, such as the starter motor or the headlights. At 12.0 volts the battery is only 25% charged, and at 10.5% the unit is considered fully discharged or possibly having one “dead” cell. (12.6V – 2.1V = 10.5V) Think of voltage as the battery’s potential to flow electricity. Whereas the current, measured in amps, is the rate at which the electricity flows. It’s important to consider the Cold Cranking Amps (CCA) rating when buying a battery for a car. The CCA is a measure of how many amps a battery can produce for a 30 second period at 0F, before the voltage drops to an unusable level. Typical car batteries are either 350, 450 and 600 CCA. The bigger the CCA figure, the better a battery will start a car, especially in cold weather. But higher CCA batteries are generally more expensive. A battery’s Ah (ampere-hours) rating is the measure of how much electrical current it can deliver over time. Typical rat- ings for car batteries are between 75 and 120 Ah. As an example, a 100 Ah battery can supply 5 amps for 20 hours, 10 amps for 10 hours, or 20 amps for 5 hours, and so on. Most modern car batteries are sealed units that incorporate a tiny vent system to allow the hydrogen gasses produced during the charging/discharging cycle to escape while also reducing the amount of electrolyte lost. Over time, temperatures, vibrations, sloshing of the electrolyte, and the constant cycle of charging/discharging causes the lead plates will deteriorate to a point where a useful current is no longer produced. At this point the battery will need to be replaced. A good-quality modern battery should last at three to five years of daily use in a well kept car’s electrical system. Batteries are classified by their physical size in categories given a «group number» by the Battery Council International (BCI). consulab.com info@consulab.com 4 96-EC-520 SA1 — Student assignment SA1 — Student assignment 1. How many cells are in a standard 12V battery? 2. How many volts are generated by each cell? 3. How are the cells wired internally? 4. What is the fluid solution inside a battery that the plates are submerged in called? 5. What is this fluid solution inside a battery made up of? 6. What gas is produced by charging a battery and is it dangerous? 7. What is the definition of Cold Cranking Amps? 8. What is the definition of the Amp hour rating of a battery? 9. What other BCI rating is used to determine correct battery application? 10. What three battery voltage measurements should be taken to determine the health of a battery and vehicle electrical system? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 5 96-EC-520 SA1 — Student assignment — Answers SA1 — Student assignment — Answers 1. How many cells are in a standard 12V battery? 6 2. How many volts are generated by each cell? 2.1 V 3. How are the cells wired internally? In series, so voltage is additive. 4. What is the fluid solution inside a battery that the plates are submerged in called? Electrolyte. 5. What is this fluid solution inside a battery made up of? A mix of 65 % water and 35 % sulphuric acid. 6. What gas is produced by charging a battery and is it dangerous? Hydrogen and yes, it’s explosive. 7. What is the definition of Cold Cranking Amps? CCA is a measure of how many amps a battery can produce for a 30 second period at 0 ºF. 8. What is the definition of the Amp hour rating of a battery? A battery’s Ah (ampere-hours) rating is the measure of how much electrical current it can deliver over time. 9. What other BCI rating is used to determine correct battery application? Physical size (group). 10. What three battery voltage measurements should be taken to determine the health of a battery and vehicle electrical system? State of charge voltage / cranking voltage / charging voltage. consulab.com info@consulab.com 6 96-EC-520 SA2 — Student assignment SA2 — Student assignment Identify the components that make up an automotive battery. 1. 2. 3. 4. 5. 6. 7. Name : Group : Date : Instructor : Grade : 6 1 2 3 4 5 7 consulab.com info@consulab.com 7 96-EC-520 SA2 — Student assignement — Answers SA2 — Student assignement — Answers 1. Battery Case 2. Separator Plates 3. Charging Plates 4. Cell Straps 5. Battery Post 6. Cell Fill Cap 7. Cell Vent 6 1 2 3 4 5 7 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. All rights reserved. What is a battery ? SA1 - Student assignement SA1 - Student assignement - Answers SA2 - Student assignement SA2 - Student assignement - Answers

Planetary gear set trainer EM-1100_053254 Rev. 2023/08 EM-1100_053254 Planetary gear set trainer consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product FEATURES TECHNICAL INFORMATION The ConsuLab EM-1100 Planetary Gear Set Trainer is a simple planetary gear assembly that consists of 3 primary components: the ring gear (the outer most gear in black), 3 planet gears (in green) that are housed by a carrier as- sembly (green circle) and a sun gear (the yellow gear in the center of the gear set). It allows the demonstration of the seven different gear ratios available with the planetary gearset. • Easy student visualization of planetary operation • Sun, ring gear and carrier can be held, driven or allowed to react • Demonstration of seven gear ratios is available • Table top portability • Optimal size for classroom • Dimensions: H 27.13” x W 21.25” D 9.38” (69 x 54 x 23.8 cm) / H 29.13” x W 23.25” D 11.38” (74 x 59 x 28.9 cm) with packaging • Weight: 28 lb (12.7 kg) / 31 lb (14 kg) with packaging

Disc & drum ABS brake trainer + faults Em-122-HN02_052621 Rev. 2023/07 EM-122-HN02_052621 Disc & drum ABS brake trainer + faults consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product EDUCATIONAL ADVANTAGES FEATURES APPLICATION TECHNICAL INFORMATION The EM-122-HN02 Four-wheel Honda ABS trainer is used to demonstrate the functionality of the ABS braking system as it operates on a real vehicle. Mechanical faults in the friction components are designed to be diagnosed by students while performing a brake inspection. This trainer also comes with six insertable, electronic faults. The trainer is built with OEM components and is based on the 2006-2010 Honda Civic platform. The trainer a provides a safe and effective method of demonstrating the principles of common an- ti-lock braking systems used on today’s vehicles. • Demonstrates full functionality of a 4-wheel ABS system. • Allows choice of wheel combinations to “lock-up” during ABS operation. • Allows choice of ABS “application” timing for clearer demonstrations. • Six system electrical faults that are manually selected by the instructor. • Mechanical faults in the friction components are designed to be diagnosed by students while performing a brake inspection. • Trainer follows OEM wiring schematics. • Trainer can be used for full mechanical service and repair operations of : - Front disc brakes - Rear drum brakes - Master Cylinder & Hydraulic system (w/ pedal) - ABS Electrical System (w/ wheel speed sensors) - ABS Hydraulic Control unit - Parking Brake system • Many ASE Education Foundation (NATEF) and Red Seal tasks can be accomplished using this trainer. • Trainer can it through a standard 30” door opening. • Provides “real world” brake pedal feedback pulsations during ABS operation. • “Real” automotive components with fully functional ABS 3-channel hydraulic system. • Equipped with DLC for scan tool data stream hookup. • OEM vehicle instrument panel with indica- tor lamps. • ABS Control Unit breakout box for easy connection of a DVOM or Oscilloscope. • Hydraulic pressure gauges at each wheel (4). • Lockable fault insertion box with 6 electri- cal faults. • Mechanical faults (4). • Disc/drum four wheel brake assemblies (NOTE- discs, drums, wheel cylinders, calipers and all friction materials are new. All other OEM components are recycled from actual vehicles). • Fully functional parking brake system. • 55A DC power supply included. • Heavy Duty metal stand with casters for easy transport of trainer. • All routine brake service procedures can be performed on this trainer including component replacement, adjustments and hydraulic bleeding. 2006-2010 Honda Civic. • Power requirements : 110V @ 20 amps or 220V @ 10 amps (specify when ordering). • Sturdy powder coated metal stand with two locking swivel and two fixed casters. • Dimensions : Height: 51” Width: 24” Depth: 50” (127.5 x 60 x 125 cm). • Weight : 325 lb (147.7 kg).