Appliance, TV and Generator Repair Level 2

About this module

At Level 1 you fixed things. At Level 2 you prove they are safe, every time, and you start to earn a name for it.

Who it is for. People who have finished Level 1, or who already repair appliances and can show the same skills. In Ghana's framework, National Proficiency II covers varied but mostly routine tasks with limited supervision, and leads to National Certificate I.

CTVET status. CTVET has approved programmes in Electronics (NP I and II), Electrical Installation (NP I and II), Small Engines Technology (NC I and II) and Generator and Power Plant Technology (NC I and II), but none for appliance repair. This module is not a CTVET curriculum.

Bridge from Level 1: what you already know

Isolation: switch off, unplug, plug in sight, let it cool
The visual check of plug, fuse, cable and casing
V = I × R and P = V × I; expected element resistance from the rating plate
Continuity and resistance tests on unplugged appliances
Cable and plug wiring colours; earth to metal body; thermal fuses and thermostats
Blender couplings and brushes; fan capacitors and bearings
TV and decoder checks from the outside; the torch test for backlights; decoder codes
Generator CO rules; oil, air filter and spark-plug service; starting-fault table; adding up loads
Job cards, costing a repair, e-waste and accessibility

The hard rules still apply

No building wiring. Sockets, breakers, ceiling fittings and generator changeovers are for Certified Electrical Wiring Professionals (CEWP) licensed by the Energy Commission.
No repair work on live circuits. Live measurement is allowed only as a supervised test, with a proved meter, after the appliance is closed up, or at a generator socket outside.
Never open a microwave oven cabinet or the inside of a CRT TV. A microwave's high-voltage parts work at about 1,800 to 4,000 volts and the capacitor stays charged after unplugging; a CRT works at tens of thousands of volts and can implode.
Generators always run outside, far from openings.
Fridges, freezers and ACs: see the Hub's Refrigeration and Air-Conditioning Basics. Phones and chargers: see Phone and Small Electronics Repair.

How the module works

Each unit has learning outcomes, performance criteria, the range and the evidence your assessor needs. You are judged Competent or Not Yet Competent. About 70% of the time is practical. Each unit has a practical task, homework, an exercise where there are sums, and three "Check yourself" questions.

Unit 1 · Fault-finding method and safety testing

A repair is not finished when it works. It is finished when you have proved it is safe and written the proof down.

Competency standard

Learning outcome	Performance criteria — the trainee…
1.1 Use a fault-finding method	follows a written method from complaint to cause
1.2 Classify appliances	tells Class I, Class II and Class III appliances apart
1.3 Inspect and test after repair	does visual, earth continuity, insulation and functional checks in order
1.4 Take supervised live readings	proves the meter, measures a socket or generator voltage safely, proves again
1.5 Record results	fills a test record and labels passes and fails

Range. Repaired training appliances; one test socket with RCD; the training generator outside. Evidence. Test records; observed live reading; faulty-equipment register.

The fault-finding method

Listen. Write the customer's complaint in their words.
Look. Visual check (Level 1). Smell for burning.
Think. List the parts that could cause this symptom, cheapest and most likely first.
Test, unplugged. Continuity and resistance from the plug towards the load.
Find the cause, not just the broken part. A thermal fuse blows because something overheated. A capacitor fails early if the motor is stiff.
Repair with a matching part.
Inspect and test (below).
Record everything on the job card and test record.

Classes of appliance

Class	How it protects you	Examples	Earth test?
Class I	Basic insulation plus metal parts connected to earth	Toasters, kettles with metal bodies, extension leads	Yes
Class II	Double insulation; no earth; marked with a square inside a square	Most modern hair dryers, TVs, many drills	No
Class III	Runs from a safety extra-low-voltage supply (max 50 V AC)	12 V lamps, phone base units	No

The inspect-and-test sequence

A UK code of practice sets four stages: visual inspection, earth continuity test, insulation test, functional test.

1. Visual inspection (Level 1 table). A failed visual check stops the test.

2. Earth continuity (Class I only). Measure from the earth pin of the plug to every accessible metal part. Watch the reading while you flex the cable where it enters the plug and the appliance; any change means a loose or broken core.

Result	Decision
Not more than 0.1 Ω	Pass
More than 0.1 Ω on an appliance with a long cord or an extension lead	Pass only if not more than 0.1 Ω plus the resistance of the cable's earth core
More than that	Fail: label "DANGER DO NOT USE"

Approximate resistance of flexible cable per metre: 0.75 mm², 0.026 Ω and up to 6 A; 1.0 mm², 0.0195 Ω and up to 10 A; 1.5 mm², 0.0133 Ω and up to 15 A.

3. Insulation resistance (500 V DC tester). Join live and neutral pins together on the tester and measure to earth (Class I) or to the outside of the case (Class II). Do not touch the appliance during the test.

Appliance	Pass
Class I	1 MΩ or more
Class I heating appliance	0.3 MΩ or more
Class II	2 MΩ or more

Some appliances with sensitive electronics need a "soft" test at lower voltage; ask your trainer.

4. Functional test. Plug into an RCD-protected test socket, switch on and check it works properly: heats, turns, switches off, thermostat cycles.

These UK limits are used here as good practice. No Ghana standard for testing repaired appliances was found for this book; ask the Ghana Standards Authority if one applies.

Supervised live readings

At Level 2 you may measure voltage at a socket or at a generator outlet, only with your trainer beside you.

Before a live reading:

Use a meter rated CAT II or higher for socket work. Check the meter, leads and probes for cracks or bare metal; never use damaged ones.
Red lead in VΩ, black in COM. Never in the current (A) port: that shorts the supply.
Prove the meter on a known live source before and after the measurement, so you know a "0 V" reading is real.
Dry hands, dry floor, one probe at a time, no rings or watches.

Steps: prove the meter → dial to AC volts (V~) → black probe in neutral, red probe in live → read → remove red first → prove again. A Ghana socket should read near 230 V. A much lower or higher reading means the supply is poor: tell the customer to protect appliances and refer the supply problem to the utility or a CEWP.

Prove it is safe

Inspect and test five repaired training appliances (at least two Class I and two Class II).
Record visual, earth continuity (with cable flexing), insulation and functional results on a test record.
Label each "PASS" with date and your initials, or "DANGER DO NOT USE" and enter it in the faulty-equipment register.
With your trainer, prove the meter, measure a test socket, and prove again. Record the voltage.

Pass or fail?

A metal toaster: earth continuity 0.06 Ω; insulation 4 MΩ. Pass or fail?
A kettle (Class I heating): earth 0.08 Ω; insulation 0.5 MΩ. Pass or fail?
A Class II hair dryer: insulation 1.5 MΩ. Pass or fail?
A 10 m extension lead of 1.0 mm² cable reads 0.25 Ω earth continuity. What is the limit? Pass or fail?
A 2,200 W kettle on 230 V: which is the smallest cable size from the table that can carry its current?

Classes at home

Find five appliances at home and decide if each is Class I or Class II (look for the square-in-square mark). Write how you decided.

Check yourself

Name the four stages of the inspect-and-test sequence in order.
Why do you flex the cable during an earth continuity test?
Why do you prove the meter before and after a live reading?

Unit 2 · Heating appliances in depth

The heating appliances that come to your bench most often are the ones people use every day: irons, kettles, rice cookers, toasters and hot plates.

Competency standard

Learning outcome	Performance criteria — the trainee…
2.1 Repair steam irons	finds steam, leak and heat faults; repairs safely
2.2 Repair kettle bases and switches	tests cordless base connectors and switch-off mechanisms
2.3 Repair rice cookers, toasters and hot plates	tests thermostat, warm circuit, elements and switches
2.4 Choose correct parts	matches element power, thermal fuse rating and cable size
2.5 Prove safety	completes the inspect-and-test sequence on every repair

Range. Steam irons, cordless kettles, rice cookers with "cook" and "warm", pop-up toasters, single and double hot plates. Evidence. Job cards; test records; repaired appliances.

Steam irons

Fault	Likely cause	What you do
No steam	Water tank empty; steam control off; holes in soleplate blocked by scale	Check settings; clean as the maker's manual says
Leaks water on the cloth	Iron not hot enough when steam used; worn valve or seal	Use steam only at the right setting; replace valve or seal
No heat	Cable, thermal fuse, thermostat, element (Level 1 order)	Test unplugged
Trips the RCD or house breaker	Water inside on the electrics; element leakage	Dry fully; insulation test (heating 0.3 MΩ minimum); replace if it fails
Cable worn at the heel	Swivel bend point flexed thousands of times	Replace with heat-resistant cable; fit the cable guard back

Water and electricity. Never fill a steam iron while it is plugged in. After any steam-iron repair, the insulation test is a must, because water inside can make the body live.

Cordless kettles

The kettle sits on a base with a round connector. Burnt, loose or corroded contacts in the base or the kettle cause no-heat faults or a burning smell. Test continuity from the base plug pins to the base contacts.
The kettle switches off at the boil because steam heats a bimetallic switch; if the lid is open or the steam path is blocked, it may not switch off.
The element is usually fully enclosed and rated about 2 to 3 kW. A 3 kW kettle draws about 13 A on 230 V, so the plug, fuse, cable and socket must all be good.
If the kettle has a concealed element under a metal plate and the element is open, the usual fix is a new kettle: tell the customer the honest cost comparison.

Rice cookers

A basic cooker heats at full power until the water is gone; then the bowl gets hotter than boiling point and the thermostat trips. Many have a small warm heater or a resistor in series with the main element that keeps the rice warm afterwards.

Fault	Likely cause
Cooks, but never keeps warm	Warm heater open; warm circuit diode or resistor open
Switches to warm too early, rice hard	Bowl dented or dirty so it does not touch the thermostat; thermostat weak
Burns rice	Thermostat not tripping; inner bowl wrong size
No heat at all	Plug, cable, thermal fuse, main switch, element

Always check the inner bowl sits flat on the plate and the plate is clean before replacing parts.

Toasters and hot plates

Toasters: check the crumb tray first (crumbs cause smoke and fire). Open elements are thin wire on mica sheets: an open element usually means a new toaster. The lever latch is often magnetic or electronic; if it will not stay down, check whether the toaster is plugged in (many latches only hold with power) and test the latch coil unplugged.
Hot plates: a solid plate element or a coiled element in a groove; the control knob is often an energy regulator that switches on and off to vary the heat. Test the element resistance against V² ÷ P, and the regulator's continuity at full setting.

Choosing the right parts

Part	Must match
Element	The same power (W) and voltage; same fixing
Thermal fuse	Same opening temperature and current rating
Thermostat	Same temperature range and current rating
Cable	Same type and core count; at least the cross-section for the current
Plug fuse	As the rating plate says

Buying parts in Ghana

Many cables and accessories on the market are not up to standard: a Ghana Standards Authority survey found about 43% of imported cable brands substandard or counterfeit, and the Energy Commission urged the industry to use GSA-approved cables and accessories under the Electrical Wiring Cables and Accessories Regulation (L.I. 2478). Buy from known dealers, ask for approved products and keep the receipt.

Heating appliance clinic

Repair one steam iron, one cordless kettle or base, one rice cooker and one toaster or hot plate.
For each, record the fault, the cause, the readings and the part used on the job card.
Complete the inspect-and-test sequence for each.
Explain each repair to your trainer as if to a customer.

Heating sums (230 V)

A steam iron is rated 2,000 W. What element resistance do you expect? You read 26.8 Ω. Good?
Its insulation reads 0.4 MΩ. Pass or fail for a heating appliance?
A toaster is rated 800 W. What resistance should the whole toaster read across the pins with the lever down (if the latch circuit allows)?
A hot plate is rated 1,800 W. What current does it draw, and which plug fuse suits it?

Parts price list

Visit two electrical parts dealers. Price a steam-iron cable, a kettle base, a rice-cooker thermostat and a thermal fuse. Ask if the cable is GSA-approved. Note the dealer and date.

Check yourself

Why must you do an insulation test after every steam-iron repair?
A rice cooker switches to "warm" before the rice is cooked. Name two things to check first.
What does L.I. 2478 cover?

Unit 3 · Motor appliances in depth

Brushes, gears and bearings wear out. Replace them properly and a good blender or mixer runs for years more.

Competency standard

Learning outcome	Performance criteria — the trainee…
3.1 Service universal motors	inspects and replaces carbon brushes; checks the commutator
3.2 Repair drives	replaces couplings, gears and belts in blenders, mixers and food processors
3.3 Test fan motors and switches	tests windings, speed switch and capacitor and compares with the good unit
3.4 Diagnose noise and heat	tells bearing, gear and overload problems apart
3.5 Prove safety	completes the inspect-and-test sequence

Range. Blenders, hand and stand mixers, food processors, table, stand and wall fans. Evidence. Job cards; test records; repaired appliances.

Universal motor service

The universal motor in blenders and mixers runs very fast and suits short use; its carbon brushes wear, and wear causes sparking.

Replace carbon brushes, step by step

Isolate. Photograph the motor and the brush holders before you touch anything.
Remove the brush caps or clips. Note which way each brush faces (the curved end matches the commutator).
Measure brush length. Compare with the maker's minimum if you have it. If not, replace when worn to about half (example rule; use the maker's figure where known).
Look at the commutator (the copper bars). Light even darkening is normal. Deep grooves, burnt or lifted bars mean the motor or armature needs replacing.
Fit new brushes of the same size and type, with the springs. Make sure they slide freely.
Rotate the shaft by hand: no rubbing or catching.
Inspect and test. Then run the motor for a short time on light load: some sparking is normal while new brushes bed in; heavy ring-shaped sparking is not.

Drives: couplings, gears and belts

Blender coupling: the drive socket under the jar. Worn teeth make the motor race while the blades do not turn. Replace with the part for that model; check the jar's matching part too.
Mixer gears: stripped plastic gears make the beaters stop or click. Replace as a set; use the grease the maker specifies.
Food processor belts: a slipping or broken belt; replace with the exact belt size.
Safety interlocks: jar, lid and bowl switches stop the motor if parts are not fitted. Never bypass them.

Fan motors and switches

Test (unplugged)	How	What it tells you
Capacitor	µF reading within about 5 to 10% of the rating	Hum, slow start or no start
Windings	Resistance between the motor wires; compare with the same model in good order	Open winding (OL) or shorted turns (much lower than normal)
Speed switch	Continuity of each position to its motor wire	One speed dead
Thermal cut-out in the motor	Continuity	Motor dead when cold
Bearings	Turn by hand; listen	Stiff, noisy, slow

Photograph and draw the wiring before you disconnect anything. Fans have several coloured wires to the switch and capacitor; a wrong connection can burn the motor.

Noise and heat

What you notice	Likely cause
Grinding that changes with load	Gears
Squeal or rumble that is the same at all loads	Bearings
Motor smells hot after short use	Overload, stiff bearings, wrong capacitor, blocked vents
Sparks in vents, burning smell	Worn brushes or damaged commutator

Motor clinic

Replace the brushes in a training blender or mixer. Record the old and new brush lengths.
Replace a coupling or gear set.
Test a fan's capacitor, windings and speed switch, and compare with a good fan of the same model.
Complete the inspect-and-test sequence for each repair.

Fan readings

Two identical fans. Good fan: winding A to common 180 Ω; capacitor 2.5 µF (marked 2.5 µF). Faulty fan: winding A to common OL; capacitor 2.4 µF.

Is the faulty fan's capacitor inside a 10% tolerance?
What does OL on winding A mean?
Should you replace the capacitor? What is the likely repair?

Brush hunt

Find which shops near you sell carbon brushes, blender couplings and mixer gears. Write prices and whether they stock parts by brand and model.

Check yourself

Why must new brushes be the same size and type?
How do you tell bearing noise from gear noise?
Why do you photograph fan wiring before you disconnect it?

Unit 4 · TVs, decoders and set-top boxes: set-up and low-voltage faults

Many TV jobs are set-up jobs: the right input, the right channel scan, the right dish angle. Do them well and people will call you first.

Competency standard

Learning outcome	Performance criteria — the trainee…
4.1 Set up a TV system	connects TV, decoder or set-top box, sound bar and aerial or dish correctly
4.2 Scan and update	runs a channel scan and a factory reset where the manual allows
4.3 Test low-voltage supplies	measures the DC output of external adaptors
4.4 Check dish signal	uses the decoder signal screen or a signal finder at ground level
4.5 Refer inside faults	writes clear referral notes for faults inside the TV

Range. LED/LCD TVs, satellite decoders, digital terrestrial set-top boxes, sound bars, external power adaptors. Still no work inside TVs. Evidence. Set-up records; adaptor test record; referral notes.

Still no work inside a TV at Level 2. TV power supplies and backlight drivers can hold dangerous voltages even after unplugging. CRT TVs: never. Training in electronics (for example CTVET's Electronics NP I and II) comes before inside work.

Digital terrestrial TV in Ghana

Ghana uses the DVB-T2 standard with MPEG-4 video for free digital terrestrial TV, chosen in 2012. By December 2023 the national network covered over 80% of people, and most stations had stopped analogue broadcasts. An older TV without a DVB-T2 tuner needs a DVB-T2 set-top box.

Set up a set-top box, step by step

Connect the aerial to the box's "RF in".
Connect the box to the TV by HDMI (or AV for an old TV).
Switch on; choose the TV input that matches the cable.
In the box menu, choose country and run an automatic channel scan.
Check signal strength and quality on the box's signal screen. Turn the aerial slowly if they are low; wait a few seconds after each move.
Save channels; show the customer how to rescan.

Satellite decoders

Keep the decoder's signal screen open while you work. Error codes such as E48-32 mean the decoder is searching for signal; heavy rain and loose dish cables are common causes.
Signal problems at a dish: loose or corroded F-connector; water in the cable; dish knocked out of line; rusted arm (common near the sea). Re-make connectors with new ones and weatherproof them.
Smartcard and subscription errors are not repairs: help the customer contact the provider.

Working at height. Dish and aerial work on roofs needs ladder and work-at-height training (see the Hub's Workplace Safety manuals). At Level 2, adjust dishes and aerials only where you can work from the ground or a firm platform with your trainer.

External power adaptors (low voltage only)

Many LED TVs, decoders and sound bars run from an external adaptor that turns 230 V AC into a low DC voltage (for example 12 V or 19 V; the voltage is printed on the label).

Read the adaptor label: output volts (V), current (A) and polarity symbol.
Unplug the adaptor from the appliance. Plug the adaptor into an RCD-protected socket (the adaptor itself is closed; you do not open it).
Meter on DC volts. Measure at the plug that goes into the appliance: centre and outside.
A good adaptor reads close to its label, often a little higher with no load. Zero, or a reading that jumps, means a faulty adaptor or cable.
Replace with an adaptor of the same voltage, same polarity and the same or higher current. Never fit a higher-voltage adaptor.

Sound bars and home theatre

Check the input (HDMI ARC, optical, AUX, Bluetooth) and the TV's sound-output setting.
If the TV and sound bar both have HDMI ARC, use that socket and switch on the TV's HDMI control setting (the name differs by brand).
No sound from one speaker: check the speaker cable and the balance setting before blaming the amplifier.

Writing a referral note

When a fault is inside the TV (backlight, power board, main board, panel), write:

Customer, TV make, model and serial number
Symptom, and what the torch test, inputs and settings showed
What you checked outside and what you did not open
Your suggestion (for example "backlight suspected")
Your name, phone and the date

TV system set-up

Set up a digital set-top box on an old TV and scan channels; record signal strength and quality.
Set up a decoder and adjust a ground-mounted dish with your trainer using the signal screen or a finder; record the signal before and after.
Test three external adaptors and record the readings against their labels.
Connect a sound bar by HDMI ARC or optical and check the TV's sound settings.
Write one referral note for an inside fault.

Set-top boxes

Visit an electronics shop. Ask which DVB-T2 set-top boxes they sell, their prices and whether they carry a conformance mark. Write what you find and the date.

Check yourself

What standard does Ghana use for digital terrestrial TV?
A 12 V adaptor reads 0 V at its plug. What do you do?
When can you adjust a dish at Level 2?

Unit 5 · Petrol generators in depth: fuel, ignition and load

Most generator breakdowns start with bad fuel and dirty carburettors. Most deaths start with a generator in the wrong place.

Competency standard

Learning outcome	Performance criteria — the trainee…
5.1 Clean a carburettor	removes, cleans and refits a small-engine carburettor without damage
5.2 Test ignition	uses a spark tester and checks the stop switch
5.3 Service exhaust and fuel system	cleans the spark arrester; checks fuel filter and lines
5.4 Check output	measures generator voltage outside, supervised
5.5 Plan loads	plans running and starting loads within the generator's ratings
5.6 Prepare for storage and transport	drains fuel, protects the cylinder and moves the generator safely

Range. Small four-stroke petrol generators up to about 3 kVA, outside only. Evidence. Service records; carburettor job card; load plan; observed output reading.

Level 1 rules first, every time. Outside only, about 6 m from the house, exhaust away from doors, windows and vents, never on a porch. Off and cool before fuel work; fuel handled outdoors; spills wiped at once. No connection to a building's wiring except through a proper changeover installed by a qualified electrician: in Ghana, a CEWP.

Clean a carburettor, step by step

Most carburettor problems come from blockages by dirt, varnish and petrol deposits. Stale fuel leaves gum that clogs the fuel system.

Tools and materials: spanners and screwdrivers to fit, a fuel-line clamp, a clean container, a parts tray, carburettor cleaner spray or parts cleaner, wooden toothpicks, a new bowl gasket, safety glasses, gloves, rags.

Generator outside, off and cool. Remove the spark-plug lead and keep it away from the plug.
Turn the fuel tap off, or clamp the fuel line.
Remove the air filter. Photograph the throttle and governor links and springs before you touch them; do not bend or stretch them.
Drain the float bowl into a container through its drain screw.
Remove the carburettor. Remove the float bowl, then the float hinge pin, float, needle valve and gasket.
Remove the main jet and emulsion tube carefully; they can be tight.
Clean metal and plastic parts in parts cleaner for no more than 15 minutes, or spray with carburettor cleaner wearing safety glasses. Blow loosened dirt out with compressed air if you have it.
Clear jet holes with a wooden toothpick, never wire: wire damages the holes.
Replace parts that are damaged or still blocked; a corroded or broken carburettor is usually replaced.
Reassemble in reverse order with a new bowl gasket. Make sure the links move freely without binding.
Refit the air filter, reconnect the plug lead, open the fuel tap and check for leaks. Start outside and listen for smooth running.

Do not turn idle or mixture screws on modern carburettors: many are factory set and tampering is not allowed on emission-certified engines.

Test the ignition

Use a spark tester (a simple tool with a window), not a loose plug held in your hand.
One method: connect the spark-plug lead to one end of the tester and clip the other end to a good ground on the engine. With the engine switch ON, pull the starter briskly and watch for a spark. With the switch OFF there should be no spark; if there is, the stop switch is faulty.
No spark with the switch ON: look for broken wires, shorts, a faulty switch or a failed coil. Coil and flywheel-key work goes to a small-engine mechanic at this level.
Spark good but engine will not run: fuel, carburettor or valves (go back to the carburettor).

Spark arrester and fuel system

The spark arrester screen in the exhaust must be cleaned every 100 hours on one common model; let the muffler cool, brush off the carbon gently, and replace the screen if it is torn.
Check fuel lines for cracks and the tank and filter for rust and dirt; replace cracked lines.

Check the output (supervised, outside)

Generator outside, running, nothing plugged in.
Prove your meter (Unit 1). Dial to AC volts.
Measure across the live and neutral holes of one generator socket. Compare with the voltage on the generator's label (230 V for Ghana-market generators). If your meter has a Hz range, check the frequency is close to 50 Hz.
Prove the meter again.
Record the readings with no load and with a known load (for example a 1,000 W heater). A big fall in voltage under a modest load points to an alternator, AVR or engine-speed problem: refer to a generator technician. CTVET's Generator and Power Plant Technology programme is the route to that skill.

About the ground terminal. Some generators have a ground (earth) terminal connected to the frame and socket earth pins; the maker says to consult a qualified electrician or the local authority before using it.

Plan the load

Maximum output is for short times; rated output is for continuous use. One model gives 2.2 kVA maximum and 1.8 kVA rated; the total of all appliances connected must be counted.
Appliance motors need more than their rated power for a moment at start-up.
Repeated overload shortens the generator's life; continuous overload can damage it.

In the exercise we treat watts and volt-amperes as equal and use a starting surge of 2 × running power for small motors. Both are simplifications for practice (example). Use the appliance and generator makers' figures for real jobs.

Load plan (example simplifications)

A generator is rated 1.8 kVA continuous and 2.2 kVA maximum. The house wants: TV 100 W, decoder 20 W, six LED bulbs of 10 W, two fans of 60 W each, a laptop 65 W.

What is the running load?
A 400 W blender starts (surge 2 × running power). What is the total at the moment it starts? Is it under the maximum?
With the blender running, what is the continuous load? Is it under the rated output?
Someone also switches on a 1,200 W iron. What is the continuous load now? Is that acceptable?

Storage and transport

Storage time	What to do
Under 1 month	Nothing special
1 to 2 months	Fresh petrol with fuel stabiliser
2 months to 1 year	Fresh petrol with stabiliser; drain the carburettor float bowl
1 year or more	Drain tank and carburettor; change oil; put about one teaspoon (5 cc) of clean oil in the cylinder and turn the engine over

Store level, in a ventilated place away from flames, with a breathable cover (not a plastic sheet, which traps moisture). Let a used generator cool for at least 15 minutes before loading it on a vehicle; transport it upright, fuel cap vent and engine switch off.

Generator workshop (outside)

Clean the training generator's carburettor following the steps. Photograph each stage for your logbook.
Test ignition and the stop switch with a spark tester.
Clean the spark arrester (engine cool).
With your trainer, measure output voltage (and frequency if possible) with no load and with a known load.
Write a load plan for a real household you know.
Prepare a generator for three months' storage.

Generator survey

Visit three homes or shops with generators. Record: make, rating, where it runs (distance from the nearest opening), hours used a day, when the oil was last changed. Give CO advice where needed and write what you said.

Check yourself

Why must you never clean a carburettor jet with wire?
With the engine switch OFF, the spark tester still shows a spark. What is faulty?
What is the difference between maximum and rated output?

Unit 6 · Quality, parts, records and customer care

Your records are your memory and your proof. They show the customer, the Assembly and a lender that you work properly.

Competency standard

Learning outcome	Performance criteria — the trainee…
6.1 Keep job and test records	completes job cards, test records and the faulty-equipment register
6.2 Source good parts	buys approved parts from known dealers and keeps receipts
6.3 Run a warranty	gives a written warranty and logs come-backs
6.4 Handle complaints	listens, checks the record and resolves fairly
6.5 Manage waste	stores and passes on e-waste and used oil safely

Range. The training workshop as a small repair shop. Evidence. A week of completed records; warranty register; complaint log.

The records every shop keeps

Record	What it holds
Job card	Customer, item, fault, findings, parts, price, dates, signatures
Test record	Visual, earth, insulation, functional results; pass or fail; date; initials
Faulty-equipment register	Items that failed and were labelled "DANGER DO NOT USE"
Generator service record	Hours, oil, filter, plug, carburettor, next service
Parts book	Part, supplier, price, date, receipt number
Warranty register	Job number, part, warranty end date, come-back, cause, cost
Uncollected items list	Item, date ready, calls made, date of final notice

Warranties and come-backs

Write your warranty on the job card: what it covers (the part you fitted and your work), for how long, and what it does not cover (misuse, power surges, other parts failing).
When an item comes back, check the record first. Was it the same fault? Was the test record complete?
Every month, count come-backs. If one kind of part comes back often, change the supplier.

Complaints

Listen without arguing; write it down.
Check the job card and test record together with the customer.
Test again in front of the customer.
If it is your fault, fix it free. If it is a new fault, explain and quote.
Record the outcome.

Uncollected items

Customers sometimes leave items for months. Tell customers at drop-off how long you keep finished items, call and message them, and write each attempt. Whether a repairer may sell or dispose of uncollected items under Ghana law was not verified: ask a lawyer or your trade association before you do.

E-waste and used oil

Ghana's Environmental Protection Act, 2025 (Act 1124) replaced the 2016 e-waste law and has a part on electrical and electronic waste; non-compliance with enforcement notices carries administrative penalties of GH¢12,000 for small undertakings.
Open burning of e-waste such as cables can lead to arrest and prosecution.
Store scrap dry and sorted. Store used engine oil in sealed, labelled containers and pass it to a collector.

Run the records for a week

For every job in the training workshop this week, complete the job card and test record.
Keep the parts book, warranty register and faulty-equipment register up to date.
Role-play a complaint with your trainer and record it.
Sort the workshop's scrap into cables, metal, plastic and boards; label used oil.

Your warranty

Write your own one-paragraph warranty for appliance repairs and one for generator servicing. Show it to a repairer and ask for comments.

Check yourself

Name four records a repair shop should keep.
What do you check first when an item comes back?
What should you never do with scrap cables?

Unit 7 · Location, service rounds, business and marketing

A bench repairs what comes to it. A service round goes out and finds steady work every month.

Competency standard

Learning outcome	Performance criteria — the trainee…
7.1 Price by time and parts	prices jobs from parts, time, transport and overheads
7.2 Plan service rounds	plans and prices a monthly generator service round
7.3 Choose location	compares a fixed stall, a home workshop and mobile service
7.4 Market and include	builds a marketing plan and makes the service accessible

Range. The trainee's own business plan. Evidence. Price list; service-round plan; marketing plan.

Pricing from time and parts

Price = parts + transport + (time × your hourly rate) + share of overheads + profit. Keep a price list for common jobs (iron cable, kettle base, blender coupling, fan capacitor, generator service) and update it when parts prices change.

Generator service rounds

Many homes, shops, salons and churches run generators nightly but never change the oil. Offer a monthly visit: oil, air filter, plug check, spark-arrester clean when due, and a CO-safety check of where the generator runs. Log hours on a sticker on the generator.

Service-round sums (all figures are examples)

For each monthly service: oil and small parts GH¢30; transport share GH¢10; one hour of your time at GH¢30. You charge GH¢120 a visit and have 12 customers.

What is the cost of one visit?
Profit per visit and per month?
Margin (profit ÷ price) and mark-up (profit ÷ cost) per visit?

Location settings that give good returns

Option	Good for	Watch out for
Fixed stall near a market or lorry station	Walk-in repairs, parts sales	Rent; security for customers' items; Assembly permit
Home workshop	Low rent	Customers must find you; generators run only outside, away from neighbours' windows
Mobile service (motorbike)	Generator rounds, decoder set-ups	Fuel cost; carrying tools safely; no fuel cans inside closed vehicles

The STMA 2025 fee list includes categories for electronics repairers and TV and radio repairers, with annual fees due by 31 March; confirm your category and fee at the STMA revenue office.

Marketing yourself

WhatsApp Business profile and catalogue of services and prices, with greeting and away messages.
Google Business Profile so people find you on Maps and Search.
A "safety-tested" sticker on every repaired item, with your phone number and the test date.
A short CO-safety leaflet for generator owners: generators outside, about 6 m from the house, never on a porch.
Partnerships: electrical shops refer repairs to you; you buy approved parts from them.

Accessibility

Ghana's Persons with Disability Act, 2006 (Act 715) protects the rights of persons with disability, including in employment. The Assemblies' disability share of the Common Fund was announced to rise from 3% to 5% from 2026; ask the disability desk about help with tools such as an insulation tester.

Task	Adjustments that help
Inspect-and-test at the bench	Seated bench with knee space; a tester with a large display or talking meter (price not verified); written test records
Carburettor and gear work	A vice and parts trays; good light; magnifier
Customer service and records	Written job cards and WhatsApp for Deaf repairers; large-print price list
Generator rounds	Work in pairs; raised platform; one person carries, one services
Dish and roof work	Refer or team up; not for anyone without work-at-height training

Business plan, Level 2

Write a price list for ten common jobs.
Plan a generator service round for 10 to 15 customers: route, day, price, cost and profit.
Choose a location type and justify it.
Write a one-page marketing plan with your WhatsApp profile text and a CO-safety leaflet.

Talk to customers

Ask five generator owners if they would pay for a monthly service, how much, and what would make them trust a repairer. Write the answers.

Check yourself

Write the price formula for a repair.
Why can a service round be steadier than a bench?
Name two adjustments that help a Deaf repairer serve customers.

Glossary

Term	Meaning
Class I / II / III	How an appliance protects against shock: earthed metal / double insulation / safety extra-low voltage
Commutator	The copper bars on a universal motor that the brushes touch
Earth continuity test	Measuring from the plug's earth pin to metal parts
Emulsion tube	A small tube in the carburettor that mixes air into the fuel
Float bowl	The part of the carburettor that holds a little fuel
Functional test	Running the appliance to check it works properly
HDMI ARC	An HDMI socket that sends TV sound to a sound bar
Insulation resistance test	A 500 V DC test between live parts and earth or the case
Main jet	The small brass part that meters fuel
Proving a meter	Testing it on a known live source before and after a live reading
RCD	Residual current device: switches off fast if current leaks to earth
Set-top box	A box that receives digital TV for an older TV
Spark arrester	A screen in the exhaust that stops sparks
Spark tester	A tool that shows whether the ignition makes a spark

Logbook

Unit 1: five test records; proved live reading signed by trainer
Unit 2: job cards and test records for four heating appliances
Unit 3: brush lengths; coupling or gear repair; fan readings
Unit 4: set-top box and decoder set-up records; adaptor readings; referral note
Unit 5: carburettor photos and job card; spark test; output readings; load plan; storage record
Unit 6: a week of records; complaint log; scrap sorting
Unit 7: price list; service-round plan; marketing plan
Every homework, dated
Any shock, burn or near miss

Self-check quiz

Name the four stages of inspecting and testing a repaired appliance.
What is the earth continuity pass value for a Class I appliance without a long cord?
What are the insulation pass values for Class I, Class I heating and Class II appliances?
Why must a meter be proved before and after a live reading?
A 2,000 W steam iron element should read about how many ohms on 230 V?
Why must you not fill a steam iron while it is plugged in?
What happens to brushes in a universal motor, and what is the sign?
Which video standard does Ghana's digital terrestrial TV use?
How do you clean a carburettor jet, and for how long may parts soak in cleaner?
How do you check a generator's stop switch with a spark tester?
Give the storage steps for a generator stored for more than a year.
Name four records a repair shop keeps.