Automotive

Training and Further Education in Automotive Engineering
Practical Automotive Laboratory Instruction and Diagnostics
2nd Edition
Contents
Qualifications Through Quality Training Systems for Automotive Engineering .................................................................................................................................. 4 Different Systems to Suit Different Needs UniTrain-I ........................................................................................................................................................................................ 6 Connect ........................................................................................................................................................................................ 8 Plug-in System .............................................................................................................................................................................. 10 Compact System .......................................................................................................................................................................... 12 Training Panel Systems .................................................................................................................................................................. 13 Training Vehicles ........................................................................................................................................................................... 14 The Entire Program at a Glance ................................................................................................................................................ 16 More than a Training System A Complete System Comprising a Diagnostic Workshop Lab for Automotive Engineering ............................................................. 18 Animated Presentation of Complex Training Contents Project-oriented Training Media Adaptable to any Training System .............................................................................................. 20
Contents
Electrics / Electronics ............................................................................................................................................................. 22-33 DC and AC Technology in Motor Vehicles Three-phase Generator Pulse-width Modulated Signals
Sensors and Actuators ......................................................................................................................................................... 34-39 Automotive Sensors Engine Management Sensors
Vehicle Lighting ..................................................................................................................................................................... 40-49 Lighting and Signalling Systems CAN Bus Extension Dashboard Training Model Incorporating CAN and LIN Buses
Comfort Systems ................................................................................................................................................................... 50-57 GPS Navigation Alarm System and Immobilizer Air-conditioning and Climate Control
Alternative Drives ................................................................................................................................................................. 58-65 Hybrid Automotive Drive Fuel Cells Photovoltaics
Engine Management ............................................................................................................................................................ 66-83 Ignition Systems Diesel Engine Management Systems Spark-ignition Engine Management Systems
Vehicle Diagnosis .................................................................................................................................................................. 84-97 On-board Diagnosis II Auto Diagnosis Trainer Software Automobile Diagnosis Units
Chassis and Driving Safety ................................................................................................................................................. 98-111 Brake Power Control ABS/ASR/ESP Hydraulic Brake System Airbag and Seat-belt Tensioner
Networked Systems .......................................................................................................................................................... 112-119 LIN Bus CAN Bus MOST Bus
Practical Automotive Workshop Lab ................................................................................................................................ 120-133 Exhaust Gas Analysis and EOBD Data Readout Axle Measurement Tool Kits Topics
Automotive Engineering
Qualifications Through Quality

Training Systems for Automotive Engineering
Advances in technology
Unusual concepts and rapid innovations in the development of automotive systems these are the challenges of today. Unique driving culture afforded by a blend of excellent comfort and superior agility place the highest demands on industry and trade. Automotive electronics in general has turned into one of the most innovative areas here.
are having a huge impact on training and education.

A host of patents and new technologies viewed as milestones in automotive technology make new training systems necessary. Advances in safety optimization, intelligent drive systems and integration of mobile communications are just a few examples of the changes occurring in this profession. The enormous demands placed on automotive trainees today involve correspondingly modern and practical hands-on systems of instruction. One of the most important training objectives is to enable students to work independently in a professional manner.
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Practical competence is a key qualification

Greater work satisfaction and independence acquired early on during the training phase are not just coincidences, but the results of purposeful instruction using Lucas-Nlles training and educational systems. All training topics are fully covered, from the fundamentals of automotive electrics through lighting and comfort systems to vehicle diagnosis and automotive experiments in the practical automotive workshop laboratory. Our modular and scaleable training systems provide an innovative and future-proof platform for first-rate, in-depth theoretical and practical training in automotive engineering.
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Different Systems to Suit Different Needs

UniTrain-I a Multimedia Laboratory with over 100 Courses
With the UniTrain-I multimedia experiment and training system, students are guided through the experiments by means of clearly structured course software including texts, graphics, animations and knowledge tests. In addition to the training software, each course comes with an experiment card for performing practical exercises. Courses such as those on the fundamentals of electrical engineering, automotive sensors and ignition systems convey the knowledge and skills needed to understand, connect, diagnose and operate modern automotive systems. Animations and numerous experiments on authentic systems found in the various courses impart the fundamentals, principles and attributes of electrical, safety, lighting and engine-management equipment.
Your benefits
Theory and practice all in one PC and new media for high levels of student motivation Quick success through structured courses Animated theory for quick understanding Practical competence through independent experimentation Constant feedback through quizzes and knowledge tests Guided trouble shooting with an integrated fault simulator Protection of low voltages ensuring safe operation Large selection of courses (covering more than 100 subjects) Sample solutions for teachers and students
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UniTrain-I system Comprehensive, portable laboratory Multimedia courses High-tech measurement and control interface Theory and practice all in one package
UniTrain-I interface with USB Oscilloscope with 2 analogue differential inputs Sampling rate of 40 Msamples/s 9 measuring ranges from 100 mV - 50 V 22 time ranges from 1 s - 10 s 16 digital inputs / outputs Function generator for frequencies up to 1 MHz 8 relays for fault simulation
UniTrain-I experimenter Holds experiment cards Experiment power supply of 15 V, 400 mA Experiment power supply of 5 V, 1 A Variable direct or three-phase current, 0 - 20 V, 1 A IrDa interface for multimeters Serial interface for additional experiment cards
Integrated measuring equipment and power supplies Multimeters, ammeters, voltmeters Dual-channel storage oscilloscope Function and waveform generator Three-fold DC power supply Three-phase power supply ... and many other instruments
LabSoft training and experiment software Large selection of courses Comprehensive theory Animations Interactive experiments with instructions Free navigation Documentation of measurement results Knowledge test
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Connect Multimedia Training System with Original Components
The Connect system consists of a series of A4-format panels with original components from corresponding engine management systems. A multimedia program provides helpful information on the individual components and overall systems. All components are described in detail in the software. Functions are elucidated by videos and animations. Due to the equipments modular nature, a variety of injection systems can be realized simply by interchanging individual components.
Your benefits
Original automotive components provide an ideal blend of theory and practice Easy to use Suitable for basic as well as specialized training: Storage of solutions, option of transferring solutions to other Connect systems Universal use in workshops and classrooms Quick checks of acquired skills Maximum operational safety Future-oriented learning
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CBT software features Instructions for use Detailed representations Result monitoring and analysis for the trainer Hardware layout and wiring diagrams Problems and questions for trainees Technical documentation Videos Animations
Connect is suitable for: Demonstrations Practical laboratory work Independent studies Group work
Topics Fundamentals Special skills Measurement of electrical variables Sensors and actuators Engine management systems Ignition systems Conversion from mechanical to electrical variables
Multimedia support Multimedia presentations of component functionality Efficient independent learning Self-explanatory user interface Simple program resumption after interruption
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Plug-in System a Classic for Students Exercises
Sound training in the fundamentals of electrical engineering is a prerequisite for understanding the complex relationships between various automotive applications. Our classic, modular plug-in system is meant for thorough and practical training in electrical engineering and electronics. Particularly suitable for students exercises, experimentation and familiarization, this robust system permits a true reproduction of circuit diagrams in experiment configurations.
Your benefits
Gold-plated contacts Extremely practical approach Students exercises tailored specially to automotive engineering 1:1 mapping of circuit diagrams on the rastered plug-in board Exploring complex relationships through experimentation Universal applications Robust components High degree of transparency
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Universal power supply A single device for all experiments Direct and alternating voltage Three-phase current source and function generator Voltages are adjustable, controllable and short-circuit proof
Compact and fast Versatile deployment Integrated power supply Integrated function generator and DC/AC source Plug-in components can be stored securely in the lid
Versatility The same board can be used in the following variants: Desktop device Portable device in a component storage case Experiment panel mounting frame for demonstration purposes
Experiments with overlay masks Experiments tailored specially to automotive applications Simple approach to teaching fundamentals using practical hands-on experiments Integrated automotive-type ground connection via the chassis
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Compact Ready for Immediate Use
The compact system provides function groups comprising all relevant components configured for the purpose of instruction. All components needed to operate the system are clearly arranged on a large housing panel. The components are original vehicle parts prepared in such a way that they can be put to use quickly and easily.
Your benefits
Practical, hands-on training using original vehicle parts All components are fully functional Complex systems are clearly depicted All necessary components have been configured for the purpose of instruction Easy and quick to set up and put into operation
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Training Panel Systems a Modular System

Whether for conventional classroom instruction or practical experiments, this system of panels permits a variety of teaching methods to be implemented. The experiment panels have an identical height of 297 mm (A4 format). Each panels front indicates the symbol associated with that particular device or circuit according to latest DIN specifications. Wherever possible and appropriate, the print on the front side is complemented by colour graphics or photos. For a better educational overview, the voltage supply bus is highlighted at the panels top and bottom edges in colour according to DIN72551.
Your benefits
Modular design for versatility and flexibility Suitable for students exercises and demonstrations Safety through dual insulation (safety sockets and leads) Practical training using original vehicle parts Clear layout with the help of high-contrast, scratch-proof print on the front panel Modern measurement technology with PC interface Experiment and technical handbooks in colour Students worksheets and sample solutions
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Training Vehicles a Practical Form of Education
To make training as practical as possible, LN training vehicles are modified specifically for educational purposes. Accordingly, all major components are made accessible to allow direct measurements of sensor and actuator signals. To emulate typical workshop situations, malfunctions can be activated via a hidden fault simulation box.
Your benefits
Practical, hands-on training using original vehicle parts All components fully functional Self-diagnosis and acquisition of operational data Fault simulation Direct measurements without a need to dismantle the vehicle Measurements of all systems possible while the engine runs Investigation of electrical and mechanical components Preparatory checks for an emission test according to 47 of German road traffic licensing regulations, and a general inspection according to 29 of these regulations
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Type diversity Availability of various models Diesel and petrol-driven vehicles Exclusive equipment configurations
Workshop documents Electronic workshop documents Circuit diagrams Electronic repair information
Diagnosis and fault localization Fault simulation A breakout box permits easy tapping of signals for diagnosis Operational data acquisition and self-diagnosis Direct measurements on control units
Prepared systems Visible display of normally concealed components Sub-systems can be dismantled for a better understanding View inside the vehicles body
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The Entire System at a Glance

Solutions for Automotive Training
Electrics / Electronics
UniTrain-I Basics of electrical engineering Basics of electronics and digital technology Pulse-width modulated signals Three-phase generator Plug-in system Basics of electrical engineering Automotive electrics and electronics Semiconductor components
Alternative Drives
UniTrain-I Hybrid automotive drive Photovoltaics Fuel cells Compact system Hybrid sectional model (Toyota Prius)
Sensors and Actuators

UniTrain-I Automotive sensors Compact system Sensor technology in engine management
Vehicle Lighting
Panel system Headlights with range adjustment Auxiliary lights Trailer lights Acoustic signals Static cornering light Compact system Dashboard training stand
Chassis and Driving Safety

UniTrain-I Airbag and belt tensioner Brake systems Transmission system technology Chassis technology Steering systems Compact system SRS airbag and seat-belt tensioner Hydraulic brake systems ABS ABS and ASR
Comfort Systems
Panel system Alarm system and immobilizer Check control Compact system Climatronic air-conditioning GPS
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Networked Systems
UniTrain-I LIN bus CAN bus Waveguides / MOST bus
Practical Lab
Compact system Exhaust gas analysis and EOBD data readout Tyre fitting machine Balancing machine Axle measurement Hydraulic lifting platform Fully automatic air-conditioning service unit Motor vehicle tool kit
Engine Management
UniTrain-I Automotive ignition systems Common rail Connect Motronic 2.8 Common rail Direct petrol injection Performance tuning at an engine test bench Compact system Common rail Electronic diesel control (EDC) Motronic ML 4.1 L-Jetronic D-Jetronic KE-Jetronic Functional engine Fuel injection engine Pump injector (TDI) Common rail
Vehicle Diagnosis
Panel system On-board diagnosis II Software Automobile diagnosis trainer Compact system On-board diagnosis II data recorder Automobile diagnosis case Diagnosis unit with an oscilloscope Common rail diagnosis set
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More than a Training System

A Complete System Comprising a Diagnostic Workshop Lab for Automotive Engineering
Lucid presentations of complex concepts with modern educational media Complete solutions for modern engine management, brake, climate control and airbag systems
Multimedia-based knowledge transfer using the UniTrain-I and panel systems
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Direct diagnosis of the vehicle: Testing and maintenance of networked systems
Functional engine: Diagnosis and maintenance of engine management systems
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Animated Presentation of Complex Training Contents

Project-oriented Training Media Adaptable to any Training System
Manuals Providing detailed descriptions of how to put training systems into operation, these handbooks also contain numerous exercises, experiments and projects.
Multimedia courses Available as multimedia courses, many of the manuals include features familiar from the UniTrain-I courses, e.g.: Tests Interactive experiment set-ups Navigation bars Animations
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QuickCharts These provide a quick overview of certain topics. The steps to be taken, the work processes and the technical relationships are explained briefly and vividly.
Presentation slides Slides on CD can provide support for your lessons, e.g. supplying background information, block circuit diagrams, physical fundamentals, specific standard characteristics, special modifications and application examples. The slides come in PowerPoint format on a CD.
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DC and AC Technology in Motor Vehicles .............................. Electronic and Digital Technology in Motor Vehicles ............... Three-phase Generator .......................................................... Pulse-width Modulated Signals (PWM) ................................... Three-phase Generator with a Multi-function Controller ........ Three-phase Generator with a Hybrid Controller .................... Fundamentals of Automotive Electrics and Electronics ............ 26 27 28 29 30 31 32
Practical Elementary Knowledge
Sound training in the fundamentals of automotive electrics is a prerequisite for understanding the complex relationships between various electrical and electronic applications in automobiles. Our training systems are geared specially to education in the area of automotive engineering. Electrical and electronic fundamentals are presented clearly by means of numerous examples, descriptions and practical exercises.
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Automotive Engineering Kraftfahrzeugtechnik
Analogue technology In electrical engineering, an analogue system is one where physical variables continuously vary in value and time. The LN case system imparts the related fundamentals in a practical manner.
Digital technology This topic deals with the processing of discrete-value and discrete-time numerical sequences as well as digital signals. Our basic courses are made up of typical automotive examples and exercises intended to provide the most practical training possible.
Training systems Our training systems cover the following topics: Electrical fundamentals Basics of automotive electronics Semiconductor components Basic electronic circuits Applied electronic circuits Basic and applied digital circuits
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DC and AC Technology in Motor Vehicles
The growing significance of electric and electronic components in motor vehicles necessitates practical training in the fundamentals of electronics.
Measurements with a computer
Training contents
Introduction to the basic concepts of current, voltage and resistance Usage of voltage sources and measuring devices Experiment-based demonstration of Ohms and Kirchhoffs laws Measurements of series / parallel connections, voltage dividers and mixed circuits Recording the characteristics of variable resistors (LDR, NTC, PTC, VDR) Trouble shooting
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UniTrain-I course SO4204-7A Lucas-Nlle
Electronic and Digital Technology in Motor Vehicles

A knowledge of the characteristics and functionality of electronic components forms the basis for understanding and analyzing such components and their circuits in motor vehicles.
Training contents
Determining a diodes valve and rectifier action Recording diode characteristics Basic transistor circuits Setting the operating point of a basic transistor circuit Gain, emitter and collector circuits Design of basic logic circuits Boolean functions and laws Static and dynamic switching characteristics of JK flip-flops Design of a counter circuit
UniTrain-I course SO4204-7B Lucas-Nlle
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Three-phase Generator
Nearly all modern motor vehicles possess a three-phase generator for supplying the necessary electrical energy.
Training contents
Generator principle Three-phase current Diode and rectifier circuits Functionality of an unregulated three-phase generator Discrete and integrated voltage controllers Regulated three-phase generator Fault diagnosis
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UniTrain-I course SO4204-7D Lucas-Nlle
Pulse-width Modulated Signals (PWM)

Many actuator systems in motor vehicles require variable power levels for the devices being controlled. Actuators which need to assume intermediate values between the ON and OFF limits are controlled by means of pulse-width modulated signals.
Training contents
Principle of pulse-width modulation Automotive applications of pulse-width modulation Adjusting the power of electrical loads with PWM Measuring a PWM signals characteristics: frequency, amplitude, mark-to-space ratio Pulse width, edges and signal shapes Control and operating-current circuits Diagnosis of PWM-controlled components
UniTrain-I course SO4204-7J Lucas-Nlle
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Three-phase Generator with a Multi-function Controller
This training system is used to examine how energy is generated on modern motor vehicles. Todays compact generators make use of a monolithic controller. This kind of multifunction controller has now largely replaced hybrid controllers. A progressive sequence of experiments gradually introduces students to the subject of electricity generation on automobiles.
Training contents
Principle of three-phase current generation Generation of 3-phase alternating voltage in vehicles Rectification and protection by power Z-diodes Characteristics of a multi-function controller Battery monitoring (sensing) Controlled pre-excitation (pulse-width modulation) Fault diagnosis
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ASA 7 equipment set Lucas-Nlle
Three-phase Generator with a Hybrid Controller

The hybrid controller is meant to maintain the generator voltage at a certain level, regardless of speed and load. The average excitation current is adjusted by varying the power-on and power-off times. This accordingly changes the magnetic field in the excitation winding and the induction of the stator winding.
Training contents
Principle of three-phase current generation and voltage control How 3-phase alternating voltage is produced in vehicles Characteristics of a hybrid controller Necessity for exciter diodes Investigation of exciter current Diagnosis of system faults
ASA 7 equipment set Lucas-Nlle
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Fundamentals of Automotive Electrics and Electronics
This systems standard patch panels can be used to configure a wide variety of circuits. The electric and electronic components available to the student can be easily plugged into the patch panel.
Training contents
Introduction to electric and electronic components - Resistors - Capacitors - Coils - Semiconductor elements Configuring basic electric and electronic circuits in motor vehicles Experiment-based determination of characteristics Working with electric measuring devices Design and functionality of analogue and digital automotive circuits
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PS4200-2A and PS4200-2B equipment sets Lucas-Nlle
Training / experiment topics

Fundamentals of automotive electronics Connection of measuring devices, voltage, current and resistance measurement Ohms law Resistor circuits Series connection Parallel connection Mixed circuits Voltage divider under load and no-load Photoresistor
u
Bridge circuits Capacitor circuits Diodes Light-emitting diodes Z-diode Transistor Thyristor Field-effect transistor
PS4200-2A equipment set
Electronic and digital circuits Rectifier circuits Transistor and thyristor as switches Voltage stabilization Schmitt trigger Flip-flops Electronic voltage controller Electronic rpm counter Bistable flip-flop
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Overvoltage protection for three-phase generators Logic gates (AND, OR, NAND, XOR) Half-adder / full-adder RS flip-flop Binary and decimal counters Shift register
PS4200-2B equipment set, supplementary set for PS4200-2A
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Automotive Sensors ................................................................ 38 Engine Management Sensors .................................................. 39

Process Control with Sensors and Actuators
A motor vehicle uses sensors to monitor rpm, speed, acceleration, gas concentrations, temperature and other input variables. Such signals have become indispensable for many process control functions of management systems, e.g. for the engine, chassis, safety and comfort. Typical automotive components integrated into training systems are used to demonstrate the functions and applications of sensors and actuators.
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Maximum learning efficiency A multimedia training platform ensures fast learning, even during independent studies. Integrated, virtual measuring devices make for an efficient work environment.
Hands-on For the most practical possible instruction, all sensors in our training and educational systems have features found typically on automotive components. The compact systems exercise stands are especially well suited for demonstrations.
Training systems Our training systems cover the following topics: Sensors on automobile body and chassis Sensors in the engine management system
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Automotive Sensors
An increasing number of components on modern motor vehicles are being electronically controlled and monitored. Sensors are designed to register physical data and convert it into electrical signals which can be processed by the relevant control units.
Recording characteristics with a PC
Training contents
Physical principles of sensors: induction, Hall effect, piezo effect Sensor functions as part of engine control Inductive and Hall speed sensors Throttle valve position measurement: throttle valve switch and potentiometer Air-flow measurement with hot-wire and hot-film sensors Pressure measurement in intake manifold Detection of shock waves with the knock sensor Temperature measurement with NTC and PTC sensors
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UniTrain-I course SO4204-7F Lucas-Nlle
Engine Management Sensors

This training system from the Compact family allows hands-on experimentation and demonstrations using various enginemanagement and chassis sensors. The systems practical design makes for highly realistic training.
Training contents
Clarifying the functionality of common sensors Conducting typical electrical measurements on various engine management sensors Interpreting and using circuit diagrams Building up diagnostic skills Planning and implementing typical diagnostic strategies Conducting typical electrical measurements on various chassis sensors
SO3230-3A equipment set Lucas-Nlle
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Vehicle Lighting
Motor Vehicle Main Lights ..................................................... Auxiliary Lighting and Signalling Systems ............................... Trailer Lights .......................................................................... Static Cornering Light ............................................................ CAN Bus Extension ................................................................ Dashboard Training Model Incorporating CAN and LIN Buses . 44 45 46 47 48 49
Vehicle Lighting
From Metal Filament Lamps to Adaptive Headlight Systems
Increasingly complex lighting systems place growing demands on trainees in the automotive field. Our modular training systems provide students with step-by-step introductions to the various systems involved here.
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Active safety provided by lighting systems Vehicle lighting components are among those contributing to active safety. A vehicles lighting components form part of its electric system. Innovations integrated into state-of-the-art headlight systems are explored and explained here in a clear and practical manner.
Source: Hella
Static cornering lights This feature involves control of the headlights via the indicator unit, yaw rate and travelling speed so as to perfectly illuminate the road ahead, even on curves. This ensures a high level of convenience and safety when cornering. The LN training system Static cornering lights can be integrated as an expansion kit into the existing lighting system.
Source: Hella
Training systems Our training systems cover the following topics: Static cornering lights Headlights with range adjustment Auxiliary lights Trailer lights
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Vehicle Lighting
Motor Vehicle Main Lights
The lighting system including all supplementary equipment is comprised of original automotive components. Besides conventional bulbs, LEDs have also been built into the tail-lights. The headlights are furnished with range adjustment as a standard feature.
Training contents
Introduction to German road traffic licensing regulations Differences between control and load circuits Use of multi-function switches Circuit protection Use of an electronic relay Optical and acoustic signalling units Manual headlight range adjustment mechanism Recording of measurement values, fault localization
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ALC 1.1 equipment set Lucas-Nlle
Auxiliary Lighting and Signalling Systems

Driving safety can be enhanced through the use of auxiliary headlights and fog lamps. There are diverse means of controlling such components. Furthermore, every vehicle must possess a signalling system by law. Circuits of practical relevance providing various means of controlling components serve as a bridge between theory and practice.
Training contents
Fog lights with relay Fog lights system including rear fog light and 2 relays Halogen lights for enhanced road illumination Reversing lights 3rd brake light Interior lights Delayed switching of interior lights Horn unit Standard-tone / loud-tone horn unit with relay
ALC 1.2 equipment set (supplementary set for ALC 1.1) Lucas-Nlle
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Vehicle Lighting
Trailer Lights
A trailers electrical system becomes notably more complex if converted from 7-pole to 13-pole assignment. Furthermore, the towing vehicles electrical system must be protected against overload, and the trailer control functions must comply with statutory regulations.
Training contents
Upgrading of lighting systems on motor vehicles Introduction to German road traffic licensing regulations Differences between control and load circuits Circuit protection Optical and acoustic signalling units Trailer lighting systems Recording of measurement values, fault localization Overload protection for the towing vehicle Trailers plug and socket assignments
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Static Cornering Lights

Thanks to a control unit mounted on a movable bearing, the curve or cornering light is activated without delay on operation of the indicator if the low beam is on, or automatically while cornering at speeds of up to 40 km/h. An auxiliary right-hand or left-hand headlight can be employed as required, and the fog lamp function switched separately as needed. The headlight can serve as a cornering light or fog lamp.
Training contents
Safety aspects on the road German legislation (StvZO) Electric circuit diagrams for static cornering light accessory set Cornering acceleration of a vehicle as measured by a yaw-rate sensor Design of turning light systems in conjunction with dipped headlights Differences between turning lights and cornering lights How turning lights work Upgrading of lighting systems on a vehicle Calibration of vehicle components
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Vehicle Lighting
CAN Bus Extension
Expand any existing automotive lighting display by one completely diagnostic-capable CAN bus node. This novel concept permits operation in low-speed mode and, with just the push of a button, in high-speed mode, too. As a result, even with a CAN bus drive you can explore the basics of the different transmission speeds and the voltage levels associated with them. With the fault simulator you only have to activate a switch to feed various ISO standard fault codes onto the CAN bus.
Training contents
Design of a steering column control unit Data transmission via a CAN bus - Data protocol for low-speed CAN (class B) - Data protocol for high-speed CAN (class C) - Fault patterns on a high-speed CAN bus - Fault patterns on a low-speed CAN bus - CAN bus diagnosis Baud rate analysis Short-circuit test of the power output stage
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Dashboard Training Model Incorporating CAN and LIN Buses

This model comprises an original dashboard (VW Golf V) with an instrument panel, drivers and front passengers airbags, as well as the entire lighting system including instrument lighting. The model includes a fault simulation circuit. Also present are diagnostic plugs for measurements on control units, e.g. for the airbag or illumination.
Training contents
CAN bus for light control / central locking / comfort window winder LIN bus for wiper and mirror control Circuit comprising headlights and range adjustment mechanism Headlight settings Indicator Hazard warning system Horn Fan, ventilation, circulating-air mode (open to allow observation) Instrument lighting Optional: xenon headlights
SO3240-1D equipment set Lucas-Nlle
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Comfort Systems
GPS Navigation ...................................................................... 54 Alarm System and Immobilizer ............................................... 55 Air-conditioning and Climate Control ..................................... 56
Comfort Systems
Interior Ventilation and Climate Control
Comfort systems increase general safety and comfort levels for the driver and passengers. On the basis of job orders and fault descriptions, students plan their measures for diagnosis, tests of individual components and repairs of comfort systems comprising original vehicle parts.
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Air-conditioning A persons ability to perform and concentrate is influenced strongly by the temperature and condition of the surrounding air. Consequently, all efforts must be made to supply the passenger compartment with fresh, filtered air whose temperature can be raised or lowered depending on the exterior temperature.
Immobilizer and alarm system The training system introduces students to the design and functionality of an alarm system including an immobilizer and remote control. The system demonstrates how vehicles can be safeguarded in actual practice.
Training systems Our training systems cover the following topics: Climatronic air-conditioning Alarm system and immobilizer GPS navigation
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Comfort Systems
GPS Navigation
To simulate navigation, this GPS system can be set to simulation mode by means of a special software. This is extremely useful for learning and understanding the various functions involved. The navigation system is housed securely in a robust yet light storage case providing protection against damage.
Your benefits
Simulation mode for navigation routes 3D map display Traffic lane guidance system Automatic route calculation Active route search function Real-time language guidance Highway information display Integrated RDS-TMC receiver Operable via remote control and touchscreen Integrated gyroscope and speedometer Switchable between DVD and navigation mode Includes a connection and switch for a reversing camera
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LM8231 equipment set Lucas-Nlle
Alarm System and Immobilizer

The alarm system issues optical and acoustic signals in the event of attempted intrusion. Arranged compactly on a panel for training purposes, this fully functional alarm system permits clear demonstrations of functionality.
Sample experiment: Alarm system and immobilizer
Training contents
Explaining the design and operation of an alarm system and immobilizer Setting and checking the theft-warning unit and immobilizer Country-specific programming of the alarm system Interaction of the alarm system with other vehicle components Trouble shooting
ALC 7 equipment set Lucas-Nlle
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Comfort Systems
Air-conditioning and Climate Control
This training system permits practical experimentation and demonstration with a Climatronic automotive air-conditioning unit with climate control. The systems very realistic design makes for equally realistic training.
Training contents
Setup and initial operation of an air-conditioning unit Enhancement of automotive comfort and safety through air-conditioning Fundamentals of refrigeration Air-conditioning systems operating principle Description of air-conditioning components Handling of refrigerants and relevant statutory regulations Open- / closed-loop control of the vehicles interior temperature Diagnosis of air-conditioning units Maintenance of air-conditioning units Repairs Trouble shooting
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Fully Automatic Air-conditioning Service Unit

This easily operable air-conditioning service unit incorporates several functions such as leakage detection, recycling, cleaning, evacuation and replenishment.
Your benefits
Recycling Recycling of residual refrigerant Cleaning Cleaning of refrigerant through drying, filtration and separation of oil as well as liquids according to the SAE standard Replenishment Refilling of the air-conditioning cycle Leakage detection Checks of the cooling system for leakages Oil separation Replacement of old oil with a fresh batch to lengthen the compressors life cycle Evacuation Emptying of hoses and system parts to ensure that exactly the required quantity of refrigerant is refilled Weighing Measurement of the filling quantity
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Alternative Drives
Hybrid Automotive Drive ........................................................ Hybrid Sectional Model (Toyota Prius) ..................................... Fuel Cells ............................................................................... Photovoltaics ......................................................................... 62 63 64 65
Alternative Drives
Hybrid Drives
Low fuel consumption, low emissions and maximum driving pleasure: these requirements need to be met in increasing measure by modern motor vehicles. Besides optimization of conventional drive concepts, the course also pursues new approaches to meeting demands for dependable mobility.
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Generator operation In generator mode, the power output of the combustion engine is higher than that needed for moving the vehicle. The remaining power is fed to the generator, where it is converted into electrical energy and stored.
Source: Bosch
Regenerative braking In this mode, the vehicle is braked entirely or partly without the service brakes frictional torque, which is replaced by the braking moment generated by the electric motor. In this process, the vehicles kinetic energy is converted into electrical energy and stored.
Source: Bosch
Training systems Our training systems cover the following topics: UniTrain-I hybrid drives Hybrid sectional model (Toyota Prius) Photovoltaics Fuel cells
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Alternative Drives
Hybrid Automotive Drive
Hybrid drives are essentially meant to meet three objectives: save fuel, reduce emissions, increase torque / power. Different hybrid concepts can be employed depending on the required application.
Training contents
Advantages of hybrid systems Serial hybrid system Parallel hybrid system Combinations of hybrid drives Design of electrical machines - Asynchronous machine - Synchronous machine Fundamentals of inverters - Three-phase rectifiers Fundamentals of frequency converters Three-phase voltage supply Measurements of: - Direct voltage - Alternating voltage - Three-phase alternating voltage Investigations of energy and power flows On-board networks for hybrid vehicles
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UniTrain-I course SO4204-6V Lucas-Nlle
Hybrid Sectional Model (Toyota Prius)

This sectional model reveals a hybrid drives design. The model is cut so as to display the components and demonstrate their functionality. The engine, generator, gearbox and drive train can be observed while in operation.
Training contents
Design of a hybrid drive Introduction to operating states such as starting, regular operation, maximum load, braking and acceleration Investigation of drives comprising a fuel-operated engine or electric motor
Equipment
Original components of the Toyota Prius The model is mounted on a rack with rollers 230 V electric motor Functions are controlled via a switch on the front side
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Alternative Drives
Fuel Cells
Motorized vehicles (cars, trucks) produce large quantities of CO2. Despite considerable advancements, the internal combustion engine still has very high CO2 emission levels. It is therefore no surprise that engineers are seeking alternative drive concepts here. One such concept involves a use of electric motors in conjunction with fuel cells.
Training contents
Use of fuel cells in motor vehicles Operating principles of fuel cells Design of fuel cells Fundamentals of the chemical process Fuel cell characteristics Recording the characteristics Efficiency of a fuel cell
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UniTrain-I course SO4204-6M Lucas-Nlle
Photovoltaics
The term photovoltaics stands for a direct conversion of sunlight into electrical energy by means of solar cells. The energy obtained in this manner can be supplied to ancillary consumers to enhance driving comfort, e.g. to additionally cool a vehicles interior in extremely bright sunshine.
Training contents
Use of a photovoltaic system on a motor vehicle Design of a photovoltaic cell Open-circuit voltage Short-circuit current V-I characteristic Power of a photovoltaic cell Series-connected photovoltaic cells Parallel-connected photovoltaic cells Direct operation Storage operation
UniTrain-I course SO4204-6N Lucas-Nlle
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Engine Management
Ignition Systems ..................................................................... Common Rail Diesel Injection System ..................................... Connect Common Rail ......................................................... Common Rail ......................................................................... Electronic Diesel Control (EDC) ............................................... Connect Motronic 2.8 (Multi-point) ...................................... Connect Direct Fuel Injection ................................................ Motronic ML 4.1 (Multi-point) ................................................ KE-Jetronic (Multi-point) ........................................................ L-Jetronic (Multi-point) ........................................................... D-Jetronic (Mono-point) ......................................................... Connect FIRE Chip Tuning ................................................. Functional Engine .................................................................. 70 71 72 73 74 75 76 77 78 79 80 81 82
Engine Management
Networked Systems in an Engine Compartment
Increasingly complex engine management systems place growing demands on trainees in the automotive field. Our modular training systems provide students with step-by-step introductions to the various systems involved here.
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Fuel mixture preparation Lucas-Nlles training systems provide students with a fully comprehensive introduction to the subject of fuel mixture preparation. The steps needed for optimizing fuel mixtures, registering and processing operational data, and outputting the data as actuator signals can be directly observed here. Practical exercises consolidate the acquired technical knowledge. Worksheets and exercise sheets are used for regular knowledge tests.
Source: Bosch
Chip tuning All modern vehicles have an engine controlled by a central processor which also monitors operating states. The Connect FIRE training system permits chip tuning on a single-cylinder, four-stroke engine.
Training systems Our training systems cover the following topics: Ignition systems Engine management systems (spark-ignition and diesel) Functional engines Chip tuning
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Engine Management
Ignition Systems
A petrol-operated engine requires a system for igniting the fuel mixture. In the course of developments, ignition systems have become increasingly complex and precise, thereby ensuring adherence to emission standards and the achievement of the extremely high performance levels required of modern spark-ignition engines.
Training contents
Generation of the ignition spark Ignition timing (mechanical and map-based) Conventional ignition system Dual-spark ignition systems Transistorized ignition systems with Hall and inductive sensors Electronic ignition system Recording and evaluating ignition oscillograms Static and rotary high-voltage distribution
70
UniTrain-I course SO4204-7C Lucas-Nlle
Common Rail Diesel Injection System

Mechanically controlled injection systems are no longer able to meet ever stricter requirements for minimizing fuel consumption, exhaust emissions and diesel engine noise. For this purpose, the injection systems need to achieve very high pressures, exact sequences and precisely dosed quantities.
Piezo-technology with up to seven injection cycles
Training contents
Requirements to be met by diesel injection systems Introduction to various designs Design and functionality of a common rail system Fault localization on a common rail system Injection characteristics of common rail systems Injection characteristics of piezo-injectors (with up to seven injection cycles) Investigation of the fuel system Distinction between low- and high-pressure circuits Component layouts and functions Electrical tests of injectors Examination of a common rail systems hydraulics
UniTrain-I course SO4204-6X Lucas-Nlle
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Engine Management
Connect Common Rail
Designed for direct injection of diesel at high pressure, the common rail system differs from conventional diesel injection systems in terms of its operating principle. As opposed to systems with directly driven injection pumps, the common rail injection system decouples pressure-generation from injection-control functions.
Compatible with On-board diagnosis II
Sample experiment: Common rail
Training contents
Combustion process Pollutant emissions Reduction in pollutant emissions Block diagrams, circuit diagrams, function diagrams, graphs Signal, material and energy flows Diagnostic, testing and measuring devices Test and measuring methods Sensors and actuators Open-loop and closed-loop control Engine management sub-systems Assembly groups and systems for fuel mixture preparation in diesel engines Adaptive systems Interfaces to other systems Fuels
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AMM 21 equipment set Lucas-Nlle
Common Rail
Common rail is an injection system for self-igniting combustion engines. Map-controlled injectors can be operated and diagnosed here just like on a real engine.
Training contents
Combustion process Pollutant emissions Reduction in pollutant emissions Block diagrams, circuit diagrams, function diagrams, graphs Signal, material and energy flows Diagnostic, testing and measuring devices Test and measuring methods Sensors and actuators Open-loop and closed-loop control Engine management sub-systems Assembly groups and systems for air-fuel mixture preparation in diesel engines Adaptive systems Interfaces to other systems Fuels
SO3230-1F equipment set Lucas-Nlle
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Engine Management
Electronic Diesel Control (EDC)
Electronic diesel control is an electronic management system for diesel engines. EDC embodies all open- and closed-loop control functions in one electronic engine control unit connected to a large number of sensors and actuators.
Training contents
Combustion process Pollutant emissions Reduction in pollutant emissions Block diagrams, circuit diagrams, function diagrams, graphs Signal, material and energy flows Diagnostic, testing and measuring devices Test and measuring methods Sensors and actuators Open-loop and closed-loop control Engine management sub-systems Assembly groups and systems for mixture preparation in diesel engines Adaptive systems Interfaces to other systems Fuels
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SO3230-1E equipment set Lucas-Nlle
Connect Motronic 2.8 (Multi-point)

Motronic 2.8 is a multi-point injection system in which each cylinder has its own injection valve. The actuators forming part of this training system are controlled as a function of corresponding sensor signals.
Automatic monitoring of learning progress
Sample experiment: Motronic 2.8
Training contents
Combustion process Pollutant emissions Reduction in pollutant emissions Block diagrams, circuit diagrams, function diagrams, graphs Signal, material and energy flows Diagnostic, testing and measuring devices Test and measuring methods Sensors and actuators Open-loop and closed-loop control Engine management sub-systems Assembly groups and systems for air-fuel mixture preparation in combustion engines Adaptive systems Interfaces to other systems Fuels
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Engine Management
Connect Direct Fuel Injection
This system comprises a blend of hardware and software with training and educational purposes in mind. The experiment hardware consists of real automotive components mounted on experiment panels. Electrical connections are established via safety sockets. This permits every component to be operated and measured under realistic conditions.
Control unit with Ethernet interface
Sample experiment: Direct fuel injection
Training contents
Exploring sensor and actuator designs and operating principles Interpreting and using circuit diagrams Building up diagnostic skills Conducting practical measurements on an ignition systems components Combustion process Diagrams and function charts Diagnostic, testing and measuring devices Test and measuring methods Sensors and actuators Open-loop and closed-loop control Engine management sub-systems Assembly groups and systems for mixture preparation in direct fuel injection engines Adaptive systems Interfaces to other systems
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Motronic ML 4.1 (Multi-point)

Motronic is a digital control system for spark-ignition combustion engines. Introduced in 1979, Motronic (an abridgement of motor electronics) for the first time combined air-fuel mixture preparation and ignition systems in a single, electronic engine control unit, in contrast to the predecessor, Jetronic, which was a pure fuel injection module with a separate ignition system.
Training contents
Combustion process Block diagrams, circuit diagrams, function diagrams, graph Signal, material and energy flows Diagnostic, testing and measuring devices Test and measuring methods Sensors and actuators Open-loop and closed-loop control Engine management sub-systems Assembly groups and systems for air-fuel mixture preparation in petrol engines
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Engine Management
KE-Jetronic (Multi-point)
Introduced in 1973, KE-Jetronic is an electronically / mechanically / hydraulically controlled fuel injection system in which the fuel is injected continuously into the intake manifold. The fuel is dosed only as a function of the intake air quantity, irrespective of the intake valve setting.
Training contents
Understanding engine management functionality Understanding the functions of the involved control circuits Conducting typical electrical measurements on various engine management components Interpreting and using circuit diagrams Building up diagnostic skills Planning and implementing typical diagnostic strategies Pressure measurements on the fuel distributor Design and function of sensors and actuators
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SO3230-1C equipment set Lucas-Nlle
L-Jetronic 4.1 (Multi-point)

LJetronic is an electronically controlled fuel injection system where the fuel is injected intermittently into the intake manifold. The fuel is dosed as a function of the intake air quantity which is electrically measured.
Training contents
Understanding engine management functionality Understanding the functions of the involved control circuits Conducting typical electrical measurements on various engine management components Interpreting and using circuit diagrams Building up diagnostic skills Planning and implementing typical diagnostic strategies Sensors and actuators Open-loop and closed-loop control Assembly groups and systems for air-fuel mixture preparation in petrol engines
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Engine Management
D-Jetronic (Mono-point)
D-Jetronic was the first electronic, pressure-controlled fuel system, introduced in 1967 by Bosch. The main constituent of D-Jetronic is its intake manifold pressure sensor (MAP sensor).
Training contents
Understanding engine management functionality Understanding the functions of the involved control loops Conducting typical electrical measurements on various engine management components Interpreting and using circuit diagrams Building up diagnostic skills Planning and implementing typical diagnostic strategies
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SO3230-1B equipment set Lucas-Nlle
Connect FIRE Software-based Performance Tuning at an Engine Test Bench

Connect FIRE is a supplement to the internationally unique, interactive, multimedia engine management system Connect. A special feature of Connect FIRE is its miniature fuel injection engine with electronically controlled loading unit, control unit, interface and intelligent teachware / software.
Map and chip tuning
Experiment: Performance tuning at an engine test bench
Training contents
Conducting measurements on various engine management components Observing the engines response to changes in timing Editing and optimizing maps for idling, ignition and injection Recording performance and torque characteristics Optimizing performance and torque (chip tuning) Investigating emission characteristics
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Engine Management
Functional Engine
Standard commercial diagnostics testers can be used to read out the functional engines error memory via the OBD terminal in order to perform typical automotive diagnoses. As in real life, all signals can be tapped from the cable harness or the plug connectors. A switch can be used to easily simulate typical electrical faults on the engine.
Example: 1.9-litre common rail
Training contents
Learning typical assembly and dismantling tasks Identifying components and getting acquainted with their operating characteristics / parameters Learning and implementing genuine diagnostic strategies Interpreting technical documentation Reading circuit diagrams Conducting typical measurements and interpreting their results Using computer-aided diagnostic devices
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Equipment
Engine models Diesel (pump injector) Diesel (common rail) Spark-ignition (direct injection) Further models available on request Safety Guards are installed to prevent inadvertent contact with any hot or rotating part Noise levels have been lowered by slightly modifying the exhaust system
Diagnosis The error memory can be read out via the OBD terminal Sensor signals can be tapped via the cable harness or the plug connectors, as in real life Signals can also be tapped easily via a breakout box An error box can be used to realistically simulate malfunctions and faults
Your benefits Documents tailored to training and educational purposes Practical training Exercises ranging from simple oil change to sophisticated engine diagnosis
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Vehicle Diagnosis
On-board Diagnosis II ............................................................. On-board Diagnosis II Data Recorder ...................................... Auto Diagnosis Trainer Software ............................................ Automobile Diagnosis Case .................................................... Automobile Diagnosis Unit with an Oscilloscope .................... PDA Vehicle Diagnosis Unit .................................................... LIN / CAN Monitor .................................................................. Common Rail Diagnosis Set High-pressure ......................... Common Rail Diagnosis Set Low-pressure ........................... 88 89 90 91 92 94 95 96 97
Vehicle Diagnosis
Developing of Diagnostic Strategies
Trouble shooting methods and strategies are used as part of systematic vehicle diagnosis. Manufacturer-specific diagnosis concepts also need to be considered in this process. Maintenance strategies are planned on the basis of customer information, visual checks and the results of independent diagnosis.
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On-board diagnosis II This is used by students to perform diagnoses in the area of engine management. Students identify the engine management system with the help of electronic information systems and vehicle-specific documents, and perform system analyses. A standard interface provides access to the engine control unit.
Engine tester The engine tester is an indispensable aid for diagnosis, maintenance and repair of all important automotive systems. It can be used to read vehicle-specific data, errors and parameters out of the control units.
Training systems Our training systems cover the following topics: On-board diagnosis II Vehicle diagnosis and trouble shooting methods Diagnoses of petrol and diesel
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Vehicle Diagnosis
On-board Diagnosis II
This course demonstrates how to read out emission data with the help of the on-board diagnosis unit (OBD II or EOBD), interpret the data and use the results as a basis for eliminating systemic faults.
Training contents
Diagnoses of systems of emission-relevant systems Systematic development of trouble shooting and diagnostic strategies Working with test devices Planning fault localization and repair measures Evaluating and documenting test results
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CO3216-1Z equipment set Lucas-Nlle
On-board Diagnosis II Data Recorder

This remote diagnosis unit can be used to record automotive data while the vehicle is moving. Recorded data can be transferred to software programs for the purpose of evaluation in tabular or graphic form.
Diagnosis while driving
CO3216-1Z
Your benefits
Compact plug-and-play device Automatic recording of all data specific to OBD II (24 hours) Evaluation by means of diagnostic software User-friendly menu guidance and data display Supported protocols - OBD II: ISO9141, SAE J1850VPW, SAE J1850 PWM - EOBD: ISO14230KPW - CAN Bus: ISO15765
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Vehicle Diagnosis
Auto Diagnosis Trainer Software
Lucas-Nlles new automobile diagnosis trainer (ADT) software is meant for students to develop and consolidate strategies for successful automotive diagnosis and trouble shooting using a training program before moving on to real vehicles.
Mathematical model of a complete engine management system
Simulation of up to 170 malfunctions
Training contents
Diagnosis and maintenance in the area of engine management Developing diagnostic strategies Planning fault localization and repair measures Documenting, monitoring and assessing implemented measures Working with block, circuit and function diagrams Working with measurement devices and diagnostic tools
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Software SO2500-1A Lucas-Nlle
Automobile Diagnosis Case

The diagnosis case was developed to meet the demands of automobile manufacturers and workshops as well as service and training centres. It serves as a universal means of contacting all connectors present on a motor vehicle. Secure contacting as part of diagnosis and trouble shooting on motor vehicles helps to quickly obtain the best possible measurement and test results.
Your benefits
High-quality, comprehensive service case for automotive diagnosis and trouble shooting Integrated, universal, laboratory multimeter Secure contacting of connectors most commonly found on motor vehicles Flexible, temperature-resistant adapter leads Needle-shaped, miniature probe tips made of spring steel and especially suited to contacting enclosed connectors
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Vehicle Diagnosis
Automobile Diagnosis Unit with an Oscilloscope
This versatile diagnosis unit incorporates the functions of an engine tester, oscilloscope, sensor tester, multimeter and vehicle database. The database contains technical information for vehicle service personnel, including comments on error codes, setpoint data, circuit diagrams and setpoint curves. Bluetooth technology allows vehicles to be tested within a radius of up to 20 m.
Wireless connection via Bluetooth
Your benefits
Wireless diagnosis of electronic control units via Bluetooth Up to 148 systems per vehicle type (all common models) Recording of current data Display of primary and secondary ignition curves Various possibilities of automotive sensor simulation Integrated 4-channel oscilloscope, battery tester and multimeter Vehicle database with technical data, service information on error codes and circuit diagrams Measuring adapters and diagnosis lines for all common vehicles included
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Includes Diagnostic unit Adapter for all common motor vehicles Diverse measurement leads Manual
Engine analysis Display of primary and secondary ignition curves DIS ignition curve Power analysis (in kW) Test and analysis of starter current Charging voltage and sensor signals
Sensor simulation Simulation of DC signals, pulse signals, standard curve shapes and manually traced curves Output voltage: -12 V to +12 V Output current: max. 40 mA
Vehicle database Technical data for vehicle servicing Service information on error codes Setpoint reference data and curves Circuit diagrams Recording of current data
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Vehicle Diagnosis
PDA Vehicle Diagnosis Unit
A handy vehicle diagnostic unit incorporating state-of-the-art technology in PDA format. Its impressive features include fast response and ease of use. The device furthermore possesses the unique capability of diagnosing two vehicles simultaneously: If data are lacking, a second vehicle can be used as a reference for direct comparison with actual data.
Your benefits
Small and handy to use Portability Wireless communication via Bluetooth at up to 25 m Large memory card, allowing for large quantities of vehicle data to be stored Read-out / deletion of fault codes Engine scan and many other functions, including gearbox, airbags, ABS tests, etc. Live data transfer Capability of accessing daily updates via internet download PC interfaces via Bluetooth and USB Printer interface via Bluetooth and USB
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LIN / CAN Monitor

The LIN / CAN monitor allows bus protocols on a LIN bus, CAN bus or any serial bus to be recorded and investigated.
Your benefits
Visual display of bus protocol structure Option for displaying in binary or hexadecimal code format Recording of bus packets Transmission of bus packets Suitable for student experiments and demonstrations Simple to put into operation Displays identifier - data length - period User-configurable graphic interface
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Vehicle Diagnosis
Common Rail Diagnosis Set High-pressure Injectors in Circulation Method
This portable diagnosis set can be used to test common rail high-pressure injectors with the engine running. All familiar common rail systems can be linked to the diagnosis set via original connecting elements. During diagnosis, the fuels reflux rate, pressure and return temperature can be measured continuously.
Training contents
Understanding the functions of common rail technology Testing high-pressure injectors in circulation method Diagnosis and maintenance of engine management systems Building up diagnostic skills Conducting measurements on common rail systems Principles of rail-pressure regulation
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Common Rail Diagnosis Set Low-pressure Circuit Tests

The pressures in the feed and return lines of the various systems here must adhere to manufacturer specifications. Low-pressure circuits are tested to permit fault localization and ensure trouble-free operation. Such tests make it possible, for instance, to detect air bubbles and impurities in the fuel system.
Training contents
Introduction to the common rail low-pressure system Understanding the functions of common rail technology Diagnosis and maintenance of engine management systems Building up diagnostic skills Principles of rail-pressure regulation Conducting measurements on common rail systems
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Electromechanical Parking Brake .......................................... Electromechanical Power Steering ........................................ Brake Systems ABS, ESP, ASR and Brake Assistant .............. Brake Power Control with ABS and ASR ............................... Anti-lock Brake System ABS ................................................. Hydraulic Brake System ........................................................ Airbag, Seat-belt Tensioner and Crash Behaviour .................. SRS Airbag and Seat-belt Tensioner ...................................... Suspension, Springs and Shock Absorbers ............................ Gearbox and Drive ............................................................... Steering Systems .................................................................. 102 103 104 105 106 107 108 109 110 111 111

Active and Passive Safety
The sensors and actuators of the systems involved here perform important functions for active and passive safety, comfort as well as engine management in motor vehicles. Driving safety and impact protection features are especially significant to the safety of a vehicles occupants. Work on such safety components requires sound qualifications acquired through first-rate training and education systems. Students are introduced to the complex subjects by a combination of e-learning courses and real-life compact systems, and are able to apply acquired skills on true replicas of original components.
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ABS ABS measures a wheels circumferential speed. During braking, the wheels slip is calculated automatically and the brake pressure regulated accordingly. This prevents the wheel from blocking. Our true replica of an original ABS system allows students to examine these functions and perform related measurements.
Airbag The airbag training environment from our family of panel systems allows practical experiments and demonstrations using an SRS airbag and seat-belt tensioner. This UniTrain-I airbag course includes a steering wheel with a fully functional, re-usable airbag.
Training systems Our training systems cover the following topics: Airbag and belt tensioner ABS and ASR Chassis technology Steering systems Transmission technology
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Electromechanical Parking Brake with AUTO-HOLD Function
An electromechanical parking brake replaces the conventional handbrake with a simple switch on the dashboard so that there is no need for a handbrake lever. On uphill starts, sensors determine how steep the slope is. If the driver stops the vehicle, the brake engages automatically until the car is started again.
Training contents
How rear-wheel brake actuators work Sensors and actuators in an electromechanical parking brake How an electromechanical parking brake works Parking brake function Dynamic pull away assistant Dynamic emergency brake function AUTO-HOLD function Gauging of brake discs Understanding how brake boosters and hydraulic brakes work Interpretation and use of technical documentation Experimental investigation of the various functions for improved understanding Assembly, configuration and testing of mechanical components Design and function of disc brakes
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CO3221-9A Lucas-Nlle
Electromechanical Power Steering

Electromechanical power steering has many advantages over hydraulic steering. It assists the driver not just in purely physical terms, but also intelligently by responding only when the driver explicitly requests it. Steering assistance is provided as a function of vehicle speed as well as steering moment and angle.
Training contents
Design of an electromechanical power steering Function of the individual assembly groups Steering geometry Inverter control CAN bus control Vehicle speed sensor Steering angle sensor Steering moment sensor
CO3221-9B Lucas-Nlle
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Brake Systems ABS, ESP, ASR and Brake Assistant
Brake systems of modern motor vehicles are becoming increasingly complex. Electronic aids such as ABS, ASR and ESP are now standard features in such systems. Electronic brakes (brake-by-wire) currently still in the experimental phase are to be introduced to the market soon.
Training contents
Design of a brake system Main brake cylinder Brake booster Drum and disc brakes ABS Traction control (ASR) Electronic stability program (ESP) Brake assistant
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UniTrain-I course SO4204-6R Lucas-Nlle
Brake Power Control with ABS and ASR

This training system permits practical experimentation and demonstrations by means of an electronically controlled ABS / ASR brake system (Bosch 5.3). All important electrical signals can be tapped centrally via 4-mm sockets.
Training contents
Understanding the functionality of a typical brake system incorporating ABS and ASR Understanding the functionality of brake boosters and hydraulic brakes Identifying the effects of typical malfunctions on brake systems incorporating ABS and ASR Conducting various electrical measurements Interpreting and employing technical documentation Building up diagnostic skills Planning and implementing typical diagnostic strategies
SO3230-2C equipment set Lucas-Nlle
105

Anti-lock Brake System ABS
The ABS system possesses four original wheel brake cylinders controlled hydraulically via authentic brake lines. The systems very realistic design makes for equally realistic training.
Training contents
Understanding the functionality of a typical ABS brake system Understanding the functionality of brake boosters and hydraulic brakes Identifying the effects of typical malfunctions on ABS brake systems Conducting various electrical measurements Interpreting and employing technical documentation Building up diagnostic skills Planning and implementing typical diagnostic strategies
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SO3230-2B equipment set Lucas-Nlle
Hydraulic Brake System

This training system contains all the relevant electrical, mechanical and hydraulic components forming part of a typical brake system in a passenger car.
Training contents
Understanding the functionality of a typical brake system in a passenger car Understanding the functionality of brake boosters and hydraulic brakes Examining the effects of typical malfunctions on a brake system Conducting pressure measurements on various brake circuits Performing typical settings and maintenance tasks on brake components Interpreting and employing technical documentation Building up diagnostic skills Planning and implementing typical diagnostic strategies
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Airbag, Seat-belt Tensioner and Crash Behaviour
Active safety systems like airbags and seat-belt tensioners have been standard features in all vehicle classes for years. Regular inspections of these features are needed to ensure that they operate properly.
Original airbag
Optional: SO3219-1P
Training contents
Active and passive safety in motor vehicles Operating principles of airbags and seat-belt tensioners Safety switch and ignition cap Operating principle of pressure and acceleration sensors Measurement of acceleration Typical crash situations Trigger times and sequences Fault management for airbag systems Trouble shooting
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UniTrain-I course SO4204-6Z Lucas-Nlle
SRS Airbag and Seat-belt Tensioner

This training environment from our family of Compact systems allows practical experimentation and demonstrations using an SRS airbag and seat-belt tensioner. The systems very realistic design makes for equally realistic training.
Training contents
Understanding the functionality of an SRS system Understanding the operating principles of pyrotechnic actuators (airbag and seat-belt tensioner) Identifying the effects of typical faults on SRS systems Conducting various electrical measurements Interpreting and employing technical documentation Building up diagnostic skills Planning and implementing typical diagnostic strategies
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Suspension, Springs and Shock Absorbers
The chassis and suspension need to perform diverse functions. For safe and comfortable driving, they must ensure a high level of traction while absorbing jolts from bumps in the road.
Training contents
Introduction to chassis functions Suspension design and components Front-axle suspension systems Rear-axle suspension systems Leaf springs Helical springs Torsion bar suspension Air suspension Rubber suspension Hydro-pneumatic suspension Stabilizer Hydraulic shock absorber Telescopic shock absorber
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UniTrain-I course SO4204-6S Lucas-Nlle
Gearbox and Drive

The gearbox is used to convert and transmit engine torques and speeds. Different gearwheel pairs are used to raise or lower gear ratios and reverse directions of rotation. In conjunction with the clutch, this makes it possible to control the transmission of power.
Training contents
Design and components of the drive train Clutches Manual and automatic gearboxes Planetary gear and torque converter Infinitely variable gear Sequential gear Differential gear Drive shafts Front, rear and 4-wheel drive
Steering Systems
The steering is used to turn the vehicles wheels. Special design features make it possible to realize a variety of turning angles. Power steering components boost the manual torque applied to a steering wheel.
Training contents
Steering design and components Steering geometry: track, pitch, trailing Spread Steering gear and linkage Measuring and setting the steering on the chassis Diagnosis
UniTrain-I courses SO4204-6U and SO4204-6T Lucas-Nlle
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Networked Systems
CAN Bus .............................................................................. CAN Lighting Technology ..................................................... CAN Comfort Technology .................................................... LIN Bus ................................................................................ Optical Waveguides ............................................................. 116 117 117 118 119
Networked Systems
Data Buses
A modern automobiles on-board networks are similar in magnitude to a medium-sized enterprises IT network, where 70 to 90 control units are linked via different data buses for the extensive exchange of information. More than two-thirds of all automotive innovations are now software-based. LN training systems cover all the educational requirements pertaining to all common bus systems.
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Optical data bus systems Large quantities of data can be transmitted with the help of light waves. The UniTrain-I course on optical waveguides contains practical examples demonstrating how to handle such waveguides.
Networks An automobile can be divided into various data communication zones, each one being assigned particular duties which place corresponding demands on the network. For this reason, the automobile is organized into a number of sub-networks. The various possibilities of doing this are described in our courses on bus systems.
Training systems Our training systems cover the following topics: CAN bus LIN bus MOST bus
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Networked Systems
CAN Bus
Modern motor vehicles incorporate numerous electronic control units which communicate with each other continually via digital bus systems. Widely used for this purpose in passenger cars as well as commercial vehicles are CAN buses, especially when it comes to comfort, engine management and diagnostic applications.
From theory to the control of real motor vehicles
Training contents
Reasons for using bus systems in motor vehicles Topology and components of a CAN bus system in a motor vehicle Differences between low-speed and high-speed CAN Electrical properties of a CAN bus Data rate, identifier, addressing and arbitration (low-speed and high-speed CAN) Design of a CAN messages frame Analyzing CAN messages with a CAN monitor and oscilloscope Editing and sending CAN messages via PC Trouble shooting
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UniTrain-I course SO4204-7K Lucas-Nlle
Training Projects Involving a CAN Bus

CAN Lighting Technology, Programming and Diagnosis
The Lighting technology training project supplements the CAN bus course with an additional control unit. The Lighting technology interface makes it possible to control any conventional lighting system. Such systems can be controlled via the switches and buttons on the UniTrain-I cards forming part of the CAN bus course.
Experiment: Vehicle lighting control via CAN bus with a SO3216-2Z interface and additional components
CAN Comfort Technology, Programming and Diagnosis

The Car door training project integrates an original car door into the experimentation system. This allows the doors essential functions (e.g. electric window winder and electrically adjustable external mirror) to be controlled by means of real CAN messages. The resultant data traffic on the CAN bus can be analyzed using the applications forming part of the LabSoft course.
Experiment: Car door control via CAN bus, SO3216-2Y equipment set
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Networked Systems
LIN Bus
In addition to the CAN bus, the somewhat simpler LIN bus is also used. This bus is employed mainly for comfort systems which are not crucial to safety.
Training contents
Development of bus systems in motor vehicles Topology and components of a LIN bus system Electrical properties of a LIN bus Addressing of a LIN bus Master / slave principle Measurement tests of data fields Message frame structure Analysis of LIN messages Editing and sending LIN messages Trouble shooting
118
UniTrain-I course SO4204-7E Lucas-Nlle
Optical Waveguides
At present, optical bus systems are used mainly to achieve high data transmission rates in luxury automobiles. However, optical buses are likely to find broader use in view of the increase in data volumes that generally require processing in automobiles.
Training contents
Data networks in motor vehicles Reasons for using optical waveguides in automotive applications Fundamentals of the MOST bus MOST protocol and control units Ring breakage diagnosis Design of optical waveguides in motor vehicles Optical bus systems in motor vehicles Fundamentals of ray optics (refraction, reflection) Attenuation by optical waveguides Data transmission and optical measurements on optical waveguides
UniTrain-I course SO4204-7H Lucas-Nlle
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Practical Automotive Workshop Lab

Exhaust Gas Analysis and EOBD Data Readout ..................... Tyre Fitting Machine ............................................................. Balancing Machine ............................................................... Axle Measurement ............................................................... Two-column Hydraulic Lifting Platform ................................. Four-column Hydraulic Lifting Platform ................................. Fully Automatic Air-conditioning Service Unit ....................... Vehicle Tool Kit 77 Pieces .................................................. Set of Socket Spanners 94 Pieces ...................................... Trolley with 64-piece Tool Kit ................................................ 124 125 126 127 128 129 130 131 132 133

Complete Solution a Practical Lab for Assembly, Dismantling and Diagnosis of Vehicles and Automotive Assembly Groups
Diagnosis and maintenance of engine management systems
Dismantling, repair and installation of automotive assembly groups and systems
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Documentation and communication, database systems
Maintenance of chassis systems
Maintenance of comfort systems
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Exhaust Gas Analysis and EOBD Data Readout
Analyses of exhaust gases from combustion engines provide information on the composition of such gases. The concentrations of individual constituents in exhaust gases depend on a variety of factors, including the type of fuel, combustion process and engine model.
Your benefits
Emission tests of vehicles with a spark-ignition or diesel engine Emission tests of EOBD vehicles with a spark-ignition or diesel engine Large LCD display for indicating results Integrated vehicle database Storage of customer-specific data Interface for export to the AU-Plus emission test module Infrared remote control Rollers for device mobility Simple operation by means of arrow keys and keypad Menu guidance and emission test log printout
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Tyre Fitting Machine

The tyre fitting machine covers all workshop requirements for modern tyre fitting technology. Stable, safe and fast, the machine complies with international specifications.
Your benefits
Ability to fit a wide range of tyres Pneumatic locking of the fitting arm and release of the fitting head Pneumatic, backward-tilting mounting column Powerful drive motor Compliant with UL / CE international specifications Quiet operation Metal / plastic fitting head compatible with various wheel types
125

Balancing Machine
Increasingly complex chassis components on modern motor vehicles entail increasingly precise wheel balancing techniques. Balancing is performed with the aid of small weights fastened to the rim using a variety of methods.
Your benefits
Three programs for aluminium rims Program for hiding weights behind rim spokes Manual entry of wheel data Simple switchover between grams and ounces Quick wheel locking and release High dependability to the nearest gram Universal tightening nut Exact indication of the imbalance position Including: - 4 cones - 2 adapter rings - Quick-clamping nut - Measurement aid - Weight pliers - Calibration weight (100 g)
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Axle Measurement
Axle measurement and adjustment are required if the vehicle drifts left or right instead of travelling straight ahead. One indicator of a possible need for axle measurement is one-sided or uneven wear of tyre tread.
Your benefits
Standard measurement Quick measurement Supplementary measurement Program for low-chassis vehicles Customer-specific vehicle database Robust measuring heads System protection against water spray Standard batteries Standard PC Self-centring clamp holder Adapter for aluminium rims (optional)
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Two-column Hydraulic Lifting Platform
The lifting platform is an essential feature at any automotive workshop - a prerequisite for repairs requiring free access to the motor vehicles underbody or full removal of load from the wheels.
Your benefits
Two-column hydraulic lifting platform with a floor-level cable receptacle Electromagnetic release of the safety mechanism 4-t load-bearing capacity Manufactured according to international standards, e.g. CE standard Concealed cables and hoses Two hydraulic cylinders each Chain guard for protecting operators Electromechanical height limitation Levelling of both lifting carriages via cable control Quiet operation
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Four-column Hydraulic Lifting Platform

This lifting platform is especially suited to axle measurement. All necessary components such as the axle jack, sliding plates and rotary disc for axle measurement are included.
Your benefits
Variable distance between the rails (1445 mm or 1595 mm, centre-to-centre) Axle jack, sliding plates and rotary disk for axle measurement included 4-t load-bearing capacity Manufactured according to international standards, e.g. CE standard Concealed cables and hoses Two hydraulic cylinders each Chain guard for protecting operators Electromechanical height limitation Levelling of both lifting carriages via cable control Quiet operation
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Fully Automatic Air-conditioning Service Unit
This easily operable air-conditioning service unit incorporates several functions such as leakage detection, recycling, cleaning, evacuation and replenishment.
Your benefits
Recycling Recycling of residual refrigerant Cleaning Cleaning of refrigerant through drying, filtration and separation of oil as well as liquids according to the SAE standard Replenishment Refilling of the air-conditioning cycle Leakage detection Checks of the cooling system for leakages Oil separation Replacement of old oil with a fresh batch to lengthen the compressors life cycle Evacuation Emptying of hoses and system parts to ensure that exactly the required quantity of refrigerant is refilled Weighing Measurement of the filling quantity
130
Vehicle Tool Kit 77 Pieces

This specially composed vehicle tool kit contains all the tools necessary for carrying out professional repairs. Made of high-quality alloys, the entire assortment of tools complies with DIN as well as ANSI standards.
Your benefits
Professional, high-quality tool kit Compliant with DIN and ANSI standards Contains all tools needed for professional repairs Tools are stored in a practical, hard-shell case
131

Set of Socket Spanners 94 Pieces
This specially composed vehicle tool kit contains all the socket spanners necessary for carrying out professional repairs. Made of highquality alloys, the entire assortment of tools complies with DIN as well as ANSI standards.
Your benefits
Professional, high-quality tool kit Compliant with DIN and ANSI standards Contains all socket spanners needed for professional repairs Tools are stored in a practical, hard-shell case
132
Trolley with 64-piece Tool Kit

Configured specially for training purposes, this indispensable tool-kit trolley meets all relevant DIN und ANSI standards.
Your benefits
Tool kit trolley with seven drawers The uppermost two drawers contain a professional, high-quality tool kit Borne on heavy-duty rollers with ball bearings Large, stable work plate with corrugated PVC surface Compliant with DIN and ANSI standards
133
Essential Product Benefits

Ensure Long-term Customer Satisfaction
Bernd Klein, instructor at the Nikolaus-August-Otto vocational school, regularly uses Lucas-Nlles automotive training systems in his lessons. Having worked with Lucas-Nlle for many years now, we are satisfied with their self-learning concepts. Our trainees are especially keen to use software-based training systems. I particularly like the new Connect program which can be used to clearly explain engine management systems.
Also very popular with instructors here are the robust lighting and signalling units.
In general, Lucas-Nlles training systems make instruction at vocational schools much more practical and hands-on.
134 Lucas-Nlle
The Whole is Greater than the Sum of its Parts

Individual Consultation with Lucas-Nlle
Do you require detailed advice or a specific quotation? You can contact us as follows: Phone: +49 2273 567-0 Fax: +49 2273 567-39
Lucas-Nlle is a byword for customized vocational training systems in the following areas:
Installation Engineering
Electropneumatics, Hydraulics
Electrical Power Engineering
Instrumentation
Power Electronics, Electrical Machines, Drive Technology
Microcontrollers
Electrical and Electronic Circuits
Automation Technology
Communications Technology
Process Control
Lab Systems
Ask for detailed information via any of the contact methods mentioned above. Our employees will be happy to advise you. Lucas-Nlle training systems meet the highest safety and quality standards. Changes in areas like environmental protection, customer benefits, design and construction entail corresponding advancements to systems or components. This can lead to discrepancies between product details and relevant items in the scope of delivery.
Further information on our products can also be found at: www.lucas-nuelle.com
Lucas-Nlle
Topics
p. 30, 31 p. 38, 39 p. 62, 63 Hybrid drives p. 44 - 47 p. 26 p. 27 p. 28 p. 29 p. 32 p. 48 p. 49 p. 54 p. 55 Alarm system and immobilizer p. 56 Air-conditioning and climate control
Fundamentals of automotive electrics/electronics
Fundamentals of electronic/digital technology
Fundamentals of DC and AC technology
Instrument panel with CAN and LIN
Pulse-width modulated signals
Engine management sensors
CAN bus for vehicle lighting
Three-phase generator
Three-phase generator
Vehicle lighting
Topics
1 Maintenance / care of vehicles and automotive systems 2
Dismantling, repair and installation of automotive assembly groups and systems
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
3 Testing / maintenance of electrical and electronic systems 4

Testing / maintenance of open-loop and closed-loop control systems
5 Testing / maintenance of power supply and starting systems 6 Testing / maintenance of engine mechanics 7 Diagnosis and maintenance of engine management systems 8 Servicing and maintenance of exhaust systems 9 Maintenance of power transmission systems 10 Maintenance of chassis and brake systems 11 Retrofitting and commissioning of auxiliary systems 12 Testing and maintenance of networked systems 13
Diagnosis and maintenance of body, comfort and safety systems
x x x
GPS navigation
x x x
14 Servicing and maintenance for statutory inspections
136 Lucas-Nlle
x x x x
Photovoltaics p. 65 p. 70 p. 71 p. 72 - 74 p. 75 - 80 p. 81 p. 82 p. 88, 89 p. 90 p. 91 p. 92 p. 94 p. 95 p. 96, 97 p. 102, 104 p. 105 - 107 Electromechanical steering p. 103 Ignition systems Common rail diesel injection
Fuel cells p. 64
x x x
Lucas-Nlle
x x x x x x x x x x x x x
Chip tuning Spark-ignition engine management systems Diesel engine management systems
x x x x x x
Functional engine On-board diagnosis II
x x x x
Auto diagnosis trainer software Automobile diagnosis case
x x x x x x x x x x x
PDA vehicle diagnosis unit
x x
LIN/CAN monitor Common rail diagnosis set
x x x x x
Brake systems Brake systems
x x x x x x x
Gearbox and drive
Automobile diagnosis unit with oscilloscope
x x
Steering systems Bus systems
x x
Airbag, seat-belt tensioner and crash behaviour Suspension, springs and shock absorbers
p. 108, 109 p. 110 p. 111 p. 111 p. 116 - 119
137
Siemensstrasse 2 D-50170 Kerpen-Sindorf Phone: +49 2273 567-0 Fax: +49 2273 567-39 www.lucas-nuelle.com
Lucas-Nlle Lehr- und Megerte GmbH
Ref. No.: P5145 Training and Further Education in Automotive Engineering 05/10-2GB (Printed in Germany) Subject to technical alterations.

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Training and Further Education in Automotive Engineering

Practical Automotive Laboratory Instruction and Diagnostics

Qualifications Through Quality

are having a huge impact on training and education.

Practical competence is a key qualification

Different Systems to Suit Different Needs

Different Systems to Suit Different Needs

Different Systems to Suit Different Needs

Different Systems to Suit Different Needs

Training Panel Systems a Modular System

Different Systems to Suit Different Needs

The Entire System at a Glance

Sensors and Actuators

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