Lesson 1Common heavy-equipment diesel configurations (inline, V, turbocharged)Reviews common heavy-equipment diesel layouts and features. Compares inline and V engines, turbocharged and naturally aspirated setups, and how configuration affects packaging, service access, and performance.
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, injectorsCovers diesel fuel storage and delivery from tank to injector. Explains component functions, flow paths, pressure stages, and filtration, plus common wear, contamination issues, diagnostic checks, and safe service procedures.
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 signsCovers lubrication system layout from sump to bearings. Explains oil grades, additives, filters, galleries, and pressure control, plus contamination sources, sampling, wear indicators, and service intervals for heavy equipment.
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 diagnosticsDetails air intake paths, filtration, and turbocharging in heavy diesels. Covers filter types, charge-air cooling, turbo components, boost control, failure symptoms, and step-by-step turbocharger diagnostic 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 failure modes and symptoms mapping (smoke colors, odors, loss of power, overheating)Links common diesel failure modes to observable symptoms. Covers smoke colors, odors, noises, power loss, and overheating, teaching systematic checks to narrow causes before detailed teardown or testing.
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 positionExplores key engine sensors and control strategies on modern diesels. Details MAP, temperature, pressure, and speed sensors, wiring basics, ECM logic, failure modes, and how to test and interpret sensor data safely.
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 engine cooling system design and operation. Covers coolant chemistry, radiators, thermostats, pumps, hoses, and caps, plus cavitation, electrolysis, leak checks, overheating diagnosis, and maintenance practices.
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 cycle. Links compression ignition, air–fuel mixing, and heat transfer to torque output, efficiency, emissions, and how operating conditions affect engine performance.
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)Introduces exhaust flow and aftertreatment on modern diesels. Explains mufflers, DOCs, DPFs, sensors, and regeneration basics, plus backpressure issues, inspection points, and safe handling of hot components.
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
