Operation manual for EC-490_053131 Cutaway diesel exhaust aftertreatment system 93-EC-490_053131_REVA © ConsuLab Educatech Inc, 2026. All rights reserved. Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space 93-EC-490_053131 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, 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 053131 and above. Table of Contents 95-EC-490 Student Assignments — Table of Contents 4 91-EC-490 Answer Keys and Theory — Table of Contents 4 96-EC-490 Instructors Manual — Table of Contents 5 Introduction 6 Operation Explanation 6 Component Identification 7 Front Panel 7 Control Panel 8 Trainer Operation 9 Exhaust Gas Molecules Associated with Color-coded Light Sequence 10 consulab.com info@consulab.com 4 93-EC-490_053131 Teacher Ressources 95-EC-490 Student Assignments — Table of Contents 95-EC-490_053131 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, 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 053131 and above. Table of Contents Product Description 3 Operational Explanation 3 Educational Advantages 3 Student Assignments SA-1 5 SA-2 6 SA-3 7 SA-4 8 SA-5 9 SA-6 10 SA-7 11 SA-8 12 91-EC-490 Answer Keys and Theory — Table of Contents 91-EC-490_053131 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, 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 053131 and above. Table of Contents Product Description 4 Operational Explanation 4 Educational Advantages 4 Student Assignments Answers SA-1 Answers 5 SA-2 Answers 6 SA-3 Answers 7 SA-4 Answers 8 SA-5 Answers 9 SA-6 Answers 10 SA-7 Answers 11 SA-8 Answers 12 We have included the table of contents from three other manuals in this operation manual. This serves as a reference to make you aware of all the documentation that comes with the product. consulab.com info@consulab.com 5 93-EC-490_053131 Teacher Ressources 96-EC-490 Instructors Manual — Table of Contents 96-EC-490_053131 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, 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 053131 and above. Table of Contents Product Description 4 Operational Explanation 4 Educational Advantages 4 Get Ready to Use the EC-490 Trainer 5 Referenced Documentation Appendix 6 Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space consulab.com info@consulab.com 6 93-EC-490_053131 Introduction Introduction The ConsuLab EC-490 is a cutaway diesel exhaust system trainer that allows students to view the components of a diesel exhaust aftertreatment system using LED’s and electronic controls to help learners understand the function, and effect on, diesel engine exhaust gases following the combustion cycle. The trainer uses multiple colored LED’s to repre- sent the gases that flow in the exhaust system and, demonstrates the chemical reactions within each of the aftertreat- ment processes. Operation Explanation The core of a modern diesel exhaust system is the urea based SCR (Selective Catalytic Reduction) system that contains a ceramic catalyst washcoated with iron and copper on a zeolite substrate. The diesel exhaust fluid (DEF), also called reductant, is injected into the exhaust upstream of the SCR catalyst. The reductant is a mixture of 32.5% urea and 67.5% water that is split into carbon dioxide (CO2) and ammonia (NH3) by the heat of the exhaust gases. The ammonia is the reduction agent in the SCR system. As the ammonia and NOX (oxides of nitrogen generated from combustion) pass through the ceramic SCR catalyst, a reduction reaction takes place and the ammonia and NOX are converted to N2 (nitrogen) and H2O (water). The term “selective” in selective catalytic reduction (SCR) refers to ammonia that prefers to react with the oxygen in NOX instead of the oxygen contained in the exhaust gas flow. The chemical reaction with SCR ammonia converts NOX molecules into nitrogen and water, and the gases efficiently revert to their original state. The SCR system works efficiently only when the catalyst temperature is between 570-750 °F and the DEF fluid is of the proper quality. The engine is able to run leaner and more efficiently because of the efficiency of the SCR system eliminat- ing the high NOX levels produced under lean combustion conditions. The exhaust system also includes the diesel oxidation catalyst (DOC) that is a ceramic catalytic converter which oxidizes hydrocarbons in the exhaust and generates heat for the SCR and DPF (Diesel Particulate Filter) to function properly. The DPF is a silicon carbide wall-flow catalyst that traps soot particulates, reducing the amount of black smoke emissions from the tail pipe. The DPF system is cleaned by a process called regeneration. The three DPF regeneration modes are active, passive and manual. As soot gathers in the system, the exhaust flow starts to be restricted. Regeneration is the process in which the soot is burned off from the inside of the DPF. Regeneration can be commanded by the PCM or the scan tool. The PCM starts a DPF regeneration if the soot load exceeds a calibrated value. The PCM determines the DPF load condition based on the exhaust gas pressure upstream of the DPF. The DPF pressure sensor provides the pressure input signal to the PCM. This soot can be reduced to ash by passive, active, or manual regeneration. EC-490 Tailpipe consulab.com info@consulab.com 7 93-EC-490_053131 Component Identification Component Identification Front Panel Gas Flow Arrow 1. Inlet Arrow 2. Diesel Oxidation Catalyst (DOC) Arrow 3. SCR Urea Injector Arrow 4. Spiral Mixing Camber Arrow 5. Selective Catalytic Reduction (SCR) Arrow 6. Diesel Particulate Filter (DPF) Arrow 7. Outlet Sensors C1. Exhaust Gas Temperature, Sensor 1 C2. Exhaust Gas Temperature, Sensor 2 C3. Nitrogen Oxides, Sensor 1 NOTE: Location may vary depending on application or year of production C4. Exhaust Gas Temperature, Sensor 3 C5. Exhaust Gas Temperature, Sensor 4 C6. Nitrogen Oxides, Sensor 2 consulab.com info@consulab.com 8 93-EC-490_053131 Component Identification Control Panel 1 2 3 4 6 7 5 8 1. Backup Push Button 2. START / PAUSE Push Button 3. Advance Push Button 4. ON / OFF Push Button 5. Light Sequence Speed Controller 6. Regeneration Push Button 7. 12VDC, 3A Transformer Input 8. 3A Slow Blow Fuse consulab.com info@consulab.com 9 93-EC-490_053131 Trainer Operation Trainer Operation Instructions 1. Plug the transformer cord in the 12VDC input receptacle located on the control panel and the transformer in a 110V, 60 Hz receptacle. The ON / OFF power LED indicator should be on. 2. Turn on the EC-490 trainer using the ON / OFF push button. When starting all LED indicators are red to indicate that the system is ready to operate. 3. Use the START / PAUSE push button to initiate the light sequence that represents the exhaust gas flow path in the system. the actions taking place in DOC, SCR and DPF areas of the aftertreatment syste. The START / PAUSE push button LED indicator becomes green to indicate that the light sequence is in automatic mode going through the cycle without stopping. Use the START / PAUSE push button again to stop the light sequence in any portion of the after- treatment trainer. In the manual mode, you can backup or advance in the sequence using the corresponding push buttons. The light sequence speed is controlled by the speed controller. 4. When the regeneration indicator is red, the light sequence goes through a complete cycle without regeneration first. The regeneration LED’s only operate in the next cycle. Normal and regeneration modes alternate subsequently. If the regeneration button is pushed, the LED indicator turns green and the regeneration mode is demonstrated in every cycle. consulab.com info@consulab.com 10 93-EC-490_053131 Exhaust Gas Molecules Associated with Color-coded Light Sequence Exhaust Gas Molecules Associated with Color-coded Light Sequence Hydrocarbon Oxygen Carbon Monoxide Carbon Dioxide Nitrogen Oxide Soot (Particulate Matter) Urea Water Nitrogen Ammonia 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2026. All rights reserved. Introduction Operation Explanation Component Identification Front Panel Control Panel Trainer Operation Exhaust Gas Molecules Associated with Color-coded Light Sequence
