Lesson 1Common heavy-equipment diesel configurations (inline, V, turbocharged)Looks at typical diesel setups in heavy equipment. It compares straight-line and V-shaped engines, turbo-boosted and naturally breathing ones, and how these choices impact fitting, access for fixes, and output in field conditions.
Straight versus V engine designsTurbo-boosted versus natural diesel enginesWet and dry sleeve block buildsOverhead cam versus block cam setupsPower strength and torque patternsFix access and fitting issuesLesson 2Fuel system components: tanks, filters, lift pumps, injection pumps, injectorsDeals with diesel fuel holding and delivery from tank to sprayer. It explains part roles, flow routes, pressure levels, and cleaning, plus usual wear, dirt problems, checks, and safe fixing steps for local fuels.
Tank build and air release in heavy gearLift pumps and low-pressure fuel linesFilter kinds, levels, and water splitHigh-pressure spray pumps and controlSprayer kinds, spray shapes, and wearFuel dirt sources and checksLesson 3Lubrication system: oil types, filters, oil galleries, pressure systems, contamination signsCovers lubrication setup from base to bearings. Explains oil types, extras, filters, channels, and pressure handling, plus dirt sources, sampling, wear signs, and service times for heavy gear in dusty areas.
Engine oil types and service levelsOil pump kinds and pressure controlMain channels, jets, and lube routesFilter materials, bypass valves, and serviceDirt sources and oil samplingLow oil pressure and noise checksLesson 4Air intake and turbocharging: filters, intercoolers, turbocharger diagnosticsDetails air entry paths, cleaning, and turbo-boosting in heavy diesels. Covers filter types, cooled air, turbo parts, boost handling, failure signs, and step-by-step turbo checks for reliable performance.
Air filter types, levels, and block checksTurbocharger parts and termsWaste gates, variable turbos, and boost controlIntercoolers and cooled air leak testsTurbo failure signs and causesBoost pressure and air flow checksLesson 5Common failure modes and symptoms mapping (smoke colors, odors, loss of power, overheating)Connects usual diesel breakdowns to visible signs. Covers smoke shades, smells, sounds, power drop, and heat buildup, teaching ordered checks to pinpoint causes before deep opens or tests in the field.
Black, blue, and white smoke checksFuel, oil, and coolant smell signsPower loss under work troubleshootingOverheating and coolant loss waysUnusual engine sounds and shakesBasic fault finding chartsLesson 6Engine sensors and controls: MAP/MAP-equivalents, coolant temp, oil pressure, crank/cam positionLooks into main engine sensors and control ways on new diesels. Details MAP, temp, pressure, and speed sensors, wiring basics, ECM thinking, failure ways, and safe testing and reading of sensor info.
MAP and boost pressure sensor workCoolant temp and fan control inputsOil pressure sensing and safety logicCrank and cam position sensor basicsECM plans for fuel and timingBasic sensor tests with metersLesson 7Cooling system: radiators, coolant types, thermostats, water pumps, hosesExplains engine cooling setup and running. Covers coolant mix, radiators, heat controls, pumps, hoses, and caps, plus bubble damage, electric rust, leak checks, heat diagnosis, and upkeep in hot climates.
Coolant types, extras, and mix rulesRadiator build, flow, and cleaningThermostats, bypass lines, and testsWater pump build, drive, and failuresHoses, clips, and pressure cap checksOverheating checks and leak findingLesson 8Diesel engine thermodynamic principles and four-stroke cycleIntroduces diesel heat rules and the four-step cycle. Links squeeze start, air-fuel blend, and heat move to twist power, saving, fumes, and how work loads, height, and heat affect engine work in varied terrains.
Squeeze start and diesel traitsIntake, squeeze, power, exhaust stepsBurn timing and pressure linesAir-fuel mix, blend form, and smokeHeat move, saving, and power outLoad, height, and temp effectsLesson 9Exhaust and aftertreatment basics: mufflers, particulate filters, DOC, sensors (if present)Introduces exhaust flow and clean-up on new diesels. Explains silencers, oxidation cats, particle traps, sensors, and regen basics, plus backflow problems, check points, and safe handling of hot parts.
Exhaust paths and backflow effectsSilencer types and noise controlDOC work and start conditionsDPF load, regen, and ashExhaust temp and pressure sensorsAftertreatment fault signs overview
