Lesson 1Common heavy-equipment diesel configurations (inline, V, turbocharged)Reviews typical diesel engine setups in heavy equipment. Compares straight and V-type engines, turbocharged and naturally aspirated options, and how these affect space, maintenance access, and output.
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, injectorsDeals with diesel fuel storage and delivery from tank to injector. Explains how components work, fuel paths, pressure levels, and filtering, plus typical wear, dirt problems, checks, and safe maintenance 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 signsCovers the lubrication setup from sump to bearings. Explains oil types, additives, filters, passages, and pressure management, plus sources of dirt, sampling, wear signs, and service times for heavy gear.
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 routes, filtering, and turbocharging in heavy diesels. Includes filter kinds, air cooling after turbo, turbo parts, boost management, failure signs, and step-by-step turbo 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 colours, odours, loss of power, overheating)Connects typical diesel faults to visible signs. Covers smoke colours, smells, sounds, power drop, and overheating, teaching orderly checks to pinpoint issues before deep inspection or tests.
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 positionLooks at main engine sensors and control methods in modern diesels. Details MAP, temp, pressure, and speed sensors, basic wiring, ECM logic, failure types, and safe testing and reading of sensor info.
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 the engine cooling setup and how it works. Covers coolant mixes, radiators, thermostats, pumps, hoses, and caps, plus bubbling, electrical issues, leak tests, overheating checks, and upkeep.
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 heat principles and the four-stroke process. Links compression start, air-fuel mix, and heat flow to torque, efficiency, emissions, and how conditions like load affect engine work.
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 cleaning systems on modern diesels. Explains silencers, DOCs, DPFs, sensors, and regen basics, plus pressure build-up issues, check points, and safe handling of hot 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
