Mechanics (Understanding And Working With Machines) 100 Hours Certificate Course

1 Introductory Mechanics

• Introduction
• Power Sources
• Engines
• Steam Engines
• Petrol Engine
• How an Engine Works
• The Operating Cycle
• Stages in a Four Stroke Spark Ignition Engine Cycle
• Stages in a Two Stroke Spark Ignition Engine Cycle
• Electric Motors
• Parts of an Electric Motor
• Types of Electric Motors
• Comparison of Electric and Petrol Engines
• Applied Tasks: Changing a Wheel, Mending a Puncture

2 Engine Features

• Measurements and Mechanical Principles: Force, Load, Pressure, Relationships in Pressure Measurements, Absolute Pressure, Force of Gravity, Centre of Gravity, Specific Gravity (Specific Weight), Density, Volumetric Efficiency, Vacuum, Work, Power, Energy, Bore, Piston Displacement, Compression Ratio (CR)
• How to Convert Imperial Measurements into Metric
• Engine Efficiency: How Does an Engine lose Power?
• Features of Electric Motors
• Applied Tasks: Spark Plugs, Checking for fouling and damage/ reading the spark plug

3 Machines and their Parts

• Parts of a Machine: Engine Systems, Lubrication System, Transmission System, Cooling System, Fuel System, Transmission System, Gearbox (transmission), Clutch (torque converter), Differential, Prop shaft/ drive shaft
• Power Source and Ignition: The Ignition System, Distributor, Coil pack
• Other Machines: Outdoor Multi Tools, Domestic Maintenance Equipment, Kitchen Equipment

4 Drive Mechanisms

• Introduction
• Cog Drive Machinery
• Belt Drive Machinery
• Transmission Drive Machinery
• The Transmission System
• Applied Tasks: Replacing Drive Belts

5 Managing Machinery Deterioration

• The Lubrication System
• The Cooling System
• Lubrication: Oil Viscosity, Delivering the Lubricant, Splash System, Pressure System, Combination Pressure and Splash
• Types of Lubrication Pumps
• Types of Filter Systems
• Materials Deterioation
• Metals - Ferrous: (Iron) Materials, Steels, Heat Treatments, Aluminium, Copper, Lead, Zinc, Tin, Nickel
• Non-Ferrous Alloys: Brass, Bronze, White Metal, Solder
• Seals
• Servicing Filters: Air Filters, Oil filters, Fuel Filters
• Servicing the Filters: Air Filters

6 Optimizing Machine Operation (Getting the most from Machines)

• Introduction: Adjustments, Controlling Power, Carburettors (for petrol engines), Types of Carburettors, How a Carburettor Controls the Fuel Mix, Number of Barrels
• Lubrication
• Exhaust Systems: Catalytic Converter, Muffler, Extractors
• Turbochargers: Intercooling, Wastegate, Blow off valves, Twin vs single turbo, Boost controller
• Superchargers: Temperature effects
• Applied Tasks: Servicing a Carburettor

7 Brake Systems

• Introduction
• Drum vs Disc Brakes
• Drum Brakes and Shoe (Pad)
• Disc Brakes
• Brake Systems –Pneumatic
• Hydraulic and Electric Brakes
• ABS (Anti-lock Brake System)
• Regenerative braking
• Applied Tasks: Servicing Brakes, Jacking up the vehicle to change or service brakes, Changing Disk Brakes, Changing Drum Brakes, Motorcycle Brakes, Push Bike Brakes

8 The Machine Workshop

• Introduction
• Tool Maintenance
• Work Bench
• Vices and Clamps
• Lifts, Ramps, Jacks, Ladders
• Tightening Pullers
• Pulleys
• Winches
• Generators, Battery Chargers
• Cleaning Equipment
• Grinders, Sharpening Equipment
• Work Pits and Hoists
• Measuring Equipment
• Spanners and Allen Keys
• How to Use Spanners
• Pliers and Grips
• Screwdrivers
• Files
• Cutting Equipment
• Hammers, Chisels and Punches
• Tap and Die Cutters
• Lubrication Equipment
• Drills
• Saws
• Soldering
• Welding: Oxy-fuel welding, Shielded metal arc welding (SMAW), Gas tungsten arc welding (GTAW), Gas metal arc welding (GMAW), Flux-cored arc welding (FCAW), Submerged arc welding (SAW), Electroslag welding (ESW), Electric resistance welding (ERW)

9 Machine Maintenance and Repair

• Introduction
• Servicing a Typical Motor Car
• Inspect Oil levels/Engine/transmission – Change oil filter, fuel filter
• Changing spark plugs/ cleaning / gapping resizing /Installing
• Inspect Coolant levels
• Inspect tyre pressure/tread condition (should be done regularly if not every 6 months)
• Change Fuel Filter
• Check brakes – brake fluid
• Wheel Alignment
• Power steering fluid
• Electrics – indicators, brake lights, headlights, windscreen wipers and fluid, hazard lights, horn
• Replacing light bulbs
• Servicing Garden Equipment
• Oil
• Dirty Spark Plugs
• Mowers
• Changing Mower Blades
• Chainsaws
• Outdoor Electric Machines
• Treating Rust
• Painting Metal