About This Course

This course is designed to give technicians a clear and practical understanding of modern High-Pressure Common Rail (HPCR) fuel systems - a critical component in today’s diesel engines. Whether you’re new to HPCR systems or looking to reinforce your knowledge, this training will help you develop a strong foundation in both theory and hands-on diagnostics.

You’ll explore the key components and operation of electronically controlled HPCR systems, along with the importance of fuel system cleanliness, safety, and contamination prevention. The course also introduces troubleshooting methods for diagnosing common fuel-related issues, including low fuel rail pressure, and drivability complaints.

The skills and knowledge you gain are directly transferable to real-world scenarios, across a wide variety of makes, models, and industries - giving you the confidence to approach HPCR diagnostics with accuracy and efficiency.

What You Will Learn

  • HPCR Fundamentals

    Gain a clear understanding of how High-Pressure Common Rail systems function within modern diesel engines. You’ll explore both the low- and high-pressure sides of the system, learn how fuel is delivered and regulated, and grasp the theory behind efficient combustion and injection control.

  • Components & Cleanliness

    Get familiar with all major HPCR components, including pumps, injectors, filters, and fuel rails, and how they work together as a system. This section also emphasizes proper handling practices, the importance of fuel cleanliness, and how to prevent contamination-related failures through clean, safe service techniques.

  • Troubleshooting & Safety

    Learn to recognize common HPCR faults such as low fuel rail pressure and drivability complaints. You’ll also cover proper de-pressurization procedures, safe service habits, and step-by-step methods to diagnose issues confidently, preparing you for more advanced HPCR diagnostic courses.

Course Curriculum & Details

    1. High-Pressure Common Rail (HPCR) Defined

    2. High-Pressure Common Rail (HPCR) Breakdown

    3. High-Pressure Common Rail (HPCR) Theory

    4. High-Pressure Common Rail (HPCR) Fueling Example

    5. High-Pressure Common Rail (HPCR) Introduction

    1. Low-Pressure System Overview

    2. Low-Pressure Operating Flow

    3. Fuel Tank

    4. Primary Fuel Filter

    5. Priming Pump Circuit

    6. Priming Cycle Flow

    7. Gear Pump

    8. Secondary Fuel Filter

    9. High Pressure Pump Assembly

    10. Fuel Pump Actuator Housing

    11. Fuel Pump Actuator

    12. Barrel and Plunger Assemblies

    13. High Pressure Pump Flow

    14. Fuel Return Manifold

    15. Low Pressure System Conclusion

    1. High-Pressure System Overview

    2. High-Pressure System Flow

    3. High-Pressure Pump

    4. Fuel Rail Supply Line

    5. Fuel Rail

    6. Fuel Rail Pressure Relief Valve

    7. Fuel Injector Supply Line

    8. High-Pressure Injector Connector

    9. Fuel Injector

    10. High Pressure System Conclusion

    1. Bosch Fuel System

    2. Bosch Fuel Pump Assembly

    1. Component Sensitivity

    2. What is a Micron

    3. Contamination Failure Examples

    4. Plunger Seizure Demonstration

    5. Clean Work Practices

    6. Cleanliness Summary

    1. Safe Service

    2. De-Pressurization

    3. Safety Summary

About this course

  • $149.00
  • 76 lessons
  • 1 hour of video content
  • Certificate Available Upon Completion

Start Learning About HPCR Systems Today

Buy Now - $149

FAQ

  • Who should take this course?

    This course is ideal for entry-level or intermediate diesel technicians who want to build a foundational understanding of HPCR systems before advancing to complex diagnostics.

  • Do I need previous HPCR experience?

    No. This is a basic course designed to introduce the fundamentals of HPCR operation, safety, and troubleshooting.

  • Do I need Cummins INSITE or any other diagnostic software for this course?

    No, this course focuses on understanding HPCR system theory, components, and troubleshooting processes. Diagnostic software is not required, but might be helpful for practical learning and putting the lessons into practice.

  • Is this course applicable to all diesel makes and models?

    Yes. In the course, we do use Bosch systems as an example, but the principles apply to most modern diesel engines that use high-pressure common rail technology.

  • Will I receive a certificate after completion?

    Yes, a certificate is available upon successful completion, confirming your knowledge of HPCR system basics.

  • Can I access the course after completing it?

    Yes. Once purchased, you’ll have lifetime access to all materials, allowing you to review lessons anytime.

  • Are group in-person training options available?

    We have held in-person group training sessions before, but availability changes depending on our capacity. Please reach out to us directly about availability.

Related Courses

  • $349.00

    Cummins HPCR Fuel System Diagnostics Virtual Classroom Training

    Buy Now