Engine Course Syllabus

1. Introduction (Registration)
   1. ABC's of the Diesel
      1. 2 Cycle Theory
      2. Importance ot Valve Timing
      3. Injector Pressures and Fuel Flow
   2. Engine Familiarization
      1. Engine Layout
      2. Torque Values
      3. Model identification
2. Crankcase
   1. Differences
      1. 645E vs. 64SF
      2. 645 vs. 710
   2. Protection
      1. Head Seat Ring and Cylinder Retainer Qualification
      2. Lower Liner Insert and Lower Liner Insert Bore Qualification
3. Crankshafts
   1. Qualification
      1. Surface Maintenance
      2. Visual inspection
      3. Checking End Play
   2. Vibration Dampers
      1. Spring Pack
      2. Gear Type
      3. Symptoms of a Bad Damper
      4. Damper Qualification
4. Accessory Drive Gear and Cover
   1. Accessory Drive Gear
      1. Damping Spring Segments
      2. Backlash
   2. Accessory Drive Housing
      1. Tools Necesary for Alignment
      2. Cover Correct Torquing Procedures
      3. Doweling the Accessory Drive Housing
5. Main Bearings
   1. Introduction
      1. Design
      2. Replacement Intervals
      3. Correct Installation and Torquing Procedures
   2. Inspection
      1. Reasons to Inspect Main Baarirgs
      2. Analysis During Inspection
      3. Main Bearing Feel Over
6. Power Assembly
   1. Bearings
      1. Qualification
      2. Troubleshooting
      3. Inspection Without Disassembly
   2. Connecting Rods
      1. Blade Rod QualificatIon
      2. Fork Rod Qualification
      3. Fork Rod Bore
      4. Thread Dowel and Serration Condition
      5. Surface Maintenance
   3. Piston Pins
      1. Rocking StyIe
      2. Standard Pin
      3. Surface Maintenance
      4. In Service Inapection
   4. Piston Pin Bearings
      1. Interchangeability
      2. Retention Systems
   5. Carriers
      1. Bearing Installation
      2. Differences
   6. Pistons
      1. Tin Plated
      2. Phosphate Coated
      3. Surface Inspection
      4. Wear Step
   7. Piston Rings
      1. Different Types
      2. Side Clearance
      3. Face Wear
      4. Breakage
   8. Liners
      1. Cast Iron
      2. Chrome
      3. Qualification
   9. Air Box Inspection
      1. Introduction to Air Box inspection (Film)
      2. Advanced Air Box inspection (Film)
      3. Four Reasons to Replace the Power Assembly
      4. Completing the Air Box inspection Form
   10. Cylinder Heads
       1. Differences
       2. Checking Compression
       3. Dissasembly and Assembly
       4. Head and Valve Service
       5. Qualification of Hydraulic Valve Lash Assemblies
       6. Correct Valve Adjustment Procedures
   11. Power Assembly Changeout
       1. Crab Bolts
       2. Conventional Crabs
       3. Plate Crabs, Including Revised Torquing Procedures
       4. Power Assembly Installation (Film)
       5. Power Assembly Removal (Film)
7. Camshafts
   1. Qualification
      1. Visual Inspection
      2. Locating Top Dead Center
      3. Valve Timing
      4. Timing the Gear Train
      5. Counterweight Application
   2. Top Deck Inspection
      1. Fuel Leaks
      2. Compression Leaks
      3. Exhaust Leaks
      4. Bad Lash Adjusters
      5. Incorrectly Positioned Rocker Arms
      6. Cam Lobe Inspection
      7. Top Deck Hinges, Latches, Covers and Seals
8. Systems
   1. Fuel Systems
      1. Operation
      2. Troubleshooting Fuel Leaks
      3. Setting the Fuel Rack
      4. Adjusting Injection Timing
      5. Pressure Testing Injectors
      6. Video, "Diesel Checks and Adjustments"
   2. Governors
      1. Operation
      2. Troubleshooting Hunting
      3. Bleeding the Governor
   3. Engine Adjustments (if an Engine is Available)
      1. Valve Timing
      2. Valve Adjustment
      3. Injection Timing
      4. Fuel Rack
      5. Injector Qualification and inspection
      6. Damper Qualification
      7. Crankshaft End Play
   4. Lube Oil Systems
      1. Operation Of
      2. Oil Usage
      3. Filter Usage
      4. Troubleshooting Low Oil Pressure
      5. Interpreting Lube Oil Analysis
   5. Cooling Systems
      1. Operation Of
      2. Coolant Usage
      3. Components
      4. Troubleshooting Coolant Leaks
9. Air Intake Systems
   1. Blowers
      1. Operation
      2. Troubleshooting
   2. Turbochargers
      1. Operation
      2. Installation and Removal
      3. Differences
   3. Troubleshooting Turbos
      1. Oil Out of the Stack
      2. Foreign Material Damage
      3. Clutch Failures
      4. Overheat - Overspeed
      5. Bearing Failure
      6. Air Box Pressure Irregularities
      7. Surging or Burping Turbos
10. Horsepower Qualification
    1. Horsepower Correction Factors
       1. Air Temperature
       2. Fuel Temperature
       3. Fuel Density
       4. Altitude Correction
    2. Flow Charting Low Horsepower
       1. Fuel Ouailficatlon
       2. Air Pressure Qualification
       3. Compression Qualification

© 1994 Technical Training Consustants, Inc.
All Rights Reserved, Including Right to Presentation!

Top | Back