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Marine Service TechnologyGrade 10 Curriculum Framework

Upper Cape Cod Technical School

© 2011

Center for Occupational Research and Development (CORD)4901 Bosque Blvd.Waco, TX 76710www.cord.org

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Developed by the Center for Occupational Research and Development

for Upper Cape Cod Technical School

To ask questions or request additional information regarding these materials, please contact:

Holly DoughtyResearch Associate, [email protected]

Bonnie RinardSenior Research Associate, [email protected]

CORD assumes no liability with respect to the use of, or for damages resulting from the use of, any information, apparatus, method, or process described in this publication.

mailto:[email protected]

mailto:[email protected]

Contents

Course Overview..............................................................................................................5

Course Alignment Matrix..................................................................................................7

Course Scope and Sequence........................................................................................15

Occupational Analysis....................................................................................................39

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Course Overview

COURSE PHILOSOPHYUpper Cape Cod Technical School’s marine service technology program teaches students technical level skills that lead to a range of marine technology careers in both the public and private sectors. The field of marine service technology involves many areas of study that include the scientific and technical principles of marine gas and diesel engines and other marine vessel systems including mechanical, electrical and hydraulic systems. Throughout the program at Upper Cape Tech, students work in a marine shop laboratory setting that provides authentic workplace experiences and develops skill sets in the use of technical manuals, tools, and equipment commonly employed in marine service work. Major topics addressed in the program (grades 10–12) include:

Engine performance Engine repair Ignition systems Electrical/electronic systems

Precision measurement Fiberglass repair Refrigeration and cooling Marine and occupational safety

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RELATED BUSINESS AND INDUSTRY EXPECTATIONSThere are a wide variety of career options in marine service technology. Positions range from private repair-related services to parts and supply specialist positions or even management or sales. Students in Upper Cape’s marine service technology program complete laboratory instruction and classroom theory content that supports the potential for matriculation into marine industry related careers or postsecondary education at a technical college. The following organizations provide industry awareness and career exploration resources for marine service technology programs.

Massachusetts Office of Business Development - Maritime Commercehttp://www.mass.gov/?pageID=ehedterminal&L=3&L0=Home&L1=Economic+Analysis&L2=Key+Industries&sid=Ehed&b=terminalcontent&f=mobd_key_industries_maritime_comm_ind&csid=Ehed

Marine and Ocean Technology Network of Massachusettshttp://www.motn.org/

Massachusetts Marine Trades Associationhttp://www.boatma.com/mmtet/index.html

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http://www.boatma.com/mmtet/index.html

http://www.motn.org/

http://www.mass.gov/?pageID=ehedterminal&L=3&L0=Home&L1=Economic+Analysis&L2=Key+Industries&sid=Ehed&b=terminalcontent&f=mobd_key_industries_maritime_comm_ind&csid=Ehed



Course Alignment Matrix

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Marine Service TechnologyStrand 2: Technical Knowledge and Skills

9 10 11 122.A Compare and contrast fasteners.2.A.01c Identify commonly used threaded fasteners. X X2.A.02c Identify SAE bolt head markings. X X2.A.03c Identify metric bolt head markings. X X2.A.04c Identify commonly used nuts. X X2.A.05c Identify commonly used washers. X X2.A.06c Explain the need for flat washers and lock washers. X X2.A.07c Identify and describe machine screws. X X2.A.08c Identify and describe commonly used snap rings. X X2.A.09c Explain the concept of fastener torque. X X2.A.10c Explain how to find fastener torque specifications. X X2.A.11c Explain when to use a general fastener torque chart. X X2.A.12c Explain what torque sequence refers to. X X2.A.13c Describe the various types of torque wrenches. X X2.A.14c Explain the basic rules to follow when using a torque wrench. X X2.B Demonstrate proper measuring procedures.2.B.01c Describe commonly used low precision measuring tools (steel rule, tape

measure, ruler, and combination square).X X

2.B.02c Identify an outside caliper and demonstrate its use. X X2.B.03c Identify and inside caliper and demonstrate its use. X X2.B.04c Identify a feeler gauge and demonstrate its use. X X2.B.05c Identify a hole gauge and demonstrate its use. X X2.B.06c Identify a telescoping/snap gauge and demonstrate its use. X X2.B.07c Identify a vernier caliper and demonstrate its use. X X2.B.08c Identify an outside micrometer and demonstrate its use. X X2.B.09c Identify an inside micrometer and demonstrate its use. X X2.B.10c Identify a depth indicator gauge and demonstrate its use. X X2.B.11c Identify a dial indicator and demonstrate its use. X X2.C Demonstrate the use of hand tools. X X2.C.01c Identify types of screwdrivers. X X2.C.02c Identify types of pliers. X X2.C.03c Identify types of combination wrenches. X X2.C.04c Identify open-end wrenches. X X2.C.05c Identify box-end wrenches. X X2.C.06c Identify types of punches. X X2.C.07c Identify types of chisels. X X2.C.08c Identify types of hammers. X X2.C.09c Identify types of pipe wrenches. X X2.C.10c Identify types of adjustable wrenches. X X2.C.11c Identify types of sockets. X X2.C.12c Identify types of extensions. X X2.C.13c Identify types of torque wrenches. X X

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9 10 11 122.C.14c Identify types of Allen wrenches. X X2.C.15c Identify various types of files. X X2.C.16c Identify types of hacksaws. X X2.C.17c Identify various types of thread cutting taps. X X2.C.18c Identify various types of thread cutting dies. X X2.C.19c Identify a tubing cutter. X X2.C.20c Identify a double flaring tool. X X2.C.21c Identify an ISO flaring tool. X X2.C.22c Identify different types of gasket scrapers. X X2.C.23c Identify types of wire brushes. X X2.C.24c Identify types of bench vises. X X2.D Demonstrate the use of power tools.2.D.01c Drill holes to given specifications using an electric drill. X X2.D.02c Identify types of drill bits. X X2.D.03c Describe the difference in drilling speed for different metals. X X2.D.04c Describe safety procedures to be followed when using an electric drill. X X2.D.05c Identify and explain the purpose of an air impact wrench. X X2.D.06c Identify and explain the purpose of impact sockets. X X2.D.07c Describe maintenance needs of an impact wrench. X X2.D.08c Describe safety procedures to follow when using an air impact wrench. X X2.D.09c Identify and explain the purpose of an electric soldering iron. X X2.D.10c Describe safety procedures to be followed when using an electric soldering

iron.X X

2.D.11c List the type of solder to use when soldering electrical component. X X2.D.12c Identify and explain the purpose of a bench grinder. X X2.D.13c Describe safety procedures to follow when using a bench grinder. X X2.E Demonstrate performance of shop practices to industry standards.2.E.01 Set up and use precision measuring tools. X X X X2.E.02 Identify fasteners by size, type, thread series, thread classes, material hardness

and compatibility. Demonstrate the ability to remove broken fasteners and install helicoils.

X X X

2.E.03 Identify various marine propulsion systems and types of watercraft. X2.E.04 Demonstrate boat hull and engine identification procedures. X2.E.05 Locate, read, interpret and understand parts manuals, microfiche, computer

data, and procuring parts for the system being worked on.X

2.E.06 Write logical and understandable statements or phrases to accurately fill out repair orders/invoices/forms commonly used in the industry.

X

2.F Conduct preventative maintenance.2.F.01 Perform basic outboard inspections correctly. X2.F.02 Perform stern drive systems basic inspections correctly. X2.F.03 Identify and service correctly hull waste systems. X2.F.04 Describe correct winterizing procedures for outboard systems. X2.F.05 Describe correct winterizing procedures for inboard/stern drive systems. X2.F.06 Describe correct winterizing procedures for potable water, waste, and wash

down systems.X

2.F.07 Inspect engine mounts/chocks. X

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9 10 11 122.F.08 Inspect cranking motor mounting bolts. X2.F.09 Service and/or replace spark plugs. X2.F.10 Check and adjust linkage. X2.F.11 Service flame arrestor. X2.F.12 Inspect and replace hoses and connectors. X2.F.13 Inspect, service, and adjust belts. X2.F.14 Remove/inspect and replace hoses and clamps. X2.F.15 Correctly service outboard powerhead systems. X2.F.16 Correctly service inboard powerhead systems. X2.F.17 Demonstrate how to shrinkwrap boats correctly. X2.F.18 Demonstrate how to clean, wax, and buff boats correctly. X2.G Maintain marine fuel and lubrication systems.2.G.01 Explain Coast Guard fuel systems regulations. X2.G.02 Describe marine fuels, engine oils, and their related systems including service

and repair, and mix ratios.X X

2.G.03 Service, repair, troubleshoot, and/or replace fuel and lubrication systems. X X2.G.04 Check fuel leak warning device. X X2.G.05 Remove/repair oil pan and/or gasket (4 cycle). X X2.G.06 Remove/repair oil pump (4 cycle). X X2.H Maintain marine ignition systems.2.H.01 Troubleshoot, service, and repair stern drive/inboard ignition systems. X2.H.02 Troubleshoot, service, and repair outboard CDI ignition systems. X2.H.03 Perform timing and synchronizing using manual. X2.H.04 Repair, service, and bench test distributor. X2.H.05 Check and adjust linkage. X2.H.06 Inspect primary and secondary circuits. X2.H.07 Remove, repair, and test distributors. X2.H.08 Rebuild distributors. X2.H.09 Remove, replace, and check control modules. X2.I Maintain marine electrical systems.2.I.01 Read and interpret Coast Guard wiring codes and regulations. X2.I.02 Read and interpret electrical meters. X2.I.03 Charge, test, and evaluate correctly engine lead-acid batteries. X2.I.04 Read electrical schematics. X2.I.05 Perform tests and service starting systems units. X2.I.06 Test, service, and repair battery. X2.I.07 Test, repair, and replace neutral safety switch. X2.I.08 Test, repair, and replace charging system components. X2.I.09 Install, troubleshoot, service, and repair electrical systems, starting systems,

and marine instrumentation.X

2.J Maintain cooling systems.2.J.01 Illustrate cooling system operations. X2.J.02 Perform proper winterizing procedures on cooling systems. X2.J.03 Diagnose, service, and repair raw water systems. X2.J.04 Diagnose, service, and repair closed water systems. X2.J.05 Troubleshoot, service, and repair correctly outboard, sterndrive, and inboard X

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9 10 11 12cooling and exhaust systems.

2.K Maintain drive systems.2.K.01 Illustrate drive systems and theory of operation for marine applications. X2.K.02 Inspect and service drive train. X2.K.03 Inspect and troubleshoot all drive system component parts. X2.K.04 Inspect, troubleshoot, and service gearcases on marine drive systems. X2.K.05 Check/align engine as required for acceptance of gearcases. X2.K.06 Tune-up stern drive, outboard, and inboard engine systems. X2.K.07 Troubleshoot and repair transom plate systems. X2.K.08 Diagnose, service, repair, and adjust Johnson/Evinrude outboard mechanical

shift lower units.X

2.K.09 Diagnose, service, and repair Johnson/Evinrude outboard shift and throttle systems.

X

2.K.10 Remove, install, and service OMC Cobra sterndrive. X2.K.11 Service/repair OMC Cobra shift and throttle systems. X2.K.12 Service/repair Mercury Outboard lower units. X2.K.13 Service/repair Outboard shift and throttle system. X2.K.14 Demonstrate the removal and installation procedures for MerCruiser

sterndrives.X

2.K.15 Service/repair MerCruiser transom plate, gimble ring, and bell ring. X2.K.16 Service/repair MerCruiser Alpha One gear housings. X2.K.17 Service/repair MerCruiser shift and throttle systems. X2.K.18 Service/repair Volvo SX, SP, and DP sterndrive transom shield. X2.K.19 Service/repair Volvo SP sterndrive upper gear, intermediate, and lower gear

housing.X

2.K.20 Demonstrate the removal and installation procedures for the Volvo sterndrives.

X

2.K.21 Service, repair, and adjust Volvo shift & throttle systems. X2.K.22 Remove/inspect and replace seals. X2.K.23 Inspect/service transom mounts. X2.L Maintain tilt and trim systems.2.L.01 Inspect, test, service, and repair/replace power trim tilt systems, including

midsections and lines.X

2.L.02 Describe how trim systems affect different hull configurations. X2.M Maintain steering systems.2.M.01 Service/repair marine Teleflex style steering systems. X2.M.02 Service/repair marine Hydraulic style steering systems. X2.M.03 Service/repair marine steering accessories. X2.N Overhaul four-stroke cycle engines.2.N.01 Identify characteristics and cycles of the four stroke/cycle engine. X X2.N.02 Disassemble/reassemble a four stroke/cycle engine. X X2.N.03 Diagnose valve and head problems using the compression tester method. X2.N.04 Remove and inspect cylinder head and gasket. X2.N.05 Remove, clean and inspect internal components, connecting rods, pistons,

camshaft, bearings, and crankshaft.X

2.N.06 Inspect and precision measure internal engine components. X X

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9 10 11 122.N.07 Measure bearing surfaces with plastigauge. X2.N.08 Hone and clean cylinders. X2.N.09 Check crankshaft end play for run-out. X2.N.10 Install pistons on piston pins and check alignment; install rings on pistons. X2.N.11 Install oil seals. X2.N.12 Demonstrate overhaul diagnostic and service procedures for four stroke/cycle

engines.X X

2.O Overhaul two-stroke cycle engines.2.O.01 Identify characteristics and cycles of the two-stroke cycle engine. X2.O.02 Diagnose engine combustion chamber problems using the compression tester

method.X

2.O.03 Remove, clean, and inspect cylinder heads for cracks, warped surfaces, and damage to spark plug threads.

X

2.O.04 Disassemble two-stroke cycle engines. X2.O.05 Demonstrate overhaul diagnostic and service procedures for two-stroke cycle

engines.X

2.O.06 Inspect, clean and measure pistons, connecting rods, crankshaft, bearing surfaces, piston pins, and all related components.

X

2.O.07 Measure cylinders for out-of-round, taper, and examine ports. X2.O.08 Hone cylinders. X2.O.09 Inspect and clean intake manifold; check/replace reed valves. X2.O.10 Reassemble engine to factory specifications. X2.P Maintain and repair outboard fuel systems.2.P.01 Remove, disassemble, clean, and rebuild outboard carburetors. X2.P.02 Adjust, synchronize, and lubricate throttle linkages. X2.P.03 Check, inspect, and repair fuel lines, fuel filters, and fuel tanks. X2.P.04 Test, inspect, and repair oil injection systems. X2.P.05 Diagnose, inspect, and repair outboard EFI fuel systems. X2.P.06 Diagnose, inspect, and repair outboard direct fuel injection systems. X2.Q Maintain and repair inboard and stern drive fuel systems.2.Q.01 Maintain, inspect, and repair fuel lines, fuel tanks, and anti-siphon systems. X2.Q.02 Remove, inspect, and repair carburetors. X2.Q.03 Check and adjust carburetor linkages and choke systems. X2.Q.04 Maintain, inspect, and repair EFI throttle body fuel systems. X2.Q.05 Maintain, inspect, and repair multi-port fuel injection systems X

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Course Scope and Sequence

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Program Name: Marine Service Technology Grade Level: 10

Instructor:

Topic/Unit: Marine Services and Boating Concepts Review

Topics MA Frameworks Competencies/Tasks/Skills

Marine Services and Boating Concepts Review

History of Marine Services

Describe the historical development of the marine services trade.

Identify and discuss career opportunities in marine services.

Describe proper work habits and attitudes essential for career success.

Describe the history of the marine services trade.

Describe the role and common tasks of modern marine service technicians.

Describe fundamental employee skills and responsibilities in marine services.

Introductory Marine and Boating Concepts and Procedures

Review basic marine and boating terminology.

Review common boater's language.

Describe common uses of boats, types of boats, hull designs and engine systems.

Describe different vessel characteristics.

Describe boat identification procedures.

Review basic boating concepts and procedures:

General boating equipment

Lines and knots

Boat safety equipment

Boat storage

Boat trailering

Boat launching

Boat docking

Boat handling

Boat anchoring

Boat navigation

2.E.03

2.E.04

Define basic boating terms.

Identify a variety of vessels and watercrafts and describe their common uses.

Identify various marine propulsion systems.

Demonstrate boat hull and engine identification procedures.

Identify and describe federal, state and local marine and boating regulatory agencies.

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Boating laws, rules and regulations

Boating and weather

Boat radio use

Boating problems

Discuss Coast Guard and American Boat Yacht Council Regulations.

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Instructor:

Topic/Unit: Marine and Occupational Safety Review


Marine and Occupational Safety Review

Marine and Boating Safety Fundamentals

Review fundamental marine and boating safety concepts:

Personal flotation device (PFD) use and laws

Vessel safety checklists

Navigation

Communication

Review MA boating safety course content.

Complete MA boating safety course and exam.

Occupational Safety Fundamentals

Identify and describe basic occupational safety precautions and procedures.

Safety color codes

Fire safety

Discuss the importance of maintaining a clean and orderly shop and work area.

Describe safety issues specific to marine services.

Identify and demonstrate basic safety practices followed in the marine services trade.

Describe the roles of OSHA and the EPS in regulating safety procedures for the marine services industry.

Describe safe work habits and procedures specific to marine shop environments.

Demonstrate proper use of shop safety equipment.

Review the proper use of marine shop-specific equipment such as: overhead doors, lifts, etc.

Identify and describe general safety signs and symbols.

Demonstrate safe personal and occupational practices.

Describe basic occupational safety practices.

Describe safety color codes and give examples of their applications.

Describe safety precautions specific to the marine services trade.

Explain the importance of safety in the marine services trade.

Demonstrate ability to locate regulatory information.

Summarize OSHA, MSDS and EPA guidelines that affect the marine services industry.

Demonstrate proper chemical handling, storage and disposal.

20


Identify chemicals that are commonly used in marine service shops.

Demonstrate safe handling, storage and disposal procedures for chemicals.

Explain the purpose of Material Safety Data Sheets (MSDS) and Right to Know Laws.

Describe the importance and proper use of Personal Protective Equipment (PPE).

Explain how to select appropriate PPE for given tasks.

Discuss the importance of following manufacturer’s safety guidelines.

Demonstrate ability to review and understand relevant MSDS information.

Describe the proper use and maintenance of PPE.

Select appropriate PPE for a given task.

Assess a given work area for safety hazards, and provide corrections for identified hazards.

Achieve 100% competency on safety skills test.

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Instructor:

Topic/Unit: Fasteners, Tools and Equipment Review


Fasteners, Tools and Equipment Review

Fasteners

Define fasteners and describe their general uses.

Describe how to identify fasteners by size, type, thread series, thread classes, material hardness and compatibility.

Identify and describe common threaded fasteners and demonstrate proper installation:

Machine screws

Machine bolts

Cap screws

Set screws

Stud bolts

Eye bolts

Anchor bolts

Identify SAE and metric bolt head markings.

Identify and describe common types of nuts and washers used with threaded fasteners.

Describe different uses of flat washers and lock washers.

Identify and describe common nonthreaded fasteners and demonstrate proper installation:

Retainers

Rings

Keys

Pins

Clamps

Rivets

Tie wraps

2.A.01c

2.A.02c

2.A.03c

2.A.04c

2.A.05c

2.A.06c

2.A.07c

2.A.08c

2.A.09c

2.A.10c

2.A.11c

2.A.12c

2.A.13c

2.A.14c

2.E.02

Identify and describe a variety of fasteners.

Identify and describe different types of thread series, classes and grades.

Compare and contrast the different uses and applications of a variety of fasteners.

Compare SAE and metric bolt head markings.

Describe the importance of selecting fasteners that are appropriate for the specific task or application.

Select and install fasteners for a given task.

Select the appropriate washers for use with threaded fasteners.

Describe the primary differences in uses between threaded and nonthreaded fasteners.

Describe the uses of snap rings.

Describe the importance of achieving the correct amount of fastener torque.

Analyze a torque chart for torque specifications.

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Explain the concept of fastener torque.

Explain how to find fastener torque specifications.

Explain when to use a general fastener torque chart.

Explain what torque sequence refers to.

Describe the various types of torque wrenches.

Explain basic torque wrench use procedures.

Demonstrate how to remove broken fasteners and install helicoils.

Hand Tools

Review basic hand tool safety.

Identify common hand tools and demonstrate proper use.

Screwdrivers

Hacksaws

Pipe cutters

Wrenches (combination, open-end, box end, pipe, adjustable, torque, Allen)

Socket wrenches, sockets and extensions

Pliers (slip joint, slip lock, locking)

Hammers (claw, ball-peen)

Punches

Chisels

Files

Thread cutting taps and dies

Tubing cutter

ISO and double flaring tools.

Gasket scrapers

Wire brushes

2.C.01c

2.C.02c

2.C.03c

2.C.04c

2.C.05c

2.C.06c

2.C.07c

2.C.08c

2.C.09c

2.C.10c

2.C.11c

2.C.12c

2.C.13c

2.C.14c

2.C.15c

2.C.16c

2.C.17c

2.C.18c

2.C.19c

2.C.20c

2.C.21c

Properly select hand tools for a given task.

Describe the advantages and disadvantages of using specific hand tools for a given application.

Properly operate hand tools for a given task.

Read, interpret and summarize key points in selected safety/operation manuals for hand tools.

Demonstrate safe hand tool use practices.

Achieve 100% competency on hand tool safety skills test.

Assess hand tool costs, maintenance and storage.

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2.C.22c

2.C.23c

2.C.24c

Power Tools

Review basic power tool safety.

Identify common power tools and demonstrate proper use.

Saws (reciprocating, band, chop, etc.)

Drills (offset, hammer, bits)

Describe safety procedures to be followed when using an electric drill.

Identify types of drill bits.

Drill holes to given specifications using an electric drill.

Describe the difference in drilling speed for different materials.

Identify and explain the purpose and uses of an electric soldering iron.

Describe safety procedures to be followed when using an electric soldering iron.

List the type of solder to use when soldering electrical component.

Identify and explain the purpose of a bench grinder.

Describe safety procedures to follow when using a bench grinder.

Identify and explain the purpose of a variety of cutting power tools.

Describe safety procedures to follow when using cutting power tools.

Identify and explain the purpose of a variety of sanding power tools.

Describe safety procedures to follow when using sanding power tools.

2.D.01c

2.D.02c

2.D.03c

2.D.04c

2.D.05c

2.D.06c

2.D.07c

2.D.08c

2.D.09c

2.D.10c

2.D.11c

2.D.12c

2.D.13c

Properly select power tools for a given task.

Describe the advantages and disadvantages of using specific power tools for a given application.

Properly operate power tools for a given task.

Read, interpret and summarize key points in selected safety/operation manuals for power tools.

Demonstrate safe power tool use practices.

Achieve 100% competency on power tool safety skills test.

Assess power tool costs, maintenance and storage.

24


Identify and explain the purpose of compressed air supply equipment.

Identify and demonstrate the use of a variety of couplers, fittings and hoses.

Identify and explain the purpose of an air impact wrench.

Identify and explain the purpose of impact sockets.

Describe maintenance needs of an impact wrench.

Describe safety procedures to follow when using an air impact wrench.

25


Instructor:

Topic/Unit: Marine Services Fundamentals – Measuring


Marine Services Fundamentals - Measuring

Introduction

Review fundamental measurement concepts:

Units of measurement.

Different systems of measurement.

Common base units and prefixes.

Accuracy and tolerance.

Identify and demonstrate fluid volume measurement devices and techniques.

Identify and describe temperature measurement devices and techniques.

Discuss the use of pressure and vacuum measuring devices.

Discuss safety guidelines that pertain to measurement devices and procedures.

Describe the different systems of measurement.

Explain the importance of accurate measurements and acceptable tolerance levels.

Measuring Tools and Procedures

Identify and demonstrate proper use of low precision measuring tools:

Steel rule

Tape measure

Ruler

Combination square

Identify and demonstrate proper use of high precision measuring tools:

Outside caliper

Inside caliper

Dial caliper

Vernier caliper

Feeler gauge

2.B.01c

2.B.02c

2.B.03c

2.B.04c

2.B.05c

2.B.06c

2.B.07c

2.B.08c

2.B.09c

2.B.10c

2.B.11c

2.E.01

Demonstrate the appropriate use of measuring tools common to marine services.

Describe the advantages and disadvantages of using specific measuring devices for a given application.

Determine precision measurements using precision devices.

Measure valve clearance with feeler gauge.

26


Hole gauge

Dial bore gauge

Plastigauge

Telescoping/snap gauge

Outside micrometer

Inside micrometer

Depth indicator gauge

Dial indicator

27


Instructor:

Topic/Unit: Welding Fundamentals

Topics MA Frameworks

Competencies/Tasks/Skills

Welding Fundamentals

Welding Equipment and Use

Discuss the use of welding in marine services.

Describe safety practices specific to welding activities.

Review fundamental oxyacetylene and MIG welding equipment and associated procedures and concepts.

Identify weldable and non-weldable materials used in marine services.

Explain how to select the correct welder type, electrode, wire type, diameter, and gas to be used in different welding situations.

Demonstrate basic welding equipment maintenance procedures.

Explain how to store, handle, and install high-pressure gas cylinders used for welding applications.

Explain the uses and applications of welding in marine services.

Describe safety procedures that should be followed during welding activities.

Pass required safety tests.

Explain the uses and applications of different types of welders, electrodes, and wire types.

Describe and perform basic maintenance procedures on welding equipment.

Welding Preparation

Demonstrate how to set up welding equipment.

Demonstrate how to adjust the welder to calibrate desired electrode stick-out, voltage, polarity, flow-rate, and wire-feed required for a variety of materials that may be welded.

Demonstrate how to determine safe work clamp (ground) locations and attachments.

Demonstrate how to clean and prepare metal to be welded, including assuring good metal fit-up, applying weld-through primer if necessary, and clamping as required.

Demonstrate how to set up and calibrate a welder for different applications.

Explain the importance of proper clamping and grounding.

Demonstrate proper metal prep for welding.

28



Welding – Types of Joints and Welds

Explain how to determine the joint type (butt weld with backing, lap, etc.), for specific welding operations.

Explain how to determine the type of weld (continuous, butt weld with backing plug, etc.) for specific welding operations.

Describe and demonstrate the following welds: continuous, stitch, tack, plug, butt-weld with backing, and lap joints.

Demonstrate how to weld high-strength steel and other metals.

Demonstrate how to weld in the flat, horizontal, vertical, and overhead positions using the proper angle of the gun to the joint and direction of gun travel.

Describe the equipment required for aluminum MIG welding.

Demonstrate aluminum MIG welding methods.

Select appropriate joint types for a specific welding task.

Select appropriate weld types for a specific welding task.

Identify elements of a quality weld.

Perform a variety of welds.

Perform welding on a variety of materials

Explain the differences in equipment and materials required for aluminum MIG welding.

Demonstrate compliance with personal safety practices associated with welding.

Welding Troubleshooting

Explain the causes of splits and sputters, burnthrough, lack of penetration, porosity, incomplete fusion, excessive spatter, distortion and waviness of bead.

Explain causes of contact tip burn-back and failure of wire to feed.

Explain how to make adjustments in techniques, equipment and materials to prevent welding problems.

Describe common welding problems and their causes.

Diagnose welding problems and make the necessary method, equipment, or material adjustments.

29


Instructor:

Topic/Unit: Metal Fabrication Fundamentals



Metal Fabrication Fundamentals

Introduction

Describe the basic functions of metal fabrication in the marine services industry.

Describe different ways that metal can be identified:

Chemical composition

Mechanical properties

Fabrication ability

Discuss ferrous versus non-ferrous metals and their different applications.

Identify metals used in marine construction and repair.

Demonstrate and describe safety practices specific to metal fabrication activities.

Identify and demonstrate proper use of basic metal fabrication tools and equipment:

Grinders

Routers

Belt sanders

Band saw

Drill press

Explain the uses and applications of metal fabrication in marine services.

Identify and compare types of metals used for marine applications.

Describe safety procedures that should be followed during metal fabrication activities.

Pass required safety tests.

Demonstrate proper use of a variety of basic metalworking equipment.

Cutting Metal

Demonstrate how to measure and mark metal stock.

Demonstrate how to determine drill size and type, cutting speed and necessary cutting lubricants.

Describe and demonstrate procedures for cold cutting round and flat metal.

Identify different types of metal cutting equipment used in marine services.

Describe cold and hot methods for metal cutting.

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Identify equipment used for cutting different metals.

Demonstrate the use of metal cutting tools and equipment:

Hacksaws

Files

Chisels

Grinders

Describe and demonstrate procedures for “hot work” cutting procedures.

Describe the components of oxyacetylene torches and plasma cutting equipment.

Demonstrate how to set up and calibrate oxyacetylene torches and plasma cutting equipment.

Demonstrate the use of oxyacetylene torches and plasma cutting equipment.

Demonstrate proper metal prep for cold and hot metal cutting.

Demonstrate the use of cold metal cutting tools and equipment.

Demonstrate metal cutting on a variety of metals.

Demonstrate how to set up and calibrate oxyacetylene torches and plasma cutting equipment for different applications.

Demonstrate compliance with personal safety practices associated with metal cutting and metal working.

Additional Metal Fabrication Processes

Describe and demonstrate the proper use of the following machining equipment:

Milling machine

Metal lathes

Describe and demonstrate the following metalworking procedures:

Bending flat and round metal

Twisting metal

Drilling holes in metal

Taping and threading metal

Fastening, bolting and riveting metal

Soldering metal

Perform metal fabrication processes using a variety of equipment.

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Instructor:

Topic/Unit: Marine Electrical Systems


Marine Electrical Systems

Introduction

Introduce the basic principles and operation of marine electrical systems.

Discuss American Boat and Yacht Club (ABYC) wiring guidelines.

Identify safety practices and procedures specific to electrical system tasks.

Review basic electrical theory and concepts:

Voltage

Current

Resistance

Voltage drop

Discuss the cause and effect relationship in Ohm’s law between voltage, current, resistance and voltage drop.

Demonstrate how to interpret schematics, diagrams, and reference information for electrical systems.

Demonstrate how to read and interpret Coast Guard wiring codes and regulations.

2.I.01

2.I.02

2.I.04

Demonstrate safe practices while conducting electrical tasks.

Describe the role of the ABYC in creating electrical standards for marine vessels.

Describe the applications of Ohm’s law to charging and electrical systems.

Interpret wiring diagrams.

Analyze and extract information from service manuals, and other information resources.

Describe how Coast Guard wiring codes and regulations effect the installation and service of marine electrical systems.

Electrical System Analysis, Diagnosis and Service

Demonstrate how to analyze the function and operation of electrical systems.

Demonstrate how to troubleshoot and diagnose electrical system problems.

Demonstrate how to use strategy-based diagnostics for determining the cause of a fault in an electrical circuit.

Check electrical circuits using a variety of tools and

2.I.02

2.I.03

2.I.05

2.I.06

2.I.07

2.I.08

Demonstrate how to install, troubleshoot, service, and repair electrical systems, starting systems, and marine instrumentation.

Demonstrate the use of diagnostic equipment for electrical systems.

Diagnose battery problems and perform corrective service.

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techniques:

Test light

Scan tool

Digital multimeter

Jumper wires

Ammeter

Voltmeter

Oscilloscope

Ohmmeter

Describe the function and operation of batteries.

Demonstrate how to test, diagnose and service batteries.

Describe the function and operation of lighting systems.

Demonstrate how to test, diagnose and service light systems.

Demonstrate how to solder electrical wiring.

Demonstrate how to repair wire harnesses and connectors.

Describe the function and operation of computer chips in electrical systems.

Describe the function and operation of gauges and electronic instrument panels and accessories.

Demonstrate how to test, diagnose and service electronic instrument panel systems.

Demonstrate how to test and service starting systems units.

Demonstrate how to test, repair, and replace neutral safety switch.

Demonstrate how to test, repair, and replace charging system components.

2.I.09

Charge, test, and evaluate lead-acid batteries.

Test light system components.

Identify lighting system switches.

Test and replace fuses.

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Instructor:

Topic/Unit: Marine Ignition Systems



Marine Ignition Systems

Introduction

Introduce the basic principles and operation of marine ignition systems.

Describe the function and general operation of ignition system components.

Analyze the operation of distributor and distributorless ignition systems and components.

Describe the function and operation of ignition systems.

Identify and describe the function of ignition system components.

Ignition System Analysis, Diagnosis and Service

Demonstrate how to analyze the function and operation of ignition systems.

Demonstrate how to troubleshoot and diagnose ignition system problems.

Demonstrate how to perform ignition system service:

Perform ignition current draw tests and determine corrective action.

Perform ignition circuit voltage drop tests and determine corrective action.

Inspect starter relays and solenoids and determine necessary action.

Replace starter relays and solenoids.

Inspect and set ignition timing.

Remove, repair or install switches, connectors, and wires of ignition control circuits.

Check and adjust linkages.

Repair, service, and bench test distributor.

Test, remove, repair, and rebuild distributors.

2.H.01

2.H.02

2.H.03

2.H.04

2.H.05

2.H.06

2.H.07

2.H.08

2.H.09

Troubleshoot, service, and repair stern drive/inboard and outboard CDI ignition systems.

Test ignition electrical circuits.

Inspect primary and secondary circuits.

Perform timing and synchronizing.

Inspect, repair and replace primary ignition digital analog switch and secondary ignition.

Inspect, repair, and replace CAM sensor.

Inspect, repair and replace crank sensors.

Disassemble, clean, inspect and test starter components.

Replace starter components.

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Remove, replace, and check control modules.

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Instructor:

Topic/Unit: Introduction to Blueprint Reading



Introduction to Blueprint Reading

Drawing Basics

Define the terms: blueprint, prints, working drawings, assembly drawings, presentation drawings, sketches, as built drawings, record drawings.

Define basic blueprint terminology.

Basic Print Components

Explain the basic layout of technical drawing and a set of prints as well as the importance of the accompanying job specifications document.

Identify and describe the different components of a set of prints. (Plot, foundation, floor, elevation, detail, electrical, HVAC, plumbing.)

Identify and describe basic print terms, abbreviations, line types, symbols and notes.

Describe different types of drawings and their purpose: pictorial, schematic, orthographic.

Describe the different components present in technical drawings.

Identify and explain the symbols used in technical drawings.

Identify different types of drawings and explain how they are used to provide different information.

Print Reading

Explain concepts fundamental to reading technical drawings and sets of prints.

Demonstrate how to interpret and follow scales.

Demonstrate how to interpret and follow drawing dimensions.

Explain how to determine true measurements from a print using an architect’s scale.

Demonstrate how to read and interpret plan, elevation, section and detail views and schedules.

Explain how to identify, develop and complete

Read and interpret schematic drawings.

Calculate measurements and complete drawings using an architect’s scale.

Calculate, measure and draw lines to scale.

Complete a material takeoff sheet from a set of prints.

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material quantity takeoff sheets.

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Instructor:

Topic/Unit: Introduction to Computer-Aided Design (CAD)



Introduction to Computer-Aided Design (CAD)

CAD Fundamentals

Define computer aided design (CAD).

Describe how CAD is used in marine services.

Discuss the impact that CAD can have on construction and engineering projects (manual vs. computer drafting, saves time, can store more information on a computer, can make corrections easier on a computer).

Identify and describe the hardware and software used for CAD.

Demonstrate how to log in/start a drawing session.

Demonstrate how to perform basic program navigation.

Demonstrate how to manage files and print drawings.

Define computer-aided design.

Describe the advantages and disadvantages of CAD.

Identify ways that CAD can be used in marine services.

Drawing Lines and Objects in AutoCAD

Explain the Cartesian coordinate system.

Demonstrate how to set drawing units, drafting settings, and layers.

Identify and describe the purposes of the toolbars and buttons.

Discuss the three main ways to draw in AutoCAD:

Using the tool bars

Typing commands in the command line

Looking up commands under the main menu

Demonstrate how to draw lines using the following options:

Describe the different AutoCAD toolbars and buttons and how to use them.

Draw lines in AutoCAD using different methods and options.

Create basic shapes in AutoCAD.

Demonstrate the use of commands from AutoCAD toolbars.

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Hidden or visible lines

Absolute, relative and polar coordinates

Demonstrate how to create basic geometric drawing objects:

Circles

Arcs

Polygons

Rectangles

Ellipses

Demonstrate how to use commands from the following toolbars:

Draw toolbar

Modify toolbar

Zoom and pan

Dimension toolbar

Inquiry toolbar

Object snap toolbar

Editing and Viewing Objects in AutoCAD

Demonstrate how to use the following editing commands:

Erase

Redraw

Oops

Redo

Undo

Copy

Rotate

Move

Mirror

Demonstrate the use of AutoCAD editing commands.

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Scales, Dimensioning, and Adding Text in AutoCAD

Define AutoCAD scales, drawing units, and unit precision.

Discuss AutoCAD dimensioning.

Demonstrate how to add text to AutoCAD drawings.

Demonstrate how to add hatching to an AutoCAD drawing.

Modify an AutoCAD drawing using different scales, drawing units, and unit precision.

Perform radial, angular, and linear AutoCad dimensioning commands on AutoCAD drawings.

Add text to an AutoCAD drawing using the text, Mtext, Dtext, and style commands.

Add hatching to an AutoCAD drawing using the hatch command.

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Occupational Analysis

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· web viewcompare sae and metric bolt head markings. describe the importance of selecting...

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