Heavy vehicle mechanic training

Lesson 1 • Workshop Safety and Hazard Control

Introduces personal protective equipment, chemical handling, and shop hazard identification. Safety habits established here apply to every subsequent practical task.

Lesson 2 • Tools, Equipment, and Measuring Instruments

Identifies hand tools, power tools, and precision measuring instruments used in heavy vehicle repair. Correct tool selection reduces errors in all later diagnostic and repair tasks.

Lesson 3 • Heavy Vehicle Classifications and Uses

Covers truck, bus, and specialty vehicle categories by gross weight and application. Establishes vocabulary used throughout the entire program.

Lesson 4 • Reading Technical Documentation

Teaches interpretation of service manuals, wiring diagrams, and parts catalogs. Accurate documentation reading is prerequisite to every diagnostic procedure in the course.

Lesson 1 • Lubrication System Operation

Explains oil pump types, pressure regulation, and filtration circuits. Proper lubrication system knowledge prevents premature wear in all engine overhaul work.

Lesson 2 • Engine Block and Cylinder Head Components

Details block construction, cylinder liners, head gaskets, and valve train geometry. Component knowledge enables accurate measurement and clearance setting in later sections.

Lesson 3 • Cooling System Components and Function

Covers coolant flow paths, thermostat operation, and radiator design in heavy diesel engines. Thermal management skills here support turbocharger and aftertreatment work ahead.

Lesson 4 • Diesel Combustion Principles

Explains compression ignition, air-fuel ratios, and combustion chamber design. This thermodynamic foundation supports all engine diagnosis covered later in the chapter.

Lesson 1 • Air Filtration and Intake Restriction

Explains air filter types, restriction indicators, and intake manifold inspection. Adequate air supply is essential for combustion efficiency and injector longevity.

Lesson 2 • Fuel Storage and Transfer Systems

Covers tank construction, fuel lines, lift pumps, and primary filtration. Clean fuel delivery is the prerequisite for accurate injection system diagnosis.

Lesson 3 • Mechanical Injection Pump Systems

Explains inline and rotary pump operation, timing, and governor function. Understanding mechanical systems provides context for diagnosing modern electronic replacements.

Lesson 4 • Turbocharging and Intercooling

Covers turbocharger construction, variable geometry vanes, and charge air cooling. Boost pressure management directly affects power output and emissions compliance.

Lesson 1 • Batteries and Charging Systems

Covers battery types, state-of-charge testing, and alternator output diagnosis. Reliable electrical supply is the foundation for all electronic control system operation.

Lesson 2 • Electronic Control Module Diagnostics

Teaches fault code retrieval, freeze frame analysis, and module programming basics. Students apply scan tool data to confirm or rule out component faults systematically.

Lesson 3 • Sensors, Actuators, and Data Networks

Covers sensor signal types, actuator control strategies, and CAN bus communication. Network knowledge is essential for interpreting scan tool data in the next section.

Lesson 4 • Starting Systems and Cranking Circuits

Explains starter motor types, solenoid operation, and voltage drop testing. Cranking system faults are among the most common heavy vehicle service calls.

Lesson 1 • Drive Axles and Differentials

Covers axle shaft types, differential gear sets, and inter-axle differential lock operation. Tandem axle configurations common in heavy trucks require specific service knowledge.

Lesson 2 • Driveshafts and Universal Joints

Details driveshaft angles, universal joint wear, and slip yoke lubrication. Incorrect driveline angles cause vibration that damages transmission and axle components.

Lesson 3 • Clutch Systems and Adjustment

Covers single and twin-plate clutch designs, release mechanisms, and free-play adjustment. Correct clutch setup prevents premature wear and transmission damage.

Lesson 4 • Manual Transmission Operation and Service

Explains gear synchronization, range and splitter sections, and shift linkage adjustment. Heavy-duty manual transmissions require precise setup for reliable gear engagement.

Lesson 1 • Retarders and Auxiliary Braking

Explains engine brakes, exhaust brakes, and hydraulic retarder operation. Auxiliary braking reduces foundation brake wear on long downhill grades.

Lesson 2 • Foundation Brake Components

Covers S-cam drum brakes, disc brake calipers, and lining wear measurement. Foundation brake condition directly determines stopping distance and vehicle safety.

Lesson 3 • Brake Valves and Control Circuits

Details foot valve, relay valve, and quick-release valve operation in air circuits. Valve function knowledge enables accurate pressure testing and fault isolation.

Lesson 4 • Air Brake System Fundamentals

Explains compressor operation, air dryer function, and reservoir circuit layout. Air brake knowledge is mandatory for safe operation and legal compliance of heavy vehicles.

Lesson 1 • Wheel Alignment and Axle Geometry

Teaches camber, caster, toe, and thrust angle measurement using alignment equipment. Correct geometry reduces tire wear and improves fuel efficiency significantly.

Lesson 2 • Front Suspension Systems

Covers leaf spring, air spring, and independent front suspension designs used on heavy vehicles. Suspension geometry affects tire wear and steering response in all operating conditions.

Lesson 3 • Steering System Components and Service

Covers recirculating ball steering gear, power steering pump, and tie rod end inspection. Steering system integrity is a primary safety requirement for heavy vehicle operation.

Lesson 4 • Rear Suspension and Load Management

Explains walking beam, air ride, and tag axle suspension systems. Load distribution knowledge is essential for legal axle weight compliance and tire longevity.

Lesson 1 • Roadworthiness Inspection and Compliance

Teaches pre-trip inspection procedures, defect categorization, and out-of-service criteria. Compliance inspection skills ensure vehicles meet mandatory roadworthiness standards.

Lesson 2 • Advanced Engine Performance Diagnosis

Applies cylinder contribution testing, fuel trim analysis, and compression testing to complex engine faults. These techniques integrate fuel, air, and electronic knowledge from prior chapters.

Lesson 3 • Systematic Diagnostic Methodology

Teaches a structured six-step diagnostic process integrating symptom analysis, test planning, and verification. Systematic methods reduce misdiagnosis and unnecessary parts replacement.

Lesson 4 • Diesel Emissions Control Systems

Covers EGR, diesel particulate filter, and selective catalytic reduction system operation. Emissions system knowledge is required for compliance with current environmental standards.