Lesson 1Common heavy machine diesel setups (straight, V-type, turbocharged)Looks at typical diesel engine layouts in heavy machines. Compares straight and V engines, turbo and non-turbo types, and how setup impacts fitting, access for repairs, and output.
Inline versus V engine architectureTurbocharged vs naturally aspirated dieselsWet and dry liner block constructionOverhead cam vs cam-in-block layoutsPower density and torque curve traitsService access and packaging concernsLesson 2Fuel system parts: tanks, filters, lift pumps, injection pumps, injectorsCovers diesel fuel storage and delivery from tank to injector. Explains part functions, fuel paths, pressure levels, filtration, common wear, dirt problems, checks, and safe repair steps.
Tank design and venting in heavy equipmentLift pumps and low-pressure fuel circuitsFilter types, ratings, and water separationHigh-pressure injection pumps and controlInjector types, spray patterns, and wearFuel contamination causes and diagnosisLesson 3Lubrication system: oil types, filters, oil passages, pressure setups, dirt signsCovers lubrication layout from sump to bearings. Explains oil types, additives, filters, passages, pressure control, dirt sources, sampling, wear signs, and service times for heavy machines.
Engine oil grades and service ratingsOil pump types and pressure regulationMain galleries, jets, and lube pathsFilter media, bypass valves, and serviceContamination sources and oil samplingLow oil pressure and noise diagnosisLesson 4Air intake and turbo: filters, intercoolers, turbo checksDetails air paths, cleaning, and turbo in heavy diesels. Covers filter types, air cooling, turbo parts, boost control, failure signs, and step-by-step turbo checks.
Air filter types, ratings, and restrictionTurbocharger components and terminologyWastegates, VGTs, and boost controlIntercoolers and charge-air leak testingTurbo failure symptoms and root causesBoost pressure and airflow diagnosticsLesson 5Common breakdowns and signs (smoke colours, smells, power drop, overheating)Links typical diesel faults to signs you can see. Covers smoke types, smells, noises, power loss, overheating, teaching checks to pinpoint issues before deep inspection.
Black, blue, and white smoke diagnosisFuel, oil, and coolant odor indicatorsLoss of power under load troubleshootingOverheating and coolant loss patternsAbnormal engine noises and vibrationBasic fault isolation flowchartsLesson 6Engine sensors and controls: MAP/MAP-like, coolant temp, oil pressure, crank/cam positionLooks at key sensors and controls in modern diesels. Details MAP, temp, pressure, speed sensors, wiring, ECM logic, faults, and safe testing and reading of data.
MAP and boost pressure sensor operationCoolant temperature and fan control inputsOil pressure sensing and protection logicCrank and cam position sensor principlesECM strategies for fueling and timingBasic sensor testing with multimetersLesson 7Cooling system: radiators, coolant types, thermostats, water pumps, hosesExplains cooling design and work. Covers coolant mix, radiators, thermostats, pumps, hoses, caps, plus bubbles, rust, leak checks, overheating fixes, and upkeep.
Coolant types, additives, and mixing rulesRadiator construction, flow, and cleaningThermostats, bypass circuits, and testingWater pump design, drive, and failuresHoses, clamps, and pressure cap checksOverheating diagnosis and leak detectionLesson 8Diesel engine heat principles and four-stroke cycleIntroduces diesel heat rules and four-stroke cycle. Links squeeze ignition, air-fuel mix, heat move to power, efficiency, smoke, and how conditions affect work.
Compression ignition and diesel propertiesIntake, compression, power, exhaust strokesCombustion phasing and pressure curvesAir–fuel ratio, mixture formation, and smokeHeat transfer, efficiency, and power outputEffects of load, altitude, and temperatureLesson 9Exhaust and aftertreatment basics: silencers, particle filters, DOC, sensors (if fitted)Introduces exhaust flow and cleaning on modern diesels. Explains silencers, DOCs, DPFs, sensors, regen basics, backpressure, checks, and safe hot part handling.
Exhaust routing and backpressure effectsMuffler types and noise control methodsDOC function and light-off conditionsDPF loading, regeneration, and ashExhaust temperature and pressure sensorsAftertreatment fault symptoms overview
