COURSE OVERVIEW:

Diesel engines serve as the primary prime movers for a vast array of industrial applications, including power generation, pumping stations, and heavy machinery. This course offers a deep dive into the mechanical architecture and operational cycles of compression-ignition engines, providing participants with the technical knowledge required to maintain these assets at peak efficiency. We will examine the critical subsystems, including fuel injection, air induction, cooling, and lubrication, and how they interact to ensure reliable combustion.

The scope of this training encompasses the full spectrum of engine care, from routine preventative checks to the complexities of a major top-end or bottom-end overhaul. Participants will explore the metallurgical and mechanical stresses placed on pistons, liners, crankshafts, and bearings, and learn how to identify early warning signs of component fatigue. Detailed coverage of modern electronic control modules (ECM) and high-pressure common rail (HPCR) systems is also included to address the technological shift in modern diesel design.

Furthermore, the course emphasizes precision measurement and diagnostic techniques. Attendees will learn how to use specialized tools such as cylinder pressure indicators, bore gauges, and fuel system testers to quantify engine health. By mastering the systematic approach to troubleshooting and the rigorous standards for reassembly, technical personnel will be able to extend the mean time between overhauls (MTBO) and minimize the risk of catastrophic engine failure in critical service environments.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Explain the four-stroke and two-stroke diesel combustion cycles.
2. Identify and describe the function of all major internal engine components.
3. Perform a comprehensive inspection of cylinder heads and valves for wear.
4. Utilize precision instruments to measure liner wear and piston clearances.
5. Troubleshoot fuel injection timing and atomization issues.
6. Evaluate the condition of turbochargers and intercooling systems.
7. Analyze lubrication oil reports to detect internal engine wear patterns.
8. Execute a systematic top-end overhaul, including valve grinding and seating.
9. Inspect crankshafts for cracks and verify bearing shell integrity.
10. Adjust fuel racks and governors for optimal speed and load control.
11. Diagnose cooling system failures and heat exchanger fouling.
12. Interpret diagnostic codes from electronic engine management systems.
13. Implement a structured preventive maintenance program based on operating hours.

TARGET AUDIENCE:

Mechanical Maintenance Technicians, Diesel Mechanics, Fleet Managers, Power Plant Operators, and Service Engineers responsible for heavy-duty diesel engines.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.