Lesson 1Common heavy-equipment diesel configurations (inline, V, turbocharged)This lesson reviews typical diesel engine setups in heavy equipment. It compares inline and V-type engines, turbocharged versus naturally aspirated options, and how these choices impact installation space, maintenance access, and overall performance in rugged terrains.
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 components: tanks, filters, lift pumps, injection pumps, injectorsThis lesson discusses diesel fuel storage and delivery from the tank to the injectors. It explains how each part works, fuel flow routes, pressure levels, filtration methods, common wear problems, contamination risks, diagnostic steps, and safe servicing practices for field use.
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 galleries, pressure systems, contamination signsThis lesson examines the lubrication system from the oil sump to the bearings. It covers oil types, additives, filters, oil passages, pressure management, sources of contamination, sampling techniques, wear signs, and service schedules tailored for heavy equipment in dusty environments.
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 turbocharging: filters, intercoolers, turbocharger diagnosticsThis lesson details air intake routes, filtration, and turbocharging in heavy diesel engines. It includes filter varieties, charge-air cooling, turbo parts, boost regulation, failure indicators, and detailed diagnostic procedures for turbochargers in operational settings.
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 failure modes and symptoms mapping (smoke colors, odors, loss of power, overheating)This lesson connects typical diesel engine failures to visible symptoms. It addresses smoke colours, smells, sounds, power reduction, and overheating, teaching methodical checks to identify causes before in-depth disassembly or testing in the workshop.
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-equivalents, coolant temp, oil pressure, crank/cam positionThis lesson investigates main engine sensors and control methods in modern diesel engines. It details MAP sensors, temperature, pressure, and position sensors, basic wiring, ECM functions, failure patterns, and safe testing and data interpretation techniques.
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, hosesThis lesson explains the design and function of engine cooling systems. It covers coolant properties, radiators, thermostats, pumps, hoses, and caps, including cavitation risks, electrolysis, leak detection, overheating diagnosis, and routine maintenance for reliability.
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 thermodynamic principles and four-stroke cycleThis lesson introduces diesel engine thermodynamics and the four-stroke process. It relates compression ignition, air-fuel mixing, and heat management to power output, efficiency, emissions, and how factors like load and environment influence performance in Namibia.
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: mufflers, particulate filters, DOC, sensors (if present)This lesson introduces exhaust flow and aftertreatment in contemporary diesel engines. It explains mufflers, diesel oxidation catalysts, particulate filters, sensors, regeneration processes, backpressure problems, inspection areas, and safe handling of heated parts.
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
