Lesson 1Electrical and electronic controls: batteries, alternators, wiring harnesses, sensors, ECUsThis section covers the electrical power and control network, including batteries, alternators, harnesses, sensors, and ECUs, focusing on safe testing, fault tracing, connector care, and protecting electronics from dust, heat, and vibration common in Kiwi fields.
Battery selection, testing, and careAlternator output and drive inspectionWiring harness routing and protectionSensor types, locations, and failuresECU functions, updates, and backupsUsing diagnostic tools and fault codesLesson 2Transmission and driveline: gearboxes, final drives, clutches and CV jointsThis section explains the transmission and driveline, including gearboxes, final drives, clutches, and CV joints, emphasising torque flow, lubrication, alignment, and preventive checks that avoid breakdowns under heavy field loads and tough terrain typical of New Zealand.
Power flow from engine to wheelsMain gearbox types and upkeepFinal drives, hubs, and reductionsClutch types, settings, and wearCV joints, shafts, and alignmentLubrication schedules and oil checksLesson 3Frame, chassis, cab and operator controls: mounting points, access panels and visibility systemsThis section examines the frame, chassis, cab, and operator controls, showing how structural integrity, mounting points, access panels, and visibility systems affect safety, comfort, serviceability, and precise control during harvesting operations in variable conditions.
Main frame layout and stress pointsChassis mounting points and bushingsCab structure, sealing, and comfortControl levers, joysticks, and pedalsVisibility systems, mirrors, and camerasAccess panels, ladders, and handrailsLesson 4Cleaning and trash management: fans, sieves, separators and chopper discharge systemsThis section examines cleaning and trash management systems, including fans, sieves, separators, and discharge chutes, focusing on airflow control, settings for different field conditions, and maintenance to limit losses and manage residue safely in NZ environments.
Fan types, speed, and airflow tuningSieve openings and angle adjustmentPrimary and secondary separator rolesChopper discharge and residue spreadSettings for wet versus dry caneDust, trash buildup, and fire risksLesson 5Diesel engine: types, cooling, fuel system, common wear pointsThis section covers diesel engine types used in harvesters, including cooling and fuel systems, air management, and common wear points, with emphasis on monitoring, routine service, and failure symptoms under high dust and load conditions prevalent in New Zealand.
Engine configurations and ratingsCooling system flow and componentsFuel supply, filtration, and injectionAir intake, turbo, and dust controlLubrication paths and oil selectionTypical wear zones and early signsLesson 6Overview of self-propelled sugarcane harvester architectureThis section provides an overall view of self-propelled harvester architecture, showing how engine, hydraulics, transmission, cutting, feeding, cleaning, and cab systems are arranged and integrated to balance capacity, stability, and service access for Kiwi operations.
Major system layout and flow pathsCenter of gravity and stability zonesPower distribution to key systemsService access and component groupingRouting of hoses, cables, and harnessesDesign trade‑offs for field conditionsLesson 7Feeding and conveyor systems: feed rollers, augers, belts, speed synchronisationThis section analyses feeding and conveyor systems, including feed rollers, augers, and belts, explaining crop flow, speed synchronisation, slip control, and adjustments that reduce blockages, cane damage, and uneven loading of downstream units in field settings.
Feed roller design and pressure setupPrimary and secondary conveyor pathsAuger pitch, direction, and loadingBelt tracking, tension, and splicingSpeed ratios and synchronization checksBlockage prevention and clearing stepsLesson 8Cutting system: base cutters, choppers, knives, knife holders and wear patternsThis section details base cutters, choppers, knives, and holders, explaining cutting geometry, wear mechanisms, and how to inspect, adjust, and replace parts to maintain clean cuts, reduce losses, and prevent overloads or failures during harvests.
Base cutter design and height controlChopper drum layout and timingKnife materials and edge geometryKnife holder alignment and fasteningWear patterns, causes, and diagnosisInspection, sharpening, and replacementLesson 9Hydraulic systems: pumps, valves, actuators, reservoirs, filtrationThis section focuses on hydraulic pumps, valves, actuators, reservoirs, and filtration, explaining circuit functions, pressure control, contamination risks, and maintenance practices that keep cutting, lifting, and steering systems responsive and reliable.
Hydraulic circuit schematics readingPump types, drives, and efficiencyControl valves, spools, and settingsCylinders, motors, and leakage testsReservoir design, levels, and aerationFilters, cleanliness, and oil sampling
