Lesson 1Common Diesel Setups in Heavy Machines (straight, V-type, turbocharged)This lesson reviews typical diesel engine arrangements in heavy machines and their features. It compares straight and V engines, turbocharged and natural breathing setups, and how these affect fitting, repair access, and output.
Straight vs V engine buildTurbocharged vs natural diesel enginesWet and dry sleeve block buildsOverhead cam vs cam-in-block designsPower strength and torque patternsRepair access and fitting issuesLesson 2Fuel System Parts: Tanks, Filters, Lift Pumps, Injection Pumps, InjectorsThis covers diesel fuel storage and supply from tank to injector. It explains part roles, flow routes, pressure levels, and filtering, plus common wear, dirt problems, fault checks, and safe repair steps for heavy equipment.
Tank design and air release in heavy machinesLift pumps and low-pressure fuel linesFilter kinds, standards, and water removalHigh-pressure injection pumps and controlsInjector kinds, spray shapes, and wearFuel dirt sources and fault-findingLesson 3Lubrication System: Oil Kinds, Filters, Oil Passages, Pressure Systems, Dirt SignsThis covers lubrication system setup from oil pan to bearings. It explains oil types, additives, filters, passages, and pressure control, plus dirt sources, sampling, wear signs, and service times for heavy machines.
Engine oil types and service gradesOil pump kinds and pressure controlMain passages, jets, and lube routesFilter materials, bypass valves, and serviceDirt sources and oil samplingLow oil pressure and noise fault-findingLesson 4Air Intake and Turbocharging: Filters, Intercoolers, Turbocharger Fault-FindingThis details air intake paths, filtering, and turbocharging in heavy diesels. It covers filter types, charge-air cooling, turbo parts, boost control, failure signs, and step-by-step turbocharger checks.
Air filter types, standards, and blockagesTurbocharger parts and termsWastegates, VGTs, and boost controlIntercoolers and charge-air leak testsTurbo failure signs and causesBoost pressure and air flow checksLesson 5Common Failure Types and Sign Matching (smoke colours, smells, power loss, overheating)This links common diesel failure types to visible signs. It covers smoke colours, smells, noises, power drop, and overheating, teaching orderly checks to pinpoint causes before full teardown or testing.
Black, blue, and white smoke checksFuel, oil, and coolant smell signsPower loss under load fixingOverheating and coolant loss patternsAbnormal engine noises and shakesBasic fault isolation chartsLesson 6Engine Sensors and Controls: MAP/MAP-like, Coolant Temp, Oil Pressure, Crank/Cam PositionThis explores main engine sensors and control methods on modern diesels. It details MAP, temperature, pressure, and speed sensors, wiring basics, ECM logic, failure types, and safe testing and data reading.
MAP and boost pressure sensor workCoolant temperature and fan control inputsOil pressure sensing and protection logicCrank and cam position sensor basicsECM methods for fueling and timingBasic sensor testing with multimetersLesson 7Cooling System: Radiators, Coolant Types, Thermostats, Water Pumps, HosesThis explains engine cooling system design and function. It covers coolant chemistry, radiators, thermostats, pumps, hoses, and caps, plus cavitation, electrolysis, leak checks, overheating fixing, and upkeep practices.
Coolant types, additives, and mixing rulesRadiator build, flow, and cleaningThermostats, bypass lines, and testingWater pump design, drive, and failuresHoses, clamps, and pressure cap checksOverheating fixing and leak findingLesson 8Diesel Engine Heat Principles and Four-Stroke CycleThis introduces diesel heat principles and the four-stroke cycle. It links compression start, air-fuel mixing, and heat move to torque output, efficiency, emissions, and how work conditions affect engine performance.
Compression start and diesel traitsIntake, compression, power, exhaust strokesCombustion timing and pressure curvesAir-fuel ratio, mixture form, and smokeHeat move, efficiency, and power outputEffects of load, height, and temperatureLesson 9Exhaust and Aftertreatment Basics: Mufflers, Particulate Filters, DOC, Sensors (if available)This introduces exhaust flow and aftertreatment on modern diesels. It explains mufflers, DOCs, DPFs, sensors, and regeneration basics, plus backpressure problems, check points, and safe handling of hot parts.
Exhaust routing and backpressure effectsMuffler types and noise control waysDOC function and light-off conditionsDPF loading, regeneration, and ashExhaust temperature and pressure sensorsAftertreatment fault signs overview
