Lesson 1Common heavy-equipment diesel configurations (inline, V, turbocharged)Looks at common diesel engine setups in heavy equipment. It compares straight and V-shaped engines, turbocharged and naturally breathing ones, and how these affect fitting, access for repairs, and overall performance in tough site conditions.
Straight versus V engine designsTurbocharged vs naturally breathing dieselsWet and dry cylinder liner buildsOverhead cam vs cam-in-block setupsPower output and torque characteristicsRepair access and fitting issuesLesson 2Fuel system components: tanks, filters, lift pumps, injection pumps, injectorsDeals with diesel fuel storage and delivery from tank to injector. It explains how parts work, fuel flow routes, pressure levels, and cleaning, plus usual wear, dirt problems, checks for faults, and safe ways to service them on site.
Tank designs and air vents in heavy gearLift pumps and low-pressure fuel linesFilter kinds, standards, and water removalHigh-pressure injection pumps and controlsInjector types, spray shapes, and wear signsFuel dirt sources and fault findingLesson 3Lubrication system: oil types, filters, oil galleries, pressure systems, contamination signsCovers the lubrication setup from oil pan to bearings. It explains oil types, additives, filters, oil channels, and pressure management, plus dirt sources, sampling methods, wear signs, and service times for heavy machinery in dusty environments.
Engine oil types and service standardsOil pump kinds and pressure controlsMain oil channels, jets, and lube routesFilter materials, bypass valves, and servicingDirt sources and oil sampling techniquesLow oil pressure and noise fault findingLesson 4Air intake and turbocharging: filters, intercoolers, turbocharger diagnosticsGoes into air intake paths, cleaning, and turbo boosting in heavy diesels. It covers filter types, cooled charge air, turbo parts, boost management, failure signs, and step-by-step checks for turbochargers in field conditions.
Air filter types, standards, and blockagesTurbocharger parts and termsWastegates, variable geometry turbos, and boost controlIntercoolers and charge-air leak testsTurbo failure signs and main causesBoost pressure and air flow checksLesson 5Common failure modes and symptoms mapping (smoke colours, odours, loss of power, overheating)Connects usual diesel faults to signs you can see. It covers smoke colours, smells, sounds, power drops, and too much heat, teaching orderly checks to pinpoint causes before deep inspections or tests in workshop settings.
Black, blue, and white smoke checksFuel, oil, and coolant smell signsPower loss under load fixingOverheating and coolant loss patternsUnusual engine sounds and shakesBasic fault finding chartsLesson 6Engine sensors and controls: MAP/MAP-equivalents, coolant temp, oil pressure, crank/cam positionLooks at key engine sensors and control methods in modern diesels. It details MAP, temperature, pressure, and speed sensors, basic wiring, engine control module logic, failure types, and safe ways to test and read sensor info.
MAP and boost pressure sensor workingsCoolant temperature and fan control signalsOil pressure sensing and safety logicCrank and cam position sensor basicsEngine control module strategies for fuel and timingBasic sensor tests with multimetersLesson 7Cooling system: radiators, coolant types, thermostats, water pumps, hosesExplains how the engine cooling system is built and works. It covers coolant mixes, radiators, thermostats, pumps, hoses, and caps, plus bubble damage, electric rust, leak tests, overheating checks, and upkeep practices for reliability.
Coolant types, additives, and mixing guidelinesRadiator builds, flow, and cleaningThermostats, bypass lines, and testingWater pump designs, drives, and failuresHoses, clamps, and pressure cap inspectionsOverheating checks and leak findingLesson 8Diesel engine thermodynamic principles and four-stroke cycleIntroduces diesel heat principles and the four-stroke process. It links squeeze ignition, air-fuel mixing, and heat movement to torque power, efficiency, emissions, and how site conditions like heat affect engine work.
Squeeze ignition and diesel traitsIntake, squeeze, power, exhaust strokesBurn timing and pressure graphsAir-fuel mix, formation, and smokeHeat movement, efficiency, and power outputEffects of load, height, and temperatureLesson 9Exhaust and aftertreatment basics: mufflers, particulate filters, DOC, sensors (if present)Introduces exhaust flow and cleaning systems in modern diesels. It explains silencers, diesel oxidation catalysts, diesel particulate filters, sensors, and regen basics, plus pressure build-up issues, check points, and safe handling of hot parts.
Exhaust paths and backpressure effectsSilencer types and noise control waysDOC workings and start-up conditionsDPF loading, regen, and ash build-upExhaust temperature and pressure sensorsAftertreatment fault signs overview
