Institute of Applied Agriculture INAG 207: Power and Machinery Syllabus: Spring 2008 Instructor: Roy S. Walls, Jr. Office hours: By appointment - 301-405-7256 Office: 1451 ANSC/AgEngr. Building FAX: 301-314-9023 Email: rwalls@umd.edu Three credits, Spring Semester only Lecture: Tuesday & Thursday - 11:00-11:50 a.m. Lab: Monday - 3:00 - 4:50 p.m. (ANSC 0504) Topic Index Course Description General Course Objectives             Textbook and Materials: Required Course Requirements:  Course Content: Behavioral Objectives: Course Description: The basic principles of compact equipment management, including selection, maintenance, operation, adjustment and troubleshooting of agricultural machinery and power units will be studied. The methods of power development, measurement, transmission through power trains both mechanical and hydraulic will be studied. A systematic disassembly, analysis, diagnosis and reassembly of a small engine will be completed by each student. Prerequisite Course(s) Required: ENBE 200: Fundamentals of Agricultural Mechanics, INAG 101: Computer Applications or suitable courses General Course Objectives:  Develop the ability of the student to understand how power units function and convert energy into productive work Develop the ability of the student to select, operate, service, adjust, and maintain the machines of agriculture, Develop the ability to calculate the cost of operating a machine through its useful life Develop an understanding of and appreciation for safe practices in working with power units and machines. Utilize electronic communications media to enhance education in power and machinery. Textbook and Materials: Required Small Engines, 2nd Edition: Radcliff, R. Bruce, Roark, Dann L., American Technical Publishers, 2004. HYDRAULICS: Compact Equipment: John Deere & Co. Briggs & Stratton Single Cylinder "L" Head Repair Instructions, Briggs &Stratton Part # 270962 (12/00 or later) (Available from your local Briggs and Stratton Dealer Course Requirements: Students must be present at the designated time and for the duration of class. Students are responsible for all materials presented in class in addition to the reading assignments. Instructions, announcements about course changes and demonstrations will be given at the beginning of each class as appropriate. Be there! Students are expected to be in class for the scheduled time. DO NOT obligate yourself for activities (work, social, medical non-emergencies) that conflict with scheduled class time. Make up of class assignments will be based of a valid University excuse. Sickness counts here, but not much else. Several labs do not have the opportunity to be made up. Do not miss lab! There is no make up opportunity for several of them. Students will have electronic or on line assignments. You must have a working WAM account, access to the internet, working knowledge of word processing, spreadsheet software, and browser and networking software. An alternate email address may also be desirable. Proper safety clothing/attire is required for lab exercises. This includes safety glasses or goggles meeting OSHA Z87 or OSHA Z87.1 specifications, appropriate safe clothing and hard top shoes. Open toe footware is not allowed in the lab!   Two exams (mid term and final) will be announced. Quizzes may or may not be announced. Material included may be from current lectures or current class assignments (readings, video, electronic communications, etc.)   A calculator may be used for the completion of any math problems, but full credit will only be given when the total solution is shown. (Always show problem solving procedure for all problems!) Written assignments or exercises may include but are not limited to: laboratory reports, lab manual (disassembly of engine) homework problems, spreadsheet excerises questions and answers on reference and text materials development of Powerpoint presentations Calculation of your final grade: 40% lab work 15% midterm exam 15% final exam 15% written activities (quizzes, out of class assignments) 15% term project Course letter grades will be assigned on the following basis: A - 90% or more B - 80% or more C - 70% or more D - 60% or more F - less than 60% Current grades will be continually posted during the semester via computer generated report. Students are expected to turn materials/assignments in on time. Unexcused late materials will loose 10% of assigned points per normal week day late. Late assignments will not be accepted after those that have been graded have been returned to students. All assignments must be completed by the last day of class.   Academic dishonesty (cheating, fabrication, facilitating academic dishonesty, plagiarism) will be dealt with in accordance with established University policies. Students are expected to abide by honor code(s). Projected Hours  Course Content: Lecture Lab I. Introduction to Power and Machinery 1   II. Power and Its Measurement A. Horsepower and its measurement B. Horsepower as a diagnostic tool 2 2 III.Economics of Machinery A. Fixed Costs and Operating Costs B. Calculating Projected Machinery Costs 2 2 III. Compact Engine Systems A. Operating Principles: Gasoline, Diesel, LP, Rotary Engines B. Four and Two Stroke Cycle Theory C. Compression Systems and Components a. Valve Train Parts, Function, Service b. Piston Assembly, Parts, Service c. Camshaft, Crankshaft Parts, Service D. Ignition and Electrical Systems a. Ignition Theory b. Magnetron Ignition Theory, Service c. Battery Ignition Systems E. Electrical Systems a. Charging System b. Starting System c. Lighting System F. Fuel Systems and Carburetion a. Fuel System Components b. Carburetion Theory c. Carburetor types, service G. Cooling Systems a. Air cooled systems b. Liquid cooled systems H. Governor Systems a. Pneumatic governor operation, service, adjust b. Mechanical governor operation, service, adjustment J. Engine Oil: Components, Analysis, Lubrication Systems K. Disassembly, diagnosis, measurement and reassembly L. Precision measurement devices 14 14 IV. Hydraulic Systems A.Hydraulic principles B.Hydraulic system components C.Hydraulic schematic symbols and circuits D.System troubleshooting, maintenance 5 6 V. Powertrain System a. Clutches b. Transmissions 1. Mechanical 2. Automatic 3. Hydraulic/Hydrostatic c. Belts, Gears, Chains, PTO's d. Differential and Final Drive VI. Machinery Adjustment, Maintenance A. Reel Set Up and Adjustment B. Reel Sharpening C. Bedknife Sharpening 2 4   Behavioral Objectives: Introduction to Power and Machinery Review course requirements Economics and Machines Identify the factors of fixed and operating costs Compute depreciation for machinery using two current methods Develop a spreadsheet to compute a complete projected machinery cost schedule Power and its measurement Define terminology related to power measurement Interpret information on engine power ratings Measure horsepower with dynamometer, plot Hp, torque curves nterpret dynamometer test results Make recommendations for improving power performance Compact Engine Systems Differentiate between gasoline and diesel engines Explain theory of operation of four cycle and two cycle engines Explain theories of operation for ignition, compression and carburetion systems Identify the components of the systems of an engine Service and maintain the components of the systems of an engine Locate and correct malfunctioning components Use repair manuals and parts lists to identify parts necessary for repairs Overhaul four stroke cycle engine Explain the relationship between the various systems of an engine Service lubrications systems, understand machine lubricant properties Service engine cooling systems Troubleshoot engine compression, electrical and fuel problems Use appropriate precision measurement tools to analyze wear of critical engine components. Compact Hydraulic systems List/describe the basic principles of hydraulics including the five basic laws and concepts of force, pressure, area, work and power Describe and explain the function of the major components of a hydraulic system. Identify and describe functions of basic hydraulic system components including: - pumps and motors cylinders - valves filters Differentiate between the two major types of hydraulic systems and list advantages and disadvantages of each. Diagram and assemble basic hydraulic circuits using standard hydraulic symbols and trace fluid flow Disassemble hydraulic components to study function and diagnose causes of failure Describe the theory operation of a hydrostatic power train Recognize safety hazards associated with hydraulics systems Develop basic skills for tracing fluid flow and trouble shooting a hydraulics system Machinery Adjustment, Maintenance Sharpen reel mower bedknife and reel Set up and adjust reel mower to manufacturer specification Adjust drive devices to specification Recognize and practice appropriate safety precautions Electronic Communications Develop ability to communicate electronically with others in class Complete and re-submit assignments via internet methods Revised Spring 2008