motor mechanic repair & maintenance of 2 wheeler

motor mechanic repair & maintenance of 2 wheeler

C o u r r s e C u r r r r i i i c u l l l a f f f o r r

S h o r r t t T e r m C o u r r s e s b a s e d o n

M o d u l l l a r r E m p l l l o y a b l l l e S k i i i l l l l l l s

( M

E

S

) i i i n

A u t t o m o t t i i i v e R e p a i i i r

S e c t t o r

[email protected] gmail.com

Course Curricula for Short Term Courses based on Modular

Employable Skills (MES) in the Automotive Repair Sector

CONTENTS

Background ................................................................................................................ 2 1.

2.

3.

4.

10.

11.

12.

13.

14.

15.

5.

6.

7.

8.

9.

Frame Work for Skill Development based on Modular Employable Skills ................ 2

Age of Participants ..................................................................................................... 3

Curriculum Development Process .............................................................................. 3

Development of Core Competencies ......................................................................... 3

Duration of the Programmes ...................................................................................... 4

Pathways to acquire Qualification .............................................................................. 4

Methodology .............................................................................................................. 5

Instructional Media Packages .................................................................................... 5

Assessment ............................................................................................................... 5

Certificate ................................................................................................................... 5

Course Matrix ............................................................................................................. 6

Modules .................................................................................................................... 7

Basic Automobile Servicing of 2 & 3 Wheeler ............................................................ 7

Basic Automotive 4 wheeler servicing ........................................................................ 9

Repair & Overhauling of Mopeds ............................................................................ 11

Repair & Overhauling of Scooters ........................................................................... 13

Repair & Overhauling of Motor Cycles…………………… ..... ……………………….15

16.

17.

18.

19.

20.

Repair & Overhauling of 3 Wheelers ...................................................................... .17

Repair & Overhauling of Engine Systems (Petrol / diesel) ...................................... .19

21.

22.

Repair & Overhauling of Chassis System (Light Vehicle) ....................................... 23

Repair & Overhauling of Chassis System (Heavy Vehicle) ..................................... 27

23.

24.

25.

26.

27.

28.

Repair of Auto Electrical & Electronics Systems ...................................................... 31

Repairing of Auto Air Conditioning System……………………… ...... …………......…34

Wheel alignment & balancing………………………...... …………………...…………..36

Minor repair of Auto body…………………………… ....... ………………………………38

Auto body Painting…………………………………… ..... …………………………..….41

Diesel

Fuel Injection Technician ……………………… ...... ……………………….… 42

Bicycle and Tricycle repair………………………………………………………… ......... 45

29.

30. Sun Control Film Fixing…………………………………………………………………..52

31. Driver cum Peon………………………………………………………………………….56.

30. List of Expert/Trade Committee Members ............

………………………………….….51

1

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 benefit 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 & 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 make 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 & certification of prior learning (skills of persons acquired informally)

2

The Short Term courses would be based on „Modular Employable Skills (MES)‟.

The concept for the MES is :

Identification of „minimum skills set‟ which is sufficient to get an employment in the labour market.

It allows skills upgradation, multiskilling, multi entry and exit, vertical mobility and life long learning opportunities in a flexible manner.

It also allows recognition of prior learning (certification of skills acquired informally) effectively.

The modules in a sector when grouped together could lead to a qualification equivalent to National Trade Certificate or higher.

Courses could be available from level 1 to level 3 in different vocations depending upon the need of the employer organisations.

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 procedure is used for developing course curricula

• Identification of Employable Skills set in a sector based on division of work in the labour market.

• Development of training modules corresponding to skills set identified so as to provide training for specific & fit for purpose

• 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.

• 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:

1. Safety consciousness and safe working practices

2. Care of equipment and tools

3. Punctuality, discipline and honesty

4. Concern for quality

5. Respect for rules and regulations

6. Concern for health and hygiene

7. Cordial relationship and Cooperation with co-workers and team Work

8. 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-II and higher courses:

1. Ability for planning, organizing and coordinating

2. Creative thinking, problem solving and decision making

3. Leadership

4. Ability to bear stress

5. Negotiation

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 provides evidence of the achievement of the competencies for the qualification.

4

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 mi nimum 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&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 persons will be awarded certificates issued by National Council for Vocational

Training (NCVT).

5

Course Matrix

Proposed Course Outline/ Pathway

Certificate-II in

Automotive

Repair

(Repair &

Overhauling

[R&O])

Certificate-I in

Automotive

Repair

(Fundamental s and

Servicing)

.

R&O of

Engine

Systems

(petrol/ diesel)

R&O of

Chassis

System

(Light vehicle)

R&O of

Chassis

System

(Heavy vehicle)

Repair of

Auto Air conditionin g System

Minor repair of

Auto body

Auto body

Painting

Repair of

Auto

Electrical

&

Electronics

Systems

Wheel balancin g & alignmen t

Diesel

Fuel

Injection

Technici an

R&O of

2 wheelers moped

R&O of

2 wheelers

Scooter

R&O of

2 wheelers

(Motor cycles)

R&O of

3 wheelers

Sun Control Film

Fixing

AUR 117

Basic

Automotive

Servicing

(4 wheelers)

Bicycle &

Tricycle repair

Driver cum peon

AUR 118

Basic

Automotive

Servicing

(2-3 wheelers)

Basic Automobile Servicing of 2 & 3 Wheeler Modules

Basic Automobile Servicing of 2 & 3 Wheeler

1. Module name : Basic Automobile Servicing of 2 & 3 Wheeler

2. Sector

3. Code

4. Entry Qualification

: Automotive Repair

: AUR102

: Minimum 5 th

Std. , 14 years of Age

5. Terminal competency

: Successful candidate would be able to carry

out minor repairs and routine servicing of 2

& 3 Wheelers

6. Duration : 180 Hours

7. COURSE CONTENT:

Practical Competencies

 Practice Health & Safety – select, use, maintain & store – tools, equipments & clothing safely

Practice 5S technic

Identify / Familiarize with the tools & equipments

 Identify components of 2 & 3 wheeler from assembly drawings & diagrams

Water washing / cleaning of 2 & 3 wheelers

 Clean/replace air cleaner, fuel strainers and oil filters

Drain & 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 & top-up brake fluid

 Adjust clutch play

 Adjust, remove links & lubricate drive chain

Replace control cables – clutch, brake & accelerator cables – adjust clutch & brake plays

Charge the battery

 Check pressure, inflate, measure tread depth, inspect for damage, do Wheel truing, Repair tyre puncture & Tuffe-up tube

 Check and replace bulbs

Underpinning Knowledge (Theory

 General health & Safety precautions to be observed in the workshop / garage

Over view on 5S technic (Sort, Set in order, Shine /

Sweep, Standardise & Sustain)-advantages in implementation of 5S

Working principle of 2 & 4 stroke engines

Procedure for dismantling, cleaning & assembling of major assemblies of vehicle

Functions &Types of lubrication & cooling systems

 Fuel system layouts (Petrol, diesel & CNG)

Functions of carburetor and adjustments

 Ignition system circuit & components

 Brief introduction on battery and its maintenance

Purpose & types of clutch, gear box & brakes

General defects in clutch, Gearbox & 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.

7

8. TOOLS & EQUIPMENT( Suggested )

s.no

1

Item

Hammer ball peen 0.75 kg

2 Screw driver 20 cm. x 9 mm blade

3

4

5

Screw driver 30 cm x 9 mm blade

6 Spanner D E set of 12 pieces (6mm to 32 mm)

7 Pliers combination 15 cm

8

9

Hand file 20 cm. Second cut

Chisel cold flat 20 mm

Philips Screw Driver Type set of 5 pieces 100 mm to

300 mm

Steel Rule 30 cm,

s.no

28 Vice grip pliers

Item

29 Circlip pliers Expanding and contracting type 15 cm and 20 cm each

30 Inspection lamp with guard

31 Hollow punch set of seven pieces 6 to 15 mm

32 Spanner off set double ended set of 7 pieces (6 mm -17 mm) Set of 12 nos.

33 Centre punch 10 mm dia x 100 mm

34 Tachometer - to read up to 5000 rpm

35 Battery 12 V

36 Vernier Caliper 250 or 200 mm inside, outside & depth

37 Hydrometer 10 Ring spanner set of 12 pieces (6 to 32 mm.)

11 Feeler gauge 20 blades (metric)

12 Steel tool box with lock & key (folding type) size

400x200x150mm

13 Allen Key set of 12 pieces (2 mm to 14 mm)

14 Prick punch 15 cm

15 Scriber 15 cm with scribing block universal

16 Hacksaw frame adjustable for 30 cm blade

17 Taps and Dies complete set in a box BA, BSW, BSF

American & metric with handle

18 Drill Twist ( assorted )

19 Hand vice 37mm

20 Hand reamer adjustable 10.5 to 11.25 mm, 11.25 to

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)

38 Drilling machine bench to drill up to 12 mm dia

39 Electric pedestal grinder

40 Latest 2 Wheelers (Moped, Scooter, Motor

Cycle) of different makes along with workshop manuals and special maintenance tools

41 Tyre repair kit

42 Battery charger 6v- 18 v

43 Torque wrench 0 – 50Nm

44 Auto Rickshaw chassis of petrol & diesel

45 Carburetors of 2 & 3 wheelers

46 Spark plug cleaner and tester

47 Water pump / Washer

48 Fire Extinguisher

22 Spanner, adjustable 20 cm.

23 Spanner for spark plugs 14 mm

49 Portable electric drill 6 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

26 Cleaning Tray 45 x 30 cm.

27 Work benches each 250 x 120x60 with 4 bench vices

12 cm jaw

52 Wheel truing machine

53 Air compressor

8

1. Module name

2. Sector

: Basic Automotive 4 wheeler servicing

: Automotive Repair

3. Code : AUR101

4. Entry Qualification : Minimum 5 th

Std , 14 years of Age

5. Terminal competency :

Successful candidate would be able to

carry out servicing and minor repairs of

4 Wheelers

6. Duration : 180 Hours

7. COURSE CONTENT :

Practical Competencies Underpinning Knowledge (Theory

 Practice Health & Safety – select, use, maintain & store tools, equipments & clothing safely

Practice 5S technic

 Identify / Familiarize with the tools & equipments

Water wash – before & after servicing

 Check / replenish

/ top up – lubricating oil, brake fluid, engine coolant, power steering hydraulic oil, wind screen wiper water, battery electrolyte and transmission oil

Clean / replace – air cleaner, oil filter & fuel filter

Apply Grease to parts / through greasing points

 Remove & refit vehicle body parts (bonnet, front bumper & door)

Remove and refit head lamp assembly

 Check power plug and inspect H.T. cables

Clean, Check and Adjust spark plug

Adjust Hand brake and replace hand brake cable

 Adjust clutch and brake pedal plays

Replace propeller shaft, wheel hub bearings & brake pads

Charge the battery

Check Tyre pressure & for defects, tread depth, inflate, rotate the tyres

 General health & Safety precautions to be observed in the workshop / garage

Over view on 5S technic (Sort, Set in order, Shine,

Standardise & Sustain)-advantages in implementation of 5S

Nomenclature of different parts of vehicle and their locations

Working principle of 4 stroke petrol & diesel engines

 Differences between petrol & diesel engines

 Lubrication and cooling system & types of lubricants

Lay out of greasing points

Torquing & detorquing technique / procedures

 Fuel supply layouts in both petrol & diesel engines

Layout of power flow from Engine to wheels.

Ignition system circuit & components

Brief introduction on ignition & injection systems

Brief introduction on injectors

 Purpose of clutch, gear box & differential

General defects in clutch, manual gearbox

Types of Brake & steering systems – working principle of drum and disc brakes

General defects in brake systems

Brief introduction on battery and its maintenance

 Tyre designation (size), reasons for general tyre defects

Procedure for repairing the punctured tube

 Need & procedure for tyre rotation

Note: -Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle.

9

8. TOOLS & EQUIPMENTS ( Suggested ) s.no Item

1 Hammer ball peen 0.75 kg

2 Screw driver 20 cm. x 9 mm blade

3 Screw driver 30 cm x 9 mm blade

s.no Item

28 Mallets (wooden/plastic)

29

30

Spanner, ring offset set of 6 (S A E)

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

6 Hand file 20 cm. Second cut

32

33

Socket Spanners with handle, T bar & ratchet

Oil can 0.5 liter cap

7

8

Centre punch 10 mm dia x 100 mm

Chisel cold flat 20 mm

10 Feeler gauge 20 blades (metric)

34 Cleaning Tray 45 x 30 cm.

35 Work bench each 250 x 120x60 with 4 bench vices

12 cm jaw

9 Ring spanner set of 12 pieces (6 to 32 mm.) 36 Pullers screw powered 2 mm with bearing puller attachment

37 Vice grip pliers

11 Steel tool box with lock & key (folding type) size 400x200x150mm .

38 Circlip pliers Expanding and contracting type 15 cm and 20 cm each

12 Allen Key set of 12 pieces (2 mm to 14 mm) 39 Inspection lamp with guard and wandering lead of

100 ft.

13 Philips Screw Driver Type set of 5 pieces

100 mm to 300 mm

14 Steel Rule 30 cm, English and metric

15 Prick punch 15 cm

40 Hollow punch set of seven pieces 6 mm to 15 mm

41

42

„V‟ Block 75 x 38 mm pair with Clamps

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 rpm

19 Drill Twist ( assorted ) 46 Battery 12 V

20 Hand reamer adjustable

21 Drilling machine

22 Electric pedestal grinder with two wheel

23 Portable electric drill 6 mm

24 Spark plug cleaner and tester similar to

Bosch / champion

25 Battery charger 6v- 18 v

26 Latest 4 Wheelers of different make (one

LMV & one HCV) along with workshop manuals

27 Grease gun

47 Hydrometer

48 Air compressor

49 Water pump / Washer

50 Fire Extinguisher

51 Tyre repair kit

52

53

54

Torque wrench 0 – 50Nm

Tryre Pressure gauge

Tread depth gauge

10

1. Module name

2. Sector

3. Code

: Repair & Overhauling of Mopeds

: Automotive Repair

: AUR203

4. Entry Qualification : Minimum 5 th

Std , 14 years of Age

MES Module on Basic Automobile Servicing

of 2 & 3 Wheeler

:

Successful candidate would be able to

5. Terminal competency

carry out major repairs and overhauling of Mopeds

6. Duration

: 210 Hours

7. COURSE CONTENT:

Practical Competencies

Practice Health & Safety – select, use, maintain & store tools, equipments & clothing safely. Handle fuels, oils, lubricants, acids & asbestos safely

Identification of Tools, measuring instruments & equipments used for the trade

Measure any components by using the micrometer

& dial gauge (practice)

 Remove broken stud

Dismantle, clean, check, assemble and adjust carburetor

Clean intake and exhaust system

Test Ignition system, find faults & rectify

 Check compression pressure & take decision for next action

 Dismantle, inspect components, rectify/ replace and assemble engine & transmission

 Measure cylinder bore-ovality, taper, wear & take decision for next action

 Check valve leak, valve bend and valve lapping

Overhaul brake & suspension system

 Replace chain/links, sprocket & adjust chain tension

Dismantle, check & assemble wheel bearings & steering column bearing

Check & repair self starter and Starting system

 Check & repair charging system components

Check voltage, continuity and resistance in electrical systems

Rectify defects in lightning system.

Check battery condition, prepare electrolyte, top up

& Maintain battery

Check speedometer & rectify the defect

Fine tune the Engine and road test the vehicle

Underpinning Knowledge (Theory

Knowledge on health & safety

Procedure for checking compression pressure

Procedure for dismantling engine

Valve / port timing diagram of 2 stroke engine

Air – fuel Ratio at different conditions,

Knowledge on micrometer, feeler gauge & dial gauges

Procedure for dismantling, inspecting/component checks, assembling, engine & transmission system (overhauling of an engine & transmission)

Do & Don't during over hauling of engine

Procedure for dismantling, checking, assembling

& adjustments of carburetor.

Procedure for overhauling transmission, brake & suspension systems

Emission norms, emission control components & their working principles

 Procedure for handling & using multi-meter

Fundamental electrical principle

- Ohm's Law

- Series & Parallel resistance circuits.

Working principle of Ignition system

Procedure for checking & over hauling starting system

 Procedure for checking & over hauling charging system

 Procedure for checking & over hauling suspension system

 Procedure for testing the engine

- Induction

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 & EQUIPMENTS ( Suggested ) s.no Item

1 Hammer ball peen 0.75 kg

s.no Item

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

3 Screw driver 30 cm x 9 mm blade

33 Outside Micrometer 0-25 mm, 25-50 mm,

34 Mallets (wooden/plastic)

4 Spanner D E set of 12 pieces (6mm to 32 mm) 35 Piston ring filer

5

6

7

8

Pliers combination 15 cm

Hand file 20 cm. Second cut

Centre punch 10 mm dia x 100 mm

Chisel cold flat 20 mm

9 Ring spanner set of 12 pieces (6 to 32 mm.)

10 Feeler gauge 20 blades (metric)

11 Steel toolbox with lock & key (folding type) size

400x200x150mm.

12 Allen Key set of 12 pieces (2 mm to 14 mm)

13 Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm

36 Spanner, ring offset set of 6 (S A E)

37 Spanner, adjustable 20 cm.

38 Spanner for spark plugs 14 mm

39 Socket Spanners with handle, T bar & ratchet

40 Oil can 0.5 liter cap

41 Cleaning Tray 45 x 30 cm.

42 Work benches

43 Hollow punch set of seven pieces 6 to15 mm

44 Vice grip pliers

14 Steel Rule 30 cm, English and metric

15 Prick punch 15 cm

16 Scriber 15 cm with scribing block universal

17 Hacksaw frame adjustable for 30 cm blade

18 Hand vice 37mm

19 Drill Twist ( assorted )

45 DMM Auto range

46 Inspection lamp with guard

47 Spark plug cleaner and tester

48 Valve spring Compressor

49 Tool valve grinding, suction type (consumable tool)

50 Valve seat cutting tools complete with guides and pilot bar (all angles) in a box

51 Cylinder bore gauge 20 Taps and Dies complete set in a box BA,

BSW, BSF American & metric with handle

21 Hand reamer adjustable 10.5 to 11.25 mm,

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

23 Circlip pliers Expanding and contracting type

15 cm and 20 cm each

24 Piston Ring compressor & Ring Expander

52 „V‟ Block 75 x 38 mm pair with Clamps

53 Compression testing gauge to read 0 to 115

54 kg/sq cm

Battery charger 6v- 18 v

25 Tachometer - to read upto 5000 rpm

26 Battery 12 V

27 Vernier Caliper 250 or 200 mm inside, outside & depth

28 Hydrometer

55 3 latest mopeds of different make along with workshop manuals and special maintenance tools

56 Carburetors of mopeds

57

58

Air compressor

Water pump / Washer

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 electric drill 6 mm

12

1. Module name

2. Sector

3. Code

4. Entry Qualification

: Repair & Overhauling of Scooters

: Automotive Repair

: AUR204

: Minimum 5 th

Std , 14 years of Age

MES Module on Basic Automobile Servicing

of 2 & 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

Practice Health & Safety – select, use, maintain & store – tools, equipments & clothing safely.

Handle fuels, oils, lubricants, acids, alkalis, adhesives, seals, solvents, gases

& asbestos safely

Identification of Tools, measuring instruments & equipments used for the trade

Measure any components by using the micrometer

& dial gauge (practice)

 Remove broken stud

Clean intake and exhaust system

 Check compression pressure & take decision for next action

Dismantle, clean, inspect/check, repair/replace & assemble carburetor

Dismantle, clean, inspect/check, repair/replace & assemble engine components (Overhauling of engine) of different models

 Set ignition timing and find faults & rectify in the ignition system

Overhaul clutch & gear box

Check & Overhaul starter motor & Starting system

 Check charging system & rectify the defects

Check Battery, prepare electrolyte and charge

 Check voltage, resistance, continuity and find fault in electrical circuits

Dismantle wheel bearing, steering stem & ball race, inspect & assemble

Check the working condition of emission control devices

 Replacement of front fork oil / oil seals

Do fine tuning & Test Engine

Underpinning Knowledge (Theory

Knowledge on health & safety

 Reading of workshop manual

Procedure for checking compression pressure

 Procedure for dismantling, checking & assembling of an engine

 Do's & Don‟ts during dismantling & assembling of an engine

 Measurement using micrometer, dial gauges & feeler gauges

Construction & operation of carburetor

Procedure for dismantling, cleaning, checking & assembling a carburetor

 Working principle of multi - plate clutch & gear box

Procedure for dismantling, inspecting & assembling clutch & gear box

Procedure for fine tuning & testing the engine

 Use of multimeter

Fundamental electrical principle

- Ohm‟s Law

- Series & Parallel resistances circuits

- Working principle, application & checking of transistors.

Wiring colour-code

Ignition system circuit and faults finding – procedure

Working principle, Procedure for dismantling, inspecting & assembling of starter motor

Working principle & procedure for overhauling & testing

Charging system components

Procedure for dismantling & assembling of shock absorbers

Lighting system circuits & fault finding procedure

Procedure for handling bearings

Emission norms, Emission control components and their working principle

13

R/O of Scooters

* Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle.

8. TOOLS & EQUIPMENTS ( Suggested ) s.no Item

1 Hammer ball peen 0.75 kg

2 Screw driver 20 cm. x 9 mm blade

3 Screw driver 30 cm x 9 mm blade

33 Vice grip pliers

34 Circlip pliers Expanding and contracting type

15 cm and 20 cm each

4 Spanner D E set of 12 pieces (6mm to 32 mm) 35 Inspection lamp with guard

5 Pliers combination 15 cm

s.no Item

32 Mallets (wooden/plastic)

36 Hollow punch set of seven pieces 6 mm to

15 mm

6 Hand file 20 cm. Second cut

7 Centre punch 10 mm dia x 100 mm

8

9

Chisel cold flat 20 mm

Ring spanner set of 12 pieces (6 to 32 mm.)

10 Feeler gauge 20 blades (metric)

11 Steel tool box with lock & key (folding type) size 400x200x150mm .

12 Allen Key set of 12 pieces (2 mm to 14 mm)

37 Valve spring Compressor

38 Tool valve grinding, suction type

(consumable tool)

39 Valve seat cutting tools complete with guides and pilot bar(all angles) in a box

40 Cylinder bore gauge

41 „V‟ Block 75 x 38 mm pair with Clamps

42 Spanner off set double ended set of 7 pieces.(6 mm -17 mm) Set of 12 nos.

43 Compression testing gauge to read 0 to 115 kg/sq cm

44 Piston Ring compressor & Ring Expander 13 Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm

14 Steel Rule 30 cm, English and metric

15 Prick punch 15 cm

16 Scriber 15 cm with scribing block universal

45 Tachometer - to read up to 7000 rpm

46 Battery 12 V

47 Vernier Caliper 250 or 200 mm inside, outside & depth

48 DMM Auto range

49 Hydrometer

17 Hacksaw frame adjustable for 30 cm blade

18 Hand vice 37mm

19 Drill Twist ( assorted )

20 Taps and Dies complete set in a box BA,

BSW, BSF American & metric with handle

21 Hand reamer adjustable 10.5 to 11.25 mm,

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

23 Outside Micrometer 0-25 mm, 25-50 mm, 50-

75mm, 75-100 mm

24 Piston ring filer

50 Bench Drilling M/C to drill up to 12 mm dia

51 Electric pedestal grinder with two 18 cm wheel

52 3 latest 2 Wheelers (Moped, Scooter) of different makes along with workshop manuals and special maintenance tools

53 Battery charger 6v- 18 v

54 Spark plug cleaner and tester similar to

Bosch / champion

55 Portable electric drill 6 mm

25 Spanner, ring offset set of 6 (S A E)

26 Spanner, adjustable 20 cm.

27 Spanner for spark plugs 14 mm

28 Socket Spanners with handle,T bar & ratchet

29 Oil can 0.5 liter cap

30 Cleaning Tray 45 x 30 cm.

31 Work bench each 250 x 120x60 with 4 bench vices 12 cm jaw

56 Carburetors of scooters

57 Air compressor

58 Water pump / Washer

59 Fire Extinguisher

60 Tyre repair kit

61 Torque wrench 0 – 50Nm

62 Tryre Pressure gauge

14

1. Module name

2. Sector

3. Code

4. Entry Qualification

: Repair & Overhauling of Motor Cycles

: Automotive Repair

: AUR205

: Minimum 5 th

Std , 14 years of Age

6. Duration

7. COURSE CONTENT :

MES Module on Basic Automobile Servicing

of 2 & 3 Wheeler

:

Successful candidate would be able to

5. Terminal competency

carry out major repairs and overhauling of

Motor Cycles

: 270 Hours

Practical Competencies

Practice Health & Safety – select, use, maintain & store – tools, equipments & clothing safely. Handle fuels, oils, lubricants, acids, alkalis, adhesives, seals, solvents, gases

& asbestos safely

Water wash & clean the vehicle

 Remove broken stud

Check compression pressure

 Clean Fuel tank

Dismantle, clean, check Engine components & assemble

Dismantle, clean, reset, fit & fine tune carburetor

Dismantle, clean, check, repair and refit clutch

& gear box.

 Lubricate and grease the vehicle

Prepare electrolyte & charge the battery

Check voltage, resistance, continuity and find fault in electrical circuits

Dismantle, clean, check, repair and assemble

– starter motor & starting system

Dismantle, clean, check, repair and reassemble –charging system

Check voltage regulator

 Set Ignition timing

Overhaul Disc & drum brakes system

Dismantle wheel bearing, steering stem & ball race, inspect & assemble

Replace front fork oil / oil seals

 Check the working condition of emission control devices

Do fine tuning & Test the vehicle

 Troubleshoot & rectify vehicle defects

Underpinning Knowledge (Theory

 Knowledge on health & 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 & operation of different circuits in a latest carburetor of motor cycle

Procedure for dismantling & assembling a carburetor

Procedure for checking compression pressure

Procedure for reading micrometer & dial gauges

Procedure for dismantling, checking components & assembling of engine & transmission

Usage of the multimeter

 Fundamental electrical principle

- Ohm‟s Law

- Series & Parallel resistances circuits

- Working principal, application of transistors

 Wiring colour-code

Working principle of starter motor & alternator

Electronic ignition system

Fault finding procedure in ignition system

Working principle of brakes (disc & drum brakes)

Procedure for handling bearings

Latest emission norms

 Controls available to meet the norms & their working principle

Purpose & function of shock absorber

 Procedure for overhauling a shock absorber

Bearing – Types (available in motor cycles), handling, procedure for assembling & 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 & EQUIPMENTS ( Suggested ) s.no Item

1 Hammer ball peen 0.75 kg

2

3

Screw driver 20 cm. x 9 mm blade

Screw driver 30 cm x 9 mm blade

s.no Item

34 Pullers screw powered 2 mm with bearing puller attachment

35 Vice grip pliers

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

7 Centre punch 10 mm dia x 100 mm

8

9

Chisel cold flat 20 mm

Ring spanner set of 12 pieces (6 to 32 mm.)

39 Valve spring Compressor

40 Tool valve grinding, suction type (consumable tool)

41 Valve seat cutting tools complete with guides and pilot bar (all angles) in a box

42 Cylinder bore gauge capacity 50 to 150 mm

10 Feeler gauge 20 blades (metric)

11 Steel tool box with lock & key (folding type) size 400x200x150mm .

12 Allen Key set of 12 pieces (2 mm to 14 mm)

13 Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm

14 Steel Rule 30 cm, English and metric

15 Prick punch 15 cm

16 Scriber 15 cm with scribing block universal

17 Hacksaw frame adjustable for 30 cm blade

43 Surface Plate 60 x 60 cm

44 „V‟ Block 75 x 38 mm pair with Clamps

45 Spanner off set double ended set of 7 pieces.(6 mm -17 mm) Set of 12 nos.

46 Compression testing gauge to read 0 to 115 kg/sq cm

47 Piston Ring compressor & Ring Expander

48 Tachometer - to read up to 5000 rpm

49 Battery 12 V

50 Vernier Caliper 250 or 200 mm inside, outside & depth

51 DMM Auto range 18 Hand vice 37mm

19 Stud remover

20 Taps and Dies complete set in a box with handle (metric)

21 Hand reamer adjustable 10.5 to 11.25 mm,

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

52 Hydrometer

53 Drilling machine bench to drill up to 12 mm dia

54 Electric pedestal grinder with two 18 cm wheel

23 Outside Micrometer 0-25 mm, 25-50 mm, 50-

75mm, 75-100 mm

24 Mallets (wooden/plastic)

25 Piston ring filer

26 Spanner, ring offset set of 6 (Metric)

27 Spanner, adjustable 20 cm.

55 3 latest motor cycles of different make along with special tools, & workshop manuals

56 Spark plug cleaner and tester

57 Battery charger 6v- 18 v

58 Portable electric drill 6 mm

59 Carburetors of motor cycles

60 Air compressor

28 Spanner for spark plugs 14 mm 61 Water pump / Washer

29 Socket Spanners with handle, T bar & ratchet 62 Fire Extinguisher

30 Oil can 0.5 liter cap

31 Cleaning Tray 45 x 30 cm.

32 Work bench each 250 x 120x60 with 4 bench

63 Torque wrench 0 – 50Nm

64 Tryre Pressure gauge

65 Wheel truing machine

16

vices 12 cm jaw

33 Ring ridge remover

17

1. Module name : Repair & Overhauling of 3 Wheelers

2. Sector

3. Code

4. Entry Qualification

: Automotive Repair

: AUR206

: Minimum 5 th

Std ,14 years of Age

6. Duration

7. COURSE CONTENT :

MES Module on Basic Automobile Servicing

of 2 & 3 Wheeler

:

Successful candidate would be able to

5. Terminal competency

carry out major repairs and overhauling of

3 Wheelers

: 270 Hours

Practical Competencies

Practice Health & Safety – select, use, maintain & store – tools, equipments & clothing safely. Handle fuels, oils, lubricants, acids, alkalis, adhesives, seals, solvents, gases

& asbestos safely

 Water wash & clean the vehicle

Remove broken stud

 Check compression pressure

Clean Fuel tank

Dismantle, clean, check Engine components & assemble

 Dismantle, clean, reset, fit & fine tune carburetor

Overhaul and test Fuel Injection Pump

Test Injector & repair the defect

 Set valve timing

Set Ignition / Injection timing

Dismantle, clean, check, repair and refit clutch & gear box.

Lubricate and grease the vehicle

 Prepare electrolyte & charge the battery

 Check voltage, resistance, continuity and find fault in electrical circuits & rectify

 Dismantle, clean, check, repair and assemble – starter motor & starting system

 Dismantle, clean, check, repair and reassemble – alternator / charging system

 Check voltage regulator

 Dismantle wheel bearing, steering stem & ball race, inspect & assemble

Overhaul Disc & 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

Underpinning Knowledge (Theory

Knowledge on safety practices

 Reading of workshop manual

Procedure for checking compression pressure

 Do‟s & don‟ts during dismantling & assembling the engine

 Valve timing of 4 stroke Petrol Engine & Single

Cylinder Diesel engine

Working principle of diesel injection pump and injector of a single cylinder engine

Procedure for reading micrometer & dial gauges

Procedure for overhauling of an engine & transmission

Usage of the multimeter

Fundamental electrical principle

- Ohm‟s Law

- Series & Parallel resistances circuits

- Working principle, application & checking of transistors.

Wiring colour-code

Fault finding procedure in ignition system

Working principle of starter motor & alternator

 Working principle of constant mesh gear box

Electronic ignition system

 Charging system circuit, system components overhauling & testing

Working principle & procedure for overhauling of brakes

Bearing – Types (available in 3 Wheelers cycles), procedure for handling, assembling & dismantling

Purpose & function of shock absorber

Procedure for overhauling a shock absorber

Latest emission norms

 Latest emission controls available to meet the norms

& their working principle

18

*

Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle.

8. TOOLS & EQUIPMENTS ( Suggested ) s.no

1

Item

Hammer ball peen 0.75 kg

2 Screw driver 20 cm. x 9 mm blade

s.no Item

35 Cleaning Tray 45 x 30 cm.

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

6 Hand file 20 cm. Second cut

7 Hollow punch set of seven pieces 6 to15mm

8 Centre punch 10 mm dia x 100 mm

9 Chisel cold flat 20 mm

10 Ring spanner set of 12 pieces (6 to 32 mm.)

11 Feeler gauge 20 blades (metric)

12 Steel toolbox with lock & key (folding type) size

400x200x150mm.

13 Allen Key set of 12 pieces (2 mm to 14 mm)

39

40

41

Vice grip pliers

Valve spring Compressor

Tool valve grinding, suction type

42 Valve seat cutting tools complete with guides and pilot bar(all angles) in a box

43 Surface Plate 60 x 60 cm

44 „V‟ Block 75 x 38 mm pair with Clamps

45 Spanner off set double ended set of 7 pieces.(6 mm -17 mm) Set of 12 nos.

46 Compression testing gauge to read 0 to 115 kg/sq cm

47 Vernier Caliper 250 or 200 mm inside, outside & depth

48 Battery 12 V 14 Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm

15 Steel Rule 30 cm, English and metric

16 Prick punch 15 cm

17 Scriber 15 cm with scribing block universal

18 Hacksaw frame adjustable for 30 cm blade

19 Hand vice 37mm

20 Stud remover

21 Taps and Dies complete set in a box with handle

(metric)

49 Tachometer - to read up to 5000 rpm

50 Drilling machine bench to drill up to 12 mm dia

51 Hydrometer

52 DMM Auto range

Straight edge gauge

53 Battery charger 6v- 18 v

54 Air compressor

22 Spanner for spark plugs 14 mm

23 Hand reamer adjustable 10.5 to 11.25 mm,

11.25 to 12.75 mm,12.75 to 14.25 mm and

14.25 to 15.75 mm

24 Cylinder bore gauge

25 Dial indicator to read 0.01 mm

26 Piston ring filer

27 Mallets (wooden/plastic)

28 Outside Micrometer 0-25 mm, 25-50 mm, 50-75mm,

75-100 mm

29 Piston Ring compressor & Ring Expander

30 Ring ridge remover

31 Spanner, ring offset set of 6 pieces

55

56

Single Cylinder Diesel Engine

Electric pedestal grinder with two 18 cm wheel

57 Portable electric drill 6 mm

58 Spark plug cleaner and tester similar to Bosch / champion

59 Injectors

60 Single cylinder FIP

61 Latest 3 Wheelers of different make along with workshop manual, special maintenance tool & spares

62 Carburetors of 3 Wheelers

63 Water pump / Washer

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

19

1. Name

2. Sector

3. Code

4. Entry Qualification

: Repair & Overhauling of Engine Systems

(Petrol / diesel)

: Automotive Repair

: AUR207

: Minimum 5 th

Std. & 14 years of Age+ MES module

On

‘Basic Automotive servicing (4 wheelers)

5. Terminal competency

6. Duration

6. COURSE CONTENT:

: Successful candidate would be able to

Repair & Overhauling of Engine Systems

: 320 Hours

Practical Competencies Underpinning Knowledge (Theory

20

Practice Health & Safety – familiarize, select, use, maintain & store – tools, equipments, consumables & clothing safely

Select proper materials for gaskets and packing

Select Locking devices and find their applications

Identify differences between Petrol & diesel

Engines.

Identify differences between carburetor engine

& 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 pressure, cylinder head & block warpage, valve leak, lubricating oil pressure, bearing (oil) clearance, measure bore

& take decision for further action, ring end gap & side clearance, fuel pressure regulator in MPFI engine, inlet manifold vacuum, cam & crank shaft bend & valve timing

Service inlet and exhaust manifolds

Remove, clean, check & overhaul engine sub assemblies / components

Remove, clean, check & overhaul electrical components

Dismantle, clean, assemble and check injectors

Knowledge on health & safety precautions to be observed in the workshop / garage

Familiarization of workshop manual

Lubrication & cooling systems

 Layout in Carburetor engine – starting, ignition, charging, fuel supply systems

Layout in MPFI engine –air induction, starting, ignition

& fuel supply systems

Layout in diesel engine –fuel supply systems

 Different valve operating mechanisms & Valve timing diagram

Procedure for handling & reading – micrometers, dial gauges, Torque wrenches /angle meter & multimeter

 Fundamental electrical principles

- Ohm‟s Law

- Series & Parallel resistances circuits

- Working principle, types & application of – capacitors & transistors,

Wiring colour-code, reading of engine electrical systems circuits

Working principle, Different types & 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 & testing of starter motor & cooling fan motor

Procedure for – dismantling, checking, assembling & testing of alternator

Procedure for removing engines from the vehicle

Measure the bore and take the decision

Replace – liner, valve guide, piston wrings

Do valve lapping & valve grinding

Overhaul piston and connecting rod assembly

Assemble the engine,

Fill up oil & coolant after preparing in correct proportion

Start the engine and set idle rpm

Find the fault on the given engine and rectify the defect

 Procedure for checking/testing – compression pressure, cylinder head & block warpage, valve leak, lubricating oil pressure, bearing (oil) clearance, bore measurement, ring end gap & side clearance, fuel pressure regulator in MPFI engine, inlet manifold vacuum, cam & crank shaft bend & valve timing

Procedure for – dismantling, checking, assembling & testing of petrol engines

 Procedure for – dismantling, checking, assembling & testing of diesel engines

Latest emission norms

Controls available to meet the norms & their working principle

Note: -Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle.

21

8. TOOLS & EQUIPMENT( Suggested ) s.n Item s.n Item

Trainees kit

1 Steel rule 15 cm. English and metric 8 Chisel cold flat 20 mm

2 Screw driver 20 cm. x 9 mm blade

3 Screw driver 30 cm x 9mm blade

9 Ring spanner set of 12 pieces (6mm to 32 mm.)

10 Feeler gauge 20 blades (metric)

4 Spanner D E set of 12 pieces (6mm to 32 mm) 11 Steel tool box with lock & 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

7 Centre punch 10 mm dia x 100 mm

13 Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm 04 Sets 34 Spanner, ring offset set

MEASURING INSTRUMENTS AND GENERAL SHOP TOOLS

1 Steel Rule 30 cm, English and metric

2 Engineer‟s square 15 cm blade

3 Divider spring joint 15 cm

4 Prick punch 15 cm 2nos.

5 Chisels Cross cut 200 mm x 6 mm

6 Ball peen Hammer 0.5 kg

7 Scriber 15 cm with scribing block universal

8 Hacksaw frame adjustable for 30 cm blade

36 Distributors

37 Carburetor (two different types)

38 Crow bar 2 each

39 Hollow punch set of seven pieces 6 mm to 15 mm 1 set

40 Cleaning tray- Aluminum 45 x 30 cm

41 Valve spring Compressor

42 Tool valve grinding, suction type (consumable tool)

43 Valve seat cutting tools complete with guides and pilot bar(all angles) in a box

44 Cylinder bore gauge capacity 50 to 150 mm 9 Engineer‟s Stethoscope 04 Screw driver 30 cm x 9 mm blade

10 Hand vice 37mm

11 File assorted (8 types )

45 Fuel feed pump 1 no.

46 Bearing puller screw powered/hydraulic with attachments Max spread 80, 200 and 300 mm

47 Hammer Copper 1 kg with handle 1 no.

48 Surface Plate 60 x 60 cm

12 Drill Twist ( assorted)

13 Taps and Dies complete set in a box (metric) with handle

14 Hand reamer adjustable 10.5 to 11.25 mm,

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

49 „V‟ Block 75 x 38 mm pair with Clamps

50 Spanner off set double ended set of 7 pieces (6 mm -17 mm)

51 Valve key inserter 1 no. 16 Micrometer outside 0-25 mm, 25-50 mm, 50-

75mm, 75-100 mm

17 Micrometer inside 25-50,50-75, 75-150 mm with extension rod

52 Compression testing gauge to read 0 to 115 kg/sq cm

22

18 Mallets (wooden/plastic)

19 Piston ring filer

20 Spanner, ring offset set of 6 (S A E) 2 sets.

21 Spanner, adjustable 20 cm

53 Vacuum gauge to read 0 to 760 mm of Hg.

54 Piston Ring compressor & Ring Expander

55 Tachometer - to read up to 5000 rpm

56 Triple leg grip puller with bearings attachment screw/ hydraulic powered max. Spread

80,160,50,450 mm

57 Pliers water pump multifix 250 mm Long

58 Battery 12 V

22 Spanner for spark plugs 14 mm

23 Spanners socket of 8 with handle, T bar and ratchet

24 Chain and Pulley block 3000 kg capacity

25 Horses

26 Screw jack 1 ton capacity double lift

27 Oil can 0.5-liter cap

28 Cleaning Trays 45 x 30 cm.

29 Torque wrench set of 3 Nos.

30 Work bench each 250 x 120x60 with 4 bench vices 12 cm jaw

31 Pullers screw powered 2 mm with bearing puller attachment

59 Vernier Caliper 250 or 200 mm inside, outside & depth

60 DMM Auto range

61 Petrol Injector

62 Petrol Fuel pump of MPFI system

63 Hydrometer

64 Piston Ring compressors

65 Valve spring lifter

32 Vice grip pliers

33 Circlip pliers Expanding and contracting type 15 cm and 20 cm each 8 sets

34 Inspection lamp with guard and wandering lead of 100 ft.

35 Stud remover

66 Fuel injection pump one with pneumatic governor one with R Q governor and one with

R.S.V. Governor

67 Fuel feed pump

68 Injectors of diesel engines

69 Engine management system‟s Sensors &

Actuators – 4 sets

GENERAL INSTALLATION

1 Petrol engine ( 4 strokes, Multi Cylinder ) of different makes in running condition. (3nos. with MPFI System & 1 Nos. with Carburettor)

2 MPFI vehicle with workshop manuals

9 Nipple forming tool to form nipple on high pressure pipe lines 6.8 and 10 mm dia

3 Diesel engine (4 stroke, Multi Cylinder) of different makes in running condition

10 Portable electric drill 6 mm

11 Spark plug cleaner and tester similar to Bosch / champion

4 Cut model of 4 stroke petrol engine on stand 12 Battery charger 6v- 18 v

5 Common Rail Diesel Injection vehicle on a stand with workshop manuals

13 Injector testing set (hand operated)

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 mm dia 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 & Overhauling of Chassis System (Light Vehicle)

1. Name

2. Sector

3. Code

4. Entry Qualification

: Repair & Overhauling of Chassis System

(Light Vehicle)

: Automotive Repair

: AUR208

: Minimum 5 th

Std. & 14 years of Age, MES module on ‘Basic Automotive Servicing ( 4 wheelers)

5. Terminal competency

6. Duration

7. COURSE CONTENT:

: Successful candidate would be able to

Repair & Overhauling Chassis System (Light Vehicle)

: 320 Hours

Practical Competencies

Practice Health & Safety – familiarize, select, use, maintain & store – tools, equipments, consumables & clothing safely

Identify different parts of chassis

Remove clutch plate from vehicle, check for defects & rectify/replace & refit

Remove gear box from vehicle, dismantle, check, rectify, fill lubricating oil & assemble

Align gear selector fork

Remove CV Joint, Dismantle, lubricate & refit

Remove crown wheel, pinion and bearings, clean parts. Check tooth contact in the crown and pinion and adjust backlash & Assemble rear axle assembly

Check and adjust parking brake and service brakes.

Dismantle wheel brake assembly– remove old lining and fit new one

Remove and refit vacuum boosters

Overhaul – master cylinder, Wheel cylinder & caliper pistons, wheel drum

Bleed vacuum assisted hydraulic brakes

Remove & clean brake drums. Check disc/drum runout, Fit new cups and brake hoses –assemble, adjust all four-wheel brakes and test for brake concern.

Check and correct the steering geometry with instruments

Remove and refit steering boxes from vehicle, checking and top-up oil in steering box. Check and adjust steering wheel play and backlash.

Underpinning Knowledge (Theory

Knowledge on health & 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 & Definition of force, work, power, torque & 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 & 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

Gear selection mechanism

 Lubrication of transmission system

Gear box faults

 Types of bearings, maintenance, their characteristics & application

Working principle of constant velocity joints

Working principle of differential

Faults in differential & C.V. Joints

BRAKE –

Forces & moments acting on vehicle, brake slip, braking force co-efficient, time element of braking operation

24

Overhaul hydraulic power assisted steering system – pump, control valve & cylinder

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.

Re-camber the leaf spring

Remove tyre, inspect/check & assemble

Rotate the tyres

Remove and refit head lamp

Check for electrical defects and rectify

Do Final road test – observe for Noise, Vibration & harshness from different part of chassis – observe for problems in transmission, brake, clutch, steering & suspension systems & rectify the defect

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 & different braking force control valves

Brake linings, pads & fluid

 Brake faults diagnostic

Introduction to anti-lock braking system (ABS).

STEERING –

Introduction, basic types of steering, steering geometry (necessity, types & effects), steering characters (over steer, under steer & neutral steer) & steering linkage

Types of steering gear, power assisted steering

(hydraulic & electronic)

Checks on steering system and fault diagnosis

SUSPENSION –

Introduction, requirement, types,

McPherson strut, shock absorber,

Checks on suspension system and fault diagnosis

WHEELS & TYRES-

necessity, functions, designation & defects analysis

Procedure for tyre rotation

Fundamental electrical principles

- Ohm‟s Law

- Series & Parallel resistances circuits

- Working principle, types & application of – capacitors & 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 & harshness from different part of chassis – observation of transmission, brake, clutch, steering & 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

5

1

2

9

10

11

8

3

4

1

2

5

6

7

8. TOOLS & EQUIPMENT( Suggested )

s.n Item s.n a) TOOL KIT

Steel rule 15 cm. English and metric

Screw driver 20cm. X 9mm Blade

Screw driver 30 cm. X 9 mm Blade

Spanner D. E. set of 12 pieces (6mm to 32mm)

18

19

20

21

Pliers combination 20 cm

Pliers side cutting 15 cm

Plier round nose 15 cm

22

23

24

Item

Hand file 20 cm. Second cut half- round

Hand file 20 cm. smooth triangular

12 Hand file 30 cm. bastard

Steel tools box with lock and key (folding type) size400X200X150mm

Circlip pliers 15 cm. Expanding type

Chisel cold flat 20 mm

Hand file 30 cm. round bastard

Plier flat nose 15 cm

25

Centre punch 10 cm

12

13

14

15

16

17

Hollow punch set of seven pieces 6mm to 15mm 1 Set

26

Ball peen Hammer 0.5kg

Drift punch copper 15 cm

Prick punch 15 cm

Chisels cross cut 200 mm X 6mm

Allen Key set of 12 pieces (2mm to 14mm)

Philips Screw Driver set of 5 pieces (100 mm to 300 mm)

Mallets wooden/ plastic

Spanners socket with speed handle, T- bar, ratchet and universal upto 32 mm set of 28 pieces with box

Hand file 20 cm. Second cut flat

27

28 Spanner, ring set of 12 metric sizes 6 to 32 mm

29

30

Spanner, adjustable 15cm

Spanner for spark plugs 14mm

31

32

33

34

Adjustable spanner (pipe wrench 350 mm)

Hand reamers adjustable 10.5 to 11.25 mm,

11.25 to 12.75 mm, 12.75 to 14.25 mm and

14.25 to 15.75 mm

Vice grip pliers

Circlip pliers Expanding and contracting type

15cm and 20cm

Circlip pliers 15 cm. Contracting type

s.n

3

4

Item s.n Item b) SHOP OUTFIT & MEASURING INSTRUMENTS

Cylinder bore gauge capacity 20 to 160 mm

Micrometer out side 0- 25 mm, 25- 50 mm, 50 – 75 mm, 75 – 100 mm

Micrometer in side 25- 50, 50- 75, 75- 150 mm with extension rod.

6

7

8

Dividers spring 15 cm

Compression testing gauge to read 0 to 50 kg/ sq. cm

Steel Rule 30 cm. English and metric

Torque wrench 5 to 35 Nm, 12 – 68 Nm & 50 – 225

Nm

Straight edge gauge 2 ft.

9

10

Engineer‟s square 15 cm Blade

Feeler gauge 20 blades (metric)

26

s.n

1

2

3

4

5

6

7

Drill Twist (assorted)

Distributor

Item s.n

C. GENERAL INSTALLATION / MACHINERIES

Surface Plate 60 x 60cm 1 No. 100 Petrol Engine of: latest model ( CNG Engine ) with workshop manuals

Hacksaw frame adjustable

34

35

36

37

Item

Taps and Dies complete sets (5 types)

Piston ring expander and remover 50 mm &

100 mm

Piston Ring compressor

Piston Ring Groove cleaner

38 Carburetor

Fuel feed pump

4 Wheeler petrol vehicle fitted with MPFI system/ carburetor system with manuals

39

40

Cylinder ridge remover/ cutter

Work bench 250 x 120 x 60 cm with 2 vices

Pullers screw powered 2 mm gap with bearing puller

8

9

10

11

12

13

V‟ Block 75 x 38mm pair with Clamps

Valve grinding tool- suction type

C. V. Joint units of 3 different types 4 sets

44

45

46

Cleaning tray- Aluminum 45 x 30 cm

Spark plug spanner 14mm x 18mm x Size

Cut model of 4 stroke Diesel engine on stand

Drum brake assembly 2 Nos.

14

15

18

19

20

Drilling machine bench to drill up to 12mm die

Engine analyzer

16 Air compressor with accessories

17 Tyre pressure gauge with accessories

47

48

49

50

Disk brake with caliper assembly 2 Nos.

Tandem master cylinder with booster 4 Nos.

Wheel cylinder 4 Nos.

Horses and wheel choke

Screw jack one tone, capacity double lift

51

52

Lead acid battery 12 V 4 Nos.

Speed counter / Tacho meter – pointed type to read up to 5000 RPM

Chain and pulley block 3000 kg. Capacity electric type

53

Petrol Engine of: latest model (CNG Engine) with workshop manuals

21

22

23

24

25

Valve seat cutting tools complete with guides and pilot bar (all angles)

Valve key inserter

Hand vice – 37 mm

Hydraulic jack with trolley capacity 3 Ton

Engineers stethoscope

Oil can 0.5/ 0.25 liter capacity

Cut model of 4 stroke Petrol engine on stand

Scriber with scribing black universal

41

42

43

Inspection lamp with guard and wandering lead of 100ft. length

Fire extinguisher ABC type 5 kg capacity

Fire Buckets (4 Nos.) with stand

54 Tubed tyre of cars

55 Electronic engine control modules

56 Wheel alignment gauges 1 set

26

Marking out table 90X60X90 cm

27 Cleaning tray 45x30 cm

28 Valve spring lifter

29

30

31

32

33

Bearing puller screw powered/ hydraulic powered with attachments Max spread 80, 200 and 300mm

Battery charger 6 – 24 V with 10 A rate

Synchromesh gear box of LCV 2 Nos.

Electric pedestal grinder with two 18cm. Wheel

Vacuum gauge to read 0 to 760 mm of Hg

57

58

59

Smoke testing machine

Triple leg grip puller with bearings attachment screw/hydraulic Powered max.

Spread 80, 160, 250, 450 mm

Spark plug testing machine

60

61

62

63

64

Crow bar

Petrol engine 4 stroke fitted with MPFI system for practice with manuals

Petrol engine 4 stroke fitted with carburetor for practice with manuals

Petrol Engine car of latest model with manuals

Diesel Engine car of latest model with manuals

65

Tyre remover pneumatic & mechanical type

27

Repair & Overhauling of Chassis System (Heavy Vehicle)

1. Name : Repair & Overhauling of Chassis System

(Heavy Vehicle)

2. Sector

3. Code

4. Entry Qualification

: Automotive Repair

: AUR209

: Minimum 5 th

Std. & 14 years of Age, , MES module on ‘Basic Automotive Servicing ( 4 wheelers)

5. Terminal competency

: Successful candidate would be able to

Repair & Overhauling Chassis System (Heavy Vehicle)

6. Duration

7. COURSE CONTENT:

: 320 Hours

Practical Competencies

Practice Health & Safety – familiarize, select, use, maintain & store – tools, equipments, consumables & clothing safely

Identify different parts of chassis

Identify different tools & equipments

Remove clutch plate from vehicle, check for defects & rectify/replace & refit

Remove gear box from vehicle, dismantle, check, rectify, fill lubricating oil & assemble

Align gear selector fork

Remove CV Joint, Dismantle, lubricate & refit

Remove crown wheel, pinion and bearings, clean parts. Check tooth contact in the crown and pinion and adjust backlash & Assemble rear axle assembly

Check and adjust parking brake and service brakes.

Dismantle wheel brake assembly– remove old lining and fit new one

Overhaul – pneumatic valves, Wheel cylinders & Drum brake/disc brakes

Check fail safe system & rectify defects

Remove & clean brake drums. Check disc/drum runout, Fit new cups and brake hoses/pipes –assemble, adjust all wheel brakes and test for brake concern.

Check and correct the steering geometry with instruments

Underpinning Knowledge (Theory

Knowledge on health & safety precautions to be observed in the workshop / garage (health hazard of asbestos dust to be emphasized)

 Familiarization of workshop manual

Familiarization of different tools & equipments

TRANSMISSION -

Power flow from engine to wheels

Units & Definition of force, work, power, torque & pressure

Description of single plate clutch. Functions of different parts of the clutch assembly. Clutch linings material.

Power flow in clutch plate.

Clutch operating mechanisms- manual & 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

 Gear selection mechanism

Lubrication of transmission system

 Gear box faults

Types of bearings, maintenance, their characteristics & application

Working principle of constant velocity joints

 Working principle of differential

Faults in differential, C.V.Joints & drive shafts

BRAKE –

Forces & moments acting on vehicle, brake slip, braking force co-efficient, time element of braking

28

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 & cylinder

Remove and refitting a leaf spring as an assembly in a

Re-camber the leaf spring. Overhaul shackles

 vehicle, changing rubber bushes of shock absorbers and independent front suspension. Lubricate suspension units.

Remove tyre, inspect/check & assemble

Rotate the tyres

Remove and refit head lamp

Check for electrical defects and rectify

Do Final road test – observe for Noise, Vibration & harshness from different part of chassis – observe for problems in transmission, brake, clutch, steering & suspension systems & rectify the defect operation

Classification of brake systems, factors affecting the braking distance

 Advantages of pneumatic brake system over hydraulic

Working principle of brake components – compressor, pressure regulator, different pneumatic valves, brake booster, wheel cylinder

 Brake linings & pads

Brake faults diagnostics and adjustments

 Introduction to anti-lock braking system (ABS).

STEERING –

Introduction, basic types of steering, steering geometry (necessity, types & effects), steering characters (over steer, under steer & neutral steer) & 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 & TYRES-

necessity, functions, designation & defects analysis

Procedure for tyre rotation

Fundamental electrical principles

- Ohm‟s Law

- Series & Parallel resistances circuits

- Working principle, types & application of – capacitors & 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 & harshness from different part of chassis – observation of transmission, brake, clutch, steering & 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.

29

8. TOOLS & EQUIPMENT( Suggested )

5

1

2

3

4

5

6

7

8

9

10

11

12

13

14

17

s.n s.n

15

16

Item s.n Item

Steel rule 15 cm. English and metric

Screw driver 20cm. X 9mm Blade

Screw driver 30 cm. X 9 mm Blade

Spanner D. E. set of 12 pieces (6mm to 32mm)

Pliers combination 20 cm

a) TOOL KIT

18

19

20

21

22

Hand file 20 cm. Second cut half- round

Hand file 20 cm. smooth triangular

12 Hand file 30 cm. bastard

Steel tools box with lock and key (folding type) size400X200X150mm

Circlip pliers 15 cm. Expanding type

Pliers side cutting 15 cm

Plier round nose 15 cm

Plier flat nose 15 cm

23

24

25

Chisel cold flat 20 mm

Centre punch 10 cm

Hand file 30 cm. round bastard

Hollow punch set of seven pieces 6mm to 15mm 1 Set 26 Ball peen Hammer 0.5kg

Drift punch copper 15 cm

Prick punch 15 cm

Chisels cross cut 200 mm X 6mm

Allen Key set of 12 pieces (2mm to 14mm)

Philips Screw Driver set of 5 pieces (100 mm to 300 mm)

Mallets wooden/ plastic

Spanners socket with speed handle, T- bar, ratchet and universal upto 32 mm set of 28 pieces with box

Hand file 20 cm. Second cut flat

27 Adjustable spanner (pipe wrench 350 mm)

28 Spanner, ring set of 12 metric sizes 6 to 32 mm

29

30

Spanner, adjustable 15cm

Spanner for spark plugs 14mm

31

32

33

34

Hand reamers adjustable 10.5 to 11.25 mm, 11.25 to 12.75 mm, 12.75 to 14.25 mm and 14.25 to

15.75 mm

Vice grip pliers

Circlip pliers Expanding and contracting type 15cm and 20cm

Circlip pliers 15 cm. Contracting type

1

2

3

4

Item s.n Item b) SHOP OUTFIT & MEASURING INSTRUMENTS

Cylinder bore gauge capacity 20 to 160 mm 6 Dividers spring 15 cm

Micrometer out side 0- 25 mm, 25- 50 mm, 50 – 75 mm, 75 – 100 mm

Micrometer in side 25- 50, 50- 75, 75- 150 mm with extension rod.

Torque wrench 5 to 35 Nm, 12 – 68 Nm & 50 – 225

Nm

Straight edge gauge 2 ft.

7

8

9

10

Steel Rule 30 cm. English and metric

Compression testing gauge to read 0 to 50 kg/ sq. cm

Engineer‟s square 15 cm Blade

Feeler gauge 20 blades (metric)

30

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Drill Twist (assorted)

C. GENERAL INSTALLATION / MACHINERIES

Surface Plate 60 x 60cm 1 No. 100 Petrol Engine of: latest model ( CNG Engine ) with workshop manuals

Hacksaw frame adjustable

Distributor

34

35

36

37

Taps and Dies complete sets (5 types)

Piston ring expander and remover 50 mm & 100 mm

Piston Ring compressor

Piston Ring Groove cleaner

38 Carburetor

Fuel feed pump

4 Wheeler petrol vehicle fitted with MPFI system/ carburetor system with manuals

39

40

Cylinder ridge remover/ cutter

Work bench 250 x 120 x 60 cm with 2 vices

Pullers screw powered 2 mm gap with bearing puller

41 Valve seat cutting tools complete with guides and pilot bar (all angles)

Valve key inserter

Hand vice – 37 mm

V‟ Block 75 x 38mm pair with Clamps valve grinding tool- suction type

C. V. Joint units of 3 different types 4 sets

Drilling machine bench to drill up to 12mm die

42

43

44

45

46

47

Inspection lamp with guard and wandering lead of

100ft. length

Fire extinguisher ABC type 5 kg capacity

Fire Buckets (4 Nos.) with stand

Cleaning tray- Aluminum 45 x 30 cm

Spark plug spanner 14mm x 18mm x Size

Cut model of 4 stroke Diesel engine on stand

Drum brake assembly 2 Nos.

15 Engine analyzer

16 Air compressor with accessories

17 Tyre pressure gauge with accessories

18 Horses and wheel choke

19

20

21

22

23

48

49

50

51

Disk brake with caliper assembly 2 Nos.

Tandem master cylinder with booster 4 Nos.

Wheel cylinder 4 Nos.

Lead acid battery 12 V 4 Nos.

Screw jack one tone, capacity double lift

Hydraulic jack with trolley capacity 3 Ton

Engineers stethoscope

Oil can 0.5/ 0.25 liter capacity

52 Speed counter / Tacho meter – pointed type to read up to 5000 RPM

Chain and pulley block 3000 kg. Capacity electric type

53

Diesel Engine of latest model (CNG Engine) with workshop manuals

54

55

56

Tubed tyre of HCV

Electronic control module

Wheel alignment gauges 1 set

24

25

26

27

Cut model of 4 stroke Petrol engine on stand

Scriber with scribing black universal

Marking out table 90X60X90 cm

Cleaning tray 45x30 cm

28 Valve spring lifter

29

Bearing puller screw powered/ hydraulic powered with

30 attachments Max spread 80, 200 and 300mm

Battery charger 6 – 24 V with 10 A rate

31

32

33

Synchromesh gear box of LCV 2 Nos.

Electric pedestal grinder with two 18cm. Wheel

Injector tester

57

58

59

60

61

62

63 EGR cut out

64 Set of sensors & actuators

65

Smoke testing machine

Triple leg grip puller with bearings attachment screw/hydraulic Powered max. Spread 80, 160,

250, 450 mm

Crow bar

Diesel engine

HCV of latest model with manuals

Tyre remover pneumatic & mechanical type

Common Rail diesel engine on a stand

66 Pneumatic brake system on a bed board

31

Repair of Auto Electrical & Electronics Systems

1. Name : Repair of Auto Electrical & Electronics Systems

2. Sector

3. Code

: Automotive Repair

: AUR215

4. Entry Qualification

6. Duration

: Minimum 8 th

Std. & 14 years of Age, , MES module on ‘Basic Automotive Servicing ( 4 wheelers)

5. Terminal competency

: Successful candidate would be able to

Repair Auto Electrical & Electronics System

: 320 Hours

7. COURSE CONTENT:

Practical Competencies

Practice Health & Safety – familiarize, select, use, maintain & store – tools, equipments, consumables & clothing safely

Identify different tools & equipments

Identify different electrical parts of a vehicle

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 & rotor condition.

Trace starter circuit in a vehicle Dismantle starter and check each components, Repair the faults, assemble

Underpinning Knowledge (Theory

Safety precautions and first aid. Care and maintenance of tools.

 Signs and symbols used in Electrical & 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 connected

 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 & checking of – switches, Circuit protectors, relays, solenoids, resistors, diodes, connectors, spark plugs

(explain radio interference suppression) & condensers

Description / working principles, types, uses, location, maintenance & checking of various automobile electrical equipments – starter motor, alternator, wiper motor, horn & battery

 Cables colour codes & sizes.

 Function, types, uses, location & checking of – Basic electronics devices such as transistors, ICs, Thysistors,

Triac, Diac, etc. Simple electronics circuits such as oscillators amplifiers, rectifier circuits, & 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 circuits 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 & actuators using engine scanner /

DMM

Check the different modes/ strategies of Electronic 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 & 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 & EGR cutout solenoid valve

(explain duty cycle)

Control Assembly, Reset keep alive memory/ ECA

Check different wiring / circuits and rectify the defect

 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 in the service manual of the particular brand of vehicle

3

4

1

2

6

7

8

9

10

11

1

2

3

8. TOOLS & EQUIPMENT( Suggested ) s.n

4

5

Item s.n Item

Ball Peen Hammer 0.75 Kg

Cold Flat Chiesel 19mm

Centre Punch 10 mm dia x 100mm

a) TRAINEES TOOL KIT

6

7

Steel rule 30mm

Plier combination 15cm

8

Insulated Screw driver 30 cm x 9mm blade

Insulated Screw driver 20 cm x 9mm blade

9

10

Steel tool box with lock & key ( folding type ) size

400x200x150mm

Hand file 20 cm second cut

Ring spanner set of 12mm

5

b) SHOP OUTFIT & MEASURING INSTRUMENTS

Electric testing screwdrivers 12 Hand vice 37 mm 2 25 Stud extractors

Allen key set of 12 pieces ( 2mm – 14 mm) 26 Poker 2 Nos

Circlip plier (External and Internal) 150mm & 200mm 27 Double ended Spanner 6 to 32 mm - set of 12 nos

Philips Screw Driver set of 5 pieces 100mm – 300mm 28 Double ended off- set Spanner (W. W) – 3 to 13.5

Star Allen keys 29 mm –set of 7 nos.

Double open ended ignition spanner set (of BA- 0 x

Prick punch 15 cm 30

1to 8x9 set of 5)

Spanner Clyburn 15 cm

31 Chisel cross cut 200mm x 6 mm

Ball Peen Hammer 0.5 Kg

Hammer copper 1 Kg with handle

Hack saw frame for 30 cm blade

Hollow punch 6,7,8,9,10 and 12 mm set

32

33

34

35

Adjustable spanner 20 cm

Spark plug spanner 14 mm 1 No.

Magneto spanner set with 8 spanners 1 set

Socket spanner set with handle, T- bar and ratchet

Drift copper (10 mm x 150 mm) 1 No.

33

21

22

23

24

13

14

15

16

17

18

19

20

12 Flat File 35 cm bastard

Flat File 25 cm second cut

36

37

Micrometer Outside 0- 25mm, 25- 50mm

Soldering iron 120 watts

38

39

Spring tension tester

A. V. O. meters

Nose Pliers (round and straight) 150 mm and 200mm

40

Alternator regulator tester

41

Double open ended spanner set (10.5mm x

12 mm; 10.5mm x 18 mm set of four) 1 set

Hydrometers

Circlip pliers

Thread pitch gauge

Stud remover

Spanner T. flocks for screwing up and up- screwing inaccessible positions

Cleaning tray 45 x 30cm

Oil cane 0.5 litres

Smp (straight & bent)

General purpose puller

42

43

44

45

46

47

48

Distributor tester

Continuity meter

Clip on meter Digital and Analog 1 each

Tachometer

Spark Plug tester “NEON” type

High rate discharge tester

Multimeter digital and Analog 1 each

Starter motor, alternator, dynamo & cut out

2 each

s.n

12

13

14

15

16

7

8

9

10

11

1

2

3

4

5

6

17

Drilling Machine ( Bench) 12 mm dia

Growler

Item s.n c) GENERAL INSTALLATION / MACHINERIES

18

19

Grease Gun

Item

Pulley set universal for bearing & bushes (set)

Battery charger 6V – 24 V

AC alternator slip ring puller

AC alternator slip ring press tool

20

21

22

Pulley puller

Glow plug

Alternator

23 Executive Auto Electrical tool kit

Electrical test bench

Car stereo 1 No

Battery 12V (Lead acid & Alkaline)

Electronic engine control module

Starter motor axial type, pre- engagement type & Co- axial type 1 each

Electrical horn( different types )

Wiper motor assemblies

24

25

26

27

28

29

30

Glow plug tester

Torque wrenches 5035 Nm, 12- 68 Nm

Starter test bench

Dynamo and voltage regulator

Alternator and inbuilt regulator

Horn and Horn relay

Engine Scanner

Anti theft devices

Melting pot

Paraffin pressure Gun

31

32

33

Air conditioned MPFI vehicle with accessories

Engine control sensors 8 types

Five Point relays 4 nos

Four Point relays 4 nos

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

34

Repairing of Auto Air Conditioning System

1. Name

2. Sector

: Repairing of Auto Air Conditioning System

: Automotive Repair

3. Code

4. Entry Qualification

: AUR210

: Minimum 5 th

Std., 14 years of Age & MES Module

on Basic Automotive Servicing (4 wheelers)

5. Terminal competency

: Successful candidate would be able to Repairing of

Auto Air Conditioning System

6. Duration : 240 Hours

7. COURSE CONTENT:

Practical Competencies

Practice Health & Safety – familiarize, select, use, maintain & store – tools, equipments, consumables & 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 & sensors on vehicle

 Measure voltage, resistance & continuity in different lines for air conditioning system

(climate control)– reconcile Ohm‟s law.

Check of circuit breakers and relays

Check sensors & actuators using engine scanner / DMM

Check duty of idle air control valve with ac on

& off with different engine RPM

Remove compressor from the vehicle, dismantle, check, rectify the defect, assemble

& refit to the vehicle

Remove expansion valve from the system, dismantle, check, rectify the defect, & refit into the system

 Remove evaporator & heater cores from the vehicle, dismantle, check, rectify the defect, assemble & refit to the vehicle

Check condenser on the vehicle, & rectify the defect

 Check the drive system & adjust if required

Check Belt tension

Check Gap in electromagnetic clutch

 Remove & refit heater control module

 Test the system for leaks

Evacuate/drain the system

Charge / fill the system

 Find the Faults & rectify in the climate control system

Underpinning Knowledge (Theory

Safety precautions and first aid. Handling of refrigerants. Proper Use, Care and maintenance of tools & equipment

Signs and symbols used in Air conditioning system

Fundamentals of air conditioning: a. Introduction – purpose, basic operation of refrigeration cycle, basic components & circuits (with fixed orifice tube & thermal expansion valve-Mechanical & Electrical circuits), use of thermometer and pressure gauges, b. Definition of technical terms – pressure, temperature, heat(heat, quantity, specific heat & heat transfer), Humidity, change of state & pressure temperature relation. c. Refrigeration cycle – high pressure side & low pressure side d. characteristics of R12 & R134a. e. lubrication. f. cooling load and capacity. g. a/c systems – car air conditioning types & features(dash type, all season type & 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 & their units. Use of multi-meter, Brief on Magnetism.

Semiconductor & application (only brief)

 Description/working principles, types, uses, location & checking of – switches, Circuit protectors, relays, solenoids, resistors, diodes & 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 type) – importance of these sensors for air conditioning system

 Construction and working principle of actuators – coolant diversion valve(for heating the cabin) & idle air control valve (Electronic controlled engines ) & duty cycle

Description / Reading of wiring diagram

 Description & operation of Main Functional parts–Compressor, Condenser,

Evaporator, and Expansion Devise/valve - Different types of above components

Description & operation of Other Functional parts – magnetic clutch, receiver/drier, blower motor, condenser fan, thermostat, pressure switches & magnetic valve(for dual air conditioner)

Repair

 Procedure for evacuating / draining the system, finding the leak & charging the system

Procedure for Fault finding (Trouble shooting charts) & rectification in car air conditioning

 Procedure for dismantling, checking, assembling different components of the system

 Difference between manual & automatic air conditioning / climate control systems

Air distribution of air conditioning system & 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 & EQUIPMENT( Suggested ) s.n

1

Screw driver

2

File

3

Crimping Tool

4

5

Hacksaw

DE Spanner Set

6

Vice

7

Hammer

8

Pliers,

9

Pipe Wrench

10 Screw Wrench

11 Ring Spanner Set

12 Hydraulic jack

Item

13 2 Torque wrenches of different capacity

14 Solder Iron

.

15 Inspection lamp with guard and wandering lead of 100 ft

16 Tripod axle stand adjustable 1500 kg capacity

17 Vehicle with dual air conditioning system along with special tools for removing and refitting air conditioning system & work shop manuals

s.n

18 DMM

24

Drilling Machine

2 sets of condensers

Item

19 2 sets of accumulator / drier

20 Mock-up board with semi-automatic air conditioning system

21 Service units with set of Compound pressure gauges-Recovery Machine & charging Unit

22 Leak detectors – electronic & UV lamp

23

25

26

27

28

29

30

31

32

2 sets of compressors of different types

2 sets of expansion valves of different types

2 sets of evaporators of different types

2 sets of air distribution doors of different types

2 sets of coolant control valves (heater control)

2 sets of A/C control assemblies of different types

2 sets of switches of different types (HP & LP

Switches)

2 sets of Thermistors

33 Heater control modules(E & C Unit)

34 2 sets of blower motor

35 2 sets of receiver/drier

36

Wheel alignment & balancing

1. Name

2. Sector

3. Code

: Wheel alignment & balancing

: Automotive Repair

: AUR211

4. Entry Qualification : Minimum 5th Std., 14 years of Age, MES

Module on Basic Automotive Servicing

5. Terminal competency

(4wheelers)

: Successful candidate would be able to do

wheel Alignment & wheel balancing

6. Duration : 120 Hours

7. COURSE CONTENT:

Practical Competencies

Practice Health & Safety – familiarize, select, use, maintain & store – tools, equipments, consumables & clothing safely

Wheel alignment

Check tyres, ride height, wheel bearings, ball joints, control arms bushings and sway bars, shock absorbers & struts & power steering

Set the aligner ready for wheel alignment tests

Check and rectify steering geometry with wheel aligner – take a print out

Wheel balancing

Remove tyre from vehicle

Check tyre & rim and also check for run out

Do static balancing

 Fit the wheel assembly on the aligner and check for dynamic imbalance & rectify the defects

Fit the tyre assembly to the vehicle

Underpinning Knowledge (Theory)

Safety precautions and first aid. Care and maintenance of tools & equipment

Wheel alignment

 Layout of steering &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/SAI(steering Axis Inclination), turning angle, included angle, set back, thrust angle & frame angle.

 Pre alignment inspection/checks

Two wheel & four wheel alignment

Reasons for Alignment problems – steering pull, off-centre steering, steering shimmy, excessive steering effort, poor self centering and memory steer, bump steer, torque steer & steering harshness-alignment diagnostics chart & steering problem diagnostic chart.

Components, brief working principle & operation of computerized wheel aligner

 Procedure to make machine to check wheel alignment

 Procedure for taking readings using wheel aligner, interpreting alignment readings & repair the same.

Procedures for test drive to confirm the repairs.

Wheel balancing

 Meaning of balance, causes & effects of imbalance, vibration. Identification of source, transfer path & responder of vibration(can be felt & can be heard)

 Analyzing & identifying complaint

Procedure for road tests(vibration diagnostic)

 Steering wheel shake – shimmy, wobble & waddle

 Brief on static balance, dynamic balance, Mounting errors(radial & lateral) & excessive(Tyre & rim) run out-lateral & radial and mismatches

Brief description of wheel balancer(block diagram balancer), fixed data & data to be fed to the machine

 Procedure for balancing the tyre, rim & 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 & EQUIPMENT( Suggested ) s.n

1

Screw drivers

Item

2

3

4

5

6

7

8

File

DE Spanner Set

Box spanner set

Hacksaw blade with frame

Tyre pressure gauge with accessories

Hammer

Vice

9

Pliers

10

Pipe Wrench

11 Torque wrenches of different capacity

s.n Item

12 Inspection lamp with guard and wandering lead of

100 ft

13 Horses and wheel chokes

14 Screw Wrench

15 Ring Spanner Set

16 Wheel aligner bay/ramp/pit with rolling jack

17 Computerized wheel aligner with all accessories along with manuals & diagnostic charts

18 Wheel changer

19 Computerized wheel balancing machine with all accessories

20 Compressor with accessories

21 FWD Vehicle with workshop manual & vehicle kit

22

38

Minor repair of Auto body

1. Name : Minor repair of Auto body

2. Sector : Automotive Repair

3. Code

4. Entry Qualification

: AUR212

: Minimum 5th Std., 14 years of Age &

MES Module on Basic Automotive

5. Terminal competency

Servicing (4 wheelers)

: Successful candidate would be able

to do minor repair of auto body

6. Duration : 210 Hours

7. COURSE CONTENT:

Practical Competencies

Practice Health & Safety – familiarize, select, proper use, maintain & store – tools, equipments, consumables & clothing safely

 Inspect & decide whether it can be repaired or replaced.

Remove and refit body panels, doors, floor wheel boxes & fenders

 Do gas welding, gas brazing, gas soldering & gas cutting on vehicle body

 Do arc welding on vehicle body

Do Resistance spot, seam & 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 & primer (repair damaged body which is ready for final paint)

Apply base coat painting

 Fit & Check the repaired components for alignment

Underpinning Knowledge (Theory

 Safety precautions and first aid. Proper Use, Care and maintenance of tools & equipment

Introduction on types & function of body & panels.

Procedure for inspection, removing & refitting of body components-panels, doors & other body parts

GAS WELDING : - Gas Welding, brazing & Soldering procedures

 Gas cutting practice

ARC WELDING: - Basic Electricity and welding power source Electrodes – types, description & 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 & 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. TOOLS & EQUIPMENT( Suggested ) s.n

1

Steel Rule 300mm

2

Steel Tape 2 meters

12 Gloves

Item s.n Item

37.

Vernier bevel protractor

38.

Try square 200 mm Blade

3

Wing Divider 200mm

4

Spring Dividers 150mm

8

Protractor with blade 150mm

9

Scriber 150mm x 3mm (Engineers)

39.

Ring spanner set at 12 metric 6 mm to 32 mm

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

44. File half round 300mm smooth

45. Round File 2 nd

Cut 250mm

10 Soldering copper 0.2 Kg

11 Goggles

46. Triangular File Smooth 250mm

47. Square File 2 nd

Cut 250mm

48. Hacksaw frame 300mm adjustable

13. Apron

14. Spark lighter

49. Hand Groover 3mm, 4mm, 5mm

50. Combination Plier

15. Hammer Chipping 0.25 Kg

16. Tin Man’s 450 mm x 600mm

17. Sheet Metal Gauge

51. Grip Wrench 200mm

52. Soldering Copper Hatchet type 500gms

53. Pneumatic riveting gun

18. Stake Round and Bottom

19. Half Moon Stake

20. Funnel Stake

21. Anvil Face Stake

22. Tinmans Horse

23. Hammer Peaning with handle

24. Hammer Creasing with handle

25. Hammer Planshing with handle

26. Hammer Block with handle

27. Soft Hammers ( Brass, Copper, Lead, Rubber and Rawhide heads with handle)

54. Trammel Point (with beam 600mm)

55. Vernier Caliper (0mm-150mm)

56. Micrometer outside (0 to 25mm)

57. Raspcut file 250mm

58. D.E. Spanner (6mm to 32mm) (set of 12 spanner)

59.

Scriber 150 mm

60. Safety Glasses

61. Hand vice 50mm

62. Steel wire Brush 50mmx150mm

63. Rivet sets snap and Dolly combined 3mm, 4mm,

6mm

28. Sher Tinmans 300mm

29. Snips straight 250mm

30. Right cut snips 250mm

64. Leather Apron

65. Tongs, Close mouth and pick up (1 each)

31. Left cut snips 250mm

32. Hand Shear Universal 250mm

33. Punch Round 3mm, 4mm &6mm Dia

34. Centre Punch 100mm

66. Portable Electric drill (Single phase) with drill bits

67. Pillar type drilling machine 12mm with drill bits

68. Crow bar 910 x25mm

69. Pop rivet gun

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,

Regulator and Torch with Burner

74. Bench lever shears 250mm Blade x 3mm

Capacity

75. Air Compressor with accessories

83. Wooden Rule 450mm

84. Portable Nibbler

85. Welding Transformer ( 300 Amps) with accessories

76. Spray Gun (Painting) 500ml

77. Guilltotine shearing Machine foot

86. Gas Welding Table 1220mm x760mm

87. Spot Welding Machine with complete accessories operation (1mt x 18G Capacity)

78.

Oxy-acetylene welding equipment with complete accessories (Low & high pressure)

88. Tin smiths bench folder 600 x 1.6mm

79. D.E. Grinder Pedestal motorized 200mm 89. Suitable Work Tables with vices

90. Polishing cloth standard size

91.

LCV Condemned

92. Consumables

80. Anvil 50 Kgs with Stand

81. Bench vice

82. Buffing and Polishing Machine

41

Auto body Painting

1. Name : Auto body Painting

2. Sector

3. Code

4. Entry Qualification

: Automotive Repair

: AUR213

: Minimum 5th Std., 14 years of Age &

MES Module on Basic Automotive

Servicing (4 wheelers)

5. Terminal competency

: Successful candidate would be able

to do auto body Painting

6. Duration : 180 Hours

7. COURSE CONTENT:

Practical Competencies

 Practice Health & Safety – familiarize, select, proper use, maintain & store – tools, equipments, consumables & clothing safely

 Prepare the damaged body for painting

Apply body filler on the affected area

Apply base coat

 Apply clear coat

Do painting

Do rubbing & polishing

 Apply anti-rust treatment

Fix wind screen glasses

Inspect the painting work

Underpinning Knowledge (Theory

 Safety precautions and first aid. Use, Care and maintenance of tools & equipment

Selection of consumable for doing painting work

 Procedure for doing painting( in chronological order), selection of material, tools & equipments - Application of body filler for surface preparation, Sanding on the affected area for smooth surface preparation, Primer coating on the affected area,

Preparing affected surface for base coating, Applying base coat painting, Clear coat painting for metallic paints, Rubbing and polishing,

Application of Paint protection treatment / Anti-rust treatment

Procedure for Inspection of painting work & fixing the wind screen glass

8. TOOLS & EQUIPMENT ( Suggested )

1 General tools

2

3

4

5

6

LCV Condemned vehicle body

Air Compressor with accessories

Spray Gun (Painting) 500ml

Buffing and Polishing Machine

Bench vice

7 Consumables

8 Sanding emery 40G, 80G, 120G, 220G, 400G, 600G,

1500G, 2000G

9 Primer, Hardener & thinner

10 Paints

11 Poly urethane body filler

12 Rubbing & polishing compounds

13 Polishing cloth standard size

14

42

Diesel Fuel Injection Technician

1. Module name

2. Sector

: Diesel Fuel Injection Technician

: Automotive Repair

3. Code

4. Entry Qualification

: AUR214

: Minimum 5th Std., 14 years of Age

& MES Module on Basic

Automotive Servicing (4 wheelers)

5. Terminal competency :

Successful candidate would be able

to carry out repair and calibration of

6. Duration

Diesel Fuel Injection pump & injectors

: 180 Hours

7. COURSE CONTENT :

Practical Competencies Underpinning Knowledge (Theory

Practice Health & Safety – select, use, maintain & store tools, equipments & clothing safely

Practice 5S technic

Identify / Familiarize with the tools & equipments

 Wash / Clean FIP and Injectors

Check the FIP on calibration bench and assess the condition

 Dismantle FIP using special tools

Clean and inspect Parts of each components

 Replace defective components

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

General health & Safety precautions to be observed in the workshop / garage

Over view on 5S technic (Sort, Set in order, Shine,

Standardise & Sustain)-advantages in implementation of 5S

Fuel supply layouts in diesel engines

Nomenclature of different types of fuel injection pumps

Working principle of FIP

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 & calibration charts

Procedure for phasing & calibration of an FIP

 Purpose, types, construction & operation of Injectors and nozzles

 Procedure for testing the Injectors as per specification

Note: -Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle

43

8. TOOLS & EQUIPMENTS ( Suggested ) s.no Item

1 Hammer ball peen 0.75 kg

2 Screw driver 20 cm. x 9 mm blade

s.no

25 Injector holders

Item

23 Portable electric drill 6 mm

24 Latest Diesel 4 Wheelers of different make (one

LMV & one HCV) along with workshop manuals

3 Screw driver 30 cm x 9 mm blade

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

7 Centre punch 10 mm dia x 100 mm

8 Chisel cold flat 20 mm

28 Spanner, adjustable 20 cm.

29 Socket Spanners with handle, T bar & ratchet

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 & key (folding type) size 400x200x150mm .

33 Pullers screw powered 2 mm with bearing puller attachment

12 Allen Key set of 12 pieces (2 mm to 14 mm) 34 Vice grip pliers

13 Philips Screw Driver Type set of 5 pieces

100 mm to 300 mm

14 Steel Rule 30 cm, English and metric

35 Circlip pliers Expanding and contracting type 15 cm and 20 cm each

36 Inspection lamp with guard and wandering lead of

100 ft.

15 Prick punch 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

19 Drill Twist ( assorted )

40 Different types of Fuel Injection Pumps

41 Different types of Injectors

20 Hand reamer adjustable

21 Drilling machine

22 Electric pedestal grinder with two wheel

42 FIP test Bench along with a set of special tools for repairing & Testing different types of FIPs

43 Injector test bench along with a set of special tools for repairing different types injectors

44

Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement