Lesson 1Common heavy machine diesel setups (straight, V, turbocharged)Looks at common diesel engine layouts and features in heavy machines. Compares straight and V engines, turbocharged and naturally breathing setups, and how these affect fitting, repair access, and output.
Straight versus V engine designTurbocharged vs naturally breathing dieselsWet and dry sleeve block buildingOverhead cam vs cam-in-block setupsPower strength and torque curve featuresRepair access and fitting concernsLesson 2Fuel system parts: tanks, filters, lift pumps, injection pumps, injectorsDeals with diesel fuel storage and delivery from tank to injector. Explains part functions, flow routes, pressure levels, and filtering, plus common wear, dirt problems, fault checks, and safe repair steps.
Tank design and air release in heavy machinesLift pumps and low-pressure fuel linesFilter kinds, strengths, and water removalHigh-pressure injection pumps and controlInjector kinds, spray shapes, and wearFuel dirt causes and fault-findingLesson 3Lubrication system: oil kinds, filters, oil channels, pressure systems, dirt signsCovers lubrication system layout from oil pan to bearings. Explains oil types, additives, filters, channels, and pressure control, plus dirt sources, sampling, wear signs, and service times for heavy machines.
Engine oil types and service ratingsOil pump kinds and pressure controlMain channels, 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-findingDetails air intake paths, filtering, and turbocharging in heavy diesels. Covers filter types, charge-air cooling, turbo parts, boost control, failure signs, and step-by-step turbocharger checks.
Air filter types, ratings, and blockageTurbocharger parts and termsWastegates, VGTs, and boost controlIntercoolers and charge-air leak testingTurbo failure signs and root causesBoost pressure and airflow fault-findingLesson 5Common failure ways and signs mapping (smoke colours, smells, power loss, overheating)Connects common diesel failure ways to visible signs. Covers smoke colours, smells, noises, power loss, and overheating, teaching orderly checks to narrow causes before detailed stripping or testing.
Black, blue, and white smoke fault-findingFuel, oil, and coolant smell signsPower loss under load troubleshootingOverheating and coolant loss patternsAbnormal engine noises and shakingBasic fault isolation flowchartsLesson 6Engine sensors and controls: MAP/MAP-like, coolant temp, oil pressure, crank/cam positionLooks into key engine sensors and control ways on modern diesels. Details MAP, temperature, pressure, and speed sensors, wiring basics, ECM logic, failure ways, and how to test and read sensor data safely.
MAP and boost pressure sensor workingCoolant temperature and fan control inputsOil pressure sensing and protection logicCrank and cam position sensor basicsECM ways for fueling and timingBasic sensor testing with multimetersLesson 7Cooling system: radiators, coolant kinds, thermostats, water pumps, hosesExplains engine cooling system design and working. Covers coolant chemistry, radiators, thermostats, pumps, hoses, and caps, plus bubbling, electrolysis, leak checks, overheating fault-finding, and upkeep practices.
Coolant kinds, additives, and mixing rulesRadiator building, flow, and cleaningThermostats, bypass lines, and testingWater pump design, drive, and failuresHoses, clamps, and pressure cap checksOverheating fault-finding and leak detectionLesson 8Diesel engine heat principles and four-stroke cycleIntroduces diesel heat principles and the four-stroke cycle. Connects compression start, air-fuel mixing, and heat move to torque output, efficiency, emissions, and how working conditions affect engine performance.
Compression start and diesel propertiesIntake, compression, power, exhaust strokesCombustion timing and pressure curvesAir-fuel ratio, mixture forming, and smokeHeat move, efficiency, and power outputEffects of load, height, and temperatureLesson 9Exhaust and aftertreatment basics: silencers, particulate filters, DOC, sensors (if there)Introduces exhaust flow and aftertreatment on modern diesels. Explains silencers, DOCs, DPFs, sensors, and regeneration basics, plus backpressure problems, check points, and safe handling of hot parts.
Exhaust routing and backpressure effectsSilencer types and noise control methodsDOC function and light-off conditionsDPF loading, regeneration, and ashExhaust temperature and pressure sensorsAftertreatment fault signs overview
