Course Overview
This course provides participants with an in-depth understanding of the construction, operation, maintenance, and troubleshooting of heavy-duty diesel engines (HDDs) used in industrial, marine, power generation, and transport applications. It emphasizes practical skills, safety, performance optimization, and reliability enhancement to ensure efficient engine operations.
Course Objectives
By the end of this course, participants will be able to:
- Understand the principles and operation of heavy-duty diesel engines.
- Identify and explain major engine components and their functions.
- Perform routine and preventive maintenance procedures.
- Diagnose and troubleshoot common engine faults and performance issues.
- Interpret engine performance parameters and maintenance documentation.
- Apply best practices in engine safety, servicing, and overhaul procedures.
Who Should Attend
This course is suitable for:
- Diesel engine mechanics and technicians
- Maintenance and reliability engineers
- Operators of diesel-powered equipment and facilities
- Marine and transport engineers
- Supervisors and managers involved in engine operations and fleet management
Course Outline
Introduction to Heavy Duty Diesel Engines
- Diesel engine fundamentals and comparison with gasoline engines
- Applications in marine, industrial, mining, transport, and power sectors
Engine Components and Functions
- Cylinder block, crankshaft, camshaft, pistons, connecting rods
- Fuel injection system: injectors, fuel pumps, filters
- Air intake and exhaust systems: turbochargers, intercoolers, mufflers
- Lubrication and cooling systems
- Electrical and starting systems
Engine Operation and Performance
- Four-stroke cycle and combustion process
- Engine timing, firing order, and power generation
- Engine performance metrics: horsepower, torque, fuel efficiency
- Load conditions and duty cycles
Maintenance Strategies and Procedures
- Preventive and predictive maintenance practices
- Routine inspections and service intervals
- Oil, coolant, and filter replacement procedures
- Valve adjustment and fuel system calibration
- Engine alignment and mounting checks
Troubleshooting and Diagnostics
- Common engine problems and symptoms
- Root cause analysis of overheating, misfiring, excessive smoke
- Use of diagnostic tools and onboard monitoring systems
- Fault code interpretation and service bulletins
Overhaul and Repair Techniques
- Engine teardown, inspection, and rebuild procedures
- Cylinder reconditioning, crankshaft grinding, bearing replacement
- Piston ring and valve seat replacement
- OEM specifications and workshop practices
Safety and Environmental Compliance
- Engine safety procedures and lockout/tagout
- Emission standards and exhaust after-treatment systems
- Handling fuel, oils, and hazardous materials
Case Studies and Practical Exercises
- Real-world examples of HDD engine failures and solutions
- Hands-on practice with maintenance tasks and diagnostic tools