Operation Manual for EM-1100_053254 Planetary gear set trainer 93-EM-1100_REVA © ConsuLab Educatech Inc, 2025. All rights reserved. Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space 93-EM-1100 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, 2025. 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 053254 and above. Table of Contents Teacher Resources 4 EM-1100-95 - Student Assignments — Table of contents 4 EM-1100-91 - Answer Keys — Table of contents 4 EM-1100-96 - Instructors Guide — Table of contents 4 Product Description 5 Main Componants 6 Educational Features 7 Setup Requirements 8 Pre-operation checks 8 ConsuLab support contact information 8 Safety Instructions 9 Maintenance Instructions 9 93-EM-1100 Teacher Resources consulab.com info@consulab.com 4 Teacher Resources 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. EM-1100-95 - Student Assignments — Table of contents EM-1100-91 - Answer Keys — Table of contents EM-1100-96 - Instructors Guide — Table of contents 91-EM-1100 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, 2025. 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. Made in Canada. The content of this manual is applicable to models 053254 and above. Table of contents Theory Basic operation 4 Main Components 5 Student Assignments Answers SA-1 — Component Identification - Answers 7 SA-2 — Power Transfer - Answers 8 Test Results and Analysis 10 SA-3 — Calculation of Gear Ratios 11 SA-3 — Calculation of Gear Ratios — Answers 13 Test Results and Analysis 14 SA-4 — Compound Gear Ratios 15 SA-4 — Compound Gear Ratios — Answers 16 Test Results and Analysis 16 SA-5 — Understanding and Calculating Ratios of an Allison 1000 Transmission (Advanced) 17 SA-5 — Understanding and Calculating Ratios of an Allison 1000 Transmission (Advanced) — Answers 18 Test Results and Analysis 19 SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) 20 SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) — Answers 21 Quiz and Additional Questions on Planatery Gear Trains 22 Part 1 : Multiple choice questions — Answers 22 Part 2 : Additional Questions — Answers 22 Part 3 : Planetary Gears and Mathematics — Answers 23 91-EM-1100 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, 2025. 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. Made in Canada. The content of this manual is applicable to models 053254 and above. Table of contents Theory Basic operation 4 Main Components 5 Student Assignments Answers SA-1 — Component Identification - Answers 7 SA-2 — Power Transfer - Answers 8 Test Results and Analysis 10 SA-3 — Calculation of Gear Ratios 11 SA-3 — Calculation of Gear Ratios — Answers 13 Test Results and Analysis 14 SA-4 — Compound Gear Ratios 15 SA-4 — Compound Gear Ratios — Answers 16 Test Results and Analysis 16 SA-5 — Understanding and Calculating Ratios of an Allison 1000 Transmission (Advanced) 17 SA-5 — Understanding and Calculating Ratios of an Allison 1000 Transmission (Advanced) — Answers 18 Test Results and Analysis 19 SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) 20 SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) — Answers 21 Quiz and Additional Questions on Planatery Gear Trains 22 Part 1 : Multiple choice questions — Answers 22 Part 2 : Additional Questions — Answers 22 Part 3 : Planetary Gears and Mathematics — Answers 23 95-EM-1100 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, 2025. 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. Made in Canada. The content of this manual is applicable to models 053254 and above. Table of contents Theory Basic operation 4 Student Assignments SA-1 — Component Identification 6 SA-2 — Power Transfer 7 SA-3 — Calculation of Gear Ratios 10 SA-4 — Compound Gear Ratios 14 SA-5 — Understanding and Calculating Ratios of an Allison 1000 Transmission (Advanced) 16 SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) 19 SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) — Student Answer Sheet 20 Quiz and Additional Questions on Planatery Gear Trains 21 Part 1 : Multiple choice questions 21 Part 2 : Additional Questions 21 Part 3 : Planetary Gears and Mathematics 22 Technical Terms Glossary 24 96-EM-1100 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, 2025. 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 053254 and above. Table of contents Trainer Use and Familiarization 4 Introduction 5 Main composants 6 Educational functions 7 Pedagogical approach 8 Task correlation 9 Additional information 10 Technical Terms Glossary 11 Scan this QR code for: Operation Manual Teacher Resources https://www.consulab.com/customer-space 93-EM-1100 Product Description consulab.com info@consulab.com 5 Product Description The ConsuLab EM-1100 is a comprehensive educational tool designed to teach the operating principles of planetary gears, enable students to physically manipulate components to better understand mechanical effects, and support hands-on labs, classroom demonstrations, and technical evaluations. The EM-1100 is a trainer representing an epicyclic gear train (or planetary gear), used in automatic transmissions, exca- vator traction systems, machinery differentials and in some starters. It is designed to provide a practical example of the operating principles of the reduction, overdrive and reverse gear systems. Planetary gears have been in use since the end of the 19th century. Henry Ford integrated them into the Model T in 1908. The Simpson system, a version consisting of two planetary gears, is still in use today. 93-EM-1100 Main Componants consulab.com info@consulab.com 6 Main Componants • Retaining pin: Located at the rear and attached to a chain. • Sun Gear : In yellow, located in the center. • Planet Pinions : In green, mounted on a planet carrier. • Ring Gear : In black, external gear surrounding the sun gear and the planet carrier. Rear side 93-EM-1100 Educational Features consulab.com info@consulab.com 7 Educational Features Trainer is used to demonstrate : • Two (2) forward reductions • Two (2) forward overdrive • Two (2) reverses • Direct drive (1:1) • Neutral Each configuration is obtained by modifying the input, output and reaction member roles, which illustrates : • Variation of the transmission ratio • Reversing the direction of rotation • Blocking or release effect of components 93-EM-1100 Setup Requirements consulab.com info@consulab.com 8 Setup Requirements The EM-1100 is a fully mechanical training bench that does not require a power supply. A solid table or workbench is needed to place the module. A well-lit environment, in a classroom or workshop is ideal for handling. It is ready to use upon delivery, requires no specialized tools, and can be easily manipulated by students for practical demonstrations and educational assignments. Pre-operation checks A quick visual inspection will ensure that all components, sun gear, planet pinions, planetary carrier and ring gear are in place and function freely. Then, the instructor can test the mechanical configurations to be demonstrated by designating the input, output and reaction members. Finally, it is recommended to prepare the necessary teaching materials, such as assignment student sheets or configuration diagrams, to ensure a smooth and structured session. ConsuLab support contact information For any technical support requests related to your ConsuLab product (damage, defects, configuration, troubleshooting and suggestions), you can contact our dedicated team immediately : • Toll-free : Canada +1 (800) 567-0791 / USA +1 (810) 222-4525 • Phone : Canada +1 (418) 688-9067 • Email : support@consulab.com • Website : www.consulab.com mailto:support@consulab.com http://www.consulab.com 93-EM-1100 Safety and Maintenance consulab.com info@consulab.com 9 Safety Instructions The EM-1100 is a safe teaching bench designed to be handled manually without a power supply, eliminating the risks associated with electricity. However, certain precautions must be observed to ensure safe use. • It is important never to force the gears: All components must rotate freely, without excessive resistance, which could indicate misalignment or sticking • It is also essential not to insert foreign objects into the mechanism; • Always handle parts with dry and clean hands to avoid slipping or damage to surfaces. These simple instructions ensure a safe and effective learning experience. Maintenance Instructions The EM-1100 requires little maintenance, but regular preventative maintenance is recommended to ensure durability. Prior to each use, a visual inspection will ensure that the gears (sun, planet pinions, ring gear) are clean, aligned and rotate freely. Cleaning should be done with a dry or slightly damp cloth, without using solvents or lubricants. It is also important to make sure that all screws and fasteners are not loosened. The bench must be stored in a dry place, pro- tected from dust and extreme temperature variations. If you have any problems or doubts, it is recommended that you contact ConsuLab Technical Support for assistance. consulab.com info@consulab.com 10 93-EM-1100 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. All rights reserved. Teacher Resources EM-1100-95 - Student Assignments — Table of contents EM-1100-91 - Answer Keys — Table of contents EM-1100-96 - Instructors Guide — Table of contents Product Description Main Componants Educational Features Setup Requirements Pre-operation checks ConsuLab support contact information Safety Instructions Maintenance Instructions

Student Assignments for EM-1100_053254 Planetary Gear Set Trainer 95-EM-1100_REVA © ConsuLab Educatech Inc, 2025. All rights reserved. 95-EM-1100 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, 2025. 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. Made in Canada. The content of this manual is applicable to models 053254 and above. Table of contents Theory Basic operation 4 Student Assignments SA-1 — Component Identification 6 SA-2 — Power Transfer 7 SA-3 — Calculation of Gear Ratios 10 SA-4 — Compound Gear Ratios 14 SA-5 — Understanding and Calculating Ratios of an Allison 1000 Transmission (Advanced) 16 SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) 19 SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) — Student Answer Sheet 20 Quiz and Additional Questions on Planatery Gear Trains 21 Part 1 : Multiple choice questions 21 Part 2 : Additional Questions 21 Part 3 : Planetary Gears and Mathematics 22 Technical Terms Glossary 24 95-EM-1100 Theory consulab.com info@consulab.com 3 Theory consulab.com info@consulab.com 4 95-EM-1100 Basic operation Basic operation • A planetary gear train consists of three main components, each of which can serve a different function depending on how the gear set is used: - Input member: the component that is driven and supplies torque - Reaction member: the component that is held stationary or controlled - Output member: the component that delivers the resulting motion and torque • When one member of a planetary gear train is driven, the other two members are forced to rotate. By selecting which component is driven, which is held, and which is used as the output, the planetary gear train can produce multiple gear ratios, including forward gears and reverse. • To transmit torque through a planetary gear train: - One member applies a rotating torque (input), - A second member resists motion by being held stationary or controlled (reaction), - The third member rotates as a result and delivers the output torque. • Each of the three members can alternate between the roles of input, reaction, and output. The different combina- tions of these roles determine: - The number of available gear ratios - Whether the output rotates in the same or opposite direction (reverse gear) • In some applications, the reaction member is not completely stationary but is allowed to rotate in either direction under control. This creates a continuously variable gear ratio and is commonly used in hybrid vehicle transmissions. • Torque transmission within a planetary gear train occurs in several stages, beginning with the driven input member and ending with the rotation of the output member. The terms drive and driven simply describe the relationship between components transmitting motion. • For clarity, in a planetary gear train: - The drive member is referred to as the input member - The held member is referred to as the reaction member - The driven member is referred to as the output member 95-EM-1100 Student Assignments consulab.com info@consulab.com 5 Student Assignments 95-EM-1100 SA-1 — Component Identification consulab.com info@consulab.com 6 SA-1 — Component Identification Name : Group : Date : Perform all tests following the procedure below as instructed. Write your answers on this page. It includes the activity description and the answer sheet. Identifying and learning the names of planetary gear train components is crucial for understanding and effectively dis- cussing the system’s operation and advancing in student assignments. Objective : Identify and label the components of a simple planetary gear set. Material Required : ConsuLab EM-1100 Planetary gear set trainer. Procedure : 1. Inspect the planetary gear set trainer. 2. Identify the components below on the EM-1100 with the correct number : Sun gear : Planet pinions : Ring gear : Planet carrier : 3. Count the number of teeth for each of the following gears : Sun gear : Planet pinions : Ring gear : 1 2 3 4 Instructor : Grade : 95-EM-1100 SA-2 — Power Transfer consulab.com info@consulab.com 7 SA-2 — Power Transfer Name : Group : Date : Perform all tests following the procedure below as instructed. Write your answers on this page. It includes the activity description and the answer sheet. This assignment helps students understand the connections between components and learn the fundamental functions of a planetary gear set. Objective : Identify the component movements according to the 6 different blocking scenarios offered by the EM-1100 trainer. Material Required : ConsuLab EM-1100 Planetary gear set trainer. To begin with, you need to understand two concepts : input value and power output value. The input value (motor) is at the gear driven by you and the output value is at the second gear that will be moving. To generate power transfer, it is necessary to hold one of the components. When none of the components are held, there is no power transfer. There- fore, rotating a gear will not produce any output value. This scenario represents the neutral position. Procedure : In the following steps, you will experiment with the 6 power transfer scenarios available with the EM-1100. Scenario #1 : 1. Install the locking pin at the sun gear. 2. Hold the planet carrier handle and rotate three times. 3. Which gear represents the power output value ? 4. Regarding the power output gear, do we have a scenario improving torque or speed ? 5. How many turns do you get at the power output gear after three complete rotations of the planet carrier ? 6. So the input/output ratio is . A B C A : Sun Gear Locking B : Planet Carrier Locking C : Ring Gear Locking 95-EM-1100 SA-2 — Power Transfer consulab.com info@consulab.com 8 Scenario #2 : 1. Install the locking pin at the ring gear. 2. Hold the planet carrier handle and rotate 180°. 3. Which gear represents the power output value ? 4. Regarding the power output gear, do we have a scenario improving torque or speed ? 5. How many turns do we get at the output gear after a complete 180° rotation of the planet carrier ? 6. So the input/output ratio is Scenario #3 : 1. Install the locking pin at the sun gear. 2. Hold the ring gear handle and rotate four times. 3. Which gear represents the power output value ? 4. Regarding the power output gear, do we have a scenario improving torque or speed ? 5. How many turns do we get at the output gear after four rotations of the ring gear ? 6. So the input/output ratio is Scenario #4 : 1. Install the locking pin at the ring gear. 2. Hold the sun gear handle and rotate four times. 3. Which gear represents the power output value ? 4. Regarding the power output gear, do we have a scenario improving torque or speed ? 5. How many turns do we get at the output gear after four rotations of the sun gear ? 6. So the input/output ratio is 95-EM-1100 SA-2 — Power Transfer consulab.com info@consulab.com 9 Scenario #5 : 1. Install the locking pin at the planet carrier. 2. Hold the sun gear handle and rotate three times. 3. Which gear represents the power output value ? 4. Regarding the power output gear, do we have a scenario improving torque or speed ? 5. How many turns do we get at the output gear after three rotations of the sun gear ? 6. So the input/output ratio is Scenario #6 : 1. Install the locking pin at the planet carrier. 2. Hold the ring gear handle and rotate 180°. 3. Which gear represents the power output value ? 4. Regarding the power output gear, do we have a scenario improving torque or speed ? 5. How many turns do we get at the output gear as a result of a 180° rotation of the ring gear ? 6. So the input/output ratio is Instructor : Grade : 95-EM-1100 SA-3 — Calculation of Gear Ratios consulab.com info@consulab.com 10 SA-3 — Calculation of Gear Ratios Name : Group : Date : Perform all tests following the procedure below as instructed. Write your answers on this page. It includes the activity description and the answer sheet. The importance of the correlation between the planetary gear train component movements and mathematics It is essential to understand that complex mechanical systems, such as planetary gears, cannot be fully understood without a solid foundation in mathematics. The movements of sun gear, planet carrier and ring gear are not random : They obey precise laws, expressed through algebraic formulas Mathematics acts here as a universal language, allowing to model, predict and optimize the behavior of the system. Without this understanding, the analysis remains superficial, even erroneous. Just take the example of the Willis for- mula, which allows the angular velocities of different components in the epicyclic gear train to be linked. This algebraic formula is essential to correctly analyze the transmission ratios in these systems The origin of the formula comes from Robert Willis, a 19th century British engineer and mechanic who contributed to the formalization of the laws of gear kinematics. He introduced this formula in his work on machine theory, notably in his book called Principles of Mechanism that was published in 1841. Willis was one of the first scientists to propose a systematic method to analyze relative speeds in complex mechanisms such as epicyclic gear trains, using the principle of motion superposition. Mastering the mathematical formulas associated with mechanical products is not a luxury, but a must. It not only en- ables better system design and diagnosis, but also efficient communication between engineers, researchers and techni- cians across language barriers. The objective of the following assignments is not to make you a proficient mathematician, but rather to allow you to handle simplified formulas already established. This will help you better understand the logic and structure underlying the operation of the system. 95-EM-1100 SA-3 — Calculation of Gear Ratios consulab.com info@consulab.com 11 Objective : Understand and calculate gear ratios for a simple planetary gear train. Material Required : Willis formulas, calculator and ConsuLab EM-1100 planetary gear set trainer. Procedure : Use the formulas required to calculate the gear ratios between the sun gear, planet carrier and ring gear. The Willis formula is a fundamental expression in the mechanics of gear systems, particularly in the analysis of epicyclic or planetary gears. It is used to link the rotational speeds of various components in the system. Each power transfer scenario can result in an algebraic formula. It is important to make the link. First, you must be able to interpret the algebraic formulas and the names of variables. To facilitate understanding, the original formulas have been adapted to allow the student to identify the variables and follow the process clearly and precisely. Simplified variables • Number : ( ) • Sun Gear : ( ) • Ring Gear or Crown : ( ) • Planet Carrier : ( ) If the planet carrier is stationary, the relationship is reversed and negative. In formulas, it is essential to understand the following algebraic abbreviations : • : Number of teeth in the ring gear • : Number of teeth in the sun gear • : Number of teeth in the planet carrier • The negative sign ( ) indicates that the output is rotating in the opposite direction to the input. Table of scenarios Scenario Stationary Component Input Output Adapted Willis Formula 1 Ring Gear Sun Gear Planet Carrier Ratio = 2 Ring Gear Planet Carrier Sun Gear Ratio = 3 Sun Gear Ring Gear Planet Carrier Ratio = 4 Sun Gear Planet Carrier Ring Gear Ratio = 5 Planet Carrier Ring Gear Sun Gear Ratio = 6 Planet Carrier Sun Gear Ring Gear Ratio = 95-EM-1100 SA-3 — Calculation of Gear Ratios consulab.com info@consulab.com 12 There are six different gear ratios that you can calculate, adding a direct drive (1 :1 ratio) and a neutral position (no output). For an enhanced experience, manipulate your ConsuLab EM-1100 planetary gear set to properly understand formulas used during scenarios. Refer to the “example” on the next page to correctly answer the questions in all steps. 1. Scenario #1 (example) : Use the suggested formula in the scenario table to calculate the ratio of the system using the following combination : Stationary ring gear, sun gear at input, planet carrier at output and explain the effect obtained by this scenario. A. Formula : Ratio = = 4,00 B. Ratio : 4,00/1 (Input/Output) C. Effect : Reduced speed and increased torque D. Direction of rotation : Same way 2. Scenario #2 : Use the suggested formula in the scenario table to calculate the ratio of the system using the following combination : Stationary ring gear, sun gear at input, planet carrier at output and explain the effect obtained by this scenario. A. Formula : B. Ratio : C. Effect : D. Direction of rotation : 3. Scenario #3 : Use the suggested formula in the scenario table to calculate the ratio of the system using the following combination : Stationary sun gear, ring gear at input, planet carrier at output and explain the effect obtained by this scenario. A. Formula : B. Ratio : C. Effect : D. Direction of rotation : 4. Scenario #4 : Use the suggested formula in the scenario table to calculate the ratio of the system using the following combination : Stationary planet carrier, nsun gear at input, ring gear at output and explain the effect obtained by this scenario. A. Formula : B. Ratio : C. Effect : D. Direction of rotation : consulab.com info@consulab.com 13 95-EM-1100 SA-3 — Calculation of Gear Ratios 5. Scenario #5 : Use the suggested formula in the scenario table to calculate the ratio of the system using the following combination : Stationary sun gear, planet carrier at input, ring gear at output and explain the effect obtained by this scenario. A. Formula : B. Ratio : C. Effect : D. Direction of rotation : 6. Scenario #6 : Use the suggested formula in the scenario table to calculate the ratio of the system using the following combination : Stationary planet carrier, ring gear at input, sun gear at output and explain the effect obtained by this scenario. A. Formula : B. Ratio : C. Effect : D. Direction of rotation : Instructor : Grade : 95-EM-1100 SA-4 — Compound Gear Ratios consulab.com info@consulab.com 14 SA-4 — Compound Gear Ratios Name : Group : Date : Perform all tests following the procedure below as instructed. Write your answers on this page. It includes the activity description and the answer sheet. In this activity, we explore a transmission system based on multiple compound planetary gearsets, a configuration commonly used in speed reduction mechanisms. We find this type of assembly, where the elements chain together to transmit movement in a fluid and controlled way, especially in Allison automatic transmissions, renowned for their per- formance in heavy vehicles. To calculate the gear ratio of a system with compound epicyclic (or planetary) gears, we use the Willis formula for each stage and then multiply the individual ratios together. P1 P2 P3 This cutaway Allison transmission from ConsuLab demonstrates technology with three compound planetary gears. The change of its 6 speeds is possible thanks to the clutch of the friction discs connected to various elements such as the sun gear, the planet carrier and the ring gear of each of the three planetary trains. Objective : Understand and calculate gear ratios for a double and then triple compound planetary set by using the math- ematical principles of Willis formulas. Material required : Willis formulas, calculator and ConsuLab EM-1100 planetary gear set. 95-EM-1100 SA-4 — Compound Gear Ratios consulab.com info@consulab.com 15 Procedure : 1. Use the formulas required to calculate the gear ratios between the sun gear, planet carrier and ring gear. Multiply the formulas to calculate the scenario involving the second identical planetary set coupled to the first as follows : A. First planetary gear set (P1) : • Sun gear : Input • Ring gear : Stationary • Planet carrier : Output • Formula : Ratio = = • Ratio : B. Second planetary gear set (P2) : • Sun gear : Input (driven by the first gear planet carrier) • Ring gear : Stationary • Planet carrier : Output • Formulas : P1 Planetary Gear Set P2 Planetary Gear Set (Ratio = ) X (Ratio = ) = • Ratio : • Effect : • Direction of Rotation : 2. Use Willis formulas to calculate the gear ratios between the sun gear, the planet carrier and the ring gear. Multiply the formulas to calculate the scenario involving the third identical planetary set coupled to the first as follows : • Sun gear : Input (driven by the second gear planet carrier) • Ring gear : Stationary • Planet carrier : Output • Formulas : P1 Planetary P2 Planetary P3 Planetary (Ratio = ) X (Ratio = ) X (Ratio = ) = • Ratio : • Effect : • Direction of Rotation : Instructor : Grade : 95-EM-1100 SA-5 — Understanding and Calculating Ratios of an Allison 1000 Transmission (Advanced) consulab.com info@consulab.com 16 SA-5 — Understanding and Calculating Ratios of an Allison 1000 Transmission (Advanced) Name : Group : Date : Perform all tests following the procedure below as instructed. Write your answers on this page. It includes the activity description and the answer sheet. Similarly to SA-4, we will study a transmission system based on three compound planetary gearsets and explore the configuration of the speed reduction mechanism used by the Allison transmission. This time you will use actual transmis- sion data to compare the manufacturer’s specifications with the results you have obtained from the suggested scenario to determine which transmission gear is engaged. Objective : Understand and calculate gear ratios for a planetary assembly used on the Allison transmission, using the mathematical principles of the Willis formula and the exact specifications of the system. Material Required : Willis formulas and calculator. Explanations : The Allison 1000 transmission is an automatic transmission equipped with several clutches (C1 to C5), electrically controlled by solenoids. It uses three epicyclic gear trains (P1, P2 and P3) to manage the gear ratios. • C1 and C2 are rotary clutches that transmit engine torque to various components of the planetary gears. C1 con- nects the input shaft to the common sun gear of planetary gears P2 and P3 • C3, C4 and C5 are stationary clutches that block certain components, such as ring gears and planet carriers, to change the gear ratio.. Input Shaft Output Shaft P1 P2 P3 C3 C4 C5 C1 C2 95-EM-1100 SA-5 — Understanding and Calculating Ratios of an Allison 1000 Transmission (Advanced) consulab.com info@consulab.com 17 Each clutch combination changes how power flows through the planetary gears. This allows different gear ratios to be obtained. The clutch combinations on the Allison transmission are as follows : Speed Ratios C1 C2 C3 C4 C5 1st 3.09:1 2nd 1.81:1 3rd 1.41:1 4th 1.00:1 5th 0.71:1 (Overdrive) 6th 0.61:1 Reverse 4.49:1 Neutral Park Clutch applied Clutch not applied Each gear on the Allison 1000 transmission has a unique and precise number of teeth that provide specific ratios : • P1 (Ring gear : 113 teeth / Sun gear : 61 teeth) → Ratio ≈ 2.85 • P2 (Ring gear : 113 teeth / Sun gear : 57 teeth) → Ratio ≈ 2.98 • P3 (Ring gear : 113 teeth / Sun gear : 54 teeth) → Ratio ≈ 3.09 Procedure : Answer the following questions by referring to the previous information and table. 1. Clutch activation : Which clutches are engaged when first gear is activated ? 2. On which gear(s) is power transferred when first gear is activated ? 3. Describe the scenario, including the clutches used and the planetary components of the power transfer (input shaft to transmission output shaft) when first gear is engaged. Refer to the illustration on the previous page ? 95-EM-1100 SA-5 — Understanding and Calculating Ratios of an Allison 1000 Transmission (Advanced) consulab.com info@consulab.com 18 4. Use the required formula to calculate the ratio (velocity #1) of the system using the previous combination and ex- plain the effect achieved by this scenario : - Formula : Ratio = - Ratio : - Effect : - Direction of rotation : Instructor : Grade : consulab.com info@consulab.com 19 95-EM-1100 SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) The operation of the Simpson system is certainly the most difficult scenario. In general, a planetary works this way : • An input member. • Another is held fixed and is called the reaction member. • The third becomes the output member. A complex feature of planetary gear technology is when two cascading planetary gears transmit power to each other on two different elements, for example, when the Allison transmission second gear is engaged, the normally fixed reaction member is now rotating, the reaction member becomes the second input member which can be difficult to assimilate as everything rotates. The Simpson epicyclic gear train is a gear system consisting of two planetary gear trains sharing a common sun and a link with the planet carrier and ring gear of the clutch, which allows great compactness and high mechanical efficiency. In this configuration, the two sun gears are mechanically linked or driven by the same shaft, this configuration causes a particular phenomenon at the level of the sun gear P3, which is driven by two sources of movement simultaneou sly : On the one hand by the sun shared with the second gear P2, and on the other hand by the mechanical link with the planet carrier P2 and the ring P3. This double contribution of power to P3 makes it a strate- gic driving element, capable of combining the effects of rotation of the two trains. This phenomenon opens the way to greater flexibility in the trans- mission ratios, since it makes it possible to modulate the speed and the torque transmitted as a function of the fixed or engaged elements (ring gear, planet carrier, sun). Thus, the Simpson train can generate multiple gear ratios with fewer compo- nents, while optimizing the continuity and fluidity of the transmission. Thanks to this architecture, the Simpson train provides multiple forward gears and reverse gear with a reduced number of components, making it a robust and economical solution for transmission systems. Input Shaft Output Shaft P1 P2 P3 C3 C4 C5 C1 C2 consulab.com info@consulab.com 20 95-EM-1100 SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) — Student Answer Sheet Name : Group : Date : 1. What is the difference between a one-member input configuration (classical system) and a two-member input config- uration (Simpson system) ? A. One-member input : B. Two-member input : 2. What is the main advantage of a two-input member Simpson system for modern automatic transmissions ? 3. In the Simpson two-input member configuration of the Allison transmission, which two components can be driven simultaneously ? What is the effect on planetary P3 ? Instructor : Grade : consulab.com info@consulab.com 21 95-EM-1100 Quiz and Additional Questions on Planatery Gear Trains Quiz and Additional Questions on Planatery Gear Trains Name : Group : Date : Part 1 : Multiple choice questions Circle the correct answer. 1. What is the main role of the EM-1100 trainer ? A. Introduce the student to basic ratio calculations B. Introduce the student to the principles of planetary gears C. Introduce the student to the principles of manual transmissions D. Introduce the student to astronomy 2. What are the three main elements of a planetary gear train ? A. Sun gear, planetary gears (planet carrier), ring gear B. Helical gear, sun gear, ring gear C. Spur gear, shaft, sprocket D. Ring gear, shaft, sun gear 3. Which component must be stationary to obtain the neutral position in the planetary system ? A. None B. Sun gear C. Planet carrier D. Crown 4. What is the main advantage of planetary gears in modern automatic transmissions ? A. Their low cost B. Their robustness and compactness C. Their low efficiency D. Their complexity Part 2 : Additional Questions 5. Name two industrial applications where planetary gears are used. consulab.com info@consulab.com 22 95-EM-1100 Quiz and Additional Questions on Planatery Gear Trains 6. Explain the difference between a torque-enhancing scenario and a speed-enhancing scenario in a planetary gear train. Give examples of application. Torque : Examples of application : Speed : Examples of application : 7. What is the main difference between straight teeth and helical teeth on a planetary gear ? 8. What are the advantages of helical teeth over straight teeth in a gear system ? Part 3 : Planetary Gears and Mathematics 9. Willis formulas are effective for finding the gear ratio. Identify the formula to use for each of the following scenarios : A. Scenario : Stationary ring gear, sun gear at the input, planet carrier at the output Formula : B. Scenario : Stationary ring gear, planet carrier at the input, sun gear at the output Formula : C. Scenario : Stationary planet carrier, sun gear at the input, ring gear at the output Formula : D. Scenario : Stationary sun gear, ring gear at the input, planet carrier at the output Formula : consulab.com info@consulab.com 23 95-EM-1100 Quiz and Additional Questions on Planatery Gear Trains 10. When we have a system consisting of two planetary gear sets in cascade, how is the total gear ratio calculated ? Give an example of formula : 11. Why is it important to master the mathematical formulas associated with planetary gears in mechanics ? Instructor : Grade : consulab.com info@consulab.com 24 95-EM-1100 Technical Terms Glossary Technical Terms Glossary Sun gear Toothed gear located at the center of the planetary system, typically shown in yellow in ConsuLab equipment. It is one of the three main components of the planetary gearset. Planet pinions Small gears (in green) that rotate around the sun gear and are mounted on the planet carrier. Ring gear Large external gear (in black) that surrounds the planet pinions. Planet carrier Support on which the planet pinions are mounted, allowing them to rotate around the sun gear. Input member The component of the planetary gearset to which motion or engine torque is applied. Output member The component of the planetary gearset that transmits motion or torque out of the system. Reaction member A component held stationary or immobilized to enable torque transmission and create different gear ratios. Locking (Immobilization) The action of holding a component (sun gear, ring gear, or planet carrier) stationary to achieve a specific operating mode or ratio. Gear ratio The ratio between the rotational speed of the input element and that of the output element. It determines the increase or decrease in speed and torque. Torque Rotational force transmitted by the gear system. Direction of rotation The orientation of the output motion relative to the input (same direction or opposite direction). consulab.com info@consulab.com 25 95-EM-1100 Technical Terms Glossary Neutral position Configuration in which no component is immobilized, preventing motion from being transmitted to the output. Direct drive (1:1) Configuration in which two components are locked together, resulting in a transmission ratio of 1:1 (same input and out- put speed). Willis formula Mathematical formula used to calculate speed ratios in a planetary gearset based on the components used as input, output, or reaction members. Compound planetary gearset A system that includes multiple planetary gearsets combined to produce more complex transmission ratios (e.g., Simp- son system). Hydraulic clutch pack A device that locks or releases certain components of the planetary gearset, commonly used in automatic transmis- sions. Allison 1000 transmission An example of an automatic transmission using multiple planetary gearsets and clutches to obtain different gear ratios. Simpson system A type of compound planetary gearset made of two assemblies sharing a common sun gear, allowing multiple forward speeds and one reverse gear. Spur teeth / Helical teeth Types of gear teeth: spur teeth are parallel to the axis, while helical teeth are angled, providing quieter and smoother operation. consulab.com info@consulab.com 26 95-EM-1100 Notes Notes 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada © ConsuLab Educatech Inc, 2025. All rights reserved. Theory Basic operation Student Assignments SA-1 — Component Identification SA-2 — Power Transfer SA-3 — Calculation of Gear Ratios SA-4 — Overlapped Gear Ratios SA-5 — Understanding and Calculating Ratios of an Allison 1000 Transmission (Advanced) SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) SA-6 — Understanding SIMPSON (2th speed) compound planetary gear ratios of an Allison 1000 Series transmission (Advanced) — Student Answer Sheet Quiz and Additional Questions on Planatery Gear Trains Part 1 : Multiple choice questions Part 2 : Additional Questions Part 3 : Planetary Gears and Mathematics Technical Terms Glossary

Consulink 2017 Ram 6.7L diesel engine trainer EM-140D-FC03_053347 Rev. 2026/08 EM-140D-FC03_053347 Consulink 2017 Ram 6.7L diesel engine trainer consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 EDUCATIONAL ADVANTAGES FEATURES The EM-140D-FC03_053327 diesel engine trainer is a fully operational engine mounted on a mobile stand. Trainer is based on 2017+ RAM trucks with Cum- mins 6.7L Vin L turbo-diesel engine platform used in RAM 2500/3500 heavy duty models — Equipped with tablet-based ConsuLink™ Student Learning Platform designed to enhance student engagement. The trainer is features easy for students and to work around all major components, wiring and con- nectors match OEM configurations — Equipped with safety guards covering all rotating components. • Built in ConsuLink™ student interface tablet that includes product manual, component I.D., schematics, and instruc- tor information. • Consulink™ Student Learning Platform including inserted faults, diagnostic case study scenarios, and instructor support information. • Allows instructional demonstrations to students without the access limitations of a complete vehicle. • Promotes student “ownership” and en- gagement with “hands-on” learning with real components. • Engine systems respond to inserted faults with real world symptoms, OEM DTC’s, scan tool data-stream PID chang- es and check engine light operation. • Original vehicle instrument panel with OEM ignition key (Extra key is available as an option). • OBDII data link connector with built in DLC Break Out Box and LED CAN Bus activity indicators. • OEM power distribution center with cir- cuit protection. • ECM Break Out Box with OEM matching terminal circuit identification and wire colors. • A totally functional engine with all OEM components. • Emergency Push Button stop switch. • Comes with a functional OEM HVAC system. • ConsuLink™ student learning platform • High Pressure Common Rail (HPCR) fuel system • 6-speed automatic transmission • Diesel Particulate Filter (DPF) • Variable Geometry Turbocharger (VGT) • Exhaust Gas Recirculation system (EGR) • Selective Catalytic Reduction (SCR) w/ DEF injection • Mobile stand constructed of 2” (5cm2) tubular steel equipped with four 5” (12.7cm) phenol casters (2-fixed and 2-swivel w/ locks). • Closed Crankcase Ventilation System • Fuel tank • DEF tank • Radiator • Charge-air cooler • Intake throttle • Batteries with master disconnect switch • Automatic regulated 12V battery charger • Custom instrument panel protection • Safety covers for all rotating devices • Custom coolant flow sight glass for V-8 diesel engine • Comes with two OEM keys • Fork lift bars • Scan tool tray • Vinyl dust cover EM-140D-FC03_053347 Consulink 2017 Ram 6.7L diesel engine trainer consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product APPLICATION TECHNICAL INFORMATIONS • Dimensions : 49 x 110 x 51 in (124 x 279 x 129 cm) / 53 x 114 x 55 in (135 x 289 x 140 cm) with packaging • Weight : 1770 lb (803 kg) / 1920 lb (871 kg) with packaging Engine – 2017+ Ram 2500/3500 Truck with Cummins 6.7L Vin L turbo diesel engine compliant with EPA 2017 standards

2019-2017 F series 6.7L diesel engine trainer EM-140D-FD02_035040 Rev. 2026/08 EM-140D-FD02_035040 2019-2017 F series 6.7L diesel engine trainer consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 EDUCATIONAL ADVANTAGES FEATURES STANDARD EQUIPMENT APPLICATION TECHNICAL INFORMATION The EM-140D diesel engine trainer is a fully operational engine mounted on a mobile stand. Trainer is based on 2019-2017 Ford Pickup F Series w/ POW- ERSTROKE 6.7L, 8-cylinder diesel engine platform. The trainer is easy to work on and all major components, wiring and connectors match OEM configura- tion. Trainer is mounted on a mobile stand constructed of 2” (5cm) tubular steel equipped with four 5” (12.5cm) phenol casters (2-fixed and 2-swivel w/ locks). Students can perform many NATEF related Engine Performance and Electrical/Electronic tasks using this trainer. Trainer is equipped with safety guards covering all rotating components. • Allows demonstration of engine systems to groups of students without the access limita- tions of a complete vehicle • Engine systems respond to inserted faults with real world symptoms, OEM DTC’s and check engine light operation • Equipped with all OEM equipment related to EPA 2010 Emission Standards • High pressure common rail fuel system with piezoelectric injectors • Automatic transmission • OBDII data link connecter for scan tool hookup • Integrated ECM breakout box with test points for oscilloscope and DMM hookup • Breakout box terminals identified with OEM terminology and numbers • Diesel Particulate Filter (DPF) • Exhaust Gas Recirculation (EGR) • Diesel Oxidation Catalyist (DOC) • Selective Catalytic Reduction (SCR) w/ DEF injection & tank • Automatic regulated 12V battery charger • Fuel tank • DEF tank • Exhaust system with catalytic converter • Safety covers for all rotating devices • Heavy Duty 2” square tubing mobile stand with 5” (12.5cm) phenol casters (2-fixed & 2-swivel w/locks) • Comes with two OEM keys • Coolant flow sight glass for V8 diesel engine • Scan tool tray • Fork lift bars • Custom vinyl dust cover with two zipper closures • Custom Electronic programmable fault box with 16 faults capable of programming intermittent fault insertion (EM-250-2) • Manual fault box for engine (EM-250) • Custom Instrument panel protection 2019-2017 Ford Pickup F Series w/ POWERSTROKE 6.7L 8-cylinder diesel engine • Ford Powerstroke 8-cylinder diesel en- gine compliant with EPA 2010 standards • Displacement – 6.7L (409 cu.in.) • Compression ratio – 16.1 : 1 • Aspiration – Dual boost variable turbo- chargers w/ wastegate, intercooled • OHV – (4 valves per cylinder) • Injection – Direct injection high pressure common rail (30,000 psi) w/ Piezoelectric injectors. Bosch high pressure injection pump. • Dimensions : 109 W x 57 L x 46 H inch (272,5 W x 142,5 L x 115 H cm) / 62 W x 114 L x 52 H inch (155 W x 285 L x 130 H cm) with packaging • Weight : 1272,7 kg (2800 lb) / 1336,4 kg (2940 lb) with packaging

ConsuLink GM 1.4L Engine trainer, AC & Stop-Start EM-140S-GM06A_053338 Rev. 2026/08 EM-140S-GM06A_053338 ConsuLink GM 1.4L Engine trainer, AC & Stop-Start consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 WHAT IS CONSULINK™ ? EDUCATIONAL ADVANTAGES The first ConsuLab engine bench to ever have 2 pedals, brake and accelera- tor. You can now do stall tests and load the engine; you can perform a basic “road test” within your classroom going up to 20mph which allows Stop-Start to function ! Combine this with the new ConsuLink™ student learning plat- form to enhance student engagement and use this bench to teach advanced driveability, engine performance and HVAC (air conditioning). ConsuLink™ will change the way that you and your students interact with our products. Instead of relying on switches and dials to turn on, off, and adjust faults, or setup different scenarios on the engine bench, you now access this important information through a touch- screen on the front of the trainer. Student benefits Through the ConsuLink™ touchscreen students have the ability to gain access to safety warnings, component locator, wiring schematics, basic operating instructions, case studies and more. The students can autonomously activate each case study which will automatical- ly adjust the engine bench to the preset parameters, giving them the customer complaints and instructions on what to do, thus liberating instructor time to work with other students. Students can proceed through these case studies on their own and bring the results to their instructor. Bring the scan tool, service info, multimeter/oscilloscope, and their desire to learn, and ConsuLink will help facilitate the rest! Teacher benefits ConsuLink™ holds all the information necessary to make teaching with the engine bench sim- pler. Once you enter your teacher pin or unlock access with the provided key, you are open to view the answer keys to all the student case studies, numerous lessons with preselected fault values, instructions, basic lesson plans, and other types of demonstrations that can be done. These have all beeb vetted out and proven by our team to save instructional time. The instructor has access to faulted schematics and the ability to create your own case studies (through manual fault insertion), along with all the information available through the student menus. • Perform a basic “road test” in your classroom and demonstrate the Stop-Start and engine auto-stop features. By attaining all the enabled criteria you can force the engine to auto-stop at a “red light/stop sign”. You can then demonstrate all the different disable criteria that turns the system off. • Equipped with OEM HVAC system and dash controls. • Tablet-based ConsuLink™ Student Learning Platform designed to enhance student en- gagement. • Trainer touchscreen can be mirrored to a TV or projector via HDMI out port. • Stall test can be performed by depressing both accelerator and brake pedals simultane- ously, this can be used to demonstrate loading the engine and for misfire detection. • OEM Instrument panel with all indicator lights • ECM Break Out Box matching OEM circuit pin identification with 2mm test receptacles • Engine systems respond to inserted faults with real world symptoms, OEM DTC’s, scan tool data-stream PID changes and check engine light operation • A DLC (datalink connector) Break Out Box specifically designed for use in educational environments with robust 2mm test pins and LED activity indicators for all 16 pins of a standard OBDII DLC EM-140S-GM06A_053338 ConsuLink GM 1.4L Engine trainer, AC & Stop-Start consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product SUPPORT MATERIALS STANDARD EQUIPMENT APPLICATION TECHNICAL INFORMATION The complete training system comes with the following support materials: • A self-contained total training package providing everything needed for engine diagnos- tics. Aligns with ASE Education Foundation and Red Seal tasks addressing Electrical (A6) & Engine performance (A8) • Over 39 student activities with instructor guides, case studies, fault insertion, diagrams, and built in system schematics to guide the students and the instructor that saves many hours of organization and preparation by instructors • Facilitates student engagement with hands-on, selfpaced, education • Product familiarization training is available through video conference • Between 75-100 or more hours of instruction is possible with this product • Recycled engine, OEM vehicle harness, electrical power distribution compo- nents, fuel pump and auxiliary systems using a 2019-2016 Chevrolet Cruze 1.4L • Built in ConsuLink™ student interface tablet that includes product manual, component I.D., schematics, and instruc- tor information • Consulink™ Student Learning Platform including inserted faults, diagnostic case study scenarios, and instructor support information • Original vehicle instrument panel with 2 OEM ignition keys • OBDII data link connector with built in DLC Break Out Box and LED CAN Bus activity indicators • OEM power distribution center with circuit protection • ECM Break Out Box with OEM matching terminal circuit identification and wire colors • Mobile stand constructed of 2” (5cm2) tubular steel equipped with four 5” (12.7cm) phenol casters (2-fixed and 2-swivel w/locks) • A totally functional engine with all OEM components • Automated 12V battery charger • Emergency Push Button stop switch • Comes with a functional OEM HVAC system • Scan tool tray • Coolant flow sight glass • Equipped with OEM HVAC system and dash controls, using r1234YF refrigerant • Vinyl dust cover • Fork Lift Bars Set • 2019-2016 Chevrolet Cruze 1.4L engine, automatic transmission, start/stop • Dimensions : 64 x 44 x 53.25 inch (163 x 112 x 135 cm) / 68 x 48.25 x 59.25 inch (173 x 123 x 150 cm) with packaging • Weight : 1120 lb. (508 kg) 1220 lb. (553 kg) with packaging • WARNING :This product must be con- nected to an exhaust removal system before operating

Starting Station, Engine & Swivel Stand 2.0L Honda EM-145S-HN03_053385 Rev. 2026/08 EM-145S-HN03_053385 Starting Station, Engine & Swivel Stand 2.0L Honda consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 EDUCATIONAL ADVANTAGES FEATURES Built to help instructors deliver confident, real‑world training, the Honda K20C2 2.0L Engine Trainer gives students full access to a genuine powertrain mounted on a rugged 360° swivel stand. Its reinforced steel plate and includ‑ ed OEM flywheel create a stable, authentic workspace for teardown, mea‑ surement, and reassembly. The integrated starting station comes pre‑configured with all essential en‑ gine connections, allowing safe live operation for functional checks and per‑ formance validation. This streamlined setup lets educators focus on guiding students while learners gain hands‑on mastery of modern engine systems. • Accessibility of engine components is enhanced by not having the requirement of a whole vehicle in the shop. • Ability to verify proper engine systems operation before and after engine repair assign- ments are completed. • Provides immediate feedback to students for confirmation of their workmanship and instruction completion. • Provides a SINGLE starting station that can be utilized with MULTIPLE swivel engine stands. • All rotating components are covered with safety shields or guards to prevent injuries. • Continuity of subject matter is provided by having students working on identical engines. • Multiple ASE Education Foundation (Formerly NATEF), Red Seal, and Alberta tasks in the Engine Repair. • Electrical/Electronics and Engine Performance areas can be instructed and practiced on these products. • Possibility to crank the engine without starting it to demonstrate the mechanical pres- sure. Each swivel engine stand (EM-145A-HN03_053386) comes equipped with: • Heavy Duty worm gear rotating mecha- nism that allows slip free positioning of the engine throughout all 360 degrees of rotation. • Stainless steel drip pan. • Full access to all internal and external engine components. • Leak proof quick-connect fittings for fuel injection supply and return lines. • OEM Starter and alternator. • OEM Port fuel injectors and throttle body assembly with attached components. • OEM Engine Management Sensors includ- ing: MAP, ECT, TPS, O2S, CKP, CMP and MAT. • Engine has Camshaft Variable ValveTiming. • OEM COP (Coil On Plug) Ignition system. • Heavy duty tubular steel frame built spe- cifically for each engine application. • 5” Phenol heavy duty casters (2-fixed and 2-swivel with locks). • Powder coated acrylic enamel finish. • Vinyl Dust Cover EM-145S-HN03_053385 Starting Station, Engine & Swivel Stand 2.0L Honda consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product The starting station (EM-145B-HN03_053387) comes equipped with: • VIN number matching all included com- ponents (allows easy replacement of needed components from local suppliers). • All OEM color matching wiring harnesses and electrical connectors necessary to operate the swivel stand engine. • Quick connect fuel lines for easy disas- sembly/assembly (Leak proof safety-type quick connect fittings for supply and return fuel lines). • Fuel tank (22L - 5.8 gals) with OEM fuel cap suitable for EVAP testing. • Fuel tank has OEM fuel pump, sending unit and mounting design. • OEM functional EVAP system with test port. • OEM Catalytic converter. • OEM Radiator and hoses. • OEM Instrument cluster with gauges and indicators. • OEM Anti-Theft system. • OBDII DLC (data link connecter) for scan tool hookup. • 12V battery. • Comes with two OEM ignition keys. • Vinyl Dust Cover The swivel engine and engine stand are also available separately in multiple quantities. *The flywheel pressure plate is included with the Starting Station(s) only and is not included with any Swivel Engine Stand. Therefore, when swapping engines, the pressure plate must be transferred between units unless additional pressure plates are purchased separately from a local auto parts supplier FEATURES (continued) APPLICATION TECHNICAL INFORMATION • Starting Station : 2016-2021 Honda Civic • Swivel Engine : The Honda K20C2 2.0L • Dimensions - Starting Station : 52 x 40 x 48 inch (132 x 101.6 x 121.9 cm) without packaging - Swivel Engine : 41 x 28 x 48 (104.1 x 71.1 x 121.9 cm) without packaging EM-145S-HN03_053385 Starting Station, Engine & Swivel Stand 2.0L Honda consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 WHAT TO EXPECT WITH CONSULAB RECYCLED ENGINES This means that when your students dismantle the engine, it may be the first time it has been opened since it left the factory. Criteria Details Maximum permissi- ble vehicle mileage 250,000 km (155,000 miles) for gasoline engines 300,000 km (185,000 miles) for diesel engines Leakage Each engine is tested to ensure no leaks of coolant or oil (any leaks found will be repaired). New parts New oil filter, air filter and accessory drive belt New drain plugs are installed, the threads in the oil pan are inspect- ed. Check engine light No powertrain DTCs for any of the swivel engines (all sensors, inputs and outputs functional). Engine block External engine block and other metallic components have been cleaned and painted. Seized bolts All externally accessible bolts that the student would touch during teardown have been checked to ensure they are not seized. Tests We run each engine to operating temperature and ensure the ther- mostat functions. Noises No excessive bearing noises from any accessories (any noisy compo- nents are changed, example: alternator, belt tensioner). No internal engine noises (knocking) are permitted. Exhaust No puffing of black, blue or white smoke permitted. Where an OEM multi-layer metal exhaust manifold gasket is used, we reuse the used gasket, as this has proven to be the best choice versus new gaskets which are often single time use. The exhaust manifold to cylinder head mating surface has been cleaned. Corrosion Corrosion is accepted on OEM specific nut and bolt heads so long as it does not interfere with using tools to remove/install the nut/bolt. Gaskets Only gaskets that present a leak are replaced. The head gasket will be the OEM one from the vehicle that recently left service on the road. Each ConsuLab engine rebuild station is built using recycled components from a real vehicle. This means that the amount of wear and tear on the engine will vary from one unit to another. Note: The engines are inspected, cleaned, and ran at operating temperature to ensure proper function. We do not dismantle the engines, so each engine may have different internal wear characteristics.

ConsuLink™ engine bench Cummins B6.7 EPA 2021 new HV-950-B6.7_035101 Rev. 2024/08 HV-950-B6.7_035101 ConsuLink engine bench Cummins B6.7 EPA 2021 new consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 WHAT IS CONSULINK™? Student benefits Teacher benefits EDUCATIONAL ADVANTAGES This is the first ever heavy vehicle diesel engine bench to have ConsuLink. The HV-950-B6.7 diesel engine bench includes a new, fully operational, Cum- mins B6.7 diesel engine, EPA 2021. ConsuLink™ will change the way that you and your students interact with our products. Instead of relying on switches and dials to turn on, off, and adjust faults, or setup different scenarios on the engine bench, you now access this important information through a touch- screen on the front of the trainer. Through the ConsuLink™ touchscreen students have the ability to gain access to safety warnings, component locator, wiring schematics, basic operating instructions, case studies and more. The students can autonomously activate each case study which will automatical- ly adjust the engine bench to the preset parameters, giving them the customer complaints and instructions on what to do, thus liberating instructor time to work with other students. Students can proceed through these case studies on their own and bring the results to their instructor. Bring the scan tool, service info, multimeter/oscilloscope, and their desire to learn, and ConsuLink will help facilitate the rest! ConsuLink™ holds all the information necessary to make teaching with the engine bench sim- pler. Once you enter your teacher pin or unlock access with the provided key, you are open to view the answer keys to all the student case studies, numerous lessons with preselected fault values, instructions, basic lesson plans, and other types of demonstrations that can be done. These have all been vetted out and proven by our team to save instructional time. The instructor has access to faulted schematics and the ability to create your own case studies (through manual fault insertion), along with all the information available through the student menus. • Includes three different educational support documents : - Operation manual - Student assignments - Instructors manual • ConsuLink™ student learning platform with a touchscreen display. • Demonstration of major engine systems to groups of students without the access limita- tions of a complete vehicle. • Engine systems respond to inserted faults with real-world symptoms, OEM DTCs, and check engine light operation. • Functional DLC using SAE J1939 protocols. • Demonstration of exhaust after-treatment emission system operation. HV-950-B6.7_035101 ConsuLink engine bench Cummins B6.7 EPA 2021 new consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product FEATURES APPLICATION TECHNICAL INFORMATION • Single camshaft • High Pressure Common Rail (HPCR) fuel system • ECM 2450 (this control module incorporates DEF dosing control) • Variable Geometry Turbocharger (VGT) • Exhaust Gas Recirculation system (EGR) • Steel tubing engine stand with four removable casters, two locking • Fuel tank • Radiator • Charge-air cooler • Air filter • Instrument panel with : - Ignition key and testing points - Indicator lamps and switches - Breakout box - Murphy PV101 control panel for J1939 parameters - J1939 Data Link Connector • Accelerator pedal • Emergency stop switches (2) • Batteries (2) with master disconnect switch and smart battery charger • Safety guards on all rotating or high temperature components • Electronic programmable fault box • Vinyl dust cover • Aftertreatment system: - Single Module DPF and SCR Cummins B6.7, EPA 2021 w/EGR, DPF, SCR • Dimensions : 50 x 58 x 73.25 inch (127 x 147.32 x 186.06 cm) without packaging / 60 x 82 x 78 inch (152.4 x 208.28 x 198.12 cm) with packaging • Weight : 2216 lb (1 005 kg) with packaging

Engine mechanical diagnosis trainer EM-141S-TY01_053234 Rev. 2026/08 EM-141S-TY01_053234 Engine mechanical diagnosis trainer consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 EDUCATIONAL ADVANTAGES FEATURES Have you ever wanted a running engine with repeatable mechanical faults that all of your students could diagnose? Would you like an engine system that has internal mechanical faults not requiring you to reinsert and repair them after each student use? The EM-141S-TY01 does exactly that. It was designed for the purposes of teaching students mechanical engine compo- nent failure diagnosis and is a real time-saver allowing instructors to instant- ly provide a “turn-key” engine mechanical fault diagnosis package. • Saves significant instructor setup time for creating common engine mechanical faults and learning exercises • Engine systems respond to inserted faults with real world symptoms, OEM DTC’s, scan tool data-stream of changes and Check Engine Light operation • Repeatable faults allow multiple students to identify and demonstrate all required diag- nostic tests required to identify cause (Prevents students from “memorizing” the faults. They would be required to perform the required testing) • Installed mechanical faults cause compression, cylinder leak down, head gaskets and engine timing negative operational issues • Recycled engine, transmission and complete assembly of components • A fully operational engine that starts/runs with OEM instrument panel • Three “permanent” inserted industry common mechanical faults and one defective com- ponent fault that can be removed/replaced. • Provides a “real world” running engine that will demonstrate all negative operational symptoms based on the faults. • Functional Electronic Throttle Control, Catalytic Converter and Variable Valve Timing systems • Emergency stop button • Customized OEM exhaust system • OEM Fuel Pump Module • OEM power distribution center with circuit protection • Scanner shelf for handheld scan tools • All electrical components match OEM wiring schematics and service information • Automatic regulated 12V battery charger with master power disconnect switch • Vinyl dust cover • Robust trainer frame and stand with special design features for : - Easy removal and installation of radiator - Front motor mount is removable providing access to front engine timing cover - Defective control component that can be replaced with a non-defective unit correcting the fault - Included tool storage tray - Removable safety shields on all rotating components - Additional instructor led assignments on engine components R&R (timing chain, etc) EM-141S-TY01_053234 Engine mechanical diagnosis trainer consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product SUPPORT MATERIALS APPLICATION TECHNICAL INFORMATION • Laminated electrical schematics • Pre-determined faults • Operation manual • Full curriculum package with student assignments & instructor answer keys 2013-2016 Toyota Corolla North American model 1.8L 2ZR-FE engine with automatic transmission. • Dimensions : 54.5 x 33.25 x 49 inch (138.5 x 84.5 x 124.5 cm) / 36 x 60 x 52 inch (90 x 150 x 130 cm) with packaging • Weight : 830 lb (376 kg) / 885 lb (401 kg) with packaging

Starting station, engine & swivel stand - GM EM-145S-GM05_053331 Rev. 2026/08 EM-145S-GM05_053331 Starting station, engine & swivel stand - GM consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 FEATURES AND STANDARD EQUIPMENT The Ecotec 1.8L engine on a swivel stand is designed for student instruction and practice covering engine mechanical inspection, disassembly, measure- ment and reassembly. The engine is securely mounted to a heavy duty rotat- ing device to allow full 360 degree rotation. A steel mounting plate is used for engine mounting that allows full access for rear main seal and flywheel service. Each engine comes equipped with a transmission flywheel (manual or automatic). The engine starting station contains all components and systems necessary for the starting and running of the Ecotec 1.8L engine. All neces- sary engine systems connections are provided to allow live running of each swivel engine stand for verification of proper student assignment completion. Each swivel engine stand (EM-145A- GM05_053328) comes equipped with : • Heavy Duty worm/ring gear rotating mechanism that allows slip free position- ing of engine throughout 360 degrees of rotation • 31” x 24” 14 gauge stainless steel drip pan • Full access to all internal and external engine components • Leak proof quick-connect fittings for fuel injection supply and return lines • OEM Starter and alternator • OEM Port fuel injectors and throttle body assembly w/attached components • OEM Engine Management Sensors includ- ing: MAP, ECT, TPS, O2S, CKP, CMP and MAT. No need to transfer components from one unit to another • OEM Sequential Port Fuel injection • Engine has Camshaft Variable Valve Timing • OEM COP (Coil On Plug) Ignition system • Heavy duty 2” x 2” x 1/8 ” square steel frame built specifically for each engine application • 5” Phenol heavy duty casters (2-fixed and 2-swivel w/locks) • Powder coated acrylic enamel finish • Custom machined 5/8” steel engine mounting plate designed to allow full access to flywheel, crankshaft and rear main seal service procedures • Equipped with a transmission flywheel (manual or automatic) for vibration free operation and starter system longevity • Vinyl Dust Cover The starting station (EM-145B-GM05_053329) comes equipped with : • Vehicle VIN number matching all included components (allows easy replacement of needed components from local suppliers) • All OEM color matching wiring harnesses and electrical connectors necessary to operate the swivel stand engine • Quick connect fuel lines for easy disas- sembly/assembly (Leak proof safety-type quick connect fittings for supply and return fuel lines) • Fuel tank (22L - 5.8 gals) with OEM fuel cap suitable for EVAP testing • Fuel tank has OEM fuel pump, sending unit and mounting design • OEM functional EVAP system with test port • OEM Catalytic converter • OEM Radiator and hoses • OEM Instrument cluster with gauges and indicators. • OEM Anti-Theft system • OEM COP (Coil-On-Plug) ignition system • OBDII DLC (data link connecter) for scan tool hookup • 12V battery • Comes with two OEM ignition key • Vinyl Dust Cover The swivel engine and engine stand are also available separately in multiple quantities. EM-145S-GM05_053331 Starting station, engine & swivel stand - GM consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 WHAT TO EXPECT WITH CONSULAB RECYCLED ENGINES Each ConsuLab engine rebuild station is built using recycled components from a real vehicle. This means that the amount of wear and tear on the engine will vary from one unit to another. Note: The engines are inspected, cleaned, and run up to operating temperature to ensure proper function. We do not dismantle the engines, so each engine may have different internal wear characteristics. This means that when your students dismantle the engine, it may be the first time it has been opened since it left the factory. Criteria Details Maximum permissible vehicle mileage 250 000 km (155 000 miles) for gasoline engines 300 000 km (185 000 miles) for diesel engines Leakage Each engine is tested to ensure no leaks of coolant or oil (any leaks found will be repaired). New parts New oil filter, air filter and accessory drive belt New drain plugs are installed, the threads in the oil pan are inspect- ed. Check engine light No powertrain DTCs for any of the swivel engines (all sensors, inputs and outputs functional). Engine block External engine block and other metallic components have been cleaned and painted. Seized bolts All externally accessible bolts that the student would touch during teardown have been checked to ensure they are not seized. Tests We run up each engine to full operating temperature and ensure the thermostat functions. Noises No excessive bearing noises from any accessories (any noisy compo- nents are changed, example: alternator, belt tensioner). No internal engine noises (knocking) are permitted. Exhaust No puffing of black, blue or white smoke permitted. Where an OEM multi-layer metal exhaust manifold gasket is used, we provide the used gasket, as this has proven to be the best choice versus new gaskets which are often single time use. The exhaust manifold to cylinder head mating surface has been cleaned. Corrosion Corrosion is accepted on OEM specific nut and bolt heads so long as it does not interfere with using tools to remove/install the nut/bolt. Gaskets Only gaskets that present a leak are replaced. The head gasket will be the OEM one from the vehicle that recently left service on the road. EM-145S-GM05_053331 Starting station, engine & swivel stand - GM consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 Scan this QR code for more about this product EDUCATIONAL EQUIPMENT APPLICATION TECHNICAL INFORMATION • Accessibility of engine components is enhanced by not having the requirement of a whole vehicle in the shop • Ability to verify proper engine systems operation before and after engine repair assign- ments are completed • Provides immediate feedback to students for confirmation of their workmanship and instruction completion • Provides a single starting station that can be utilized with multiple swivel engine stands • All rotating components are covered with safety shields or guards to prevent injuries • Continuity of subject matter is provided by having students working on identical engines • Multiple NATEF, Red Seal and Alberta tasks in the Engine Repair. Electrical/Electronics and Engine Performance areas can be instructed and practiced on these products • Possibility to run the engine without starting it to demonstrate the mechanical pressure • Easy access to the two crankcase seals • Starting Station : 2012-2015 Chevrolet Sonic • Swivel Engine : GM Ecotec 1.8L LUW • Dimensions - Starting station : 56 x 36 x 54 inch (142.24 x 91.44 x 137.16 cm) / 60 x 40 x 56 inch (152.4 x 101.6 x 142.24 cm) with packaging - Swivel Engine : 42 x 28.25 x 47.75 inch (106.68 x 71.12 x 119.38 cm) / 60 x 70 x 78 inch (152.4 x 177.8 x 198.12 cm) with packaging • Weight - Combine : 1210 lb (548.85 kg) with packaging - Swivel engine alone : 920 lb (417.31 kg) with packaging

Rev. 2026/07 Cutaway Toyota Prius Hybrid Drive Train EC-140H_052944 EC-140H_052944 Cutaway Toyota Prius Hybrid Drive Train consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 The trainer consists of all cutaway drive train components from a Toyota Hybrid Synergy Drive system including: • ICE (internal combustion engine) • Torque damper assembly • MG1 (motor/generator # 1) • Planetary gearset • MG2 (motor/generator # 2) • Control Panel • Accelerator Pedal • Brake Pedal • Transaxle • Inverter • HV (high voltage) battery (non-functional) The ICE, MG1, MG2 and differential output/drive wheels are driven with external electric motors via connecting chains. This design allows the demonstration of eight of the possible hybrid operating modes. All components are cutaway to allow clear student visual learning. GENERAL DESCRIPTION EDUCATIONAL ADVANTAGES APPLICATIONS The EC-140H Cutaway Toyota Prius Hybrid Drive Train is a training system designed specifically for teaching how a typical hybrid drive train operates. • Clear cutaways allow clear student visualization of hybrid drive train components. • Students can observe the eight basic operational modes of a typical hybrid drive train. • Completely safe. No high voltages normally associated with hybrids are used. • Clear protective plexiglass enclosure for all rotating components. • Intuitive control panel/dashboard showing power flow, component speed, and direction of rotation. • Three individual motors for ICE, MG1 and MG2. • Allows students to observe the continually variable ratio function using a simple plane- tary gear set (power split device) and varying input speeds. • 2010-2015 Toyota Prius. • 1.8L 2ZR-FXE (4-cylinder with VVT-i Atkinson cycle with Hybrid Synergy Drive). EC-140H_052944 Cutaway Toyota Prius Hybrid Drive Train consulab.com info@consulab.com 400-6330 Zéphirin-Paquet St. Québec QC G2C 0M3 Canada Toll-free: +1 (800) 567-0791 U.S.A.: +1 (810) 222-4525 Canada: +1 (418) 688-9067 Fax: +1 (418) 843-3444 STANDARD EQUIPMENT AND FEATURES TECHNICAL INFORMATIONS • OEM components, wiring, connectors and wire colors • 120 VAC 60 Hz Power Supply with master ON/OFF switch used to power the EC-140H Hybrid trainer. Includes 1.5A protection fuse • Mobile stand constructed of 2” (5cm2) tubular steel equipped with four 5” (12.7cm) phe- nol casters (2-fixed and 2-swivel w/locks). • Control panel • Driving modes including: - Reverse - Engine start - Low speed and low acceleration (stealth) - Normal drive (cruise) - High speed and full-throttle acceleration - High speed energy recirculation - Coasting - Regenerative braking • Drive train information section including a battery charging lamp, a MG2 regeneration lamp, a steady state lamp, a MG1 regeneration lamp, an engine cold temperature lamp, a battery voltage display, a MG2 RPM display, a vehicle speed display, a MG1 RPM display, an engine RPM display, two opposite rotation LED indicators, two RPM x10 LED indica- tors, two system main relay control LED indicators and a drive train schematic diagram. • Accelerator pedal • Brake pedal • Emergency panic disconnect button • Dimensions: 30.5 x 60 x 55 in (77.5 x 152.4 x 140 cm) / 36 x 64 x 78 in (91.5 x 163 x 198 cm) with packaging • Weight: 720 lbs (326.5 kg) / 847 lbs (385 kg) with packaging