Lesson 1Common heavy-equipment diesel configurations (inline, V, turbocharged)Reviews typical diesel setups in heavy equipment and their features. Compares inline and V engines, turbocharged and naturally aspirated systems, and how these affect space, access for servicing, and overall performance in practical use.
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, injectorsDiscusses diesel fuel storage and delivery from tank to injector. Explains how components work, fuel flow paths, pressure levels, and filtration, including common wear, contamination problems, diagnostic methods, and safe servicing 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 galleries, pressure systems, contamination signsExamines lubrication system from sump to bearings. Covers oil grades, additives, filters, galleries, and pressure management, plus sources of contamination, sampling techniques, wear signs, and service schedules for heavy equipment maintenance.
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 diagnosticsOutlines air intake routes, filtration, and turbocharging in heavy diesels. Includes filter types, charge-air cooling, turbo parts, boost management, failure signs, and detailed steps for diagnosing turbocharger issues effectively.
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 colours, odours, loss of power, overheating)Connects typical diesel failure modes to visible symptoms. Covers smoke colours, odours, noises, power loss, 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 odour 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 positionInvestigates main engine sensors and control methods in modern diesels. Details MAP, temperature, pressure, and speed sensors, basic wiring, ECM functions, failure types, and safe ways to test and read sensor data accurately.
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, hosesDescribes engine cooling system design and function. Includes coolant chemistry, radiators, thermostats, pumps, hoses, and caps, plus cavitation, electrolysis, leak tests, overheating diagnosis, and routine maintenance tips.
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 cycleIntroduces diesel thermodynamics and the four-stroke process. Relates compression ignition, air-fuel mixing, and heat transfer to torque, efficiency, emissions, and how conditions like load or altitude impact engine output.
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)Covers exhaust flow and aftertreatment in modern diesels. Explains mufflers, DOCs, DPFs, sensors, and regeneration processes, including 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
