Student Assignments for HV-950 Diesel Engine Training Bench 95-HV-950_REVA © ConsuLab Educatech Inc, 2026. All rights reserved. 95-HV-950 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. Table of Contents General description 3 Educational Advantages 3 Student Assignments SA-1 Component identification — Basic 5 SA-2A Component Identification — Specific 7 SA-2B Component Identification — Dashboard Specific ID 9 SA-3 Component Identification — Sensors ID / HD Diesel 12 SA-4 Component Identification — Actuator ID/HD Diesel 14 SA-5 Charging System Verification 15 SA-6 Wiring Diagram Practice 16 SA-7 Expected Voltages 20 SA-8 Measured Voltages 24 SA-9 Engine Performance Fault Diagnosis Template 28 consulab.com info@consulab.com 3 95-HV-950 General description General description The HV-950 family of diesel engine trainers are fully operational engines mounted on a mobile stand. The trainers are easy to work on and all major components, wiring and connectors match OEM configuration. Each trainer is either a one or two piece construction design depending on the model. The one piece diesel bench has the actual engine mounted on a mobile stand constructed of 2” (5 cm) tubular steel equipped with four 5” (12.5 cm) phenol casters (2-fixed and 2-swivel w/locks), and may or may not include the after-treat- ment unit on top. The two piece diesel bench has the exhaust after-treatment unit apart that must be properly con- nected to the engine prior to demonstrations or assignments. Students can perform many ASE Educational Foundation related Engine Performance and Electrical/Electronic tasks using this trainer. Trainers are equipped with safety guards covering all rotating components. Educational Advantages • Demonstration of major engine systems to groups of students without the access limitations of a complete vehicle. • Engine systems respond to inserted fauts with real world symptoms, OEM DTC’s and check engine light operation. • Functional DLC using SAE J1939 protocols. • Demostration of exhaust after treatment emission system operation if applicable. TWO-PIECE DIESEL ENGINE TRAINER ONE-PIECE DIESEL ENGINE TRAINER consulab.com info@consulab.com 4 95-HV-950 Student Assignments Student Assignments consulab.com info@consulab.com 5 95-HV-950 SA-1 Component identification — Basic SA-1 Component Identification — Basic (2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step one in getting familiar with this trainer. Using service information fill in each blank with as much information as possible. Component Function Location HV-950 Diesel Engine Application: Engine Gas or Diesel Engine mounts Transmission Transmission fluid level inspection Coolant Hoses Coolant reservoir & cap Thermostat Cooling Fan Radiator Oil Filter Oil Drain plug Oil dipstick Air Filter Fuel Filter(s) Throttle (body) Positive Crankcase Ventilation system consulab.com info@consulab.com 6 95-HV-950 SA-1 Component identification — Basic Component Function Location Batteries Starter Alternator Belt(s) Exhaust After Treatment DEF Fluid reservoir Fuse box - power DLC Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 7 95-HV-950 SA-2A Component Identification — Specific SA-2A Component Identification — Specific (2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two A in getting familiar with this trainer. Using service information fill in each blank with as much descriptive information as possible. Engine system Engine specific information HV-950 Diesel Engine Application: VIN & decode Engine type Gasoline Diesel Engine model Engine displacement Numbers of cylinders Cylinder numbering Firing order Direction of engine rotation Compression ratio Aspiration Turbo N/A Supercharged Camshaft configuration OHV SOHC DOHC Turbo type Charge air cooler location & function Fuel system type DEF Fluid reservoir J1939 parameter display unit consulab.com info@consulab.com 8 95-HV-950 SA-2A Component Identification — Specific Engine system Engine specific information Glow Plugs (if applicable) Emission Controls EGR DOC SCR w/DEF DPF Other technologies : Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 9 95-HV-950 SA-2B Component Identification — Dashboard Specific SA-2B Component Identification — Dashboard Specific (3 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step two B in getting familiar with this trainer. Using service information fill in each blank with as much descriptive information as possible. Dash icon & name Description 1. 2. 3. 4. 5. 6. 7. 8. 9. consulab.com info@consulab.com 10 95-HV-950 SA-2B Component Identification — Dashboard Specific Dash icon & name Description 10. 11. 12. 13. Switch Position Function 14. I O 1-2-3 15. I O 16. I O consulab.com info@consulab.com 11 95-HV-950 SA-2B Component Identification — Dashboard Specific Switch Position Function 17. AUTO 18. I O 19. I O 20. I O 21. I O 22. I O 23. 24. Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 12 95-HV-950 SA-3 Component Identification — Sensors ID / HD Diesel SA-3 Component Identification — Sensors ID / HD Diesel (2 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This ex- ercise is step three in getting familiar with this trainer and sensors. Using service information fill in each blank with as much information as possible. Sensor Function Location ECM/PCM Connector & Pin #’s HV-950 Diesel Engine Application: Accelerator pedal position 1 Accelerator pedal position 2 Accelerator Pedal PWM Aftertreatment Intake NOx Aftertreatment Outlet NOx Ambient Air Temp Atmospheric Pressure Boost Pressure Camshaft Position Crankcase Pressure Crankshaft Position DEF Tank Level DEF Tank Temp DEF Dosing Pressure DEF Differential Pressure DPF Outlet Pressure Exhaust Gas Recirculation (EGR) temp consulab.com info@consulab.com 13 95-HV-950 SA-3 Component Identification — Sensors ID / HD Diesel Sensor Function Location ECM/PCM Connector & Pin #’s EGR Differential Pressure Engine Coolant Temp Exhaust Gas Pressure Fan Speed Fuel Contamination Fuel Level Fuel Tank Pressure Fuel Rail Pressure Intake Air Temp/Pressure Manifold Absolute Pressure Mass Air Flow Mass Gas Flow NOx Oil Pressure Universal Exhaust Gas Oxygen (UEGO) Turbo/Intake Air Temp Turbo Speed Sensor Vehicle Speed Sensor Water in Fuel INSERT ANY SENSORS SPECIFIC TO THIS ENGINE Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 14 95-HV-950 SA-4 Component Identification — Actuator ID/HD Diesel SA-4 Component Identification — Actuator ID/HD Diesel In preparation to diagnosing any engine management issues, one has to know what they are working on first. This ex- ercise is step four in getting familiar with this trainer and actuators. Using service information fill in each blank with as much information as possible. Actuator Function Location ECM/PCM Connector & Pin #’s HV-950 Diesel Engine Application: Camshaft Position Actuators DEF Tank Heater Control Valve DEF Dosing Valve Engine Intake Throttle Motor Fuel Pump Actuator Injector 1 Injector 2 Injector 3 Injector 4 Injector 5 Injector 6 Throttle Actuator Controller Variable Geometry Turbo- charger INSERT ANY ACTUATORS SPECIFIC TO THIS ENGINE Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 15 95-HV-950 SA-5 Charging System Verification SA-5 Charging System Verification In preparation to diagnosing any engine management issues, one has to know that the battery, charging system and all related wiring is working correctly first. This exercise is step five in getting familiar with the correct order of diagnosis – battery first! HV-950 Diesel Engine Application: Task Record results & interpret Visual Inspection of Battery Visual Inspection of Alternator Visual Inspection of the Belt Open Circuit Voltage (OCV) State of charge = What can affect this voltage ? Cranking Voltage Lowest voltage observed = Charging System Voltage Is this 2V over OCV ? YES NO Is this system functioning properly ? Voltage drops to verify system integrity Note : Current has to be flowing to perform an accu- rate Voltage Drop Chassis Ground Engine Ground Charging Circuit (+) Charging Circuit (–) Starter (+) Circuit Voltage Drop Starter (–) Circuit Voltage Drop Over or under charging? OVER UNDER Final Charging Voltage Are there any issues that would prevent proceed- ing with diagnosing engine performance issues? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 16 95-HV-950 SA-6 Wiring Diagram Practice SA-6 Wiring Diagram Practice (4 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step six in getting familiar with this trainer and wiring to the ECU. Using service information fill in each blank with as much information as possible. HV-950 ECU connector Pin wire Color Circuit # Function (Signal / Control / Reference / ?) Example 1 DK BLU 1161 APP sensor 1 signal consulab.com info@consulab.com 17 95-HV-950 SA-6 Wiring Diagram Practice Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 18 95-HV-950 SA-6 Wiring Diagram Practice Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 19 95-HV-950 SA-6 Wiring Diagram Practice Pin wire Color Circuit # Function (Signal / Control / Reference / ?) Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 20 95-HV-950 SA-7 Expected Voltages SA-7 Expected Voltages (4 pages) Developing an accurate, dependable diagnostic strategy will depend on your understanding of how a system works and what measurements are expected when testing any system. This is an exercise designed to verify a student’s under- standing of certain common engine management systems. Prior knowledge of the principles of operation for the follow- ing systems is required. Having completed SA-6 but before proceeding to SA-8 (where you will actually take voltage measurements at the BOB PIN’s), complete the following chart as best possible with the voltage reading you would expect at the PIN’s identified. Start by verifying B+ at battery and at dashboard test point, then test all BOB PIN points with the KEY OFF to determine if there are any “HOT ALL TIME” PIN’s. HV-950 ECU connector Pin wire Key off KOEO KOER Component / Sensor* Example 1 5 V 4.2 V Engine Coolant Sensor consulab.com info@consulab.com 21 95-HV-950 SA-7 Expected Voltages Pin wire Key off KOEO KOER Component / Sensor* consulab.com info@consulab.com 22 95-HV-950 SA-7 Expected Voltages Pin wire Key off KOEO KOER Component / Sensor* consulab.com info@consulab.com 23 95-HV-950 SA-7 Expected Voltages Pin wire Key off KOEO KOER Component / Sensor* Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 24 95-HV-950 SA-8 Measured Voltages SA-8 Measured Voltages (4 pages) In preparation to diagnosing any engine management issues, one has to know what they are working on first. This exer- cise is step eight in getting familiar with this trainer and break out box. Follow instructions for ignition “KEY” position and then take voltage measurements at the indicated PIN at the breakout box, then record value measured in each blank provied below. Compare results to Student Assignment #7 (SA-7). HV-950 ECU connector Pin wire System / Voltage Key off ACC KOEO KOER Example 1 APP sensor 1 signal 0 V .9V .9V .9V consulab.com info@consulab.com 25 95-HV-950 SA-8 Measured Voltages Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 26 95-HV-950 SA-8 Measured Voltages Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 27 95-HV-950 SA-8 Measured Voltages Pin wire System / Voltage Key off ACC KOEO KOER Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 28 95-HV-950 SA-9 Engine Performance Fault Diagnosis Template SA-9 Engine Performance Fault Diagnosis Template Using all the information gathered in Student Activities 1-8 and the repair order style chart below, verify customer con- cern and document your diagnostic process. Be prepared to defend each step. HV-950 Fault # Details Customer Concern Student Observation Explain Strategy Tests Performed Fault Component Input/Output? Name : Group : Date : Instructor : Grade : consulab.com info@consulab.com 29 95-HV-950 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2026. All rights reserved. General description Educational Advantages Student Assignments SA1 Student assignment #1 Component identification — Basic (2 pages) SA2-A Student assignment #2A Component Identification — Specific (2 pages) SA2-B Student assignment #2B Component Identification — Dashboard Specific ID (3 pages) SA3 Student assignment #3 Component Identification — Sensors ID / HD Diesel(2 pages) SA4 Student assignment #4 Component Identification — Actuator ID/HD Diesel SA5 Student assignment #5 Charging System Verification SA6 Student assignment #6 HV-950 — Wiring diagram practice — ECU connector (4 pages) SA7 Student assignment #7 HV-950- — Expected voltages — ECU connector (4 pages) SA8 Student assignment #8 HV-950- — Measured voltages — ECU connector (4 pages) SA9 Student assignment template HV-950 — Engine performance fault diagnosis — Fault # (4 pages)

Purpose - The MF500-HT-TSE is an instructors “dream-come-true” with respect to teaching state-of-the-art, electronically-controlled hydrostatic transmission systems - hands-on. It can even be driven as if it were on a construction site - in real-time. Driving a skid-steer loader around a construction site and operating the MF500-HT-TSE in the lab amounts to the same thing - without the hazards! The electronically-controlled, infinitely variable, wheel-load system allows students to drive the hydrostatic transmission under any type of operating condition, i.e., up-hill, downhill, level surface - it can even simulate a runaway condition. Safety - the driving force behind the design and development of the MF500-HT-TSE - Skid-steer type loaders are today’s hydrostatic transmission training simulators – you will find one in the lab of almost every technical college in the country. However, these types of vehicles offer a host of unique safety hazards. Some of the more serious hazards include: unexpected vehicle motion, rotating wheels and shafts; noxious exhaust emis- sions; hot engine components; improperly supported vehicle, disconnecting of critical manufacturer installed safety devices, confined space, hot oil, etc. The MF500-HT-TSE eliminates ALL of the hazards associated with using a skid-steer type loader as a hydrostatic transmission training simulator because it is designed for educators not for a construction site. NOTE: The MF500-HT-TSE is painted standard ORANGE as shown here. Other colors are available. A premium may apply for non-standard color options. Interested in incorporating some of your company’s implements and/or components? Let’s discuss it! In addition to the numerous safety hazards posed by skid-steer type loaders in a lab, there are additional distinct disadvantages which include: the compactness of the vehicle makes it impos- sible for the instructor to engage in any type of demonstration or group activity with regard to component adjustment and or diag- nostics procedures. It is also impossible to safely load the hy- drostatic drive. These disadvantages erase 90% of the vehicle’s educational value. The MF500-HT-TSE is the solution fluid power instructors have been looking for because: • It has the look and feel of a skid-steer type loader with outstanding teaching and learning capability. • The hazards associated with using diesel-driven mobile machinery are eliminated. • Instructors can perform meaningful group discussions and demonstrations associ- ated with hydrostatic transmission pre-start, adjustment, and diagnostic procedures while the system is operating under any type of load conditions. The results are guar- anteed: students will benefit because they are learning and understanding “need-to-know” information. • Students can drive it, load it, troubleshoot it, and even “abuse” it, in the confines of a lab without ever putting rubber on the ground. The MF500-HT-TSE is, without a doubt, the safest and most effective training simulator available for teaching and learning hydrostatic drives. MF500-HT-TSE Hydrostatic Transmission Training Simulator Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time MF500-HT-TSE Hydrostatic Transmission Training Simulator 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org Features and Benefits: 1. Teaching and Learning in real-time - Bridges the gap between simulated learning and real-world experience. Learning hydrostatic transmission systems on the MF500-HT-TSE more than adequately prepares students to meet the challenges associated with maintaining, servicing, repairing and troubleshooting hydrostatic transmission systems safely and effectively because they learn on a fully functional system. 2. The MF500 will rapidly transform students into much needed highly-skilled hydrostatic transmission technicians who have the skill-sets to safely and correctly perform the following: • Pump and/or motor installation procedures • Pump and/or motor pre-start checks and adjustments • Pump and/or motor start-up checks and adjustments • How to set charge pressure relief valves on systems with and without hot oil shuttle valves • How to set main pressure relief valves and pressure over- ride valves • How to perform null adjustments on electronic displace- ment control valves • How and where to check pump and motor case pressures • How to perform mechanical adjustments on electronic and mechanical displacement control valves • How to perform *diagnostic procedures on a hydrostatic transmission system *for more information about the extent of the diagnostic procedures please refer to the troubleshooting section in the course workbook. 3. Extremely versatile - Teach any type or make of hydrostatic transmission on the MF500-HT-TSE. The standard trainer is equipped with a dual tandem-pump configuration with dual joysticks and electronic pump displacement controls. You can purchase the MF500-HT- TSE with the hydrostatic transmission of your choice (prices may vary), or you can easily adapt a different type of pump at a later time. The same applies to the wheel drive motors. The standard MF500-HT-TSE is equipped with dual high torque/low speed motors. However, it can also be equipped with low torque/high speed motors. Or a low speed/high torque motor can be installed on one side and a high speed/low torque motor on the other. 4. Nothing, including an actual vehicle, can match the MF500- HT-TSE’s troubleshooting teaching and learning capability - The perfect situation for a student to learn how to troubleshoot a hydrostatic transmission is to give them an actual machine, which is experiencing a real-time problem. There is a remote possibility that this can happen. However, what is virtually im- possible is to find machines with every type of failure a typical hydrostatic transmission can experience so students can learn broad troubleshooting skills. 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time MF500-HT-TSE Hydrostatic Transmission Training Simulator Dual tandem-pumps with dual joysticks and electronic pump displacement controls MF500-HT-TSE shown with optional MF500-IS Implement & Steering System Training Module 5. Nothing else matches the MF500-HT-TSE’s diagnostic learning capabilities - Over three decades of hydrostatic transmission trouble- shooting experience is designed into the MF500-HT-TSE. Its diagnostic capability is so advanced that every fault a typical hydrostatic transmission can experience in the field can be automatically introduced into the system for real- world troubleshooting in real-time. Faults include worn pump(s), worn motor(s), electronic problems, operation in one direction and not the other, sluggish operation, over- heating, etc. 6. MF500-HT-TSE safety features are endless - • No wheels on the ground equals no unforeseen safety hazards - Tires and tracks on hydrostatically- propelled vehicles offer unique hazards in a confined space - even when they are elevated. Hydrostatic drives are extremely sensitive and on most machines can “drive- through” their park brakes. The hazard level is heightened when a group of students are working on a machine with the engine running. • No hazardous rotating wheels or moving tracks - Rotating wheels and moving tracks present a variety of considerable safety hazards, which include: snagging clothing, crushing, etc. Every moving part on the MF500-HT-TSE was carefully analyzed for potential hazards. The four drive wheels are contained in heavy-duty, transparent plastic enclosures and all moving drive-train components are covered. • No fatigue because all major components are mounted waist high - Learning while crouched in the “belly” of a compact loader/excavator causes fatigue and frustration. It also results in students having to execute solo activities, which wastes valuable learning time. All hydraulic compo- nents on the MF500-HT-TSE are mounted where students work upright in a team-based learning environment. • No slip hazards or environmental problems - To minimize oil spillage all hydraulic components are equipped with self-draining oil pans. Also, all quick-connect/disconnect connections are flat-face, zero-leak type. • No confined space hazards - Learning a task is challenging enough without a student having to do it while standing on his/her head. Almost every hydraulic component in a compact mobile machine is extremely difficult to access, which makes team-based learning difficult or impossible. It also decreases retention. The lab is where students must learn and understand how to do the task safely and efficiently - and also generically. Once they know how, they will be able to deal with the access problems they will encounter in the field. • Two (2) emergency stops - In the unlikely event that something goes wrong, every work- station has easy access to an emergency stop button - pump controls, hydraulic motors (left and right), implement directional control, and steering. • Equipped with FPTI™’s exclusive Safe-T-Bleed® system - Safe-T-Bleed® is a product developed by FPTI™ and is exclusive to FPTI™ training simulators. The Safe-T-Bleed® system is designed to permit students to learn how to execute critical lockout and tagout procedures in accordance with State and Federal laws. Safe-T-Bleed® provides a means to safely bring a hydraulic system to zero mechanical state, which means no discharging high-pressure oil to atmosphere. Safe-T-Bleed® is also installed on the cylinders so students can learn how to purge air from cylinders without loosening connectors. • Industry-standard lockout devices - All electrical panels and moving parts are equipped with industry-standard safety lockout/locking devices. The implement and steering mechanisms are equipped with self-contained mechanical locking devices identical to those found on actual machinery. • Industry-standard Warning and Caution decals - Industry-standard, multi-lingual warning and caution decals are placed appropriately throughout the machine(s). Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time MF500-HT-TSE Hydrostatic Transmission Training Simulator 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org All FPTI™ simulators are available for operation at any voltage or frequency Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time MF500-HT-TSE Hydrostatic Transmission Training Simulator Specifications - Prime mover: Electric motor; 25HP (15 kw); TEFC; C-face; 1800 RPM; 3-phase - 460V (optional 3-phase - 230V available) Pumps: Dual, tandem-mount, axial piston type pumps; 2000 PSI (138 bar); 10 GPM (38 Lpm); electronic displacement control Motors: Dual, high torque/low speed motors; fixed displacement 5.0 in3/rev. (82 cm3/rev.) Reservoir capacity: 110 gallons (416 liters) Dynamic wheel load: Independent left-hand and right-hand wheel drive with infinitely variable electronic load control in forward and reverse Panel PC: Panel PC, Microsoft® Windows™ software; 24” (61cm) full-color touch-screen with pre- loaded learning software and diagnostic activities Diagnostics: Pre-programmed activities covering every fault published in a typical hydrostatic transmission manufacturer’s troubleshooting flow charts Safety features: • Transparent wheel covers - Drive wheels enclosed in Lexan® enclosures • Safe-T-Bleed® - Pumps equipped with Safe-T-Bleed® system for safe de-energization and verification • Emergency stops - The MF500 has two (2) emergency stop switches • Redundant electrical lockout - High voltage enclosure is equipped with a redundant lockout • Oil drip/recirculating tray - Drip tray which automatically recycles spilled oil in to the reservoir is located below the pump. • Industry-standard Warning and Caution decals - Multi-lingual warning and caution decals are placed where- ever necessary on the machine Options: Pumps: Any make or type currently available, e.g., Sauer Danfoss®, Rexroth®, Eaton®, Linde®, etc. Pump controls: Mechanical, hydraulic pilot Motors: High-speed/Low torque, fixed or variable displacement motors 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time MF500-HT-TSE Hydrostatic Transmission Training Simulator 82.00” (208cm) 69.00” (175cm) 47.00” (119cm) 69.25” (176cm) 52.5” (133cm) 82.5” (210cm) Shipping Specifications - Shipping weight (does not include optional MF500-IS- TSE Implement and Steering System training module, pallet or packaging): Unit weight: 2,200 lbs (998 kgs) Shipping weight: 3,300 lbs (1,497 kgs) Shipping dimensions: 85” (193cm) tall x 82” (183cm) wide x 90” (213cm) long Warranty - FPTI™ warrantees it’s products against defect in materials or workmanship for a period of two (2) years from date of delivery. Electrical Requirements for Operation - 208/230 VAC Electrical Circuit: 100 Amp dedicated circuit, non-instantaneous trip breaker. Portable cord must be 4-gauge wire, 4-conductor, 50-foot (15.24m) length max. 460 VAC Electrical Circuit: 40 Amp dedicated circuit, non-instantaneous trip breaker. Portable cord must be 8-gauge wire, 4-conductor, 50-foot (15.24m) length max. 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org MF500 (07/17/25) • COPYRIGHT © 2025 Adding the optional, and affordable, “plug-and- play” hydraulic implement and articulated steering system trainer to the MF500-HT- TSE hydrostatic transmission trainer transforms it into a fully-functional front-end loader with articulated hydraulic steering, and a cylinder service center. Purpose - Instructors who use actual front-end loaders for teaching bucket control hydraulic systems and hydraulic steering systems encounter the same problems as they do using a skid-steer type loader for teaching hydrostatic transmission systems - inherent safety hazards and the inability to safely load the bucket control and steering systems. Which arguably makes these types of vehicles useless for the purpose of technical education. The MF500-IS-TSE hydraulic implement and articulated steering module is designed exclusively for educational purposes, which made safety our number one design objective. Safety - The MF500 designers identified four potential hazards associ- ated with the use of front-end loaders in an educational setting: 1. Bucket riding - It is possible for a student to ride in the bucket of a front-end loader. 2. Foot pinch-point - It is possible for the bucket of a front- end loader to be inadvertently lowered onto a student’s foot. This problem is of particular concern if the bucket is equipped with a float option. The float option makes it possible for the bucket to free-fall to the ground from any elevation if the float position is inadvertently selected. 3. Unsecured load - If a student placed an object in the bucket of a front-end loader to simulate load there is a possibility the load could fall out if the bucket is inadvertently tipped forward. 4. Lift arm and rollback mechanical locks - Most bucket mechanisms have integrated mechanical locking devices. However, some lock the cylinder rods only. In the event of a cylinder being removed it is possible to compromise safety. MF500-IS-TSE Hydraulic Implement and Articulated Steering System Module (optional) Hydraulic Training Systems 888-222-3421 The MF500 designers eliminated these hazards: 1. No floor surface in the bucket - Without a floor surface to stand on, students are not enticed into “riding” the bucket. 2. Bucket lip and sides do not touch the ground - The entire lower surface of the bucket is designed to stop at least 4” (10cm) off the ground to prevent foot crush hazards. 3. Safe and secure load - No floor means no loose loads, which can fall out accidentally. The load fastens securely to the bucket with redundant safety locks and pins. 4. Mechanical locks - The lift/lower, rollback/dump, and articulated steering mechanisms, are void of pinch- points. However, to give students a sense of reality, safety locking mechanisms identical to those used in industry were added so they can practice and learn how important mechanical locks are and how to properly use them. In addition, the lift-cylinders are equipped with integral, non-adjustable, safety flow control orifices, which are designed to regulate descent velocity in the event of a hydraulic hose failure and when lowering a loaded bucket. Teaching and learning hydraulics in real-time Optional hydraulic implement and articulated steering training module 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org Cylinder rebuild station (optional) - The integral cylinder rebuild station is designed to permit two groups of students to disassemble/assemble cylinders at the same time. This feature enhances safety because without it students are forced to wrestle cylinders, which are either locked in a vice, or lying on a workbench. If the parts unexpectedly fall they can cause severe injuries to the legs and feet. The cylinder repair station is designed with safety in mind. The student simply slides the cylinder into a cradle (no tools nec- essary) and installs a locking pin, which not only secures the cylinder but also prevents it from rotating when the student is loosening/tightening the gland. Even if the student forgets to install the locking pin, the cylinder cannot move even when the load lifts up. To prevent oil from spilling onto the ground, two (2) removeable oil drip trays are strategically located on the table top. MF500-IS-TSE Hydraulic Implement and Articulated Steering System Module (optional) Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time Features and Benefits: Load is mobile, safe, and environmentally friendly - The load consists of a 70 gallon (265 liter) water tank, which is contained on a mobile fixture. Heavy-duty casters with four-wheel brakes support the load. Load engagement in the bucket is simple, safe, and semi-auto- matic. The load assembly has two steel arms welded to a steel support bar. When the load is rolled into the bucket the arms engage two slots (one on either side) in the rear plate of the bucket. Once through the slots, the arms are locked into place with pins (chained to the bucket). If a student forgets to install the pin(s) a redundant locking system automatically locks onto the bucket as it begins upward movement. Compact - Lab floor space is limited and ex- pensive. The MF500-HT-TSE is designed with this in mind. With a footprint of only 64.0” (163cm) wide x 76.0” (193cm) long, it is a fraction of the size of an actual articulated machine, which makes it easy to maneuver and store. The optional implement and articulated steering mechanism (MF500-IS-TSE) with a footprint of only 42.0” (107cm) wide x 75.0” (191cm) long sits on three wheels, which are positioned in the form of a tricycle making it easy to move and store. Attaching or detaching the module is simple – wheel it into place, install two pins, connect two quick-connect fittings, plug in the 24VDC receptacle – and it’s ready to go. 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time Specifications - Pump: Gear type - 0.77 in3/rev. (12.61 cm3/rev.) fixed displacement Pressure: 2000 PSI (138 bar) maximum pressure Directional control valve: Sectional type (four sections) - inlet section, two spool sections, and outlet section. Section 1 - Inlet section with integral, adjustable pressure relief valve (cartridge-type) Section 2 - Three-position, four-way, cylinder spool configuration, load check valves, cylinder port relief valve (cartridge-type) and anti-cavitation valve (cartridge-type) Section 3 - Three-position, four-way, cylinder spool configuration, load check valves, two cylinder port/anti-cavitation combination valves (cartridge-type) Section 4 - Outlet section with power- beyond capability Steering Orbitrol valve: Closed-center Differential Pressure Unloading valve: Cartridge-type Cross-port Relief valves: Adjustable, cartridge-type Cylinders: Dual lift/lower, double-acting single rod cylinder: Bore - 1.5” (3.81 cm) Rod - 1” (2.54 cm) Stroke - 14” (35.56 cm) Gland type - threaded Dual rollback/dump cylinders: Bore - 1.5” (3.81 cm) Rod - 1” (2.54 cm) Stroke - 4” (10 cm) Dual steering cylinders: Bore - 1.0” (2.54 cm) Rod - 5/8” (1.59 cm) Stroke - 8” (20.3 cm) Accumulator: 1 quart (0.95 Liter). Bladder-type. Safety features: • Self-contained mechanical lock - lift/lower mechanism • Self-contained mechanical lock – rollback/dump mechanism • Self-contained mechanical locks – steering mechanism • Safe-T-Bleed® installed on all cylinder ports to facilitate safe de-energization and verification procedures and drip-free and safe air-bleeding procedures • Industry-standard Warning and Caution decals - Multi-lingual warning and caution decals are placed where- ever necessary on the machine • Zero pinch-points Diagnostics: Diagnostics on the implement system are in real-time because the implement system operates under actual working and load conditions. Wear-type faults are designed into the pump, pressure relief valve, directional control valves, and cylinders. Directional control valve diagnostics includes precision leak detection us- ing FPTI™’s exclusive pressure/leak test technology. Students learn to isolate leakage between a cylinder port cartridge valve and wear between the spool and bore. Options: Pump: Pressure-compensated, variable volume Pressure-compensated, variable volume with load-sense Directional Control Valve: Electro-hydraulic control Hydraulic pilot with joystick control - - Single-axis Load-sense Cylinders: Internal magnet for position feedback MF500-IS-TSE Hydraulic Implement and Articulated Steering System Module (optional) All FPTI™ simulators are available for operation at any voltage or frequency 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org MF500-IS-TSE Hydraulic Implement and Articulated Steering System Module (optional) Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time Shipping Specifications - Shipping weight (does not include pallet or packaging): 560 lbs (254 kgs) Shipping dimensions: 45.0” (114cm) tall x 42.0” (107cm) wide x 75.0” (191cm) long 39.00” (99cm) 48.50” (123cm) 32.50” (83cm) 27.50” (70cm) 86.50” (220cm) Warranty - FPTI™ warrantees it’s products against defect in materials or workmanship for a period of two (2) years from date of delivery. 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org 888-222-34212170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org MF500 (07/17/25) • COPYRIGHT © 2025

The 1-HumanPower™, zero-emissions hydraulic training system is designed to help students clearly understand fundamental hydraulics as it relates to horsepower, flow and pressure. It’s the only training system that lets students literally see how increases and decreases in pedal speed relates to increases and decreases in actuator speed. Also, the clever use of areas and weights let’s students actually see the relationship of pressure to actuator force and torque. Changes in “human-power” in reaction to increases and decreases in pedal speed (flow) and pedal force and torque (pressure) makes it possible for students to relate those changes to input horsepower in a hydraulic system. The MF600-1HP lets students pedal their way to really understanding vital fundamentals that are sometimes hard to grasp with theory. • Prime mover – student. • Power supply - human-mechanical energy is converted into fluid energy when a student exerts a force on pedals, which is con- verted to torque. The torque rotates a weighted fly-wheel, which is connected to a hydraulic pump through a belt drive. • Seat - comfortable gel-seat, which has convenient wrench-free height and lateral adjustment. • Crane: Has three functions: boom raise/lower, mast rotation left/right (180° either way), and hydraulic winch with belt and hook (for attaching weight). Digital panel-mounted instrumentation - • Flow meter • Pressure gauge • Digital tachometer. 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org 888-222-3421 Hydraulic components: • Fixed displacement gear pump • Dual double-acting, single rod cylinder - boom raise and boom lower • Double-acting, single-rod cylinder - mast extension • 2 x bi-directional, fixed displacement hydraulic motors - belt reel and rotation. • Four (4) D03 solenoid controlled directional control valves. • Flow control valves one-way • Hydraulic tank - plastic 0.75 gallon (3.79 liter) capacity • Weight - approximately 50lbs. (22.7 kg) MF600-1HP (1-HumanPower™) - Basic Hydraulics Training System Hydraulic Training Systems Teaching and learning hydraulics in real-time MF600-1HP (1-HumanPower™) - Basic Hydraulics Training System Features - • Boom cylinder permits students to see how pressure responds to changes in surface area when the load is constant. • Due to the fact the student is the prime mover, the student can see first-hand how changes in pedal speed relate to changes in actuator speed. • This also allows student to see first-hand how they must respond by exerting more or less power in response to changes in flow and pressure. 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time MF600-1HP (10/23/25) • COPYRIGHT © 2025 Learning Activities - What the MF600-1HP 1-HumanPower will teach students: 1. Hydraulic safety. 2. Force and torque – each student calculates the amount of torque he/she generates at the flywheel. 3. Flow relative to flywheel and pump speed. 4. How changes in flow effect changes in actuator speed. 5. How to calculate actuator speed. 6. Where pressure comes from. 7. Why a hydraulic pump has everything to do with pressure in a hydraulic system. 8. How to calculate force and torque output. 9. How pressure changes in response to changes in load. 10. How pressure changes in response to changes in area and displacement. 11. How changes in area relate to changes is pressure when the load is constant. 12. Hydraulic horsepower. 13. How to calculate hydraulic horsepower. 14. Pressure differential. Shipping Specifications - Shipping weight (does not include pallet and pack- aging): 700 lb (318 kgs) Footprint dimensions: 80” (2032cm) tall x 51.50” (1308cm) wide x 89” (2261cm) deep (at full boom extension). Warranty - FPTI™ warrantees it’s products against defect in materials or workmanship for a period of two (2) years from date of delivery. 71.0” (1.803 m) 89.0” (2.261 m) 42.50” (1.08 m) 80” (2.032 m)

Teachers, you wanted a pneumatic training system with some “must have” features: • Must have the ability to accept almost any, and every, type of pneumatic component, including your own. • Must have the ability to adapt to any skill level from basics through electro-pneumatics. • Must have industry-standard safety lockout valves: the same ones used in industry so you can teach your students to think safety and work safely. • Must have a light-weight frame that is compact, rigid, mobile, and extremely durable. • Must have been handcrafted with pride in the USA with unrivalled quality. • Must have the ability to grow as your needs and budget grow. We love it when teachers know what they must have to teach pneumatics brilliantly. Plug-and-Play component mounting system: All components store neatly along the bottom of the mounting panel. Each component is tagged with its appropriate ISO symbol. The student simply selects the component that corresponds with the symbol on a schematic and constructs the system - it’s that simple! MF700-PN Pneumatic Training System 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org Pneumatic Training Systems 888-222-3421 Teaching and learning pneumatics in real-time Build completely operational pneumatic systems Component storage slots on front of trainer allow quick and easy access to most commonly used components Components (Model MF700-PN) - 1 Frame assembly with 4 swivel casters with locks. 1 Panel assembly. 1 Air compressor (optional). 2 Roller operated DCV, 2-position, 3-way. 1 Hand-lever operated DCV, 2-position, 3-way, spring return. 1 Single remote piloted DCV, 2-position, 4-way, air return. 1 Single solenoid operated DCV, normally closed, 2-position, 3-way, air return. Unique valve lock- ing design allows for easy on/off in- stallation of valves and components MF700-PN Pneumatic Training System 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org Pneumatic Training Systems Teaching and learning pneumatics in real-time Spacious front tray with lip allows students to build systems while working with their books and manuals Convenient hose storage on both sides of the trainer keeps hoses organized and out of the way Keep the work area clean and clutter free: All hoses with quick-connect/disconnect valves are stored in a convenient rack. 1 Double solenoid operated DCV, 3-position, 4-way, spring centered. 4 One-way flow control valves. 1 Double-acting, single rod cylinder, 10” stroke, 1.5” bore. 2 Single-acting, single rod cylinder, 6” stroke, 1.5” bore. 1 Filter/regulator/E-stop with 4-port distribution block. 1 Quick exhaust valve. 3 0-150 PSI pressure gauges, 1.5” display. 8 30” hose assemblies. 1 100’ hose roll. 1 Tubing cutter. 20 Hose fitting assembly. 10 Tee fitting. 1 Student workbook. 1 Instructor Answer CD with PowerPoint. Lined work surface: A convenient, lined, work surface provides a place for students to put their workbooks leaving their hands free to assemble and disassemble circuits. Adapt any pneumatic component to the MF700-PN, even if it’s not one of ours: FPTI™’s unique, plug-in style mounting hardware makes it possible to mount *any component in either a vertical or horizontal position. *to mount components other than those provided by FPTI,™ a special mounting adaptor will be required. And, it’s a rather simple system to operate: Plug it in to a standard 115V - single-phase recep- tacle, insert your Powerpoint CD, hand out the text books and simulator activity manuals to your students, and let the teaching and learning begin! Your compressor or ours: We can supply an air compressor, or you can simply plug the simulator into your local air sup- ply. The on-board air filter, water separator, and pressure regulator, insures that the components operate at a safe pressure level, and that there is always a clean and water-free supply of air. MF700-PN Pneumatic Training System Shipping Specifications - Shipping weight (does not include pallet and packaging): Double-sided simulator - 405 lbs (184 kgs) Single-sided simulator - 405 lbs (184 kgs) Shipping dimensions: 84” (213 cm) tall x 54” (137 cm) wide x 42”(107 cm) deep 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org Pneumatic Training Systems 888-222-3421 Teaching and learning pneumatics in real-time MF700-PN (10/23/25) • COPYRIGHT © 2025 All FPTI™ simulators are available for operation at any voltage or frequency Course Materials and Visual Aids - • Manual - Parker Corporation’s “Pneumatic Technology for Industry” • Visual Presentation - Pneumatic Technology for Industry Full-color, PowerPoint presentation on CD Warranty - FPTI™ warrantees it’s products against defect in materials or workmanship for a period of two (2) years from date of delivery.

Purpose- With the advances in electronic systems today and their use in automotive systems, instructors need a better way to introduce students, who may have only mechanical backgrounds, to the world of automotive electronics sys- tems. The MF900-VETS is designed to help instructors to help students with: • Fundamentals of electrical and electronics circuits • Understanding electrical automotive systems • Learn automotive starter system • Learn alternator’s battery charging system • Learn about speed, coolant temperature and oil pressure sensors • Understand CAN-BUS multiplexing systems (J1939 and OBD-II) • Learn about DTC (Diagnostic Trouble Code) • Troubleshooting of automotive lighting systems • Understand the difference between LED and Incan- descent Lights • Learn about automotive electronics modules How the MF900-VETS will benefit instructors, students and the college: 1. Instructors will benefit because they will: a. Teach with an already interconnected, automo- tive system. b. Produce faults for troubleshooting. c. Not have to deal with automotive connectors as the trainer has electronic connectors which can be disconnected manually, or via the computer. d. Teach the multiplexing system that is interactive with the computer. e. Teach the kind of outputs produced by automo- tive sensors. f. Teach what digital and analog inputs/outputs are. g. Teach “pull up type” and ladder resistor inputs. h. Have easy access to many points of the electrical system with banana-plug style test points. i. Teach the Starting and Charging systems with the modules included. j. Teach with the aid of the on-board software that interacts with the trainer. Training Systems 888-222-3421 Teaching and learning hydraulics, pneumatics, electronics in real-time MF900-VETS Vehicle Electrical Training System - 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org 2. Students will benefit because they will: a. Have the skill to troubleshoot automotive elec- trical systems. b. Have the skill to avoid unnecessary replacement of electronic modules. c. Understand multiplexing systems and failure cases. d. Understand the Starting and Charging systems. e. Have the skills necessary to understand other manufacturers electrical schematics. f. Learn the effects of bad grounding connections. g. Learn about voltage drops and bad connections. h. Learn the importance of using more testing tools (e.g., oscilloscopes, protocol analyzers, etc.) due to the complexity of today’s electronics. i. Understand modern electrical systems from an Input/Output/Modules point of view. j. Have a better understanding of electronic com- ponents in one multiplexing system and what they need for connectivity. k. Learn about multiplexing system communica- tion protocols (J1939). l. Have the skills to stay updated with modern electronics already present in today’s automo- tive systems. Training Systems 888-222-3421 Teaching and learning hydraulics, pneumatics, electronics in real-time 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org 3. Colleges will benefit because they will: a. Attract students because students will see, and appreciate, the investment the college has made in lab equipment that is specifically de- signed for teaching skills safely. b. Graduate students who will have the skill-sets needed to get, and keep, good paying jobs. c. Serve industry well – properly trained techni- cians means increased productivity and profit- ability for employers. d. Invest in training simulators that are designed for teaching specific skills safely leaving less chance for accidents and thus reducing liability. Hands-on Activities - Hands-on activities include: • Starter system, cold and hot start • Alternator charging system, load current, battery current • Understanding the automotive system of the MF900 • Identifying the electronics modules (Lights Module , Sensors Module and Switch Module) • Lights Module: control of the lights Sensors Module: Sensors reading (TPS, speed, coolant) Switch Module: Low current switches, dimmer, mul tifunction switch • Inputs, Outputs of the modules, types • Power Distribution Module, fuses and relays identifi- cation • Multiplexing system, communication between the modules, CAN-BUS and J1939 • Diagnostic Trouble Code, Testing with a J1939 generic Reader or an OBD-II reader • Troubleshooting the electrical system Course material - • Interactive Software on trainer, includes schematics and fault generation. The MF900-VETS consists of the following components: • One (1) 12V starter with cold and hot start selection, through software, with one 12V battery. • One side panel with LED’s and Incandescent Lights. • A multi-function switch with steering wheel. • Wiper Motor. • Automotive panel with gauges and indicators. • Power distribution module with relays and fuses. • Standard automotive switches and R-ladder switches (Transmission switch, multifunction switch). • Three (3) Electronics Modules for the multiplexing system. • Electronic connectors with indicators. • Banana-plug type test points. • CAN-BUS/J1939 and OBD-II available for trouble- shooting. • Magnetic and Hall effect speed sensors on main panel. • Coolant Temperature and Oil Pressure automotive sensors on main panel. • TPS sensor on main panel. • Battery and alternator current sensors for monitor- ing charging and crank current. • Touch-screen computer with interactive software for generating faults, seeing J1939 messages in real- time, interactive schematics, etc. Warranty - As with all FPTI™ training systems, the MF900-VETS Hy- draulic Training Simulator is covered for two (2) years from date of delivery. Warrantee covers defects in materials and quality of work. Warrantee does not cover damage caused by abuse or modifications. MF900-VETS Vehicle Electrical Training System - Training Systems 888-222-3421 Teaching and learning hydraulics, pneumatics, electronics in real-time 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org MF900-VETS Vehicle Electrical Training System - Shipping Specifications - (Subject to change) Shipping weight (does not include pallet and packag- ing): Training simulator - 920 lbs (417 kgs) Shipping dimensions (does not include pallet): 78” (198 cm) tall x 48” (122 cm) wide x 30” (76 cm) deep 888-222-3421 MF900-VETS (07/17/25) • COPYRIGHT © 2025 All FPTI™ simulators are available for operation at any voltage or frequency 78” (198 cm) 48” (122cm) 30” (76cm) Electrical Requirements for Operation - 110 VAC, 20 Amp dedicated circuit is required. If an extension cord is used, it must be 12-gauge wire or larger, 3-conductor (neutral, hot, ground), 50-foot (15.24m) length max.

Answer Key and Theory for HV-950 Diesel Engine Training Bench 91-HV-950_REVA © ConsuLab Educatech Inc, 2026. All rights reserved. Teacher Only 91-HV-950 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. Table of Contents General description 3 Educational Advantages 3 Student Assignments — Answers SA-1 Component identification — Basic — Answers 5 SA-2A Component Identification — Specific — Answers 7 SA-2B Component Identification — Dashboard Specific ID — Answers 9 SA-3 Component Identification — Sensors ID / HD Diesel — Answers 12 SA-4 Component Identification — Actuator ID/HD Diesel — Answers 14 SA-5 Charging System Verification — Answers 15 SA-6 Wiring Diagram Practice — Answers 16 SA-7 Expected Voltages — Answers 20 SA-8 Measured Voltages — Answers 24 SA-9 Engine Performance Fault Diagnosis Template — Answers 28 consulab.com info@consulab.com 3 91-HV-950 General description General description The HV-950 family of diesel engine trainers are fully operational engines mounted on a mobile stand. The trainers are easy to work on and all major components, wiring and connectors match OEM configuration. Each trainer is either a one or two piece construction design depending on the model. The one piece diesel bench has the actual engine mounted on a mobile stand constructed of 2” (5 cm) tubular steel equipped with four 5” (12.5 cm) phenol casters (2-fixed and 2-swivel w/locks), and may or may not include the after-treat- ment unit on top. The two piece diesel bench has the exhaust after-treatment unit apart that must be properly con- nected to the engine prior to demonstrations or assignments. Students can perform many ASE Educational Foundation related Engine Performance and Electrical/Electronic tasks using this trainer. Trainers are equipped with safety guards covering all rotating components. Educational Advantages • Demonstration of major engine systems to groups of students without the access limitations of a complete vehicle. • Engine systems respond to inserted fauts with real world symptoms, OEM DTC’s and check engine light operation. • Functional DLC using SAE J1939 protocols. • Demostration of exhaust after treatment emission system operation if applicable. TWO-PIECE DIESEL ENGINE TRAINER ONE-PIECE DIESEL ENGINE TRAINER consulab.com info@consulab.com 4 91-HV-950 Student Assignments — Answer Key Student Assignments Answer Key consulab.com info@consulab.com 5 91-HV-950 SA-1 Component identification — Basic — Answers SA-1 Component Identification — Basic — Answers (2 pages) As our HV-950 diesel engine trainers all vary slightly in their applications, it is recommended that an advanced student compile the answers to this assignment for the instructor to use as a future reference guide. This will ensure the answers are specific to this particular trainer. Component Function Location HV-950 Diesel Engine Application: Engine Gas or Diesel Engine mounts Transmission Transmission fluid level inspection Coolant Hoses Coolant reservoir & cap Thermostat Cooling Fan Radiator Oil Filter Oil Drain plug Oil dipstick Air Filter Fuel Filter(s) Throttle (body) Positive Crankcase Ventilation system consulab.com info@consulab.com 6 91-HV-950 SA-1 Component identification — Basic — Answers Component Function Location Batteries Starter Alternator Belt(s) Exhaust After Treatment DEF Fluid reservoir Fuse box - power DLC consulab.com info@consulab.com 7 91-HV-950 SA-2A Component Identification — Specific — Answers SA-2A Component Identification — Specific — Answers (2 pages) As our HV-950 diesel engine trainers all vary slightly in their applications, it is recommended that an advanced student compile the answers to this assignment for the instructor to use as a future reference guide. This will ensure the answers are specific to this particular trainer. Engine system Engine specific information HV-950 Diesel Engine Application: VIN & decode Engine type Gasoline Diesel Engine model Engine displacement Numbers of cylinders Cylinder numbering Firing order Direction of engine rotation Compression ratio Aspiration Turbo N/A Supercharged Camshaft configuration OHV SOHC DOHC Turbo type Charge air cooler location & function Fuel system type DEF Fluid reservoir J1939 parameter display unit consulab.com info@consulab.com 8 91-HV-950 SA-2A Component Identification — Specific — Answers Engine system Engine specific information Glow Plugs (if applicable) Emission Controls EGR DOC SCR w/DEF DPF Other technologies : consulab.com info@consulab.com 9 91-HV-950 SA-2B Component Identification — Dashboard Specific — Answers SA-2B Component Identification — Dashboard Specific — Answers (3 pages) Dash icon & name Description 1. MAIN SWITCH LAMP Green lamp notifies the operator that the engine is powered by the batteries. 2. EMERGENCY STOP SWITCH Notifies the operator that one of the emergency stop switches has been activated. 3. MALFUNCTION INDICATOR LAMP (MIL) Notifies the operator that an emission related system error occurred. The MIL is an OBD component and is subject to all OBD requirements for all 2016 and beyond engine installations. 4. ENGINE SHUTDOWN Notifies the operator that a serious system error occurred, and protection actions are approaching. When the abnormal operating condition remains and a shutdown condition is met, the engine will shut down in 30 seconds un- less the operator activates the Engine Protection Shutdown Override Switch. 5. WARNING Indicates engine conditions which require prompt operator attention and flashes diagnostic fault codes. 6. IGNITION SWITCH Indicates that the ignition switch is turned to the ON position. 7. ENGINE OIL PRESSURE Notifies the operator that the engine oil pressure is too low. 8. GLOW PLUG Indicates that the ignition is turned on until the plugs are heated sufficiently to start the engine. 9. ENGINE RETARDER Notifies the operator that the engine retarder is in operation. consulab.com info@consulab.com 10 91-HV-950 SA-2B Component Identification — Dashboard Specific — Answers Dash icon & name Description 10. DPF LAMP Notifies the operator that the diesel particulate filter (DPF) needs to regen- erate within the next several hours of engine operation. It is turned ON to indicate the initial level of regeneration is needed in DPF. It starts blinking when the situation is more urgent. 11. DIESEL EXHAUST FLUID LAMP Alerts the vehicle operator that the DEF fluid is low and must be replen- ished. 12. HIGH EXHAUST SYSTEM TEMPERATURE (HEST) LAMP Indicates that high exhaust temperatures may exist due to aftertreatment regeneration. 13. ENGINE EMISSIONS SYSTEM MALFUNCTION Illuminates when an emission-related fault occurs. Switch Position Function 14. ENGINE RE- TARDER I Activates the engine retarder. O Deactivates the engine retarder. 1-2-3 Sets the engine retarder level. 15. CRUISE CON- TROL I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. 16. PTO SYSTEM CONTROL 17. PTO ENGINE SPEED I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. consulab.com info@consulab.com 11 91-HV-950 SA-2B Component Identification — Dashboard Specific — Answers Switch Position Function 18. REGENERA- TION Forces a stationary regeneration when the engine is running at low idle speed and specific entry conditions are satisfied. AUTO Permits an active regeneration of the Diesel Particulate Filter when all required entry conditions are satisfied. Inhibits an active regeneration of the Diesel Particulate Filter. 19. PARKING BRAKE I Engages the parking brake O Disengages the parking brake. 20. SERVICE BRAKE I Applies the service brake. O Releases the service brake 21. CLUTCH I Disengages the clutch. O Engages the clutch 22. FAN OVERRIDE I Forces the radiator fan to operate O Normal operating mode 23. DIAGNOSTIC REQUEST I Activates diagnostic request O Normal operating mode consulab.com info@consulab.com 12 91-HV-950 SA-3 Component Identification — Sensors ID / HD Diesel — Answers SA-3 Component Identification — Sensors ID / HD Diesel — Answers (2 pages) As our HV-950 diesel engine trainers all vary slightly in their applications, it is recommended that an advanced student compile the answers to this assignment for the instructor to use as a future reference guide. This will ensure the answers are specific to this particular trainer. Sensor Function Location ECM/PCM Connector & Pin #’s HV-950 Diesel Engine Application: Accelerator pedal position 1 Accelerator pedal position 2 Accelerator Pedal PWM Aftertreatment Intake NOx Aftertreatment Outlet NOx Ambient Air Temp Atmospheric Pressure Boost Pressure Camshaft Position Crankcase Pressure Crankshaft Position DEF Tank Level DEF Tank Temp DEF Dosing Pressure DEF Differential Pressure DPF Outlet Pressure Exhaust Gas Recirculation (EGR) temp consulab.com info@consulab.com 13 91-HV-950 SA-3 Component Identification — Sensors ID / HD Diesel — Answers Sensor Function Location ECM/PCM Connector & Pin #’s EGR Differential Pressure Engine Coolant Temp Exhaust Gas Pressure Fan Speed Fuel Contamination Fuel Level Fuel Tank Pressure Fuel Rail Pressure Intake Air Temp/Pressure Manifold Absolute Pressure Mass Air Flow Mass Gas Flow NOx Oil Pressure Universal Exhaust Gas Oxygen (UEGO) Turbo/Intake Air Temp Turbo Speed Sensor Vehicle Speed Sensor Water in Fuel INSERT ANY SENSORS SPECIFIC TO THIS ENGINE consulab.com info@consulab.com 14 91-HV-950 SA-4 Component Identification — Actuator ID/HD Diesel — Answers SA-4 Component Identification — Actuator ID/HD Diesel — Answers As our HV-950 diesel engine trainers all vary slightly in their applications, it is recommended that an advanced student compile the answers to this assignment for the instructor to use as a future reference guide. This will ensure the answers are specific to this particular trainer. Actuator Function Location ECM/PCM Connector & Pin #’s HV-950 Diesel Engine Application: Camshaft Position Actuators DEF Tank Heater Control Valve DEF Dosing Valve Engine Intake Throttle Motor Fuel Pump Actuator Injector 1 Injector 2 Injector 3 Injector 4 Injector 5 Injector 6 Throttle Actuator Controller Variable Geometry Turbo- charger INSERT ANY ACTUATORS SPECIFIC TO THIS ENGINE consulab.com info@consulab.com 15 91-HV-950 SA-5 Charging System Verification — Answers SA-5 Charging System Verification — Answers As our HV-950 diesel engine trainers all vary slightly in their applications, it is recommended that an advanced student compile the answers to this assignment for the instructor to use as a future reference guide. This will ensure the answers are specific to this particular trainer. HV-950 Diesel Engine Application: Task Record results & interpret Visual Inspection of Battery Visual Inspection of Alternator Visual Inspection of the Belt Open Circuit Voltage (OCV) State of charge = What can affect this voltage ? Cranking Voltage Lowest voltage observed = Charging System Voltage Is this 2V over OCV ? YES NO Is this system functioning properly ? Voltage drops to verify system integrity Note : Current has to be flowing to perform an accu- rate Voltage Drop Chassis Ground Engine Ground Charging Circuit (+) Charging Circuit (–) Starter (+) Circuit Voltage Drop Starter (–) Circuit Voltage Drop Over or under charging? OVER UNDER Final Charging Voltage Are there any issues that would prevent proceed- ing with diagnosing engine performance issues? consulab.com info@consulab.com 16 91-HV-950 SA-6 Wiring Diagram Practice — Answers SA-6 Wiring Diagram Practice — Answers (4 pages) As our HV-950 diesel engine trainers all vary slightly in their applications, it is recommended that an advanced student compile the answers to this assignment for the instructor to use as a future reference guide. This will ensure the answers are specific to this particular trainer. HV-950 ECU connector Pin wire Color Circuit # Function (Signal / Control / Reference / ?) Example 1 DK BLU 1161 APP sensor 1 signal consulab.com info@consulab.com 17 91-HV-950 SA-6 Wiring Diagram Practice — Answers Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 18 91-HV-950 SA-6 Wiring Diagram Practice — Answers Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 19 91-HV-950 SA-6 Wiring Diagram Practice — Answers Pin wire Color Circuit # Function (Signal / Control / Reference / ?) consulab.com info@consulab.com 20 91-HV-950 SA-7 Expected Voltages — Answers SA-7 Expected Voltages — Answers (4 pages) As our HV-950 diesel engine trainers all vary slightly in their applications, it is recommended that an advanced student compile the answers to this assignment for the instructor to use as a future reference guide. This will ensure the answers are specific to this particular trainer. Having completed SA-6 but before proceeding to SA-8 (where you will actually take voltage measurements at the BOB PIN’s), complete the following chart as best possible with the voltage reading you would expect at the PIN’s identified. Start by verifying B+ at battery and at dashboard test point, then test all BOB PIN points with the KEY OFF to determine if there are any “HOT ALL TIME” PIN’s. HV-950 ECU connector Pin wire Key off KOEO KOER Component / Sensor* Example 1 5 V 4.2 V Engine Coolant Sensor consulab.com info@consulab.com 21 91-HV-950 SA-7 Expected Voltages — Answers Pin wire Key off KOEO KOER Component / Sensor* consulab.com info@consulab.com 22 91-HV-950 SA-7 Expected Voltages — Answers Pin wire Key off KOEO KOER Component / Sensor* consulab.com info@consulab.com 23 91-HV-950 SA-7 Expected Voltages — Answers Pin wire Key off KOEO KOER Component / Sensor* consulab.com info@consulab.com 24 91-HV-950 SA-8 Measured Voltages — Answers SA-8 Measured Voltages — Answers (4 pages) As our HV-950 diesel engine trainers all vary slightly in their applications, it is recommended that an advanced student compile the answers to this assignment for the instructor to use as a future reference guide. This will ensure the answers are specific to this particular trainer. Follow instructions for ignition “KEY” position and then take voltage measurements at the indicated PIN at the breakout box, then record value measured in each blank provied below. Compare results to Student Assignment #7 (SA-7). HV-950 ECU connector Pin wire System / Voltage Key off ACC KOEO KOER Example 1 APP sensor 1 signal 0 V .9V .9V .9V consulab.com info@consulab.com 25 91-HV-950 SA-8 Measured Voltages — Answers Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 26 91-HV-950 SA-8 Measured Voltages — Answers Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 27 91-HV-950 SA-8 Measured Voltages — Answers Pin wire System / Voltage Key off ACC KOEO KOER consulab.com info@consulab.com 28 91-HV-950 SA-9 Engine Performance Fault Diagnosis Template — Answers SA-9 Engine Performance Fault Diagnosis Template — Answers As our HV-950 diesel engine trainers all vary slightly in their applications, it is recommended that an advanced stu- dent compile the answers to this fault diagnosis for the instructor to use as a future reference guide. This will ensure the answers are specific to this particular trainer. HV-950 Fault # Details Customer Concern Student Observation Explain Strategy Tests Performed Fault Component Input/Output? consulab.com info@consulab.com 29 91-HV-950 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2026. All rights reserved. General description Educational Advantages Student Assignments SA1 Student assignment #1 Component identification — Basic (2 pages) SA2-A Student assignment #2A Component Identification — Specific (2 pages) SA2-B Student assignment #2B Component Identification — Dashboard Specific ID (3 pages) SA3 Student assignment #3 Component Identification — Sensors ID / HD Diesel(2 pages) SA4 Student assignment #4 Component Identification — Actuator ID/HD Diesel SA5 Student assignment #5 Charging System Verification SA6 Student assignment #6 HV-950 — Wiring diagram practice — ECU connector (4 pages) SA7 Student assignment #7 HV-950- — Expected voltages — ECU connector (4 pages) SA8 Student assignment #8 HV-950- — Measured voltages — ECU connector (4 pages) SA9 Student assignment template HV-950 — Engine performance fault diagnosis — Fault # (4 pages)

Operation manual for HV-950-X15_035103 Diesel engine bench Cummins X15 EPA 2017 recycled 93-HV-950-X15_035103_REVA © ConsuLab Educatech Inc, 2026. All rights reserved. Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space https://www.consulab.com/customer-space 93-HV-950-X15 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 035103 and above. Table of Contents 95-HV-950 Student Assignments — Table of Contents 4 91-HV-950 Answer Key & Theory — Table of Contents 4 96-HV-950 Instructors Manual — Table of Contents 5 Main features 6 Functional aftertreatment systems 6 Optional equipment 6 Instructions 7 Batteries and Master Disconnect Switch 7 Diesel Tank 7 DEF Storage Tank 7 Exhaust system warning 8 Diesel Exhaust Particulate Filter Cleaning Warning 8 Connection and coupling of the exhaust aftertreatment unit 8 Fuse and relay identification 9 Starting 9 Lamp Identification and Function (if available) 10 Switch Identification and Function (if available) 11 EM-250-2 Electronic Programmable Fault Box 12 Fault Box Electrical Schematic 17 Emergency Stop Electric Schematic 18 Intelligent Battery Charger Instructions 19 93-HV-950-X15 Teacher Resources consulab.com info@consulab.com 4 95-HV-950 Student Assignments — Table of Contents 91-HV-950 Answer Key & Theory — Table of Contents 95-HV-950 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. Table of Contents General description 3 Educational Advantages 3 Student Assignments SA-1 Component identification — Basic 5 SA-2A Component Identification — Specific 7 SA-2B Component Identification — Dashboard Specific ID 9 SA-3 Component Identification — Sensors ID / HD Diesel 12 SA-4 Component Identification — Actuator ID/HD Diesel 14 SA-5 Charging System Verification 15 SA-6 Wiring Diagram Practice 16 SA-7 Expected Voltages 20 SA-8 Measured Voltages 24 SA-9 Engine Performance Fault Diagnosis Template 28 91-HV-950 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. Table of Contents General description 3 Educational Advantages 3 Student Assignments — Answers SA-1 Component identification — Basic — Answers 5 SA-2A Component Identification — Specific — Answers 7 SA-2B Component Identification — Dashboard Specific ID — Answers 9 SA-3 Component Identification — Sensors ID / HD Diesel — Answers 12 SA-4 Component Identification — Actuator ID/HD Diesel — Answers 14 SA-5 Charging System Verification — Answers 15 SA-6 Wiring Diagram Practice — Answers 16 SA-7 Expected Voltages — Answers 20 SA-8 Measured Voltages — Answers 24 SA-9 Engine Performance Fault Diagnosis Template — Answers 28 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. 93-HV-950-X15 Teacher Resources consulab.com info@consulab.com 5 96-HV-950 Instructors Manual — Table of Contents 96-HV-950 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. Table of Contents Trainer Use and Familiarization 4 General Description 5 Educational Advantages 5 Introduction to the HV-950 Family of Diesel Engine Benches 6 Student Assignments Basic Orientation Thru Advanced And Troubleshooting 9 Student Assignment 1 9 Student Assignment 2A 9 Student Assignment 2B 9 Student Assignment 3 9 Student Assignment 4 9 Student Assignment 5 10 Student Assignment 6 10 Student Assignment 7 10 Student Assignment 8 11 Student Assignment 9 11 Explanation of Recommended Student Assignment Outcomes 13 Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space https://www.consulab.com/customer-space consulab.com info@consulab.com 6 93-HV-950-X15 Main features Main features • Recycled EPA 2017 Cummins X15 diesel engine • VGT Turbocharger Engine brake • Mounting frame • Radiator • Charge Air System • Noiseless and flexible exhaust gas system w/DPF • After-treatment unit (SCR, DPF, DEF) • Bent tube intake system and filters • OEM Engine harness • Murphy PV-101 display unit featuring a customized setup and display feature for data available on the diesel engine bench • Accelerator pedal • OEM electronic control module • OEM Filters • DLC Data Link Connector • Custom tubular steel stands with casters • 5-gallon (19L) fuel tank • DEF storage tank • Emergency stop switch (2) • Master battery disconnect switch • 12V batteries (2) w/intelligent battery charger • Breakout box • Electronic programmable fault box Functional aftertreatment systems • EGR – Exhaust Gas Recirculation system • DOC – Diesel Oxydation Catalyst • DPF – Diesel Particulate Filter • SCR – Selective Catalytic Reduction (DEF Injection) Optional equipment • Dust cover • Dynamometer consulab.com info@consulab.com 7 93-HV-950-X15 Instructions Instructions This section of the manual provides instructions to follow when preparing and starting your diesel engine for demonstra- tion or maintenance purposes. We recommend that students wear protective eyewear at all times. Batteries and Master Disconnect Switch The batteries must always be connected while operating the trainer. ECM and DEF supply module power must be main- tained for 70 seconds after key off for all applications, even for those applications where the ECM is powered through a battery disconnect main switch. BATTERIES MASTER DISCONNECT SWITCH Diesel Tank Fill the tank with clean ultra-low sulfur diesel fuel before starting the engine. All diesel engine benches equipped with an aftertreatment system require the use of 15 PPM maximum, ultra-low sulfur diesel fuel. DO NOT use 500 PPM low sulfur diesel in this engine. This tank is equipped with a fuel level sensor. DIESEL TANK DEF Storage Tank Fill the tank with clean, fresh, Cummins recommended, DEF. DEF TANK consulab.com info@consulab.com 8 93-HV-950-X15 Exhaust system warning Exhaust system warning When running an engine bench in an indoor environment, use an exhaust removal system to prevent inhalation of dan- gerous gases. Diesel Exhaust Particulate Filter Cleaning Warning Exhaust outlet temperature can exceed 300°C (572°F) during this procedure. To help prevent personal injury or proper- ty damage from fire or burns, ensure the following: • Do not connect any shop exhaust removal hoses to the tailpipe during the regenerative process. We suggest that the regeneration mode be conducted with the trainer placed outside. • Move the trainer outdoors and set up a safe area. Confirm that nothing is on or near the exhaust system surfaces, keep all combustible material away during this procedure. • Do not leave the trainer unattended. • Due to the elevated engine temperatures created while performing this procedure it is imperative to ensure proper airflow across the radiator by keeping all obstructions clear. Connection and coupling of the exhaust aftertreatment unit The HV-950-X15 diesel training bench is equipped with an exhaust aftertreatment unit that must be properly connected to the engine prior to trainer use. Exhaust aftertreatment unit connected and coupled to the diesel training bench Follow the procedure below to install the exhaust aftertreatment unit to the bench. All the connectors and wires are combined into the OEM exhaust after-treatment wiring harness. Refer to Cummins operation and maintenance manual for further details on sensor and component location. Connect the after-treatment connectors, the emergency stop button connectors, the coolant line quickconnectors and the exhaust line. Refer to the plasticized document attached to the engine for getting more details about the aftertreat- ment component pinouts. Aftertreatment Connectors Coolant Line Quick-connectors Exhaust Line consulab.com info@consulab.com 9 93-HV-950-X15 Fuse and relay identification & Starting Fuse and relay identification # AMP Protected component F1 5A ECM Ignition Fuse F2 10A Key Battery Fuse F3 5A Accessories Fuse F4 5A DLC Fuse F5 5A Display Unit Fuse F6 5A Test Point Fuse F7 5A Fan Clutch Fuse F8 5A Fault Box Fuse R1 Starter Lockout Relay R2 Brake Lamp Relay R3 Fan Clutch Relay Starting 1. Turn the master disconnect switch to the ON position. 2. Start up the engine using the ignition key switch on the instrument panel. 3. On startup closely monitor the Murphy PV-101 oil pressure screen for proper pressure. Shut down the engine imme- diately if low pressure is observed. consulab.com info@consulab.com 10 93-HV-950-X15 Lamp Identification and Function (if available) Lamp Identification and Function (if available) Symbol Lamp Name Function MAIN SWITCH LAMP Green lamp notifies the operator that the engine is powered by the batteries. EMERGENCY STOP SWITCH Notifies the operator that one of the emergency stop switches has been activated. MALFUNCTION INDICATOR LAMP (MIL) Notifies the operator that an emission related system error occurred. The MIL is an OBD component and is subject to all OBD requirements for all 2016 and beyond engine installations. ENGINE SHUTDOWN Notifies the operator that an emission related system error occurred. The MIL is an OBD component and is subject to all OBD requirements for all 2016 and beyond engine installations. WARNING Indicates engine conditions which require prompt operator attention and flashes diagnostic fault codes. IGNITION SWITCH Indicates that the ignition switch is turned to the ON position. ENGINE OIL PRESSURE Notifies the operator that the engine oil pressure is too low. GLOW PLUG Indicates that the ignition is turned on until the plugs are heated suffi- ciently to start the engine. ENGINE RETARDER Notifies the operator that the engine retarder is in operation. DPF LAMP Notifies the operator that the diesel particulate filter (DPF) needs to regenerate within the next several hours of engine operation. It is turned ON to indicate the initial level of regeneration is needed in DPF. It starts blinking when the situation is more urgent. DIESEL EXHAUST FLUID LAMP Alerts the vehicle operator that the DEF fluid is low and must be replenished. HIGH EXHAUST SYSTEM TEMPERATURE (HEST) LAMP Indicates that high exhaust temperatures may exist due to aftertreat- ment regeneration. ENGINE EMISSIONS SYSTEM MALFUNCTION Illuminates when an emission-related fault occurs. consulab.com info@consulab.com 11 93-HV-950-X15 Switch Identification and Function (if available) Switch Identification and Function (if available) Switch Position Function ENGINE RETARDER I Activates the engine retarder. O Deactivates the engine retarder. 1-2-3 Sets the engine retarder level CRUISE CONTROL (left switch) CRUISE CONTROL (Right switch) I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. PTO SYSTEM CONTROL (left switch) PTO ENGINE SPEED (Right switch) I Activates the Power Take-off system control. O Deactivates the Power Take-off system control and returns to idle speed. Allows the engine speed to be ramped up by pressing and holding the switch. Allows the engine speed to be ramped down by pressing and holding the switch. REGENERATION Forces a stationary regeneration when the engine is running at low idle speed and specific entry conditions are satisfied. AUTO Permits an active regeneration of the Diesel Particulate Filter when all required entry conditions are satisfied. Inhibits an active regeneration of the Diesel Particulate Filter. PARKING BRAKE I Engages the parking brake O Disengages the parking brake. SERVICE BRAKE I Applies the service brake. O Releases the service brake CLUTCH I Disengages the clutch. O Engages the clutch consulab.com info@consulab.com 12 93-HV-950-X15 EM-250-2 Electronic Programmable Fault Box consulab.com info@consulab.com 2 EM-250-2-96_V2023-1 Electronic Programmable Fault Box EM-250-2 Electronic Programmable Fault Box Explanatory video : Link to video part 1 https://youtu.be/LH7cTzXuja0 Link to video part 2 https://youtu.be/bgS357skp6c EM-250-2 Electronic Programmable Fault Box consulab.com info@consulab.com 13 93-HV-950-X15 Electronic programmable fault box EM-250-2 consulab.com info@consulab.com 3 EM-250-2-96_V2023-1 General description General description The EM-250-2 is an electronic programmable fault box designed for any ConsuLab standard or custom engine training benches. Operation guide for the EM-250-2 In addition to manual fault insertion capabilities, the EM-250-2 fault box also permits the user to insert all faults remote- ly through software provided, to be installed on your Windows based computer and connected to the EM-250-2 fault box with a USB cable provided. The EM-250-2 fault box provides for two types of fault circuits : Simulated Signal Fault Circuit • Any simulated signal that is inserted in a circuit will be reflected in scan tool data, engine operational symptoms as well as any measurements made at the break-out box on the trainer. • Depending on which engine bench you have, the EM-250-2 is capable of simulating various input signals such as : - Variable voltage or current - Pulse width modulation - Variable frequency - Voltage drops - Open circuit Open/Closed Fault Circuit • Any simple open that is inserted in a circuit that will be reflected in scan tool data, engine operational symptoms as well as any measurements made at the break-out box on the trainer ALL faults are inserted between the engine and PCM, so all testing HAS TO BE PERFORMED at break out box and with a scan tool. No testing or disconnecting should be done at the component location. Note: Simulation is only possible when a given sensor is installed on your engine and ConsuLab has preprogrammed the related fault in. All the fault names and fault box models mentioned in this guide may not refer to your specific EM-250-2 fault box. consulab.com info@consulab.com 14 93-HV-950-X15 Electronic programmable fault box EM-250-2 consulab.com info@consulab.com 4 EM-250-2-96_V2023-1 Operating instructions Operating instructions Power Pressing this button starts and stops the fault box and can be used from any displayed menu. When you set up one or multiple faults, a data log is saved in the internal flash memory only after the fault box has been powered off. The saving procedure is automatically started upon shutdown. The faults will remain when the fault box is powered back on 1. ESC The back-up key. It backs you up one menu display screen per push of the button. ENT Pressing the ENT button confirms and sets any desired function that is flashing. NOTE : Flashing text is ALWAYS the one selected when the ENT button is pushed. Left arrow The left arrow key can be used for selecting which menu flashes or to decrease various signal values once the > > cursor appears next to that value. Right arrow The right arrow key can be used for selecting which menu flashes or to increase various signal values once the > > cursor appears next to that value. 1. We strongly recommend only operating the fault box with the supplied battery charger plugged in for consistent results. consulab.com info@consulab.com 15 93-HV-950-X15 Electronic programmable fault box EM-250-2 consulab.com info@consulab.com 5 EM-250-2-96_V2023-1 Quick guide to fast and simple operation Quick guide to fast and simple operation A. Turn on/off Press Qté: - REV:A DESCRIPTION: # DE PIÈCE: OUIBiseaux: Aimants NON 40008-01 ID. Façade, Bte Fautes EM-250-2C MATÉRIEL: Gravoply 1/16" gravé BlancNNOOIIRR XXNNOONN OUI X 8 ,2 7 " 9,40" and wait until the red light is flashing. B. Select manual or intermittent mode Arrow left or right and press ENT when MANUAL is flashing. Arrow left or right and press ENT when INTERMITTENT is flashing (see H below for details on intermittent fault insertion) C. Choose a system/sensor to fault Arrow left or right and press ENT when your choice is flashing. D. Adjusting simulated fault values Arrow left or right and press ENT when % is flashing. Flashing cursor (> > ) indicates value can now be adjusted. Arrow left or right to adjust %, then press ESC when finished. ** Don’t let the % confuse ! It is just a percentage of the original reference voltage. Keep it simple and adjust values while comparing it to a scan tool that reads the actual values the PCM will see. E. Activating the fault Pushing ESC after simulated value is set will return you to screen with NORMAL flashing, press ENT. Arrow left or right to allow change from NORMAL to FAULT. NOTE : The GREEN light next to the fault description will turn RED when FAULT is active. Press ESC and fault is set. F. Inserting OPEN faults There are only two choices with an OPEN fault. Arrow left or right to allow NORMAL or FAULT to flash, then press ENT to select. FAULT will be active when light turns RED. G. Inserting multiple faults The EM-250-2 has the capability of inserting multiple faults at once. Once one fault is inserted, push ESC and select another, follow the same procedure to activate and then push ESC. The more faults, the more red lights are illuminated. consulab.com info@consulab.com 16 93-HV-950-X15 Electronic programmable fault box EM-250-2 consulab.com info@consulab.com 6 EM-250-2-96_V2023-1 Quick guide to fast and simple operation H. Inserting intermittent faults At the opening menu, arrow right to allow INTERMITTENT to flash, press ENT. Arrow right or left to select sensor or system you want to insert an intermittent fault in, then press ENT. Four lines of information are now visible : 1. First line reminds us of the type of fault and system. 2. Second line is STATE : - This tells us the state of the fault, if the fault is ON or OFF. 3. Third line is DUTY : - Expressed as a % of the TIME chosen that the fault actually occurs. ‣ Example: an open injector that remains open for 50% (1.5 min) of the chosen 3.0 minute, 0 second time frame. 4. Fourth line is TIME: - This is the total window of time you choose for an intermittent fault to occur. - You choose what % of that window of time is actually a faulted condition (above on the Third line). I. Saving faults When you set up one or multiple faults, a data log is saved in the internal flash memory only after the fault box has been powered off. - The saving procedure is automatically started upon shutdown. The faults will remain when the fault box is powered back on. consulab.com info@consulab.com 17 93-HV-950-X15 Fault Box Electrical Schematic Fault Box Electrical Schematic 38 -1 J B OB F1 T CE R OS NE S MI S V5 -0 2FF34FF5F7F89F F1011 FF12 TL UA F X OB MI S V5 -0MI S V5 -0MI S V5 -0 T MI R OS NE S P MI R OS NE S P D- R GE R OS NE S P- PK C R OS NE S R OT CE J NI #1 PK C R OS NE S P M C R OS NE SEG P R OS NE S B NI PPIN 31 NI P 3 NI P F NI P 3 NI P 3 NI P 3 NI P YL R UC E 68 58 30 a7 8 V2 1 6F SP A R OS NE S )A (6 NI P IG N R OS NE S T R GE R OS NE S B NI P 26 -1 J 54 -1 JJ1-6636 -1 J 52 -1 JJ1-3181 -1 J 63 -1 J )V 5 -0 ( 01 -2 J 50 -2 J 56 -1 J 38 -1 J 26 -1 J 54 -1 J 66 -1 J 36 -1 J 52 -1 J 13 -1 J 81 -1 J 63 -1 J )V 5 -0 ( 01 -2 J 50 -2 J 56 -1 J SIM 0-5V 3 NI P DE R KL B 01 1 NP S 50 1 NP S 20 1 NP S 11 4 NP S 10 1 NP S 15 6 NP S 09 1 NP S 32 7 NP S 90 21 NP S 19 NP S E NI G NE P OT S K NA R C O N 21 4 NP S CI TS O NG AI D ED OC T L UA F T H W T H W T H W T H W T H W T H W T H W T H W W H TDE R LP PR ED ) M WP ( 55 - 2 J ) M WP ( 55 - 2 J © C onsuLab Educatech 2020 all rights reserved consulab.com info@consulab.com 18 93-HV-950-X15 Emergency Stop Electric Schematic Emergency Stop Electric Schematic EM ER G EN C Y STO P EN G IN E D EU TSC H 3 PIN S EM ER G EN C Y STO P LAM P EM ER G EN C Y STO P AFTER TR EATM EN T FU SE BO X 12V BATT D ASH R ED W H T G R N GRNRED BLK R ED D T 0 4 - 6 P BCA D T 0 6 - 6 S BLK W H T 1 2 3 4 BCA K EY B A TTER Y FU SE 10 A M P BLK W H T G R N 1 2 3 4 LO C K A C C O N STA R T BLK W H T G R N C ÂBLES AW G #16/3 R EV. D ESC R IPTIO N D ATE BY D R AW N BY: C H EC KED BY: D ATE: - - - - - - - - - --- N O ÉM IE AN C TIL M IC H AEL BLO U IN 2022-04-20 H V -950-X 15_035103 H V -950-X 15_035103 EM ERG EN CY STO P ELECTRICA L SCH EM A TIC R 0 © C onsuLab Educatech 2020 all rights reserved consulab.com info@consulab.com 19 93-HV-950-X15 Intelligent Battery Charger Instructions Intelligent Battery Charger Instructions OPERATION MANUAL HV-950-X15-93 CONSULAB.COM 21 INTELLIGENT BATTERY CHARGER INSTRUCTIONS Visiter le site de OPTIMATE pour télécharger le manuel de l'utilisateur : https://static1.squarespace.com/static/58ee35f3e6f2e1f4c4896f44/t/5a7b12734192028e230a2c74/ 1518015093415/TM194_OptiMate6_12-24V.pdf 6 USING THE OPTIMATE 6 VERY FLAT NEGLECTED BATTERIES: If the battery is deeply discharged (and possibly sulfated), remove from the vehicle or equipment and inspect the battery before connecting the charger for a recovery attempt. The charger’s TURBO recovery mode cannot engage if it senses that the battery is still connected to a circuit which effectively offers a lower electrical resistance than the battery on its own. However, if the deep-discharged battery is not removed for recovery, neither battery nor vehicle or equipment electronics will be damaged. Pay particularly close attention to the following A battery left deep-discharged for an extended period may develop permanent damage in one or more cells. Such batteries may heat up excessively during high current charging. Monitor the battery temperature during the first hour, then hourly there-after. Check for unusual signs, such as bubbling or leaking electrolyte, heightened activity in one cell compared to others, or hissing sounds. If at any time the battery is uncomfortably hot to touch or you notice any unusual signs, DISCONNECT THE CHARGER IMMEDIATELY. CHARGING TIME Charge time on a flat but otherwise undamaged battery is slightly less than 25% of the battery’s Ah rating, so a 100Ah battery should take no more than about 25 hours to progress to the self-discharge check (§ 5). Deep-discharged batteries may take significantly longer. If using the OptiMate 6 on a severely discharged battery of larger than 240Ah capacity, a full charge may not be achieved within the 72 hour charge safety limit. In this case follow the reset procedure below. RESETTING THE CHARGE & TEST CYCLE Disconnect from the AC mains. Wait for the POWER ON LED #1 to go out. Upon reconnection to AC power LEDs #6, 7 and 8 will flash twice to confirm micro processor health, irrespective if the charger remains connected to a battery or not. ECO POWER SAVING MODE WHEN THE CHARGER IS CONNECTED TO AC SUPPLY: The power converter switches to ECO mode when the charger is not connected to a battery resulting in a very low power draw of less than 1.7W, equivalent to power consumption of 0.042 kWh per day. When a battery is connected to the charger power consumption depends on the current demand of the battery and its connected vehicle / electronic circuitry. After the battery has been charged and the charger is in long term maintenance charge mode (to keep the battery at 100% charge) the total power consumption is estimated to be 0.060 kWh or less per day. PROCEEDING TO CHARGE The LED indicators below are sequenced as they may come on through the course of the program. 2 1 AC:100-240V REVERSE POLARITY 7 6 6 5 5 TEST MAINTAIN AMPS 5A max. 1A - 4A ampmatic 0.2 - 1A 10 9 OPTIMIZE CHARGESAVE LED MODE - - - - 4 4 3 3 TURBO SAVE 8 POWER ON: LED #1 - Confirms AC power supply to the charger. HIGH and LOW intensity indication: The"POWER ON" LED #1 will indicate brightly when current is delivered to the battery. The "POWER ON" LED #1 will reduce intensity to a low level to indicate low power "ECO" mode. This will occur if there is no battery connected, or when a battery is connected and the program finds itself in the voltage retention test mode or the 'rest' periods of Maintenance Charge mode. REVERSE POLARITY PROTECTION: LED #2 - Lights when the battery connections are incorrect. The charger is electronically protected so no damage will result, and the output will remain disabled until the connections are corrected. CHARGE CURRENT BAR: LED #8, 9, 10 - Lights when pulsed or continuous current is delivered to the battery. Current level indications: LED #8: 0.4A minimum current. LED#8 and 9: 0.4A - 4.5A The ampmatic™ charge current program automatically determines the most efficient rate of charge current for the connected battery. LED #8, 9 and 10: 5A maximum current. consulab.com info@consulab.com 20 93-HV-950-X15 Notes Notes consulab.com info@consulab.com 21 93-HV-950-X15 Notes Notes consulab.com info@consulab.com 22 93-HV-950-X15 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2026. All rights reserved. Main features Functional aftertreatment systems Optional equipment Instructions Batteries and Master Disconnect Switch Diesel Tank DEF Storage Tank Exhaust system warning Diesel Exhaust Particulate Filter Cleaning Warning Connection and coupling of the exhaust aftertreatment unit Fuse and relay identification Starting Lamp Identification and Function (if available) Switch Identification and Function (if available) EM-250-2 Electronic Programmable Fault Box Fault Box Electrical Schematic Emergency Stop Electric Schematic Intelligent Battery Charger Instructions

MF102-H-TSE Training System - The model 102-H-TSE has the same features and capabilities as the model MF102-H-TS but the letter “E” denotes “electronic troubleshooting.” This is FPTI™’s flagship, and best-selling, training system loaded with features and benefits you will NEVER find on any other training simulator. “In a side-by-side comparison we conducted with competitive products that boast troubleshooting capability the MF102-H-TSE outperformed the entire field so convincingly that it was, quite frankly, embarrassing.” Technical Training Director – Mine Training Institute Over a decade of research - • FPTI™’s founder and chief designer is not only a legendary teacher, but he is also one of the most respected hydraulic diagnostics technicians in the country. His contribution to safe and effective troubleshooting is remarkable: • He conducted a ten-year study of leakage rates in hydraulic components. • He developed a technique that makes it possible to test over 95% of the components in any hydraulic system with the power unit safely locked out. There is no need to remove or disassemble the components, and each test averages 15 minutes. • He wrote a best practices manual on safe techniques for testing hydraulic components. • He is aware of the critical shortage of hydraulic diagnostic technicians the USA, and indeed the world, faces. In collaboration with industry and education FPTI™ developed a much-needed solution - It took FPTI™ over ten years to develop the most effective hydraulic training system on the planet. In the hands of a properly trained teacher the model MF102-H-TSE training system has the power to turn ordinary technicians into extraordinary hydraulic tech- nicians because they will have the skillsets needed to revolutionize the industry. Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time Model MF102D-H-TSE shown with power unit & hose caddy in swing-out position 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org MF102-H-TSE Hydraulic Training System - Here are just a few of the MF102-H-TSE’s most outstanding and exclusive features: • Safety – the MF102-H-TSE is equipped with the same lockout system used in industry. It also has FPTI™’s exclusive Safe-T-Bleed® system for de-energizing and air-bleeding hydraulic systems and components. Almost every page in the brilliant textbooks, every Power- Point™ slide, and every trip to the training system is designed to remind students of their most important responsibility – safety. MF102-H-TSE Hydraulic Training System - Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org The training system activities are designed to let students practice what they are taught about theory, protocols, and practical demonstrations performed by their teachers. In no time at all you will have your students challenging each other as to who can trou- bleshoot a problem in the least amount of time, with the least number of attempts, and having replaced the least number of components: Isn’t that exactly what industry is crying for? • Learn in real time on real systems – You can achieve a level of training on the MF102-H-TSE that’s almost impossible to achieve on an actual machine: if, for no other reason than safety. You can give the student a copy of the hydraulic schematic for any type of machine. Then, while it’s operating in real time under actual load cycles, the students can learn to troubleshoot it – in the safety and comfort of the classroom. The MF102-H-TSE – A winner that begets winners When well-trained technicians can troubleshoot hy- draulic systems safely, effectively, and time efficiently everyone wins. The technicians win because they are safe, produc- tive and proud. Their company wins because prob- lems are solved safely, efficiently and cost effectively. Teachers win because they provided students with the tools they needed to become brilliant technicians. And finally, schools win because they fulfilled their responsibility to the teachers, students, industry, and society. • Load-cycle capable – At the push of a lever the cylinder lifts an onboard load into the air, and the bi-directional hydraulic motor has infinitely variable torque capability for a realistic training and trouble- shooting experience. • Pressure/leak Testing – this revolutionary tech- nique, developed by FPTI™, will teach students how to test 95% of the components in a hydraulic system with the power unit safely locked out. There is no need to remove or disassemble components, and each test averages 10 to 15 minutes. Quite frankly, there is no other way to test these components. • Electronic auto-fault insertion – the onboard panel PC with 22” (56cm) touch-screen makes it possible for almost every component on the MF102- H-TSE to automatically “wear out.” FPTI™ studied wear patterns in hydraulic compo- nents for a decade and designed the identical wear patterns into the components on the training system. • Masterfully develops thinking skills – the single most important skill technicians must learn is to think. The MF102-H-TSE teaches this skill masterfully. When a student is given an assignment, timely and satisfactory completion of the task is determined by how much “thinking” the student applies to the prob- lem. The student starts out with a “chief complaint” and one, or more symptoms: identical to a real world situation. Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org Because a pressure compensator is a pressure relief valve. Why does it teach flow control valves before load sensing systems? Because the flow compensator in a load-sensing pump is a pressure- compensated flow control valve. Six directional control valves - • Three (3) industrial-type (parallel) • One (1) industrial-type (series) • One (1) mobile-type (cylinder spool center) • One (1) mobile-type (motor spool center) Why these features are important: Students graduate from learning simple, single-valve/ single actuator, circuits to constructing the types of circuits they will see in any plant or on any construc- tion machine. There is almost no limit to the number and variety of circuits students can construct on the MF102-H-TSE training system. Teach any type of system or component - • Fixed displacement pump - standard • Pressure-compensated pump – standard • Load-sensing pump – optional Students advance from fixed displacement pump circuits, to pressure-compensated pump circuits, and, if the curriculum permits, load-sensing circuits, on one training system. Why this feature is important: The most logical learning path for a student is to begin with fixed displacement pumps, and then advance to pressure-compensated pumps and then to load- sensing pumps. The MF102-H-TSE training system provides instruc- tors the opportunity to teach all of these popular systems. Unprecedented student retention - MF102-H-TSE training system achieves the highest student retention of any hydraulic training system currently available – bar none! Hardware in perfect harmony with the software - The MF102-H-TSE training system works in perfect harmony with the equally as well engineered curricu- lum, visual aids, textbooks, PowerPoint™ presenta- tions, animations, and support. Why does our course teach pressure control valves before pumps? MF102-H-TSE Hydraulic Training System - Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time Port identification consistent with industry standards - It is absolutely critical that students learn how im- portant it is to make proper transmission line con- nections when installing hydraulic components or reconnecting transmission lines. An error can result in severe injury or death. Component manufactur- ers typically use letters and/or numbers for port identification. All compo- nents on FPTI™ training systems are marked with the appropriate identifica- tion. Also, all hydraulic schematics in the student activities manuals show the appropriate markings. Not just a training simulator, an entire turn- key training system - Not only do you get the most advanced hydraulic training simulator in the world, you also get every- thing you need to conduct a world-class course: • Textbooks - written and produced by one of the most successful and renowned hydraulics instructors in the industry - FPTI™’s founder Rory S. McLaren. Every topic is to the point and safety-based. • Student workbooks - well written and superbly illustrated with need-to-know information. • PowerPoint™-based CD’s covering at least 40 hours of instruction in hydraulics and another 40 hours of advanced diagnostics. • Instructor answer books. • Student workbook and Instructor answerbook available for purchase. 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • info@fpti.org MF102-H-TSE Hydraulic Training System - Everything you need to conduct a “world-class” course is included It’s limits? - Your imagination - Teach any pump/system – fixed displacement, pres- sure compensated, load-sensing. Teach any type of component - even the one’s it doesn’t have – with the optional Flex-Plate modules. Simply fasten your unique component to a univer- sal mounting plate (available from FPTI™) and when needed clip it on the FlexPlate - no hardware needed. There is also a convenient 24VDC power supply and illuminated on/off switch for electric valves. Many of the add-on valves are available - ready- to-use - from FPTI™. See the entire assortment at: www.fpti.org If you don’t see what you are looking for on our website let us know and we will build it for you - ready to use. Plug-and-Play modules give the MF102 series unlimited training flexibility - Want to teach mobile directional control valves; proportional direction/flow control valves; stacked valves; orbitrol steeringsystems; logic valves; etc? Simply purchase an affordable plug-and-play module, which easily attaches to either side of the MF102 series simulator. The modules are designed to integrate seamlessly with the components on any model MF102. Most plug-and-play modules are available with diagnostics capability. Flex-Plate modules expand the capability of your MF102 series training system Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time Specifications (Model MF102-H-TSE) - The model MF102-H-TSE training systems are equipped with the following components: 1. Pump - Axial piston-type, variable volume, pressure-compensated; 1.0 GPM (3.78 Lpm); 1000 PSI (69 bar); adjustable pressure com- pensator; adjustable flow 2. Electric motor - Single-phase; 115V; TEFC; 1750 RPM; C-face; thermal overload protection 3. Electric motor on/off switch - Lockout/tagout mechanism; thermal overload protection with manual reset 4. Hydraulic reservoir - capacity 4.5 gallon (17 liter) 5. Filtration - 10 micron, spin on/off element w/by-pass gauge 6. Directional control valves - seven (7) total; • One (1) DO3-type; tandem-center; 3-position; 4-way; spring-centered; solenoid-controlled; 24V coils. Also includes sandwich-mounted, knob-adjustable pump port flow control valve • Two (2) DO3-type; closed-center; 3-position; 4-way; spring-centered; solenoid-controlled; 24V coils. Also includes sandwich-mounted, dual, knob-adjustable flow control valves • One (1) DO3-type; float-center; 3-position; 4-way; spring-centered; solenoid-controlled; 24V coils. Also includes sandwich-mounted, knob-adjustable pump port flow control valve • One (1) Monoblock type valve; cylinder spool; 3-position; 4-way; spring-centered; hand-lever operated w/pressure relief valve • One (1) Monoblock type valve; motor spool; 3-position; 4-way; spring-centered; hand-lever operated w/pressure relief valve • One (1) 2-position, 3-way, solenoid-operated, cartridge type, directional control valve 7. Pilot-operated pressure relief valve w/knob adjustment 8. Direct-operated pressure relief valve w/knob adjustment 9. Sequence valve w/knob adjustment 10. Pressure reducing valve w/knob adjustment 11. Counterbalance valve with internal reverse flow check w/knob adjustment 12. Needle valve w/knob adjustment 13. Flow control valve w/knob adjustment 14. Pressure-compensated flow control valve restrictor-type; reverse flow bypass; w/knob adjustment 15. Check valve 16. Pilot-operated check valve w/manual over- ride 17. Cylinder - single-rod; double-acting; 14” (36 cm) stroke 18. Cylinder - double-rod; double-acting; 14” (36 cm) stroke; w/load engage/disengage mechanism 19. Motor - bi-directional; gear-type; w/infinitely variable torque capability 20. Flow meters - two (2); 0-2.0 GPM (7.56 Lpm) 21. Tachometer - hydraulic motor shaft speed (displayed on the panel-mounted touchscreen) 22. Ammeter - (displayed on the panel-mounted touchscreen) 23. Dual scale temperature gauge - Oil temperature & ambient temperature (displayed on the panel-mounted touchscreen) 24. Stopwatch - (displayed on the panel-mounted touchscreen) 25. Pressure gauges - three (3); 0-1500 PSI (103 bar); PSI and bar scales; 2.5” (6.35 cm); glycerine-filled; Bourdon tube type; w/flat-face type quick-connect/disconnect type valves 26. Load - 100 lb (45 Kg); Engage/disengage with mechanical latch. Entire weight is contained within a transparent safety enclosure. 27. Hose storage caddy - stow-away/swing-out 28. Hoses (per side) - • Four (4) - 60” (152 cm) • Eight (8) - 46” (117 cm) • Six (6) - 26” (66 cm) SAE 100-R1; w/flat-face type quick- connect/disconnect type valves 29. T’s - eight (8) (per side) w/flat-face type quick-connect/disconnect type valves 30. Pressure/leak test pump w/quick-connect/ disconnect valve 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • info@fpti.org MF102-H-TSE Hydraulic Training System - Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time Shipping Specifications - (Subject to change) Ship weight (does not include pallet or packaging): Double unit: 1200 lbs (544 kgs) Single unit: 920 lbs (417 kgs) Shipping dimensions (all models): 84” (213cm) H x 54” (137cm) W x 42” (106cm) D Warranty - FPTI™ warrantees it’s products against defect in materials or workmanship for a period of two (2) years from date of delivery. Electrical Requirements for Operation - 110 VAC, 20 Amp dedicated circuit per workstation (panel). If an extension cord is used, it must be 12-gauge wire or larger, 3-conductor (neutral, hot, ground), 50-foot (15.24m) length max. Optional Diagnostic Accessories - 1. Inline flow meter - 2.0 GPM (7.6 Lpm); with integrated load cell and pressure gauge 0-1500 PSI (103 bar). 2. Tachometer - digital; laser-guided; contact and non-contact; with storage case. 3. Pressure gauge - case pressure testing; 0-100 PSI (6.9 bar); with test connector. 4. Vacuum gauge - 0-30” (76 cm) Hg (mercury); with test connector. 37” (94 cm) 37” (94 cm) 23” (58 cm) 23” (58 cm) 77” (196 cm) 48” (122 cm) 12” (30 cm) 12” (30 cm) 30” (76 cm) 30” (76 cm) MF102-H-TSE (07/17/25) • COPYRIGHT © 2025 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • info@fpti.org MF102-H-TSE Hydraulic Training System - All FPTI™ training systems are available for operation at any voltage or frequency Optional diagnostic accessories package - PART #: MF102-DA Simulator Dimensions

You can spend hours trying to explain to students what cavitation is and when you’re done they’ll still probably be doubtful, or you can turn on the totally transparent MF200-CAV and erase all doubt. Wouldn’t it be satisfying to know that when the cavitation lesson is over, your students will KNOW, and more impor- tantly UNDERSTAND, everything that is good and bad about the operation at the inlet side of a pump? The Good - Students will learn what is good for a pump: • How the inlet side of a hydraulic pump works. • Variables that have a negative effect on the operation at the inlet side of a pump. • How to properly maintain and troubleshoot the inlet side of a hydraulic pump. • How to accurately troubleshoot problems at the inlet side of a pump. The Bad - Students will learn what is bad for a pump: • The exact set of operating conditions relative to pump speed, inlet restriction, and temperature, that causes the dissolved air to come out of the oil and cause pump cavitation. • Exactly what cavitation looks like. • The negative effect cavitation has on the oil with respect to lubrication, sealing, heat dissipation, and cooling. • The effect cavitation has on a hydraulic system’s temp- erature, pressure, and flow. • The noise caused by the “implosions” as the cavities come into contact with pressure at the outlet port of a pump. • Symptoms of cavitation. • Why air (aeration) getting into the inlet side of a pump is not cavitation. • Why aeration caused by an air leak at the inlet side of a hydraulic pump is referred to as “pseudo-cavitation.” • Why pseudo-cavitation is considerably more damaging to a hydraulic system than cavitation. • Symptoms of pseudo-cavitation. MF200-CAV Pump Cavitation Simulator 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org Hydraulic Training Systems 888-222-3421 The Benefit to Industry - Industry benefits because students know: • How and why to determine a pump inlet restriction’s “point-of-reference” or, normal inlet restriction. • How a pump inlet restriction’s “point-of-reference” is a vital link in averting unexpected and catastrophic pump failures. • What diagnostic instruments are needed to maintain and troubleshoot the inlet side of a hydraulic pump. • How to safely and correctly use these diagnostic instruments. • Critical proactive maintenance procedures that must be performed at the inlet side of a pump. • How to troubleshoot the inlet side of a hydraulic pump. Teaching and learning hydraulics in real-time The MF200-CAV gives credence to the term: “What students see they totally understand” Demonstrate vortex - Occurs when oil levels are neglected or because of poor design MF200-CAV Pump Cavitation Simulator Demonstrate Laminar Flow - Occurs when air enters the oil flow Demonstrate turbulence - Caused by oil discharging above surface Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time Demonstrate cavitation and pseudo-cavitation - Occurs when inlet is restricted or when there is an air leak present A Teaching and Learning Masterpiece - This exceptional simulator is a teaching and learning masterpiece because it leaves absolutely nothing to the imagination because it can simulate every situation in real time: • Normal operation at the inlet side of a pump - students will see with a vacuum gauge, flow meter, pressure gauge, and temperature gauge exactly how a well-designed and maintained pump inlet works. • High inlet restriction – as you operate the “oil-restrictor” valve students will see the pump inlet restriction gradually climbing until the dissolved air comes out of the oil and the pressure causes the loud implosions. • Low inlet restriction – as you lower the oil level in real time the students see what happens when air enters the inlet side of the pump. They will see the oil begin to foam in the reservoir and in the transmission lines as the now s e m i - f i l l e d o i l pump/air compres- sor pumps harmful air into the system. • Oil return lines now become exposed – as the oil level continues to drop, the oil return line that was once below the oil level is now pumping oil in above the oil level. Students will witness what they will probably never witness again: the violent turbulence that is caused as the discharge flow begins to churn up the oil in the reservoir and cause it to foam. • Vortex begins – a further drop in the oil level makes it encroach on the opening in the pump inlet transmis- sion line. Students will again witness a situation they will only have witnessed when emptying a bathtub or a sink: the swirling motion of the oil as it enters the pump’s inlet transmission line, and then the “explosion” as the air and oil return to the reservoir “blows” through the oil to the surface. It’s truly an experience the students will never forget – and isn’t that really the point? 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org MF200-CAV Pump Cavitation Simulator Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time The MF200-CAV consists of: • Extremely attractive aesthetic design suitable for classroom or lab use. Ideally sized for instructor led group activities. • Transparent components include: oil reservoir; pump inlet transmission line; and pump outlet transmission line. • Lighting: all transparent components have back lighting to increase visual effects. • Controls (panel-mounted): pump inlet restrictor valve (adjustable); air inlet valve (adjustable); pressure control valve (adjustable); pump inlet opening in reservoir (height adjustable). • Diagnostic instruments (panel-mounted): flowmeter 7.6 Lpm (0-2.0 GPM); vacuum gauge 75cm (0-30”) Hg (mercury), 10cm (4”) glycerine-filled, Bourdon tube type; pressure gauge 41 bar (0-600 PSI), 10cm (4”) glycerine-filled, Bourdon tube type; dual-scale tem- perature gauge, digital, oil and ambient temperatures. • Pump: fixed-displacement external gear type, 6.8 Lpm (1.8 GPM). Transparent, back-lit suction & pressure lines See how cavitation affects flow Digital oil/ambient temperature gauge Air inlet valve Increase/decrease pump inlet restriction See how cavitation affects pressure Vacuum gauge Increase/decrease pressure Power-unit ON/OFF switch Actually see how high or low inlet restriction affects the oil Demonstrate how discharging oil above the surface level causes turbulence Raise and lower pump inlet inside the reservoir • *Electric motor: 1 HP TEFC, 1800 RPM; 115V s ingle-phase; 15 amps. • On/off switch, panel-mount- ed, with light a n d t h e r m a l overload pro- tection. • Pre-set safety pressure relief valve. • Reservoir - Transparent with baffle, oil filler/breather cap. • Reservoir capacity: 17 liters (4.5 gallons). • Oil filter: return-line w/bypass valve; spin on/off; 10 micron. • Steel and aluminum construction. • All parts finished with durable powder coat. • Heavy-duty storage shelf. • Four (4) wheel, medium-duty swivel casters w/brakes. *All FPTI™ simulators are available for operation at any voltage or frequency 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org MF200-CAV Pump Cavitation Simulator Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time MF200 (07/17/25) • COPYRIGHT © 2025 Course Materials and Visual Aids - • Manual - Operation at the Inlet Side of a Pump (includes laboratory activities) • Instructor’s guide and answer sheets • Visual Presentation - Operation at the Inlet Side of a Pump. Full-color, PowerPoint presentation in CD format • Student workbook and Instructor answerbook available for purchase. Shipping Specifications - Shipping weight (does not include pallet and packaging): 84 kgs (185 lbs) Shipping dimensions: 145 cm (57”) T x 76 cm (30”) W x 51 cm (20”) D Warranty - FPTI™ warrantees it’s products against defect in materials or workmanship for a period of two (2) years from date of delivery. Electrical Requirements for Operation - 110 VAC, 20 Amp dedicated circuit per simulator. If an extension cord is used, it must be 12-gauge wire or larger, 3-conductor (neutral, hot, ground) 50-foot (15.24m) length max. 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org

Purpose- The MF400-HCTS is designed to help instructors teach and students learn how to safely and correctly perform the following skills: • Overhaul a hydraulic cylinder. • Identify and use the tools needed to overhaul a hydraulic cylinder. • Inspect the components in a hydraulic cylinder to determine root cause of failure. • Replace piston and gland seals. • Test a hydraulic cylinder. • Air bleed a hydraulic cylinder. How the MF400-HCTS will benefit instructors, students and the college: 1. Instructors will benefit because they will: • Teach a cylinder overhaul course with materials that were developed by cylinder overhaul specialists. • Teach overhaul techniques that are based on best industry practices that foster safety and efficiency in the lab and ultimately in the work-place. • Teach need-to-know information – cylinder defects are consistent with the most common causes of cylinder failure. • Efficient simulator design makes good use of valuable lab space while creating a safe and meaningful learning environment. 2. Students will benefit because they will: • Have skills that enable them to overhaul hydraulic cylinders safely and efficiently. • Have the skills needed to correctly analyze root causes of cylinder failure and remedy them. • Have skills that will set them apart from others when applying for jobs. Their unique abilities will afford them higher wages and long-term employment. • Be empowered not only to work safely themselves but also to promote a safe working environment. • Be an asset to their respective companies because their skills will increase productivity and profitability. • They will avoid safety hazards caused by trial and error cylinder overhaul practices. Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time MF400-HCTS Hydraulic Cylinder Training Simulator - 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org 3. Colleges will benefit because they will: • Attract students because students will see and appreciate the investment the college has made in lab equipment that is specifically designed for teaching skills safely. • Graduate students who will have the skill-sets needed to get, and keep, good paying jobs. • Serve industry well – properly trained technicians means increased productivity and profitability for employers. • Invest in training simulators that are designed for teaching specific skills safely leaving less chance for accidents and thus reducing liability. Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org Hands-on Activities - Hands-on activities include: • Steps on preparing a cylinder for service – removing, draining the oil, and securing it so it cannot move. • Tools - selection and safe and proper use. • Correct disassembly procedures. • Component inspection and failure analysis. • When to hone a cylinder tube. • Correct procedures for installing piston seals and rod seals. • Correct assembly procedures. • Correct test procedures. • Correct installation and air-bleeding procedures. Course material and Visual Aids - • Student manual – How to Service Hydraulic Cylinders – a guide for beginners. The MF400-HCTS consists of the following components: • Four-station mobile training module equipped with (4) swivel-lock casters. Steel and aluminum construc- tion with powder coat finish. • Welded steel anchors and cradles with mechanical locks to secure the cylinders for safety and handling. • Four (4) clear acrylic, cylinder safety covers at each cylinder station to protect the student from oil spray in the event they did not reassemble the cylinder, or install the seals, correctly. • Can store up to eighteen (18) hydraulic cylinders (available for purchase separately). CYLINDER TYPE PART # Round-weld type hydraulic cylinder MF400-RWC Tie-rod type hydraulic cylinder MF400-TRC *Cylinder seal kits MF400-SK *NOTE: Fits both -RWC & -TRC cylinders. The MF400-HCTS teaches students, in addition to proper and safe cylinder overhaul procedures, how to correctly analyze the most common types of cylinder failures – in real time. • Safe and ergonomic cylinder fixture design. Cylinders are anchored and secured in fixtures to prevent: - Barrel rotation while tightening/loosening rod glands. - Rod rotation while tightening/loosening piston retaining nuts. - Inadvertent cylinder movement/falling prevents the potential for leg/foot injuries. Warranty - As with all FPTI™ training systems, the MF400-HCTS Hydraulic Training Simulator is covered for two (2) years from date of delivery. Warranty covers defects in materials and quality of work. Warranty does not cover damage caused by abuse or modifications. MF400-HCTS Hydraulic Cylinder Training Simulator - 29.0” (74cm) 45.0” (114cm) 69.0” (175cm) Hydraulic Training Systems 888-222-3421 Teaching and learning hydraulics in real-time 2170 South 3140 West, Salt Lake City, UT 84119 • Tel. 801.908.5456 • Fax: 801.908.5734 • info@fpti.org MF400-HCTS Hydraulic Cylinder Training Simulator - Shipping Specifications - Shipping weight: (does not include pallet and packaging) 825 lbs (374 kgs) Shipping dimensions: (includes pallet and packaging) 84” (213cm) Tall X 54” (137cm”) Wide X 42” (107cm) Deep Warranty - FPTI™ warrantees it’s products against defect in materials and/or workmanship for a period of two (2) years from date of delivery. Electrical Requirements for Operation - 110 VAC, 20 Amp dedicated circuit per simulator. If an extension cord is used, it must be 12-gauge wire or larger, 3-conductor (neutral, hot, ground), 50-foot (15.24m) length max. MF400-HCTS (10/22/25) • COPYRIGHT © 2025