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motor mechanic repair & maintenance of 2 wheeler

1. s n Item s n Item 1 Screw drivers 12 Inspection lamp with guard and wandering lead of 100 ft 2 File 13 Horses and wheel chokes 3 DE Spanner Set 14 Screw Wrench 4 Box spanner set 15 Ring Spanner Set 5 Hacksaw blade with frame 16 Wheel aligner bay ramp pit with rolling jack 6 Tyre pressure gauge with accessories 17 Computerized wheel aligner with all accessories along with manuals amp diagnostic charts 7 Hammer 18 Wheel changer 8 Vice 19 Computerized wheel balancing machine with all accessories 9 Pliers 20 Compressor with accessories 10 Pipe Wrench 21 FWD Vehicle with workshop manual amp vehicle kit 11 Torque wrenches of different capacity 22 38 Minor repair of Auto body 1 Name 2 Sector 3 Code 4 Entry Qualification Minor repair of Auto body Automotive Repair AUR212 Minimum 5th Std 14 years of Age amp MES Module on Basic Automotive Servicing 4 wheelers 5 Terminal competency Successful candidate would be able to do minor repair of auto body 210 Hours 6 Duration 7 COURSE CONTENT Practical Competencies Underpinning Knowledge Theory v Y VV V WV Practice Health amp Safety familiarize select proper use maintain amp store tools equipments consumables amp clothing safely Inspect amp decide whether it can be repaired or replaced Remove and refit body panels doors floor wheel boxes amp
2. 8 TOOLS amp EQUIPMENT Suggested s n Item s n Item a TOOL KIT 1 Steel rule 15 cm English and metric 18 Hand file 20 cm Second cut half round 2 Screw driver 20cm X 9mm Blade 19 Hand file 20 cm smooth triangular 3 Screw driver 30 cm X 9 mm Blade 20 12 Hand file 30 cm bastard 4 Spanner D E set of 12 pieces 6mm to 32mm 21 Steel tools box with lock and key folding type size400X200X150mm 5 Pliers combination 20 cm 22 Circlip pliers 15 cm Expanding type 6 Pliers side cutting 15 cm 23 Chisel cold flat 20 mm 7 Plier round nose 15 cm 24 Hand file 30 cm round bastard 8 Plier flat nose 15 cm 25 Centre punch 10 cm 9 Hollow punch set of seven pieces 6mm to 15mm 1 Set 26 Ball peen Hammer 0 5kg 10 Drift punch copper 15 cm 27 Adjustable spanner pipe wrench 350 mm 11 Prick punch 15 cm 28 Spanner ring set of 12 metric sizes 6 to 32 mm 12 Chisels cross cut 200 mm X 6mm 29 Spanner adjustable 15cm 13 Allen Key set of 12 pieces 2mm to 14mm 30 Spanner for spark plugs 14mm 14 Philips Screw Driver set of 5 pieces 100 mm to 300 31 Hand reamers adjustable 10 5 to 11 25 mm 11 25 mm to 12 75 mm 12 75 to 14 25 mm and 14 25 to 15 75 mm 15 Mallets wooden plastic 32 Vice grip pliers 16 Spanners socket with speed handle T bar ratchet 33 Circlip pliers Expanding and contracting type 15cm a
3. Hollow punch 6 7 8 9 10 and 12 mm set 35 Drift copper 10 mm x 150 mm 1 No 33 12 Flat File 35 cm bastard 36 Double open ended spanner set 10 5mm x 12 mm 10 5mm x 18 mm set of four 1 set 13 Flat File 25 cm second cut 37 Hydrometers 14 Micrometer Outside 0 25mm 25 50mm 38 Spring tension tester 15 Soldering iron 120 watts 39 A V O meters 16 Nose Pliers round and straight 150 mm and 200mm 40 Alternator regulator tester 17 Circlip pliers 41 Distributor tester 18 Thread pitch gauge 42 _ Continuity meter 19 Stud remover 43 Clip on meter Digital and Analog 1 each 20 Spanner T flocks for screwing up and up screwing 44 Tachometer inaccessible positions 21 Cleaning tray 45 x 30cm 45 Spark Plug tester NEON type 22 Oil cane 0 5 litres 46 High rate discharge tester 23 Smp straight amp bent 47 Multimeter digital and Analog 1 each 24 General purpose puller 48 Starter motor alternator dynamo amp cut out 2 each s n Item s n Item c GENERAL INSTALLATION MACHINERIES 1 Drilling Machine Bench 12 mm dia 18 Grease Gun 2 Growler 19 Pulley set universal for bearing amp bushes set 3 Battery charger 6V 24 V 20 Pulley puller 4 AC alternator slip ring puller 21 Glow plug 5 AC alternator slip ring press tool 22 Alternator 6 Executive Auto Elec
4. Make joints on simple strapped conductors sieving or taping with insulation tape Measure conductor using wire gauge Practice Soldering on wire joints Solder and crimp of lugs with wire ends Measure voltage drop total resistance current flow in different line by connecting two or three resistors in parallel and series using a battery bulb motor resistors reconcile Ohm s law Check blowing of fuse with wires short circulated Identify various electrical equipments on the mock up wiring board i e starter motor dynamo control box etc Follow up starting system wiring Identify marking on terminal joints Remove and repeat connections Do Similar practice on charging system wiring Checking of circuit breakers and relays Construct simple circuit by using relay Test check alternator output voltage circuit voltage drop and trouble shooting in a charging system Dismantling alternators and components tests diodes rotor condition rotor winding insulation amp rotor condition Trace starter circuit in a vehicle Dismantle starter and check each components Repair the faults assemble v VVVVV Safety precautions and first aid Care and maintenance of tools Signs and symbols used in Electrical amp electronics Voltage Current and Resistance and its units Effects of resistance on the length and cross sectional area of a conductor conductors and insulators Cumulative resistance of parallel and series con
5. 64 Tryre Pressure gauge 32 Work bench each 250 x 120x60 with 4 bench 65 Wheel truing machine 16 vices 12 cm jaw 33 Ring ridge remover 17 1 Module name 2 Sector 3 Code 4 Entry Qualification Repair amp Overhauling of 3 Wheelers Automotive Repair AUR206 Minimum 5 Std 14 years of Age MES Module on Basic Automobile Servicing of 2 amp 3 Wheeler Successful candidate would be able to carry out major repairs and overhauling of 3 Wheelers 270 Hours 5 Terminal competency 6 Duration 7 COURSE CONTENT Practical Competencies Underpinning Knowledge Theory VVVV WV gt gt gt gt gt gt Practice Health amp Safety select use maintain amp store tools equipments amp clothing safely Handle fuels oils lubricants acids alkalis adhesives seals solvents gases amp asbestos safely Water wash amp clean the vehicle Remove broken stud Check compression pressure Clean Fuel tank Dismantle clean check Engine components amp assemble Dismantle clean reset fit amp fine tune carburetor Overhaul and test Fuel Injection Pump Test Injector amp repair the defect Set valve timing Set Ignition Injection timing Dismantle clean check repair and refit clutch amp gear box Lubricate and grease the vehicle Prepare electrolyte amp charge the battery Check voltage resistance continuity and find fau
6. ABS STEERING Introduction basic types of steering steering geometry necessity types amp effects steering characters over steer under steer amp neutral steer amp steering linkage Types of steering gear power assisted steering hydraulic amp electronic Checks on steering system and fault diagnosis SUSPENSION Introduction requirement types McPherson strut shock absorber Checks on suspension system and fault diagnosis WHEELS amp TYRES necessity functions designation amp defects analysis Procedure for tyre rotation Fundamental electrical principles Ohm s Law Series amp Parallel resistances circuits Working principle types amp application of capacitors amp transistors Usage of multimeter Wiring colour code reading of engine electrical systems circuits Fault finding in electrical circuits Final road test procedure observation of Noise Vibration amp harshness from different part of chassis observation of transmission brake clutch steering amp suspension systems for their satisfactory working Note Do the practical works as per the manufacturer s recommendations mentioned in the service manual of the particular brand of vehicle 25 8 TOOLS amp EQUIPMENT Suggested s n Item s n Item a TOOL KIT 1 Steel rule 15 cm English and metric 18
7. amp rectify the defect gt Procedure for testing the engine Fine tune the Engine and road test the vehicle VVVV VV Note Do the practical works as per the manufacturer s recommendations mentioned in the service manual of the particular brand of vehicle 11 8 TOOLS amp EQUIPMENTS Suggested s no Item s no Item 1 Hammer ball peen 0 75 kg 32 Spanner off set double ended set of 7 pieces 6 mm 17 mm Set of 12 nos 2 Screw driver 20 cm x 9 mm blade 33 Outside Micrometer 0 25 mm 25 50 mm 3 Screw driver 30 cm x 9 mm blade 34 Mallets wooden plastic 4 Spanner D E set of 12 pieces 6mm to 32 mm 35 Piston ring filer 5 Pliers combination 15 cm 36 Spanner ring offset set of 6 S A E 6 Hand file 20 cm Second cut 37 Spanner adjustable 20 cm 7 Centre punch 10 mm dia x 100 mm 38 Spanner for spark plugs 14 mm 8 Chisel cold flat 20 mm 39 Socket Spanners with handle T bar amp ratchet 9 Ring spanner set of 12 pieces 6 to 32 mm 40 Oil can 0 5 liter cap 10 Feeler gauge 20 blades metric 41 Cleaning Tray 45 x 30 cm 11 Steel toolbox with lock amp key folding type size 42 Work benches 400x200x150mm 12 Allen Key set of 12 pieces 2 mm to 14 mm 43 Hollow punch set of seven pieces 6 to15 mm 13 Philips Screw Driver Type set of 5 pieces 100 44 Vice grip pliers mm to 300 mm 14 Ste
8. ratchet 24 Chain and Pulley block 3000 kg capacity 59 Vernier Caliper 250 or 200 mm inside outside amp depth 25 Horses 60 DMM Auto range 26 Screw jack 1 ton capacity double lift 61 Petrol Injector 27 Oil can 0 5 liter cap 62 Petrol Fuel pump of MPFI system 28 Cleaning Trays 45 x 30 cm 63 Hydrometer 29 Torque wrench set of 3 Nos 64 Piston Ring compressors 30 Work bench each 250 x 120x60 with 4 bench 65 Valve spring lifter vices 12 cm jaw 31 Pullers screw powered 2 mm with bearing 66 Fuel injection pump one with pneumatic puller attachment governor one with R Q governor and one with R S V Governor 32 Vice grip pliers 67 Fuel feed pump 33 Circlip pliers Expanding and contracting type 15 68 Injectors of diesel engines cm and 20 cm each 8 sets 34 Inspection lamp with guard and wandering lead 69 Engine management system s Sensors amp of 100 ft Actuators 4 sets 35 Stud remover GENERAL INSTALLATION 1 Petrol engine 4 strokes Multi Cylinder of 9 Nipple forming tool to form nipple on high different makes in running condition 3nos pressure pipe lines 6 8 and 10 mm dia with MPFI System amp 1 Nos with Carburettor 2 MPFI vehicle with workshop manuals 10 Portable electric drill 6 mm 3 Diesel engine 4 stroke Multi Cylinder of 11 Spark plug cleaner and tester similar to Bosch different makes in running condition champion 4 Cut model of 4 stroke petrol engine on stand 12
9. 15 cm 37 Hollow punch set of seven pieces 6 mm to 15 mm 16 Scriber 15 cm with scribing block universal 38 V Block 75 x 38 mm pair with Clamps 17 Hacksaw frame adjustable for 30 cm blade 39 Spanner off set double ended set of 7 pieces 6 mm 17 mm Set of 12 nos 18 Hand vice 37mm 40 Different types of Fuel Injection Pumps 19 Drill Twist assorted 41 Different types of Injectors 20 Hand reamer adjustable 42 FIP test Bench along with a set of special tools for repairing amp Testing different types of FIPs 21 Drilling machine 43 Injector test bench along with a set of special tools for repairing different types injectors Electric pedestal grinder with two wheel 44
10. 5 liter cap 7 Centre punch 10 mm dia x 100 mm 34 Cleaning Tray 45 x 30 cm 8 Chisel cold flat 20 mm 35 Work bench each 250 x 120x60 with 4 bench vices 12 cm jaw 9 Ring spanner set of 12 pieces 6 to 32mm 36 Pullers screw powered 2 mm with bearing puller attachment 10 Feeler gauge 20 blades metric 37 Vice grip pliers 11 Steel tool box with lock amp key folding type 38 Circlip pliers Expanding and contracting type 15 size 400x200x150mm cm and 20 cm each 12 Allen Key set of 12 pieces 2 mm to 14mm 39 Inspection lamp with guard and wandering lead of 100 ft 13 Philips Screw Driver Type set of 5 pieces 40 Hollow punch set of seven pieces 6 mm to 15 mm 100 mm to 300 mm 14 Steel Rule 30 cm English and metric 41 V Block 75 x 38 mm pair with Clamps 15 Prick punch 15 cm 42 Spanner off set double ended set of 7 pieces 6 mm 17 mm Set of 12 nos 16 Scriber 15 cm with scribing block universal 43 Spark Plug Spanner 17 Hacksaw frame adjustable for 30 cm blade 44 Different types of Injectors 18 Hand vice 37mm 45 Tachometer to read upto 5000 rom 19 Drill Twist assorted 46 Battery 12 V 20 Hand reamer adjustable 47 Hydrometer 21 Drilling machine 48 Air compressor 22 Electric pedestal grinder with two wheel 49 Water pump Washer 23 Portable electric drill 6 mm 50 Fire Extinguisher 24 Spark plug cleaner and tester similar to 51 Tyre repair kit Bosch champion 25 Battery
11. 61 Torque wrench 0 50Nm 31 Work bench each 250 x 120x60 with 4 bench 62 Tryre Pressure gauge vices 12 cm jaw 14 1 Module name 2 Sector 3 Code 4 Entry Qualification AUR205 Repair amp Overhauling of Motor Cycles Automotive Repair Minimum 5 Std 14 years of Age MES Module on Basic Automobile Servicing of 2 amp 3 Wheeler 5 Terminal competency Successful candidate would be able to carry out major repairs and overhauling of Motor Cycles 6 Duration 7 COURSE CONTENT Practice Health amp Safety select use maintain amp store tools equipments amp clothing safely Handle fuels oils lubricants acids alkalis adhesives seals solvents gases amp asbestos safely Water wash amp clean the vehicle Remove broken stud Check compression pressure Clean Fuel tank Dismantle clean check Engine components amp assemble Dismantle clean reset fit amp fine tune carburetor Dismantle clean check repair and refit clutch amp gear box Lubricate and grease the vehicle Prepare electrolyte amp charge the battery Check voltage resistance continuity and find fault in electrical circuits Dismantle clean check repair and assemble starter motor amp starting system Dismantle clean check repair and reassemble charging system Check voltage regulator Set Ignition timing Overhaul Disc amp drum brakes system Dismantle wheel bearing steering s
12. 6mm to 32mm set of 12 spanner 23 Hammer Peaning with handle 59 Scriber 150 mm 24 Hammer Creasing with handle 60 Safety Glasses 25 Hammer Planshing with handle 61 Hand vice 50mm 26 Hammer Block with handle 62 Steel wire Brush 50mmx150mm 27 Soft Hammers Brass Copper Lead Rubber 63 Rivet sets snap and Dolly combined 3mm 4mm and Rawhide heads with handle 6mm 28 Sher Tinmans 300mm 64 Leather Apron 29 Snips straight 250mm 65 Tongs Close mouth and pick up 1 each 30 Right cut snips 250mm 66 Portable Electric drill Single phase with drill bits 31 Left cut snips 250mm 67 Pillar type drilling machine 12mm with drill bits 32 Hand Shear Universal 250mm 68 Crow bar 910 x25mm 33 Punch Round 3mm 4mm amp 6mm Dia 69 Pop rivet gun 34 Centre Punch 100mm 70 Lazy Tong 35 Gloves for Welding Leather and Asbestos 71 Screw Driver 250mm 36 Chisel cold flat 25mm x250mm 72 C Clamp 150mm 40 73 Liquified Petroleum Gas LPG Cylinder 83 Wooden Rule 450mm Regulator and Torch with Burner 74 Bench lever shears 250mm Blade x 3mm 84 Portable Nibbler Capacity 75 Air Compressor with accessories 85 Welding Transformer 300 Amps with accessories 76 Spray Gun Painting 500ml 86 Gas Welding Table 1220mm x760mm 77 Guilltotine shearing Machine foot 87 Spot Welding Machine with complete accessori
13. Battery charger 6v 18 v 5 Common Rail Diesel Injection vehicle on a 13 Injector testing set hand operated stand with workshop manuals 6 Cut model of 4 stroke diesel engine on stand 14 Injector dismantling jig with mounting bench 7 Drilling machine bench to drill up to 12 mmdia 15 Engine cranker with 12V and 24 V Ac to DC Power supply system 8 Electric pedestal grinder with two 18 cm wheel 16 Engine scanner 23 Repair amp Overhauling of Chassis System Light Vehicle 1 Name Repair amp Overhauling of Chassis System Light Vehicle 2 Sector Automotive Repair 3 Code AUR208 4 Entry Qualification Minimum 5 Std amp 14 years of Age MES module on Basic Automotive Servicing 4 wheelers 5 Terminal competency Successful candidate would be able to Repair amp Overhauling Chassis System Light Vehicle 6 Duration 320 Hours 7 COURSE CONTENT Practical Competencies Underpinning Knowledge Theory e Practice Health amp Safety familiarize select use maintain amp store tools equipments consumables amp clothing safely e Identify different parts of chassis e Remove clutch plate from vehicle check for defects amp rectify replace amp refit e Remove gear box from vehicle dismantle check rectify fill lubricating oil amp assemble e Align gear selector fork e Remove CV Joint Dismantle lubricate amp refit e Remove crown wheel pinion a
14. Electric pedestal grinder 400x200x150mm 13 Allen Key set of 12 pieces 2 mm to 14 mm 40 Latest 2 Wheelers Moped Scooter Motor Cycle of different makes along with workshop manuals and special maintenance tools 14 Prick punch 15 cm 41 Tyre repair kit 15 Scriber 15 cm with scribing block universal 42 Battery charger 6v 18 v 16 Hacksaw frame adjustable for 30 cm blade 43 Torque wrench 0 50Nm 17 Taps and Dies complete set in a box BA BSW BSF 44 Auto Rickshaw chassis of petrol amp diesel American amp metric with handle 18 Drill Twist assorted 45 Carburetors of 2 amp 3 wheelers 19 Hand vice 37mm 46 Spark plug cleaner and tester 20 Hand reamer adjustable 10 5 to 11 25 mm 11 25 to 47 Water pump Washer 12 75 mm 12 75 to 14 25 mm and 14 25 to 15 75 mm 21 Spanner ring offset set of 6 S A E 48 Fire Extinguisher 22 Spanner adjustable 20 cm 49 Portable electric drill 6 mm 23 Spanner for spark plugs 14 mm 50 Tyre dread depth gauge 24 Spanners socket of 8 with handle T bar and ratchet 51 Tryre Pressure gauge 25 Oil can 0 5 liter cap 52 Wheel truing machine 26 Cleaning Tray 45 x 30 cm 53 Air compressor 27 Work benches each 250 x 120x60 with 4 bench vices 12 cm jaw 1 Module name Basic Automotive 4 wheeler servicing 2 Sector Automotive Repair 3 Code AUR101 4 Entry Qualification Minimum 5 Std 14 years of Age 5 Terminal competency Suc
15. TOOLS amp EQUIPMENT Suggested s n Item s n Item 1 Steel Rule 300mm 37 Vernier bevel protractor 2 Steel Tape 2 meters 38 Try square 200 mm Blade 3 Wing Divider 200mm 39 Ring spanner set at 12 metric 6 mm to 32 mm 4 Spring Dividers 150mm 40 Adjustable Spanner 10 cm 5 Ordinary Wooden Mallet 50mm 41 File flat 250mm second cut and smooth 6 Cross Peen Hammer 0 25 Kg with handle 42 File flat 250mm smooth 7 Ball peen Hammer 0 5 Kg with handle 43 File flat 300mm bastard 8 Protractor with blade 150mm 44 File half round 300mm smooth 9 Scriber 150mm x 3mm Engineers 45 Round File Fa Cut 250mm 10 Soldering copper 0 2 Kg 46 Triangular File Smooth 250mm 11 Goggles 47 Sonare File 2 Cut 250m 12 Gloves 48 Hacksaw frame 300mm adjustable 13 Apron 49 Hand Groover 3mm 4mm 5mm 14 Spark lighter 50 Combination Plier 15 Hammer Chipping 0 25 Kg 51 Grip Wrench 200mm 16 Tin Man s 450 mm x 600mm 52 Soldering Copper Hatchet type 500gms 17 Sheet Metal Gauge 53 Pneumatic riveting gun 18 Stake Round and Bottom 54 Trammel Point with beam 600mm 19 Half Moon Stake 55 Vernier Caliper Omm 150mm 20 Funnel Stake 56 Micrometer outside 0 to 25mm 21 Anvil Face Stake 57 Raspcut file 250mm 22 Tinmans Horse 58 D E Spanner
16. fenders Do gas welding gas brazing gas soldering amp gas cutting on vehicle body Do arc welding on vehicle body Do Resistance spot seam amp butt welding on vehicle body Do minor repair of auto body cut open beat out strip out old paint make smooth surface by using different grade of sanders apply putty on affected area amp primer repair damaged body which is ready for final paint Apply base coat painting Fit amp Check the repaired components for alignment VV V VV WV gt Safety precautions and first aid Proper Use Care and maintenance of tools amp equipment Introduction on types amp function of body amp panels Procedure for inspection removing amp refitting of body components panels doors amp other body parts GAS WELDING Gas Welding brazing amp Soldering procedures Gas cutting practice ARC WELDING Basic Electricity and welding power source Electrodes types description amp Specification Arc Welding procedure RESISTANCE WELDING Resistance welding process spot seam and Butt welding Method of fixation of wind screen glass Procedure for cut open beat out of dents stripping of old paints sanding at different stages smooth surface preparation at different stages putty application amp primer application at different stages of affected area Chronological order for repair of auto body Fitment of repaired part and aligning to the original shape 8
17. s n Item Trainees kit 1 Steel rule 15 cm English and metric Chisel cold flat 20 mm 2 Screw driver 20 cm x 9 mm blade 9 Ring spanner set of 12 pieces 6mm to 32 mm 3 Screw driver 30 cm x 9mm blade 10 Feeler gauge 20 blades metric 4 Spanner D E set of 12 pieces 6mm to 32 mm 11 Steel tool box with lock amp key folding type size 400x200x150mm 5 Pliers combination 12 Allen Key set of 12 pieces 2 mm to 14 mm 6 Hand file 20 cm Second cut 13 Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm 04 Sets 34 Spanner ring offset set 7 Centre punch 10 mm dia x 100 mm MEASURING INSTRUMENTS AND GENERAL SHOP TOOLS 1 Steel Rule 30 cm English and metric 36 Distributors 2 Engineer s square 15 cm blade 37 Carburetor two different types 3 Divider spring joint 15 cm 38 Crow bar 2 each 4 Prick punch 15 cm 2nos 39 Hollow punch set of seven pieces 6 mm to 15 mm 1 set 5 Chisels Cross cut 200 mm x 6 mm 40 Cleaning tray Aluminum 45 x 30 cm 6 Ball peen Hammer 0 5 kg 41 Valve spring Compressor 7 Scriber 15 cm with scribing block universal 42 Tool valve grinding suction type consumable tool 8 Hacksaw frame adjustable for 30 cm blade 43 Valve seat cutting tools complete with guides and pilot bar all angles in a box 9 Engineer s Stethoscope 04 Screw driver 30cm 44 Cylinder bore ga
18. 1 Petrol engine 4 stroke fitted with MPFI system for practice with manuals 29 Bearing puller screw powered hydraulic powered with 62 Petrol engine 4 stroke fitted with carburetor attachments Max spread 80 200 and 300mm for practice with manuals 30 Battery charger 6 24 V with 10 A rate 63 Petrol Engine car of latest model with manuals 31 Synchromesh gear box of LCV 2 Nos 64 Diesel Engine car of latest model with manuals 32 Electric pedestal grinder with two 18cm Wheel 65 Tyre remover pneumatic amp mechanical type 33 Vacuum gauge to read 0 to 760 mm of Hg 27 Repair amp Overhauling of Chassis System Heavy Vehicle 1 Name Repair amp Overhauling of Chassis System Heavy Vehicle 2 Sector Automotive Repair 3 Code AUR209 4 Entry Qualification Minimum 5 Std amp 14 years of Age MES module on Basic Automotive Servicing 4 wheelers 5 Terminal competency Successful candidate would be able to Repair amp Overhauling Chassis System Heavy Vehicle 6 Duration 320 Hours 7 COURSE CONTENT Practical Competencies Underpinning Knowledge Theory gt Knowledge on health amp safety precautions to be observed in the workshop garage health hazard of e Practice Health amp Safety familiarize select use asbestos dust to be emphasized maintain amp store tools equipments consumables amp gt Familiarization of workshop manual clothin
19. 100 mm workshop manual special maintenance tool amp spares 29 Piston Ring compressor amp Ring Expander 62 Carburetors of 3 Wheelers 30 Ring ridge remover 63 Water pump Washer 31 Spanner ring offset set of 6 pieces 64 Fire Extinguisher 32 Spanner adjustable 20 cm 66 Tyre repair kit 33 Socket Spanners with handle T bar and ratchet 67 Torque wrench 0 50Nm 34 Oil can 0 5 liter cap 68 Tryre Pressure gauge 1 Name Repair amp Overhauling of Engine Systems Petrol diesel 2 Sector Automotive Repair 3 Code AUR207 4 Entry Qualification Minimum 5 Std amp 14 years of Age MES module On Basic Automotive servicing 4 wheelers 5 Terminal competency Successful candidate would be able to Repair amp Overhauling of Engine Systems 6 Duration 320 Hours 6 COURSE CONTENT Practical Competencies Underpinning Knowledge Theory 20 Practice Health amp Safety familiarize select use maintain amp store tools equipments consumables amp clothing safely Select proper materials for gaskets and packing Select Locking devices and find their applications Identify differences between Petrol amp diesel Engines Identify differences between carburetor engine amp MPFI Engines Remove broken studs Remove engine from vehicle Drain engine oil and coolant Water wash engine decrease Dismantle completer engine and their components Check test compression press
20. 13 Philips Screw Driver Type set of 5 pieces 100 44 Piston Ring compressor amp Ring Expander mm to 300 mm 14 Steel Rule 30 cm English and metric 45 Tachometer to read up to 7000 rom 15 Prick punch 15 cm 46 Battery 12 V 16 Scriber 15 cm with scribing block universal 47 Vernier Caliper 250 or 200 mm inside outside amp depth 17 Hacksaw frame adjustable for 30 cm blade 48 DMM Auto range 18 Hand vice 37mm 49 Hydrometer 19 Drill Twist assorted 50 Bench Drilling M C to drill up to 12 mm dia 20 Taps and Dies complete set in a box BA 51 Electric pedestal grinder with two 18 cm BSW BSF American amp metric with handle wheel 21 Hand reamer adjustable 10 5 to 11 25 mm 52 3 latest 2 Wheelers Moped Scooter of 11 25 to 12 75 mm 12 75 to 14 25 mm and different makes along with workshop 14 25 to 15 75 mm manuals and special maintenance tools 22 Dial indicator to read 0 01 mm 53 Battery charger 6v 18 v 23 Outside Micrometer 0 25 mm 25 50 mm 50 54 Spark plug cleaner and tester similar to 75mm 75 100 mm Bosch champion 24 Piston ring filer 55 Portable electric drill 6 mm 25 Spanner ring offset set of 6 S AE 56 Carburetors of scooters 26 Spanner adjustable 20 cm 57 Air compressor 27 Spanner for spark plugs 14 mm 58 Water pump Washer 28 Socket Spanners with handle T bar amp ratchet 59 Fire Extinguisher 29 Oilcan 0 5 liter cap 60 Tyre repair kit 30 Cleaning Tray 45 x 30 cm
21. 4 Nos with stand 11_ V Block 75 x 38mm pair with Clamps 44 Cleaning tray Aluminum 45 x 30 cm 12 Valve grinding tool suction type 45 Spark plug spanner 14mm x 18mm x Size 13 C V Joint units of 3 different types 4 sets 46 Cut model of 4 stroke Diesel engine on stand 14 Drilling machine bench to drill up to 12mm die 47 Drum brake assembly 2 Nos 15 Engine analyzer 48 Disk brake with caliper assembly 2 Nos 16 Air compressor with accessories 49 Tandem master cylinder with booster 4 Nos 17 Tyre pressure gauge with accessories 50 Wheel cylinder 4 Nos 18 Horses and wheel choke 51 Lead acid battery 12 V 4 Nos 19 Screw jack one tone capacity double lift 52 Speed counter Tacho meter pointed type to read up to 5000 RPM 20 Chain and pulley block 3000 kg Capacity electric type 53 Petrol Engine of latest model CNG Engine with workshop manuals 21 Hydraulic jack with trolley capacity 3 Ton 54 Tubed tyre of cars 22 Engineers stethoscope 55 Electronic engine control modules 23 Oil can 0 5 0 25 liter capacity 56 Wheel alignment gauges 1 set 24 Cut model of 4 stroke Petrol engine on stand 57 Smoke testing machine 25 Scriber with scribing black universal 98 Triple leg grip puller with bearings attachment screw hydraulic Powered max Spread 80 160 250 450 mm 26 Marking out table 90X60X90 cm 59 Spark plug testing machine 27 Cleaning tray 45x30 cm 60 Crow bar 28 Valve spring lifter 6
22. Ales Be A aa sas 52 DIEDAN CUI CON AEREE E TEE E O E ETN 56 List of Expert Trade Committee Membets ccceeeeeeeeeeeeeeeeaeeeeeeeaeeaes 51 Skill Development based on Modular Employable Skills MES Background The need for giving emphasis on the Skill Development especially for the less educated poor and out of school youth has been highlighted in various forums The skill level and educational attainment of the work force determines the productivity income levels as well as the adaptability of the working class in changing environment Large percentage of population in India is living below poverty line One of the important causes is lower percentage of skilled persons in the workforce The skill development at present is taking place mostly in the informal way i e persons acquire skill at the work place when they help their parents relatives and employers etc Such persons do not have a formal certificate and thus earn lower wages and are exploited by employers They have come through informal system due to socio economic circumstances of the family and the compulsions of earning a livelihood rather than attending a formal course While their productivity is low their contribution to the national GDP cannot be ignored If the country can create a system of certification which not only recognizes their skills but also provides education and training in a mode that suits their economic compulsions it will not only benefi
23. Course Curricula for Short Term Courses based on Modular Employable Skills MES Automotive Repair Sector global village human gmail com ENO O R a Course Curricula for Short Term Courses based on Modular Employable Skills MES in the Automotive Repair Sector CONTENTS BACK QGOUNG pestis cnas coccsecstn ened cde cues E A iai A E A 2 Frame Work for Skill Development based on Modular Employable Skills 2 Age of PAMIGIDAINS sinana A etches lade Sioeel A ed eielstas 3 Curriculum Development ProceSS cccceeeeeeeeeeeeeceeeeeeeeeeeeeeeeaaeaeeeeeeeeeeeeennaaeaes 3 Development of Core Competencies 0 ceeeeeecenecceeeeeeeeeeeeeeaeeeeeeeeeeeeeeeeeeeeaeeeeeees 3 Duration of the Programmes sve suscexigz cues peas ciel voseeecatcieweagh hase tet ites aes ated 4 Pathways to acquire Qualification nasa aes ane ele nase elas 4 Method lggy sete satis ce atc shes siden te nei ade ashetaid Sed i i epeeele 5 Instr ctonal Media PACKAGQSS vices sts tics cate anea a a cues catermentalet 5 ASSESSMENT coe hicks red ca hee tebe a a ated eed e 5 COMICAL ana aie ein aha Ri aac cede tan E E S E tech cree E hth 5 COUISE Wat Dein aia aA cata a A a eins Ane or rea le et aia eat Cache 6 ilete seme ea ee me Dare me Acre ek A EE OCR ARC Rn eri A T 7 Basic Automobile Servicing of 2 amp 3 Wheeler cceeccccceeeeeeeeeeeneeeeeeeeeeeeeeeeenneeeeeeees 7 Basic Automotive 4 wheeler servicing ceeeeeee
24. Driver Type set of 5 pieces 100 46 Compression testing gauge to read 0 to 115 mm to 300 mm kg sq cm 14 Steel Rule 30 cm English and metric 47 Piston Ring compressor amp Ring Expander 15 Prick punch 15 cm 48 Tachometer to read up to 5000 rom 16 Scriber 15 cm with scribing block universal 49 Battery 12 V 17 Hacksaw frame adjustable for 30 cm blade 50 Vernier Caliper 250 or 200 mm inside outside amp depth 18 Hand vice 37mm 51 DMM Auto range 19 Stud remover 52 Hydrometer 20 Taps and Dies complete set in a box with 53 Drilling machine bench to drill up to 12 mm dia handle metric 21 Hand reamer adjustable 10 5 to 11 25 mm 54 Electric pedestal grinder with two 18 cm wheel 11 25 to 12 75 mm 12 75 to 14 25 mm and 14 25 to 15 75 mm 22 Dial indicator to read 0 01 mm 55 3 latest motor cycles of different make along with special tools amp workshop manuals 23 Outside Micrometer 0 25 mm 25 50 mm 50 56 Spark plug cleaner and tester 75mm 75 100 mm 24 Mallets wooden plastic 57 Battery charger 6v 18 v 25 Piston ring filer 58 Portable electric drill 6 mm 26 Spanner ring offset set of 6 Metric 59 Carburetors of motor cycles 27 Spanner adjustable 20 cm 60 Air compressor 28 Spanner for spark plugs 14 mm 61 Water pump Washer 29 Socket Spanners with handle T bar amp ratchet 62 Fire Extinguisher 30 Oil can 0 5 liter cap 63 Torque wrench 0 50Nm 31 Cleaning Tray 45 x 30 cm
25. Hand file 20 cm Second cut half round 2 Screw driver 20cm X 9mm Blade 19 Hand file 20 cm smooth triangular 3 Screw driver 30 cm X 9 mm Blade 20 12 Hand file 30 cm bastard 4 Spanner D E set of 12 pieces 6mm to 32mm 21 Steel tools box with lock and key folding type size400X200X150mm 5 Pliers combination 20 cm 22 Circlip pliers 15 cm Expanding type 6 Pliers side cutting 15 cm 23 Chisel cold flat 20 mm 7 Plier round nose 15 cm 24 Hand file 30 cm round bastard 8 Plier flat nose 15 cm 25 Centre punch 10 cm 9 Hollow punch set of seven pieces 6mm to 15mm 1 Set 26 Ball peen Hammer 0 5kg 10 Drift punch copper 15 cm 27 Adjustable spanner pipe wrench 350 mm 11 Prick punch 15 cm 28 Spanner ring set of 12 metric sizes 6 to 32 mm 12 Chisels cross cut 200 mm X 6mm 29 Spanner adjustable 15cm 13 Allen Key set of 12 pieces 2mm to 14mm 30 Spanner for spark plugs 14mm 14 Philips Screw Driver set of 5 pieces 100 mm to 300 31 Hand reamers adjustable 10 5 to 11 25 mm mm 11 25 to 12 75 mm 12 75 to 14 25 mm and 14 25 to 15 75 mm 15 Mallets wooden plastic 32 Vice grip pliers 16 Spanners socket with speed handle T bar ratchet 33 Circlip pliers Expanding and contracting type and universal upto 32 mm set of 28 pieces with box 15cm and 20cm 17 Hand file 20 cm Second cut flat 34 Circlip pliers 15 cm Contracting type s n Item s n Item b SHOP OUTFIT amp MEASURING INSTRUMENTS 1 Cylinder
26. Health amp Safety familiarize select use maintain amp store tools equipments consumables amp clothing safely Identify various components of air condition system on the mockup board Identify various electrical equipments i e junction box ground connections switches modules amp sensors on vehicle Measure voltage resistance amp continuity in different lines for air conditioning system climate control reconcile Ohm s law Check of circuit breakers and relays Check sensors amp actuators using engine scanner DMM Check duty of idle air control valve with ac on amp off with different engine RPM Remove compressor from the vehicle dismantle check rectify the defect assemble amp refit to the vehicle Remove expansion valve from the system dismantle check rectify the defect amp refit into the system Remove evaporator amp heater cores from the vehicle dismantle check rectify the defect assemble amp refit to the vehicle Check condenser on the vehicle amp rectify the defect Check the drive system amp adjust if required e Check Belt tension e Check Gap in electromagnetic clutch Remove amp refit heater control module Test the system for leaks Evacuate drain the system Charge fill the system Find the Faults amp rectify in the climate control system Rep gt gt Safety precautions and first aid Handling of refrigerants Proper Use Care and maintenance of tools amp
27. Health amp Safety select use maintain amp store tools equipments amp clothing safely Practice 5S technic Identify Familiarize with the tools amp equipments Identify components of 2 amp 3 wheeler from assembly drawings amp diagrams Water washing cleaning of 2 amp 3 wheelers Clean replace air cleaner fuel strainers and oil filters Drain amp replenish lubricants Remove clean check refit replace fuel tank fuel pipes fuel tap operation Clean Check and Adjust spark plug Replace brake components adjust brake amp top up brake fluid Adjust clutch play Adjust remove links amp lubricate drive chain Replace control cables clutch brake amp accelerator cables adjust clutch amp brake plays Charge the battery Check pressure inflate measure tread depth inspect for damage do Wheel truing Repair tyre puncture amp Tuffe up tube Check and replace bulbs VVVVVV VV V General health amp Safety precautions to be observed in the workshop garage Over view on 5S technic Sort Set in order Shine Sweep Standardise amp Sustain advantages in implementation of 5S Working principle of 2 amp 4 stroke engines Procedure for dismantling cleaning amp assembling of major assemblies of vehicle Functions amp Types of lubrication amp cooling systems Fuel system layouts Petrol diesel amp CNG Functions of carburetor and adjustments Ignition system circuit amp compone
28. ONTENT Practice Health amp Safety select use maintain amp General health amp Safety precautions to be observed store tools equipments amp clothing safely in the workshop garage Practice 5S technic Over view on 5S technic Sort Set in order Shine Identify Familiarize with the tools amp equipments Standardise amp Sustain advantages in Wash Clean FIP and Injectors implementation of 5S Check the FIP on calibration bench and assess the Fuel supply layouts in diesel engines condition Nomenclature of different types of fuel injection Dismantle FIP using special tools pumps Clean and inspect Parts of each components Working principle of FIP Replace defective components Components of an FIP and detailed functioning of each one of them Differences between different types of fuel injection pumps Working principle of Injection Timers and Governors Brief on the FIP Test rig amp calibration charts Procedure for phasing amp calibration of an FIP Purpose types construction amp operation of Injectors and nozzles Procedure for testing the Injectors as per specification Vv VV VV Assemble FIP using special tools Calibrate FIP using calibration test bench Test the Injectors using Injector Tester Replace defective nozzles using special tools Assemble injectors and test gt gt gt gt gt gt gt gt Note Do the practical works as per the manufacturer s recommendations mentioned in the ser
29. afety consciousness and safe working practices Care of equipment and tools Punctuality discipline and honesty Concern for quality Respect for rules and regulations Concern for health and hygiene Cordial relationship and Cooperation with co workers and team Work Positive attitude and behavior 9 Responsibility and accountability 10 Learn continously 11 Communication Skills 12 Concern for environment and waste disposal Following competencies should also be developed during level I and higher courses 1 Ability for planning organizing and coordinating 2 Creative thinking problem solving and decision making 3 Leadership 4 5 Negotiation Ability to bear stress Duration of the Programmes Time taken to gain the qualification will vary according to the pathway taken and will be kept very flexible for persons with different backgrounds and experience Duration has been prescribed in hours in the curriculum of individual module which are based on the content and requirements of a MES Module However some persons may take more time than the prescribed time They should be provided reasonable time to complete the course Pathways to acquire Qualification Access to the qualification could be through An approved training programme Or A combination of an approved training programme plus recognition of prior learning including credit transfer Or The recognition of prior learning that
30. ake training cost effective Testing of skills of trainees by independent assessing bodies who would not be involved in conduct of the training programme to ensure that it is done impartially Testing amp certification of prior learning skills of persons acquired informally gt 9 22 The Short Term courses would be based on Modular Employable Skills MES The concept for the MES is a Identification of minimum skills set which is sufficient to get an employment in the labour market a It allows skills upgradation multiskilling multi entry and exit vertical mobility and life long learning opportunities in a flexible manner a It also allows recognition of prior learning certification of skills acquired informally effectively a The modules in a sector when grouped together could lead to a qualification equivalent to National Trade Certificate or higher a Courses could be available from level 1 to level 3 in different vocations depending upon the need of the employer organisations a MES would benefit different target groups like o Workers seeking certification of their skills acquired informally o workers seeking skill upgradation o early school drop outs and unemployed o previously child labour and their familly Age of participants The minimum age limit for persons to take part in the scheme is 14 years but there is no upper age limit Curriculum Development Process Following pr
31. ance continuity and find fault in electrical circuits Dismantle wheel bearing steering stem amp ball race inspect amp assemble gt Check the working condition of emission control devices gt Replacement of front fork oil oil seals Do fine tuning amp Test Engine Knowledge on health amp safety Reading of workshop manual Procedure for checking compression pressure Procedure for dismantling checking amp assembling of an engine Do s amp Don ts during dismantling amp assembling of an engine Measurement using micrometer dial gauges amp feeler gauges Construction amp operation of carburetor Procedure for dismantling cleaning checking amp assembling a carburetor Working principle of multi plate clutch amp gear box Procedure for dismantling inspecting amp assembling clutch amp gear box Procedure for fine tuning amp testing the engine Use of multimeter Fundamental electrical principle Ohm s Law Series amp Parallel resistances circuits Working principle application amp checking of transistors Wiring colour code Ignition system circuit and faults finding procedure Working principle Procedure for dismantling inspecting amp assembling of starter motor Working principle amp procedure for overhauling amp testing Charging system components Procedure for dismantling amp assembling of shock absorbers Lighting system circuits amp fault finding procedure P
32. andling amp reading micrometers dial gauges Torque wrenches angle meter amp multimeter Fundamental electrical principles Ohm s Law Series amp Parallel resistances circuits Working principle types amp application of capacitors amp transistors Wiring colour code reading of engine electrical systems circuits Working principle Different types amp application of starter motor alternator carburetor FIPs Injectors filters fuel pumps liners pistons piston rings valves valve drives bearings used on engines MPFI system components Procedure for dismantling checking assembling amp testing of starter motor amp cooling fan motor Procedure for dismantling checking assembling amp testing of alternator Procedure for removing engines from the vehicle Procedure for checking testing compression pressure cylinder head amp block warpage valve leak lubricating oil pressure bearing oil clearance bore measurement ring end gap amp side clearance fuel pressure regulator in MPFI engine inlet manifold vacuum cam amp crank shaft bend amp valve timing Procedure for dismantling checking assembling amp testing of petrol engines Procedure for dismantling checking assembling amp testing of diesel engines Latest emission norms Controls available to meet the norms amp their working principle 21 8 TOOLS amp EQUIPMENT Suggested s n Item
33. application e Remove amp clean brake drums Check disc drum run gt Working principle of constant velocity joints out Fit new cups and brake hoses pipes assemble gt Working principle of differential adjust all wheel brakes and test for brake concern gt Faults in differential C V Joints amp drive shafts e Check and correct the steering geometry with gt BRAKE Forces amp moments acting on vehicle brake instruments slip braking force co efficient time element of braking Remove and refit steering boxes from vehicle check and top up oil in steering box Check and adjusting steering wheel play and backlash Overhaul hydraulic power assisted steering system pump control valve amp cylinder Remove and refitting a leaf spring as an assembly in a vehicle changing rubber bushes of shock absorbers and independent front suspension Lubricate suspension units Re camber the leaf spring Overhaul shackles Remove tyre inspect check amp assemble Rotate the tyres Remove and refit head lamp Check for electrical defects and rectify Do Final road test observe for Noise Vibration amp harshness from different part of chassis observe for problems in transmission brake clutch steering amp suspension systems amp rectify the defect Vv vVVV WV operation Classification of brake systems factors affecting the braking distance Advantages of pneumatic brake system over hydraulic Workin
34. ard with semi automatic air conditioning system 4 Hacksaw 21 Service units with set of Compound pressure gauges Recovery Machine amp charging Unit 5 DE Spanner Set 22 Leak detectors electronic amp UV lamp 6 Vice 23 Drilling Machine 7 Hammer 24 2 sets of condensers 8 Pliers 25 2 sets of compressors of different types 9 Pipe Wrench 26 2 sets of expansion valves of different types 10 Screw Wrench 27 2 sets of evaporators of different types 11 Ring Spanner Set 28 2 sets of air distribution doors of different types 12 Hydraulic jack 29 2 sets of coolant control valves heater control 13 2 Torque wrenches of different capacity 30 2 sets of A C control assemblies of different types 14 Solder Iron 31 2 sets of switches of different types HP amp LP Switches 15 Inspection lamp with guard and wandering lead of 100 32 2 sets of Thermistors ft 16 Tripod axle stand adjustable 1500 kg capacity 33 Heater control modules E amp C Unit 17 Vehicle with dual air conditioning system along with 34 2 sets of blower motor special tools for removing and refitting air conditioning system amp work shop manuals 35 2 sets of receiver drier 36 Wheel alignment amp balancing 1 Name Wheel alignment amp balancing 2 Sector Automotive Repair 3 Code AUR211 4 Entry Qualification Minimum 5th Std 14 years of Age MES Module on Basic Automotive Servicing 4wheelers 5 Terminal competency Successful cand
35. auge 20 blades metric 45 Spanner off set double ended set of 7 pieces 6 mm 17 mm Set of 12 nos 12 Steel toolbox with lock amp key folding type size 46 Compression testing gauge to read 0 to 115 400x200x150mm kg sq cm 13 Allen Key set of 12 pieces 2 mm to 14 mm 47 Vernier Caliper 250 or 200 mm inside outside amp depth 14 Philips Screw Driver Type set of 5 pieces 100 48 Battery 12 V mm to 300 mm 15 Steel Rule 30 cm English and metric 49 Tachometer to read up to 5000 rpm 16 Prick punch 15 cm 50 Drilling machine bench to drill up to 12 mm dia 17 Scriber 15 cm with scribing block universal 51 Hydrometer 18 Hacksaw frame adjustable for 30 cm blade 52 DMM Auto range 19 Hand vice 37mm Straight edge gauge 20 Stud remover 53 Battery charger 6v 18 v 21 Taps and Dies complete set in a box with handle 54 Air compressor metric 22 Spanner for spark plugs 14 mm 55 Single Cylinder Diesel Engine 23 Hand reamer adjustable 10 5 to 11 25 mm 56 Electric pedestal grinder with two 18 cm wheel 11 25 to 12 75 mm 12 75 to 14 25 mm and 14 25 to 15 75 mm 24 Cylinder bore gauge 57 Portable electric drill 6 mm 25 Dial indicator to read 0 01 mm 58 Spark plug cleaner and tester similar to Bosch champion 26 Piston ring filer 59 Injectors 27 _ Mallets wooden plastic 60 Single cylinder FIP 28 Outside Micrometer 0 25 mm 25 50 mm 50 75mm 61 Latest 3 Wheelers of different make along with 75
36. bearings attachment screw hydraulic Powered max Spread 80 160 250 450 mm 26 Marking out table 90X60X90 cm 59 Crow bar 27 Cleaning tray 45x30 cm 60 Diesel engine 28 Valve spring lifter 61 HCV of latest model with manuals 29 Bearing puller screw powered hydraulic powered with 62 Tyre remover pneumatic amp mechanical type attachments Max spread 80 200 and 300mm 30 Battery charger 6 24 V with 10 A rate 63 EGR cut out 31 Synchromesh gear box of LCV 2 Nos 64 Set of sensors amp actuators 32 Electric pedestal grinder with two 18cm Wheel 65 Common Rail diesel engine on a stand 33 Injector tester 66 Pneumatic brake system on a bed board 31 Repair of Auto Electrical amp Electronics Systems as ol Entry Qualification Terminal competency Duration Repair of Auto Electrical amp Electronics Systems Name Sector Automotive Repair Code AUR215 Minimum 8 Std amp 14 years of Age MES module on Basic Automotive Servicing 4 wheelers Successful candidate would be able to Repair Auto Electrical amp Electronics System 320 Hours COURSE CONTENT Practical Competencies Underpinning Knowledge Theory Practice Health amp Safety familiarize select use maintain amp store tools equipments consumables amp clothing safely Identify different tools amp equipments Identify different electrical parts of a vehicle
37. bore gauge capacity 20 to 160 mm 6 Dividers spring 15 cm 2 Micrometer out side 0 25 mm 25 50 mm 50 75 7 Steel Rule 30 cm English and metric mm 75 100 mm 3 Micrometer in side 25 50 50 75 75 150 mm with 8 Compression testing gauge to read 0 to 50 extension rod kg sq cm 4 Torque wrench 5 to 35 Nm 12 68 Nm amp 50 225 9 Engineer s square 15 cm Blade Nm 5 Straight edge gauge 2 ft 10 Feeler gauge 20 blades metric 26 s n Item s n Item C GENERAL INSTALLATION MACHINERIES 1 Drill Twist assorted 34 Taps and Dies complete sets 5 types 2 Surface Plate 60 x 60cm 1 No 100 Petrol Engine of 35 Piston ring expander and remover 50 mm amp latest model CNG Engine with workshop manuals 100 mm 3 Hacksaw frame adjustable 36 Piston Ring compressor 4 Distributor 37 Piston Ring Groove cleaner 5 Carburetor 38 Cylinder ridge remover cutter 6 Fuel feed pump 39 Work bench 250 x 120 x 60 cm with 2 vices 7 4 Wheeler petrol vehicle fitted with MPFI system 40 Pullers screw powered 2 mm gap with carburetor system with manuals bearing puller 8 Valve seat cutting tools complete with guides and pilot 41 Inspection lamp with guard and wandering bar all angles lead of 100ft length 9 Valve key inserter 42 Fire extinguisher ABC type 5 kg capacity 10 Hand vice 37 mm 43 Fire Buckets
38. cessful candidate would be able to carry out servicing and minor repairs of 4 Wheelers 6 Duration 180 Hours 7 COURSE CONTENT Practice Health amp Safety select use maintain amp gt General health amp Safety precautions to be observed store tools equipments amp clothing safely in the workshop garage Practice 5S technic gt Over view on 5S technic Sort Set in order Shine Identify Familiarize with the tools amp equipments Standardise amp Sustain advantages in Water wash before amp after servicing implementation of 5S Check replenish top up lubricating oil brake Nomenclature of different parts of vehicle and their fluid engine coolant power steering hydraulic oil locations wind screen wiper water battery electrolyte and Working principle of 4 stroke petrol amp diesel engines transmission oil Differences between petrol amp diesel engines Clean replace air cleaner oil filter amp fuel filter Lubrication and cooling system amp types of lubricants Apply Grease to parts through greasing points Lay out of greasing points Remove amp refit vehicle body parts bonnet front Torquing amp detorquing technique procedures bumper amp door Fuel supply layouts in both petrol amp diesel engines Remove and refit head lamp assembly Layout of power flow from Engine to wheels Check power plug and inspect H T cables Ignition system circuit amp components Clean Check and Adjust spark pl
39. charger 6v 18 v 52 Torque wrench 0 50Nm 26 Latest 4 Wheelers of different make one 53 Tryre Pressure gauge LMV amp one HCV along with workshop manuals 27 Grease gun 54 Tread depth gauge 10 1 Module name Repair amp Overhauling of Mopeds 2 Sector Automotive Repair 3 Code AUR203 4 Entry Qualification Minimum 5 Std 14 years of Age MES Module on Basic Automobile Servicing of 2 amp 3 Wheeler 5 Terminal competency Successful candidate would be able to carry out major repairs and overhauling of Mopeds 6 Duration 210 Hours 7 COURSE CONTENT Underpinning Knowledge Theory Practice Health amp Safety select use maintain amp Knowledge on health amp safety store tools equipments amp clothing safely Handle Procedure for checking compression pressure fuels oils lubricants acids amp asbestos safely Procedure for dismantling engine Identification of Tools measuring instruments amp Valve port timing diagram of 2 stroke engine equipments used for the trade Air fuel Ratio at different conditions Measure any components by using the micrometer Knowledge on micrometer feeler gauge amp dial amp dial gauge practice gauges Remove broken stud gt Procedure for dismantling inspecting component Dismantle clean check assemble and adjust checks assembling engine amp transmission carburetor system overhauling of an engine amp Clean intake and exhaust system transmi
40. e with guides and pilot 41 Inspection lamp with guard and wandering lead of bar all angles 100ft length 9 Valve key inserter 42 Fire extinguisher ABC type 5 kg capacity 10 Hand vice 37 mm 43 Fire Buckets 4 Nos with stand 11_ V Block 75 x 38mm pair with Clamps 44 Cleaning tray Aluminum 45 x 30 cm 12 valve grinding tool suction type 45 Spark plug spanner 14mm x 18mm x Size 13 C V Joint units of 3 different types 4 sets 46 Cut model of 4 stroke Diesel engine on stand 14 Drilling machine bench to drill up to 12mm die 47 Drum brake assembly 2 Nos 15 Engine analyzer 48 Disk brake with caliper assembly 2 Nos 16 Air compressor with accessories 49 Tandem master cylinder with booster 4 Nos 17 Tyre pressure gauge with accessories 50 Wheel cylinder 4 Nos 18 Horses and wheel choke 51 Lead acid battery 12 V 4 Nos 19 Screw jack one tone capacity double lift 52 Speed counter Tacho meter pointed type to read up to 5000 RPM 20 Chain and pulley block 3000 kg Capacity electric type 53 Diesel Engine of latest model CNG Engine with workshop manuals 21 Hydraulic jack with trolley capacity 3 Ton 54 Tubed tyre of HCV 22 Engineers stethoscope 55 Electronic control module 23 Oil can 0 5 0 25 liter capacity 96 Wheel alignment gauges 1 set 24 Cut model of 4 stroke Petrol engine on stand 57 Smoke testing machine 25 Scriber with scribing black universal 98 Triple leg grip puller with
41. eeneeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeeeeenueeeeeeeees 9 Repair amp Overhauling of MOpeds ccceeeeecceecceeeeeeeeeeeeeeeaeeeeeeeeeeeeesescnaaeeeeeeeees 11 Repair amp Overhauling of Scooters 4 00 cn acee cane nada dk 13 Repair amp Overhauling of Motor Cycles cc cees derer cone cece deen eceeneceneeeenee 15 Repair amp Overhauling of 3 Wheelers c ccceeeeeeeeeeeeeeeeeneeeeeeeeeeeeeeeeeeneeeeeeeeeeeees 17 Repair amp Overhauling of Engine Systems Petrol diesel eeceeseeeeeeeeeeeeees 19 Repair amp Overhauling of Chassis System Light Vehicle ceeeeeeeeeeeeeeeeeees 23 Repair amp Overhauling of Chassis System Heavy Vehicle ceceeeeeeeeeeeeeees 27 Repair of Auto Electrical amp Electronics Systems 0 ceeeceeeeeeeeeeeeeeeeeeeeeeteeeeeeeeees 31 Repairing of Auto Air Conditioning System eceeeeeeee errre eens eee eeeeeeeeeees 34 Wheel alignment amp balancing 0 cc2 220sceccceeeeceetey ee ceceeeeteteedeeeneagereeceeetaee eens 36 Minor repair of AUIO DOGY sa22escwvrcnnsd suis seneab ena seRamonlseewaute tise deeds Mab hese heats 38 Auto body Paintings eein to sates Sls ot ds Puello EAA 41 Diesel Fuel Injection Technician cccccceee cece cee ee ee ee esse eeeeeaeeeaeeeneees 42 Bicycle and Tricycle Tepalf s2 c02ieartccarbceaseeteitearceest a leacestegiee essbecey teense 45 Sut Control Fili Pixie ecstacy ss Agee e Sean
42. el Rule 30 cm English and metric 45 DMM Auto range 15 Prick punch 15 cm 46 Inspection lamp with guard 16 Scriber 15 cm with scribing block universal 47 Spark plug cleaner and tester 17 Hacksaw frame adjustable for 30 cm blade 48 Valve spring Compressor 18 Hand vice 37mm 49 Tool valve grinding suction type consumable tool 19 Drill Twist assorted 50 Valve seat cutting tools complete with guides and pilot bar all angles in a box 20 Taps and Dies complete set in a box BA 51 Cylinder bore gauge BSW BSF American amp metric with handle 21 Hand reamer adjustable 10 5 to 11 25 mm 52 V Block 75 x 38 mm pair with Clamps 11 25 to 12 75 mm 12 75 to 14 25 mm and 14 25 to 15 75 mm 22 Dial indicator to read 0 01 mm 53 Compression testing gauge to read 0 to 115 kg sq cm 23 Circlip pliers Expanding and contracting type 54 Battery charger 6v 18 v 15 cm and 20 cm each 24 Piston Ring compressor amp Ring Expander 55 3 latest mopeds of different make along with workshop manuals and special maintenance tools 25 Tachometer to read upto 5000 rom 56 Carburetors of mopeds 26 Battery 12 V 57 Air compressor 27 Vernier Caliper 250 or 200 mm inside outside amp 58 Water pump Washer depth 28 Hydrometer 59 Fire Extinguisher 29 Drilling machine bench to drill up to 12 mm dia 60 Torque wrench 0 50Nm 30 Electric pedestal grinder with two 18 cm wheel 61 Tryre Pressure gauge 31 Portable e
43. equipment Signs and symbols used in Air conditioning system Fundamentals of air conditioning a Introduction purpose basic operation of refrigeration cycle basic components amp circuits with fixed orifice tube amp thermal expansion valve Mechanical amp Electrical circuits use of thermometer and pressure gauges b Definition of technical terms pressure temperature heat heat quantity specific heat amp heat transfer Humidity change of state amp pressure temperature relation c Refrigeration cycle high pressure side amp low pressure side d characteristics of R12 amp R134a e lubrication f cooling load and capacity g a c systems car air conditioning types amp features dash type all season type amp dual air conditioner type heater cooler independent system reheat air condition system semi air mix type full air mix type automatic temperature control systems Electrical basics Ohm s law Current Potential difference Resistance amp their units Use of multi meter Brief on Magnetism Semiconductor amp application only brief Description working principles types uses location amp checking of switches Circuit protectors relays solenoids resistors diodes amp Heater Control Module Working principle of sensors throttle position Potentiometer Air temperature Thermistor Engine coolant temperature NTC type crank shaft position engine speed sensors magnetic pick up t
44. es operation Imt x 18G Capacity 78 Oxy acetylene welding equipment with 88 Tin smiths bench folder 600 x 1 6mm complete accessories Low amp high pressure 79 D E Grinder Pedestal motorized 200mm 89 Suitable Work Tables with vices 80 Anvil 50 Kgs with Stand 90 Polishing cloth standard size 81 Bench vice 91 LCV Condemned 82 Buffing and Polishing Machine 92 Consumables 4 Auto body Painting 1 Name 2 Sector 3 Code 4 Entry Qualification Auto body Painting Automotive Repair AUR213 Minimum 5th Std 14 years of Age amp MES Module on Basic Automotive Servicing 4 wheelers ol Terminal competency Successful candidate would be able to do auto body Painting 6 Duration J COURSE CONTENT 180 Hours Practical Competencies Underpinning Knowledge Theory gt Practice Health amp Safety familiarize select gt Safety precautions and first aid Use Care and maintenance of proper use maintain amp store tools tools amp equipment eae equipments consumables amp clothing safely gt Selection of consumable for doing painting work gt Prepare the damaged body for painting gt Procedure for doing painting in chronological order selection S Aoo body fll ton he aeGed area of material tools amp equipments Application of body filler for PRY Pedy surface preparation Sanding on t
45. g Types available in 3 Wheelers cycles procedure for handling assembling amp dismantling Purpose amp function of shock absorber Procedure for overhauling a shock absorber Latest emission norms Latest emission controls available to meet the norms amp their working principle Do the practical works as per the manufacturer s recommendations mentioned in the service manual of the particular brand of vehicle 8 TOOLS amp EQUIPMENTS Suggested s no Item s no Item 1 Hammer ball peen 0 75 kg 35 Cleaning Tray 45 x 30 cm 2 Screw driver 20 cm x 9 mm blade 36 Work bench each 250 x 120x60 with 4 bench vices 12 cm jaw 3 Screw driver 30 cm x 9 mm blade 37 Circlip pliers Expanding and contracting type 15 cm and 20 cm each 4 Spanner D E set of 12 pieces 6mm to 32 mm 38 Inspection lamp with guard and wandering lead of 100 ft 5 Pliers combination 15 cm 39 Vice grip pliers 6 Hand file 20 cm Second cut 40 Valve spring Compressor 7 Hollow punch set of seven pieces 6 to15mm 41 Tool valve grinding suction type 8 Centre punch 10 mm dia x 100 mm 42 Valve seat cutting tools complete with guides and pilot bar all angles in a box 9 Chisel cold flat 20 mm 43 Surface Plate 60 x 60 cm 10 Ring spanner set of 12 pieces 6 to 32 mm 44 V Block 75 x 38 mm pair with Clamps 11 Feeler g
46. g principle of brake components compressor pressure regulator different pneumatic valves brake booster wheel cylinder Brake linings amp pads Brake faults diagnostics and adjustments Introduction to anti lock braking system ABS STEERING Introduction basic types of steering steering geometry necessity types amp effects steering characters over steer under steer amp neutral steer amp steering linkage Types of steering gear power assisted steering hydraulic Checks on steering system and fault diagnosis SUSPENSION Introduction requirement types leaf spring shock absorber Checks on suspension system and fault diagnosis WHEELS amp TYRES necessity functions designation amp defects analysis Procedure for tyre rotation Fundamental electrical principles Ohm s Law Series amp Parallel resistances circuits Working principle types amp application of capacitors amp transistors Usage of multimeter Wiring colour code reading of engine electrical systems circuits Fault finding in electrical circuits Final road test procedure observation of Noise Vibration amp harshness from different part of chassis observation of transmission brake clutch steering amp suspension systems for their satisfactory working 29 Note Do the practical works as per the manufacturer s recommendations mentioned in the service manual of the particular brand of vehicle
47. g safely gt Familiarization of different tools amp equipments e Identify different parts of chassis gt TRANSMISSION Power flow from engine to wheels e Identify different tools amp equipments gt Units amp Definition of force work power torque amp pressure e Remove clutch plate from vehicle check for defects amp gt Description of single plate clutch Functions of different reculy teplace rem l l parts of the clutch assembly Clutch linings material e Remove gear box from vehicle dismantle check Power flow in clutch plate rectify fill lubricating oil amp assemble Clutch operating mechanisms manual amp hydraulic e Align gear selector fork Clutch faults e Remove CV Joint Dismantle lubricate amp refit Type of gears and their application advantages and e Remove crown wheel pinion and bearings clean disadvantages gear ratio parts Check tooth contact in the crown and pinion and Types of gear box adjust backlash amp Assemble rear axle assembly Working principle of constant mesh synchromesh gear e Check and adjust parking brake and service brakes boxes VV Vv Vv Dismantle wheel brake assembly remove old lining gt Gear selection mechanism and fit new one gt Lubrication of transmission system e Overhaul pneumatic valves Wheel cylinders amp Drum gt Gear box faults brake disc brakes gt Types of bearings maintenance their characteristics amp e Check fail safe system amp rectify defects
48. he affected area for smooth gt Apply base coat surface preparation Primer coating on the affected area gt Apply clear coat Preparing affected surface for base coating Applying base coat gt Do painting painting Clear coat painting for metallic paints Rubbing and gt Do rubbing amp polishing polishing gt Apply anti rust treatment gt Application of Paint protection treatment l Anti rust treatment gt Fix wind screen glasses gt Procedure for Inspection of painting work amp fixing the wind ra screen glass gt Inspect the painting work 8 TOOLS amp EQUIPMENT Suggested 1 General tools 8 Sanding emery 40G 80G 120G 220G 400G 600G 1500G 2000G 2 _ LCV Condemned vehicle body 9 Primer Hardener amp thinner 3 Air Compressor with accessories 10 Paints 4 Spray Gun Painting 500ml 11 Poly urethane body filler 5 Buffing and Polishing Machine 12 Rubbing amp polishing compounds 6 Bench vice 13 Polishing cloth standard size 7 Consumables 14 42 Diesel Fuel Injection Technician 1 Module name Diesel Fuel Injection Technician 2 Sector Automotive Repair 3 Code AUR214 4 Entry Qualification Minimum 5th Std 14 years of Age amp MES Module on Basic Automotive Servicing 4 wheelers 5 Terminal competency Successful candidate would be able to carry out repair and calibration of Diesel Fuel Injection pump amp injectors 6 Duration 180 Hours 7 COURSE C
49. idate would be able to do wheel Alignment amp wheel balancing 6 Duration 120 Hours 7 COURSE CONTENT Practical Competencies Underpinning Knowledge Theory gt Practice Health amp Safety familiarize select use maintain amp store tools equipments consumables amp clothing safely Wheel alignment gt Check tyres ride height wheel bearings ball joints control arms bushings and sway bars shock absorbers amp struts amp power steering Set the aligner ready for wheel alignment tests Check and rectify steering geometry with wheel aligner take a print out VV Wheel balancing Remove tyre from vehicle Check tyre amp rim and also check for run out Do static balancing Fit the wheel assembly on the aligner and check for dynamic imbalance amp rectify the defects gt Fit the tyre assembly to the vehicle VVVV gt Safety precautions and first aid Care and maintenance of tools amp equipment Wheel alignment gt gt gt VV V gt gt gt Layout of steering amp suspension systems function of each part Brief on suspension and its effects on steering Steering geometry Description and purposes of Ackerman steering toe castor camber king pin inclination SAl steering Axis Inclination turning angle included angle set back thrust angle amp frame angle Pre alignment inspection checks Two wheel amp four wheel alignment Reasons for Alignment proble
50. ing procedure for assembling amp dismantling 15 Do the practical works as per the manufacturer s recommendations mentioned in the service manual of the particular brand of vehicle 8 TOOLS amp EQUIPMENTS Suggested s no Item s no Item 1 Hammer ball peen 0 75 kg 34 Pullers screw powered 2 mm with bearing puller attachment 2 Screw driver 20 cm x 9 mm blade 35 Vice grip pliers 3 Screw driver 30 cm x 9 mm blade 36 Circlip pliers Expanding and contracting type 15 cm and 20 cm each 4 Spanner D E set of 12 pieces 6mm to 32 mm 37 Inspection lamp with guard 5 Pliers combination 15 cm 38 Hollow punch set of seven pieces 6 to 15 mm 6 Hand file 20 cm Second cut 39 Valve spring Compressor 7 Centre punch 10 mm dia x 100 mm 40 Tool valve grinding suction type consumable tool 8 Chisel cold flat 20 mm 41 Valve seat cutting tools complete with guides and pilot bar all angles in a box 9 Ring spanner set of 12 pieces 6 to 32 mm 42 Cylinder bore gauge capacity 50 to 150 mm 10 Feeler gauge 20 blades metric 43 Surface Plate 60 x 60 cm 11 Steel tool box with lock amp key folding type 44 V Block 75 x 38 mm pair with Clamps size 400x200x150mm 12 Allen Key set of 12 pieces 2 mm to 14 mm 45 Spanner off set double ended set of 7 pieces 6 mm 17 mm Set of 12 nos 13 Philips Screw
51. lectric drill 6 mm 12 1 Module name 2 Sector 3 Code 4 Entry Qualification Repair amp Overhauling of Scooters Automotive Repair AUR204 Minimum 5 Std 14 years of Age MES Module on Basic Automobile Servicing of 2 amp 3 Wheeler 5 Terminal competency Successful candidate would be able to carry out major repairs and overhauling of Scooters 6 Duration 7 COURSE CONTENT 240 Hours Practical Competencies Underpinning Knowledge Theory Practice Health amp Safety select use maintain amp store tools equipments amp clothing safely Handle fuels oils lubricants acids alkalis adhesives seals solvents gases amp asbestos safely Identification of Tools measuring instruments amp equipments used for the trade Measure any components by using the micrometer amp dial gauge practice Remove broken stud Clean intake and exhaust system Check compression pressure amp take decision for next action Dismantle clean inspect check repair replace amp assemble carburetor Dismantle clean inspect check repair replace amp assemble engine components Overhauling of engine of different models Set ignition timing and find faults amp rectify in the ignition system Overhaul clutch amp gear box Check amp Overhaul starter motor amp Starting system Check charging system amp rectify the defects Check Battery prepare electrolyte and charge Check voltage resist
52. lt in electrical circuits amp rectify Dismantle clean check repair and assemble starter motor amp starting system Dismantle clean check repair and reassemble alternator charging system Check voltage regulator Dismantle wheel bearing steering stem amp ball race inspect amp assemble Overhaul Disc amp drum brakes systems Replace front fork oil oil seals Check the working condition of emission control devices Do fine tuning Test rectify the vehicle defects Knowledge on safety practices Reading of workshop manual Procedure for checking compression pressure Do s amp don ts during dismantling amp assembling the engine Valve timing of 4 stroke Petrol Engine amp Single Cylinder Diesel engine Working principle of diesel injection pump and injector of a single cylinder engine Procedure for reading micrometer amp dial gauges Procedure for overhauling of an engine amp transmission Usage of the multimeter Fundamental electrical principle Ohm s Law Series amp Parallel resistances circuits Working principle application amp checking of transistors Wiring colour code Fault finding procedure in ignition system Working principle of starter motor amp alternator Working principle of constant mesh gear box Electronic ignition system Charging system circuit system components overhauling amp testing Working principle amp procedure for overhauling of brakes Bearin
53. ms steering pull off centre steering steering shimmy excessive steering effort poor self centering and memory steer bump steer torque steer amp steering harshness alignment diagnostics chart amp steering problem diagnostic chart Components brief working principle amp operation of computerized wheel aligner Procedure to make machine to check wheel alignment Procedure for taking readings using wheel aligner interpreting alignment readings amp repair the same Procedures for test drive to confirm the repairs Wheel balancing v VVVV v VYY Meaning of balance causes amp effects of imbalance vibration Identification of source transfer path amp responder of vibration can be felt amp can be heard Analyzing amp identifying complaint Procedure for road tests vibration diagnostic Steering wheel shake shimmy wobble amp waddle Brief on static balance dynamic balance Mounting errors radial amp lateral amp excessive Tyre amp rim run out lateral amp radial and mismatches Brief description of wheel balancer block diagram balancer fixed data amp data to be fed to the machine Procedure for balancing the tyre rim amp assembly Balancing tolerance values Reasons for more imbalance Note Do the practical works as per the manufacturer s recommendations mentioned in the service manual of the particular brand of vehicle 37 8 TOOLS amp EQUIPMENT Suggested
54. n the service manual of the particular brand of vehicle 8 TOOLS amp EQUIPMENT Suggested s n Item s n Item OL KIT Ball Peen Hammer 0 75 Kg a TRAINEES TO 6 Steel rule 30mm 2 Cold Flat Chiesel 19mm 7 Plier combination 15cm 3 Centre Punch 10 mm dia x 100mm 8 Steel tool box with lock amp key folding type size 400x200x150mm 4 Insulated Screw driver 30 cm x 9mm blade 9 Hand file 20 cm second cut 5 Insulated Screw driver 20 cm x 9mm blade 10 Ring spanner set of 12mm b SHOP OUTFIT amp MEASURING INSTRUMENTS 1 Electric testing screwdrivers 12 Hand vice 37 mm 2 25 Stud extractors 2 Allen key set of 12 pieces 2mm 14 mm 26 Poker 2 Nos 3 Circlip plier External and Internal 150mm amp 200mm 27 Double ended Spanner 6 to 32 mm set of 12 nos 4 Philips Screw Driver set of 5 pieces 100mm 300mm 28 Double ended off set Spanner W W 3 to 13 5 mm set of 7 nos 5 Star Allen keys 29 Double open ended ignition spanner set of BA 0 x 1to 8x9 set of 5 6 Prick punch 15 cm 30 Spanner Clyburn 15 cm 7 Chisel cross cut 200mm x 6 mm 31 Adjustable spanner 20 cm 8 Ball Peen Hammer 0 5 Kg 32 Spark plug spanner 14 mm 1 No 9 Hammer copper 1 Kg with handle 33 Magneto spanner set with 8 spanners 1 set 10 Hack saw frame for 30 cm blade 34 Socket spanner set with handle T bar and ratchet 11
55. nd bearings clean parts Check tooth contact in the crown and pinion and adjust backlash amp Assemble rear axle assembly e Check and adjust parking brake and service brakes Dismantle wheel brake assembly remove old lining and fit new one e Remove and refit vacuum boosters e Overhaul master cylinder Wheel cylinder amp caliper pistons wheel drum e Bleed vacuum assisted hydraulic brakes e Remove amp clean brake drums Check disc drum run out Fit new cups and brake hoses assemble adjust all four wheel brakes and test for brake concern e Check and correct the steering geometry with instruments e Remove and refit steering boxes from vehicle checking and top up oil in steering box Check and adjust steering wheel play and backlash VVV WV VV VV Vv VV v VVV WV Knowledge on health amp safety precautions to be observed in the workshop garage health hazard of asbestos dust to be emphasized Familiarization of workshop manual TRANSMISSION Power flow from engine to wheels Units amp Definition of force work power torque amp pressure Description of single plate clutches Functions of different parts of the clutch assembly Clutch linings material Power flow in clutch plate Clutch operating mechanisms manual amp hydraulic Clutch faults Type of gears and their application advantages and disadvantages gear ratio Types of gear box Working principle of constant mesh synchromesh gear boxes Gea
56. nd universal upto 32 mm set of 28 pieces with box and 20cm 17 Hand file 20 cm Second cut flat 34 Circlip pliers 15 cm Contracting type s n Item s n Item b SHOP OUTFIT amp MEASURING INSTRUMENTS 1 Cylinder bore gauge capacity 20 to 160 mm 6 Dividers spring 15 cm 2 Micrometer out side 0 25 mm 25 50 mm 50 75 7 Steel Rule 30 cm English and metric mm 75 100 mm 3 Micrometer in side 25 50 50 75 75 150 mm with 8 Compression testing gauge to read 0 to 50 kg sq extension rod cm 4 Torque wrench 5 to 35 Nm 12 68 Nm amp 50 225 9 Engineer s square 15 cm Blade Nm 5 Straight edge gauge 2 ft 10 Feeler gauge 20 blades metric 30 C GENERAL INSTALLATION MACHINERIES 1 Drill Twist assorted 34 Taps and Dies complete sets 5 types 2 Surface Plate 60 x 60cm 1 No 100 Petrol Engine of 35 Piston ring expander and remover 50 mm amp 100 latest model CNG Engine with workshop manuals mm 3 Hacksaw frame adjustable 36 Piston Ring compressor 4 Distributor 37 Piston Ring Groove cleaner 5 Carburetor 38 Cylinder ridge remover cutter 6 Fuel feed pump 39 Work bench 250 x 120 x 60 cm with 2 vices 7 4 Wheeler petrol vehicle fitted with MPFI system 40 Pullers screw powered 2 mm gap with bearing carburetor system with manuals puller 8 Valve seat cutting tools complet
57. nected circuits Exercises on series and parallel circuits The parts of a simple electrical circuit Ohm s law Exercises on Ohm s law Introduction on Magnetism Usage of multimeter Method of using AVO meter Semiconductor Type of solder and flux required for soldering aluminum and copper conductor Introduction to equipment used for soldering Description working principles types uses location amp checking of switches Circuit protectors relays solenoids resistors diodes connectors spark plugs explain radio interference suppression amp condensers Description working principles types uses location maintenance amp checking of various automobile electrical equipments starter motor alternator wiper motor horn amp battery Cables colour codes amp sizes Function types uses location amp checking of Basic electronics devices such as transistors ICs Thysistors Triac Diac etc Simple electronics circuits such as oscillators amplifiers rectifier circuits amp power supplies Principles of Digital electronics Number systems and Truth table concept and application logic gates and 32 and check starter motor on a test rig Check spark plugs HT leads ignition coil and condenser Test the batteries with Hydrometer and cell tester prepare electrolyte follow safety rules top up battery with distilled water Connect batteries for charging Construct a simple electronic ci
58. nts Brief introduction on battery and its maintenance Purpose amp types of clutch gear box amp brakes General defects in clutch Gearbox amp brakes Tyre designation size Procedure for repairing the punctured tube Note Do the practical works as per the manufacturer s recommendations mentioned in the service manual of the particular brand of vehicle 8 TOOLS amp EQUIPMENT Suggested s no Item s no Item 1 Hammer ball peen 0 75 kg 28 Vice grip pliers 2 Screw driver 20 cm x 9 mm blade 29 Circlip pliers Expanding and contracting type 15 cm and 20 cm each 3 Screw driver 30 cm x 9 mm blade 30 Inspection lamp with guard 4 Philips Screw Driver Type set of 5 pieces 100 mm to 31 Hollow punch set of seven pieces 6 to 15 300 mm mm 5 Steel Rule 30 cm 32 Spanner off set double ended set of 7 pieces 6 mm 17 mm Set of 12 nos 6 Spanner D E set of 12 pieces 6mm to 32 mm 33 Centre punch 10 mm dia x 100 mm 7 Pliers combination 15 cm 34 Tachometer to read up to 5000 rpm 8 Hand file 20 cm Second cut 35 Battery 12 V 9 Chisel cold flat 20 mm 36 Vernier Caliper 250 or 200 mm inside outside amp depth 10 Ring spanner set of 12 pieces 6 to 32 mm 37 Hydrometer 11 Feeler gauge 20 blades metric 38 Drilling machine bench to drill up to 12 mm dia 12 Steel tool box with lock amp key folding type size 39
59. ocedure is used for developing course curricula e Identification of Employable Skills set in a sector based on division of work in the labour market e Development of training modules corresponding to skills set identified so as to provide training for specific amp fit for purpose e Organization of modules in to a Course Matrix indicating vertical and horizontal mobility The course matrix depicts pictorially relation among various modules pre requisites for higher level modules and how one can progress from one level to another e Development of detailed curriculum and vetting by a trade committee and by the NCVT Close involvement of Employers Organizations State Governments experts vocational training providers and other stake holders is ensured at each stages Development of Core Competencies Possession of proper attitudes is one of the most important attribute of a competent person Without proper attitudes the performance of a person gets adversely affected Hence systematic efforts will be made to develop attitudes during the training programme The trainees deal with men materials and machines They handle sophisticated tools and instruments Positive attitudes have to be developed in the trainees by properly guiding 3 them and setting up examples of good attitudes by demonstrated behaviors and by the environment provided during training Some important core competencies to be developed are oOo N OOF W N S
60. provides evidence of the achievement of the competencies for the qualification Methodology The training methods to be used should be appropriate to the development of competencies The focus of the programme is on performing and not on Knowing Lecturing will be restricted to the minimum necessary and emphasis to be given for hands on training The training methods will be individual centered to make each person a competent one Opportunities for individual work will be provided The learning process will be continuously monitored and feedback will be provided on individual basis Demonstrations using different models audio visual aids and equipment will be used intensively Instructional Media Packages In order to maintain quality of training uniformly all over the country instructional media packages IMPs will be developed by the National Instructional Media Institute NIMI Chennai Assessment DGE amp T will appoint assessing bodies to assess the competencies of the trained persons The assessing body will be an independent agency which will not be involved in conducting the training programmes This in turn will ensure quality of training and credibility of the scheme Keeping in view the target of providing training testing of one million persons through out the country and to avoid monopoly more than one assessing bodies will be appointed for a sector or an area Certificate Successful per
61. r selection mechanism Lubrication of transmission system Gear box faults Types of bearings maintenance their characteristics amp application Working principle of constant velocity joints Working principle of differential Faults in differential amp C V Joints BRAKE Forces amp moments acting on vehicle brake slip braking force co efficient time element of braking operation 24 e Overhaul hydraulic power assisted steering system pump control valve amp cylinder e Remove and refit a leaf spring as an assembly in a vehicle changing rubber bushes of shock absorbers and independent front suspension Lubricate suspension units e Re camber the leaf spring e Remove tyre inspect check amp assemble e Rotate the tyres e Remove and refit head lamp e Check for electrical defects and rectify e Do Final road test observe for Noise Vibration amp harshness from different part of chassis observe for problems in transmission brake clutch steering amp suspension systems amp rectify the defect Vv vVVV WV Classification of brake systems factors affecting the braking distance Advantages of hydraulic brake system over pneumatic Working principle of brake components brake booster tandem master cylinder caliper assembly wheel cylinder amp different braking force control valves Brake linings pads amp fluid Brake faults diagnostic Introduction to anti lock braking system
62. rcuits using electronic trainer kit to study the components functions Assemble and study rectifier circuits and power supplies measure outputs Construct simple logic circuits using digital trainer kit Check ignition coil of E DIS Electronic distributor less Ignition system Check sensors amp actuators using engine scanner DMM Check the different modes strategies of Electronic Control Assembly Reset keep alive memory ECA Check different wiring circuits and rectify the defect their applications Simple digital circuits Demonstration of digital trainer kits Demonstration on micro processor kits and familiarization with different related devices Demonstration and familiarization with automobile micro processor system Working principle of instruments and gauges Working principle of sensors throttle position Potentiometer Air temperature Thermistor Engine coolant temperature Air temperature manifold absolute pressure Piezo Resistive amp Piezo electric type vehicle speed Camshaft and crank shaft position sensors magnetic pick up type Construction and working principle of actuators idle air control valve injector amp EGR cutout solenoid valve explain duty cycle Basic structure and operation of a microcomputer Explanation of simple electronic circuits Different strategies modes available in the ECA Note Do the practical works as per the manufacturer s recommendations mentioned i
63. rocedure for handling bearings Emission norms Emission control components and their working principle Do the practical works as per the manufacturer s recommendations mentioned in the service manual of the particular brand of vehicle 8 TOOLS amp EQUIPMENTS Suggested s no Item s no Item 1 Hammer ball peen 0 75 kg 32 Mallets wooden plastic 2 Screw driver 20 cm x 9 mm blade 33 Vice grip pliers 3 Screw driver 30 cm x 9 mm blade 34 Circlip pliers Expanding and contracting type 15 cm and 20 cm each 4 Spanner D E set of 12 pieces 6mm to 32mm 35 Inspection lamp with guard 5 Pliers combination 15 cm 36 Hollow punch set of seven pieces 6 mm to 15 mm 6 Hand file 20 cm Second cut 37 Valve spring Compressor 7 Centre punch 10 mm dia x 100 mm 38 Tool valve grinding suction type consumable tool 8 Chisel cold flat 20 mm 39 Valve seat cutting tools complete with guides and pilot bar all angles in a box 9 Ring spanner set of 12 pieces 6 to 32 mm 40 Cylinder bore gauge 10 Feeler gauge 20 blades metric 41 V Block 75 x 38 mm pair with Clamps 11 Steel tool box with lock amp key folding type 42 Spanner off set double ended set of 7 size 400x200x150mm pieces 6 mm 17 mm Set of 12 nos 12 Allen Key set of 12 pieces 2 mm to 14 mm 43 Compression testing gauge to read 0 to 115 kg sq cm
64. sons will be awarded certificates issued by National Council for Vocational Training NCVT Course Matrix in Automotive Repair Proposed Course Outline Pathway Certificate Il in R amp O of R amp O of R amp O of Repair of Auto Repair of Wheel Diesel R amp O of R amp O of R amp O of R amp O of Automotive Repair Engine Chassis Chassis Auto Air body Auto balancin Fuel 2 2 2 3 Systems System System conditionin Painting Electrical Injection wheelers wheelers wheelers wheelers R ir amp petrol Light Heavy g System amp i Technici moped Scooter Motor Repair diesel vehicle vehicle Electronics an cycles Overhauling Systems R amp 0 Certificate in Sun Control Film Basic Bicycle amp Basic Automotive oe Automotive Tricycle Driver Automotive P Fixing rvicin ae Repair AUR 117 gt ae 8 repair cum peon Servicing Fundamental 4 wheelers AUR 118 2 3 wheelers s and Servicina Basic Automobile Servicing of 2 amp 3 Wheeler 1 Module name Basic Automobile Servicing of 2 amp 3 Wheeler 2 Sector 3 Code 4 Entry Qualification 5 Terminal competency Automotive Repair AUR102 Minimum 5 Std 14 years of Age Successful candidate would be able to carry out minor repairs and routine servicing of 2 amp 3 Wheelers 6 Duration 180 Hours 7 COURSE CONTENT Practical Competencies Underpinning Knowledge Theory Practice
65. ssion Test Ignition system find faults amp rectify gt Do amp Don t during over hauling of engine Check compression pressure amp take decision for gt Procedure for dismantling checking assembling next action amp adjustments of carburetor Dismantle inspect components rectify replace and gt Procedure for overhauling transmission brake amp assemble engine amp transmission suspension systems Measure cylinder bore ovality taper wear amp take gt Emission norms emission control components amp decision for next action their working principles Check valve leak valve bend and valve lapping gt Procedure for handling amp using multi meter Overhaul brake amp suspension system gt Fundamental electrical principle Replace chain links sprocket amp adjust chain tension Ohm s Law Dismantle check amp assemble wheel bearings amp Series amp Parallel resistance circuits steering column bearing Induction Check amp repair self starter and Starting system gt Working principle of Ignition system Check amp repair charging system components gt Procedure for checking amp over hauling starting Check voltage continuity and resistance in system electrical systems gt Procedure for checking amp over hauling charging Rectify defects in lightning system system Check battery condition prepare electrolyte top up Procedure for checking amp over hauling amp Maintain battery suspension system Check speedometer
66. t the workforce to earn a decent living but also contribute to the national economy by better productivity of this workforce Another related problem to be tackled is large number of students drop outs About 63 of the school students drop out at different stages before reaching Class X Frame work for Skill Development based on Modular Employable Skills MES Very few opportunities for skill development are available for the above referred groups out of school youth amp existing workers especially in the informal sector Most of the existing Skill Development programmes are long term in nature Poor and less educated persons can not afford long term training programmes due to higher entry qualifications opportunity cost etc Therefore a new frame work for Skill Development for the Informal Sector has been evolved by the DGET to address to the above mentioned problems The key features of the new frame work for skill development are Demand driven Short term training courses based on modular employable skills decided in consultation with Industry Flexible delivery mechanism part time weekends full time Different levels of programmes Foundation level as well as skill upgradation to meet demands of various target groups Central Government will facilitate and promote training while Vocational Training VT Providers under the Govt and Private Sector will provide training Optimum utilisation of existing infrastructure to m
67. tem amp ball race inspect amp assemble Replace front fork oil oil seals Check the working condition of emission control devices Do fine tuning amp Test the vehicle Troubleshoot amp rectify vehicle defects 270 Hours VVVV VVVVV WV VV vV VVVVVVV V VV Vv Underpinning Knowledge Theory Knowledge on health amp safety practices Reading of workshop manual Working principle of clutch Working principle of constant mesh gear box Valve timing of 4 stroke Petrol Engine Construction amp operation of different circuits in a latest carburetor of motor cycle Procedure for dismantling amp assembling a carburetor Procedure for checking compression pressure Procedure for reading micrometer amp dial gauges Procedure for dismantling checking components amp assembling of engine amp transmission Usage of the multimeter Fundamental electrical principle Ohm s Law Series amp Parallel resistances circuits Working principal application of transistors Wiring colour code Working principle of starter motor amp alternator Electronic ignition system Fault finding procedure in ignition system Working principle of brakes disc amp drum brakes Procedure for handling bearings Latest emission norms Controls available to meet the norms amp their working principle Purpose amp function of shock absorber Procedure for overhauling a shock absorber Bearing Types available in motor cycles handl
68. trical tool kit 23 Glow plug tester 7 Electrical test bench 24 Torque wrenches 5035 Nm 12 68 Nm 8 Car stereo 1 No 25 Starter test bench 9 Battery 12V Lead acid amp Alkaline 26 Dynamo and voltage regulator 10 Electronic engine control module 27 _ Alternator and inbuilt regulator 11 Starter motor axial type pre engagement type amp Co 28 Horn and Horn relay axial type 1 each 12 Electrical horn different types 29 Air conditioned MPFI vehicle with accessories 13 Wiper motor assemblies 30 Engine control sensors 8 types 14 Engine Scanner 31 Five Point relays 4 nos 15 Anti theft devices 32 Four Point relays 4 nos 16 Melting pot 33 Bearing puller set 100 300mm for extracting both outer and inner races with box containing a 8 internal extractors b counter stays c Pulling chuck of capacity 5 x 32 mm d 2 arm cooler capacity 80 and 160 mm e Slide hammer 2 sets 17 Paraffin pressure Gun 34 Repairing of Auto Air Conditioning System 1 Name Repairing of Auto Air Conditioning System 2 Sector Automotive Repair 3 Code AUR210 Minimum 5 Std 14 years of Age amp MES Module on Basic Automotive Servicing 4 wheelers 4 Entry Qualification 5 Terminal competency Successful candidate would be able to Repairing of Auto Air Conditioning System 6 Duration 240 Hours 7 COURSE CONTENT Practical Competencies Underpinning Knowledge Theory Practice
69. ug Brief introduction on ignition amp injection systems Adjust Hand brake and replace hand brake cable Brief introduction on injectors Adjust clutch and brake pedal plays Purpose of clutch gear box amp differential Replace propeller shaft wheel hub bearings amp brake General defects in clutch manual gearbox pads Types of Brake amp steering systems working Charge the battery principle of drum and disc brakes Check Tyre pressure amp for defects tread depth General defects in brake systems inflate rotate the tyres Brief introduction on battery and its maintenance Tyre designation size reasons for general tyre defects Procedure for repairing the punctured tube Need amp procedure for tyre rotation VVVVVVV VV VV VV Vv Vv Note Do the practical works as per the manufacturer s recommendations mentioned in the service manual of the particular brand of vehicle 8 TOOLS amp EQUIPMENTS Suggested s no Item s no Item 1 Hammer ball peen 0 75 kg 28 Mallets wooden plastic 2 Screw driver 20 cm x 9 mm blade 29 Spanner ring offset set of 6 S A E 3 Screw driver 30 cm x 9 mm blade 30 Spanner adjustable 20 cm 4 Spanner D E set of 12 pieces 6 to 32 mm 31 Spanner for spark plugs 14 mm 5 Pliers combination 15 cm 32 Socket Spanners with handle T bar amp ratchet 6 Hand file 20 cm Second cut 33 Oil can 0
70. uge capacity 50 to 150 mm x 9mm blade 10 Hand vice 37mm 45 Fuel feed pump 1 no 11 File assorted 8 types 46 Bearing puller screw powered hydraulic with attachments Max spread 80 200 and 300 mm 12 Drill Twist assorted 47 Hammer Copper 1 kg with handle 1 no 13 Taps and Dies complete set in a box metric 48 Surface Plate 60 x 60 cm with handle 14 Hand reamer adjustable 10 5 to 11 25 mm 49 V Block 75 x 38 mm pair with Clamps 11 25 to 12 75 mm 12 75 to 14 25 mm and 14 25 to 15 75 mm 15 Dial indicator to read 0 01 mm 50 Spanner off set double ended set of 7 pieces 6 mm 17 mm 16 Micrometer outside 0 25 mm 25 50 mm 50 51 Valve key inserter 1 no 75mm 75 100 mm 17 Micrometer inside 25 50 50 75 75 150 mm 52 Compression testing gauge to read 0 to 115 with extension rod kg sq cm 22 18 Mallets wooden plastic 53 Vacuum gauge to read 0 to 760 mm of Hg 19 Piston ring filer 54 Piston Ring compressor amp Ring Expander 20 Spanner ring offset set of 6 SAE 2 sets 55 Tachometer to read up to 5000 rpm 21 Spanner adjustable 20 cm 56 Triple leg grip puller with bearings attachment screw hydraulic powered max Spread 80 160 50 450 mm 22 Spanner for spark plugs 14 mm 57 Pliers water pump multifix 250 mm Long 23 Spanners socket of 8 with handle T bar and 58 Battery 12 V
71. ure cylinder head amp block warpage valve leak lubricating oil pressure bearing oil clearance measure bore amp take decision for further action ring end gap amp side clearance fuel pressure regulator in MPFI engine inlet manifold vacuum cam amp crank shaft bend amp valve timing Service inlet and exhaust manifolds Remove clean check amp overhaul engine sub assemblies components Remove clean check amp overhaul electrical components Dismantle clean assemble and check injectors Measure the bore and take the decision Replace liner valve guide piston wrings Do valve lapping amp valve grinding Overhaul piston and connecting rod assembly Assemble the engine Fill up oil amp coolant after preparing in correct proportion Start the engine and set idle rom Find the fault on the given engine and rectify the defect Note Do the practical works as per the manufacturer s recommendations mentioned in the service manual of the particular brand of vehicle Knowledge on health amp safety precautions to be observed in the workshop garage Familiarization of workshop manual Lubrication amp cooling systems Layout in Carburetor engine starting ignition charging fuel supply systems Layout in MPFI engine air induction starting ignition amp fuel supply systems Layout in diesel engine fuel supply systems Different valve operating mechanisms amp Valve timing diagram Procedure for h
72. vice manual of the particular brand of vehicle 43 8 TOOLS amp EQUIPMENTS Suggested s no Item s no Item 1 Hammer ball peen 0 75 kg 23 Portable electric drill 6 mm 2 Screw driver 20 cm x 9 mm blade 24 Latest Diesel 4 Wheelers of different make one LMV amp one HCV along with workshop manuals 3 Screw driver 30 cm x 9 mm blade 25 Injector holders 4 Spanner D E set of 12 pieces 6 to 32 mm 26 Mallets wooden plastic 5 Pliers combination 15 cm 27 Spanner ring offset set of 6 S A E 6 Hand file 20 cm Second cut 28 Spanner adjustable 20 cm 7 Centre punch 10 mm dia x 100 mm 29 Socket Spanners with handle T bar amp ratchet 8 Chisel cold flat 20 mm 30 Oil can 0 5 liter cap 9 Ring spanner set of 12 pieces 6 to 32 mm 31 Cleaning Tray 45 x 30 cm with 6 1 compartments 10 Feeler gauge 20 blades metric 32 Work bench each 250 x 120x60 with 4 bench vices 12 cm jaw 11 Steel tool box with lock amp key folding type 33 Pullers screw powered 2 mm with bearing puller size 400x200x150mm attachment 12 Allen Key set of 12 pieces 2 mm to 14mm 34 Vice grip pliers 13 Philips Screw Driver Type set of 5 pieces 35 Circlip pliers Expanding and contracting type 15 100 mm to 300 mm cm and 20 cm each 14 Steel Rule 30 cm English and metric 36 Inspection lamp with guard and wandering lead of 100 ft 15 Prick punch
73. ype importance of these sensors for air conditioning system Construction and working principle of actuators coolant diversion valve for heating the cabin amp idle air control valve Electronic controlled engines amp duty cycle Description Reading of wiring diagram Description amp operation of Main Functional parts Compressor Condenser Evaporator and Expansion Devise valve Different types of above components Description amp operation of Other Functional parts magnetic clutch receiver drier blower motor condenser fan thermostat pressure switches amp magnetic valve for dual air conditioner air Procedure for evacuating draining the system finding the leak amp charging the system Procedure for Fault finding Trouble shooting charts amp rectification in car air conditioning Procedure for dismantling checking assembling different components of the system Difference between manual amp automatic air conditioning climate control systems Air distribution of air conditioning system amp different types of actuation of distribution doors Note Do the practical works as per the manufacturer s recommendations mentioned in the service manual of the particular brand of vehicle 35 8 TOOLS amp EQUIPMENT Suggested s n Item s n Item 1 Screw driver 18 DMM 2 File 19 2 sets of accumulator drier 3 Crimping Tool 20 Mock up bo

motor mechanic repair & maintenance of 2 wheeler

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motor mechanic repair &amp; maintenance of 2 wheeler

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motor mechanic repair & maintenance of 2 wheeler