Repairing Your Outdoor Power Equipment (Trade)
Part 1 SHOP INFORMATION AND SKILLS 1. Safety and Certification: Terms to Know, Introduction, Small Engines, Safe Work Area, Fire Safety, Personal Protective Equipment, Hand Tool Safety, Power Tool Safety, Cleaning Chemical Safety, Case Study, Engine Operation Safety, Hazard Communication, Small Engine Careers and Certification, Review Questions, Discussion Topics and Activities. 2. Tools: Terms to Know, Introduction, Wrenches, Torque Indicating Wrenches, Case Study, Power Wrenches, Pliers, Screwdrivers, Hammers, Punches, Chisels, Twist Drills, Reamers, Hacksaws, Files, Threading Tools, Pullers, Special Tool Sets, Review Questions, Discussion Topics and Activities. 3. Measuring Tools: Terms to Know, Inch Measuring System, Metric Measuring System, Converting Between Measuring systems, Rule, Feeler Gauge, Outside Micrometer, Case Study, Inside Micrometer, Telescoping Gauge, Small Hole Gauge, Dial Indicator, Review Questions, Discussion Topics and Activities. 4. Measuring Electricity, Pressure, and Vacuum: Terms to Know, Measuring Electricity, Case Study, Measuring Pressure, Measuring Vacuum, Review Questions, Discussion Topics and Activities. 5. Threaded Fasteners: Introduction, Threaded Fasteners, Thread Size and Designation, Fasteners Grade Markings, Case Study, Thread Identification, Thread Repair, Thread Compounds, Review Questions, Discussion Topics and Activities. PHOTO SEQUENCE P1- Using a Tap to Repair a Thread. 6. Non Threaded Fasteners: Terms to Know, Introduction, Keys, Pins, Snap rings, Case Study, Electrical Wire and Electrical Fasteners, Review Questions, Discussion Topics and Activities. 7. Service Information: Terms to Know, Engine Identification, Service Information, Customer Care, Case Study, Review Questions, Discussion Topics and Activities. PART 2 ENGINE OPERATION 8. Four Stroke Engine Operation and Cylinder Block Parts: Terms to Know, Basic Engine Principles, Four Stroke Cycle, Case Study, Multiple Cylinder Four Stroke Engines, Crankcase and Main Bearings, Cylinder and Block, Cylinder Head and Cylinder Head Gasket, Crankshaft, piston, Piston Rings, Connecting Rod, Connecting Rod Bearing, Piston pin, Review Questions, Discussion Topics and Activities. 9. Four Stroke Engine Valve System Parts: Terms to Know, Valve Systems, Valves, Valve Spring and Retainor, Valve Rotator, Valve Seat, Valve Guide, Camshaft, Valve Timing, Case Study, Valve Lifter (Tappet), Push Rod, and Rocker Arm, Valve Clearance, Review Questions, Discussion Topics and Activities. 10. Two Stroke Engine: Terms to Know, Introduction, Basic Parts and Operation, Two Stroke Cycle Engine Port Control, Case Study, Engine Parts, Review Questions, Discussion Topics and Activities. 11. Engine Specifications and Selection: Terms to Know, Internal Engine Size Specifications, Horsepower and Torque, Measuring Horsepower, Engine Efficiency, Engine Selection, Case Study, Review Questions, Discussion Topics and Activities. PART 3 ENGINE SYSTEMS 12. Ignition Systems/Magneto: Terms to Know, Introduction, Electricity, Magnetism, Induction, Armature and Coil, Magnet and Coil Operation, Breaker Point Triggered Magneto Systems, Case Study, Electronically Triggered Magneto Systems, Transistor Triggered Magneto Systems, Battery Ignition, Review Questions, Discussion Topics and Activities. 13. Ignition Systems/High Voltage Components: Terms To know, Spark Plug Wires, Spark Plug, Case Study, Kill (stop) Switch, Safety Interlocks, Review Questions, Discussion Topics and Activities. 14. Fuel System/Fuels, Tanks, and Pumps: Terms to Know, Introduction, Fuels, Case Study, Clean Air Standards, Fuel Tanks, Lines, and Fittings, Fuel Filters, Fuel Pumps, Review Questions, Discussion Topics and Activities. 15. Fuel System/Carburetors and Air Cleaners: Terms to Know, The Carburetor, Vacuum Carburetor, Float Carburetor, Case Study, Diaphragm Carburetor, Suction Feed Diaphragm Carburetor, Automatic Choke, Air Cleaner, Review Questions, Discussion Topics and Activities. 16. Governor and Throttle Control Systems: Terms to Know, Introduction, Manual Throttle Control, Case Study, Governor Throttle Control, Air Vane Governor, Centrifugal governor, Flywheel Brake, Review Questions, Discussion Topics and Activities. 17. Lubrication Systems: Terms to Know, Introduction, Reducing Friction, Engine Oil, Four Stroke Lubricating Systems, Low Oil Level Alert Systems, Crankcase Breather, Case Study, Review Questions, Discussion Topics and Activities. 18. Cooling and Exhaust Systems: Terms to Know, Air Cooling Systems, Liquid Cooling Systems, Exhaust Systems, Review Questions, Discussion Topics and Activities. 19. Manual Starting Systems: Terms to Know, Introduction, Ball Rewind Starter, Case Study, Dog Rewind Starter, Ratchet Recoil Starter, Gear Starter, Windup Spring Starter, Compression Release, Manual Starter Troubleshooting and Service, Review Questions, Discussion Topics and Activities. PHOTO SEQUENCE P2- Removing and Replacing a Starter Rope and Starter Spring. 20. Electrical Starting and Charging Systems: Terms to Know, Electrical Starting Systems, Storage Battery, Starter Motor, Starter Drives, Solenoid, Starter Switch and Wiring, Case Study, Charging System, Review Questions, Discussion Topics and Activities. PART 4 TROUBLESHOOTING, MAINTENANCE, AND TUNE-UP 21. Troubleshooting: Terms to Know, Before You Troubleshoot, Troubleshooting Starting Problems, Case Study, Troubleshooting Engine Performance Problems, Troubleshooting Vibration Problems, Troubleshooting Engine Noises, Troubleshooting Engine Oil Consumption, Troubleshooting Overheating Problems, Review Questions, Discussion topics and Activities. PHOTO SEQUENCE P3 MEASURE ENGINE COMPRESSION 22. Preventative Maintenance: Terms to Know, Introduction, Maintenance Schedules, Engine Oil Maintenance, Cooling System Maintenance, Air Cleaner Maintenance, Valve Clearance Adjustment, Off Season Storage, Battery Maintenance, Case Study, Review Questions, Discussion Topics and Activities. PHOTO SEQUENCE P4 ADJUST OVERHEAD VALVES 23. Ignition Tune-Up: Terms to Know, Introduction, Ignition System Troubleshooting, Spark Plug Service, Flywheel, Magnets, Keys, and Keyway Service, Breaker Points and Condenser Service, Case Study, Timing Adjustment, Magneto Coil and Solid State Trigger Testing, Flywheel Installation and Armature Gap Setting, Review Questions, Discussion Topics and Activities. PHOTO SEQUENCE P5 REMOVE AND REPLACE A SPARK PLUG 24. Fuel System Tune-Up: Terms to Know, Introduction, Troubleshoot The Fuel System, Fuel Tank Service, Fuel Pump Troubleshooting and Service, Case Study, Carburetor Troubleshooting and Service, Vacuum Carburetor Overhaul, Diaphragm Suction Feed Carburetor Overhaul, Float Carburetor Overhaul, Diaphragm Carburetor Overhaul, Carburetor Adjustment, Governor Troubleshooting and Adjustment, Review Questions, Discussion Topics and Activities. PHOTO SEQUENCE P6 ADJUST A CARBURETOR PART 5 ENGINE SERVICE 25. Engine Disassembly and Failure Analysis: Terms to Know, Introduction, Problem History, External Examination, Case Study, Engine Disassembly, Internal Component Failure Analysis, Engine Part Cleaning, Review Questions, Discussion Topics and Activities. 26. Valve Service: Terms to Know, Introduction, Valve, Valve Seat, and Guide Inspection, Measuring Valve Guides, Valve Guide Service, Valve Seat Service, Cylinder Head Inspection, Valve Service, Valve Spring Service, Camshaft and Valve Lifter Service, Setting Non-Adjustable Valve Clearance, Valve Assembly Testing, Case Study, Review Questions, Discussion Topics and Activities. PHOTO SEQUENCE P7 RECONDITIONING VALVE SEATS WITH A VALVE SEAT CUTTER 27. Crankshaft, Connecting Rod, and Bearing Service: Terms to Know, Introduction, Crankshaft Inspection and Measurement, Crankshaft Reconditioning, Connecting Rod Inspection and Measurement, Connecting Rod Bearing Inspection, Case Study, Plain Main Bearing Inspection and Measurement, Plain Main Bearing Reconditioning, Caged Needle, Tapered Roller, and Ball Bearing Service, Review Questions, Discussion Topics and Activities. 28. Cylinder and Piston Service: Terms to Know, Introduction Four Stroke Cylinder Inspection and Measurement, Two Stroke Cylinder Inspection and Measurement, Ridge Removing, Glaze Breaking, Cylinder Resizing, Piston Inspection and Measurement, Fitting a Piston, Case Study, Review Questions, Discussion Topics and Activities. 29. Engine Assembly: Terms to Know, Introduction, Order New Parts, Clean Assembly Area, Installing Valves, Installing Piston on Connecting Rod, Installing Four Stroke Piston Rings, Installing Two Stroke Piston Rings, Installing Four Stroke Crankshaft and Piston Assembly, Case Study, Installing Four Stroke Connecting Rod Cap, Installing Two Stroke Piston, Connecting Rod, and Crankshaft, Installing Camshaft and Valve Lifters, Installing Crankshaft Cover, Final Assembly and Start-up, Review Questions, Discussion Topics and Activities. PART 6 EQUIPMENT OPERATION AND SERVICE 30. Rotary and Reel Walk Behind Mowers: Terms to Know, Introduction, Mower Safety, Rotary Mower Parts and Operation, Case Study, Rotary Mower Troubleshooting, Rotary Mower Service, Reel Mower Parts and Service, Self Propelled Mowers, Belt Inspection and Replacement, Review Questions, Discussion Topics and Activities. PHOTO SEQUENCE P8 SHARPEN AND BALANCE A ROTARY MOWER BLADE 31. Lawn and Garden Tractors: Terms to Know, Introduction, Lawn and Garden Tractor Safety, Case Study, Tractor Parts, Tractor Troubleshooting, Tractor Service, Variable Speed Pulley Tractors, Review Questions, Discussion Topics and Activities. 32. Edgers, Tillers, and Snow Throwers: Terms to Know, Introduction, Edger, Tiller, and Snow Thrower Safety, Case Study, Lawn Edgers, Snow Throwers, Review Questions, Discussion Topics and Activities. PHOTO SEQUENCE P9 REMOVE AND REPLACE AN EDGER BLADE 33. Chain Saws, String Trimmers, and Blowers: Terms to Know, Introduction, Chain saw, String Trimmer, and Blower Safety, Case Study, Chain Saws, String Trimmers, Blowers, Review Questions, Discussion Topics and Activities. PHOTO SEQUENCE P10 REMOVE, REPLACE AND TENSION A CHAIN SAW CHAIN 34. Portable Pumps and Generators: Terms to Know, Introduction, Pump and Generator Safety, Portable P...