🎯 Course Description:
This comprehensive 5-day course equips participants with the knowledge and practical skills necessary to operate, inspect, troubleshoot, and maintain heavy diesel-powered equipment such as loaders, excavators, bulldozers, graders, dump trucks, and cranes.
The course combines mechanical theory, diesel engine fundamentals, hydraulic systems, electrical components, and preventive maintenance practices to maximize equipment reliability and reduce unplanned downtime. Emphasis is placed on operator safety, fluid management, diagnostic techniques, and OEM-compliant maintenance procedures.
👥 Who Should Attend:
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Heavy equipment operators
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Diesel mechanics and maintenance technicians
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Fleet and equipment supervisors
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Site engineers and maintenance planners
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Safety and reliability personnel
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New hires working with off-road mobile machinery
🗓️ Day 1: Introduction to Heavy Diesel Equipment and Systems
| Time | Topic |
|---|---|
| 08:30 – 09:00 | Welcome, Course Overview, Participant Introductions |
| 09:00 – 10:30 | Types of Heavy Equipment and Applications – Mining, construction, logistics |
| 10:30 – 10:45 | ☕ Coffee Break |
| 10:45 – 12:15 | Diesel Engine Fundamentals – 4-stroke cycle, air/fuel, powertrain |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Basic Systems Overview – Powertrain, hydraulics, electrical |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Identifying system components on actual/heavy equipment diagrams |
🗓️ Day 2: Diesel Engines and Powertrain Maintenance
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Engine Lubrication and Cooling Systems – Fluids, filters, maintenance |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Fuel System and Air Intake Maintenance – Filters, turbochargers |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Transmission and Drivetrain Systems – Manual, automatic, final drives |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Diesel engine inspection and maintenance checklist review |
🗓️ Day 3: Hydraulics, Electrical Systems, and Controls
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Hydraulic System Principles – Pumps, valves, hoses, fluid power |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Hydraulic System Maintenance and Troubleshooting |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Electrical Systems in Heavy Equipment – Alternators, starters, wiring |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Interpreting schematics and locating faults |
🗓️ Day 4: Maintenance Strategies and Diagnostics
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Preventive and Predictive Maintenance – OEM intervals, checklists |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Common Failures and Root Cause Analysis – Leaks, overheating, misalignment |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 02:45 | Diagnostic Tools and Techniques – Fault codes, sensors, OBD, CAN bus |
| 02:45 – 03:00 | ☕ Coffee Break |
| 03:00 – 04:30 | Workshop: Troubleshooting scenario using diagnostic procedures |
🗓️ Day 5: Equipment Operation, Safety, and Best Practices
| Time | Topic |
|---|---|
| 08:30 – 10:00 | Safe Operation Practices – Operator pre-checks, SOPs, stability risks |
| 10:00 – 10:15 | ☕ Coffee Break |
| 10:15 – 12:15 | Equipment Walkaround and Operator Inspection Routine |
| 12:15 – 01:15 | 🍽 Lunch Break |
| 01:15 – 03:00 | Group Exercise: Maintenance and inspection plan for selected equipment |
| 03:00 – 03:15 | ☕ Coffee Break |
| 03:15 – 04:30 | Final Q&A, Feedback, Course Wrap-Up & Certificates |
📂 Course Materials Provided:
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Heavy equipment maintenance manual (diesel-specific)
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Daily/weekly/monthly inspection checklist templates
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Hydraulic and electrical schematics for practice
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Engine troubleshooting and diagnostic flowcharts
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Safety procedure handbook for heavy equipment operation
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Maintenance log templates and service records
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Case studies from mining, construction, and transport industries
