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COMPETENCY STANDARDS

OF

AUTOMOBILE & DIESEL TECHNOLOGY

(DAE - Level- 5)

CONTENTS Sr. No

TABLE OF CONTENTS Pages

1. Introduction 8

2. Purpose of the qualification 8

3. Date of Validation 8

4. Date of Review 8

5. Code of Qualification 9

6. Qualification Development Committee 9

7. Qualification Validation Committee 11

8. Entry Requirements 12

9. Regulations for the Qualification and Schedule of Units

10. Packaging of the qualification

11. Summary of Competency Standards 12

12. Occupations of Automobile &Diesel Technology. 21

CORE COMPETENCIES

Internal Combustion Engine (AD-133) 30

CS1 Identify Engine Types Their Component and Interpret its Specifications

31

CS2 Identify Basic Engine Parts and Interpret Assembly Procedure

33

CS3 Understand Engine Cooling System Components and Their Relationship

35

CS4 Understand Engine Lubrication System and working of its Components

37

CS5 Understand Petrol Engine’s Fuel System Components and their Relations

38

CS6 Understand Diesel Engine’s Fuel System Components with their Relations

40

CS7 Understand the Engine Exhaust System Components 42

CS8 Diagnosing Engine Faults and fix them 43

CS9 Understand Spark Ignition System of Internal Combustion Engine

45

CS10 Perform Overhauling of Four Stroke Motor Cycle Engine 47

Automotive Electricity and Electronics (AD-143) 49

CS1 Perform Basic Electricity Measurements 50

CS2 Understand the Electromagnetism and its application 51

CS3 Perform Battery Service of Vehicle 52

CS4 Repair Engine Starting System 54

CS5 Repair Spark Ignition System of Internal Combustion Engine

56

CS6 Adjust Ignition Timing of Spark Ignition Engine 58

CS7 Repair Distributer-Less Ignition Systems of Spark Ignition Engine

59

CS8 Repair Battery Charging System 60

CS9 Repair Lightning System of Vehicle 62

CS10 Repair Vehicle Electrically Operated Accessories 63

Workshop Practice-1 (MT-164) 65

CS1 Perform Bench Work on Metallic Surfaces 66

CS2 Perform Shaper Machine Operations 69

CS3 Perform Lathe Turning Operations 71

CS4 Read and Interpret Manufacturing Drawings 73

CS5 Perform Welding Procedure Specifications (WPS) 75

CS6 Prepare Materials for Welding 77

CS7 Perform Shielded Metal Arc Welding (SMAW) in Vertical (3F, 3G) and Overhead (4F, 4G) Positions

79

CS8 Perform Forging Operations 81

Basic Engineering Drawing and CAD-I Mech-163 83

CS1 Perform Drawing, Sketch Making 84

CS2 Draw Pictorial Drawing 86

CS3 Perform Basic Dimensioning System in Working Drawing 87

CS4 Perform Sectioning and Pictorial Drawing 89

CS5 Draw Auxiliary Drawing 90

Problems in Internal Combustion Engines AD-203 91

CS1 Diagnose Engine Fault 92

CS2 Perform Engine Overhauling (Petrol/Diesel) 94

CS3 Diagnose Engine Cooling System Faults and Repair 96

CS4 Diagnose Faults in Engine Lubrication System 98

CS5 Diagnose Faults of Carburetor Fuel System 99

CS6 Diagnose Diesel Fuel System and Adjust 101

CS7 Diagnose Faults of Ignition System 103

Suspension, Steering & Brakes AD-213 105

CS1 Repair Vehicle Brake System 106

CS2 Repair Vehicle Steering System 108

CS3 Maintain Vehicle Suspension System 110

CS4 Carry out Wheel Alignment 112

CS5 Carry Out Wheel Balancing 114

CS6 Replace SRS System 116

Workshop Practice-II AD-224 117

CS1 Arrange Common Automotive Hand Tools and their Use 118

CS2 Carry Out Measurements with Automotive Measuring Tools

120

CS3 Perform Test on Vehicle with Automotive Workshop Equipment

122

CS4 Diagnose Faults by Computerized Performance Testing Equipment

124

CS5 Categorize Automotive Fasteners Types and their Uses 125

CS6 Specify Vehicle’s Lubricants Types 126

CS7 Differentiate Vehicle Oil Seals Types and Specifications Coding

127

CS8 Specify Vehicle Bearing’s Types and Coding 128

CS9 Read and Interpret Quality Control Standards and Certification

129

CS10 Plan and Organize Safe Workshop and Hazard Prevention Practices

130

Metrology MT-252 132

CS1 Recognize Graduated Instruments 133

CS2 Carry-Out Linear Measuring 134

CS3 Carry-out Precise Measuring 136

CS4 Perform Angular Measuring 138

CS5 Identify the Types of Gauges 140

CS6 Identify Comparators Instrument 142

Applied Thermodynamics AD-232 144

CS1 Analyses HVAC/R Systems Thermodynamic Performance

145

CS2 Carry-out Smooth Boiler Operation 147

CS3 Recognize Fundamentals of Thermodynamics Problems 149

CS4 Read and Interpret Perfect Gases Laws, Properties and Solve problems

150

CS5 Read and Derived Thermodynamics Processes and Cycles

151

CS6 Analyze Reciprocating & Rotary Air Compressors Performance

153

CS7 Solves Problems of Internal Combustion Engine 154

Motor Vehicle Driving AD-302 155

CS1 Inspect Vehicle Controls for pre Operational & Pre Starting

156

CS2 Read and Interpret Traffic Signals, Road Signs and Marking Lanes on Roads

159

CS3 Apply Power& Parking Brakes to Vehicle 161

CS4 Drive Car in Different Condition 162

CS5 Drive Vehicle with Manual& Automatic Transmission 164

CS6 Drive Motorcycle 166

CS7 Drive Vehicle on Economy Speed for Fuel Saving 168

CS8 Perform Safety Practices While Driving 170

Motor Vehicle Inspection AD-312 171

CS1 Inspect Tires& Wheels of Light & Heavy Duty Transport Vehicles (LTV& HTV)

172

CS2 Inspect Vehicle Suspension System 174

CS3 Inspect Vehicle Steering System and Wheel Alignment 176

CS4 Inspect Light & Heavy Duty Vehicle Brake System 178

CS5 Inspect Vehicle Light System 180

CS6 Inspect Vehicle Electric System 182

CS7 Inspect Vehicle Glazing System 184

CS8 Inspect Vehicle Fuel System 186

CS9 Inspect Vehicle Body Accessories 188

CS10 Inspect Vehicle Exhaust System 190

CS11 Prepare Comprehensive Vehicle Inspection Report 191

CS12 Prepare Vehicle Title Certificate 193

Fuel Injection and Carburetion AD-343 194

CS1 Diagnose Faults of Intake System 195

CS2 Diagnose Faults of Exhaust System 196

CS3 Diagnose Faults of Fuel Supply System 197

CS4 Diagnose Faults & Repair Hybrid System 200

CS5 Diagnose Faults & Repair Engine Valve Control System 202

Automotive Transmission AD-363 203

CS1 Diagnose Faults &Repair Clutch 204

CS2 Diagnose Faults &Repair Manual Gear Box 206

CS3 Diagnose Faults &Repair Automatic Gear Box 208

CS4 Diagnose Faults &Repair Final Drive 210

Auto Body Building & Finishing AD-383 212

CS1 Understand Vehicle Body Shell 213

CS2 Prepare Cost Estimate for Damaged Vehicle Body and Chassis

215

CS3 Perform Vehicle Body and Chassis Alignment and Repair

217

CS4 Perform Vehicle Body Repairs Work 219

CS5 Carryout Panel Repair with Washer Welder Machine 221

CS6 Repair Vehicle Body Fittings 224

CS7 Perform Welding Operations on Vehicle Body 226

CS8 Maintain Machinery, Tools and Equipment 228

CS9 Remove and Fix Glass Items 231

CS10 Perform Body Surface Cleaning by Mechanical Process 233

CS11 Perform Body Surface Cleaning with Chemical Process 235

CS12 Maintain Vehicle Body Repair Tools, Equipment and Machinery

237

CS13 Maintain Paint Booth and Stores 240

CS14 Apply Polyester Putty 243

CS15 Prepare Paint Booth and Vehicle 247

CS16 Apply Primer Surfacer 249

CS17 Perform Color Matching & Mixing 252

CS18 Apply Body Sealer 255

CS19 Perform Masking 257

CS20 Apply Under Coat 259

CS21 Apply Final Coats 263

CS22 Perform Polishing to Body Surface 266

CS23 Prepare Paint Work Estimation 269

Workshop Practice-III AD-324 271

CS1 Perform Engine Preventive Maintenance (Tune-Up) 272

CS2 Perform Periodic Maintenance 274

CS3 Arrange Workshop Equipment According to Lay-out 275

CS4 Prepare Documentation for Automotive workshop 276

CS5 Maintain Service Station Equipment 277

CS6 Maintain Emission control system 278

CS7 Perform Engine Overhauling 280

CS8 Maintain Climatic Control System 282

CS9 Perform Engine Output Testing 284

CS10 Read and Interpret Hydraulic and Pneumatic Code and Symbols

285

Generic Skills

CS1 Participate In Workplace Communication 287

CS2 Perform Work in Team Environment 289

CS3 Read and Develop Career Professionalism 291

CS4 Practice Occupational Health and Safety Procedures 293

CS5 Lead Small Teams 295

CS6 Develop Negotiation Skills 297

CS7 Solve Problems Related To Work Activities 299

CS8 Develop Communication Skill 301

CS9 Develop Administrative Skills 303

CS10 Work effectively in a customer service/ sales environment

304

CS11 Develop Professionalism 307

ENTREPRENEURSHIP SKILLS

CS1 Manage the Operations of Workshop Security Units 310

CS2 Organize Training On Multiple Workshop Units 313

CS3 Administer Multiple Commercial Units 315

CS4 Supervise performance of Technician 317

CS5 Plan Work to Meet Expected Outcomes 319

CS6 Work Effectively In a Team 320

CS7 Maintain Healthy, Safe and Secure Working Environment 321

CS8 Deal with Emergencies and Incidents at Workshop 323

CS9 Maintain Effective Communication with Companies 325

1. INTRODUCTION OF AUTOMOBILE TECHNOLOGY

Automobile engineering is the one of the stream of mechanical engineering. It deals with the various types of automobiles, their mechanism of transmission systems and its applications. Automobiles are the different types of vehicles used for transportation of passengers, goods, etc. Basically all the types of vehicles works on the principle of internal combustion processes or sometimes the engines are called as internal combustion engines. Different types of fuels are burnt inside the cylinder at higher temperature to get the transmission motion in the vehicles. Most of the automobiles are internal combustion engines vehicles only. Therefore, every mechanical and automobile engineer should have the knowledge of automobile engineering its mechanism and its various applications. Automobile engineering is a branch of engineering which deals with everything about automobiles and practices to propel them. Automobile is a vehicle driven by an internal combustion engine and it is used for transportation of passengers and goods on the ground. Automobile can also be defined as a vehicle which can move by itself, for example Car, jeep, bus, truck, scooter, etc. Therefore, industry expectations for skilled workforce are also dynamic which can only be managed through setting relevant competency standards in collaboration with the leading industries. Being cognizant of this fact, National Vocational & Technical Training Commission (NAVTTC) developed competency standards for Civil Technology under National Vocational Qualifications Framework (NVQF). These competency standards have been developed by a Qualifications Development Committee (QDC) and validated by the Qualifications Validation Committee (QVC) having representation from the Auto Mobile industry of the country.

2. PURPOSE OF THE QUALIFICATION

The purpose of these qualifications is to set high professional standards for automobile industry. The specific objectives of developing these qualifications are as under:

1. Improve the professional competence of the trainees 2. Provide opportunities for recognition of skills attained through non-formal or informal pathways 3. Improve the quality and effectiveness of training and assessment for automobile industry 4. Enable the existing workforce to capacitate themselves in new technologies and methods.

3. Date of Validation

These national qualifications have been validated by the Qualification Development Committee (QVC) on 27-29 May 2019.

4. Date of REVIEW

These national qualifications may be reviewed in May 2022.

5. Codes of Qualifications

The International Standard Classification of Education (ISCED) is a framework for assembling,

compiling and analyzing cross-nationally comparable statistics on education and training. ISCED codes

for these qualifications are assigned as follows:

ISCED Classification for DAE Auto Mobile Technology level-5

Code Description

000000000 1st Semester National Certificate of level-5, in “Auto Mobile Technology”

000000000 2nd Semester National Certificate of level-5, in “Auto Mobile Technology”

000000000 3rd Semester National Certificate of level-5, in “Auto Mobile Technology”

000000000 4th Semester National Certificate of level-5, in “Auto Mobile Technology”



6. Qualifications Development Committee

The following members participated in the qualifications development workshop 31st December 2018 to

4th January 2019 at Hospitality Inn, Lahore:

S. No. Name & Designation Organization

1. Ijaz Hamid, Chief Instructor Auto & Diesel/ DACUM Facilitator,

GCT, Railway Road, Lahore PTEVTA

2. Abdul Ateeq, CEO

Rehman Motors Workshop, Model Town, Lahore


3. Abdul Waheed,

CEO Honda Pitspot, Johar Town Motors, Lahore

4. Syed Kazim Hussain,

Technical Advisor Toyota Township Motors, Lahore

5. Adeel Ahmad, Assistant Manager (Tech)

Lahore Transport Company, Lahore

6. Abdul Basit, Technical Advisor

Toyota Garden Motors, Lahore

7. Adnan Siddique, Technician

Toyota Garden Motors, Lahore

8. Rehman Ali, Assistant Manager

Al-Haj Faw Motors (PVT) LTD; Lahore

9. Atif Mahmood,

Service Manager Suzuki Mini Motors, Lahore

10. Aamir Javed, Service Manager

Suzuki Khalid Motors, Lahore

11. Skindar Shahzad,

Sr. Instructor/ DACUM Facilitator Aman Tech, Karachi

12. Abdul Aleem,

Jr. Instructor GCT, Sahiwal, PTEVTA

13. Tanveer Abass,

Jr. Instructor GCT, Railway Road, Lahore PTEVTA

14. Shakeel Ahmad

Jr. Instructor GCT, Faisalabad, PTEVTA

15. Majid Khan,

Jr. Instructor GCT, Attock, PTEVTA

16. Shahbaz Ali,

Instructor GSPTC, Gujrat, PTEVTA

17. Bashir Hussain Arshad,

Sr. Instructor GCT, Sahiwal, PTEVTA

18. Muzamil Hussain,

Instructor GCT, Rawalpindi, PTEVTA


19. Muhammad Azhar Khan,

Instructor Auto & Farm GCT, Bahawalpur, PTEVTA

20. Muqeem-ul-Islam,

DG (SS&C) NAVTTC, HQ

21. Muhammad Ishaq,

Dy Director (TE) NAVTTC, HQ

7. Qualifications Validation Committee

The following members participated in the qualifications development and validation workshop on 11th

February 2019 to 15th February 2019 at Garvaish Hotel, Faisalabad:


1. Mr Sikandar Masood Director

NAVTTC HQ

2. Mr Ijaz Hameed Chief Instructor (DACUM )

GCT railway road Lahore

3. Mr Muzamil Hussain Sr Instructor

GCT Rwp (PTEVA representative)

4. Mr Sikandar Shahzad Sr Instructor

AMAN TECH Karachi

5. Mr Abid Iqbal Associate Professor

GCT Peshawar (KPK TEVTA Representative)

6. Mr Fiaz Ali Ujjan Regional Manager

Sindh TEVTA Representative

7. Mr Abdul Waheed CEO Johar Town Honda

Industry Representative

8. Mr Abdul rehman Research Assistant

PBTE representative

9. Mr Aamir Ali Khan Assistant Director

Regional Director General Office ICT, NAVTTC

8. Entry Requirements

The entry for D.A. E National Certificate level 5, in Auto Mobile Technology are

1. A person having National Vocational Certificate level 4, in Auto Mobile Technology.

2. A person having Matric certificate with Science subjects

9. Summary of Competency Standards

Code Competency Standards Level Credits Category

Internal Combustion Engine (AD-133)

CU-1: Identify Engine Types Their Component and Interpret its

Specifications

2 Technical

CU-2: Identify Basic Engine Parts and Interpret Assembly

Procedure

2 Technical

CU-3: Understand Engine Cooling System Components and

Their Relationship

2 Technical

CU-4: Understand Engine Lubrication System and working of its

Components

2 Technical

CU-5: Understand Petrol Engine’s Fuel System Components

and their Relations

2 Technical

CU-6: Understand Diesel Engine’s Fuel System Components

with their Relations

2 Technical

CU-7: Understand the Engine Exhaust System Components 2 Technical

CU-8: Diagnosing Engine Faults and fix them 2 Technical

CU-9: Understand Spark Ignition System of Internal Combustion

Engine

2 Technical


CU-10: Perform Overhauling of Four Stroke Motor Cycle Engine 2 Technical

Automotive Electricity and Electronics (AD-143)

CU-11: Perform Basic Electricity Measurements 2 Technical

CU-12: Understand the Electromagnetism and its application 2 Technical

CU-13: Perform Battery Service of Vehicle 2 Technical

CU-14: Repair Engine Starting System 2 Technical

CU-15: Repair Spark Ignition System of Internal Combustion

Engine 2 Technical

CU-16: Adjust Ignition Timing of Spark Ignition Engine 2 Technical

CU-17: Repair Distributer-Less Ignition Systems of Spark Ignition

Engine 2 Technical

CU-18: Repair Battery Charging System 2 Technical

CU-19: Repair Lightning System of Vehicle 2 Technical

CU-20: Repair Vehicle Electrically Operated Accessories 2 Technical

Workshop Practice-1 (MT-164)

CU-21: Perform Bench Work on Metallic Surfaces 2 Technical

CU-22: Perform Shaper Machine Operations 2 Technical

CU-23: Perform Lathe Turning Operations 2 Technical

CU-24: Read and Interpret Manufacturing Drawings 2 Technical

CU-25: Perform Welding Procedure Specifications (WPS) 2 Technical

CU-26: Prepare Materials for Welding 2 Technical

CU-27: Perform Shielded Metal Arc Welding (SMAW) in Vertical

(3F, 3G) and Overhead (4F, 4G) Positions 2 Technical

CU-28: Perform Forging Operations 2 Technical

Basic Engineering Drawing and CAD-I Mech-163

CU-29: Perform Basic Drawing, Sketch Making 2 Allied

CU-30: Draw Pictorial Drawing 2

2

Allied

CU-31: Perform Basic Dimensioning System in Working Drawing Allied

CU-32: Perform Sectioning and Pictorial Drawing 2 Allied

CU-33: Draw Auxiliary Drawing 2 Allied

Problems in Internal Combustion Engines AD-203


CU-34: Perform Engine Fault Diagnosing and Adjustment 3 Technical

CU-35: Perform Complete Engine Overhauling (Petrol/ Diesel) 3 Technical

CU-36: Diagnose Engine Cooling System Faults and Repair 3 Technical

CU-37: Diagnose Engine Lubrication System Faults and Repair 3 Technical

CU-38: Diagnose Faults of Engine Fuel System (Carburetor

Type) and Adjust 3 Technical

CU-39: Diagnose Diesel Engine Fuel System and Adjust 3 Technical

CU-40: Diagnose Faults of Spark Ignition System and Adjust 3 Technical

Suspension, Steering & Brakes AD-213

CU-41: Repair Vehicle Brake System. 3 Technical

CU-42: Repair Vehicle Steering System. 3 Technical

CU-43: Repair Vehicle Suspension System. 3 Technical

CU-44: Carry out Wheel Alignment 3 Technical

CU-45: Carry Out Wheel Balancing 3 Technical

CU-46: Repair SRS System 3 Technical

Workshop Practice-II AD-224

CU-47: Identify Common Automotive Hand Tools and their Use 3 Technical

CU-48: Carry Out Measurements With Automotive Measuring

Tools 3 Technical

CU-49: Perform Test on Vehicle with Automotive Workshop

Equipment 3 Technical

CU-50: Diagnosing Faults by Computerized Performance Testing

Equipment 3 Technical

CU-51: Identify Automotive Fasteners Types and their Uses 3 Technical

CU-52: Identify Vehicle’s Lubricants Types with Specifications 3 Technical

CU-53: Identify Different Types and Specifications Coding of

Vehicle Oil Seals 3 Technical

CU-54: Identify Vehicle Bearing’s Types with Specifications Cods 3 Technical

CU-55: Read and Interpret Quality Control Standards and

Certification 3 Technical

CU-56: Plan and Organize Safe Workshop and Hazard 3 Technical


Prevention Practices

Metrology MT-252

CU-57: Recognize Graduated Instruments 3 Functional

CU-58: Carry-Out Linear Measuring 3 Functional

CU-59: Carry-out Precise Measuring 3 Functional

CU-60: Perform Angular Measuring. 3 Functional

CU-61: Identify the Types of Gauges. 3 Functional

CU-62: Identify Comparators Instrument 3 Functional

Applied Thermodynamics AD-232

CU-63: Analyses HVAC/R Systems Thermodynamic

Performance 3 Functional

CU-64: Carry-out Smooth Boiler Operation 3 Functional

CU-65: Recognize Fundamentals of Thermodynamics Problems 3 Functional

CU-66: Read and Interpret Perfect Gases Laws, Properties and

Solve problems 3 Functional

CU-67: Read and Derived Thermodynamics Processes and

Cycles 3 Functional

CU-68: Analyze Performance of Air Compressors (Reciprocating

& Rotary) 3 Functional

CU-69: Solves Problems of Internal Combustion Engine 3 Functional

Motor Vehicle Driving AD-302

CU-70: Perform Inspections of Vehicle Controls for pre

Operational & Pre Starting 4 Technical

CU-71: Read and Interpret Traffic Signals, Road Signs and

Marking Lanes on Roads. 4 Technical

CU-72: Apply Power & Parking Brakes to Vehicle 4 Technical

CU-73: Drive Car in Different Condition 4 Technical

CU-74: Drive Vehicle with Manual & Automatic Transmission 4 Technical

CU-75: Drive Motorcycle 4 Technical

CU-76: Driving Vehicle on Economy Speed for Fuel Saving 4 Technical

CU-77: Perform Safety Practices While Driving 4 Technical


Motor Vehicle Inspection AD-312

CU-78: Inspect Tires & Wheels of Light & Heavy Duty Transport

Vehicles (LTV & HTV). 5 Technical

CU-79: Inspect Vehicle Suspension System. 5 Technical

CU-80: Inspect Vehicle Steering System and Wheel Alignment 5 Technical

CU-81: Inspect Light & Heavy Duty Vehicle Brake System 5 Technical

CU-82: Inspect Vehicle Lighting System. 5 Technical

CU-83: Inspect Vehicle Electric System 5 Technical

CU-84: Inspect Vehicle Glazing System 5 Technical

CU-85: Inspect Vehicle Fuel System 5 Technical

CU-86: Inspect Vehicle Body Accessories. 5 Technical

CU-87: Inspect Vehicle Exhaust System. 5 Technical

CU-88: Prepare Comprehensive Vehicle Inspection Report. 5 Technical

CU-89: Prepare Vehicle Title Certificate. 5 Technical

Fuel Injection and Carburetion AD-343

CU-90: Diagnose Faults & Repair Intake System. 5 Technical

CU-91: Diagnose Faults & Repair Exhaust System 5 Technical

CU-92: Diagnose Faults & Repair Fuel Supply System. 5 Technical

CU-93: Diagnose Faults & Repair Hybrid System 5 Technical

CU-94: Diagnose Faults & Repair Engine Valve Control System 5 Technical

Automotive Transmission AD-363

CU-95: Diagnose Faults & Repair Clutch. 5 Technical

CU-96: Diagnose Faults & Repair Manual Gear Box. 5 Technical

CU-97: Diagnose Faults & Repair Automatic Gear Box. 5 Technical

CU-98: Diagnose Faults & Repair Final Drive.

5 Technical

Auto Body Building & Finishing AD-383

CU-99: Understand Vehicle Body Shell 5 Technical

CU-100: Prepare Cost Estimate for Repairs Damaged Vehicle

Body and Chassis 5 Technical

CU-101: Perform Vehicle Body and Chassis Alignment and Repair 5 Technical


CU-102: Perform Vehicle Body Repairs Work 5 Technical

CU-103: Carryout Panel Repair with Washer Welder Machine 5 Technical

CU-104: Repair vehicle body fittings 5 Technical

CU-105: Perform Welding Operations on Vehicle Body 5 Technical

CU-106: Maintain Machinery, Tools and Equipment 5 Technical

CU-107: Remove and Fix Glass Items 5 Technical

CU-108: Perform Body Surface Cleaning by Mechanical Process 5 Technical

CU-109: Perform Body Surface Cleaning with Chemical Process 5 Technical

CU-110: Maintain Vehicle Body Repair Tools, Equipment and

Machinery 5 Technical

CU-111: Maintain Paint Booth and Stores 5 Technical

CU-112: Apply Polyester Putty 5 Technical

CU-113: Prepare Paint Booth and Vehicle 5 Technical

CU-114: Apply Primer Surfacer 5 Technical

CU-115: Perform Color Matching & Mixing 5 Technical

CU-116: Apply Body Sealer 5 Technical

CU-117: Perform Masking 5 Technical

CU-118: Apply Under Coat 5 Technical

CU-119: Apply Final Coats 5 Technical

CU-120: Perform Polishing to Body Surface 5 Technical

CU-121: Prepare Paint Work Estimation 5 Technical

Workshop Practice-III AD-324

CU-122: Perform Engine Preventive Maintenance (Tune-Up) 5 Technical

CU-123: Perform Periodic Maintenance 5 Technical

CU-124: Arrange Workshop Equipment According to Lay-out 5 Technical

CU-125: Prepare Documentation for Automotive workshop 5 Technical

CU-126: Maintain Service Station Equipment 5 Technical

CU-127: Maintain Emission control system 5 Technical

CU-128: Perform Engine Overhauling 5 Technical

CU-129: Maintain Climatic Control System. 5 Technical

CU-130: Perform Engine Output Testing 5 Technical


CU-131: Read and Interpret Hydraulic and Pneumatic Code and

Symbols 5 Technical

Generic

CU-132: Participate In Workplace Communication 2 Generic

CU-133: Practice Occupational Health and Safety Procedures 2 Generic

CU-134: Perform Work In Team Environment 3 Generic

CU-135: Read and Develop Career Professionalism 4 Generic

CU-136: Lead Small Teams 4 Generic

CU-137: Develop and Practice Negotiation Skills 5 Generic

CU-138: Solve Problems Related To Work Activities 5 Generic

CU-139: Develop Communication Skill 5 Generic

CU-140: Develop Administrative Skills 5 Generic

CU-141: Work effectively in a customer service/ sales environment 4 Generic

CU-142: Develop Professionalism 4 Generic

Entrepreneur

CU-143: Manage the Operations of Workshop Security Units 5 Entrepreneur

CU-144: Organize Training On Multiple Workshop Units 5 Entrepreneur

CU-145: Administer Multiple Commercial Units 5 Entrepreneur

CU-146: Supervise and Evaluate performance of Technician 5 Entrepreneur

CU-147: Plan and Organize Work to Meet Expected Outcomes 5 Entrepreneur

CU-148: Work Effectively In a Team 5 Entrepreneur

CU-149: Maintain Healthy, Safe and Secure Working Environment 5 Entrepreneur

CU-150: Deal with Emergencies and Incidents at Workshop 5 Entrepreneur

CU-151: Maintain Effective Communication with Companies 5 Entrepreneur

Automotive Maintenance Specialist

CU-152: Repair and Maintain the Process Control Systems 5 Technical

CU-153: Plan and Arrange for Installation of New Systems 5 Technical

Digital skills

CU-154: Use computer operating systems and hardware Digital Skills

CU-155: Operate digital media technology Digital Skills

CU-156: Perform computer operations Digital Skills

CU-157: Use computer applications Digital Skills

CU-158: Create user documentation Digital Skills

CU-159: Create technical documentation Digital Skills

CU-160: Create basic databases Digital Skills

CU-161: Use social media tools for collaboration and engagement Digital Skills

CU-162: E-Commerce- SEO (Search Engine Optimization) Digital Skills

CU-163: E-Commerce- SCM (Supply Chain Management) Digital Skills

CU-164: E-Commerce- Social Media Marketing Digital Skills

CU-165: Use digital devices Digital Skills

CU-166: Operate word-processing applications- Digital Skills

CU-167: Operate spreadsheet applications Digital Skills

CU-168: Operate presentation packages Digital Skills

CU-169: Perform writing and editing tasks Digital Skills

CU-170: Write and Edit Copy Digital Skills

CU-171: Build Java applets Digital Skills

CU-172: Build Java applets Digital Skills

CU-173: Manipulate Images (Illustrator) Digital Skills

CU-174: Manipulate Images (Photoshop) Digital Skills

CU-175: Design simple web page layouts Digital Skills

CU-176: Apply introductory programming techniques Digital Skills

Soft skills

CU-177: Develop workplace policy and procedures for

sustainability

Soft Skills

CU-178: Manage meetings Soft Skills

CU-179: Manage recruitment selection and induction processes Soft Skills

CU-180: Manage personal work priorities and professional

development

Soft Skills

CU-181: Manage workforce planning Soft Skills

CU-182: Undertake project work Soft Skills

CU-183: Identify and communicate trends in career development Soft Skills

CU-184: Apply specialist interpersonal and counseling interview

skills

Soft Skills

CU-185: Work safely in an office environment Soft Skills

CU-186: Develop workplace documents Soft Skills

CU-187: Prepare and implement negotiation Soft Skills

CU-188: Maintain professionalism in the workplace Soft Skills

CU-189: Maintain professional development and career

professionalism

Soft Skills

CU-190: Organize schedules Soft Skills

Entrepreneur

CU-191: Develop Entrepreneurial Skills Entrepreneur

CU-192: Apply project information management and

communications techniques

Entrepreneur

CU-193: Apply project human resources management approaches Entrepreneur

CU-194: Direct human resources management of a project

program

Entrepreneur

CU-195: Develop a project management plan Entrepreneur

CU-196: Maintain business resources Entrepreneur

CU-197: Develop a sales plan Entrepreneur

CU-198: Plan and implement business-to-business marketing Entrepreneur

CU-199: Address customer needs Entrepreneur

CU-200: Manage personal finances Entrepreneur

CU-201: Solve problems which jeopardize safety and security Entrepreneur

CU-202: Coordinate a work team Entrepreneur

CU-203: Lead small teams Entrepreneur

CU-204: Plan and organize work Entrepreneur

CU-205: Develop teams and individuals Entrepreneur

CU-206: Apply problem solving techniques in the workplace using

critical thinking

Entrepreneur

CU-207: Manage human resource services Entrepreneur

Suggested by DG (SS&C)

10. Occupations of Automobile & Diesel Technology

Level Name of Occupation/Nomenclature

Generic Competencies

Allied competencies require

Core /Technical Competencies required

1. Mechanical Service Department

Level-2 Pro Auto Mechanic 1, 2,3, 4, 5, 6, 7, 8, 9, 10,

Level-3 Auto Diagnostic Mechanic 29,30,32,33,34,42,43,44,45,46,47,48,49,50,51

Level-4 Vehicle Drive Test Technician 108,109,110,111, 112,113,114,115

Level-5 Master Technician 64,65,66,67,68,69,70,71,72

Level-5 Service Advisor 96,97,98,99,100, 101,102,103,104, 105

Level-5 Vehicle Examiner 52,53,54,55,56,57,58,59,60,61,62,63

2. Electrical Department

Level-2 Pro Auto Electrician 11, 12, 13, 14, 15, 16, 17, 18, 19, 20

Level-3 Diagnostic Auto Electrician 31,35

3. Chassis Department Level-3 Steering, Suspension and

Brake Mechanic 36,37,38

Level-3 Wheel Alignment Technician 39,40,41

4. Auto Body Shop Level-5 Auto Body Technician 73,74,75,76,77,78,

79,80,81

Level-5 Auto Paint Technician 82,83,84,85,86,87,88,89,90,91,92,93,94,95

5. Mechanical Works Level-2 Mill Wright Auto Mechanic 21,22,23,24

Level-2 Pro Welder 25, 26, 27, 28

Level-3 Boiler Supervisor (B-Class) 29,30,32,33,34,42,43,44,45,46,47,48,49,50,51

11. Leveling of the Competency Standards

(000000000)

1stSemester National Certificate of level-2 (Auto and Diesel Technology)

Code Name of Competency/ Duty/ Module Credit Category Courses

0000 Perform Basic Electricity Measurements Technical

y

0000 Repair Lightning System of Vehicle Technical

0000 Repair Vehicle Electrically Operated Accessories Technical

0000 Understand the Electromagnetism and its application Technical

0000 Perform Bench Work on Metallic Surfaces Technical

0000 Perform Shaper Machine Operations Technical

0000 Perform Lathe Turning Operations Technical

0000 Perform Basic Drawing, Sketch Making Functional

0000 Draw Pictorial Drawing Functional

0000 Perform Basic Dimensioning System in Working Drawing Functional

0000 Perform Sectioning and Pictorial Drawing Functional

0000 Draw Auxiliary Drawing Functional

0000 Manage the Operations of Workshop Security Units Generic

0000 Practice Occupational Health and Safety Procedures Generic

(000000000)

2nd Semester National Certificate of level-2, (Auto and Diesel Technology)

Code Name of Competency/ Duty/ Module Credit Category

000000000 Identify Engine Types Their Component and Interpret its Specifications

Technical

000000000 Identify Basic Engine Parts and Interpret Assembly Procedure

Technical

000000000 Understand Engine Cooling System Components and Their Relationship

Technical

000000000 Understand Engine Lubrication System and working of its Components

Technical

000000000 Understand Petrol Engine’s Fuel System Components and their Relations

Technical

000000000 Understand Diesel Engine’s Fuel System Components with their Relations

Technical

000000000 Understand the Engine Exhaust System Components Technical

000000000 Diagnosing Engine Faults and fix them Technical

000000000 Understand Spark Ignition System of Internal Combustion Engine

Technical

000000000 Perform Overhauling of Four Stroke Motor Cycle Engine Technical

000000000 Repair Engine Starting System Technical

000000000 Perform BatteryService of VePerform BatteryService of Vehicle hicle

Technical

000000000 Repair Battery Charging System Technical

000000000 Repair Spark Ignition System of Internal Combustion Engine

Technical

000000000 Adjust Ignition Timing of Spark Ignition Engine Technical

000000000 Repair Distributer-Less Ignition Systems of Spark Ignition Engine

Technical

000000000 Preform Welding Procedure Specifications (WPS) Technical

000000000 Prepare Materials for Welding Technical

000000000 Perform Shielded Metal Arc Welding (SMAW) in Vertical (3F, 3G) and Overhead (4F, 4G) Positions

Technical

000000000 Perform Forging Operations Technical

(000000000)

3rd Semester National Certificate of level-3 (Auto and Diesel Technology)


000000000 Repair Vehicle Brake System

Technical

000000000 Repair Vehicle Steering System

Technical

000000000 Repair Vehicle Suspension System

Technical

000000000 Identify Common Automotive Hand Tools and their Use

Technical

000000000 Carry Out Measurements With Automotive Measuring Tools

Technical

000000000 Perform Test on Vehicle with Automotive Workshop Equipment

Technical

000000000 Diagnosing Faults by Computerized Performance Testing Equipment

Technical

000000000 Identify Automotive Fasteners Types and their Uses

Technical

000000000 Identify Vehicle’s Lubricants Types with Specifications Technical

000000000 Identify Different Types and Specifications Coding of Vehicle Oil Seals

Technical

000000000 Identify Vehicle Bearing’s Types with Specifications Cods

Technical

000000000 Read and Interpret Quality Control Standards and Certification

Technical

000000000 Plan and Organize Safe Workshop and Hazard Prevention Practices

Technical

000000000 Analyses HVAC/R Systems Thermodynamic Performance

Functional

000000000 Carry-out Smooth Boiler Operation

Functional

000000000 Recognize Fundamentals of Thermodynamics Problems

Functional

000000000 Read and Interpret Perfect Gases Laws, Properties and Solve problems

Functional

000000000 Read and Derived Thermodynamics Processes and Cycles

Functional

000000000 Analyze Performance of Air Compressors (Reciprocating & Rotary)

Functional

000000000 Solves Problems of Internal Combustion Engine

Functional

000000000 Perform Work In Team Environment

Generic

(000000000)

4th Semester National Certificate of level-3, (Auto and Diesel Technology)


000000000 Perform Engine Fault Diagnosing and Adjustment Technical

000000000 Perform Complete Engine Overhauling (Petrol/ Diesel) Technical

000000000 Diagnose Engine Cooling System Faults and Repair Technical

000000000 Diagnose Engine Lubrication System Faults and Repair Technical

000000000 Diagnose Faults of Engine Fuel System (Carburetor Type) and Adjust

Technical

000000000 Diagnose Diesel Engine Fuel System and Adjust Technical

000000000 Diagnose Faults of Spark Ignition System and Adjust Technical

000000000 Carry out Wheel Alignment Technical

000000000 Carry Out Wheel Balancing Technical

000000000 Repair SRS System Technical

000000000 Recognize Graduated Instruments Functional

000000000 Carry-Out Linear Measuring Functional

000000000 Carry-out Precise Measuring Functional

000000000 Perform Angular Measuring Functional

000000000 Identify the Types of Gauges Functional

000000000 Identify Comparators Instrument Functional

000000000 Read and Develop Career Professionalism generic

000000000 Lead Small Teams generic

(000000000)

5th Semester National Certificate of level-4, (Auto and Diesel Technology)


000000000 Diagnose Faults & Repair Clutch Technical

000000000 Diagnose Faults & Repair Manual Gear Box Technical

000000000 Diagnose Faults & Repair Automatic Gear Box Technical

000000000 Diagnose Faults & Repair Final Drive Technical

000000000 Perform Inspections of Vehicle Controls for pre Operational & Pre Starting

Functional

000000000 Read and Interpret Traffic Signals, Road Signs and Marking Lanes on Roads

Functional


Functional


Functional


Functional


Functional


Functional


Functional

000000000 Work effectively in a customer service/ sales environment Generic

000000000 Develop Professionalism Generic

(000000000)

6th Semester National Certificate of level-5 (Auto and Diesel Technology)


000000000 Inspect Tires & Wheels of Light & Heavy Duty Transport Vehicles (LTV & HTV)

Technical

000000000 Inspect Vehicle Suspension System Technical

000000000 Inspect Vehicle Steering System and Wheel Alignment Technical

000000000 Inspect Light & Heavy Duty Vehicle Brake System Technical

000000000 Inspect Vehicle Lighting System Technical

000000000 Inspect Vehicle Electric System Technical

000000000 Inspect Vehicle Glazing System Technical

000000000 Inspect Vehicle Fuel System Technical

000000000 Inspect Vehicle Body Accessories Technical

000000000 Inspect Vehicle Exhaust System Technical

000000000 Prepare Comprehensive Vehicle Inspection Report Technical

000000000 Prepare Vehicle Title Certificate Technical

000000000 Repair and Maintain the Process Control Systems Functional

000000000 Plan and Arrange for Installation of New Systems Functional

000000000 Develop and Practice Negotiation Skills Generic

000000000 Solve Problems Related To Work Activities Generic

000000000 Develop Communication Skill Generic

000000000 Develop Administrative Skills Generic

000000000 Manage the Operations of Workshop Security Units Entrepreneur

000000000 Organize Training On Multiple Workshop Units Entrepreneur

000000000 Administer Multiple Commercial Units Entrepreneur

000000000 Supervise and Evaluate performance of Technician Entrepreneur

000000000 Plan and Organize Work to Meet Expected Outcomes Entrepreneur

000000000 Work Effectively In a Team Entrepreneur

000000000 Maintain Healthy, Safe and Secure Working Environment Entrepreneur

000000000 Deal with Emergencies and Incidents at Workshop Entrepreneur

000000000 Maintain Effective Communication with Companies Entrepreneur

Internal Combustion Engine (AD-133)

1. Specify Engine Types and its Component

Overview:

This Learning Module is designed to provide skills and knowledge for different types of power producing units (engines) their understanding the working principles, construction, types, components and their relationship between different components, system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.

Unit of Competency Performance Criteria

1. Identify Petrol Engine

P1. Observe vehicle systems, identify the typical petrol engines and function of their main components.

P2. Identify spark plugs and it functions P3. Identify distributor and its function P4. Identify ignition coil and its functions P5. Identify plug leads and its functions P6. Identify carburetor and its function P7. Identify EFI engine and its main components

2. Identify Diesel Engine

P1. Observe vehicle systems, identify the typical diesel engines and function of their main components.

P2. Identify fuel injectors and its function P3. Identify high pressure fuel pump and its functions P4. Identify heater plug and its function

Knowledge & Understanding

• Describe the vehicle engines in a variety of forms and locations as following: a. Types (Petrol four stroke, diesel four stroke, and rotary/Wankel). b. Aspirated (Natural, turbocharged, supercharged) c. Cylinder layout (single, multi, in-line, V shape, horizontally opposed). d. Locations(front, rear, mid, transverse, longitudinal)

Critical Evidences Required

• Capable to identify petrol/diesel engine.

• Capable to differentiate petrol EFI and carburetor engine.

• Capable to explain different parts in petrol/diesel engine.

List of Tools and Equipment

S. No. Description

1 Measuring tools (Verniercaliper, micrometer, Cylinder bore gauge)

2 Hand tools trolley

3 Special tools (ring compressor, belt tensioner, torque wrench)

4 Engine Petrol/ diesel

5 Vehicle

2. Identify Engine Parts and Interpret Assembly Procedure

Overview

These competency standards designed to provide skills and knowledge for engines their understanding the working principles, construction, types, components and their relationship between different components, system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Understand Engine block assembly procedure.

P1. Select appropriate tools and perform dismantling/assembly of the all engine components as specified procedure in the manual.

P2. Select appropriate tools and perform crankshaft assembly in the engine block with all related components.

P3. Select appropriate tools and perform piston ring assembly in the block under the specified procedure.

2. Understand Engine head assembly procedure.

P1. Select appropriate tools and perform dismantling/ assembly of engine head valve train as specified procedure in the manual.

P2. Select appropriate tools and perform dismantling/ assembly of rocker assembly on the engine head under the specified procedure in the manual.

P3. Set the camshaft on the engine head and fit bearing caps under the specified procedure.


• Describe the engine terms as following: Top dead Centre (TDC), bottom dead Centre (BDC),bore, stroke, engine capacity, clearance volume, swept volume, compression ratio, single overhead cam, double overhead cam, overhead valve,

• Describe the main engine components and functions: Components: cylinder heads, cylinder blocks, liners(wet/dry), manifolds, valve operating mechanisms, timing, gears, camshafts, pistons, pushrods, connecting rods, crankshafts, flywheels, machined faces, securing devices, journals/bearings, seals.

• K-4describes the faults in engine as following: White smoke, black smoke, engine oil level decreasing, incorrect adjustment of tappets, incorrect adjustment of ignition timing, incorrect adjustment of engine timing.

Critical Evidences Required

• Capable to assemble the engine components

• Capable to adjust engine timing and ignition timing

• Capable to service air filter and spark plugs


S. No. Description

1 Measuring tools (Verniercaliper, micrometer, Cylinder bore gauge)


3 Special tools (ring compressor, belt tensioner, torque wrench)

4 Engine Petrol/ diesel

5 Vehicle

Consumable Items:

• Engine Oil, Gasket Set, Piston Rings, Oil Seals, Valve Seats, Silicon, Emery Paste and Stick, Cotton Waste.

3. Maintain Engine Cooling System Components

Overview

This Learning Module is designed to provide skills and knowledge for understanding the working principles, construction, types, components and their relationship between different components to service and repair air and water cooled engine cooling systems and to diagnose fault/s and other maintenance issues by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Identify Cooling system in the vehicle.

P1. Identify main components of cooling system their functions. P2. Identifies the water pump and understand the function of its

components. P3. Identify the thermostat and understand the function of its

components. P4. Identify the radiator, its types and understand the function of the

components. P5. Identify the radiator fan and understand its drive types.

2. Use Antifreeze/inhibitors

P1. Identify the antifreeze its compositions and types. P2. Identify the rust corrosion in the engine and preventions.


• Describe the operating principles and terminologies of cooling system as following: Air cooled engine, liquid cooled engine, operating temperature, thermal efficiency, pressurized system, heat exchange method (conduction, radiation, and convection), corrosion, and inhibitors/antifreeze)

• Describe the functions and purpose of engine cooling system components as: Electrical motor operated fan with thermo switch, belt operated fan, temperature controlled/viscous coupling fan, pressure cap, water body/pump, drive belt, thermostat, radiator, core plug, hoses/clamps, and gasket/ seals.

Critical Evidence(s) Required

• Capable of diagnose, adjust and rectify the cooling system faults.


S. No. Description


2 Radiator leak tester

3 Vehicle/ simulator with a cooling system

5 Drive belt tensioner gauge

Consumable Items:

• Coolants, Sealant/gasket, Hose Pipe, Thermostat Valve

4. Maintain Engine Lubrication System

Overview

This Learning Module is designed to provide skills and knowledge for understanding the working principles, construction, types, components and their relationship between different components to repair different types of engine lubricating systems by Auto Mechanic, in accordance with the manufacturer’s Manual.

Units of Competency Performance Criteria

1. Identify the Lubrication system

P1. Identify the main components of engine lubrication system and understand its functions.

P2. Identify types of oil pumps and understand its function P3. Identify oil coolers for the high performance engine (air

cooled/Water cooled type)

2. Use different Lubricants in the vehicle

P1. Identify the types of engine oil used in the engine with respect to viscosity.

P2. Identify the function of oil filter and its components. P3. Identify the oil sump and its components.


• The functions/operating principle and main components of engine lubrication system as following.

• Wet sump, dry sump, total loss, Oil pumps and its types, pressure relief valves, oil filter,oil cooler, ventilation/PCV Valve, hoses, and oil level indicators.

• Lubricant (oils viscosity, viscosity index, oil classifications, Reduction of frictional forces, cooling effect, cleaning effect, corrosion resistance, and noise reduction).

• The (Law of friction, static/dynamic friction (difference), coefficient of friction).


• Capable of explain the lubrication system components.

• Capable to know the engine oil and filter.


S. No. Description


2 Car Lift


4 Sealant/gasket

5. Retain Fuel System of Petrol Engine

Overview

This Learning Module is designed to provide skills and knowledge for understanding the working principles, construction, types, components and their relationship between different components to repair Carburetor type fuel system and basic EFI petrol engine by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Fuel system (carburetor type engine)

P1. Understand in the petrol engine function of Air Filter. P2. Understand in the petrol engine function of Fuel pump

(Mechanical and Electrical). P3. Understand the petrol engine (Carburetor type) main components

and function of Carburetor. P4. Understand the petrol engine (Carburetor type) main components

and function of Fuel filter. P5. Understand the petrol engine’s (Carburetor type) main

components and function of fuel lines/clips. P6. Understand the petrol engine’s (Carburetor type) main

components and function of fuel sending unit.

2. Fuel system (EFI type engine)

P1. Identifies the EFI main components and understand the working principle of main components.

P2. Identify the sensors in the vehicle and understand the function of each.

P3. Identify the actuators in the vehicle and understand the functions of each.

P4. Identify the ECU and engine malfunctioning light and understand its functions.


• Describe the features of main components of engine fuel system as following: Fuel tanks, filler cap/ security, venting, fuel level sender, lines/ filters, carburetor, and fuel lift

pumps (mechanical/ electrical), fuel (octane rating, Octane number, cetane Number, cetane rating, leaded, unleaded fuel).


• Capable understanding the petrol engine fuel system of carburetor type engine.

• Capable understanding the petrol engine fuel system of EFI type engine


S. No. Description

1 Toll trolley (Complete set)

2 Test lamp/DMM (Digital multimeter)

4 Diesel injector pressure tester /Petrol Injector Tester

5 Safety wears

Consumable Items:

• Carburetor cleaner, Carburetor Gasket Set, Petrol, Injector seals/O ring,

6. Retain Fuel System of Diesel Engine

Overview

This Learning Module is designed to provide skills and knowledge for diesel engine fuel system their understanding the working principles, construction, types, components and their relationship between different components, system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Fuel system (diesel engine)

P1. Inspect diesel engine main components and understand the performance of heater plug.

P2. Inspect diesel engine main components and understand the performance of injectors.

P3. Inspect diesel engine main components and understand the performance of injection pump.

P4. Inspect diesel engine main components and understand the performance of sediment /filter.

2. Fuel system (EFI diesel engine)

P1. Identifies the EFI main components and understands the working principle.

P2. Identify the sensors in the diesel EFI engine and understand the functions of each.

P3. Identify the actuators in the diesel engine and understand the functions of each.

P4. Identify the ECU and engine malfunctioning light and understand the its functions.


• Describe the features of main components of engine fuel system as following. Fuel tanks, filler cap/security, venting, fuel level sender, lines/filters, carburetor, and fuel lift pumps (mechanical/electrical),fuel (octane rating, Octane number , cetane Number ,cetane rating, leaded, unleaded).

• Describe the Diesel injection systems main components as following. Single/multi-hole injectors, inline fuel injection pump, rotary fuel injection pump, fuel injection pressure, bleed points, fuel cutoff switch, governor operation, in Combustion chamber types, main features of pressure/volume diagrams/effects of advanced/retarded/no fuel injection

• Describe the as following statements. Diesel fuel composition, effects of low temperature, viscosity, volatility, calorific value, cetane rating.


• Capable understanding the diesel engine fuel system

• Capable understanding the diesel EFI engine fuel system


S. No. Description


2 Diesel engine vehicle or simulator

4 Safety wears

7. Maintain Engine Exhaust System

Overview

This Learning Module is designed to provide skills and knowledge for engine exhaust system their understanding the working principles, construction, types, components and their relationship between different components, system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Exhaust system components

P1. Inspect the performance of main components of exhaust manifold P2. Remove and assemble exhaust manifold from engine P3. Replace the muffler, resonator and catalytic converter under the

specified procedure. P4. Replace the gasket/packing of silencer under the specified procedure.

2. Emission control system

P1. Identify catalytic converter and understand the function. P2. Identify the positive crankcase ventilation (PCV) and understand the

function. P3. Identify and understand the functions of exhaust gas recirculation

system(EGR) P4. Identify the main components of Evaporative control system of fuel

system.


• Describe the purpose of exhaust system and its functions.

• Describe the muffler assembly operation.

• Describe the catalytic converter operation

• Describe the positive crank case ventilation PCV system and it operation

• Describe the exhaust gas recirculation and its operation


• Capable of understanding the exhaust system

• Capable of understanding EGR.

• Capable of understanding Catalytic converter.


S. No. Description

1 Vehicle

2 Tools trolley (Complete set of hand tools)

3 Gas analyzer

4 Vacuum pump

8. Diagnosing Engine Faults

Overview

This competency standard is developed to provide skills and knowledge to Overhaul Engine (Petrol and Diesel), in accordance with the Manufacturer Manual. You will be able to diagnose fault/s and other maintenance issues of automobile engines while ensuring safe use of tools equipment and materials


1. Engine fault P1. Understand engine adjustment/setting faults of Engine Timing, Setting Distributor timing, tappet adjustment, drive belt/fan belt adjustment.

P2. Understand the faults of engine head gasket, Crank main oil seal, Engine timing belt, manifold packing, and exhaust muffler.

P3. Start the engine and identify the condition of engine missing, stalling, and lack of power, back fire, knocking, black smoke/heavy fuel consumption, excessive oil consumption, and leakages.

2. Engine assembly P1. Selects appropriate tools and perform dismantling/assembly of the all engine components as specified procedure in the manual.

P2. Assemble engine manifolds intake and exhaust.


• Describe the following: Valve timing: lead, lag, overlap, timing diagrams, valve, clearances/adjustment/adjustment

methods. Terms: Top Dead Centre (TDC), Bottom Dead Centre (BDC),Bore, Stroke, Capacity, Clearance Volume, Swept Volume, Compression Ratio, Crank Throw, Torque at REVS/min, Brake power at revs/min, Specific Fuel Consumption (SFC),Volumetric efficiency, OHV, and OHC.

• Describe the possible causes of high fuel consumption as following: Overload the engine, excessive oil consumption, faulty air filter, carburetor poor setting, engine over cooled and hard/jam running of engine.


• Capable of understand engine faults


S. No. Description

1 Tools trolley (complete set of tools)

2 Compression tester

3 Measuring tools (Complete set for engine overhauling)

4 Fuel pressure Tester

5 Special Service Tools

Consumable Items:

Piston ring, Engine oil, Silicon, Oil sump Jain, oil filter, head Gaskit, grease, cotton waste.

9. Perform Ignition System of Petrol Engine

Overview:

These competency standards designed to diagnose and troubleshoot conventional spark ignition system as well as conceptualize the ignition system mechanism in the engine of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Repair Ignition System

P1. Identify the vehicle Ignition system and understand procedure of testing ignition coil under the specified procedure.

P2. Identify the vehicle Ignition system and understand procedure of testing fuse in fuse box under the specified procedure.

P3. Identify the vehicle Ignition system and understand procedure of testing the performance of plug cable and plugs under the specified procedure.

P4. Identify the vehicle Ignition system and understand procedure of inspecting distributor cap/rotor for the performance under the specified procedure.

P5. Identify the vehicle Ignition system and understand procedure of inspecting vacuum advancer, assess C.B Point condition/gap for the performance under the specified procedure.

P6. Identify the vehicle Ignition system and understand procedure of correct ignition timing under the specified procedure.

P7. Identify the vehicle Ignition system and understand the performance of CDI of distributor under the specified procedure.

2. Adjust ignition timing

P1. Installation of distributer assembly under specified procedure and start the engine, adjust ignition timing with the help of timing gun.

P2. Inspect/ Replace ignition switch, inspect/replace ignition coil, and Repair/ replace electrical connectors under specified procedure.


• The Purpose and function of ignition system’s following parts. Spark ignition system contact breaker type, spark ignition system breaker less type.Ignition switch, Ignition coil, resister, plug cable, distributer cap, rotor arm, vacuum advancer, centrifugal advancer, contact breaker assembly, condenser, high tension leads/connectors, suppression, spark plug(construction, heat range type, size), Magnetic Reflector, hall effect trigger/amplifier, differentiate the performance of contact breaker and contact breaker less type.

• Describe primary circuit, secondary circuit of ignition system, identifies change in the spark timing in accordance to the load and speed of the engine.

• Explain Faradays law of mutual induction and calculate the primary and secondary voltages and current.


• Troubleshot the vehicle ignition system (Non EFI engines)

• Capable to adjust the ignition timing

• Capable to service the ignition system.


S. No. Description

1 vehicle/ simulator

2 Digital Multileter (DMM).

3 Tools box

4 test lamp

5 Timing gun

10. Perform Overhauling of Four Stroke Single Cylinder Engine

Overview:

This competency standard is designed to provide skills and knowledge to Overhauling Motorcycle Engine of motorcycle by Motorcycle Mechanic, in accordance with the Manufacturer’s Manual.


1. Overhauling Four stroke motorcycle engines

P1. Arrange proper tools and equipment’s to service cylinder head. P2. Disconnect cables, wires, and muffler from cylinder head for

dismantling cylinder head. P3. Remove cylinder head assembly and its components from the

engine to identify damage parts. P4. Replace/clean cylinder head and its components by using

appropriate tools as per shop manual P5. Refit cylinder head and its components; connect all the cables/

wires and muffler as per shop manual. P6. Test engine performance to verify servicing of cylinder head.

2. Service cylinder, Piston and Piston Rings

P1. Arrange proper tools and equipment to service cylinder and piston. P2. Remove cylinder head assembly from the cylinder block to service

cylinder block piston and piston Rings as per shop manual. P3. Remove cylinder block, piston and inspect its components to

identify the damage parts as per Shop manual. P4. Service/ clean cylinder block, piston and its components to remove

dust. P5. Refit Cylinder Block, piston, piston rings, cylinder head And

connect all the wires, cables to the engine as per shop manual. P6. Test engine performance to verify servicing of cylinder piston and

piston rings as per shop


The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out the tasks covered in this competency standard.

This includes the knowledge of:

• Knowledge about PPEs

• Different types of fire extinguishers

• Safe work environment

• Safety measures and precautions

• First Aid

• Proper use and handling of equipment

• Knowledge about securing measuring tools

• Types of engines

• Schedule of Motorcycle Maintenance

• Different parts of Motorcycle

• Working principles and comparison of 2 and 4 Stroke Engine

• Types and procedure of Oiling & greasing

• Inspections and Measurements

• Cleaning process of different Motorcycle parts / Components.

• Replacement of Motorcycle Parts / Components

• Adjustment of Motorcycle parts /Components

• Working principles of engine and its terminologies

• Different systems of engine

• Parts of engine

• Diagnostic procedure of Engine

• Engine dismantling procedure

• Engine inspection and repair procedure

• Engine assembling procedure

• Engine oil circuits

• Engine Timing

• Manufacturers and workshop manual of given vehicle

• Working principle Fuel system

• Exhaust system

• Euro standards

• Motorcycle driving tips and safety


The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:

• Remove and install engine from motorcycle


S. No. Description



3 Measuring tools (Complete set for engine overhauling)

4 Fuel pressure Tester

5 Special Service Tools

Consumable Items:

Piston ring, Engine oil, Silicon, Oil sump Jain, oil filter, head Gaskit, grease, cotton waste.

Automotive Electricity and Electronics (AD-143)

1. Perform Electricity Measurements

Overview

These competency standards designed to enable the learner to perform electrical related calculations and measurements, as well as conceptualize different automotive functions related to the electrical operations.


1. Basic Electricity P1. Prepare series circuit on work bench using appropriate tools. P2. Prepare parallel circuit on work bench using appropriate tools. P3. Prepare series parallel circuit on work bench using appropriate

tools.

2. Basic Electricity Measurement

P1. Measure/ record voltage by using Digital Multi METER (DMM) P2. Measure/ record current by using Digital Multi Meter (DMM) P3. Measure/ record resistance by using Digital Multi Meter. P4. Measure/ record continuity by using Digital Multi Meter.


• Describe the following terms: Atom and its particles (electron, neutrons & protons), EMF, current, voltage, resistance, magnetism, electro magnetism, flux, inductance, mutual inductance, capacitance, and diode.

• Calculation of ohm law, (V= IR) calculation of power law (P= VI).


• Calculation involving the series, parallel, and series parallel circuits

• Correct use of Digital multimeter (DMM)

• Point out electromagnets in the vehicle.


S. No. Descriptions

1 Digital Multimeter (DMM).

2 Load (resistors)

3 Wires

4 Test bench (Complete accessories)

5 Lamps

Consumable Items:

• Wires, Bulb and Bulb Holder, Thimble (Male & Female),Circuit Board, Wire Clumps, Battery

2. Prepare Electromagnetism applications

Overview

These competency standards designed to enable the learner to perform electrical related calculations and measurements, as well as conceptualize different automotive functions related to the electrical operations.


1. Basic Electricity P1. Prepare turn signal light circuit on work bench using appropriate tools.

P2. Prepare horn/ light circuits on work bench using appropriate tools.

P3. Prepare brake light circuit on work bench using appropriate tools.

2. Basic Electricity Measurement

P1. Measure/ record voltage by using Digital Multi Meter P2. Measure/ record current by using Digital Multi Meter P3. Measure/ record resistance by using Digital Multi Meter. P4. Measure/ record continuity by using Digital Multi Meter


• Describe the following components: Electricity generation, storage, types of current, circuits (open/close), switches, relay, fuses, circuit breaker, motors(DC/AC), generator (DC/AC), and resistors/color coding.


• Calculation involving the series, parallel, and series parallel circuits

• Correct use of Digital Multimeter (DMM)

• Point out electromagnets in the vehicle.


S. No. Descriptions

1 Digital Multileter (DMM).

2 Load (resistors)

3 Wires

4 Test bench (Complete accessories)

5 Lamps

Consumable Items:

• Wires, Bulb and Bulb Holder, Thimble (Male & Female),Circuit Board, Wire Clumps, Battery

3. Perform Battery Service of Vehicle

Overview

These competency standards designed to enable the learner to diagnose the problem related to the battery and starting system and enable the learner to troubleshoot the system if not working, repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Service of battery P1. Perform the battery test by use of hydrometer, Terminal clean, tight, and insulated, secure with battery holder as per given specification.

P2. Inspect and change the Ground (Earth) cable from the vehicle body.

P3. Test battery by using the load tester/battery tester and assess the battery performance.

2. Battery replacement

P1. Perform Safe removal and installation of Battery from the vehicle Inspect/service the battery and assess safety fitting and correctness under specified procedure.

P2. Carry out safe procedure to charge the battery using an external charger.


• Lead Acid battery and its internal components: Material, acid and water ratio, plates, cells, ampere hour rating, voltage drop, corroded/lose terminals, maintenance free batteries.

• Describe the chemical activities in Lead Acid Battery while charging and discharging.


• Troubleshoot the problems related to the vehicle battery.


S. No. Descriptions

1 Vehicle or simulator.

2 Tool box

3 Safety goggles

4 Gloves

5 Battery External charger

6 Battery load tester

7 DMM

8 Wires

9 Hydrometer

4. Repair Engine Starting System

Overview

These competency standards designed to enable the learner to diagnose the problem related to the starting system and enable the learner to troubleshoot the system if not working,repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual


1. Repair starting system

P1. Inspect the vehicle starting system and troubleshoot the following:

Low cranking speed/ not cranking, Ignition switch operation malfunctioning.

P2. Inspect the vehicle starting system and troubleshoot the following:

Unusual noise during operation, corrosive battery terminals, safety neutral switch, incorrect pinion engagement/ disengagement, blown fuse/ relay, lose/ corroded main starting wire.

2. Service Starter Motor. P1. Carryout safe procedure to replace the starter motor from the vehicle.

P2. Service/replace components of starter motor and perform bench testing.


• Short circuits and battery related hazards.Wrong battery installation, touch the positive terminal with the body, un-insulated wire touches with the vehicle body, battery size not matches with the maker, battery acid injury (human eye/ body), disposal of faulty batteries.

• Describe the Wiring diagram associated with the electrical/electronic symbols. Circuit protection device (Fuse, fusible link, circuit breaker) Circuit switching device (manual switches, electromagnet switch/relay normal open and normal close, pressure switch, temperature switch) Resister (Rating, identification method, effect of change of temperature) Electronic devices (Diode, Zener diode, bipolar transistor, Thyristor, thermistor, heat sink, LED)

• Distinguish between increase/decrease cranking current consumption, voltage drop in a system, electrical load, and reason of high ampere draw from a system/overload.

• Describe the Lenz’s law of motor principle, single phase, three phase motor, AC Motor, DC Motor.


• Troubleshoot the problems related to the vehicle battery.

• Capable to describe the fault related to the battery and take appropriate decisions.

• Capable to troubleshoot the vehicle starting system.

• Service the starter motor.


S. No. Descriptions

1 Vehicle or simulator.

2 Tool box

3 Safety goggles

4 Gloves

5 Battery External charger

6 Battery load tester

7 DMM

8 Wires

9 Hydrometer

5. Repair Ignition System of Petrol Engine

Overview

These competency standards designed to diagnose and troubleshoot conventional spark ignition system as well as conceptualize the ignition system mechanism in the engine, repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.



P1. Inspect vehicle Ignition system and diagnose the following: Crank engine and test presence of spark in a system, identify faulty fuse in fuse box (Note: follow safe working procedure).

P2. Inspect vehicle Ignition system and diagnose following:

Test performance of plug cable (high tension leads) and plugs, inspect distributor cap/rotor for performance, assess correct ignition timing, inspect vacuum advancer, assess C.B. Point condition/gap and test condenser. (Note: follow safe working procedure).

2. Repair Ignition System (CDI System)

P1. Inspect the vehicle Ignition system and diagnose the ignition coil performance, (Note: follow safe working procedure).

P2. Inspect the vehicle Ignition system and diagnose the CDI of distributor. (Note: follow safe working procedure).


• Describe the Purpose and function of ignition system’s following parts in Spark ignition system contact breaker type, spark ignition system breaker less type.Ignition switch, Ignition coil, resister, plug cable, distributer cap, rotor arm, vacuum advancer, centrifugal advancer, contact breaker assembly, condenser, high tension leads/connectors, suppression, spark plug(construction, heat range type, size), Magnetic Reflector, Hall Effect trigger/amplifier, differentiate the performance of contact breaker and contact breaker less type.






S. No. Descriptions

1. Vehicle/ Simulator

2. Digital Multileter (DMM).

3. Tools box

4. Test Lamp

5. Timing gun

6. Adjust Ignition Timing of Petrol Engine

Overview:

These competency standards designed to diagnose and troubleshoot conventional spark ignition system as well as conceptualize the ignition system mechanism in the engine, repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual


1. Adjust Ignition Timing


P2. Inspect/ Replace ignition switch, inspect/ replace ignition coil, and Repair/ replace electrical connectors under specified procedure.


P1. Inspection of crank position sensor under specified procedure and starts the engine.

P2. Inspection/replace of ignition fuse under specified procedure and starts the engine.









S. No. Descriptions

1. Vehicle/ Simulator

2. Digital Multileter (DMM).

3. Tools Box

4. Test Lamp

5. Timing Gun

7. Repair Distributer-Less Ignition Systems of Petrol Engine

Overview

These competency standards designed to enable the learner to troubleshoot the electronic ignition related problems in the vehicle, repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Troubleshoot Distributer Less Systems

P1. Use of scanner and find out the fault related to the ignition coil and reset the trouble code by use of scanner.

P2. Use of scanner and find out the fault related to the crank sensor and reset the trouble code by use of scanner.

P3. Use of scanner and find out the fault related to the crank sensor and reset the trouble code by use of scanner.

2. Repair Distributor Less Systems

P1. Use test lamp and identify the faulty fuse in the fuse box under the specified procedure.

P2. Replace the faulty fuse with the same color and start the engine under the specified procedure.

P3. Replace the faulty ignition coil and faulty sensor under the specified procedure.


Describe the following

• Ignition advance mechanism in Distributor less system, Dual coil system, Coil on plug system, crank sensor signals,


• Capable to diagnose and troubleshoot the electronic ignition system.

• Capable to replace faulty parts of electronic ignition system.


S. No. Descriptions


2 Scanner

3 Test lamp

4 DMM (Multimeter)

8. Repair Battery Charging System

Overview

These competency standards designed to enable the learner to troubleshoot battery charging related problems and conceptualize electronics used in the system.


1. Repair charging system

P1. Inspect vehicle charging system and diagnose the following. Battery warning light indication on instrument panel, test output voltage of alternator, drive belt condition, alternator bearing noise, wire harness, fuse, and proper insulated wires.

P2. Dismantle/service of alternator as following;Repair connector, replace carbon brushes, Replace Rectifier Bridge, replace voltage regulator and replace stator winding.

2. Replace alternator P1. Perform safe working practice to remove the alternator from the vehicle and refit under the specified procedure.

P2. Perform test bench of alternator to confirm the operation.


• Describe the Purpose and function of Alternator’s following parts. Rotor, stator windings, Voltage regulator, Rectifier Bridge, Internal cooling fan, Bearings, carbon brush, mounting/adjustment bolts), drive belt and its types, ratio alternator/ crank pulleys, RPM, Alternator input/ output voltages.

• Describe the functions and uses of the following. Semiconductor and its types, Rectification (Half wave/ full wave), transformer and its types, capacitor and its types.


• Capable to troubleshoot the vehicle charging system

• Capable to describe the fault related to the alternator and take appropriate decisions.

• Capable to Service the alternator


S. No. Descriptions

1 Vehicle/simulator

2 Test lamp

3 DMM

4 Tool kit

5 Ampere meter

6 Fuses

7 Relay

9. Repair Light System of Vehicle

Overview

These competency standards designed to enable the learner to rectify electrical related troubles in the vehicle and understand the Wiring of the vehicle, repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Troubleshoot The Lightening System

P1. Inspect vehicle lightening system and diagnose following; under specified testing instructions, Blown fuse finding from interior or exterior fuse box.(Note: follow safe working procedure).

P2. Inspect vehicle lightening system and diagnose following; under specified testing instructions, faulty relay and faulty flasher. (Note: follow safe working procedure).

2. Repair Lights P1. Inspect vehicle lightening system and diagnose following under specified testing instructions. Inspect/Replace head lamp, parking bulb and indicator bulb(Note: follow safe working procedure).

P2. Inspect vehicle lightening system and diagnose following under specified testing instructions. Back light bulb, reverse light bulb.(Note: follow safe working procedure).


• Identify the terms used and calculations associated with the electricity. Definitions (magnetism, self/mutual induction). Laws (amperes rule, Fleming’s rule)Switch (manual, magnet, pressure, temperature)sender (fuel level, temperature)


• Capable to troubleshoot the vehicle lightening system

10. Repair Vehicle Accessories

Overview

These competency standards designed to enable the learner to rectify electrical related troubles IN the vehicle and understand the Wiring of the vehicle, repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Repair Cooling System and Vehicle Accessories

P1. Inspects the Radiator fan operation for correct operation under specified testing instructions.

P2. Inspects the thermal switch for correct operation under specified testing instructions.

P3. Inspects the temperature sender for correct operation under specified testing instructions.

2. Repair Electrical Accessories

P1. Inspects the oil warning switch operation for correct operation under specified testing instructions.

P2. Inspects fuse, relay operation for correct operation under specified testing instructions.

P3. Inspects the fuel sender operation for correct operation under specified testing instructions.

P4. Inspects the wiper motor, washer motor for correct operation under specified testing instructions.

P5. Inspects heating Elements for correct operation under specified testing instructions


• Identify terms used and calculations associated with electricity. Definitions(magnetism, self/mutual induction).Laws (amperes rule, Fleming’s rule)

• Describe the use of following materials in vehicle with example. Conductor (Good/ bad), Insulator, semiconductors, electrical Cable (Color coding, ampere rating, wire harness, cross sectional area, cable identification method).

• Differentiates each in following. Switch (manual, magnet, pressure, temperature)sender (fuel level, temperature)


• Capable to troubleshoot the vehicle lightening system

• Capable to describe fault related to electrical lights, cooling system, and take appropriate decision.


S. No. Descriptions

1 Vehicle/ simulator

2 Digital Multi Meter (DMM).

3 Tools box

4 test lamp

Workshop Practice-1 (MT-164)

1. Perform Bench Work on Metallic Surfaces

Overview:

These competency standards identify the competencies you need to perform bench work operations using different tools and equipment, in accordance with approved procedures. You will be expected to perform sawing, filing, threading and reaming using hand tools. You will be required to operate the tools and equipment safely by comply the organizational safety policy and approved procedures. Your underpinning knowledge will be sufficient to provide you the basis for your work.

Competency Units Performance Criteria

1. Carry-Out Sawing P1. Select appropriate blade and set in hacksaw frame according to the job requirement

P2. Select appropriate marking tool(s), mark the work piece and clamp it in the vice firmly as per standard practices

P3. Adopt sawing methods and techniques that are safe and suitable to cut the work-piece as required

P4. Follow marked line during sawing of work piece to ensure accuracy

2. File the Work-Piece P1. Select appropriate file and marking tool(s) according to the job requirement

P2. Mark the work-piece and clamp it in the vice firmly as per standard practices

P3. Adopt filing method and technique which is safe and suitable to produce the work-piece as per drawing

P4. Follow drawing dimensions and surface finish of field work-piece to ensure accuracy and precision

3. Carry out Drilling P1. Setup drill machine for producing hole in the work piece according to the job requirement

P2. Select drill bit and marking tools according to the material and job requirement, respectively

P3. Mark the work-piece according to the drawing and clamp it in the vice firmly as per standard practices

P4. Set the suitable RPM. P5. Adopt proper drilling method (manual/auto-feed, applying

coolants) which is safe and suitable to produce the hole in work-piece

P6. Follow drawing dimensions of drilled hole to ensure accuracy and precision

4. Produce Threads on Work-Piece

P1. Select tap and die according to the type of thread to be produced on work-piece as per drawing


P2. Clamp the work-piece in the clamping device firmly as per standard practices

P3. Ensure the tap and die alignment as per prescribed standard P4. Make thread with die and follow appropriate sequence P5. Ensure the safety and dimensional accuracy of threads on work-

piece as per drawing

5. Perform Hand Reaming

P1. Select reamer according to the work-piece requirement P2. Clamp the work-piece in the clamping device firmly as per

standard practices P3. Ensure the reamer alignment as per prescribed standard P4. Produce reamed hole by following safety and prescribed method P5. Ensure the accuracy and size of reamed hole of work-piece

according to the drawing

Knowledge and Understanding

The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out the tasks covered in this competency standard. This includes the knowledge of:

• Mechanical Properties and strength of materials

• Combination of feed and speed settings according to the work-piece, and tools& materials

• Usage of bench-work tools and equipment

• Interpret basic drawings

• Measurement systems

• Use of measuring and marking tools

• Usage of bench working tools

• Procedure of safe clamping the work-piece

• Personal Protective Equipment (PPEs) and workplace safety



• Utilization of tools (measuring, marking & cutting) equipment and their working method

• Produce a component containing the following operations marking, sawing & filing

• Produce a component containing operations with marking, drilling, threading & reaming


S. No. Descriptions

1 Hacksaw

2 Drill set

3 Drill Machine

4 Shaper Machine

5 Lathe Machine

6 Milling Machine

7 Grinder

2. Perform Shaper Machine Operations

Overview:

This competency standard identifies the competencies you need to perform shaping operations on shaper machine in accordance with approved procedures. You will be expected to perform Facing, Step cutting, Squaring, Slotting, V-shape cutting with point cutting tool. You will be required to operate the shaper machine safely by complying the organizational safety policy and approved procedures. Your underpinning knowledge will be sufficient to provide you the basis for your work.


1. Prepare Materials for Shaping Operations

P1. Interpret drawing and arrange the material accordingly P2. Prepare work-piece by required machining (sawing and filing

etc.) and get ready to clamp P3. Check and verify the dimensions of work-piece for shaping

according to the drawing

2. Select Tools and Equipment

P1. Select the material and shape of tool(s) according to the job requirements

P2. Arrange the measuring instruments and holding devices to attain accuracy of the work as per prescribed method

3. Set Shaper Machine for Operations

P1. Clamp the material of work-piece and tool into its holding devices as per standard practice

P2. Maintain safe distance between surface of work-piece and tooltip as per prescribed method

P3. Adjust the ram placement and stroke length according to the length of job

P4. Adjust the parameters of shaping (speed and feed) from control unit as per prescribed method

P5. Start shaping operation by locating the initial touching point and adjust the depth of cut according to the prescribed procedure

4. Perform Shaping Operations (Square Job)

P1. Ensure the proper clamping of work-piece and the tool according to the standard practice

P2. Start the shaping operation at top surface of work piece to get flatness as per initial requirements

P3. Re-clamp the work-piece by rotating 90° for next surface as per prescribed method

P4. Shape entire work-piece by following the above stated method for next surface to get square shaped work piece according to drawing

5. Perform Shaping Operations (Angular Job

P1. Ensure proper clamping of the work-piece and the tool according to standard practice

P2. Mark work-piece according to the drawing P3. Set and align the sliding degree of head according to required

angle P4. Start the angular shaping operation to get required angle as per


marked line P5. Shape entire work-piece, by setting the required degree of head,

to get angle of work-piece according to the drawing






• Knowledge of shaping machines

• Types of shaping machines

• Ram and stroke settings


• Knowledge of shaping tools

• Feed and speed settings

• Working procedure of shaping

• Shaping tools and holding devices

• Housekeeping of tools and equipment



• Produce a component containing the following operations with marking: o Square job as prescribed method o Angular job as prescribed method o Setting of machine, tool and stork per minute

Tools and equipment required

Sr. No. Items

1 Hacksaw

2 Shaper Machine

3 Flat File

4 Marking Tools

5 Chapping Tools

6 Measuring Tools

7 Tool Grinder

3. Perform Lathe Turning Operations

Overview:

This Competency Standard identifies the competencies required to perform lathe machine operations by a Machinist in accordance with the organization’s approved guidelines and procedures. You will be expected to perform facing, turning drilling/boring, taper turning, knurling and threading operations using lathe machine. Your underpinning knowledge will be sufficient to provide you the basis for your work.


1. Prepare Materials for Lathe Operations

P1. Interpret drawing and arrange the material accordingly P2. Prepare work-piece by required machining (sawing and filing

etc.) and get it ready for clamping P3. Check and verify the dimensions of work-piece for lathe

operations as per drawing

2. Select Tools and Equipment

P1. Select the tool(s) according to material of job and shape of the job requirements

P2. Arrange the measuring instruments and holding devices to attain accuracy of the work as per prescribed method

3. Set Lathe Machine for Operations

P1. Clamp the material of work-piece and tool into its holding devices as per standard practice

P2. Maintain the safe distance between work-piece and tool tip as per prescribed method

P3. Adjust the revolution per minute (rpm) of chuck according to the specifications of work-piece.

P4. Adjust the parameters of speed and feed from control unit as per prescribed method

4. Carry-Out Lathe Operations

P1. Ensure the proper clamping of work-piece and the tool into the holding devices according to the required operation

P2. Maintain the alignment of work-piece and locate the tool tip at center position of the work-piece as per standard practice

P3. Start the lathe operations as required according to the drawing and replacing the required tool

P4. Check the work-piece by using appropriate measuring tools and instruments as per standard practice





• Personal Protective Equipment and workplace safety



• Use of measuring and marking tools

• Knowledge of Lathe machines and its types

• Knowledge of holding devices and lathe attachments

• Knowledge of lathe tools

• True running of job(s) and center alignment of tool tip

• Calculation of feed and speed according to the work-piece and tool materials

• Procedure of safe clamping the work-piece

• Importance and usage of coolants



• Produce a component containing the following operations with marking as prescribed method:

• Facing

• Parallel Turning

• Step Turning

• Taper Turning

• Drilling

• Boring

• Threading (internal/external)

• Grooving


Sr. No.

Items

1 Hacksaw

2 Drill set

3 Drill Machine

4 Lathe Machine

5 Tool Grinder

6 Lathe Cutting Tools

7 Measuring Tools

4. Read and Interpret Manufacturing Drawings

Overview

This competency standard is designed to gain basic knowledge and skills required to read and interpret manufacturing drawings and welding symbols. The standard covers specific knowledge related to reading and understanding manufacturing drawings, interpreting welding symbols, recognizing materials and specifications, and bill of material/s and manufacturing parts according to manufacturing drawings.


1. Read and Understand Manufacturing Drawings

P1. Recognize basics of lines used in engineering drawings P2. Describe uses of lines in engineering drawings P3. Recognize and explain orthographic and isometric views of a

drawing P4. Identify manufacturing requirements according to drawings P5. Prepare job layout according to manufacturing requirements

2. Interpret Welding Symbols

P1. Understand basic and supplementary welding symbols used in manufacturing drawings

P2. Understand and differentiate between types of welds and joints P3. Identify welding requirements according to welding symbols given

in the manufacturing drawings

3. Recognize Material Specifications and Bill of Material (BOM)

P1. Identify material specifications according to manufacturing drawing

P2. Identify bill of material (BOM) according to manufacturing drawing

4. Manufacture Parts P1. Interpret dimensional tolerances according to manufacturing drawing

P2. Assemble and tack weld parts according to manufacturing drawing


The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:

• Basic elements of engineering drawing

• Drawing symbols

• Dimensioning techniques

• Tolerances

• General tolerance

• Angular tolerance

• Geometric tolerance

• Drawing techniques

• Perspective

• Exploded view

• Hidden view technique

• Projections

• First angle projections

• Third angle projections



• Prepare and interpret technical drawings and sketches based on provided specifications

Tools and Equipment Required

The tools and equipment required for this competency standard are given below:

S. No. Descriptions

1 Drawing or Sketch

2 Layout Tools

3 Measuring Devices

4 Handheld Calculator

5 Fabrication and Welding Equipment

6 Base Metals

7 Welding Consumables

5. Perform Welding Procedure Specifications (WPS)

Overview:

This competency standard is designed to gain basic knowledge and skills required to prepare Welding Procedure Specifications (WPS). The standard covers specific knowledge related to recognizing, interpreting and explaining and preparing Welding Procedure Specifications (WPS).


1. Recognize Welding Procedure Specifications (WPS)

P1. Describe and understand contents of Welding Procedure Specifications (WPS)

P2. Recognize common acronyms used in Welding Procedure Specifications (WPS)

2. Interpret and Explain Welding Procedure Specifications (WPS

P1. Recognize materials specifications (base metals and fillers) according to Welding Procedure Specifications (WPS)

P2. Recognize weld type and joint design according to Welding Procedure Specifications (WPS)

P3. Recognize welding positions and parameters according to Welding Procedure Specifications (WPS)

3. Prepare a Welding Procedure Specifications (WPS)

P1. Prepare sample Welding Procedure Specifications (WPS) following a simple welding procedure

P2. Follow written Welding Procedure Specifications (WPS) to produce a production/sample weld



• Written communication skills (reading and comprehension)

• Purpose of Welding Procedure Specifications

• Common contents of WPS

• Groupings of materials

• Thickness range

• Types of welds

• Joint design

• Welding processes

• Welding positions

• Welding consumables

• Electrical characteristics - volts, current, polarity

• Shielding gases

• Purge gas

• Gas flow rate

• Nozzle diameter

• Pre-heat/Post-heat

• Welding speed



• Interpret a range of WPS documents.


S. No. Descriptions

1 Hacksaw

2 Drill set

3 Drill Machine

4 Shaper Machine

5 Lathe Machine

6 Milling Machine

7 Cylindrical Grinder

8 Surface grinder

6. Prepare Materials for Welding

Overview:

This competency standard is designed to gain basic knowledge and skills required to prepare materials for a specific job. The standard covers specific knowledge of marking the material as per drawing/job requirement, setting up cutting equipment, cutting and preparing edges of base materials, cleaning surfaces and edges, preparing welding consumables and fitting up base materials.


1. Select and Mark Material/s as per Drawing/Job Requirement

P1. Select and obtain required material/s as per job requirements P2. Select appropriate marking tools as per job requirements P3. Mark the area to be cut as per drawing/ job requirements

2. Cut and Prepare Edge/s of Base Materials

P1. Select appropriate cutting equipment as per job requirements P2. Set-up cutting equipment as per manufacturer’s instructions/job

requirements P3. Cut the base material as per job specifications and dimensions

provided in the drawing P4. Prepare edges of the base materials as per drawing/ WPS P5. Check dimensions of the prepared edges as per drawing/ WPS P6. Select proper tools and chemicals for cleaning P7. Clean the edges of the base materials as per job requirements

3. Prepare Welding Consumables

P1. Select relevant welding consumables as per job requirements/ WPS

P2. Prepare consumables in accordance with required specifications

4. Fit-up Base Materials

P1. Select proper tools and equipment to fit-up base materials P2. Tack weld joint/s as per drawing/ welding procedure

specifications (WPS) P3. Check root gap as per drawing/welding procedure specifications

(WPS) P4. Check alignment as per applicable code/standard



• Interpretation of drawings and sketches

• Selection of appropriate method of edge preparation

• Selection of appropriate cutting equipment, accessories and supplies

• Operation of cutting equipment such as mechanical, gas and plasma

• Operation of grinding equipment

• Safety procedures for cutting and grinding



• Perform edge preparation in accordance with WPS and safety procedures


S. No. Descriptions 1 Hacksaw

2 Drill set

3 Drill Machine

4 Shaper Machine

5 Lathe Machine

6 Milling Machine

7 Cylindrical Grinder

8 Surface grinder

7. Perform Shielded Metal Arc Welding (SMAW) in Vertical (3F, 3G) and Overhead (4F, 4G) Positions

Overview:

This Competency Standard is designed to gain basic knowledge and skills required to perform Shielded Metal Arc Welding (SMAW) operations in Flat (1F, 1G) and Horizontal (2F, 2G) positions at workplace. The standard covers specific knowledge of performing Shielded Metal Arc Welding (SMAW) by selecting and setting up welding equipment, installing consumables, adjusting welding parameters and making fillet and groove welds in Flat (1F, 1G) and Horizontal (2F, 2G) positions of plate. The standard also covers post welding operations comprising cleaning, measuring, inspecting and repairing welds at workplace.


1. Prepare Welding Machine and Accessories for SMAW

P1. Identify welding requirements from the job, welding procedure specifications and/or technical drawings

P2. Prepare SMAW welding machine in accordance with welding procedure specifications/ manufacturer instructions

P3. Set up welding machine accessories and consumables as per job requirements, welding procedure specifications and/or manufacturer’s instructions

P4. Connect welding machine to an independent power supply P5. Set polarity indicated in the welding procedure specifications

2. Make Fillet Welds on Carbon Steel Plate

P1. Adjust welding parameters (current, voltage etc.) as per welding procedure specifications/job requirements to produce acceptable weld

P2. Maintain gap between electrode and base metal as per standard practices

P3. Carry out welding in Flat (1F) and Horizontal (2F)positions following standard procedures

P4. Follow applicable manufacturing codes and standards for acceptance criteria of visual welding defects

3. Make Groove Welds on Carbon Steel Plate

P1. Adjust welding parameters (current, voltage etc.) as per welding procedure specifications/job requirements to produce acceptable weld

P2. Maintain gap between electrode and base metal as per standard practices

P3. Carry out welding in Flat (1G)and Horizontal (2G) positions following standard procedures

P4. Deposit root pass as per welding procedure specifications/ job requirements

P5. Deposit filling passes as per welding procedure specifications/job requirements

P6. Deposit capping pass as per welding procedure specifications/job requirements

P7. Check root, filling and capping passes for any visual discontinuities as per acceptance standards


P8. Follow applicable manufacturing codes and standards for acceptance criteria of visual welding defects

4. Perform Post Welding Operations

P1. Carry out finishing work of welds following standard procedures P2. Inspect weld visually and mark any visual defects, as required P3. Carry out repair work in accordance with approved procedures,

as required P4. Clean work area in accordance with workplace safety practices P5. Maintain and store tools/ equipment/ consumable materials in

accordance with organization guidelines



• Understanding of technical drawings

• Electrical supply AC and DC

• Polarity setting according to standard specifications

• Specifications/ classification of electrode/s required for the job

• Welding procedure specifications (WPS)

• Method of Pre- heating of base metal

• Electrical parameters like (voltage, current etc.) and their effects on weld

• Welding techniques as per WPS/instruction sheet

• Visual welding defects

• Welding codes and standards



• Perform SMAW fillet weld at 1F, 2F positions, groove weld at 1G, 2G positions as per given job specification


S. No. Descriptions

1 Hacksaw

2 Drill set

3 Drill Machine

4 Welding Machine

5 Lathe Machine

6 Milling Machine

8. Perform Forging Operations

Overview:

This Competency Standard is designed to gain basic knowledge and skills required to Perform main operation of forging (Drawing down and Swaging).The standard covers specific knowledge of performing of Forging in drawing down and swaging.


1. Drawing down P1. Make fire in available forge furnace P2. Put the stock in forge furnace. P3. Heat the stock upto bright red condition ( Plastic State) P4. Grip the heated stock by tong and put on anvil. P5. Apply firm blows of sledge hammer on both sides of stock. P6. Put the stock again in forge furnace and repeat process P7. Always wear safety dress before start the performance.

2. Swaging P1. Make fire in forge furnace P2. Put the round stock in forge furnace. P3. Heat the stock upto bright red condition. P4. Fix the bottom swage in hardy hole. P5. Put the red hot round bar in the bottom swage. P6. Put the top swage over round bar with the help of handle. P7. Apply firm blows of sledge hammer and move round bar

longitudinally and circumferentially. P8. Always wear safety dress before start the performance.


The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the Knowledge of:

• Understanding of techniques of drawing down

• Proper preparation and selection of stock.

• Understand the use of proper equipment.

• Using proper safety dress before starting performance.

• Complete the drawing down and swaging process rapidly.


The candidate needs to produce following critical evidence(s) in order to be competent in

• Prepare the job through drawing down process.

• Prepare the job through Swaging process


S. No. Descriptions

1 Hacksaw

2 Drill set

3 Drill Machine

4 Welding Machine

5 Lathe Machine

6 Milling Machine

Basic Engineering Drawing and CAD-I Mech-163

1. Perform Drawing, Sketch Making

Over View

This competency standard of manual drawing identifies the competencies to apply basic of drawing making sketches.

Competency Unit Performance Criteria

1. Draw Different Forms of Drawing

P1. Draw convention layout drawing P2. Draw convention electrical circuit drawing P3. Draw lines with different scale of measurement P4. Select the sheet format P5. Select the tool and equipment

2. Draw different lines for free hand sketching

P1. Draw horizontal lines P2. Draw vertical lines P3. Draw arcs P4. Draw circles P5. Draw ellipse P6. Draw all conic section P7. Draw projection of lines P8. Sketch different objects

3. Draw different lines with measurement

P1. Draw single Stroke lettering P2. Draw double stroke gothic letter P3. Draw different types of letter P4. Draw alphabet of lines in original scale P5. Apply alphabet of lines in drafting



This includes the knowledge of draw development by

• Draw mechanical drawing

• Draw electrical drawing

• Draw civil drawing

• Draw terms use in drawing

• Draw application of drawing forms

• Draw scales used in drawing

• Draw fundamentals units i.e. Arcs, circles and ellipse

• Draw single stroke and double stroke gothic letters


S. No. Descriptions

1 T square

2 Set square

3 Compass

4 Eraser

5 Pencil

6 Sharpener

7 Drawing sheet

8 Paper tape

9 Drawing board

2. Draw Pictorial Drawing

Over View:-

This Competency standard of manual drawing identifies the competencies to draw pictorial drawings.

Competency unit Performance criteria

1. Draw different types of pictorial drawing

P1. Draw oblique drawing P2. Draw axonometric drawing P3. Draw perspective drawing P4. Draw Multiview drawing

2. Draw multi view projection

P1. Draw principle plane of projection P2. Draw projector / projection lines P3. Draw auxiliary view of objects P4. Draw Multiview drawing of machine components



Draw development by

• Draw oblique drawing

• Draw axonometric drawing

• Draw perspective drawing

• Draw multi view drawing

• Draw plan of projection

• Draw projection drawing

• Draw multi view drawing of machine equipment


S. No. Descriptions

1 T square

2 Set square

3 Compass

4 Eraser

5 Pencil

6 Sharpener

7 Drawing sheet

8 Paper tape

9 Drawing board

3. Perform Basic Dimensioning System in Working Drawing

Over View

This Competency standard of manual drawing identifies the competencies to apply skills in having expertise in dimensioning systems and geometrical construction.

Competency Unit Performance Criteria

1. Draw dimensional geometrical constructions

P1. Draw the types of dimensioning ( size of dimension and location of dimension

P2. Draw system of dimensioning P3. Draw dimensioning of holes P4. Draw dimensioning of arc P5. Draw dimensioning circles P6. Draw dimensioning of angles P7. Draw all conic sections separately P8. Draw engineering involute curve of a circle

2. Draw working Drawing

P1. Draw preliminary designee sketching P2. Draw detail Drawing of an object P3. Draw Assembly Drawing of an object P4. Draw working drawing of machine component



Draw development by

• Draw types of dimensioning

• Draw system of dimensioning

• Draw dimensioning in size of holes

• Draw dimension in size of arc

• Draw dimensions in size of circle

• Draw all conic section separately

• Draw detail drawing of an object

• Draw assembly drawing of an object

• Draw working drawing of machine components


S. No. Description

1 T square

2 Set square

3 Compass

4 Eraser

5 Pencil

6 Sharpener

7 Drawing sheet

8 Paper tape

9 Drawing board

4. Perform Sectioning and Pictorial Drawing

Over View:-

This Competency Standard of manual Drawing. Identifies the competencies to apply skill in sectioning and pictorial drawing.


1. Draw sectioning P1. Draw material symbols used in sectioning P2. Draw full section of an object P3. Draw half section of an object P4. Draw broken section of an object P5. Draw sectional view of machine components

2. Draw pictorial Drawing

P1. Draw isometric view of an object P2. Draw isometric view of arc P3. Draw isometric view of circle P4. Draw oblique view of a rectangular block P5. Draw isometric views of an object / components



Draw development by

• Draw material symbols used in engineering drawing

• Draw full section of an object

• Draw half section of an object

• Draw sectional views of machine components

• Draw oblique view of a rectangular block

• Draw isometric views of an object


S. No. Descriptions

1 T square

2 Set square

3 Compass

4 Eraser

5 Pencil

6 Sharpener

7 Drawing sheet

5. Draw Auxiliary Drawing

Over view

This Competency Standard of manual Drawing. Identifies the competencies to apply skill in auxiliary drawing


1. Draw primary auxiliary view

P1. Draw Primary auxiliary view of frontal projection P2. Draw primary auxiliary view of horizontal projection P3. Draw primary auxiliary view of profile projection P4. Draw Example of all these

2. Draw true length line P1. Draw true length line in auxiliary view of different objects P2. Draw auxiliary view in different objects P3. Draw auxiliary view of objects P4. Draw auxiliary view of component part P5. Draw example of above two



Draw development by

• Apply auxiliary views

• Draw primary auxiliary views of frontal projection

• Draw primary auxiliary view in horizontal projection

• Draw primary auxiliary view in profile projection

• Draw true length line in the auxiliary view of different objects

• Draw secondary auxiliary view in different objects


S. No. Descriptions

1 T square

2 Set square

3 Compass

4 Eraser

5 Pencil

6 Sharpener

7 Drawing sheet

Problems in Internal Combustion Engines AD-203

1. Diagnose Engine Fault

Overview

These competency standards designed to enable the learner to find out the faults and rectify accordingly, learner will be able to overhaul the engine under the specified format in the service manual.


1. Engine fault adjustment

P1. Perform engine adjustment/setting of Engine Timing, Setting Distributor timing, tappet adjustment, drive belt/fan belt adjustment.

P2. Change the engine head gasket, Crank main oil seal, Engine timing belt, manifold packing, and exhaust muffler.

2. Engine fault diagnosing

P1. Use the compression tester and test engine compression to diagnose fault in piston rings or valve seats/burnt valve under specified procedure.

P2. Start the engine and identify the condition of engine missing, stalling, and lack of power, back fire, knocking, black smoke/heavy fuel consumption, excessive oil consumption, and leakages.


• Describe the following;

Valve timing: lead, lag, overlap, timing diagrams, valve, clearances/adjustment/adjustment methods.

Terms: Top Dead Centre (TDC), Bottom Dead Centre (BDC),Bore, Stroke, Capacity, Clearance Volume, Swept Volume, Compression Ratio, Crank Throw, Torque at Revs/Min, Brake power at Revs/min, Specific fuel consumption (SFC),Volumetric Efficiency, OHV, and OHC.


• Capable of adjustments.

• Capable of changing faulty components.


S. No. Descriptions


2 Compression tester, compression gauge)

3 Measuring tools (Verniercalliper, micrometre, bore gauge, dial gauge, Steel rule, filler gauge, try square)

4 Torque wrench

5 Impact gun

6 Oil can

7 Belt tensioner

8 Spray gun

9 Valve lapping tool

10 Timing gun

11 Engine analyzer

12 Tachometer

13 Scraper

Consumable Items:

S. No. Descriptions

1 Fuel (petrol/diesel)

2 Cotton rag

3 WD 40 spray

4 Carb cleaner spray

5 Kerosene oil

6 Engine oil

7 Engine coolant

8 fan belt

9 Timing belt

10 oil seals

11 Gasket

12 Silicone

13 Emery paste

2. Perform Engine Overhauling (Petrol/Diesel)

Overview

These competency standards designed to enable the learner to find out the faults and rectify accordingly, learner will be able to overhaul the engine under the specified format in the service manual.


1. Engine sub-assemblies

P1. Make the engine sub-assemblies and inspect the performance for (setting piston rings, piston pin and connecting road),

P2. Make the engine sub-assemblies and inspect the performance for (valve train and test for the leakage from valve seats),

P3. Make the engine sub-assemblies and inspect the performance for (fitting crankshaft with main bearings and pistons with the big end bearings),

P4. Perform the straightness inspect of engine head and block straightness/warpage level and make decision for correctness.

2. Engine measurement P1. Use appropriate measuring tool and Measure piston bore, measure crankshaft main journals, crankshaft big end journals,

P2. Use appropriate measuring tool and Measure Camshaft main journals, Cam loops,

P3. Use appropriate measuring tool and Measure engine thrust washer, and piston connecting pin.

P4. Assemble the engine block with the engine head and adjust tappets, engine timing, and spark distributor of petrol engine under specified procedure.


• The possible causes of high fuel consumption as following.

• Overload the engine, excessive oil reducing, faulty air filter, carburetor poor setting, engine over cooled and hard/jam running of engine, faulty fuel injectors, faulty fuel pump/fuel filter.


• Capable to take decision for engine overhauling.

• Capable of knowing the engine faults

• Capable to assemble the engine.

• Capable to measure the engine components


S. No. Description


2 Compression tester, compression gauge)

3 Measuring tools (Verniercalliper, micrometre, bore gauge, dial gauge, Steel rule, filler gauge, try square)

4 Torque wrench

5 Impact gun

6 Oil can

7 Belt tensioner

8 Spray gun

9 Valve lapping tool

10 Timing gun

11 Engine analyzer

12 Tachometer

13 Scraper

Consumable Items:

S. No. Description

1 Fuel (petrol/diesel)

2 Cotton rag

3 WD 40 spray

4 Carb cleaner spray

5 Kerosene oil

6 Engine oil

7 Engine coolant

8 fan belt

9 Timing belt

10 oil seals

11 Gasket

12 Silicone

13 Emery paste

3. Diagnose Engine Cooling System Faults and Repair

Overview

These competency standards designed to enable the learner to diagnose the fault related to the vehicle cooling system and troubleshoot accordingly by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Cooling system service

P1. Inspect engine cooling system’s main components and diagnose the performance of (Radiator cap, water body/pump, drive belt/fan belt, thermostat Valve, radiator, Drain plug, hoses/clamps, and gasket/ seals)

P2. Inspect/service the radiator and top up with the coolant/antifreeze as per specified ratio in the manual.

2. Repair Cooling system P1. Change the water body under specified procedure and start the engine to confirm correct operation.

P2. Adjust fan belt tension under specified procedure and start the engine to confirm correct operation.


• Describe the operating principles and terminologies of cooling system as following. Air cooled engine, liquid cooled engine, operating temperature, thermal efficiency, pressurized system, heat exchange method (conduction, radiation, and convection), corrosion, and inhibitors/antifreeze)

• Describe the functions and purpose of engine cooling system components as following. Electrical motor operated fan with thermo switch, belt operated fan, temperature controlled/viscous coupling fan, pressure cap, water body/pump, drive belt, thermostat, radiator, core plug, hoses/clamps, and gasket/ seals.


• Capable of diagnose, adjust and rectify the cooling system faults.


S. No. Description


2 Radiator leak tester


5 Drive belt

Consumable Items:

S. No. Description

10 Sealant

11 Hose pipe

12 Thermostat valve

4. Diagnose Faults in Engine Lubrication System

Overview

These competency standards designed to enable the learner to diagnose the fault related to the lubrication system and troubleshoot accordingly by Auto Mechanic, in accordance with the manufacturer’s Manual.

Units of Competency Performance Criteria

1. Lubrication system

P1. Inspect engine lubrication system’s main components and check (engine oil level)

P2. Inspect engine lubrication system’s main components and check (oil leakage)

P3. Inspect engine lubrication system’s main components and check (oil warning switch)

P4. Inspect engine lubrication system’s main components and check (and PCV valve)

2. Repair Lubrication system

P1. Inspect/replace of oil warning switch, PCV valve, oil sump, oil sump seal/gasket, and oil pump under the specified procedure.

P2. Carryout safe procedure to change the engine oil and oil filter.


• Describe the functions/operating principle and main components of engine lubrication system as following. Wet sump, dry sump, total loss, Oil pumps and its types, pressure relief valves, oil filter, oil cooler, ventilation/PCV Valve, hoses, and oil level indicators. Lubricant (oils viscosity, viscosity index, oil classifications, Reduction of frictional forces, cooling effect, cleaning effect, corrosion resistance, and noise reduction).

• Describes the (Law of friction, static/dynamic friction (difference), coefficient of friction).


• Capable of diagnose, adjust and rectify the lubrication system faults.

• Capable to change the engine oil and filter.


S. No. Description


2 Car Lift


4 Sealant/gasket

5. Diagnose Faults of Carburetor Fuel System

Overview

These competency standards designed to enable the work on vehicle fuel system to diagnose and rectify the faults in petrol and diesel engines by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Service of Fuel system (carburetor type engine)

P1. Diagnose performance of petrol engine’s (Carburetor type) main components and Service/replace under the specified procedure of (Air Filter).

P2. Diagnose the performance of petrol engine’s (Carburetor type) main components and Service/replace under the specified procedure of (Fuel pump).

P3. Diagnose the performance of petrol engine’s (Carburetor type) main components and Service/replace under the specified procedure of (Carburetor and Fuel filter).

P4. Diagnose the performance of petrol engine’s (Carburetor type) main components and Service/replace under the specified procedure of (fuel lines/clips, fuel sending unit).

2. Repair of Fuel system (carburetor type engine)

P1. Start the engine and set air fuel mixture by adjusting required engine RPM at idling and at speed under specified procedure.

P2. Perform service of carburetor under specified procedure.


• Describe the features of main components of engine fuel system as following: Fuel tanks, filler cap/security, venting, fuel level sender, lines/filters, carburetor, and fuel lift pumps (mechanical/electrical),Fuel (Octane Rating, Octane Number , CetaneNumber , Cetane Rating, Leaded, Unleaded).


• Capable to diagnose and troubleshoot the petrol engine (Carburetor type)

• Capable to adjust air fuel ratio

• Capable to service of carburetor


S. No. Descriptions




5 Safety wears

Consumable Items:

• Carburetor cleaner, Carburetor Gasket Set, Petrol, Injector Rings,

6. Diagnose Diesel Fuel System and Adjust

Overview

These competency standards designed to enable the work on vehicle fuel system to diagnose and rectify the faults in petrol and diesel engines by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Service Fuel System (diesel engine)

P1. Use injector pressure tester machine and Service/set pressure of fuel injector as specified in the manual.

P2. Apply safety precautions and perform air bleeding from low pressure side and high pressure side under the specified procedure.

2. Repair Fuel System (diesel engine)

P1. Inspect diesel engine main components and diagnose the performance of (heater plug).

P2. Inspect diesel engine main components and diagnose the performance of (injectors).

P3. Inspect diesel engine main components and diagnose the performance of (injection pump, sediment /filter).

P4. Inspect diesel engine main components and diagnose the performance of (sediment /filter).


• Describe the Diesel injection systems main components as following. Single/multi-hole injectors, inline fuel injection pump, rotary fuel injection pump, fuel injection

pressure, bleed points, fuel cutoff switch, governor operation, in Combustion chamber types, main features of pressure/volume diagrams/effects of advanced/retarded/no fuel injection

• Describe the as following statements. Diesel fuel composition, effects of low temperature, viscosity, volatility, calorific value, cetane

rating.


• Capable to Check the fuel pressure with the help of pressure gauge

• Capable to diagnose and troubleshoot the diesel engine.

• Capable to service the injectors.

• Capable to bleed the air from the diesel fuel system.


S. No. Descriptions




5 Safety wears

Consumable Items:

• Carburetor cleaner, Carburetor Gasket Set, Petrol, Injector Rings,

7. Diagnose Faults of Ignition System

Overview

These competency standards designed to diagnose and troubleshoot conventional spark ignition system as well as conceptualize the ignition system mechanism in the engine.



P1. Inspect the vehicle Ignition system and diagnose the following (Note: follow safe working procedure).

P2. Crank the engine and test presence of spark in a system, identify faulty fuse in fuse box, test the performance of plug cable and plugs, inspect distributor cap/rotor for the performance, assess the correct ignition timing, inspect vacuum advancer, assess C.B Point condition/gap and test condenser, test ignition coil performance, and test CDI of distributor.

2. Adjust ignition timing


P2. Inspect/Replace ignition switch, inspect/replace ignition coil, and Repair/replace electrical connectors under specified procedure.


• Describe the Purpose and function of ignition system’s following parts. Spark ignition system contact breaker type, spark ignition system breaker less type. Ignition switch, Ignition coil, resister, plug cable, distributer cap, rotor arm, vacuum advancer,

centrifugal advancer, contact breaker assembly, condenser, high tension leads/connectors, suppression, spark plug(construction, heat range type, size), Magnetic Reflector, hall effect trigger/amplifier, differentiate the performance of contact breaker and contact breaker less type.








S. No. Description

1 Vehicle/ Simulator

2 Digital Multi-meter (DMM).

3 Tools Box

4 Test Lamp

5 Timing Gun

Suspension, Steering & Brakes AD-213

1. Repair Vehicle Brake System

Overview:

These competency standards designed to enable the learner to work on vehicle brake system, and replacing the faulty parts. These competency standards designed to enable the learner to work on vehicle electronic features and troubleshoot on ABS system by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Brake system P1. Inspect the vehicle brake system for the brake fluid level, vacuum booster performance, master cylinder pressure, brake wheel cylinder for oil leakage, disc run out, brake pad/shoe fading/worn, and drum brake performance under the specified procedure.

P2. Service/Replace the Master cylinder, vacuum booster, wheel cylinder, brake disk, brake pad, and brake shoe under the specified procedure.

P3. Perform brake bleeding of the vehicle brake system under the specified procedure.

2. Brake system ABS

P-1. Check vehicle instrument panel and identify ABS mall functioning light.

P-2. Diagnose the vehicle ABS system with the use of scanner for wheel Sensors performance test, ABS Modular/actuator test under the specified procedure.

P-3. Change the wheel sensors, actuator and related fuse under the specified procedure.


• Describe the purpose and function of the following. Disc brakes, drum brakes (reduce vehicle speed, stop vehicle), use of friction and friction

materials, hydraulic system in a vehicle brake system, vehicle mechanical/ hand bake, engine braking in the vehicle.

• Describe the brake main Components as following Master cylinder (single/tandem), wheel cylinder, calipers (single/tandem), pipes/flexible hoses,

brake shoes (leading/ trailing), brake pads, brake discs, brake drum, handbrake operating mechanism, pedal, limiting valves, adjusters, brake fluid, brake warning light, brake light, brake light switch, wear indicator.

• Describe the principles and functions of ABS system in a vehicle as following. ABS system, Traction control system, vehicle stability control system, Wheel sensors, ECU,

ABS modulator assembly, vehicle body (Honda G-CON) (Toyota GOA).


• Capable of servicing brake system

• Capable of performing brake bleeding

• Capable to diagnose and rectify the ABS system.


S. No. Description

1 Vehicle equipped with the ABS


3 Hydraulic jack /safety stand

4 Car lift

5 Automotive scanner

6 Vacuum gun

Consumable Items:

S. No. Description

1 Brake oil

2 Master cylinder kit

3 Wheel cylinder kit

2. Repair Vehicle Steering System

Overview

These competency standards designed to enable the learner to work on vehicle steering system, and replacing the faulty parts. These competency standards designed to enable the learner to work on vehicle power assisted steering system and troubleshoot accordingly by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Steering system P1. Inspect the vehicle steering system for rubber boots on (inner and outer ball joint), Tie road condition, and inner/outer ball joints play, steering rack and pinion box, mounting for the steering box under the specified procedure.

P2. Replace/service the Outer tie road, inner tie road, steering mountings, steering boots (inner and outer ball joint), under the specified procedure.

P3. Service the steering gear (Rack and pinion) box under the specified procedure.

2. Power steering system

P1. Inspect/replace power assisted steering system components for Pump, control valve, complete steering box.

P2. Replace the power steering oil and perform air bleeding from the system under the specified procedure.


• Describe the purpose and function of the following: Steering systems (non-assisted/manual), power assisted system, electronic steering system

with a motor.

• Describe the main components and mechanism of the following: Ackerman principle, true rolling motion, steering ratio, toe in/out, camber, caster, steering axes

inclination, steering wheel/column, rack and pinion, steering gearboxes, steering ball joints, steering arm, front hubs, bearings/seals.


• Capable of servicing steering system

• Capable of performing power steering bleeding

• Capable to diagnose and rectify the steering system problems.


S. No. Description

1 Vehicle equipped with the power steering



4 Car lift


6 Ball joint removal

7 Grease gun

8 Steering fluid pressure tester

9 Oil can

Consumable Items:

S. No. Description

1 Grease

2 Steering oil

3 Seals

4 Kerosene Oil

5 Cotton rag

6 Spray gun

3. Maintain Vehicle Suspension System

Overview

These competency standards designed to enable the learner to work on vehicle electronic features and troubleshoot on ABS system, Electronic power steering, and Automatic gear in the vehicle while using the scanner where needed by Auto Mechanic, in accordance with the manufacturer’s Manual


1. Inspect Suspension system

P1. Inspect the vehicle suspension system and diagnose the rubber bush for damage, Leaking the shock absorber oil, broken coil spring/ leaf spring,

P2. Inspect the vehicle suspension system and diagnose the rubber bush for lower arm ball joints under the specified procedure.

2. Repair Suspension System

P1. Replace the shock absorber, Coil spring, leaf spring, and rubber bushes under the specified procedure.

P2. Inspect the vehicle ride height, trim height, axle displaced under the specified procedure.


• Describe the purpose and function of the following. Independent suspension system, non-independent suspension system, semi-independent

system, sprung weight, un-sprung weight.

• Describe the effect of road surface irregularities on passengers/vehicle/load, maintaining wheel contact with the road, supporting the sprung weight, minimizing un-sprung weight, absorbing torque reaction.

• Describe the Suspension main Components as following Beam axle, live axle, strut/McPherson strut, wishbone, trailing arm/semi trailing arm,

torsion beam, springs (Coil, leaf, torsion, air), antiroll bars, sub-frame assemblies, shackles, hangers, u bolt, damper bushes.


• Capable of servicing suspension system

• Capable to diagnose and rectify the suspension system problems.


S. No. Description

1 Vehicle



4 Car lift



7 Grease gun

8 Oil can

Consumable Items:

S. No. Description

1 Grease

2 Seals

3 Kerosene Oil

4 Cotton rag

5 Spray gun

4. Carry out Wheel Alignment

Overview

These competency standards designed to enable the learner to handle the wheel alignment machine and perform wheel alignment of the vehicle as well as the learner will be able to balance the wheel using the wheel balancing machine by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Pre alignments checks

P1. Check for the vehicle pre alignment for proper Tire pressure/inflation, and axle bushes under specified procedure.

P2. Check for the vehicle pre alignment for loose ball joints, wheel bearings, and tie road ends under specified procedure.

P3. Check for the vehicle pre alignment for faulty spring, tire deformation, and vehicle ride height under specified procedure.

P4. Check for the vehicle pre alignment for loose stabilizer bar under specified procedure.

2. Perform wheel alignment

P1. Drive the vehicle and load/offload it on wheel alignment machine following safety rules as specified in the manual.

P2. Perform wheel alignment using the wheel alignment machine as described procedure in the machine manual and adjust Toe, camber of front and rear wheels under specified procedure.


• Describe the following functions/principles of wheel alignment. Ackerman principle for a true rolling motion, steering pull, steering center point, steering wheel

vibration causes.

• Describe the wheel alignment faults as following. Toe in, toe out, positive camber, negative camber, positive caster, steering axes inclination,

included angle, tire wear, ride height, trim height of vehicle.


• Capable to perform wheel alignment of the vehicle.


S. No. Description

1 Vehicle


3 Hydraulic jack

4 Wheel alignment machine

5 Wheel balancing / tire changing machine

6 Air pressure compressor and gauge

5. Carry Out Wheel Balancing

Overview

These competency standards designed to enable the learner to handle the wheel alignment machine and perform wheel alignment of the vehicle as well as the learner will be able to balance the wheel using the wheel balancing machine by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Use Tire changing machine.

P1. Use the tire changing machine and replace/inflate the tire as described in the machine manual under specified procedure.

P2. Replace the valve of the tire under the specified procedure.

2. Perform wheel balancing

P1. Use the wheel balancing machine and balance the wheel as described in the machine manual under the specified procedure.

P2. Keep the weights firmly with the rim

P3. Perform wheel balancing on allow rim under the specified procedure.


• Describe the wheel balancing machine features as following. Setting procedure, Digital data setting procedure, cycle time, weight installation and removal

procedure, machine calibration.


• Capable to perform wheel balancing

• Capable to perform tire changing.


S. No. Description

1 Vehicle


3 Hydraulic jack




Consumable Items:

S. No. Description

1 Weights

2 Cotton rag

6. Replace SRS System

Overview

These competency standards designed to enable the learner to apply safe working practice and handle the SRS system of the vehicle as well as the learner will be able to use scanner apparatus by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Check the Supplementary Restrain System (SRS)

P1. Check for vehicle SRS sensor under the specified procedure. P2. Check for the vehicle SRS wiring under the specified

procedure.

2. Installation of new Supplementary Restrain System (SRS)

P1. Reinstall the SRS spiral cable under the specified procedure. P2. Start the vehicle and confirm the malfunctioning light is

removed.


• Understand the purpose, construction and working of supplementary restrained systems (SRS) air bag control system. State the purpose of P2-Air Bag Control System.

• Enlist the Components of Air Bag Control system.

• Describe the construction & Working of Air Bag Control System.


• Capable to troubleshoot the SRS System.


S. No. Description

1 Vehicle


3 Hydraulic jack




Workshop Practice-II AD-224

1. Arrange Common Automotive Hand Tools and their Use

Overview:

These competency standards designed to enable the learner to handle appropriate hand tools and the importance of housekeeping in the workplace under the specified procedure of the vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Common Hand Tools P1. Demonstrate use of general hand tools under specified instructions and keep in secure location.

P2. Demonstrate service of general hand tools under specified instructions and keep in secure location.

2. Perform 5s at Workplace

P1. Demonstrate tools 5s (Sort, Set In Order, Shine, Standardize, Sustain)


• Describe the types and use of the following automobile workshop hand tools. Screw driver, Hammers, Pliers, Lock pliers, Spanners, Wrenches, Socket sets, Torque

wrench, Pullers, Oil seal extractor/installer, Tube bender, Tube cutter, Flaring tool, Strap wrench, Automotive stethoscope, Valve spring compressor, piston ring expender, piston ring compressor, grease gun, flexible wire magnet, pop rivet plier, tin snap, hacksaw, punches, chisels, hollow punch set, spark plug spanner, Allen key


• Capable to use and service the hand tools


S. No. Descriptions

1 Screw driver set

2 Hammers

3 Pliers

4 Lock pliers

5 Spanners

6 Wrenches

7 Socket sets

8 Torque wrench

9 Pullers

10 Oil seal extractor/installer

11 Tube bender

12 Tube cutter

13 Flaring tool

14 Strap wrench/oil filter spanner

15 Valve spring compressor

16 piston ring expender

17 grease gun

18 flexible wire magnet

19 pop rivet plier

20 Punches

21 Chisels

22 spark plug spanner

23 Allen key set

24 Files

25 Steel foot rule

26 Vernier calliper

27 Micrometre (inside/Outside)

28 Dial gauge

29 Feeler gauge

30 Thread pitch gauge

2. Carry Out Measurements with Automotive Measuring Tools

Overview

These competency standards designed to enable the learner to handle appropriate measuring tools and the importance of housekeeping in the workplace under the specified procedure.


1. Measuring tools P1. Demonstrate service of measuring tools under specified instructions and keep in secure location.

P2. Demonstrate use of measuring tools under specified instructions and keep in secure location.

2. Perform 5s at workplace

P1. Demonstrate measuring tools 5s (Sort, Set In Order, Shine, Standardize, Sustain)


• Describe the types and use of the following automobile workshop measuring tools. Steel foot rule, Spring scale, Vernier caliper, Micrometer (inside/Outside), Dial gauge, Feeler

gauge, Thread pitch gauge, wire gauge, Belt tension gauge, Telescoping gauge, Tire pressure gauge.


• Capable to measure with the measuring tools


S. No. Descriptions

1 Screw driver set

2 Hammers

3 Pliers

4 Lock pliers

5 Spanners

6 Wrenches

7 Socket sets

8 Torque wrench

9 Pullers

10 Oil seal extractor/installer

11 Tube bender

12 Tube cutter

13 Flaring tool

14 Strap wrench/oil filter spanner

15 Valve spring compressor

16 piston ring expender

17 grease gun

18 flexible wire magnet

19 pop rivet plier

20 Punches

21 Chisels

22 spark plug spanner

23 Allen key set

24 Files

25 Steel foot rule

26 Verniercaliper

27 Micrometer (inside/Outside)

28 Dial gauge

29 Feeler gauge

30 Thread pitch gauge

3. Perform Test on Vehicle with Automotive Workshop Equipment

Overview

These competency standards designed to enable the learner to handle appropriate workshop equipment and the importance of housekeeping in the workplace under the specified procedure.


1. Workshop Equipment

P1. Demonstrate of workshop equipment under specified instructions and keep in secure location.

P2. Demonstrate use of workshop equipment under specified instructions and keep in secure location.

2. Perform 5s at workplace

P1. Demonstrate equipment 5s (Sort, Set In Order, Shine, Standardize, Sustain)


• Describe the types and use of the following automobile workshop equipment. Chain pulley block, Car lift, Crane, Spark plug cleaner machine, Tire changer, Electronic

injector testing machine, Tire inflator, Engine repairing stand/repair trolley, Compressor and pneumatic tools, Ramp and pits, Waste oil receptacle, Hydraulic press, Mechanical arbor press, Drill machine (bench and portable), Grinder (Bench and portable), Hydraulic jack, Mechanical jack, Radiator pressure cap tester, Safety floor stands, Creeper, Valve grinding and re facing machine, cleaning tank, Engine timing gun, Scanner


• Capable to maintain workshop equipment


S. No. Descriptions

1 Plug wire gauge

2 Tire pressure gauge

3 Car lift

4 Tire inflator

5 Engine repairing stand/repair table

6 Waste oil receptacle

7 Hydraulic jack

8 Mechanical jack

9 Radiator pressure cap tester

10 Safety floor stands

11 Creeper

12 Engine timing gun

13 OBD II Scanner


4. Diagnose Faults by Computerized Performance Testing Equipment

Overview

These competency standards designed to enable the learner to handle appropriate automotive testing and diagnosing instruments the importance of housekeeping in the workplace under the specified procedure.


1. Engine Testing Equipment Mechanical

P1. Use of compression tester in the engine to diagnose condition of valve under the specified procedure

P2. Use of compression tester in the engine to diagnose condition of piston rings under the specified procedure.

P3. Use of vacuum tester to identify the intake manifold pressure to diagnose the engine condition.

P4. Use of engine leak tester in the engine to diagnose condition of valve, piston ring, and head gasket under the specified procedure

P5. Clean and service the equipment and place on safe location.

2. Engine testing Equipment Electronic

P1. Use of timing gun in the engine to identify correct engine timing under the specified procedure.

P2. Use of tachometer in the engine to identify correct engine RPM under the specified procedure


• Describe the functions and operating principle of the following equipment: Tachometer, Compression Gauge, Vacuum Gauge, Engine Leakage Tester, Ignition Timing

Gun.


• Capable to use the equipment and explain the operating principles.

Tools and Equipment

S. No. Descriptions

1 Tachometer

2 Compression Gauge

3 Vacuum Gauge

4 Engine Leakage Tester

5 Ignition Timing Gun

5. Categorize Automotive Fasteners Types and their Uses

Overview

These competency standards designed to enable the learner to Categorize Automotive Fasteners Types and their Uses the importance of housekeeping in the workplace under the specified procedure.


1. Fastener Types P1. Inspect and understand the Types of permanents Fasteners.

P2. Inspect and understand the Types of Temporary Fasteners.

2. Fastener Uses P1. Perform application of permanents fasteners

P2. Perform application of Temporary fasteners


• Describe the functions and operating principle of the following Permanents Fastener. Electric arc welding, Gas welding, spot welding, riveting, soldering and Brazing.

• Describe the functions and operating principle of the following Temporary Fastener. Nuts and bolts, screw and studs


• Capable to use the Permanents and explain the operating principles.

• Capable to use the Temporary and explain the operating principles

Tools and Equipment

S. No. Descriptions

1 Permanents Fasteners

2 Temporary Fastener

6. Specify Vehicle’s Lubricants Types

Overview

These competency standards designed to enable the learner to handle lubricants and the importance of housekeeping in the workplace under the specified procedure of the vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Engine Lubricants P1. Identify different viscosity of engine oils and there different climate under the specification of SAE.

P2. Understand the viscosity index and select the appropriate engine oil under the weather condition.

P3. Understand the mineral oil formula oil and synthetic oil under the specification of manufacturer.

2. Vehicle lubricants P1. Identify the different kind of grease with respect to the use in the vehicle system under the specification.

P2. Identify the power steering fluid and understand its properties.

P3. Identify the ATF fluid and understand its properties.

P4. Identify the brake fluid and understand its properties


• Describe the following: Lubricant (oils viscosity, viscosity index, oil classifications, Reduction of frictional forces,

cooling effect, cleaning effect, corrosion resistance, and noise reduction).Multipurpose grease, CV joint grease, brake oil (DOT standard), automatic transmission fluid


• Capable to explain the lubricants use in engine

• Capable to explain the lubricants use in vehicle

Tools and equipment

S. No. Descriptions

1 Complete Tool trolley (Tools kit)

2 Workshop tools equipment

3 Special service tools

4 Measuring tools

7. Differentiate Vehicle Oil Seals Types and Specifications Coding

Overview

These competency standards designed to enable the learner to differentiate oil seals types and specifications and the coding specified procedure of the vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Identify Seals and Gasket

P1. Demonstrates oil seal replacement procedure under the specified procedure.

P2. Identify material and types of gaskets and seals

P3. Identify causes and remedies of seals and gasket failure.

2. Replace main oil seal

P1. Change engine main oil seal under specified procedure.

P2. Change gear main oil seal under specified procedure


• Describe the head gasket types and thickness, main oil seal temperature resistant property.

• Problems in head gasket blown


• Capable of replacing the head gasket

Tools and Equipment

S. No. Descriptions



3 Special service tools

4 Measuring tools

5 Seals and Gas kit

8. Specify Vehicle Bearing’s Types and Coding

Overview

These competency standards designed to enable the learner understand purpose, types, materials and application of bearing on the vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.


1. Bearing P1. Demonstrate bearing replacement procedure under the specified procedure

P2. Identify material, types (Friction & Antifriction), size, and application of Bearings.

P3. Install Antifriction bearings in vehicle with special reference (load and size).

P4. Inspect antifriction Bearing.

2. Diagnose Bearing faults

P1. Change axle bearing under specified procedure.

P2. Change alternator under specified procedure.


• Describe the different types of bearing, application of bearing.

• Describe the Problems in bearing during working.


• Capable of replacing the bearings.

Tools and Equipment

S. No. Descriptions



3 Special service tools (Bearing Puller)

4 Measuring tools

5 Bearing

9. Read and Interpret Quality Control Standards and Certification

Overview

These competency standards designed to enable the learner understand quality control standard and their certification of the vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual..


1. Quality Control Standards

P1. Elaborate the quality control standards

P2. Describe the quality control standard Application

2. Quality Control Certification

P1. Elaborate the quality control certification

P2. Describe the quality control certification Application


• Describes the quality control standard and its importance.

• Describe the quality control certification and its importance.


• Describe the quality control standard Application

• Describe the quality control certification Application

10. Plan and Organize Safe Workshop and Hazard Prevention Practices

Overview

These competency standards designed to enable the learner to follow the safety rules and know the first aid techniques at workplace as well as candidate will be able to response in any emergency situation.


1. Safe Working Practice

P1. Use the appropriate personal protective equipment before starting the job to ensure the implementation of safety and health regulations.

P2. Identify the workshop associated hazards that can cause injury, burn, pinch, short circuit, and damages.

P3. Report to the supervision to analyze potential level of hazards that can cause damage.

P4. Demonstrate first aid procedure in case of minor injury and burn.

2. Fire, Preventions and Emergency.

P1. Extinguish the different kind of fires using the appropriate equipment and procedures.

P2. Identify the expiry date, filing level of fire extinguishers and report to the supervision.

P3. Demonstrate the Emergency situations and perform safe evacuations drill.


• Describe the causes of accidents and preventions as following: Human (Carelessness, lake of training, improper behavior, and over confidence)

Environmental (untidy workplace, bad ventilation, unguarded/faulty machines, noise, and bad lighting).

• Describes the hazards at workplace as following. Vehicle battery handling, Rotating Pulleys and Belts, Jack and safety Stand, Venting the

Engine’s Exhaust

• Describe the flammable materials/liquids and toxic substance, safe disposal of used oil, asbestos, batteries, and recycling AC gas.

• Describes personal hygiene, care of eye, care of lungs, and allergy.

• Describe the fire triangle, types of fire, types of fire extinguishers, emergency situations (Earth quack, fire, terrorism)


• Select and use appropriate PPE’s at workplace.

• Identify workplace hazards and its potential to harm.

• Perform First aid

• Use of fire extinguisher at different type of fire.

• Inspect the fire extinguisher for expiry and pressure.

• Execute emergency evacuation.


S. No. Descriptions

1 Personal protective equipment

2 First aid box

3 Fire extinguisher

4 Emergency alarm

Metrology MT-252

1. Recognize Graduated Instruments

Overview

These competency standards designed to enable the learner identify and uses of graduated instrument as Steel Rule, Hook Rule, Folding Rule, and Measuring Tape.


1. Steel Rule P1. Inspect and measure different kind of measurement (mm and inches) under the specified procedure.

P2. Conversion different kind of measurement under specified procedure

2. Hook Rule P1. Inspect and measure different kind of measurement (mm and inches) under the specified procedure.


3. Folding Rule P1. Inspect and measure different kind of measurement (mm and inches) under the specified procedure.


4. Measuring Tape P1. Inspect and measure different kind of measurement (mm and inches) under the specified procedure.



• Describes the main functions these tools. Steel Rule, Hook Rule, Folding Rule, Measuring Tape

• Describe the taking measuring method of these tools.


• Capable to use steel rule.

• Capable to use Hook rule

• Capable to use Folding rule

• Capable to use Measuring Tape

• Capable to conversion method.


S. No. Descriptions

1 Steel Rule, Hook Rule, Folding Rule, Measuring Tape

2 Object for measurement

2. Carry-Out Linear Measuring

Overview

These competency standards designed to enable the learner identify and uses of graduated instrument as Surface plate, Tool makers surface plate, Glass surface plate, Angle plate, Cast Iron cubes, Vee block, Straight Edge ,Spirit level, Engineer’s level, Engineer’s parallel


1. Surface Plate P1. Perform different kind of measurement with surface plate.

P2. perform different kind of measuring tools adjust with surface plate

2. Toolmakers Surface Plate

P1. Perform different kind of measurement with Toolmaker surface plate.

P2. Perform different kind of measuring tools adjust with Toolmaker surface plate

3. Glass Surface Plate, P1. Perform different kind of measurement with Glass surface plate.

P2. Perform different kind of measuring tools adjust with Glass surface plate

4. Angle Plate P1. Perform different kind of measurement with Angle plate.

P2. Perform/adjust Angle plate with surface plate for measurement.

5. Cast Iron Cubes P1. Perform different kind of use OF cast iron Cubes.

P2. Perform/adjust Cast Iron cubes other measurement tools.

6. VeeBlock P1. Perform/uses of VeeBlocks.

P2. Perform/adjust Vee Block with U-Clamp and work piece with operation.

7. Straight Edge P1. Perform measurement different kind of Steel straight edge.

P2. Perform/ adjust straight edge with surface plate and sprit level..

8. Spirit Level P1. Perform / measure Horizontal surface with spirit level.

P2. Perform / measure Angle or inclination surface with spirit level.

P3. Perform / measure Vertical surface with spirit level.

9. Engineer’s level P1. Perform measurement with Engineer level.

10. Engineer's parallel P1. Perform measurement with engineer parallel.


• Describe Linear Measurement instruments functions as following: o Surface plate 2-Tool makers surface plate 3-Glass surface plate 4-Angle plate

o Cast Iron cubes 6-Vee block 7-Straight Edge 8-Spirit level 9-Enginer's level 10-Engineer's parallel


• Capable to use Surface plate

• Capable to use Tool makers surface plate

• Capable to use Glass surface plate

• Capable to use Angle plate

• Capable to use of Cast Iron cubes

• Capable to use Vee block

• Capable to use Straight Edge

• Capable to use Spirit level

• Capable to use Engineer’s level

• Capable to use Engineer's parallel


S. No. Description

1 Surface plate

2 Tool makers surface plate

3 Glass surface plate

4 Angle plate

5 Cast Iron cubes

6 Vee block

7 Straight Edge

8 Spirit level

9 Engineer’s level

10 Engineer's parallel

3. Carry-out Precise Measuring

Overview

These competency standards designed to enable the learner identify and uses of Precise Measuring instruments. Micrometer, outside micrometer, inside micrometer, Depth Micrometer, Plug Micrometer, Vernier Micrometer. Vernier caliper, Vernier Height gauge, Vernier depth gauge,Dial Vernier caliper.


1. Micrometer P1. Inspect and measure different kind of measurement with Outside micrometer (mm and inches) under the specified procedure.

P2. Inspect and measure different kind of measurement with Inside micrometer (mm and inches) under the specified procedure.

P3. Inspect and measure different kind of measurement with Depth Micrometer (mm and inches) under the specified procedure.

P4. Inspect and measure different kind of measurement with Plug Micrometer (mm and inches) under the specified procedure.

P5. Inspect and measure different kind of measurement with Vernier Micrometer (mm and inches) under the specified procedure.


2. Vernier caliper P1. Inspect and measure different kind of measurement with Vernier caliper (mm and inches) under the specified procedure.

P2. Inspect and measure different kind of measurement with Vernier Height gauge (mm and inches) under the specified procedure.

P3. Inspect and measure different kind of measurement with Vernier depth gauge (mm and inches) under the specified procedure.

P4. Inspect and measure different kind of measurement with Dial Vernier caliper (mm and inches) under the specified procedure.



• Describe the different kind of measuring tools and its uses. Micrometer, Outside micrometer, Inside micrometer, Depth Micrometer, Plug Micrometer, Vernier Micrometer. Vernier caliper, Vernier Height gauge, Vernier depth gauge, Dial Vernier caliper.

Critical Evidence(s) required

• Capable to use Micrometer

• Capable to use Outside micrometer

• Capable to use Inside micrometer

• Capable to use Depth Micrometer

• Capable to use of Plug Micrometer

• Capable to use Vernier Micrometer.

• Capable to use Vernier caliper

• Capable to use Vernier Height gauge

• Capable to use Vernier depth gauge

• Capable to use Dial Vernier caliper


S. No. Descriptions

1 Micrometer, Outside micrometer,Inside micrometer,Depth Micrometer,Plug Micrometer, Vernier Micrometer.

2 Vernier caliper,Vernier Height gauge,Vernier depth gauge,Dial Vernier caliper.

4. Perform Angular Measuring

Overview:

These competency standards designed to enable the learner Angular Measuring Instrument as Bevel protector, Bevel protector Vernier, and Single bar


1. Bevel protector P1. Inspect and measure different kind of measurement with Bevel protector (Degree, Minute and second) under the specified procedure.

P2. Perform Adjustment of Bevel Protector

2. Bevel Protector Vernier

P1. Inspect and measure different kind of measurement with Bevel Vernier protector under the specified procedure.

P2. Perform Adjustment of Bevel Protector

3. Side bar

P1. Inspect and measure Known angle with the help of sine bar under the specified procedure.

P2. Measures the object with the help of formula of sine bar.

P3. Inspect and measure Unknown angle with the help of sine bar under the specified procedure.

P4. Measures the object with the help of formula of sine bar.

P5. Inspect and measure Unknown angle of Heavy workpiece with the help of sine bar under the specified procedure.


• Describes the different kind of measuring tools and its uses. Bevel protector, Bevel protector Vernier and Sine bar

• Describe the operational principles of Bevel protector, Bevel protector Vernier and Sine bar

• Understand different kind of formulas use in sine bar measurement


• Capable to measurement with Bevel protector.

• Capable to measurement with Bevel protector Vernier.

• Capable to measurement with Sine bar.

• Capable/ Understand different kind of formulas use in sine bar measurement.


S. No. Descriptions

1 Bevel protector

2 Bevel protector Vernier

3 Side bar

4 Given Object

5. Identify the Types of Gauges

Overview

These competency standards designed to enable the learner Fixed gauges, Adjustable gauges, Indicating gauges, thread gauges


1. Fixed Gauges Inspect and use following gauge under the specified procedure:

P1. Fixed Master gauge under the specified procedure.

P2. Fixed Limit gauge under the specified procedure.

P3. Fixed Plug gauge under the specified procedure.

P4. Fixed Ring gauge under the specified procedure.

P5. Fixed snap gauge under the specified procedure.

P6. Feeler gauge under the specified procedure.

P7. Sheet metal and wire gauge under the specified procedure.

2. Adjustable Gauges Inspect and use following gauge under the specified procedure:

P1. Surface gauge under the specified procedure.

P2. Depth gauge under the specified procedure.

P3. Height gauge under the specified procedure.

P4. Dial gauge under the specified procedure.

P5. Snap gauge under the specified procedure.

3. Indicating Gauges P1. Inspect run-out gauge under the specified procedure.

P2. Inspect back lash gauge under the specified procedure.

P3. Inspect end play under the specified procedure.

P4. Inspect cylinder bore under the specified procedure.

4. Thread Gauges P1. Inspect and use of thread gauge measure different kind of thread under the specified procedure.

5. Ziess Micrometer P1. Inspect and use of ziess micrometer under the specified procedure.


• Describes the different kind of Gauges and its uses.

• Fixed gauges, Adjustable gauges, Indicating gauges, thread gauges


• Capable to use of Fixed gauges.

• Capable to use of Adjustable gauges.

• Capable to use of Indicating gauges.

• Capable to use of thread gauges.


S. No. Descriptions

1 Fixed gauges

2 Adjustable gauges

3 Indicating gauges

4 Thread gauges

6. Identify Comparators Instrument

Overview

These competency standards designed to enable the learner identify and uses of graduated instrument as Electrical/Electronic comparators, Pneumatic comparators, Optical/Projection comparators, Mechanical comparators, Automatic gauging comparators, Gauge block comparators, Microscope (Tool Maker microscope)


1. Electrical/Electronic comparators

P1. Understand the parts and principle of Electrical/Electronic comparators

P2. Inspect and measurement with Electrical/Electronic comparators under the specified procedure.

P3. Performs the use of AC wheat stone bridge circuit incorporating a galvanometer.

2. Pneumatic comparators

P1. Understand the parts and principle Pneumatic comparators comparators

P2. Inspect and measurement with Pneumatic comparators under the specified procedure.

3. Optical/Projection comparators

P1. Inspect and measurement with Optical/Projection comparators under the specified procedure.

P2. Adjust Optical/Projection comparators according to job condition under the specified procedure.

4. Mechanical comparators

P1. Inspect and measurement with rack and pinion comparators under the specified procedure.

P2. Inspect and measurement with Cam and gear train comparators under the specified procedure.

P3. Inspect and measurement with lever and tooth sector comparators under the specified procedure.

P4. Inspect and measurement with compound comparators under the specified procedure.

P5. Inspect and measurement with Twisted taut strip comparators under the specified procedure.

5. Automatic gauging comparators

P1. Understand the parts and principle Automatic gauging comparators

P2. Inspect and measurement with Automatic gauging comparators under the specified procedure.

6. Gauge block comparators

P1. Inspect and measurement with Gauge block comparators under the specified procedure.


7. Microscope (Tool Maker microscope)

P2. Understand the parts and principle Microscope (Tool Maker microscope).

P3. Inspect and measurement with Microscope (Tool Maker microscope).


• Describes the different kind of measuring tools and its uses. 1-Electrical/Electronic comparators2- Pneumatic comparators 3-Optical/Projection comparators4-Mechanical comparators5-Automatic gauging comparators6-Gauge block comparator7-Microscope (Tool Maker microscope)

• Describe the different type attachment with above comparators.


• Capable identify/ Measurement with the Electrical/Electronic comparators .

• Capable identify/Measurement with the Pneumatic comparators

• Capable identify/Measurement with the Optical/Projection comparators

• Capable identify/Measurement with the Mechanical comparators

• Capable identify/Measurement with the Automatic gauging comparators

• Capable identify/Measurement with the Gauge block comparator

• Capable identify/Measurement with the Microscope (Tool Maker microscope)


S. No. Descriptions

1 Electrical/Electronic comparators

2 Pneumatic comparators

3 Optical/ Projection comparators

4 Mechanical comparators

5 Automatic gauging comparators Gauge block comparator

6 Microscope (Tool Maker microscope)

Applied Thermodynamics AD-232

1. Analyses HVAC/R Systems Thermodynamic Performance

Overview

This Competency Standard covers the analysis of heating, ventilating, air conditioning and refrigeration (HVAC/R) systems to provide solution to thermodynamic performance issues. It encompasses working safely, apply extensive knowledge of thermodynamic parameters, gathering and analyzing data, applying problem solving techniques, developing and documenting results and solutions for use in design work to provide you the basis for your work.


1. Prepare to analyze the thermodynamic performance of HVAC/R systems

P1. Observe safe work practices and personal protective OHS processes and procedures for a given work area are identified, obtained and understood.

P2. Establish OHS risk control measures and procedures are followed in preparation for the work.

P3. Determine extent of the thermodynamic issues from performance specifications, situation reports and in consultations with relevant persons

P4. Plan activities to meet scheduled timelines in consultation with others involved in the work

P5. Form effective strategies to ensure solution development and implementation to carry out efficiently.

2. Analyze the thermodynamic performance of HVAC/R systems

P1. Apply thermodynamic principles to analytical solutions on refrigeration and air conditioning systems.

P2. Obtain Parameters, specifications and performance requirements in relation to refrigeration and air conditioning systems in accordance with established procedures.

P3. Carry out approaches to analyzing thermodynamic parameters to provide the most effective solution.

P4. Deal unplanned events with safely and effectively, consistent with regulatory requirements and enterprise policy.

P5. Monitor quality of work against personal performance agreement and/or establish organizational & professional standards

3. Report and action on the results of thermodynamic performance analysis

P1. Evaluate to determine their effectiveness of solutions for thermodynamic issues and modify where necessary. P2: Report the analysis including details of all findings, calculations and assumptions.

P2. Report analysis to appropriately personnel to establish appropriate action to be taken based on findings.

P3. Take actions regarding equipment, documented for inclusion in work/project or development records in accordance with professional standards and manufacturers specifications.


This describes the essential skills and knowledge and their level, required for this unit. Evidence shall show that knowledge has been acquired of safe working practices and analyzing the thermodynamic performance of HVAC/R systems.

• Understanding the thermodynamic performance issues

• Forming effective strategies for analyzing refrigeration and air conditioning systems performance

• Obtaining thermodynamic performance parameters, specifications and performance requirements appropriate to each situation.

• Evaluating the results of the analysis

• Documenting analysis details of all findings, calculations and assumptions.

2. Carry-out Smooth Boiler Operation

Overview

This Competency Standard covers the competencies required to enable the student to prepare boiler for smooth operation. This unit covers the knowledge low pressure boiler, application of boiler in HVAC technology, its controls, chemical treatment of boiler/ water and feed water tanks to provide you the basis for your work.


1. Prepare the Boiler for Operation

P1. Review operational order and where required check with appropriate personal

P2. Identify and report health and safety hazards / maintenance requirements to appropriate personnel according to workplace reporting procedures

P3. Identify and set quantity of steam to be generated for allocated Process

P4. Purge the boiler according to workplace procedure

P5. Perform pre-operational checks to confirm operational status of boiler and related equipment

2. Operate and Monitor Boiler

P1. Use equipment in line with organizational safety procedures, manufacturer’s instructions and environmental protection practices.

P2. Apply complete pre-operational safety and pre start-up checks to ensure operational effectiveness.

P3. Start boiler and bring safely on line; communicate recent performance to appropriate personnel.

P4. Monitor boiler operation, diagnose status and adjust to maintain safe and efficient operation.

3. Shut down and Store Boiler

P1. Shut down boiler according to workplace procedures and manufacturer's recommendations

P2. Clean boiler internally and externally according to workplace procedures and manufacturer's recommendations

P3. Remove valves and fittings in preparation for maintenance

P4. Store the boiler in the appropriate storage mode according to workplace procedures and manufacturer's recommendations

P5. Store and record boiler house chemicals, in line with safety procedures and environmental protection practices.

P6. Follow emergency shutdown procedures in cases of fire.

P7. Complete operating log, record fuel efficiency and report to appropriate personnel.

4. Analyze and Respond to Abnormal Performance (Trouble Shooting

P1. Analyze operating data and plant operating conditions to identify causes of abnormal performance

P2. Take action correctively in accordance with workplace procedures in response to Hazards, out-of-specification test results and/or plant performance


of Boiler) P3. Implement emergency procedures as required according to workplace procedures and manufacturer's recommendations



• Safe work procedures including awareness of health and safety hazards related to boiler operation and associated control measures. Hazards typically include working around hot surfaces, manual handling, fuel and steam leaks

• Purpose and limitations of protective clothing and equipment

• Hierarchy of hazard control measures

• Duty of care of the boiler operator

• Purpose and basic principles of combustion and boiler operation. This includes principles of heat transfer and properties of steam

• Boiler system layout and steam cycle

• The purpose of purging a boiler

• The effect of fuel quality on boiler operation

• Impact of ash removal on efficient boiler operation and impact of sluice water flow

• Relationship to other processes. This includes an understanding of the impact of sudden load changes on boiler pressure and plant operation

• Purpose and limitations of protective clothing and equipment

• Methods used to render equipment safe to inspect, maintain and/or clean including lock-out, tag-out and isolation procedures

3. Recognize Fundamentals of Thermodynamics Problems

Overview:

The user/ individual on the job needs to know and understand how to Solve problems of fundamentals of thermodynamics ,heat, mass & weight, force, work done and power. Develop skill, mathematical attitudes and logical perception in the use of mathematical instruments as required in the automobile fields.


1. Perform the conversation of Temperature scales

P1. Measuring the temperature and convert to K to C.

P2. Solve the problem with the help formula.

P3. Measuring the temperature with appropriate tool.

2. Measuring the vacuum and pressure gauge

P1. Measure the vacuum use with vacuum gauge on engine.

P2. Measure the pressure use with the pressure gauge in different scales.

P3. Perform the conversation of vacuum and pressure in different scales.

P4. Solve the problems of mathematical attitudes and logical perception in the use of mathematical instruments

3. Understand and Solve the problems of Different Energies

P1. Solve the problems of following energies: a. Potential Energy b. Kinetic Energy c. Thermal Energy d. Chemical Energy

P2. Drive the law of a. Laws of thermodynamics

b. Law of conservation of energy

4. Derive the mathematical relations

P1. Drive the following laws: a. Boyles Law b. Charles Law c. Joules Law

P2. Solve the mathematical problems applying the laws



• Safe work.

4. Read and Interpret Perfect Gases Laws, Properties and Solve problems

Overview:

The user/ individual on the job needs to know and understand how to the knowledge of fundamentals of thermodynamics, laws and properties of gases, thermodynamic processes and cycles, steam and Gas turbines , I.C. Engines.

Competency Units Knowledge Criteria

1. Applying Gas Laws in problems

P1. Derive the following mathematical relations: a. General gas equation b. Characteristic Gas equation c. Universal Gas equation

P2. Understand the specific heats of a gas and derive its mathematical relations.

2. Derive the mathematical equation

P-1. Derive the mathematical equation of Enthalpy of a Gas.

Understanding and Knowledge:

• Perfect gas and its properties.

• Derive the mathematical relations. a. Boyle’s law. b. Charles’s law c. Joule’s law

• The mathematical relations.. a. General gas equation b. Characteristic Gas equation c. Universal Gas equation

• Describe the following. a. The two specific heats of a gas and derive its mathematical relations.

• State the following. a. Enthalpy of a Gas

5. Read and Derived Thermodynamics Processes and Cycles

Overview:

The user/ individual on the job needs to know and understand how to prepare the properties of steam, steam boilers and their performance , steam and Gas turbines , I.C. Engines, Air compressors and their problems.


1. Draw the different Cycles

P1. Explain CARNOT CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation.

P2. OTTO CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation

P3. DIESEL CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation.

P4. Joule’s Cycle with the help of P-V diagram, also derive its mathematical relations for air standard efficiency during cycle of operation.

P5. DUAL COMBUSTION CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation.

2. Evaluate the performance of steam boilers

P1. Working and general construction of a boiler, Classification of boilers, Selection factors of a good steam boiler, Important terms used for steam boilers.

P2. The construction and working of Simple Vertical Boiler with the help of neat sketch.

P3. The construction and working of COCHRAN Boiler (Multi tubular boiler) with the help of neat sketch.

P4. The construction and working of Babcock and Wilcox Boiler with the help of neat sketch..

3. Derived and solved the mathematically problems of I.C engines

P1. Solve and Derived following a. Torque, and it’s unit in SI system. b. Mean effective pressure. c. Indicated power and its formula.. d. Brake Horse power and its formula. e. Measurement of Brake Horse power

P2. Solve and Derived following a. Friction Horse power. b. Mechanical efficiency. c. Thermal efficiency.

Understanding and Knowledge:

• Explain CARNOT CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation.

• Explain OTTO CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation.

• Explain DIESEL CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation..

• Explain DUAL COMBUSTION CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation.

• Solve the mathematical expressions of following: i. Performance of boiler ii. Equivalent evaporation of boiler iii. Efficiency of boiler

• Derived formula of Comparison between Water tube and Fire tube boilers.

6. Analyze Reciprocating & Rotary Air Compressors Performance

Overview:

This Competency standard identifies the competencies to transfer the knowledge of fundamentals of Air compressors its types and their performance.


1. Inspect/Understand component of air compressor and their types

P1. Describe the introduction of Air Compressors, types of Air Compressors(Reciprocating & Rotary) a. And terms used for Air Compressors

P2. Describe the construction and working of single stage reciprocating air compressor with the help of PV diagram and sketch.

2. Derived the work done as per cycle.

P1. Derived and draw Describe the work done per cycle by a single stage reciprocating Air Compressor without and with clearance volume, considering the following laws of compression. a. Isothermal Compression. b. Isentropic compression. c. Polytrophic compression

P2. Solve the multistage compression and understand its advantages.

3. Derive mathematical expression two stage reciprocating air problems.

P1. Derive its mathematical Expression for the work done per cycle considering polytrophic law of compression

P2. Drive a single stage and two stages reciprocating Air compressors; also derive its formulae.

Knowledge & Understanding:

• Describe the work done per cycle by a single stage reciprocate Compressor without and with clearance volume, considering the following laws of compression. a. Isothermal Compression. b. Isentropic compression. c. Polytrophic compression.

• Describe the multistage compression and its advantages.

• Describe the two stage reciprocating air compressor with intercooler; also derive its mathematical Expression for the work done per cycle considering polytrophic law of compression.

7. Solves Problems of Internal Combustion Engine

Overview:

This Competency standard identifies the competencies required to develop and transfer the knowledge of fundamentals, types of, IC. engines and their performance.


1. Understand and solve the IC. engine

P1. Perform the following. a. Torque, and it’s unit in SI system. b. Mean effective pressure. c. Indicated power and its formula.. d. Brake Horse power and its formula

2. Calculate the different powers/ Efficiency IC. Engine

P1. Perform the following. a. Measurement of Brake Horse power. b. Friction Horse power. c. Mechanical efficiency. d. Thermal efficiency e. Volumetric efficiency

Understand and Knowledge:

• Explain Torque, and it’s unit in SI system.

• Explain Mean effective pressure.

• Explain Indicated power and its formula.

• Explain Brake Horse power and its formula.

• Explain Measurement of Brake Horse power.

• Explain Friction Horse power.

• Explain Mechanical efficiency.

• Explain Thermal efficiency.

Motor Vehicle Driving AD-302

1. Inspect Vehicle Controls for pre Operational & Pre Starting

Overview

These competency standards designed to enable the learner to check performance of vehicle different controls and perform pre operational and pre starting inspection.


1. Practice to use of Different Vehicle Controls

P1. Check the performance & Working of following controls. Dashboard instruments cluster lights and dials controls o Speedometer o Tachometer o Fuel gauge o Temperature gauge o Warning lights for fuel, oil, engine, water

P2. Steering Wheel control o Steering wheel o Windscreen wipers o Indicators o Headlights on full beam and dip o Horn

P3. Floor controls: o Accelerator pedal o Brake pedal o Clutch pedal (for manual cars) o Gear lever o Handbrake or park brake

2. Carry out Pre operational Inspection on Vehicle.

P1. Inspect the following o Vehicle tire pressure. o Fuel level. o Oil pressure. o Coolant level. o Battery Electrolyte level. o Brake Fluid level. o Head Lights, Turn Signal Lights, brake light and Horn working. o Brake Paddle Play, Accelerator Paddle Play, Clutch Paddle

Play. o Hand brake operation. o Steering operation.

P2. Check the working of different interiors and exteriors of a car.

3. Perform Basic Pre Starting inspection on Engine

P1. Perform following operations

• Set the position of choke on.

• Ignition Switch different Positions (Off, Acc, On, ST).

• Release of Ignition switch key just after the engine start.

• Engine Warm up Period.

• Glow of Oil pressure light, Battery charging light and Vehicle


Malfunction Indication Light just after Starting the engine.

• Abnormal engine noises.

• Engine Stopping.


• Describes the performance & Working of following controls. Dashboard instruments cluster lights and dials controls o Speedometer o Tachometer o Fuel gauge o Temperature gauge o Warning lights for fuel, oil, engine, water

• Explain Steering Wheel control o Steering wheel o Windscreen wipers o Indicators o Headlights on full beam and dip o Horn

• Explain Floor controls o Accelerator pedal o Brake pedal o Clutch pedal (for manual cars) o Gear lever o Handbrake or park brake.

• Explain the following o Vehicle tire pressure. o Fuel level. o Oil pressure. o Coolant level. o Battery Electrolyte level. o Brake Fluid level. o Head Lights, Turn Signal Lights, brake light and Horn working. o Brake Paddle Play, Accelerator Paddle Play, Clutch Paddle Play. o Hand brake operation. o Steering operation.

• Explain following operations o Set the position of choke on. o Ignition Switch different Positions (Off, Acc, On, ST). o Release of Ignition switch key just after the engine start. o Engine Warm up Period. o Glow of Oil pressure light, Battery charging light and Vehicle Malfunction Indication Light just

after Starting the engine. o Abnormal engine noises. o Engine Stopping.


• Capable to Practice to use of Different Vehicle Controls

• Capable to Carry out Pre operational Inspection on Vehicle.

• Capable to Perform Basic Pre Starting inspection on Engine


S. No. Descriptions

1 Vehicle Equipped with manual transmission

2. Read and Interpret Traffic Signals, Road Signs and Marking Lanes on Roads

Overview

These competency standards designed to enable the learner to Identify Traffic Signals, Road signs, marking Lanes on Roads.


1. Identify and follow Traffic signals.

P1. Follow the following traffic signals, o Red signals. o Yellow signals. o Green signals. o Traffic signal blackout.

2. Identify and follow different Road signs.

P1. Follow the following road signs. o Regulatory signs o Guidance signs o Warning signs o Information signs o Octagonal stop sign o Triangular yield sign o Diamond-shaped pedestrian priority sign

3. Identify and follow Marking lanes on roads.

P1. Follow the following marking lanes on roads

o Regulatory markings o Warning markings o Guidance markings


• Describe the following traffic signals, o Red signals. o Yellow signals. o Green signals. o Traffic signal blackout.

• Describe the following road signs. o Regulatory signs o Guidance signs o Warning signs

• Explain the following marking lanes on roads

o Regulatory markings o Warning markings o Guidance markings


• Capable to Identify and follow Traffic signals

• Capable to Identify and follow different Road signs.

• Capable to Identify and follow marking lanes on roads.


S. No. Descriptions

1 Vehicle

2 Driving charts

3. Apply Power& Parking Brakes to Vehicle

Overview

These competency standards designed to enable the learner to use of brake & parking brake of vehicle and park the vehicle in proper place Under the specified procedure.


1. Perform brake operation on road.

P1. Brake controls on vehicle

P2. Start driving and apply brake in different condition and situation

P3. Check and observe breaking distance

2. Properly park the car at proper place.

P1. Drive car and take to proper parking place

P2. Observe road signs and road lanes and marking on roads

P3. Park the vehicle at proper place

P4. Apply parking brake


This competency standard will provide knowledge related to:

• Purpose of Brake and parking brake.

• Factors effecting Vehicle Stopping.

• Types of road surfaces and their effects on braking.

• Vehicle Skidding.

• Road Resistance / Road Grip.

• Over Speeding and its Disadvantages.

• Vehicle tires wear & tear and its limits.

• Car Speed / Vehicle inertia to Braking



• Capable to apply braking in different situations

• Capable to drive a car in accordance to breaking distance.

• Capable to park vehicle in proper place and observe rules while parking.


S. No. Descriptions

1 Vehicle

4. Drive Car in Different Condition

Overview

These competency standards designed to enable the learner to work on vehicle final drive and repair or replace the faulty components as directed in the manual.


1. Drive Car on Straight Road

P1. Driving on straight Road

• Proper use of indicators

• Proper use Road lanes.

• Proper use of horn

• Understanding road signs

• Proper use of brake.

2. Driving In Hilly Area

P1. Driving in Hilly area

• Proper use of Clutch

• Proper gear shifting

• Understanding Warning Signs.

• Observing Speed limits.

3. Vehicle Overtaking

P1. Vehicle Overtaking

• Proper use indicators

• Proper use of Road lanes.

• Check oncoming lanes

• Check mirrors

• Go back to own lane after overtaking by using indicators.


• Describe the Driving on straight Road o Proper use of indicators o Proper use Road lanes. o Proper use of horn o Understanding road signs o Proper use of brake.

• Describe the Driving in Hilly area o Proper use of brake o Proper use of Clutch o Proper gear shifting o Understanding Warning Signs. o Observing Speed limits.

• Describe Vehicle Overtaking o Proper use indicators o Proper use of Road lanes.

o Check oncoming lanes o Check mirrors o Go back to own lane after overtaking by using indicators.


• Capable to Drive Car on Straight Road

• Capable to Driving In Hilly Area

• Capable to Vehicle Overtaking


S. No. Descriptions

1 Vehicle

5. Drive Vehicle with Manual& Automatic Transmission

Overview

These competency standards designed to enable the learner to driving of manual, automatic vehicle & motorcycle


1. Drive Car With Manual Transmission

P1. Drive Car With Manual Transmission and follow the following

• Adjust mirrors

• Adjust seats

• Adjust Steering

• Know the Different pedals & their uses.

• Proper using of Clutch.

• Use proper gear Shifting & Gear position.

• Proper use of indicator.

• Know the Different pedals & their uses.

• Parking in proper place.

2. Drive Car With Manual Transmission

P1. Drive Car With Manual Transmission and follow the following

• Adjust mirrors

• Adjust seats

• Adjust Steering

• Know the use of Brake & Accelerator.

• Shifting of gear lever in proper position



3. Drive Four Stroke Motorcycle

P1. Drive Four Stroke Motorcycle and follow the following

• Adjust back view mirror

• Start motorcycle in proper sequence.

• Proper use of front wheel brake

• Proper use of rear wheel brake

• Proper use of clutch

• Proper use of indicator while turning


• Park in proper place

• Wear helmet before driving motorcycle


Describes the following

• Adjustment of mirrors

• Adjustment of seats

• Adjustment of Steering

• Different pedals & their uses.


• Gear Shifting & Gear position.



Explain the following


• Starting of motorcycle in proper sequence.




• proper use of indicator while turning




• Capable to drive car with manual transmission

• Capable to drive car with manual transmission

• Capable to drive four stroke motorcycle


S. No. Descriptions

1 Vehicle Equipped with manual transmission

2 Vehicle Equipped with Automatic transmission

3 Motorcycle 125cc

6. Drive Motorcycle

Overview

These competency standards designed to enable the learner to driving of manual, automatic vehicle & motorcycle


1. Drive Four Stroke Motorcycle

P1. Drive Four Stroke Motorcycle and follow the following


• Start motorcycle in proper sequence.




• Proper use of indicator while turning



2. Safe driving techniques

P1. Drive Motorcycle and monitor the following:

• Wear helmet before driving motorcycle

• Understand motor vehicle act , traffic regulations

• Safe Overtaking

• Safe driving in different situations

• Parking at side stand

• Parking at double stand


• Describes the following

• Adjustment of back view mirrors

• Different grips, pedals & their uses.


• Gear Shifting & Gear position.


• Explain the following

• Starting of motorcycle in proper sequence.




• proper use of indicator while turning


• Park at single & double stand


• Capable to drive four stroke motorcycle


S. No. Descriptions

1 Motorcycle 125cc

7. Drive Vehicle on Economy Speed for Fuel Saving

Overview

These competency standards designed to enable the learner to drive the vehicle on economy speed for fuel saving


1. Perform pre starting


• Set the position of choke on.

• Ignition Switch different Positions (Off, Acc, On, ST).

• Release of Ignition switch key just after the engine start.

• Engine Warm up Period.

• Glow of Oil pressure light, Battery charging light and Vehicle Malfunction Indication Light just after Starting the engine

• Warm up the engine to normal temperature.

2. Drive the vehicle at economic speed for fuel saving


• Avoid Aggressive Driving

• Drive Steadily at Posted Speed Limits

• Avoid over Speeding

• Avoid Idling Your Vehicle in Both Summer and Winter

• Make Sure Your Tires Are Proper

• Select the Right Gear

• Use Your Air Conditioner Sparingly on Older Cars

• Use the Cruise Control

• Choose the Octane Fuel Which Best Suits Your Car

• Avoid Putting Your Car in Neutral When Idling


• Describe the Aggressive Driving.

• Describe the steadily driving at Posted Speed Limits

• Explain the over Speeding

• Explain proper gear shifting


• Capable to Drive the vehicle at economic speed for fuel saving

• Capable to Drive Steadily at Posted Speed Limits

• Capable to use proper gear shifting


S. No. Descriptions

1 Vehicle

8. Perform Safety Practices While Driving

Overview

These competency standards designed to enable the learner driving safety and first aid procedures.


1. First aid given according to accepted medical regulations in case of road Accident to Treat minor injuries

P1. First aid cut injury

P2. First aid eye injury

P3. First aid burn injury

P4. Provide artificial respiration

2. Perform rescue drill and training exercise in case of accidents to treat life saving

P1. Provide artificial respiration.

P2. Support head & neck to avoid them twisting

P3. Do not cover her eyes.

P4. Keep talking to them.

P5. Keep checking that they are still breathing.

P6. Keep the patient away from vehicle.

P7. Call the Ambulance



• Explain First Aid (according to accepted medical regulations in case of road Accident to Treat minor injuries)

• Describe rescue drill and training exercise in case of accidents to treat life saving



• Capable to give first aid according to accepted medical regulations in case of road accident to treat minor injuries

• Capable to Perform rescue drill and training exercise in case of accidents to treat life saving


S. No. Descriptions

1 First Aid Box

Motor Vehicle Inspection AD-312

1. Inspect Tires& Wheels of Light & Heavy Duty Transport Vehicles (LTV& HTV)

Overview

These competency standards designed to enable the learner to inspect tires & wheels of HTV and LTV vehicles According to specifications under the specified procedure.


1. Check the condition & quality of Light vehicle (LTV) tires and wheels.

P1. Check And Inspect the following in tire,

• Tire inflation

• Tire tread

• Side wall

• Pledge on tire

• Tire type

• Retreading

• Broken fabrics

• Broken wires

P2. Check And Inspect the following in wheels,

• Welded wheel

• Broken wheel

• Broken stud and nut.

• Missing nut

• Damage wheel

• Oval hole in Wheel

2. Check the condition & quality of Heavy vehicle (HTV) tires and wheels

P1. Check And Inspect the following in heavy tire,

• Tire inflation

• Tire tread

• Side wall

• Pledge on tire

• Tire type

• Retreading

• Broken fabrics

• Broken wires

• Re-grooved

• Restriction mark on tire

• Same size of all tires

P2. Check And Inspect the following in wheels,

• Welded wheel

• Broken wheel


• Missing nut

• Damage wheel


• Check stem


• Check cap


• Describes the following in Heavy and Light vehicle tire,

• Tire inflation

• Tire tread

• Side wall

• Pledge on tire

• Tire type

• Retreading

• Broken fabrics

• Broken wires

• Explain the following in Heavy and Light vehicle wheels,

• Welded wheel

• Broken wheel


• Missing nut

• Damage wheel



• Capable to check the condition & quality of Light vehicle (LTV) tires and wheels.

• Capable to check the condition & quality of Heavy vehicle (HTV) tires and wheels.


S. No. Descriptions

1 Light vehicles tires

2 Light vehicles wheel/rim

3 Heavy vehicle tires

4 Heavy vehicle wheel/rim

5 Tool kit complete

2. Inspect Vehicle Suspension System

Overview

These competency standards designed to enable the learner to Inspect vehicle suspension system According to specification. Under the specified procedure.


1. Check performance of spring, shock-absorber and tracking

P1. Coil spring inspection

• Breakage

• Height

P2. Leaf spring inspection

• Center bolt

• U bolt

• Leaves

• Bushes

P3. Shock absorber inspection o Leakage o Bushes o Attachments o Tracking inspection o By tracking gauge. o By wet road test.

2. Check performance of the electronic control suspension system.

P1. Check & verify the following,

• Height sensor • Actuator • Shock Absorber • Compressor • Switch

• Fuses

• Wring & relays


• Describe the inspection of following o Shock absorber inspection o Shock absorber inspection

• Describe the following in electronic suspension system o Height sensor o Actuator o Shock Absorber o Compressor o Switch o Fuses o Wring & relays


• Capable to Identify Faults of spring, shock-absorber and tracking and rectify it

• Capable to check performance of the electronic control suspension system

• Capable to Identify Faults of electronic control system and rectify it.


S. No. Descriptions

1 Vehicle equipped with electronic suspension system

2 Vehicle equipped with Manual suspension system

3 Tool kit complete

3. Inspect Vehicle Steering System and Wheel Alignment

Overview

These competency standards designed to enable the learner to inspect vehicle steering system and wheel alignment under the specified procedure.


1. Inspect and check the performance of steering system and wheel alignment

P1. Inspect the vehicle steering system for rubber boots on (inner and outer ball joint), Tie road condition, and inner/outer ball joints play, steering rack and pinion box, Mounting for the steering box under the specified procedure.

P2. Replace/service the Outer tie road, inner tie road, steering mountings, steering boots (inner and outer ball joint), under the specified procedure.

P3. Service the steering gear (Rack and pinion) box under the specified procedure.

P4. Inspect and check the following components of steering system

• Lose steering Column

• Defective energy absorbing steering column

• Steering wheel play

• Steering linkage play

• Steering gear lash

• Steering wheel Hardness

• Lose Ball joint

• Front wheel bearing

2. Inspect and check the wheel alignment

P1. Check for the vehicle pre alignment for proper Tire pressure/inflation, loose ball joints, wheel bearings, tie road ends, axle bushes, faulty spring, tire deformation, vehicle ride height, and loose stabilizer bar under specified procedure.

P2. Drive the vehicle and load/offload it on wheel alignment machine following safety rules as specified in the manual.

P3. Perform wheel alignment using the wheel alignment machine as described procedure in the machine manual and adjusts Toe, camber of front and rear wheels under specified procedure.


• Describe the purpose and function of the following. Steering systems (non-assisted/manual), power assisted system, electronic steering system

with a motor.

• Describe the main components and mechanism of the following. Ackerman principle, true rolling motion, steering ratio, toe in/out, camber, caster, steering axes

inclination, steering wheel/column, rack and pinion, steering gearboxes, steering ball joints, steering arm, front hubs, bearings/seals.

• Describe the following functions/principles of wheel alignment. Ackerman principle for a true rolling motion, steering pull, steering center point, steering wheel

vibration causes.

• Describe the wheel alignment faults as following. Toe in, toe out, positive camber, negative camber, positive caster, steering axes inclination,

included angle, tire wear, ride height, trim height of vehicle.



• Capable of servicing steering system

• Capable of performing power steering bleeding

• Capable to diagnose and rectify the steering system problems.

• Capable to perform wheel alignment of the vehicle.


S. No. Descriptions




4 Car lift



7 Grease gun


9 Oil can

4. Inspect Light & Heavy Duty Vehicle Brake System

Overview

These competency standards designed to enable the learner to Inspect Light & heavy Duty Vehicle Brake system as directed in the manual.


1. Inspect Light Vehicle (LTV) Brake system.

P1. Check brake performance test on road

P2. Check brake performance at inspection station on brake tester

P3. Check The following

• Master cylinder

• Brake fluid leve

• Brake fluid leakage

• Gas kit

• Brake servo

• Wheel cylinder leakage

• Break line damage

• Disk brake lining

• Drum lining

P4. Check vehicle instrument panel and identify ABS mall functioning light.

P5. Diagnose the vehicle ABS system with the use of scanner for wheel Sensors performance test, ABS Modular/actuator test under the specified procedure.

P6. Change the wheel sensors, actuator and related fuse under the specified procedure.

2. Inspect heavy Vehicle (HTV) Brake system.

P1. Check brake performance test on road

P2. Check brake performance at inspection station on brake tester

P3. Check The following

• Master cylinder

• Brake fluid leve

• Brake fluid leakage

• Gas kit

• Brake servo

• Wheel cylinder leakage

• Break line damage

• Disk brake lining

• Drum lining

• Brake drum diameter.

• Drum thickness.

• Paddle reservoir

P4. Check performance of brake booster.


• Describe the purpose and function of the following. Disc brakes, drum brakes (reduce vehicle speed, stop vehicle), use of friction and friction

materials, hydraulic system in a vehicle brake system, vehicle mechanical/ hand bake, engine braking in the vehicle.

• Describe the brake main Components as following Master cylinder (single/tandem), wheel cylinder, calipers (single/tandem), pipes/flexible hoses,

brake shoes (leading/ trailing), brake pads, brake discs, brake drum, handbrake operating mechanism, pedal, limiting valves, adjusters, brake fluid, brake warning light, brake light, brake light switch, wear indicator.

• Describe the principles and functions of ABS system in a vehicle as following. ABS system, Traction control system, vehicle stability control system, Wheel sensors, ECU,

ABS modulator assembly, vehicle body (Honda G-CON) (Toyota GOA).


• Capable of servicing brake system

• Capable of performing brake bleeding

• Capable to diagnose and rectify the ABS system.


S. No. Descriptions

1 Vehicle equipped with the ABS



4 Car lift


6 Vacuum gun

5. Inspect Vehicle Light System

Overview

These competency standards designed to enable the learner Inspect vehicle Lighting System as directed in the manual.


1. Check The Performance Of LTV Vehicle Lighting System

P1. Check Head Light Aiming Through Head Light Aimer.

P2. Check The Beam of head light

P3. Check Head light DIM and FULL Light Position

P4. Check The Presence and working of Fog Lights

P5. Check Parking Lights

P6. Check Left Right Indicators

P7. Check the double indicate switch

P8. Check Brake lights

P9. Check Reverse indication light.

P10. Check Number plate lights

P11. Check Warning lights present in dash board.

P12. Check door lights

P13. Check all interior lights.

2. Check The Performance Of HTV Vehicle Lighting System

P1. Check Warning lights present in dash board

P2. Check door lights

P3. Check all interior lights.

P4. Check Brake lights

P5. Check Reverse indication light.

P6. Check Number plate lights

P7. Check Parking Lights

P8. Check Left Right Indicators

P9. Check the double indicate switch

P10. Check Head Light Aiming Through Head Light Aimer.

P11. Check The Beam of head light

P12. Check Head light DIM and FULL Light Position

P13. Check The Presence and working of Fog Lights


• Describes the following

• Head Light Aiming Through Head Light Aimer.

• Beam of head light

• Head light DIM and FULL Light Position

• Fog Lights

• Parking Lights

• Indicators

• Brake lights

• Reverse indication light.

• Warning lights present in dash board.

• Door lights


• Capable to check the performance of LTV vehicle lighting system

• Capable to Check the performance of HTV vehicle lighting system


S. No. Descriptions

1 Head light aimer

2 Tool kit

3 12 Volt tester

6. Inspect Vehicle Electric System

Overview

These competency standards designed to enable the learner to Inspect Vehicle Electric System as directed in the manual.


1. Check and Inspect the Performance of Light Vehicle Electric system.

P1. Check Wiring Condition

P2. Check Wiring Color coding

P3. Check alternator condition and its performance

P4. Check ignition switch condition and working

P5. Check safety starting switch performance

P6. Check fuse box Inspect all fuses

P7. Check horn circuit and its performance

P8. Check wind screen wiper motor circuit and its performance

P9. Check and inspect wind screen washer motor circuit and check its performance.

P10. Inspect vehicle defogger system performance

P11. In case of key less ignition check push starting button.

P12. Check and inspect the performance of starting motor of vehicle.

2. Repair charging system

P1. Inspect the vehicle charging system and diagnose the following.

P2. Battery warning light indication on instrument panel, test output voltage of alternator, drive belt condition, alternator bearing noise, wire harness, fuse, and proper insulated wires.

P3. Dismantle/service of alternator as following.

P4. Repair connector, replace carbon brushes, replace Rectifier Bridge, replace voltage regulator, and replace stator winding.



• Check Wiring Condition

• Check Wiring Color coding

• Check alternator condition and its performance

• Check ignition switch condition and working

• Check safety starting switch performance

• Check fuse box Inspect all fuses

• Check horn circuit and its performance

• Check wind screen wiper motor circuit and its performance

• Check and inspect wind screen washer motor circuit and check its performance.

• Inspect vehicle defogger system performance

• In case of key less ignition check push starting button.

• Check and inspect the performance of starting motor of vehicle.

• Describe the Purpose and function of Alternator’s following parts. Rotor, stator windings, Voltage regulator, Rectifier Bridge, Internal cooling fan, Bearings, carbon brush, mounting/adjustment bolts), drive belt and its types, ratio alternator/crank pulleys, RPM, Alternator input/output voltages.


• Capable to Check and Inspect the Performance of Light Vehicle Electric system.

• Capable to troubleshoot the vehicle charging system


S. No. Descriptions

1 Vehicle/simulator

2 Test lamp

3 DMM

4 Tool kit

5 Ampere meter

6 Fuses

7 Relay

7. Inspect Vehicle Glazing System

Overview

These competency standards designed to enable the learner to Inspect Vehicle glazing System as directed in the manual.


1. Check and inspect Front Screen

P1. Check and inspect front screen for breakage.

P2. Check the type of glass used

P3. Check that glass is according to automotive safety glazing.

P4. Check for electric defogger system present on screen

P5. Check the installation of front screen

2. Check and inspect Rear screen

P-1. Check and inspect Rear screen for breakage.

P-2. Check the type of glass used for rear screen

P-3. Check that Rear screen glass is according to automotive safety glazing.

P-4. Check the installation of Rear screen

3. Check and inspect Side glasses

P1. Check and inspect all side glasses for breakage

P2. Check that all glasses are properly installed and operate able.

P3. Check all glasses are according to automotive safety glazing,


This competency standard will provide knowledge related to explain the following

• Check and inspect front screen for breakage.

• Check the type of glass used

• Check that glass is according to automotive safety glazing.

• Check for electric defogger system present on screen

• Check the installation of front screen

• Describe the following

• Check and inspect Rear screen for breakage.

• Check the type of glass used for rear screen

• Check that Rear screen glass is according to automotive safety glazing.

• Check the installation of Rear screen

• Check and inspect all side glasses for breakage

• Check that all glasses are properly installed and operate able.

• Check all glasses are according to automotive safety glazing,



• Capable to Check and inspect Front Screen

• Capable to Check and inspect Rear screen

• Capable to Check and inspect Side glasses


S. No. Descriptions

1 Tempered glass

2 Laminated glass

3 Front screen with defogger

4 Rear screen with defogger

8. Inspect Vehicle Fuel System

Overview

These competency standards designed to enable the learner to inspect vehicle fuel system According to specification Under the specified procedure.


1. Check and Inspect Petrol Engine Fuel System

P1. For inspection of Petrol engine fuel system check the performance of following,

• Fuel tank

• Fuel gauge unit

• Fuel pump

• Fuel lines

• Fuel filter

• Charcoal canister

• Carburetor

P2. For EFI system Also Check

• Electric Fuel Pump

• Fuel rail

• Fuel injectors

• Pressure regulator Valve

2. Check and Inspect Diesel Engine Fuel System

P1. For inspection of Diesel engine fuel system check the performance of following,

• Fuel tank

• Fuel gauge unit

• Fuel Pump

• Diesel Fuel Filter

• Fuel Lines

• Fuel Injection Pump

• Fuel injectors


Describes the following petrol components

• Fuel tank

• Fuel gauge unit

• Fuel pump

• Fuel lines

• Fuel filter

• Charcoal canister

• carburetor

For EFI system Also Check

• Electric Fuel Pump

• Fuel rail

• Fuel injectors

• Pressure regulator Valve

Explain the following diesel components

• Fuel tank

• Fuel gauge unit

• Fuel Pump

• Diesel Fuel Filter

• Fuel Lines

• Fuel Injection Pump

• Fuel injectors


• Capable to check and Inspect Petrol Engine Fuel System.

• Capable to check and Inspect Diesel Engine Fuel System.


S. No. Descriptions

1 Diesel engine

2 Petrol engine

3 Tool kit


5 Engine analyzer

9. Inspect Vehicle Body Accessories

Overview

These competency standards designed to enable the learner to Inspect vehicle body accessories According to specification under the specified procedure.


1. Check and Inspect the Performance of Vehicle Body Accessories exterior

Check and inspect the following

P1. Front and rear bumper (car)

P2. Side skirts

P3. Bumper lips

P4. Bumper canards

P5. Bumper diffusers

P6. Bumper splitters

P7. Bumper grilles

P8. Fenders with vents

P9. Fender flares

P10. Wide body fenders and quarter panels

P11. Spoilers

P12. Custom hoods

P13. Hood Scoops

P14. Roof scoops

P15. Side scoops

2. Check and Inspect the Performance of Vehicle Body Accessories interior.

Check and inspect the following

P1. Dashboard

P2. Console box

P3. Seats

P4. Trims

P5. Roof

P6. Seat belts

P7. Interior lights

P8. Rear view mirror


Describe the following Interiors

• Front and rear bumper (car)

• Side skirts

• Bumper lips

• Bumper canards

• Bumper diffusers

• Bumper splitters

• Bumper grilles

• Fenders with vents

• Fender flares

https://en.wikipedia.org/wiki/Bumper_(car)

https://en.wikipedia.org/wiki/Bumper_canards

https://en.wikipedia.org/wiki/Bumper_(car)

https://en.wikipedia.org/wiki/Bumper_canards

• Wide body fenders and quarter panels

• Spoilers

• Custom hoods

• Hood Scoops

• Roof scoops

• Side scoops Describe the following exteriors

• Dashboard

• Console box

• Seats

• Trims

• Roof

• Seat belts

• Interior lights

• Rear view mirror


• Capable to check and Inspect the Performance of Vehicle Body Accessories exterior

• Capable to check and Inspect the Performance of Vehicle Body Accessories interior.


S. No. Descriptions

1 Tool kit complete

10. Inspect Vehicle Exhaust System

Overview

These competency standards designed to enable the learner to inspect vehicle exhaust according to the specified procedure.


1. Exhaust system components

P1. Inspect the performance of main components of exhaust manifold

P2. Remove and assemble exhaust manifold from engine

P3. Inspect the performance of Muffler.

P4. Dismantle and assemble the Muffler from pipe.


P1. Identify catalytic converter and understand the function.

P2. Identify the positive crankcase ventilation (PCV)and understand the function.

P3. Identify and understand the functions of exhaust gas recirculation system(EGR)


• Describe the exhaust manifold types and its functions.






S. No. Descriptions




4 Car lift



7 Grease gun


9 Oil can

11. Prepare Comprehensive Vehicle Inspection Report

Overview

These competency standards designed to enable the learner to Inspect Light & heavy Duty Vehicle Brake system as directed in the manual.


1. Make Vehicle inspection report

Vehicle inspection report consist of following system inspection,

P1. Complete lighting system of vehicle conditions

P2. Complete mirrors and glasses condition

P3. Engine condition

P4. Fuel system condition

P5. Exhaust system condition

P6. Brake system condition

P7. Vehicle interior conditions

P8. Vehicle body condition

P9. Vehicle suspension system condition

P10. Vehicle steering system condition

P11. Vehicle all lubricants condition

P12. Vehicle power train condition

P13. Vehicle tires and wheels condition

P14. Vehicle alignment condition

P15. Cooling system condition

P16. Vehicle heating and A/C system condition.

P17. SRS system condition



• Complete lighting system of vehicle conditions

• Complete mirrors and glasses condition

• Engine condition

• Fuel system condition

• Exhaust system condition

• Brake system condition

• Vehicle interior conditions

• Vehicle body condition

• Vehicle suspension system condition

• Vehicle steering system condition

• Vehicle all lubricants condition

• Vehicle power train condition

• Vehicle tires and wheels condition

• Vehicle alignment condition

• Cooling system condition

• Vehicle heating and A/C system condition.

• SRS system condition


S. No. Descriptions

1 Vehicle



4 Car lift


6

12. Prepare Vehicle Title Certificate

Overview

These competency standards designed to enable the learner to prepare certificate of title for a vehicle.


1. Make a Certificate of title

The certificate of title Includes the following,

P1. Vehicle owners name

P2. Vehicle owners address

P3. Vehicle owners contact

P4. Vehicle registration no

P5. Vehicle chassis. No.

P6. Vehicle engine no

P7. Vehicle maker detail

P8. Vehicle year of manufacture

P9. Vehicle Body type

P10. Vehicle loading capacity

P11. Vehicle seating capacity

P12. Color of vehicle

P13. Vehicle body type

P14. Vehicle tax detail

P15. Vehicle fitness certification



• Vehicle owners name

• Vehicle owners address

• Vehicle owners contact

• Vehicle registration no

• Vehicle chassis. No.

• Vehicle engine no

• Vehicle maker detail

• Vehicle year of manufacture

• Vehicle Body type

• Vehicle loading capacity

• Vehicle seating capacity

• Color of vehicle

• Vehicle body type

• Vehicle tax detail

• Vehicle fitness certification

Fuel Injection and Carburetion AD-343

1. Diagnose Faults of Intake System

Overview

These competency standards designed to enable the learner intake system, adjust and service the intake related problems as well under the specified procedure in the manual.


1. Intake system P1. Inspect the main components intake system.

P2. Change/service the intake manifold specified procedure.

P3. Change/service air cleaner.

P4. Replace throttle body/carburetor from intake manifold

P5. Remove and dismantle turbocharger from intake manifold

2. Exhaust system P1. Inspect the main components turbocharger system

P2. Dismantle and assemble turbocharger/supercharger

P3. Fault trace of Turbo charger/super charger


• Describes the intake system main components and their functions as following.

• Plenum, Runner, Tuned intake manifold, motor, resonator, pipe.

• Describe the operational principles of intake system systems.

• Describe the operation of turbocharger/super charger

• Describe the components of turbocharger/super charger


• Capable to service intake system.

• Capable to change intake system.

• Capable to change Tuned intake motor vehicle.

• Capable to replace faulty components for intake manifold system.

• Capable to check tuned intake manifold motor

• Capable to check fault turbocharger/super charger

• Capable to service turbocharger/super charger


S. No. Descriptions

1 Vehicle

2 Tools trolley (Complete set of Hand Tools)

3 Multi-meter

4 Special Service tools

2. Diagnose Faults of Exhaust System

Overview

These competency standards designed to enable the learner to inspect and service of exhaust system under the specified procedure in the manual.


1. Service exhaust system

P1. Inspect the performance of main components of exhaust manifold





P1. Inspects catalytic converter under the specified procedure.

P2. Inspect and perform service of positive crankcase ventilation (PCV) P-1. Inspect and perform service of exhaust gas recirculation

system(EGR)








• Capable identify/service the Muffler assembly.

• Capable to service catalytic converter.

• Capable to service PCV System.

• Capable to service EGR system.


S. No. Descriptions

1 Vehicle


3 Gas analyzer

4 Vacuum pump

3. Diagnose Faults of Fuel Supply System

Overview

These competency standards designed to enable the learner to inspect and fuel supply system faulty parts or repairable parts to be changed under the specified procedure in the manual.


1. Conventional Fuel Supply System of Petrol Engine

P1. Inspect fuel, fuel tank, filter and lines and identify fault/s according to set standards.

P2. Inspect Fuel pump and identify fault/s in fuel supply to Carburetor according to set standards.

P3. Inspect Fuel pump operating function by camshaft

P4. Check and identify fault/s to ensure the proper functioning of Carburetor.

2. Conventional Fuel Supply System of Diesel Engine

P1. Inspect fuel, fuel tank, primary fuel pump, Fuel injection pump, filter and lines and identify fault/s according to set standards.

P2. Inspect Fuel pump and identify fault/s in fuel supply to Fuel injection pump, according to set standards.

P3. Inspect Primary Fuel pump operating function by camshaft

P4. Check and identify fault/s to ensure the proper functioning of Fuel injection.

P5. Adjust the procedure of phasing and calibration of diesel fuel injection pumps.

P6. Adjust the procedure of setting of timing of diesel fuel injection pump.

P7. Inspect and replace diesel engine glow plug.

3. Electronic Fuel injection system of petrol engine

P1. Inspect the components of EFI system Fuel pump, fuel line, fuel filter, pressure regulator, common rail, injector

P2. Inspect and replace fuel pump

P3. Inspect and replace pressure regulator

P4. Inspect and replace fuel filter

P5. Inspect and replace fuel gallery

P6. Inspect and replace injector

P7. Inspect and replace fuel line

4. Electronic Fuel injection system of Diesel engine

P1. Inspect the components of EFI system Fuel pump, fuel line ,fuel filter, pressure regulator, common rail, injector

P2. Inspect and replace fuel pump

P3. Inspect and replace pressure regulator

P4. Inspect and replace fuel filter

P5. Inspect and replace injector

P6. Inspect and replace fuel line


5. Sensors P1. Inspect the of EFI system sensors Air Flow meter ,Map sensor ,Air temperature sensor, Water temperature sensor, Throttle position sensor, , Knock sensor, RPM sensor, Oxygen sensor.

P2. Inspect and replace Air Flow meter

P3. Inspect and replace Map sensor

P4. Inspect and replace Air temperature sensor

P5. Inspect and replace Water temperature sensor

P6. Inspect and replace Throttle position sensor

P7. Inspect and replace Knock sensor

P8. Inspect and replace Knock sensor

P9. Inspect and replace Oxygen sensor

6. Compressed Natural Gas

P1. Inspect the components of CNG system Cylinder, line, filler cap, Mechanical gauge, change over switch, converter, petrol and CNG solenoid.

P2. Inspect and replace cylinder

P3. Inspect and replace filler valve

P4. Inspect and replace gauge

P5. Inspect and replace change over switch

P6. Inspect and service convertor

P7. Inspect and replace petrol and CNG solenoid

P8. Inspect , install and repair CNG wiring

P9. Diagnose the CNG system problem

7. Liquid petroleum gas

P1. Inspect the components of LPG system Cylinder, line, filler cap, Mechanical gauge, change over switch, converter, petrol and LPG solenoid.

P2. Inspect and replace cylinder

P3. Inspect and replace filler valve

P4. Inspect and replace gauge

P5. Inspect and replace change over switch

P6. Inspect and service convertor

P7. Inspect and replace petrol and LPG solenoid

P8. Inspect , install and repair LPG wiring

P9. Diagnose the LPG system problem



• Describe construction of fuel tank

• Describe construction and working of fuel gauge and its circuit

• State the function of fuel pump, it’s types

• Adjustment the ideal Air / Fuel ratio of different fuels

• Describe air-fuel ratio for different engine working conditions.

• Describe air-fuel mixture adjustment at idle speed

• Describe Carburetor types according to No of barrels, No of Venturies, Air draft and fix & variable Venturies.

• Methods of Carburetor troubleshooting and remedies for the faults i.e.

o Excessive Fuel Consumption. o Engine Dieseling. o Engine Missing. o Fuel Blockage. o Engine starving o Carburetor over flow

• Describe Fuel injection pump according to operation.

• Describe the components of EFI system

• Describe the function of EFI system sensors Air Flow meter ,Map sensor ,Air temperature sensor, Water temperature sensor, Throttle position sensor, , Knock sensor, RPM sensor, Oxygen sensor.

• Describe the components of CNG system

• Describe the components of LPG system


Capable identify/service the Petrol Engine.

• Capable to service Diesel engine.

• Capable to service LPG System.

• Capable to service CNG system.


S. No. Descriptions

1 Vehicle (petrol and Diesel)


3 Complete CNG kit and LPG kit

4 Special service tool for EFI System

4. Diagnose Faults & Repair Hybrid System

Overview

These competency standards designed to enable the learner to work on vehicle Hybrid system and repair or replace the faulty components as directed in the manual.


1. Perform Inspection.

P1. Identify the type of system

P2. Check the components:

• Cable

• Switches

• Modules

• Cooling devices

• Protective devices

P3. Identify the components.

• Missing

• Damage

• Leak

• Loose

• Worn

• Defective components

2. Repair Hybrid system

P1. Diagnose complex system faults

P2. Diagnose and repair high voltage rechargeable energy storage systems in battery electric vehicles

P3. Diagnose and repair traction motor speed control systems in battery electric vehicles

P4. Diagnose and repair traction motor speed control systems in battery electric vehicles

P5. Diagnose and repair auxiliary motors and associated components in battery electric vehicles

3. Diagnose Hybrid system

P1. Diagnose and repair system instrumentation and safety interlocks in battery

P2. Diagnose and repair HVAC and rechargeable energy storage cooling systems in battery electric vehicle

P3. Diagnose and repair DC to DC converters in battery electric vehicles

P4. Diagnose and repair high voltage rechargeable energy storage systems in hybrid electric vehicles

P5. Diagnose complex faults in light vehicle safety systems

4. Verify Repair of hybrid Systems and Components

P1. Use testing tools manually

P2. Verify through computerized system.

P3. Evaluate performance of the components through test drive

P4. Verify the codes pressure, vibration , noise and leak points

P5. Ensure all the devices affix properly.


• Describe the final drive main components and functions as following Battery, generator, inverter, Motor, wiring(Harness)

• Describe the function of hybrid Battery

• Describe the function of Generator.

• Describe the function of inverter.


• Capable identify the faults in Hybrid system.

• Capable to check and replace battery.

• Capable to replace Motor generator.

• Capable to replace the motor.


S. No. Descriptions

1 Vehicle


3 Hybrid system repair kit

4 Scanner

5. Diagnose Faults & Repair Engine Valve Control System

Overview

These competency standards designed to enable the learner to work engine valve control system and repair or replace the faulty components as directed in the manual.


1. Engine Valve control system

P1. Inspect, adjust and replace components of variable valve timing Intelligence (VVT-i).

P2. Inspect, adjust and replace components of variable valve timing and electric lift control systems (VTEC).

P3. Inspect ,adjust and replace the components VANOS


• State the Purpose of Variable valve timing control systems (VVT-I,VTEC ,VANOS)

• Enlist the components of Variable valve timing control systems (VVTI,VTEC ,VANOS)

• Describe the working principles of Variable valve timing control systems (VVT-I,VTEC,VANOS)


• Capable identify the faults valve control system.

• Capable to check and replace Variable valve timing control systems (VVT-I, VTEC,VANOS).


S. No. Descriptions

1 Vehicle


3 Special service kit

4 Scanner

Automotive Transmission AD-363

1. Diagnose Faults &Repair Clutch

Overview

These competency standards designed to enable the learner to adjust and service the clutch related problems of mechanical and hydraulic system as well under the specified procedure in the manual.


1. Repair Clutch System (Manual)

P1. Inspect the main components of clutch for paddle free play, smooth gear changing, clutch cable, drive the can and check pickup, release bearing abnormal noise under the specified safe procedure.

P2. Change/service the clutch cable under specified procedure.

P3. Change the clutch plate while inspecting the release bearing, pilot bearing, clutch pressure plate, fork operation under specified procedure.

2. Repair Clutch System (Hydraulic)

P1. Service/replace clutch master cylinder, slave cylinder under the specified procedure in the manual.

P2. Perform clutch oil bleeding and top up the clutch oil reservoir under specified procedure.


• Describes the clutch main components and their functions as following. Clutch cables, self-adjusting mechanisms, master/slave cylinders, pressure plate/cover, clutch

plates, release bearings, gear input shaft front support bearings (pilot),release bearing carriers, fluid, fluid/hydraulic pipes.

• Describe the operational principles of clutch systems. Transmitting torque (turning moment), gradual drive, take-up, neutral gear (at park), drive path

(flywheel/gearbox input).


• Capable to service/adjust clutch system.

• Capable to change clutch cable.

• Capable to change clutch plate from the vehicle.

• Capable to replace faulty components for hydraulic clutch system.

• Capable to perform clutch bleeding


S. No. Descriptions

1 Vehicle


3 Hydraulic jack

4 Clutch special tools

Consumable Items:

S. No. Descriptions

1 Master cylinder kit

2 Clutch Fluid

3 Cotton Waste

2. Diagnose Faults &Repair Manual Gear Box

Overview

These competency standards designed to enable the learner to inspect and repair faulty gearbox parts. No repairable parts to be changed under the specified procedure in the manual.


1. Inspect Gearbox (Manual)

P1. Inspect the performance of main components of gear box for lake of drive, noisy operation, difficulty engaging/disengaging gears, jumping out of gears, oil leakage, vibration, excessive movement of gear lever, speedometer inoperative under the specified procedure.

2. Service Gearbox (Manual)

P1. Change the gear shift lever foundation to correct excessive movement of gear lever under the specified procedure.

P2. Change and top up the gear oil under the specified procedure.

P3. Service the gearbox while repairing the faults under the specified procedure.

3. Over Drive Units P1. Inspect the performance of main components of over drive units for lake of drive, noisy operation, difficulty engaging/disengaging gears, oil leakage, vibration, under the specified procedure.

P2. Service of over drive unit under the specified procedure.

P3. Change and top up the gear oil under the specified procedure.


• Describe the gearbox main types and there functions as following. Types of gear (Spur, Bevel, Helical) used in gearbox, difference between transaxle and

transmission, front wheel drive and rear wheel drive, difference between all-wheel drive and 4X4

• Describe main components and functions gearbox as following. Input shaft, output shaft, gear selector shaft, reverse gear, synchronizer, gear ratios, reverse

switch, differential, and speedometer sender in the transaxle. Inputs shaft, counter/lay shaft, output shaft, gear ratio, reverse switch, speedometer sender,

synchronizer, and selector shafts in the Transmission.

• Describe the main components and function overdrive as following Input shaft, planetary gear, locking device, output shaft,


• Capable identify the faults in the gear system.

• Capable to service the gear system.

• Capable to replace gear shift lever foundation.

• Capable to replace the gear oil.

• Capable identify the faults in the over drive system.

• Capable to service the over drive system.


S. No. Descriptions

1 Vehicle


3 Hydraulic jack

4 Gear service special tools

3. Diagnose Faults &Repair Automatic Gear Box

Overview

These competency standards designed to enable the learner to inspect and repair no the gearbox faulty parts or repairable parts to be changed under the specified procedure in the manual.


1. Diagnose Faults in Automatic Transmission System

P1. out road test at different speeds for smooth operations of torque converter and gear shifting according to Manufacturer standard

P2. Check automatic transmission mounting for faults.

P3. Check automatic transmission fluid (ATF) level, according to standard specification and identify leaks if any

P4. Check automatic transmission solenoid by using automotive scanner and identify faults if any

P5. Check electrical controls and Hydraulic pressure of automatic transmission for faults if any

2. Disassemble Automatic Transmission System and Ancillary Components

P1. Remove automatic transmission and disassemble it to check for worn-out/ faulty parts and replace them as per Manufacturer Repair Manual

P2. Check automatic transmission performance by ensuring proper linkages and controls as per standards

P3. Reassemble automatic transmission and refit to the vehicle according to standards



• Occupational Health & Safety (OHS) precautions

• Describe the function of Manual gear box(input shaft, idler shaft, counter shaft, reverse shaft)

• Describe the importance mechanical transmission fluid.

• Describe the function/operation Automatic transmission(Torque converter, pump, clutches, brake band, planetary gear, valve body)

• Describe the function of Automatic transmission fluid.



• Capable to service of Manual gear box.

• Capable to service and adjust shift cable.

• Capable to check and replace the gear box oil.

• Capable to service automatic transmission.

• Capable to service and adjust shift cable.

• Capable to replace the Automatic transmission fluid.


S. No. Descriptions

1 Vehicle


3 Hydraulic jack

4 Gear service special tools

4. Diagnose Faults &Repair Final Drive

Overview

These competency standards designed to enable the learner to work on vehicle final drive and repair or replace the faulty components as directed in the manual.


1. Repair propeller shaft

P1. Inspect the performance of main components of propeller shaft like as slip joint, Universal joint, Central bearing, Flexible coupling.

P2. Replace/service the propeller shaft like as slip joint, Universal joint, Central bearing under the specified procedure in the manual.

2. Repair Axle P1. Inspect the performance of main components of final drive for Axle noise during turning of a vehicle, axle rubber boots conditions on CV joints under the specified procedure.

P2. Replace/service the Axle CV Joints outer and inner under the specified procedure in the manual.

3. Repair differential

P1. Inspect the performance of main components of differential for uneven noise during the acceleration, propeller shaft free play, oil leakage, and breather valve assembly under the specified procedure in the manual.

P2. Service/adjust differential assembly under the specified procedure.


• Describe the Propeller shaft and main components functions as following Slip joint, Universal joint, Central bearing, Flexible coupling.

• Describe the function dead and live axle, CV joint.

• Describe the operational principles of final drive and differential systems. Final drive, final gear reduction and ratio, differential unit (torque equalizer), torque reaction on

a live rear axle, driving/braking conditions, pinion location in relation to crown wheel.


• Capable to service of propeller shaft (slip joint, Universal joint, Central bearing, Flexible coupling).

• Capable to service the axle CV Joints.

• Capable to replace differential system.

• Capable to replace the differential oil.


S. No. Descriptions

1 Vehicle


3 Hydraulic jack

4 special tools

Auto Body Building & Finishing AD-383

1. Understand Vehicle Body Shell

Overview

This unit covers the competencies required to identify external body parts internal body parts, and welded parts, bolted parts and fundamental construction of car body ensuring safe working in such operations and also in the use of related tools and equipment.


1. Identify the body construction

P1. Inspect and identify the external body parts.

P2. Inspect and identify the external body parts.

P3. Identify welded body parts

P4. Identify bolted body parts

P5. Identify the classification of vehicle by shape

2. Identification of Monocoque and Frame type vehicle

P1. Identify the engine support method

P2. Identify center member method

P3. Identify direct mounted method.

P4. Identify fundamental construction of passenger car body

P5. Identify the vehicle classification by space

P6. Identify the crash impact absorbing front & rear area

3. Identification Characteristic of Monocoque & frame type vehicle.

P1. Identify FF type vehicle

P2. P-2 Identify FR type vehicle

P3. P-3 Identification MR type vehicle

P4. P-4 Identification 4WD type vehicle


• Basic knowledge of passenger vehicle and commercial vehicle construction.

• Basic Knowledge of Monocoque and Frame type vehicle

• Basic knowledge of FF type vehicle

• Basic knowledge of FR type vehicle

• Basic knowledge of side body FF and FR type vehicle

• Basic knowledge of welded parts

• Basic knowledge of bolted parts

• Basic knowledge of fundamental construction of car body

• Knowledge of various types of car body shape


S. No. Descriptions

1 Marker

2 Pen/ Pencil

3 Cotton gloves (PPE)

4 Goggles (PPE)

5 Safety Helmet (PPE)

2. Prepare Cost Estimate for Damaged Vehicle Body and Chassis

Overview

This unit covers the competencies required to inspect a damaged automobile, generate a job sheet, estimate the cost of damage, prepare a quotation and cost a job. In the process of preparing an estimate for repairs, safe working in such operations as well as in the use of related tools and equipment shall be ensured.


1. Assess extent of necessary repair/replacement and identify work to be done

P1. Inspect the vehicle body to ascertain the extent of damage

P2. Identify body work and chassis work to be done

P3. Measurements taken to quantify damage

P4. Identify vehicle body fittings that need to be replaced

P5. Prepare Job sheet for the necessary repairs

2. Obtain quotations and calculate the cost of spare parts/components to be replaced

P1. Prepare Quotations for the necessary replacement parts/components obtained

P2. Prepare Quotations evaluated and the most reasonable quotation based on the price, quality and the choice of the customer,

P3. Calculated Total cost of replacement parts

3. Prepare an estimate of the total cost to the client/insurance company

P1. Calculated Total material cost by getting quotations for materials necessary for the repair

P2. Calculated Total cost of labor by estimating the number of man hours necessary in each category of craftsmen

P3. Calculated Total machinery running and equipment usage cost by listing out the machinery and equipment necessary to carry out the identified load of repair work

P4. Calculated Individual or total overhead cost according to company Policy

P5. Calculated Profit margin in accordance with company policy

P6. Calculated Total cost of repair estimated

P7. Provided Estimate to client / insurance company


• Knowledge of body repair & basic of automobile working principles and arithmetic.

• Basic geometry including angular measurements and longitudinal measurements.

• Techniques of measuring body repair work areas, for estimation purposes.

• Safety precautions connected with inspection of damaged vehicles.

• Conversion of measurements from imperial to metric units.

• Knowledge of body layouts.

• Use of current industrial norms in estimation.

• Estimation procedures according to company principles.

• Awareness of current insurance requirements.

• Estimation of current rates for labor material

• Replacement and repair of parts.

• Knowledge of simple metal working practices.

• Knowledge of dismantling procedures.

• Care and maintenance of tools.


S. No. Descriptions

1 Measuring Tape

2 Measuring Tools

3 General Hand Tools

4 Calculator

5 Pen/ Pencil

3. Perform Vehicle Body and Chassis Alignment and Repair

Overview:

This unit covers the competencies required to inspect a damaged vehicle body, diagnose the chassis damage, prepare and align the chassis, and reassemble the automobile chassis and body parts ensuring safe working in such operations, and also in the use of related tools and equipment.


1. Inspect a damaged automobile and diagnose the chassis damage

P1. Inspected to identify the total extent of chassis damage.

P2. Assess direct and indirect damage estimated in order to commence repairs / replacements.

P3. Identify the types of metal replacements required to repair the chassis identified.

P4. Identify the Chassis repairs and alignment required determined according to manufacturer’s specifications and company policies.

2. Select tools and equipment and align the chassis

P1. Select Tools and equipment for aligning the chassis to restore the vehicle to original condition

P2. Remove body parts and fittings to facilitate the repair and stored in such a manner as to facilitate retrieval for reassembly.

P3. Protect Electrical/electronic systems to avoid damage during repair.

P4. Carried out Necessary repairs to the chassis follow the safety practices.

P5. Chassis aligned using jigs according to manufacturer’s specifications.

P6. Components welded to complete repair according to manufacturer’s specifications, follow the safety practices.

P7. Verified Chassis measurements according to manufacturer’s specifications.

P8. Prepared and repaired metal areas and painted with primer / prescribed anticorrosive paints according to manufacturer’s specifications.

3. Reassemble chassis and body parts and complete the job

P1. Replaced Chassis parts, aligned and refitted according to manufacturer’s specifications.

P2. Interpreted Wheel alignment report and adjustments made, if necessary, according to manufacturer’s specifications.

P3. Replaced Body parts, aligned and refitted according to manufacturer’s specifications.

P4. Removed all accessories from the automobile, reassembled and fixed to meet original specifications.

P5. All repairs and replacements done recorded for the purpose of costing the job to the customer, according to company policies.

P6. Keep clean work place, tools & equipment properly


• Knowledge of body repair & basic knowledge of automobile working principles

• Basic arithmetic

• Basic geometry including angular measurements and longitudinal measurements

• Techniques of interpreting measurements of body work areas listed in estimates

• Safety precautions connected with working with metal sheets and in welding

• Conversion of measurements from imperial to metric units

• Knowledge of body layouts

• Repair procedures according to company principles based on estimate provided.

• Types of chassis and chassis frame construction

• Interpretation of wheel alignment report & diagnosis of chassis defects

• Stiffening of thin sheet metal by mechanical methods such as edging, seaming and flanging

• Knowledge of preventing rust and scale formation

• Basic knowledge of welding consumables.

• Knowledge of reducing warping and distortion of sheet metal during welding

• Use of different types of fire extinguishers.


S. No. Descriptions

1 Measuring Tape

2 Measuring Tools

3 Universal Measuring Systems


5 Body Repair Tools

6 Wire Brush

7 Hydraulic, Pneumatic And Mechanical Pullers

8 Cotton Gloves

9 Welding Unit

10 MIG Welding Wire

11 Welding Gloves

12 Centering Gauges

13 Industry Approved Body Frame Aligner Equipment

14 Drill Machine

15 Grinding Disc

16 Cutting Disc

17 Safety Shoes

18 Safety Helmet

19 Calculator

20 Pen/ Pencil

21 Body Repair Manual

4. Perform Vehicle Body Repairs Work

Overview

This unit covers the competencies required to inspect a damaged automobile, diagnose the body damage, prepare and align the bodywork and reassemble body parts of all types of automobiles, ensuring safe working in such operations and also in the use of related tools and equipment and compliance with government regulation.


1. Diagnose body Damage

P1. Inspect & identify damage body work

P2. Amount of direct and indirect damage identified in order to commence repairs / replacements

P3. Types of metal required to repair the vehicle, determined

P4. Misaligned and damaged parts identified for repair / replacement Any chassis repairs and alignment required, identified

2. Align and repair Bodywork

P1. Tools and equipment required to align and repair the body according to manufacturer’s specifications

P2. All serviceable components that are obstructing the repair removed and stored in such a manner as to facilitate retrieval for reassembly

P3. Electrical/electronic systems protected to ensure that they are not damaged during repair

P4. Necessary repairs to the bodywork carried out and body aligned as necessary to regain the original shape

P5. Bodywork aligned according to manufacturer’s specifications Components welded and sealants applied to complete repair according to manufacturer’s specifications.

P6. Body measurements verified according to manufacturer’s specifications

P7. Parts and fittings checked during repair for damage caused and rectified as necessary

3. Finish body work by preparing the surface for painting

P-1. Repaired metal areas cleaned and primer and under coating applied according to manufacturer’s specifications

P-2. Repaired areas leveled by applying metal filler to restore the body shape so that excessive putty application is not required

P-3. All accessories removed for the repair, refitted in original positions Linings, sound deadener pads and sealers fixed according to manufacturer’s specifications

P-4. Tools and equipment cleaned and returned to appropriate places and work area cleaned


• Knowledge of body repair &basic knowledge of automobile working principles



• Techniques of interpreting measurements of body repair work areas listed in estimates




• Repair procedures according to company principles based on estimate provided.

• Removal of rust and de-rusting mechanically and chemically

• Application procedures of anticorrosive paints & body primer

• Interpretation of wheel alignment report & diagnosis of chassis defects affecting body work

• Use of different types of fire extinguishers

• Government regulations applicable to vehicle specification


S. No. Descriptions

1 Measuring Tape

2 Measuring Tools



5 Body Repair Tools

6 Wire Brush


8 Cotton Gloves

9 Welding Unit (MIG Welder)

10 Washer Welder

11 MIG Welding Wire

12 Welding Gloves

13 Welding Goggle

14 Welding Apron

15 Centering Gauges


17 Drill Machine

18 Grinder Machine

19 Sealant Gun

20 C-Clamps

21 Equipment For Painting

22 Body Jack

23 Grinding Disc

24 Cutting Disc

25 Safety Shoes

26 Safety Helmet

27 Calculator

28 Pen/ Pencil


5. Carryout Panel Repair with Washer Welder Machine

Overview

After successful completion of this module the trainee will be able to perform each task of the following according to the relevant standards and specifications

1. Assessing the range of damage. 2. Repair using hammer and dolly technique. 3. Repair using washer welder. 4. Repair using shrinking method. 5. Assess the repaired panel. 6. Apply anti rust agent in back side of repaired sheet.


1. Assess the range of damage.

P1. Visual inspect and Asses the range of damage

P2. Apply inspection rules –Observe-Touch-Press and compare.

P3. Mark the damage area with marker.

2. Repair using hammer and dolly.

P1. Inspect complete panel and mark the damage area.

P2. Select the hammer and dolly according to required area.

P3. Hold hammer and dolly with S.O.P.

P4. Apply method hammer and dolly technique at damage area.

P5. Time to time check damage surface with undamaged surface.

P6. After completion of repair process it must be compare with undamaged surface.

P7. Clean work place.

P8. Clean tools and equipment’s and store safe place.

3. Repair using washer welder.

P1. Select tool and equipment which is required.

P2. Prepare the panel before repair.

P3. Mark assess the range of damage.

P4. Remove old paint with appropriate method.

P5. Weld the washer for earthling.

P6. Sliding hammer attached with washer welding gun with star bit.

P7. Set the parameter of washer welder first.

P8. Apply washer welder at damage area for removing dents.

P9. Apply copper electrode for removing the burrs.

P10. Check damage area to undamaged area.

P11. Off the washer welder after the completion the work.

P12. Keep the tools and equipment neat and clean and safe condition.

4. Repair using shrinking method.

P1. Select tools and equipment according to the job.

P2. Set the parameter of washer welder.

P3. Attach copper electrode with washer welder gun.

P4. Apply shrinking method.

P5. Cool the surface with air blow gun.

P6. Check the strength of surface from undamaged area.

P7. All tools and equipment cleaned and stored in appropriate places.


5. Assess the repaired area after the completion of panel repair

P1. Inspect all damage area

P2. Apply straight ruler according the S.O.P

P3. Compare damage and undamaged area

P4. The damage area should be lower than the undamaged surface

P5. Apply anti rust agent in back side of repaired sheet


• Guideline for Inspection criteria and asses the range of damage

• Knowledge about repairing technique for damage panel

• Knowledge about Remove old paint film according to standard

• Knowledge about hammer and dolly technique with respect to job

• Operation method of washer welder

• Shrinking method application process.

• Washer welder parameter setting procedure

• Assess the repaired area after when work finish to undamaged surface

• Anti-rust application


S. No. Descriptions

1 Measuring Tape

2 Measuring Tools



5 Body Repair Tools

6 Wire Brush


8 Cotton Gloves


10 Washer Welder

11 MIG Welding Wire

12 Welding Gloves

13 Welding Goggle

14 Welding Apron

15 Centring Gauges


17 Drill Machine

18 Grinder Machine

19 Sealant Gun

20 C-Clamps


22 Body Jack

23 Grinding Disc

24 Cutting Disc

25 Safety Shoes

26 Safety Helmet

27 Calculator

28 Pen/ Pencil


6. Repair Vehicle Body Fittings

Overview

This unit covers the competencies required to inspect a damaged automobile, diagnose the body damage, prepare and align the bodywork and reassemble body parts of all types of automobiles, ensuring safe working in such operations and also in the use of related tools and equipment and compliance with government regulation.


1. preparations for the repair of automobile fittings

P1. Identified Damaged and missing fittings by inspecting vehicle body

P2. Remove Wire harness and all other fittings including which are obstructing the repair, using specified tools and methods.

P3. Undamaged fittings labeled and stored to be retrieved when re-fixing them.

P4. Damaged fittings dismantled for repair or replacement.

P5. Fittings that are irreparable, including missing fittings, identified.

P6. Misalignments and damage caused to repairable fittings identified and the necessary repairs assessed.

P7. Orders placed for the replacement fittings to be received, before Commencement of re-assembly.

P8. Job orders to repair damaged and misaligned fittings by straightening, welding and leveling initiated.

2. Repair fittings and refit them

P1. Tools and equipment required to carry out the repair according to manufacturer’s specifications and government regulations selected.

P2. Necessary repairs to the fittings carried out and shaping done to restore them to original condition.

P3. Fittings aligned according to manufacturer’s specifications.

P4. Fittings welded and leveled to complete repair according to manufacturer’s specifications and government regulations.

P5. Other fittings / parts checked for any damage caused during repairs and rectified as necessary.

P6. Surface protection provided to all repaired fittings as necessary.

P7. Remove other fittings and accessories from the vehicle, refitted.

P8. Arrange Wire harness and re-fixed in original position.

P9. Clean work place, tools & equipment and stored in appropriate places.


• Knowledge of body repairing & basic knowledge of automobile working principles



• Techniques of interpreting measurements of work areas listed in estimates

• Safety precautions connected with working with metal sheets and in reverting, soldering and welding



• Repair procedures and company policies

• Use of different types of fire extinguishers.

• Removing methods of upholstery


S. No. Descriptions

1 Measuring Tape

2 Measuring Tools



5 Body Repair Tools

6 Wire Brush


8 Cotton Gloves


10 Washer Welder

11 MIG Welding Wire

12 Welding Gloves

13 Welding Goggle

14 Welding Apron

15 Centring Gauges


17 Drill Machine

18 Grinder Machine

19 Sealant Gun

20 C-Clamps


22 Body Jack

23 Grinding Disc

24 Cutting Disc

25 Safety Shoes

26 Safety Helmet

27 Calculator

28 Pen/ Pencil


7. Perform Welding Operations on Vehicle Body

Overview

This unit covers the competencies required to perform welding operations in the body repair work of automobiles, ensuring safe working in such operations and also in the use of related tools and equipment.


1. Preparations for welding of automobile body, chassis and other components.

P1. Inspected and identify the body for welding work

P2. Disconnected battery, wire harness and all other components which are obstructing the repair removed, and the serviceable ones labeled and stored to be retrieved when reassembling after welding.

P3. Dismantle damaged components that are to be welded

P4. Select Tools and equipment for leveling, aligning and clamping the components to enable the repair to be carried out according to manufacturer’s specifications.

P5. Surfaces to be welded prepared by grinding, facing and aligning.

2. Weld automobile Chassis, body and other components.

P1. Tools and equipment required for welding the components to enable the repair to be carried out according to manufacturer’s specifications selected.

P2. The type of welding to be carried out on the item determined.

P3. Body and components arranged for welding.

P4. Set the parameter of MIG welding machine according repair

P5. Components aligned according to manufacturer’s specifications.

P6. Components welded and leveled to complete repair according to manufacturer’s specifications.

P7. Quality of fabrication checked by visual inspection.

P8. All components and accessories removed from the automobile before the repair.

P9. Component measurements verified according to manufacturer’s specifications.

P10. Surface protection provided to all repaired components.

P11. Wire harness arranged and re-fixed in original position.

P12. Clean work place, body repair tools, welding equipment and store them in appropriate places


• Knowledge of body repairing & basic knowledge of automobile working principles


• Basic geometry including angular and longitudinal measurements

• Techniques of interpreting measurements of body work areas, listed in estimates



• Knowledge of welding with gas, arc, spot, TIG, MIG/MAG and polymer welding equipment in respect to automobile

• Knowledge of minimizing warping, distortion and stress formation in sheet metal while welding

• Safe handling and care of various types of welding equipment

• Repair procedures according to S.O.P

• Interpretation of the wheel alignment report & diagnosis of chassis defects affecting the bodywork

• Knowledge of visual inspection / non-destructive testing methods.


S. No. Descriptions

1 Measuring Tape

2 Measuring Tools



5 Body Repair Tools

6 Wire Brush


8 Cotton Gloves


10 Washer Welder

11 MIG Welding Wire

12 Welding Gloves

13 Welding Goggle

14 Welding Apron

15 Centring Gauges


17 Drill Machine

18 Grinder Machine

19 Sealant Gun

20 C-Clamps


22 Body Jack

23 Grinding Disc

24 Cutting Disc

25 Safety Shoes

26 Safety Helmet

27 Calculator

28 Pen/ Pencil


8. Maintain Machinery, Tools and Equipment

Overview

After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications.

1. Label tools and equipment for easy identification and store safely. 2. Maintain MIG welder 3. Prepare a monthly plan for maintenance of hand tools 4. Maintain washer welder 5. Maintain frame aligner 6. Inform relevant sections about malfunctioning equipment 7. Use of welding equipment 8. Maintain plasma & gas cutter 9. Maintain pneumatic and power tools


1. Maintain MIG welder

P1. Remove all dirt, dust or debris from the machine and its accessories

P2. MIG welder is to keep covered when not in use

P3. Check all electrical component of MIG welder machine

P4. Drive rolls should be clean & settled properly

P5. Adjust the driver rolls tension properly

P6. Clean gun & nozzle regularly

2. Maintain Washer welder machine


P2. Washer welder is to keep covered when not in use

P3. Clean earth cable with dry sand paper

P4. Clean the sliding hammer properly

P5. Service at the proper time

P6. Check all electrical component of washer welder machine

3. Maintain spot welder machine


P2. Spot welder is to keep covered when not in use

P3. Check all electrical component of spot welder machine

P4. Clean the air filter of machine

P5. service at the proper time

P6. Clean spot gun properly

P7. Clean & replace welding tools

4. Maintain Grinder P1. Check all bolts and screws for tightness

P2. Check condition of hub or drum assembly and replace flaps, cutters or axles if required

P3. Check the security of all hoses clamps and fittings,

P4. Clean air filter lubricator

P5. Check the vibration of grinder


5. Maintain frame aligner

P1. Remove any dirt or sealer from all pulling clamp of body aligner

P2. Check the leakage of hydraulic oil from pump

P3. Clean all accessories of frame aligner

P4. Check whether there were leaks at the places where the hose was fixed

P5. Check & clean all safety cable of frame aligner

6. Maintain pneumatic tools

P1. Check that all screws on tool are tight.

P2. Keep magazine and feeder mechanism clean.

P3. Lubricate "O" rings that are replaced.

P4. Clean filter element-then blow air through filter in direction opposite to normal flow.

P5. Drain airline filter(daily) and Keep lubricator filled

7. Top up oil level of compressor

P1. Check the oil level of the compressor every day in the morning

P2. Select the type of oil according to that given by the manufacturer

P3. If the oil level has dropped, fill oil up to the marked level

8. Drain water in the air tank of compressor

P1. Check whether there was water in the air tank of the compressor every day in the morning

P2. Drain water by opening the drain tap

P3. Close the tap to prevent air leakage

P4. If there was water while painting, drain the water collected in the air tank following Steps 2 and 3 above

9. Replace air filter of compressor

P1. Decide whether a filter has to be fixed to the compressor or not

P2. Decides a suitable type of filter?

P3. Collect necessary raw materials and equipment after replacing the filter, and operate the compressor again and check whether the air produced was free from water clean and store the equipment

10. Drain water in air regulator

P1. Decide whether water had to be drained from the regulator

P2. Drain the water by activating the knob or the switch key of the regulator

P3. Check a number of times whether the air coming through the regulator was free from water


• Guidelines on maintenance of tools and equipment

• Guidelines to be followed and matters to be considered when storing of equipment

• Guidelines to be considered in storage

• Documents used in storing and their maintenance

• Guidelines to be considered in maintaining the frame aligner

• Maintain MIG welder, washer welder, spot welder

• Aspects to be considered in using welding machine.

• Functioning of the welding machine and guidelines to be considered in its maintenance

• Aspects to be considered in updating maintenance register

• Knowledge about the components of the air compressor and pneumatic tools

• Knowledge about guidelines for maintaining air compressors and pneumatic tools


S. No. Descriptions


2 Cotton Gloves

3 Cutting Disc

4 Safety Shoes

5 Safety Helmet

6 Compressor oil

7 Lubrication oil

8 Cleaning thinner

9. Remove and Fix Glass Items

Overview

This unit covers the competencies required to remove glass items from automobiles before body repairing and painting, and re-fixing after repairs, ensuring safe working in such operations and also in the use of related tools and equipment.


1. Determine the scope of the task in removing specified glass items from frame and re-fixing them

P1. Inspected and identify the specified glass items.

P2. Identify any uneven surfaces, cracks / corrosion on the frames of the specified glass items.

P3. Remove glass without any damages wit specified procedure

P4. Fixing the glass without damages with specified procedure

2. Remove glass items from automobiles and re-fix them

P1. Select Tools and equipment to remove and re-fix glass items from the automobile selected.

P2. Operations to be carried out on the glass frame and beading for removal and fixing without damage

P3. Remove Glass carefully without damaging either the glass or the frame.

P4. Cleaned glass with kerosene, water, detergents etc. as appropriate and stored carefully in a safe place for easy retrieval when re-fixing.

P5. Frame cleaned with kerosene, water, detergents and cutting compound as necessary to produce a smooth surface.

P6. Condition of the prepared frame surfaces checked by visual inspection or by any method using measuring instruments if applicable, to ensure compatibility with the respective glass items.

P7. Any specified paints or other appropriate material applied on the frame surfaces for the prevention of corrosion

P8. Appropriate sealing material applied as required, to ensure a proper fit.

P9. Glass fixed carefully into the frame, ensuring that it is correctly fitted.

P10. Leak test carried out with water to ensure that the joint is leak proof.

P11. Glass and surrounding area cleaned to complete the job.

P12. All glass fixing tools cleaned and stored in appropriate places.


• Basic knowledge about different type of glass

• Basic geometry including angular and longitudinal measurements

• Techniques of interpreting measurements of body repair work areas listed in estimates

• Safety precautions connected with working with glass items and frames

• Conversion of measurements

• Knowledge of glass removal and fixing

• Repair procedures according to company standard

• Interpretation of the alignment report & diagnosis of glass frame defects due to accidents and corrosion in the bodywork

• Knowledge of various types of safety glass such as laminated, tempered, reflective, and polymer types such as flexi glass polycarbonates

• Knowledge of various types of paints, sealants and adhesives, and their uses


S. No. Descriptions


2 Cotton Gloves

3 Goggles

4 Safety Shoes

5 Measuring Tape

6 Mallets in Rubber

7 Cutting Disc

8 Grinders

9 Wire Brushes

10 Sealant Gun

11 Files

12 Glass cleaning equipment

13 Glass primer

14 Glass Sealant

15 Special equipment for fixing glass

16 Suction type glass holders

17 Hand Drills

18 Sealant cutting tool

19 Safety Shoes

20 Safety Helmet

21 Compressor oil

22 Lubrication oil

23 Cleaning thinner

10. Perform Body Surface Cleaning by Mechanical Process

Overview


1. Use power operated wire brush and normal grinder 2. Use double action sander 3. Remove paint on aluminum panels using single action sander 4. Remove rust on vehicle body parts using wire brush and Sandpaper


1. Remove paint in aluminum body using single action sander

P1. Select the areas from which Paint had to be removed.

P2. Take necessary tools and equipment

P3. Prepare the single action sander for removing paint

P4. Removes existing paint using the single action sander.

P5. Smoothen the body surface by applying dry sandpaper

P6. Clean the body surface

P7. Clean the work place and tools and store them properly

2. Surface preparation

P1. Examine the areas marked for removing rust

P2. Take necessary tools and equipment, check their workability.

P3. Prepare the single action sander for removing rust

P4. Remove rust using the single action sander check whether all the rust had been removed

P5. Clean the body using dry sandpaper

P6. Clean the workplace and tools and store them

3. Remove rust using power wire brush

P1. Determine the areas to be clean

P2. Using a power wire brush

P3. Take necessary tools and equipment

P4. Prepare the power wire brush appropriately for relevant job

P5. Remove rust from the determined areas using the power wire brush

P6. Apply dry sandpaper only on places cleaned using the power wire brush

P7. Clean the de-rusted vehicle body parts

P8. Clean the workplace and tools and store them properly

4. Remove rust using Dry sandpaper

P1. Mark the areas from where rust had to be removed.

P2. Select dry sandpaper according to the extent of rusting.

P3. Remove the rust completely using dry sand paper.

P4. Cleans the vehicle body parts and keeps in a suitable place.

P5. Clean the work place and tools and store them properly.


• Rusting and steps to be taken to prevent it

• Instructions for removing rust

• Use of double action sander, normal grinder, power wire brush and sand paper and hints on maintaining the above mentioned equipment

• Aspects to be considered when using double action grinder

• Types of double action sander and their functioning

• Aspects to be considered for proper operation of sanders

• Distinguishing properties of aluminum metal

• Dry sandpaper and distinguishing properties of different types, methods and situations of using them

• Hints for selecting required sandpaper


S. No. Descriptions


2 Cotton Gloves

3 Dust mask

4 Goggles

5 Safety Shoes

6 Measuring Tape

7 Mallets in Rubber

8 Cutting Disc

9 Grinders

10 Single Action Sander

11 Double action sander

12 Wire Brushes

13 Power Wire Brush

14 Files

15 Sand papers

16 Shop Cloth

17 Glass Sealant

18 Safety Shoes

19 Safety Helmet

11. Perform Body Surface Cleaning with Chemical Process

Overview:


1. Remove rust from corroded vehicle body / body parts using chemicals. 2. Remove existing paint from body parts of vehicles using chemicals. 3. Remove oil and grease on vehicle body / body parts using chemicals. 4. Remove dampness in vehicle body parts using chemicals. 5. Remove silicon in vehicle parts using chemicals.


1. Remove rust using chemicals

P1. Mark the areas from which rust had to be removed

P2. Prepare the necessary tools and chemicals

P3. Wear PPE according to instruction

P4. Mask the areas where rust removing chemicals were not applied

P5. Remove rust by applying the rust removing chemical

P6. Check whether all the rust was removed

P7. Clean vehicle body, tools and equipment and workplace using detergents.

2. Remove existing paint using chemicals

P1. Determine the areas on the body parts from which paint had to be removed

P2. Collect required chemicals and other materials


P4. Remove paint only from areas where paint had to be removed using chemicals

P5. Examine whether all paint had been removed

P6. Perform work in well-ventilated area

P7. Clean the tools, vehicle body parts and the workplaces after finishing work

3. Remove oil and grease using chemicals

P1. Mark the areas covered with oil and grease

P2. Collect the chemicals to be applied and tools

P3. Apply chemicals in relevant areas and remove oil and grease

P4. Examine whether all the oil and grease were removed

P5. Perform work in well-ventilated area

P6. Clean the tools and the workplace after finishing work

4. Remove dampness of body surface

P1. Select the areas with oil and grease on the vehicle body

P2. Prepare necessary tools and chemicals


P4. Apply chemicals on the damp areas and remove oil and grease

P5. Check whether vehicle body was fully dry


5. Remove silicon using chemicals

P1. Examine well and identify the area from which silicon had to be removed


P2. Prepare the required chemicals and tools

P3. Apply chemicals on areas coated with silicon

P4. Remove silicon using chemicals according to the instructions of the manufacturer

P5. Check whether silicon had been removed



• Types of chemicals used to remove existing paint, rust, oil and Grease, dampness and silicon from vehicle body parts and their qualities.

• Guidelines and safety measures to be followed in the use of chemicals.


S. No. Descriptions


2 Chemical resistance gloves

3 Respirator

4 Goggles

5 Safety Shoes

6 Paint Remover

7 Rust Remover

8 Degreaser

9 Shop Cloth

10 Masking Tape

11 Masking Paper

12 Sealant cutting tool

13 Safety Shoes

14 Safety Helmet

15 Cleaning thinner

12. Maintain Vehicle Body Repair Tools, Equipment and Machinery

Overview


1. Label tools and equipment for easy identification and store safely. 2. Maintain polisher 3. Prepare a monthly plan for maintenance of hand tools 4. Make a sanding block 5. Maintain sanding machine 6. Inform relevant sections about malfunctioning equipment 7. Dismantle spray gun and record its performance 8. Use spray gun cleaner 9. Connect the spray gun to the air compressor and activate the air compressor.


1. Maintain polisher P1. Remove, wash, dry and store the pads of the polisher

P2. Clean the polisher with compressed air and store

P3. Service the polisher at the proper time

2. Maintain sanding machine

P1. Clean the dust extraction bag

P2. Check the amount of oil required for the machine

P3. Control air current obtained from the compressor

P4. Clean the sanding machine with compressed air and store it

P5. Service at the proper time

3. Clean spray gun manually

P1. Dismantle separately the spray gun, the nozzle, the bottle and the cap after applying one kind of paint

P2. Wash each of them separately using cleaning thinner kerosene

P3. Cleaning the nozzle, did you insert a thin wire and remove the paint in the vent

P4. Place the nozzle inside the bottle of spray gun and store all the parts securely

4. Clean spray gun using gun cleaner

P1. Dismantle the spray gun into separate parts

P2. Prepare spray gun cleaning liquid and pour it into the gun cleaner

P3. Place in the cleaning machine the parts dismantled from the spray gun(nozzle, bottle, cap, control lever (trigger)

P4. Activate the machine and wash the parts twice or more number of times(until all the paint was removed)

P5. Put thinner to the washed and cleaned parts and assemble again

P6. Store the spray gun in a secure place

5. Replace compressor air hose

P1. Take the tools needed to fix the hose to the air compressor to the relevant place

P2. Select the hose to be fixed to the air compressor according to the instructions of the manufacturer

P3. Fix the hose to the compressor using couplings

P4. Check whether there were leaks at the places where the hose was


fixed by activating the compressor

P5. Clean and store the tools and equipment

6. Replace spray gun repair kit

P1. Dismantle parts of the spray gun separately according to the instructions of the manufacturer

P2. Select the repair kit of the spray gun according to the part number of the manufacturer

P3. Assemble the spray gun again using the repair kit according to the instructions of the manufacturer

P4. Check whether there were air leaks by connecting the spray gun to the air compressor

P5. Clean and store securely the spray gun

7. Top up oil level of compressor

P1. Check the oil level of the compressor every day in the morning

P2. Select the type of oil according to that given by the manufacturer

P3. If the oil level has dropped, fill oil up to the marked level

8. Drain water in the air tank of compressor

P1. Check whether there was water in the air tank of the compressor every day in the morning

P2. Drain water by opening the drain tap

P3. Close the tap to prevent air leakage

P4. If there was water while painting, drain the water collected in the air tank following Steps 2 and 3 above

9. Replace air filter of compressor

P1. Decide whether a filter has to be fixed to the compressor or not

P2. Decides a suitable type of filter?

P3. Collect necessary raw materials and equipment after replacing the filter, and operate the compressor again and check whether the air produced was free from water clean and store the equipment

10. Drain water in air regulator

P1. Decide whether water had to be drained from the regulator

P2. Drain the water by activating the knob or the switch key of the regulator

P3. Check a number of times whether the air coming through the regulator was free from water


• Guidelines on maintenance of tools and equipment

• Guidelines to be followed and matters to be considered when storing finishing equipment

• Guidelines to be considered in storage

• Documents used in storing and their maintenance

• Guidelines to be considered in maintaining the polisher

• Maintain single action and double action sander and their functions

• Aspects to be considered in using sanding machine.

• Functioning of the sanding machine and guidelines to be considered in its maintenance

• Aspects to be considered in updating maintenance register

• Knowledge about the components of the air compressor and the spray gun

• Knowledge about guidelines for maintaining air compressors and spray gun

•


S. No. Descriptions


2 Cotton Gloves

3 Compressor Oil

4 Lubrication Oil

5 Cleaning Thinner

13. Maintain Paint Booth and Stores

Overview


1. Maintain paint booth Sealing filters, Floor filter, pre filter 2. Replacement of paint booth filter 3. Fuel filling in fuel tank of paint booth burner 4. Store material in order position 5. Update the documents relevant to stores when raw materials and chemical 6. Understanding of 5S and ISO method


1. Maintain paint booth filters

P1. Take the air filter out and blow air into it

P2. Cleans the inside of paint booth using an air hose

P3. Fixes the air filter blowing air to clean it

P4. Operate air filter in the paint booth for at least half an hour

P5. Air filter was more than 18 month old replace it with a new one

2. Maintain cleanliness of paint booth

P1. Decide on the parts to be cleaned

P2. Gather the tools / equipment and materials

P3. Test the functioning of tools /equipment

P4. Remove the vehicle, paint and other material

P5. Clean the interior of the paint booth using a vacuum cleaner

P6. Close doors to prevent the entry of dust

P7. Store the tools / equipment properly

3. Replace paint booth filter

P1. Decide on the task to be performed

P2. Gather tools and equipment

P3. Test the condition of tools and equipment If paint dust remains inside often after painting about 100 vehicles,

P4. Remove filters from their attachments

P5. Clean the places where filters and their supports were fixed using a vacuum cleaner

P6. Select filter according to the accessory number of paint booth manufacturer

P7. Fix that filter according to the instructions of manufacturer

P8. Test the functioning of the filter

P9. Store the tools / equipment properly after completion the work.

4. Fill fuel in paint booth furnace / burner

P1. Identify the fuel tanks of the paint booth

P2. Examine the fuel tanks of the paint booth

P3. Fill the fuel tanks with not more than the required quantity of fuel

P4. Remove electric wires and inflammable materials

P5. Fix fire extinguishing equipment

P6. Fix alarm sign

5. Store materials P1. Separate raw materials (types of chemical paints), inflammable materials and poisonous materials


P2. label all the materials for easy identification (using suitable diagrams or names) and store them in the correct places

P3. Store inflammable materials separately from other materials

P4. Store these materials under environmental conditions as stated by the manufacturer of such materials

P5. Keep records of receipts and issues of materials

6. Maintain paint stores

P1. label paint and other chemicals and store them separately

P2. Store tools and equipment enabling easy access

P3. Note down places where fans and blowers required for raw materials are fixed

P4. Update the documents relevant to stores when raw materials and chemical substances get spilled inside the stores,

P5. Mention how they should be removed without catching fire

P6. Remove unusable materials from the stores

7. Store tools and equipment

P1. Separate tools and equipment according to their use and value

P2. Provide numbers / labels to identify every tool and equipment

P3. Decide on the place for storing each tool and equipment

P4. Decide about safe places for storing valuable tools and equipment

P5. Label such places

P6. Store tools and equipment at the relevant places

P7. Enter information about tools and equipment in the stock-book

P8. Sort out the malfunctioning tools and equipment and store them separately

P9. Maintain data about malfunctioning tools and equipment


• Different materials used in painting and their properties

• Types of filters and their properties, their applications and manufacturer’s instructions

• The guidelines to be considered in maintaining filters

• A brief introduction about the 5S method and ISO 14000

• Fuel tanks and their maintenance

• Guidelines regarding stores and maintenance of materials stored

• Techniques of cleaning

• Classification of paints, cost of painting materials and distinguishing inflammable materials

• Aspects to be considered in storing paint

• Safety precautions to be adopted in maintaining stores


S. No. Descriptions


2 Cotton Gloves

3 Dust Mask

4 Air Compressor

5 Air blow Gun

6 Shop cloth

14. Apply Polyester Putty

Overview


1. Assessment the range of damage 2. Surface preparation 3. Putty application 4. Putty shaping 5. Putty sanding 6. Filler application


1. Assessment the range of damage

P1. Collect the necessary tools & equipment

P2. wear the necessary safety gear.

P3. Clean the panel so aS. No.t to overlook damage

P4. Assess damaged area by (observe, Touch, Press, Compare )

P5. Mark the top, bottom, left and right limits and define the range of damage.

P6. Assess the dent and bump on the surface.

P7. Check the tension of the damage panel

P8. Assess the differences by comparing damaged area to undamaged area

P9. Define the range of damage

2. Surface preparation

P1. Identify the areas to be prepare

P2. Collect the necessary tools, equipment and materials

P3. Prepare the areas to be protected

P4. Prepare the panel for putty application

P5. Remove old paint coat and rust to within the marked area.

P6. Sand the surface with a single-action sander using 60 to 80 grit sandpaper

P7. Smooth out the step between the bare metal and original paint film

P8. Attach 120 grit sandpaper to the dual action sander for sanding

P9. Remove dirt, dust and grease from the surface to prevent irregularities.

P10. Wipe off the area with a shop cloth

P11. Blow air after removing any dirt or dust with a shop cloth

P12. Apply primer to exposed bare metal

3. Apply polyester putty manually

P1. Identify the areas for applying the putty

P2. Collect the tools & equipment and materials


P4. Mix the putty and the hardener

P5. Mix the putty by moving the mixing stick up and down while turning the can.

P6. Tighten the cap of tube and massage the entire tube to mix the


hardener

P7. Combine the putty and hardener for mixing ratio follow the manufacturer instruction.

P8. Apply putty thinly within 10mm of the outer edge of the scuffed area.

P9. Apply putty higher than the undamaged surface overlaps 1/3 of the previously applied putty.

P10. Clean the workplace tools & equipment and store them properly.

4. Putty sanding by Dry sanding machine

P1. Identify the areas to be sanded

P2. Collect the tools equipment and materials


P4. Identify the parts to be protected

P5. Adjust the tools and equipment for sanding

P6. Stand in a position where the sander can reach both ends of the putty application area easily

P7. Start sanding when the putty and panel reach room temperature

P8. Use a sander with 80 grit sandpaper to remove dent or bump from putty surface

P9. Sand the putty surface to 80% of the correct surface with 120 grit sand paper

P10. Sand the putty surface to 90% of the correct surface with 180 to 220 grit sand paper

P11. Sand with 320 grit sandpaper for surface finishing

P12. Check the finish of putty surface remove all abrasion mark

P13. Clean the work place tools & equipment and store them properly

5. Putty sanding by Hand sanding block

P1. Identify the areas to be sanded

P2. Collect the tools equipment and materials


P4. Identify the parts to be protected

P5. Attached the hand sanding block with dust extraction machine

P6. Stand in a position where the hand sanding block can reach both ends of the putty application area easily

P7. Start sanding when the putty and panel reach room temperature

P8. Use a hand sanding block with 80 grit sandpaper to remove dent or bump from putty surface

P9. Sand the putty surface to 80% of the correct surface with 120 grit sand paper

P10. Sand the putty surface to 90% of the correct surface with 180 to 220 grit sand paper

P11. Sand with 320 grit sandpaper for surface finishing

P12. Check the finish of putty surface remove all abrasion mark


6. Apply one pack nitrocellulose primer filler

P1. Take a decision regarding the weather

P2. Decide on the areas for application of NC filler

P3. Decide on the areas to be protected


P4. COLLECT the tools, equipment and materials

P5. Check the workability of tools and equipment


P7. Mix NC paint using weighing scale according to ( MSDS )

P8. Filter the paint and pour in to the spray gun

P9. Adjust the pressure of air

P10. Adjust the spray gun according repair area

P11. Clean the surface with cleaning thinner

P12. Air blowing on surface to remove dirt particle on surface

P13. Apply tack cloth

P14. Apply paint on surface according to paint spraying method

P15. Clean the spray gun after work finish

P16. Clean the work place, tools & equipment and store them properly

7. Apply 2 pack Urethane type filler

P1. Take a decision regarding the weather

P2. Decide on the areas for application of urethane type filler

P3. Decide on the areas to be protected

P4. Collect the tools, equipment and materials

P5. Check the workability of tools and equipment


P7. Mix urethane primer and hardener using weighing scale according to ( MSDS)

P8. Filter the primer and pour in to the spray gun

P9. Adjust the pressure of air

P10. Adjust the spray gun according repair area

P11. Clean the surface with cleaning thinner

P12. Air blowing on surface to remove dirt particle on surface

P13. Apply tack cloth

P14. Apply paint on surface according to paint spraying method


P16. Clean the work place, tools & equipment and store them properly

8. Apply nitrocellulose putty

P1. Make a decision about the weather

P2. Determine the areas to be filled

P3. Identify the areas to be protected

P4. Collect the tools, equipment and materials


P6. Test the workability of the rubber pad

P7. apply putty between 900- 600 for small holes / defects

P8. apply again using reduced pressure

P9. Clean the workplace and the tools / equipment and store the tools /equipment

P10. Allow to dry for 1 hours


• Types of metal filler, high filler, and one pack nitrocellulose primer filler, nitrocellulose putty; their qualities and information on using them

• Guidance to be followed in the use of above material

• Hints on leveling metal filler by wet method and dry method

• Hints for deciding areas that do not require any application

• Hints for deciding the suitable weather for applications

• Properties of raw materials used for application and their usage

• Types of metal fillers and their properties

• Instructions to be followed during applications

• Hints for leveling using a machine

• Hints on detecting defects of the vehicle body by touch and observation

• Information about sand papers

• Types of high fillers and instructions on using them

• Instructions to be followed polyester putty & filler

• Types of nitrocellulose; their use and properties

• Information on polyester putty and its use


S. No. Descriptions


2 Solvent Resistance Gloves

3 Apron

4 Google

5 Respirator

6 Dry Sanding Machine

7 Sanders

8 Hand Sanding Block

9 Weighing Scale

10 Paint Mixing Stick

11 Putty Spatula

12 Air Compressor

13 Spray Gun

14 Air blow Gun

15 Shop cloth

16 Polyester Putty

17 NC Putty

18 NC Primer

19 Urethane Primer

20 Orbital Sand Papers

21 Sand Paper for Hand Block

15. Prepare Paint Booth and Vehicle

Overview



1. Mask required body parts

P1. Decide what coating to be applied

P2. Decide what body parts do not need the particular coating

P3. Select materials and tools required to mask those body parts

P4. Cover such body parts with masking tape or some other material to prevent paint dripping on to them when applying

P5. Clean tools and equipment and store them

2. Remove dust on painted surface

P1. Identify the areas to be painted

P2. Select the required equipment and material

P3. Use suitable water sand paper

P4. Scrub off the dust layer

P5. Check whether parts covered with dust were scrubbed off

P6. Clean the place where the task was performed and store equipment and material

3. Adjust paint booth temperature

P1. Determine the weather condition in making the decision

P2. Check whether the sensors in the paint booth were kept in the places mentioned by the manufacturer

P3. Adjust the temperature regulator in the room to the required temperature

P4. Measure the internal temperature.

P5. Determine correctly the task at hand and the relevant temperature

P6. Check whether the machines and equipment operated as stated by manufacturer

4. Fix water separating filter

P1. Examine whether there was a defect in the water separating filter

P2. Prepare the required tools and equipment

P3. Unfix and remove the water separating filter

P4. Select water separating filter of the particular type

P5. Fix it at the correct location

P6. Clean and store tools and equipment

5. Adjust paint booth burner / furnace

P1. Mask the parts that needed to be protected

P2. Gather the tools / equipment and the materials

P3. Check whether there was fuel / electricity leakage in the vehicle that was painted

P4. Remove paint / thinner from the paint booth

P5. Check whether the burners were in working order

P6. Locate the vehicle at the center of the paint booth

P7. Close all the doors of paint booth

P8. Check whether the fire extinguishing equipment was functioning

P9. Adjust both / all the plugs in the burners to emit a high temperature

P10. Operate all the burners


P11. Prepare for the next task until the green bulb in the thermometer turned red and stopped automatically

6. Adjust paint booth heating timer

P1. Decide the time required for heating according to the intended paint

P2. application and the job

P3. Adjust both / all the timers as to indicate the same time

P4. Adjust the relevant timers according to the required time

7. Operate paint booth ventilator feed air fan

P1. Gather the tools / equipment and material

P2. Check whether they were functioning properly

P3. Prepare the vehicle to be painted/ paint and were you ready

P4. Check whether the feed / exhaust air fan in paint booth was functioning

P5. Switch on the fan

P6. Switch off the feed / exhaust fan in the paint booth after painting


• Instructions for removing dust on the body parts before painting

• Aspects to be taken into consideration in removing dust (safety)

• Instruction for controlling the internal temperature of the paint booth

• Instruction for safety precautions to be adopted when adjusting the internal temperature

• Instruction for functioning of a water separating filter

• Reasons for draining water from the air system

• Aspects to be taken into consideration in adjusting the heating furnace in the paint booth

• Instruction for safety precautions to be adopted in adjusting the heating furnace

• Instruction the necessity of adjusting the heating timer in the paint booth

• Aspects to be considered in adjusting the heating timer


S. No. Descriptions


2 Cotton Gloves

3 DustMask

4 Air Compressor

5 Air blow Gun

6 Shop cloth

7 Masking tape

8 Masking Paper

9 Sand Paper

16. Apply Primer Surfacer

Overview



1. Scuffing for primer Surfacer with sanding machine

P1. Determine the areas for scuffing primer Surfacer

P2. Determine the areas that need to be masking

P3. Collect tools, equipment and material

P4. Check functioning of equipment


P6. Attached 320 grit sand paper with dual action sander

P7. Adjust the revolution speed of dual action sander

P8. Scuff the surface to a distance of 100mm from the edge

P9. Bring the sander into contact with the panel before starting the sander

P10. Scuffing the act of finely scratching a surface with sandpaper

P11. Clean the work place

P12. Clean tools & equipment and store them properly

2. Scuffing for primer Surfacer with hand sanding block

P1. Determine the areas for scuffing primer Surfacer

P2. Determine the areas that need to be masking

P3. Collect tools, equipment and material

P4. Check the pad of sanding block


P6. Attached 320 grit sand paper with hand sanding block

P7. Attached hand sanding block with dust extraction machine

P8. Scuff the surface to a distance of 100mm from the edge

P9. Hold the sanding block at 45degrees to direction of sanding

P10. Scuffing the act of finely scratching a surface with sandpaper



3. Cleaning &degreasing before primer Surfacer application

P1. Determine the area for cleaning & degreasing

P2. Collect the necessary tools / equipment and materials


P4. Wipe the area with shop cloth which is socked in degreaser

P5. Blow air on the surface to dry the degreaser

P6. Wipe away any dirt or dust with a tack cloth Without applying pressure

P7. Clean work area


4. Masking before primer Surfacer application

P1. Determine the parts & body for masking

P2. Gather tools / equipment and materials

P3. Protect all body for over spray use masking foil

P4. Mask the openings after remove fittings.


P5. Mask the gaps between the panel

P6. Use reverse masking to avoid creating a step around the edge of the repainted area


P8. Clean Tools & equipment and store them properly

5. Mixing of primer Surfacer

P1. Decide the area where primer Surfacer is to be applied

P2. Calculate the amount of primer to be Mixed

P3. Collect tools / equipment and materials

P4. Mix it primer Surfacer & hardener according to manufacturer’s instructions

P5. Calibrate the weighing scale at zero

P6. Pour the primer Surfacer in to the mixing container according to job

P7. Pour the hardener in to the container according to manufacture instruction

P8. Mix all component properly using a mixing stick

P9. Clean work place

P10. Clean tools / equipment and store them properly

6. Primer Surfacer application

P1. Determine the areas Primer Surfacer to the applied

P2. Mask the body that need to be protected

P3. COLLECT tools / equipment and materials

P4. Check whether the tools / equipment are functioning

P5. Strain the primer Surfacer using a strainer according to instruction

P6. Pour the primer Surfacer in to the spray gun

P7. Adjust the air pressure according to instruction

P8. Adjust the spray gun

P9. Apply primer Surfacer according to specified method



7. Drying of primer Surfacer From infrared heater

P1. Determine the area for drying of primer Surfacer

P2. Collect tools / equipment and materials


P4. Connect the power cable securely

P5. Adjust the distance of infrared heater between panel

P6. Adjust the timer of infrared heater according to standard

P7. Dry the primer Surfacer according to manufacturer instruction

P8. Clean and store tools/ equipment and store them securely


• Types of primer Surfacer

• Mixing of primer Surfacer

• Types of anticorrosive paints and their properties

• Instructions to be followed when using anticorrosive paints

• Types of infrared heater and drying procedure

• Types of foam and properties

• Instructions for mixing of hardener

• Types of mixing thinner and there use according to temperature

• Instructions on determining application condition

• Types of hardener and there use

• Instructions related to application of primer Surfacer


S. No. Descriptions



3 Spray Suit

4 Spray Gun

5 Respirator

6 Air Compressor

7 Air blow Gun

8 Paint Booth

9 Weighing Scale

10 Mixing Stick

11 Shop cloth

12 Masking tape

13 Masking Paper

14 Sand Paper P-300

15 Primer Surfacer

16 Hardener

17 Mixing Thinner

17. Perform Color Matching & Mixing

Overview

After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications


1. Decide type of paint to be applied

P1. Discuss to decide the customers requirement

P2. Decide on different types of paint to be applied

P3. Prepare approximate estimates

P4. Decide on the type of color

P5. Decide on the price based on agreement with the customer

2. Measure existing color of vehicle body

P1. Decide the area where paint is to be applied

P2. Select the required tools and equipment

P3. Take the vehicle to a place with suitable lighting condition

P4. Keep the color gauge on the vehicle and obtain data

P5. Get paint prepared and examined from a color matching

3. Match colors to be applied

P1. Obtain information about the color to be applied by discussing with the customer

P2. Compare the required color with the color card

P3. Prepare colors by mixing primary colors in different ratios

P4. Apply paint on a part of the vehicle and compare (by looking at 450 )

4. Mix paint colors

P1. Select primary color mixtures

P2. Prepare necessary weighing scale and measuring instruments for matching colors

P3. Get color volumes from the computer for matching color

P4. Mix colors according to volumes to get the required color

P5. Match colors by applying on another metal sheet before applying it on the vehicle

P6. Compare either with color code or with the color of vehicle to check whether the required color was obtained

P7. Calculate the volumes of paints to be used Accordingly

P8. Prepare the required quantities (liters) of paint

P9. Clean and store the tools and equipment used for mixing

5. Mix component colors using computer

P1. Operate color mixing computer at color matching room

P2. Obtains the available color code or color catalogue number according to customer’s request

P3. Enter the color code in the computer and obtain primary colors ratios

P4. Measure volume ratios using an electronic weighing machine

P5. Pour the measured volumes of paint into a clean vessel and stir it

P6. Compare the prepared mixture with the color to be applied


P8. Shut down the computer after getting the relevant information

6. Decide basic color ratios

P1. Identify clearly the given colors


P2. Decide the primary colors of which the particular color is made of

P3. Mix primary colors in different ratios to find the ratio of primary colors

P4. Calculate the primary color ratios after it was matched


7. Adjust paint viscosity

P1. Mix paint to be applied using a mixing stick

P2. Measure the paint using ICI measuring ruler and pour into a clean vessel

P3. Measure an equal volume of thinner with the same measuring rulerand pour into the vessel

P4. Mix paint and thinner According to manufacture instruction

P5. Check the viscosity of the mixture using measured volumes ofpaint and thinner until the required viscosity was obtained

P6. clean the used equipment with thinner after obtaining the required viscosity


• Guideline for shade card, formula chart, color tint guide

• Guide lines to use the color gauge

• Techniques used to match colors

• Guide lines to mix colors manually

• Paint colors and their characteristics

• Guide line to select basic colors and ratios

• Decide quality of paints

• Effects of light conditions in matching colors and color matching light

• Understand basic color, secondary color, and complimentary color

• Identify types of paints using different methods

• Factors to be considered in comparing colors

• Calculate the quantity of paint

• Hints on obtaining the required colors mixing quickly by identifying new colors

• Use of computers for mixing ratio


S. No. Descriptions



3 Google

4 Spray Suit

5 Spray Gun

6 Respirator

7 Air Compressor

8 Air blow Gun

9 Paint Booth

10 Weighing Scale

11 Mixing Stick

12 Shop cloth

13 Computer with formula software

14 Mixing color with mixing rack

15 Mixing Container

16 Mixing Thinner

17 Mixing Stick

18 Sand Paper P-300

19 Primer Surfacer

20 Hardener

21 Mixing Thinner

18. Apply Body Sealer

Overview



1. Scuffing for body sealing

P1. Collect tools & equipment for scuffing


P3. Scuff the area with double action sander use 600 grit sand paper

P4. Scuff with 600 grit scuffing material in locations where it is impossible to use a dual action sander

P5. Scuff the area, as it will be difficult to scuff after applying body sealer the paint manufacturer


2. Nozzle processing

P1. Collect tools & equipment for nozzle processing


P3. Cut the tip of nozzle according to required shape of the sealer

P4. Cutting both size to form a peak shape

P5. Cutting one side of a peak shape

P6. Press with pliers

P7. Cut the other side so that it is flat


3. Cleaning & degreasing

P1. Decide on the areas to be clean

P2. Collect necessary tools & material

P3. Clean and degrease the surface where body sealer is to be applied

P4. Blow air across the surface to remove dirt and dust

P5. Wipe the surface with a shop cloth soaked id degreaser

P6. Wipe away any dirt or dust with a tack cloth



4. Application of body sealer

P-1. Wear PPE according to instruction P-2. Collect the essential equipment and materials P-3. Grasp the lever with your dominant hand, and hold your other in the

vicinity of the nozzle P-4. Adjust the air pressure Use low air pressure to apply the sealer in

a narrow and thin manner P-5. Adjust the air pressure Use high air pressure to apply the sealer in

a wide and thick manner P-6. Adjust the angle of sealing gun P-7. Adjust speed and movement of sealer gun P-8. Find a position that allows you to stand in one place and apply the

sealer from start to finish without moving P-9. Use a rubber spatula to shape the body sealer P-10. Clean the work place tools & equipment and store them properly


• Types and composition of body sealer

• Preparation for body sealer

• Purpose of body sealer application

• Instructions on preparation for application of body sealer

• Relevant details of body sealer

• Guidelines and safety precautions to be followed in the application of body sealer

• Understanding of location and shape of body sealer


S. No. Descriptions



3 Google

4 Body Sealing Gun

5 Spatula

6 Respirator

7 Air Compressor

8 Air blow Gun

9 Knife Cutter

10 Weighing Scale

11 Mixing Stick

12 Shop cloth

13 Mixing Thinner

14 Mixing Stick

15 Body Sealer

16 Cleaning Thinner

19. Perform Masking

Overview



1. Preparation before masking

P1. Determine the area for cleaning & degreasing

P2. Collect the necessary tools / equipment and materials


P4. Wipe the area with shop cloth which is socked in degreaser

P5. Blow air on the surface to dry the degreaser

P6. Wipe away any dirt or dust with a tack cloth Without applying pressure

P7. Clean work area


2. Masking on opening area

P1. Collect tools & equipment for masking


P3. Insert your middle finger into the hole in the roll, pull out the desired length of tape

P4. Mask the openings left after fittings are removed

P5. Make sure that masking tape will not be peeled off by the air pressure

3. Masking on gaps P1. Collect tools & equipment for masking


P3. Mask the gaps between the panels use gap tape

P4. Pay extra attention to the upper and lower edges when masking the front and rear door gaps

4. Masking on fitting & glass

P1. Collect tools & equipment for masking


P3. Mask the borders of the fittings last using 18mm masking tape

P4. Leave a gap the thickness of the paint coat between the panel surface and the masking tape

P5. Mask the areas that require fine line tape first

P6. Mask the glass moldings that come into direct contact with the paint surface

P7. After painting, remove the masking tape at a 90-degree angle to the vehicle’s surface.


• Purpose of masking

• Types of masking tape and masking paper and masking foil

• Use of masking material

• Instructions on preparation for masking

• Relevant details of masking equipment

• Guidelines and safety precautions to be followed in masking procedure


S. No. Descriptions


2 Cotton Gloves

3 Masking Dispenser

4 Knife Cutter

5 Masking Tape

6 Shop cloth

7 Masking Papers

8 Masking Foil

9 Cleaning Thinner

20. Apply Under Coat

Overview



1. Apply undercoats

P1. Collect necessary tools & equipment


P3. Mask all the body parts of the vehicle except those that were to be painted

P4. Mix filler or primer with thinner according to the instructions of the paint manufacturer

P5. Measure the viscosity of the mixture According to instruction of the paint manufacture

P6. Fill the spray gun with the prepared mixture and start the air compressor

P7. Adjust the nozzle of the spray gun and test the uniformity of the spray

P8. Start the spray gun and apply the undercoat uniformly follow the method of application

P9. Check the under coat was uniformly applied covering all the areas

P10. Allow it to dry for 15 minutes

P11. Wash the vessels and equipment used with thinner

2. Apply one pack solid color paint

P1. Collect necessary tools & equipment


P3. Obtain paints and thinner

P4. Open the can, safely and mix the paint to have a uniform color

P5. Measure the quantity of paint by putting it into a separate vessel

P6. Close the can with the remaining paint and keep it air tight

P7. Mix paint and thinner according to MSDS

P8. Adjust the air pressure to the required level

P9. Add paint to the spray gun (to 3/4 of its volume)

P10. Spray paint by holding the spray gun at the appropriate distance in accordance with the prescribed method

P11. Allowing it to dry for the required period


3. Apply two pack metallic pearl color paint

P1. obtain the required brands and quantities of 2K metallic pearl color paint and thinner

P2. Collect the essential equipment and materials

P3. Obtain the spray gun 1.2 mm or 1.3 mm nozzle

P4. Mix the paint homogeneously

P5. Measure the required quantity of paint with the gauge and put into a clean vessel

P6. Measure hardener with the gauge in the required proportion, add to the vessel of paint and mix


P7. Measure thinner with the gauge in the required proportion, add it to the vessel containing paint and hardener and mix

P8. Prepare the paint mixture according to the instructions of the paint manufacturer (4 parts of paint, 1 part of hardener and 10% of thinner).

P9. Adjust the temperature of the paint booth to the required level

P10. Fill 3/4 of the spray gun with the paint mixture

P11. Adjust air pressure to the prescribed level and draw air in through the air filter

P12. Apply paint on the vehicle body follow the prescribed method

P13. Allow to dry the paint


P15. Keep the painted body/body parts safely for drying

4. Apply two pack solid color paint

P1. Prepare the surface to be applied with 2K solid color paint

P2. Arrange required quantities of paint and thinner

P3. Collect essential equipment and materials

P4. Select 1.2 mm or 1.5 mm nozzle spray gun

P5. Mix the paint well till it was homogeneous

P6. Measure the required amount of paint with the gauge and put into a clean vessel

P7. Measure hardener with the gauge in the required proportion, add to the vessel of paint and mix

P8. Measure thinner with the gauge in the required proportion, add it to the Vessel containing paint and hardener and mix (Viscometer may be used).

P9. Maintain the required temperature in the paint booth

P10. Draw air through the air filter under the prescribed pressure

P11. Add the required amount of paint mixture to the spray gun (about 3/4).Did you adjust the flame of the spray gun to the required level

P12. Apply paint on the vehicle body follow the prescribed method

P13. Check that the painting was in good condition

P14. Bake the body after bringing the painting booth temperature to the prescribed level


5. Apply transparent colored silver paint

P1. Check the areas well prepared

P2. Obtain the necessary products

P3. Collect essential tools and equipment

P4. Read and understand the instructions/data in the manufacturer’s information leaflet

P5. Mix the silver paint well to the first application

P6. Add the mixed paint to another vessel

P7. Measure with the gauge the required quantity of thinner and add

P8. Take the ambient temperature into consideration

P9. Get air through the air filter under the prescribed pressure

P10. Add the required amount of paint (about 3/4) to the spray gun

P11. Adjust the flame of the spray gun(about 3/4)


P12. Make the spray at the correct distance

P13. Allow the parts to stand for the required time to dry

P14. Select the color for the second coat

P15. Apply the second paint color follow the above steps


6. Apply one pack metallic pearl color paint

P1. Take weather conditions into consideration

P2. Decide on the areas to be painted

P3. Collect the necessary equipment

P4. Obtains paint and thinner.

P5. Mix paint well after opening the can

P6. Measure the required quantity of paint with the gauge and add it to a clean vessel

P7. Add and mix thinner according to the standard proportion

P8. Draw the required amount of air in through filters

P9. Filter the mixed one pack metallic pearl color paint

P10. Add the required quantity of paint (about 3/4) to the spray gun

P11. Wear the safety gear

P12. Apply paint in the paint booth,

P13. Adjust the temperature to suit the paint

P14. Adjust the flame of the spray gun as required

P15. Perform spraying by holding the spray gun at the appropriate distance

P16. Allow the body to dry for an appropriate period

P17. Bake the vehicle body well in the paint booth



• The types of fillers and primers used for the binding layer and how they are used

• Preparation of paint for the spray gun

• Types of one pack solid color paints and their qualities

• Instructions on preparation for application of one pack solid color paint

• Relevant details of application method

• Guidelines and safety precautions to be followed in the application of type of paint

• Types of two pack metallic pearl color paints and their basic qualities


S. No. Descriptions



3 Masking Dispenser

4 Spray Suit

5 Respirator

6 Air Compressor

7 Spray Gun

8 Air Blow Gun

9 Mixing Stick

10 Weighing Scale

11 Paint Booth

12 Shop cloth

13 Masking Papers

14 Masking Foil

15 Masking Tape

16 Sand Paper

17 Under Coat Paint

18 Hardener

19 Mixing Thinner

20 Cleaning Thinner

21. Apply Final Coats

Overview



1. Perform two tone painting

P1. Find out the customers need


P3. Determine the color to be painted

P4. Collect necessary equipment and raw material,

P5. Other sections were covered with masking

P6. Pour paint into the spray gun and adjust the spray gun & air pressure

P7. Apply the main color that had to be applied

P8. Allow to dry for 24 hours,

P9. Check again whether the components and areas that need to be covered were fully covered

P10. Apply the second color

P11. Open the top coat tin and mix until a uniform mixture was obtained

P12. Obtain required thinner

P13. Measure with a scale and pour top coat into a clean vessel

P14. Pour thinner to standard ratio and mix

P15. Obtain standard air of required amount through filters

P16. Strain (though strainer) the mixed paint

P17. Pour required amount of top coat into the spray gun

P18. Wear safety gear

P19. Adjust the required flame of the spray gun

P20. Applying the basic colors, cover both colors with top coat

P21. Clean the used equipment, and surroundings

P22. Store equipment properly

2. Perform touch up work

P1. Discus about special requirements with the customer

P2. Determine the sections to be newly painted

P3. Measure the condition and color of the applied paint

P4. Gather the necessary raw materials tools and equipment

P5. Clean the surface of the applied paint in sections that had to be newly painted

P6. Prepare the required paint mixture

P7. Pour paint into the spray gun, provide the necessary air pressure and adjust the spray gun

P8. Paint the sections that need to be painted follow safety procedure

P9. Clean & store tools and equipment at the end of the task

3. Apply one pack paint with retarder

P1. Collect necessary equipment and raw materials

P2. Use retarder type of paint selected for painting according to weather condition

P3. Add only 10% of the retarder to the quantity of paint used for


painting and prepare the mixture

P4. Pour paint into the spray gun, provide necessary air pressure and adjust the spray gun

P5. Apply paint with retarder mixture

P6. Clean and store the used tools and equipment

4. Apply one pack solid color paint with lacquer

P1. Decide that there was a suitable weather condition

P2. Collect necessary tools & equipment and raw materials

P3. Use lacquer relevant type of paint

P4. Mix paint and lacquer (1/4 liter of lacquer to be added to 1 liter of paint)

P5. Fill paint to 3/4 of spray gun

P6. Provide required air pressure and adjust the flame

P7. Apply the mixed paint

P8. Clean the used tools and equipment and the surroundings

5. Apply mat finish paint

P1. Determine the type of mat finish paint to be painted

P2. Decide that there was a suitable weather condition

P3. Collect necessary equipment and raw materials

P4. Mix paint with mat finish until it was uniform

P5. Add lacquer and other raw materials to paint according tospecified instructions

P6. Take required quantity of paint and keep the balance securely closed

P7. Fill paint to 3/4th of the spray gun

P8. Adjust required air pressure and adjust the flame

P9. Clean the used tools and equipment and the surroundings


• Instructions to be followed when using chemicals

• Points to consider when storing paint, chemicals and equipment

• Aspects to consider in two tone painting

• Hints to identify places with lapses after color painting

• Points to follow when touching up

• Distinguishing characteristics of paints that require use of retarder

• Distinguishing characteristics of paints and retarder

• Points to consider when applying one pack paint with retarder

• Safety required when applying one pack paint with retarder

• Reactions that take place when mixing paints (chemical ratios)

• Characteristics of lacquer and one pack paint and their use

• Points to consider when applying paint and lacquer

• Basic characteristics of mat finish paint

• Point to consider when applying mat finish paint

• Instructions regarding mixing of paints

• Properties of one pack clear lacquer


S. No. Descriptions



3 Spray Suit

4 Respirator

5 Air Compressor

6 Spray Gun

7 Air Blow Gun

8 Mixing Stick

9 Weighing Scale

10 Paint Booth

11 Shop cloth

12 Masking Papers

13 Masking Foil

14 Masking Tape

15 Sand Paper

16 Under Coat Paint

17 Top coat paints

18 Hardener

19 Retarder

20 Mixing Thinner

21 Cleaning Thinner

22. Perform Polishing to Body Surface

Overview



1. Assess and repair the paint surface

P1. Identify the areas to be cut using compound

P2. Gather the required tools & equipment and materials


P4. Press the paint coat with a finger to determine whether the surface is dry enough for compound polishing.

P5. Use the reflection of a fluorescent light to check the surface

P6. Wipe any dirt and dust off the panel with a clean shop cloth

P7. Correcting dirt particle & paint run using a rubber sanding block

P8. Sand the surface with P1500 – P3000 grit sand paper to produce a texture with slightly higher depressions and ridges than the original texture


2. Perform compound polishing

P1. Collect tools & equipment and material


P3. Select suitable materials for cutting

P4. Mask the fittings on the bordering section and panel edges

P5. Wipe any dirt and dust off the panel with a clean shop cloth

P6. Attach the buff pad in the center of the polisher

P7. Clean the buff pad to remove any foreign particles before use

P8. Spread the compound without spinning the polisher to prevent spattering

P9. Move the polisher so that each pass of the polisher overlaps the previous pass by 2/3

P10. Polish the surface using the polishing compounds in order from fine to ultra-fine

P11. Eliminate any swirl marks made during the rough polishing process to produce gloss.

P12. Use a polisher with a sponge buff pad to perform finish polishing with ultra-fine polishing compound

P13. Use the color matching light to check whether there are any remaining swirl marks

P14. Clean work place tools & equipment and store them properly

3. Paste body stickers

P1. Decide what to do after consulting the customer

P2. Decide the parts where stickers have to be pasted

P3. Gather the required tools, equipment and material

P4. Cut the relevant parts according to required shapes

P5. Clean those parts with a mixture of water and a kind of shampoo


using a manual spray gun

P6. Spray shampoo on the side where the sticker was pasted

P7. Place it / them to fit into the required part

P8. Spray shampoo outside the sticker

P9. Removing shampoo, and check the sticker past systematically without trapping air bubbles


4. Apply wax P1. Decide the parts to be waxed

P2. Whether the weather condition was suitable

P3. Gather the required raw materials

P4. Remove dust in areas where wax was to be applied

P5. Apply wax on the required parts

P6. Use a clean piece of cloth to scrub the wax applied

P7. Clean the surroundings and store raw materials properly

5. Clean body moldings

P1. Decide the type of beadings to be cleaned

P2. Gather raw materials used for cleaning

P3. Clean the beadings with water only or with any detergent (shampoo) that iS. No.t harmful to them

P4. Clean the beadings and other components without damaging them

P5. Clean the working area and store raw materials and equipment properly

6. Clean buffers and tires

P1. Obtain the required raw materials for cleaning

P2. Wash the buffers and tires to be painted with a detergent (a kind of shampoo) and clean them

P3. Remove the stains and dirt using another chemical substance (if necessary)

P4. Clean the working area and store materials and equipment

7. Re-fix emblem & logo

P1. Select special points to fix badges

P2. Gather the required tools / equipment and materials

P3. Mark the points where the badges were to be fixed

P4. Bore the relevant points as required

P5. Paste double side tape on the inner sides of the badges

P6. Paste the inner sides of the badges with excess tape

P7. Apply primer paint on the bored holes

P8. Paste / fix the badges as required

P9. Tighten the relevant nuts and bolts

P10. Clean and store the equipment


• The types of detergents used in washing vehicles and the aspects to be considered in using them

• The Types of polishing compound and polishing method, the aspects to be considered in following each of these methods and the safety procedures to be adopted

• Different types of wax and their properties

• Aspects to be considered in applying wax

• Different types of stickers and the aspects to be considered in pasting them

• Aspects to be considered in cleaning upholstery, windscreen, glass, body moldings, buffers and tires

• Aspects to be considered in fixing badges


S. No. Descriptions


2 Cotton Gloves

3 Safety Glass

4 Dust mask

5 Polisher

6 Dual Action Polisher

7 Polishing compound

8 Fine Polishing Compound

9 Ultra-Fine Polishing Compound

10 Weighing Scale

11 Shop cloth

12 Masking Tape

13 Cleaning Thinner

23. Prepare Paint Work Estimation

Overview



1. Decide work to be done

P1. Determine the customer’s requirements

P2. Inspect the parts to be repaired

P3. Determine the amount of work to be done

P4. Prepare the technical report (job card)

2. Study gathered information related to market

P1. Collect information on price lists for different parts / raw materials from the market

P2. Find out work done related to vehicles in the market

P3. Collect information about present charges for such work

P4. Collect information about existing charges / payments for essential services

P5. Collect information about number of workers employed and level of work for relevant work in the market

P6. Study this information in preparing estimates and determine the cost

3. Calculate overheads

P1. Determine the amount to be spent on electricity

P2. Determine the amount to be spent on water

P3. Determine the amount of stationary to be used

P4. Determine the amount to be spent on equipment and machinery

P5. Determine the expenditure on buildings and paint booth

P6. Determine the factory insurance cost

P7. Determine the expenditure on telephone, computer, typewriter etc.

P8. Determine the cost of specific tools and equipment

P9. Determine the cost of floor area of establishment

P10. Determine the amount spent for dependent workers who do not participate in the relevant job

P11. Determine the expenditure on insurance services

P12. Determine the expenditure on vehicles of the establishment

P13. Determine the total expenditure Accordingly, did you determine/Calculate a percentage to be added

4. Calculate material cost

P1. Obtain relevant information from the customer

P2. Identify the jobs to be done

P3. Determine the nature / type of raw materials of correct standard

P4. Determines the raw materials to be expended? (Thinner, paint, filler tape, Lacquer, water and dry sandpaper etc.)

P5. Calculate the total cost of raw materials

5. Calculate labor P1. Check the job


cost P2. Determine the extent of work relevant to the job

P3. Determine the time to be spent on the job

P4. Determine whether specialist assistance was necessary

P5. Allocate time according to type of workers

P6. Calculate the cost of an hour according to level of workers

P7. Calculate the cost of time according to level of workers

P8. Determine the total cost

6. Calculate cost of body parts

P-1. Determine customer’s preferences P-2. Examine the job P-3. Determine the parts to be newly fixed P-4. Obtain the parts of specific standard at the lowest quotation P-5. Obtain information about part number and manufacturing type of

parts P-6. obtain information about cost of partsIf the body part is to be

imported, calculate the expenditure cost

7. Calculate gross amount

P-1. Obtain correct and current data for calculation P-2. Calculate by adding together overheads, raw material cost, labor

costand cost of body parts (if any) P-3. Calculate expenditure on wastage P-4. Calculate government taxes and other charges relevant to above

basicexpenses P-5. get the percentage for profit used in the establishment P-6. Calculate the profit according to the percentage P-7. Calculate the gross amount follow the above steps


• Methods to be used for collecting data

• Methods of analyzing data

• Determination of cost of raw material

• Deployment of labor according to jobs

• Calculation of cost of labor per hour

• Financial and institutional rules and regulations

• Salient features about import market

• Methodology about estimation

• Points to consider when preparing a technical report


S. No. Descriptions

1 Calculator

2 Pen Writing Pad

Workshop Practice-III AD-324

1. Perform Engine Preventive Maintenance (Tune-Up)

Overview

These competency standards designed to enable the learner perform engine tune-up Petrol or Gasoline Engine, Diesel Engine under the specified procedure in the manual.


1. Tune-up Petrol or Gasoline “Conventional Carburetor” Engine

P1. Inspect the main components of Engine system

P2. Service/Replace the air cleaner

P3. Change/service the spark plug specified procedure.

P4. Adjust valve clearance

P5. Inspect/Replace/adjust CB Point gap from distributer.

P6. Adjust/service carburetor specified procedure.

2. Tune-up Petrol or Gasoline “Electronic Fuel injection” Engine

P1. Inspect the main components of EFI system.

P2. Service/ Replace the air cleaner

P3. Change/ service the spark plug specified procedure.

P4. Inspect fuel pressure.

P5. Use the scanner specified procedure.

3. Service of Mechanical Fuel injection Diesel Engine

P1. Inspect the main components of mechanical fuel injection diesel engine system.

P2. Service/Replace the air cleaner

P3. Change/ service the Glow plug specified procedure.

P4. Inspect/adjust fuel from fuel injection pump

4. Service of Electronic Fuel injection Diesel Engine

P1. Inspect the main components of EFI system.

P2. Service/ Replace the air cleaner.

P3. Use the scanner specified procedure.


• Describes the main components of engine and their functions as following: Air cleaner, spark plug, Distributer, HT Leads, Carburetor.

• Describe the operational principles of Mechanical and Electrical Fuel pump.

• Describe the operation of different types Fuel injection pump.

• Describe the different types of smoke.


• Capable to tune-up petrol engine.

• Capable to tune-up FFI Engine.

• Capable to Tune-up diesel engine.

• Capable to Tune-up EFI Diesel engine.

• Capable to check different types of smoke

• Capable to check fault Fuel injection pump


S. No. Descriptions

1 Vehicle (Diesel and petrol)


3 Multi-meter

4 Special service tools (Scanner)

2. Perform Periodic Maintenance

Overview

These competency standards designed to enable the learner to understand for periodic maintenance under the specified procedure in the manual.


1. Service of petrol Vehicle

P1. Inspect the performance of main components of vehicle.

P2. Perform the periodic service of engine according to shop manual.

2. Service of diesel vehicle

P3. Inspect the performance of main components of vehicle.

P4. Perform the periodic service of engine according to shop manual.


• Describe the periodic maintenance schedule of petrol vehicle.

• Describe the periodic maintenance schedule of diesel engine.


• Capable to periodic maintenance of petrol vehicle. .

• Capable to periodic maintenance of diesel engine.


S. No. Descriptions

1 Vehicle(petrol and diesel)


3 Gas analyzer

4 Scanner

3. Arrange Workshop Equipment According to Lay-out

Overview

These competency standards designed to enable the learner understand lay-out of workshop and use workshop equipment under the specified procedure in the manual.


1. Lay-out of work shop

P1. Marks the bay/pit different works.

P2. Mark the area for storage used oil.

P3. Mark the area for salvage.

2. Workshop equipment

P1. Mark the place hand tools

P2. Mark the place of measuring tools

P3. Mark the place of power tools and equipment


• Describe the lay out function of work shop.

• Describe the importance of lay-out of workshop.

• Describe the importance of lay-out for workshop tools and equipment


• Capable prepare layout of workshop bay/pit.

• Capable prepare lay-out work shop tools and equipment.


S. No. Descriptions

1 Vehicle

2 Hand tools ,Power Tools ,Measuring Tools

3 Workshop

4. Prepare Documentation for Automotive workshop

Overview

These competency standards designed to enable the learner understand the documentation of workshop under the specified procedure.


1. Service department documentation

P1. Prepare the job card and time sheet.

P2. Read the shop manual

P3. Read the service bulletin

P4. Read the parts catalog(Manual and e-catalog).

P5. Prepare the technical report

2. Parts Department documentation

P1. Prepare the main stock register

P2. Prepare the sub store register

P3. Order the parts through online.


• Describe the importance of shop manual.

• Describe the importance of service bulletin.

• Describe the importance of inventory register.


• Capable read the shop manual.

• Capable read parts catalog.

• Capable to prepare inventory register.

• Capable to prepare technical report.


S. No. Descriptions

1 Shop manual

2 Parts catalogue

3 Inventory register

5. Maintain Service Station Equipment

Overview

These competency standards designed to enable the learner maintain the service station equipment under the specified procedure.


1. Working with equipment

P1. Operate the hydraulic jack.

P2. Operate the crane

P3. Operate the car lift

2. Maintain the equipment

P1. Maintain the hydraulic jack.

P2. Maintain the crane

P3. Maintain the car lift


• Describe the importance and operation of hydraulic jack.

• Describe the importance and operation crane.

• Describe the importance and operation of car lift.


• Capable operate the hydraulic jack.

• Capable operate the crane.

• Capable to operate the car lift.


S. No. Descriptions

1 Hydraulic jack.

2 crane

3 car lift

6. Maintain Emission control system

Overview

These competency standards designed to enable the learner understand and service emission control system under the specified procedure in the manual.


1. Service of exhaust manifold

P1. Inspect performance of main components of exhaust manifold


P3. Inspect and perform service of positive crankcase ventilation (PCV)

P4. Inspect and perform service of exhaust gas recirculation system(EGR)

2. Service of Muffler



3. Service of catalytic convertor

P1. Inspects catalytic converter under the specified procedure.

P2. Replace the catalytic convertor

4. Service of PCV P1. Inspect and perform service of positive crankcase ventilation (PCV)

P2. Inspect the PCV through vacuum pump

P3. Remove and assemble PCV through engine

P4. Inspect and perform service of exhaust gas recirculation system(EGR)

5. Service of EGR Valve

P1. inspect and identify location of exhaust gas recirculation system(EGR)

P2. Check the EGR valve operation(vacuum and electric controlled)








• Capable identify/service Muffler assembly.

• Capable to service catalytic converter.

• Capable to service PCV System.

• Capable to service EGR system.


S. No. Descriptions

1 Vehicle


3 Gas analyzer

4 Vacuum pump

7. Perform Engine Overhauling

Overview

These competency standards designed to enable the learner understand and service emission control system under the specified procedure in the manual.


1. Petrol engine P1. Remove Engine from Vehicle.

P2. Remove Auxiliary components from Engine.

P3. Remove Cylinder Head.

P4. Dismantle engine block.

P5. Dismantle cylinder head.

P6. Clean dismantled parts

P7. Inspect engine block

P8. Repair Connecting rod and piston assembly

P9. Repair valve mechanism

P10. Repair cylinder Head

P11. Assembled Cylinder Head

P12. Assembled Crank Shaft to cylinder block

P13. Assembled Piston assembly

P14. Fix piston assembly to the cylinder block

P15. Mount Cylinder head to the cylinder block

P16. Set Valve Timing

P17. Fix Auxiliary Accessories

P18. Place to the engine vehicle

P19. Ready to start the engine

P20. Check performance

2. Diesel engine P1. Remove Engine from Vehicle.





















3. Motor cycle Engine

P1. Remove Engine from Motorcycle.





















• Describe the importance of engine overhauling.

• Describe the process of engine overhauling.


• Capable to petrol engine overhauling.

• Capable to diesel engine overhauling.

• Capable to Motor cycle engine overhauling.


S. No. Descriptions

1 Petrol engine ,diesel engine ,Motorcycle engine


3 Engine overhauling kit

4 Gas analyzer

8. Maintain Climatic Control System

Overview

These competency standards designed to enable the learner to inspect Heating ventilation and air conditioning system and faulty parts to be changed under the specified procedure in the manual.


1. Check and identify defects / or need for servicing of the Automobile Air Conditioner

P1. Job card/ estimate traced and vehicle located, and repair/ servicing initiated.

P2. Air conditioner switched on and checked the extent of repair/ or servicing ascertained, according to standard procedures.

P3. Defects localized and identified using specified test instrument as per manufacturer’s instructions and standard procedures.

P4. Equipment / items, material and accessories required for job

2. Repair / or service refrigerant system of the Automobile Air conditioner

P1. Refrigerant in the system recovered where necessary using specified recovery equipment following safety procedures.

P2. Condition of the compressor checked for defects and defective parts serviced / or replaced, oil level checked and topped up where necessary according to specifications and manufactures instructions.

P3. Evaporator checked visually and pressure tested for leaks / clogs and serviced / or replaced where necessary.

P4. Expansion valve checked for proper operation and serviced / or replaced as necessary.

P5. Condenser checked visually and pressure tested for leaks / clogs and serviced / or replaced as necessary using specified test equipment, adhering to safety practices.

P6. Cooling / blower fans checked for performance, tested and serviced/ or replaced as necessary according to manufacturer’s instructions, adhering to safety practices.

P7. Filter/receiver driers inspected and replaced as necessary according to manufacturers specifications.

P8. Refrigerant liquid lines and hoses pressure tested using specified test equipment adhering to safety practices and leaks repaired, and pressure tested after repair of leaks.

P9. Sight glass, oil separator, gas accumulator checked and replaced as necessary.

P10. Refrigerant circuit flushed with specified flushing agent.

P11. System pressure tested using dry nitrogen and evacuated using vacuum pump and tested according to specifications

P12. The recovered refrigerant and the cylinder weighed, and recorded.

P13. The recovered refrigerant cylinder coupled to the empty cylinder and to the recycling machine observing standard procedure and safety practices.

P14. The recycling machine started up, the process monitored and proper operation ensured.

P15. All refrigerant recycled, hoses disconnected and cylinder reweighed


to determine the weight of refrigerant recovered.

P16. Recycling of all recovered refrigerant ensured.



• Describe construction air condition system.

• Describe construction and working of AC compressor

• State the function of evaporator

• State the function of dryer

• Describe the function condenser.

• Understand and trace the fault of AC system


• Capable identify/ service of AC system.

• Capable to service of gas charging


S. No. Descriptions

1 Vehicle


3 Complete AC service kit

9. Perform Engine Output Testing

Overview

These competency standards designed to enable the learner use dynamometer and other equipment for testing engine under the specified procedure.


1. Use of dynamometer

P1. Inspect the dynamometer condition

P2. Attach the dynamometer with engine

P3. Operate the engine and check its condition.

P4. Record the data during testing

2. Measure volumetric efficiency

P1. Calculate the engine volume

P2. Measure vacuum pressure

P3. Measure Air volume

P4. Induction time


• Describe the dynamometer

• Describe the function of dynamometer.

• Describe the importance engine testing with dynamometer.


• Capable to attach the dynamometer with engine.

• Capable to record data.

• Capable to analyze engine condition.


S. No. Descriptions

1 E engine


3 Dynamometer

10. Read and Interpret Hydraulic and Pneumatic Code and Symbols

Overview

These competency standards designed to enable the learner to understand International Hydraulic and Pneumatic Code and Symbols.


1. Hydraulic symbol P1. Identify the hydraulic symbol.

P2. Identify the Hydro pneumatic symbol

P3. Inspect and read different hydraulic circuit diagram.

2. Pneumatic Symbol

P1. Identify the pneumatic symbol.

P2. Identify the Electro pneumatic symbol

P3. Inspect and read different pneumatic circuit diagram


• Describe the different hydraulic symbol

• Describe the different hydro pneumatic symbol.

• Describe the pneumatic symbol.

• Describe the different electro pneumatic symbols.


• Capable to identify the hydraulic symbol.

• Capable to identify the pneumatic symbol.

Generic

1 Participate In Workplace Communication

Overview

This unit covers the knowledge, skills and attitudes required to gather, interpret and convey information in response to workplace requirements


1. Obtain and convey Workplace information

P1. Assess the Specific and relevant information from the appropriate sources

P2. Convey and gather the information of Effective questioning, active listening and speaking skills.

P3. Transfer the information using the appropriate medium and ideas.

P4. Use appropriate nonverbal communication.

P5. Identify and follow appropriate lines of communication with supervisors and colleagues.

P6. Use the defined workplace procedures for the location and storage of information.

P7. Carry out Personal interaction clearly and concisely.

2. Participate in workplace meetings and discussions

P1. Attend the team meetings on time

P2. Clearly express your own opinions and listen other’s point of view without interruption.

P3. Established the protocols in the courteous manner of meeting inputs with the meeting purpose and Workplace interactions.

P4. Questions about simple routine workplace procedures and matters concerning working conditions of employment are asked and responded to Meetings outcomes are interpreted and implemented

3. Complete relevant work related documents

P1. Range of forms relating to conditions of employment are completed accurately and legibly

P2. Workplace data is recorded on standard workplace forms and documents

P3. Perform the basic mathematical processes that are used for routine calculations

P4. Identify the errors in recording information on forms/ documents and properly acted upon

P5. Reporting requirements to supervisor are completed according to organizational guidelines


Describe the following.

• Appropriate sources: Team members, Suppliers, Trade personnel, Local government, Industry bodies

• Medium: Memorandum, Circular, Notice, Information discussion, Follow-up or verbal, instructions, Face to face communication.

• Storage: Manual filing system, Computer-based filing system.

• Forms: Personnel forms, telephone message forms, safety reports.

• Workplace interactions: Face to face, Telephone, Electronic and two way radio, Written including electronic, memos, instruction, and forms, non-verbal including gestures, signals, signs and diagrams

• Protocols: Observing meeting, Compliance with meeting decisions, Obeying meeting instructions









2 Perform Work In Team Environment

Overview

This unit covers the skills, knowledge and attitudes to identify role and responsibility as a member of a team


1. Describe team role and scope

P1. Identify the role and objective of the team from available sources of information.

P2. Identify team parameters, reporting relationships and responsibilities from team discussions and appropriate external sources.

2. Identify own role and responsibility within team

P1. Identify the individual role and responsibilities within the team environment.

P2. Identify and recognize the roles and responsibility of other team members.

P3. Reporting relationships within team and external to team are identified

3. Work as a team member

P1. Effective and appropriate forms of communications used and interactions undertaken with team members who contribute to known team activities and objectives

P2. Effective and appropriate contributions made to complement team activities and objectives, based on individual skills and competencies and workplace context

P3. Observed protocols in reporting using standard operating procedures

P4. Contribute to the development of team work plans based on an understanding of team’s role and objectives and


• Role and objective of team: Work activities in a team environment with enterprise or specific sector, Limited discretion, initiative and judgment maybe demonstrated on the job, either individually or in a team environment.

• Sources of information: Standard operating and/or other workplace procedures, Job procedures, Machine/equipment manufacturer’s specifications and instructions, Organizational or external personnel, Client/supplier instructions, Quality standards, OHS and environmental standards.

• Workplace context: Work procedures and practices, Conditions of work environments, Legislation and industrial agreements, Standard work practice including the storage, safe handling and disposal of chemicals, Safety, environmental, housekeeping and quality guidelines.

3 Read and Develop Career Professionalism

Overview

This unit covers the knowledge, skills and attitudes in promoting career growth and advancement.


1. Integrate personal objectives with organizational goals

P1. Personal growth and work plans are pursued towards improving the qualifications set for the profession

P2. Maintain the Intra- and interpersonal relationships in the course of managing oneself based on performance evaluation.

P3. Demonstrate the commitment to the organization and its goal in the performance of duties.

2. Set and meet work priorities

P1. Competing demands are prioritized to achieve personal, team and organizational goals and objectives.

P2. Manage work priorities and commitments in order to utilize the resources efficiently and effectively.

P3. Practices along economic use and maintenance of equipment and facilities are followed as per established procedures

3. Maintain professional growth and development

P1. Identify the trainings and career opportunities and avail on the bases of job requirements.

P2. Recognitions are sought/received and demonstrated as proof of career advancement

P3. Obtained and renewed the licenses and/or certifications relevant to job and career.


• Evaluation: Performance Appraisal, Psychological Profile, Aptitude Tests.

• Resources: Human, Financial, Technology, Hardware, Software

• Trainings and career opportunities: Participation in training programs, Technical, Supervisory, Managerial, Continuing Education, Serving as Resource Persons in conferences and workshops.

• Recognitions: Recommendations, Citations, Certificate of Appreciations, Commendations, Awards, Tangible and Intangible Rewards.

• Licenses and/or certifications: National Certificates, Certificate of Competency, Support Level Licenses, Professional Licenses





4 Practice Occupational Health and Safety Procedures

Overview

This unit covers the outcomes required to comply with regulatory and organizational requirements for occupational health and safety


1. Identify hazards and risks

P1. Identify the safety regulations and workplace safety and hazard control practices and procedures are clarified and explained based on organization procedures

P2. Identify the hazards/risks in the workplace and their corresponding indicators to minimize or eliminate risk to co-workers, workplace and environment in accordance with organization procedures.

P3. Contingency measures during workplace accidents, fire and other emergencies are recognized and established in accordance with organization procedures

2. Evaluate hazards and risks

P1. Identify the terms of maximum tolerable limits which when exceeded will result in harm or damage are identified based on threshold limit values (TLV)

P2. Identify the effects of the hazards.

P3. Identify the OHS issues and/or concerns and safety hazards are reported to designated personnel in accordance with workplace requirements and relevant workplace OHS legislation.

3. Control hazards and risks

P1. Identify the occupational Health and Safety (OHS) procedures for controlling hazards/risks in workplace are consistently followed

P2. Procedures for dealing with workplace accidents, fire and emergencies are followed in accordance with organization OHS policies

P3. Use of Personal protective equipment (PPE) in accordance with organization OHS procedures and practices.

P4. Provide the appropriate assistance in the event of a workplace emergency in accordance with established organization protocol.

4. Maintain OHS awareness

P1. Practice the emergency-related drills and trainings as per established organization guidelines and procedures.

P2. Update and complete the OHS personal records in accordance with workplace requirements.


• Safety regulations: May include but are not limited to: Clean Air Act, Building code, National Electrical and Fire Safety Codes, Waste management statutes and rules, Philippine Occupational Safety and Health Standards, DOLE regulations on safety legal requirements, ECC regulations.

• Hazards/Risks: May include but are not limited to: Physical hazards – impact, illumination, pressure, noise, vibration, temperature, radiation, Biological hazards- bacteria, viruses, plants,

parasites, mites, molds, fungi, insects, Chemical hazards – dusts, fibers, mists, fumes, smoke, gasses, vapors Ergonomics, Psychological factors – over exertion/ excessive force, awkward/static positions, fatigue, direct pressure, varying metabolic cycles Physiological factors – monotony, personal, relationship, work out cycle.

• Contingency measures: May include but are not limited to: Evacuation, Isolation, Decontamination, (Calling designed) emergency personnel.

• PPE: May include but are not limited to: Mask, Gloves, Goggles, Hair Net/cap/bonnet, Face mask/shield, Ear muffs, Apron/Gown/coverall/jump suit, Anti-static suits.

• Emergency-related drills and training: Fire drill, Earthquake drill, Basic life support/CPR, First aid, Spillage control, Decontamination of chemical and toxic, Disaster, preparedness/management.

• OHS personal records: Medical/Health records, Incident reports, Accident reports, OHS-related training completed.









5 Lead Small Teams

Overview

This unit covers the knowledge, skills and attitudes to lead small teams including setting and maintaining team and individual performance standards.


1. Provide team leadership

P1. Identify the work requirements and present it to team members

P2. Communicate the reasons for instructions and requirements to team members.

P3. Deal with the team members and discuss the queries and concerns.

2. Assign responsibilities

P1. Identify the duties, and responsibilities are allocated having regard to the skills, knowledge and aptitude required to properly undertake the assigned task and according to company policy

P2. Identify the duties are allocated having regard to individual preference, domestic and personal considerations, whenever possible

3. Set performance expectations for team members

P1. Understand the performance expectations are established based on client needs and according to assignment requirements

P2. Demonstrate the Performance expectations are based on individual team members duties and area of responsibility

P3. Demonstrate Performance expectations are discussed and disseminated to individual team members

4. Supervised team performance

P1. Demonstrate the monitoring of performance takes place against defined Performance Criteria and/or assignment instructions and corrective action taken.

P2. Provide a feedback by the Team members, positive support and advice on strategies to overcome any deficiencies

P3. Identify the performance issues which cannot be rectified or addressed within the team are referenced to appropriate personnel according to employer policy

P4. Inform the team members and keep informed of any changes in the priority allocated to assignments or tasks which might impact on client/customer needs and

P5. satisfaction

P6. identify the team operations are monitored to ensure that employer/client needs and requirements are met

P7. Follow-up communication is provided on all issues affecting the team

P8. Identify the all relevant documentation is completed in accordance with company procedures


• Work requirements: Client Profile, Assignment instructions.

• Team member’s concerns: Roster/shift details.

• Monitor performance: Formal process, Informal process.

• Feedback: Formal process, Informal process.

• Performance issues: Work output, Work quality, Team participation, Compliance with workplace protocols, Safety, Customer service.









6 Develop Negotiation Skills

Overview

This unit covers the skills, knowledge and attitudes required to collect information in order to negotiate to a desired outcome and participate in the negotiation.


1. Plan negotiations P1. Identify the Information on preparing for negotiation and included in the plan.

P2. Perform positive negotiating and create Information of nonverbal environments and included in the plan.

P3. Identify the information on active listening is identified and included in the plan

P4. Identify the information on different questioning techniques and included in the plan

P5. Check the Information to ensure it is correct and up-to- date.

2. Participate in negotiations

P1. Identify the criteria for successful outcome are agreed upon by all parties

P2. Considered Appropriate language is used on desired outcome of all parties throughout the negotiation.

P3. Use a variety of questioning techniques are used The issues and processes are documented and agreed upon by all parties

P4. Assess possible solutions that are discussed and their viability.

P5. Identify the areas for agreement is confirmed and recorded Follow-up action is agreed upon by all parties.


• Preparing for negotiation: Background information on other parties to the

• Negotiation: Good understanding of topic to be negotiated, Clear understanding of desired outcome/s,

• Personal attributes, (self-awareness, self-esteem, objectivity, empathy, respect for others)

• Interpersonal skills, (listening/reflecting, nonverbal communication, assertiveness, behavior labeling, testing understanding, seeking information, self-disclosing

• Analytic skills (observing differences between content and process, identifying bargaining information, applying strategies to manage process, applying steps in negotiating process, strategies to manage conflict, steps in negotiating process, options within organization and externally for resolving conflict.

• Nonverbal environments: Friendly reception, Warm and welcoming room, Refreshments offered, Lead in conversation before negotiation begins.

• Active listening: Attentive, Don’t interrupt, Good posture, Maintain eye contact, Reflective listening.

• Questioning techniques: Direct, Indirect, Open-ended

7 Solve Problems Related To Work Activities

Overview

This unit covers the skills, knowledge and attitudes required to collect information in order to solve problems to a desired outcome and participate in the work activities.


1. Identify the problem

P1. Identify the Variances from normal operating parameters; and product quality Extent,

P2. Identify the cause and nature are of the problem are defined through observation, investigation and analytical techniques

P3. Demonstrate the Problems are clearly stated and specified

2. Determine fundamental causes of the problem

P1. Identify the Possible causes that are based on experience and the use of problem solving tools / analytical techniques.

P2. Develop possible cause statements based on findings

P3. Identify the fundamental causes as per results of investigation conducted.

3. Determine corrective action

P1. Report on recommendations are prepared

P2. Recommendations are presented to appropriate personnel.

P3. Recommendations are followed-up, if required


• Analytical techniques: Brainstorming, Intuitions/Logic, Cause and effect diagrams, Pareto analysis, SWOT analysis, Gant chart, Pert CPM and graphs, Scatter grams.

• Problem: Non – routine process and quality problems, Equipment selection, availability and failure, Teamwork and work allocation problem, Safety and emergency situations and incidents.

• Action plans: Priority requirements, Measurable objectives, Resource requirements, Timelines, Co-ordination and feedback requirements, Safety requirements, Risk assessment, Environmental requirements






8 Develop Communication Skill

Overview:

The user/ individual on the job needs to know and understand how to writing skills, reading skills and oral communications skills (Listening and speaking)


1. Writing Skills The user/ individual on job needs to know and understand how to:

P1. Document instructions, itinerary and task lists

P2. Maintain documents and reports pertaining to security operations, emergency response, personnel and equipment

P3. Document activities and incidents in a chronological order

P4. Write letters/ memos, feedback and reports

P5. Use computers to generate Management Information System (MIS), emails and other reports

P6. Write in English and at least in one vernacular language proficiently

2. Speaking and Listening Skills

The user/ individual on job needs to know and understand how to:

P1. Read and assimilate organizational procedures, site and security instructions, and correspondence, as applicable

P2. Read security registers, documents, feedback, reports and applications Oral Communication (Listening and Speaking skills)The user/individual on the job needs to know and understand how to:

P3. Speak clearly and emphatically

P4. Receive briefings and instructions from superiors and ask queries

P5. Brief and instruct subordinates and receive debriefings

P6. Reply to the queries from stakeholders

P7. Ask questions from visitors

P8. Raise alarm/ make announcements/ speak over phone/ radio

3. Professional Skills

Decision Making The user/individual on job needs to know and understand how to: SB1 take decisions pertaining to security operations, training, administration and emergency situations Plan and Organize. The user/individual on the job needs to know and understand how to:

P1. Plan security operations as per site instructions and resources available assess and assign tasks to teams and individuals

P2. Conduct training, rehearsals and mock drills Customer Centricity The user/individual on the job needs to know and understand how to:

P3. Manage relationships with stakeholders and visitors Problem Solving The user/individual on the job needs to know and understand how to:

P4. Think through the problem, evaluate the possible solution(s) and adopt a best possible solution(s)

P5. Handle disruption in security operations Analytical Thinking The user/individual on the job needs to know and understand how to:


P6. Anticipate and identify potential risk and threats and take suitable actions

P7. Observe people, activities and movements keenly Critical Thinking The user/individual on the job needs to know and understand how to:

P8. Analyze and evaluate a situation and available information to take appropriate action













• Capable to

9 Develop Administrative Skills

Overview:

The user/ individual on the job need to know and understand how to develop administrative skills.


1. Decision making P1. Perform decisions pertaining to security operations, training and administration

P2. Perform emergency situations

2. Make Plan and Organize the workshop

The user/individual on job needs to know and understand how to:

P1. Plan security operations as per site instructions and resources available assess and assign tasks to teams and individuals

P2. Conduct training, rehearsals and mock drills

P3. Manage relationships with stakeholders and visitors

3. Evaluate the possible solution

P1. Think through the problem, evaluate the possible solution(s) and adopt a best possible solution(s)

P2. Handle disruption in security operations

P3. Anticipate and identify potential risk and threats and take suitable actions

P4. Observe people, activities and movements keenly

P5. Analyze and evaluate a situation and available information to take appropriate action













10 Work effectively in a customer service/ sales environment

Overview:

This Competency standard identifies the competencies required Work Effectively in a Customer Service/Sales Environment as per Organization’s approved guidelines and procedures. You will be expected to work within organizational requirements, support the work team, maintain personal presentation, develop effective work habits, portray ethical behavior and acquire up to date product / service knowledge. You’re underpinning knowledge about Work Effectively in a Customer Service/Sales Environment will be sufficient for you to provide the basics of the work.


1. Work within organizational requirements.

You must be able to:

P1. Identify and read organization’s requirements and responsibilities and seek advice from appropriate people where necessary.

P2. Interpret staff rosters and provide sufficient notice of unavailability for rostered hours according to workplace policy and procedures.

P3. Develop and use a current working knowledge and understanding of employee and employer rights and responsibilities.

P4. Comply with relevant duty of care and legal responsibilities, and support organizational culture.

P5. Identify roles and responsibilities of colleagues and immediate supervisors.

P6. Identify standards and values considered to be detrimental to the Organization and communicate this through appropriate channels.

P7. Identify, recognize and follow behaviour that contributes to a safe and sustainable work environment.

2. Support the work team.


P1. Display courteous and helpful behavior at all times.

P2. Take opportunities to enhance the level of assistance offered to colleagues and meet all reasonable requests for assistance within acceptable workplace timeframes.

P3. Complete allocated tasks as required.

P4. Seek assistance when difficulties arise.

P5. Use questioning techniques to clarify instructions or responsibilities.

P6. Identify and display a non-discriminatory attitude in all contacts with customers and other staff members.

3. Maintain personal Presentation.


P1. Observe appropriate dress code and presentation as required by the workplace, job role and level of customer contact.

P2. Follow personal hygiene procedures according to organizational policy and relevant legislation.

4. Develop effective work habits.


P1. Interpret, confirm and act on work place information, instructions and procedures relevant to the particular task.

P2. Ask questions to seek and clarify workplace information.

P3. Plan and organize daily work routine within the scope of the job


role.

P4. Priorities and complete tasks according to required timeframes.

P5. Identify work and personal priorities and achieve a balance between competing priorities

5. Portray ethical behavior


P1. Follow ethical code of conduct.

P2. Understand your costumer’s code of ethics.

P3. Declare conflict of interest.

P4. Maintain confidentiality.

P5. Honor your commitments (timeframe, deliverables etc.)

P6. Use internet for business only on company time.

6. Acquire up to date product / service Knowledge


P1. Gather information about your product / services.

P2. Identify the components of your product and services.

P3. Recognize the essential selling features of your products and services.

P4. Translate all essential features of your product and services.

P5. Analyze product success.

P6. Identify your market position.

P7. Familiar with all product promotions, sales manuals and product Literature.

P8. Keep information of latest technology advances and seek ways to use these technologies in your work.


• Define industry awards and agreements that relate to personal job role and terms and conditions of employment.

• Differentiate between employer and employee responsibilities.

• Explain different relevant legislation and statutory requirements.

• Explain the importance of team work

• Define workplace relations

• Explain workplace policies, plans and procedures, including, Dealing with Grievances, Discriminatory, behavior, Equal opportunity, issues, Staff rosters and notification of shift Availability or nonattendance Providing customer service to colleagues and customers.

• Explain hygiene and personal presentation

• Explain the importance of workplace ethics.

• Explain staff counseling and disciplinary procedures

• Describe workplace organizational structure

• Explain the importance of ethical behavior.

• Explain the importance of commitment in sales and customer services

• Explain: a. Price per product. b. Profit per product /service. c. Price flections

d. Product strengths e. Product weaknesses. f. Warranty / guarantee policies. g. Packaging facilities and potential.

• Explain how your product/service fits into your customers overall operations, business plan, sales success, operation cost etc.








11 Develop Professionalism

Overview:

This Competency standard identifies the competencies required to Develop Professionalism as per Organization’s approved guidelines and procedures. You will be expected to create a personal vision / mission, manage your attitude, practice self-discipline, manage time, manage your professional development, and participate in trainings and performance review. Your underpinning knowledge about Develop Professionalism will be sufficient for you to provide the basics of the work.


1. Create a personal vision / mission


P1. Clarify / prioritize self-values and consider the value of others.

P2. Clarify expectations of yourself and expectations others have of you.

P3. Identify what you need to do to be successful (personal standards, targets, goals, principals)

P4. Set specific short and long term goals.

P5. Translate the vision into actionable steps.

P6. Integrate the vision into daily practice.

P7. Recount frequently with your vision and change accordingly.

2. Manage your attitude


P1. Challenge yourself, break old habits, and move out of your comfort zone.

P2. Practice innovative techniques for out of the box creative thinking.

P3. Seek out support and feedback from others on the team, in the organization / community etc.

P4. Identify daily, weekly accomplishments.

P5. Read inspirational material, audiotapes etc.

3. Practice self-discipline


P1. Accountable for your performance.

P2. Identify what you need to do to be successful.

P3. Communicate your priorities to others.

P4. Make and honor appointments with yourself and others.

P5. Practice relaxation and energizing techniques.

4. Manage time You must be able to:

P1. Isolate key success activities and prioritize them.

P2. Breakdown large tasks down into manageable action steps (set time frame).

P3. Create or adopt action plans and follow it.

P4. Set aside appropriate blocks of time for goal related activities.

P5. Make the best possible use of support people / recourses to

accomplish tasks.

5. Manage your professional development


P1. Take inventory of your personal interests, abilities, skills, knowledge etc.

P2. Identify and prioritize the strengths and gaps.

P3. Use available assessment tools.

P4. Create a personal growth strategy / career path.

P5. Set personal goals and timeframe for achieving them.

P6. Learn from your mistakes.

6. Participate in trainings and performance review


P1. Analyze, evaluate and improve performance, and report significant issues/problems to senior management

P2. Demonstrate to-do attitude in profession

P3. Demonstrate understanding of skills requirements

P4. Use the competences acquired in trainings

Understand and Knowledge:

• Explain long and short term goals.

• Explain why personal vision and mission is important for success.

• Describe the advantages of personal vision and mission.

• Explain the importance of personal and professional motivation

• Identify your positive attitude.

• Explain the advantages of innovative ideas and techniques during job.

• Explain the importance of communication.

• Explain the advantages of self-discipline.

• Explain the importance of time management to achieve different tasks.

• Explain the importance and need of professional development.

• Define concept about performance standards.

• Explain policies, procedures and regulations regarding human resources of the organization.

• Explain self-planning and management techniques.

• Define goals and strategies of self- development.

• Explain relevant knowledge about training / job requirements.




Entrepreneur

1. Manage the Operations of Workshop Security Units

Overview

This Competency Standard identifies the competencies required to prepare for managing the operations, manage resources of a security unit, organize guarding operations, control entry to and exit from premises, control screening and search operations and organize traffic control and parking. Your underpinning knowledge regarding workshop security units will be sufficient to provide the basis for this task.


1. Prepare to manage the operations

P1. Observe organizational procedures related to security operations Security Operations: Access control, screening & search, escort, duties by unarmed & armed security guards and personal security officers (PSO), observation & surveillance, control room operations, traffic control, parking management, information gathering, key-control, dealing with emergencies, investigations, security equipment operation, documentation and reporting

P2. Plan operations as per site instructions and availability of resources Site Instructions: Instructions covering the details of deployment and operations at a particular site

P3. Develop personnel and resources in an efficient and economical manner

P4. Review functioning of teams and shifts and carry out improvements P5. Assess training and performance standards of security unit

Training Requirements P6. Check and report functioning of provided security equipment to

facilitate access control, search and screening, parking, surveillance and smoke & fire detection

P7. Check and report functioning of personal protection equipment P8. Initiate actions to rectify faulty equipment P9. Organize security operations manually in the event of equipment

malfunction P10. Check and carry out periodic / surprise inspections P11. Communicate effectively with team members and stakeholders P12. Take report and feedback from team members P13. Coordinate, organize, train and rehearse emergency response

teams (ERT) P14. Respond to emergencies and irregular situations Emergencies by

security unit members P15. Take preventive actions and call for assistance to control irregular

situations

2. Manage resources of a security unit

P1. Plan and organize required personnel and equipment as per site instructions

P2. Assess and report suitability of provided personnel and equipment P3. Carry out adjustments in deployment to cover deficiency of

personnel and equipment


P4. Record and report status and issues related to personnel and equipment

3. Organize guarding Operations

P1. Organize security and guarding operations against likely threats and risks

P2. Organize briefing of guards and supervisors between the shifts P3. Carry out periodic review of the deployment and operations P4. Control functioning and operations of CCTV control room, if

provided P5. Follow the laid down procedure of key control P6. Prepare, issue and monitor patrolling plan P7. Debrief guards/ patrols/ supervisors after the tasks P8. Take feedback P9. Deal with lost and found property

4. Control entry to and exit from premises

P1. Identify likely threats and risks to premises from outside P2. Summarize access control procedure and functioning of the

equipment in use P3. Train team members in operation of the equipment P4. Brief team members regarding people/ vehicles/ material

authorized to enter/ leave premises P5. Identify papers, passes, permission and documentation to facilitate

entry and exit of people/ vehicles/ material to and from the premises

P6. Organize receipt of postal mail and couriers, if assigned

5. Control screening and search operations

P1. Identify procedure of screening and search operations and the functioning of equipment in use

P2. Train team members in operation of the equipment P3. Sensitize subordinates to respect persons’ right to dignity, privacy

and gender/ religious/ cultural sensitivity P4. Deal with persons and vehicles violating laid down procedures P5. Identify presence of prohibited/ unauthorized items P6. Segregate material containing prohibited/ unauthorized items

Knowledge and Understanding Units:


• Reporting procedures

• Category of authorized people/ people debarred entry

• Types of identity/ authorization documents in use

• Areas within the premises having restricted/ controlled entry

• Details of unauthorized/ prohibited items

• Action to be taken in case of recovery of unauthorized/ prohibited items

• Procedure for receipt of postal mail and couriers

• Action to be taken in case of delivery of a suspicious package

• Method of securing and storing letters and packages

• Methods and techniques adopted by miscreants to defeat security measures and equipment

• Knowledge of security equipment installed in the premises

• Capability and limitations of the security equipment in use

• Understanding of signals emanating from equipment

• Common faults occurring in the equipment

• Procedure re for carrying out operations manually, in case of equipment failure

• Indications regarding suspicious packages

• Items that cannot be put through screening and search equipment

• Procedure for vehicle search

• Personal protective gear required for security operations

• Layout of the parking areas and traffic plan in the premises

• Suitability of prevailing conditions for parking

• Traffic signals, signage and markings

• Category of vehicles

• Untoward situations faced during security operations

• Procedure for dealing with untoward situations




2. Organize Training On Multiple Workshop Units

Overview

This Competency Standard identifies the competencies required to organize training on multiple workshop units. Your underpinning knowledge regarding organize training will be sufficient to provide the basis for this task.


1. Assess the training Requirements

P-1. Identify relevant legislation/ regulations, organizational requirements relating to standards of training in the automobile sector.

P-2. Assess site-specific training requirements for technician and experts.

P-3. Report to superiors on existing training standards and additional training required

P-4. Assess time required for conduct of training P-5. Decide on learning objectives of the training P-6. Maintain environmental and situational awareness to upgrade

training Standards

2. Plan and Schedule training for technicians

P-1. Keep in view availability of time on the type and method of training and resources

P-2. Chalk out training program(s) P-3. Arrange for required trainers and training infrastructure i.e.

Training areas, trainers, curriculum/ course content, classrooms, equipment, aids and simulators

P-4. Brief security unit on training schedule P-5. Carry out/ facilitate pre-induction training P-6. Carry out/ facilitate on-the-job training P-7. Train team members in the operation of security and

communication equipment P-8. Carry out routine checks to assess training efficacy P-9. Assess and report on standards of training and performance



• Category of authorized people/ people debarred entry

• Types of identity/ authorization documents in use

• Areas within the premises having restricted/ controlled entry

• Details of unauthorized/ prohibited items

• Action to be taken in case of recovery of unauthorized/ prohibited items

• Procedure for receipt of postal mail and couriers

• Action to be taken in case of delivery of a suspicious package

• Method of securing and storing letters and packages

• Methods and techniques adopted by miscreants to defeat security measures and equipment

• Knowledge of security equipment installed in the premises

• Capability and limitations of the security equipment in use

• Understanding of signals emanating from equipment

• Common faults occurring in the equipment

• Procedure re for carrying out operations manually, in case of equipment failure

• Indications regarding suspicious packages

• Items that cannot be put through screening and search equipment

• Procedure for vehicle search

• Personal protective gear required for security operations

• Layout of the parking areas and traffic plan in the premises

• Suitability of prevailing conditions for parking

• Traffic signals, signage and markings

• Category of vehicles

• Untoward situations faced during security operations

• Procedure for dealing with untoward situations




3. Administer Multiple Commercial Units

Overview

This Competency Standard identifies the competencies required to administer multiple commercial units. Your underpinning knowledge regarding Implementation of SOP Process and administer multiple bay units will be sufficient to provide the basis for this task.


1. Control the operations of workshop

P1. Commence operations at a new or existing site, as per site instructions

P2. Assess site-specific administrative requirements i.e. accommodation, transportation, food, medical, hygiene & sanitation, support staff, shift timings, working hours, rest, leave, entitlement of salary/ allowances, payment to staff, documentation, addressing grievances, welfare, security of female guards and handling of petty cash

P3. Inform superiors about the requirements P4. Issue identity cards to team members P5. Inform superior about complaints/ suggestion received from

principal employer P6. Interact with team members frequently P7. Resolve grievances of staff P8. Maintain confidentiality of information P9. Receive/ issue/ account for stores meant for security unit P10. Prepare attendance sheet, overtime details and MIS reports P11. Document new entrants/ those leaving the site Documents i.e.

Master roll, attendance sheet, pay roll, site assignment document, individual’s verification & identification documents, personnel movement control documents, duty roster, leave & absence register, medical register

P12. Handle and account for petty cash P13. Pursue pending issues of security unit and agency with principal

employer

2. Administer a workshop/bayUnit

P1. Identify and address important administrative concerns P2. Arrange for accommodation, transportation and food for the unit P3. Enforce dress code P4. Maintain discipline P5. coordinate with own agency/ principal employer to resolve issues P6. Ensure privacy and personal safety of the unit, especially of female

staff P7. Motivate team through personal example and concern P8. Assess performance and standards of team members P9. Counsel team members on their performance and conduct P10. Recommend deserving personnel for promotion and reward



• The site instruction

• Details of personnel and equipment required

• Channel of reporting and communication with stakeholders Stake holders: Principal employer, superior, own management, subordinates, visitors and residents/tenants

• Contact details of stakeholders, superiors and team members

• Documentation formats

• Reporting procedure

• Organizational standards on grooming, conduct, behavior and performance

• Leadership and management fundamentals Leadership: Administration, discipline, motivation, impartiality, punctuality, concern for subordinates, welfare and leading by example

• Organizational protocol for resolution of concerns/ grievances

• Management information system

• Performance management system

• Compensation management

• Accounting and issue procedure for stores, material and equipment




4. Supervise performance of Technician

Overview

ThisCompetencyStandardidentifiesthecompetenciesrequiredtosupervise and evaluate performance of technician. Your underpinning knowledge regarding supervision and evaluation the performance of subordinates ensure higher levels of motivation will be sufficient to provide the basis for this task.


1. Supervise the staff P1. Ensure and implement strict adherence of all activities performed by subordinates to organizational guidelines

P2. Monitor and supervise all the activities performed by subordinates and ensure optimization to achieve the set goals

P3. Document all performance indicators and metrics of subordinates in the prescribed format of organization

P4. Ensure and implement proper process flow for feedbacks and queries received from subordinates

2. Evaluate performance of all subordinates and reporting executives

P1. Set goals and targets as per organizational directives for all reporting executives

P2. Create quantified measures and metrics to analyze the performance delivered by subordinates

P3. Set tangible and achievable incentives for subordinates as per the goals and targets assigned

P4. Assist and support reporting executives whenever necessary or applicable

P5. Evaluate performance of subordinates and reporting executives on the designed measures and metrics as per the guidelines of the organization

P6. Perform all appraisal related process flow for subordinates, as per respective performance documents

P7. Handover all the documents and appropriate support measures to human resources department for official records



• Standard operating procedures of the organization for appraisals, incentives, promotions and performance evaluation.

• Standard operating procedures for query and problem reporting and their redressal in the organization

• Framework and guidelines prescribed by the organization for query and problem redressal

• Framework and guidelines prescribed by the organization for performance evaluations and based appraisals out of it

• Documentation requirements for each procedure carried out as part of roles and responsibilities

• Institutional and professional code of ethics and standards of practice

• Safety and health policies and regulations for the workplace.




5. Plan Work to Meet Expected Outcomes

Overview

This Competency Standard identifies the competencies required to plan and organize work to meet expected outcomes. Your underpinning knowledge regarding planning and organizing individual’s work in order to complete it to the required standards, on time and within budget in terms of cost and material will be sufficient to provide the basis for this task.


1. Set quality standards for Work requirements including various activities within the given time

P1. Keep immediate work area clean and tidy P2. Treat confidential information as per the organization’s guidelines P3. Work in line with organization’s policies and procedures P4. Work within the limits of job role P5. Obtain guidance from appropriate people, where necessary P6. Ensure work meets the agreed requirements

2. Use Appropriate resources

P1. Establish and agree on work requirements with appropriate people

P2. Manage time, materials and cost effectively P3. Use resources in a responsible manner



• The organization’s policies, procedures and priorities for area of work, role and responsibilities in carrying out that work

• The limits of responsibilities and when to involve others

• Specific work requirements and who these must be agreed with

• The importance of having a tidy work area and how to do this

• How to prioritize workload according to urgency and importance and the benefits of this

• The organization’s policies and procedures for dealing with confidential information and the importance of complying with these

• The purpose of keeping others updated with the progress of work

• Who to obtain guidance from and the typical circumstances when this may be required

• The purpose and value of being flexible and adapting work plans




6. Work Effectively In a Team

Overview

This Competency Standard identifies the competencies required to work effectively in a team. Your underpinning knowledge regarding working effectively with colleagues, either in own work group or in other work groups within organization will be sufficient to provide the basis for this task.


1. Interact and communicate effectively with colleagues

P1. Maintain clear communication with colleagues (by all means including face-to-face, telephonic as well as written)

P2. Support colleagues to integrate work P3. Pass on information to colleagues in line with organizational

requirements both through verbal as well aS. No.n-verbal means P4. Accomplish work in ways that show respect for colleagues P5. Carry out commitments made to colleagues P6. Identify problems in working with colleagues and take the initiative

to solve these problems

2. Interact & communicate with other stack holders.

P1. Maintain clear communication with stockholder (by all means including face-to-face, telephonic as well as written)

P2. Follow the automobile sector policies and procedures for working with stockholders.

P3. Present all types of information to stack holders when it is required. P4. Obey the rules and regulations as per govt. policy.



• The organization’s policies and procedures for working with colleagues, role and responsibilities in relation to this

• The importance of effective communication and establishing good working relationships with colleagues

• Different methods of communication and the circumstances in which it is appropriate to use these

• The importance of creating an environment of trust and mutual respect

• The implications of own work on the work and schedule of others.




7. Maintain Healthy, Safe and Secure Working Environment

Overview

This Competency Standard identifies the competencies required to maintain healthy, safe and secure working environment. Your underpinning knowledge regarding monitoring work place practices and making sure they meet requirements for health, safety, security and environmental concerns will be sufficient to provide the basis for this task.


1. Need Resources to maintain a safe, secure working environment

P1. Comply with organization’s current health, safety and security policies and procedures

P2. Report any identified breaches in health, safety, and security policies and procedures to the designated person

P3. Coordinate with other resources at the workplace to achieve the healthy, safe and secure environment for all incorporating all government norms esp. for emergency situations like fires, earthquakes etc.

P4. Identify and correct any hazards like illness, accidents, fires or any other natural calamity safely and within the limits of individual’ authority

P5. Report any hazards outside the individual’s authority to the relevant person in line with organizational procedures and warn other people who may be affected

P6. Follow organization’s emergency procedures for accidents, fires or any other natural calamity

P7. Identify and recommend opportunities for improving health, safety, and security to the designated person

P8. Complete all health and safety records are updates and procedures well defined



• The organization’s policies and procedures for working with colleagues, role and responsibilities in relation to this

• The importance of effective communication and establishing good working relationships with colleagues

• Different methods of communication and the circumstances in which it is appropriate to use these

• The importance of creating an environment of trust and mutual respect

• The implications of own work on the work and schedule of others.

8. Deal with Emergencies and Incidents at Workshop

Overview

This Competency Standard identifies the competencies required to deal with emergencies and incidents at work shop. Your underpinning knowledge regarding to deal with emergencies and incidents at workshop will be sufficient to provide the basis for this task.


1. Deal with emergencies and incidents at workshop

P1. Follow organizational procedures while responding to emergencies and incidents at workshop.(SOP)

P2. Review organizational procedure periodically Procedures: Laid down SOPs for dealing with accidents, emergency or untoward security situation

P3. Train and prepare Staff to respond to emergencies and incidents at workshop.

P4. Take appropriate action Appropriate Actions: Respond with equipment/ aid at hand, Request for qualified assistance, Evacuate people; isolate area; inform and brief relevant authorities and maintain order, Maintain safety of self and others

P5. Identify and investigate causes of alarms Alarm and Sensors: Against intrusion & forced entry, for heat, smoke & fire, SOS from residents, medical emergencies, elevator/ escalator crisis, gas leak, electrical short circuit, other alarms from building management system, environmental hazards, and CCTV

P6. Communicate information and seek assistance P7. Ensure health and safety while responding to risks and threats

2. Reduce risks to health and safety at the workplace

P1. Carry out security operations in line with workplace health and safety norms

P2. Identify the main safety and health related threat/ risks within the premises i.e. Fires, Electric short circuit; electric shock and electrocution, Medical emergency, Inflammable & toxic chemicals gases, Falls; trips and slips, Natural calamities, Equipment malfunction, Poor ventilation and suffocation, Improper use of personal safety gear and no adherence to safety norms, Ergonomic risks pertaining to long and static postures; prolonged use of computer and viewing of monitor, Poor hygiene and sanitation conditions, Extreme temperature conditions

P3. Participate in discussions/ training on safety and health issues P4. Implement health and safety related procedures P5. Enforce the use of personal protective equipment (PPE) by stake-

holders P6. Ensure safety of self and others while carrying out duties P7. Identify key people for anchoring safety and health related roles P8. Organize required equipment/ resources P9. Organize awareness training for stakeholders P10. Organize and train emergency response teams (ERT) P11. Maintain the desired state of readiness for dealing with


emergencies P12. Ensure placement of equipment and signage as per plan P13. Organize periodic mock drills/ rehearsals P14. Deal with hazards and report based on operational procedures P15. Report and record safety and health incidents.



• Policy/ procedures/ guidelines related to workplace health and safety

• Responsibilities of the security function related to health and safety

• Limits and responsibilities of the security unit

• Organizational procedure for handling different levels of risks

• Reporting protocol for health and safety matters

• Communication protocol

• Documentation formats and reports to be maintained The seer/individual on the job needs to know and understand:

• Organizational procedures relating to communication

• Details of stakeholders/ concerned agencies

• Means of available communication

• Details of security functions that need employers’ approval

• Format and process for obtaining feedback Format: Written and electronic

• Organization’s standards of communication, behavior and courtesy

• Resolution process for queries/ complaints of stakeholders

• Communication etiquette to be followed by the security unit

• Gender, cultural, religious and other sensitivities

• Organizational procedure for recording and sharing of information

• Timelines and periodicity for submission of reports/ documentation. Documentation: Relating to operations, training and administration

• Frequency for reviewing records maintained by security unit

• Storage and archival policy/ processes followed by the organization

• Details of stakeholders/ agencies authorized to receive information




9. Maintain Effective Communication with Companies

Overview

This Competency Standard identifies the competencies required to maintain effective communication with HVAC companies. Your underpinning knowledge regarding effective communication with HVAC companies/ dealers and also carry out the review role-related documentation will be sufficient to provide the basis for this task.


1. Communicate effectively with Stakeholders

P1. Communicate effectively with stakeholders on security functions i.e. residents, residents welfare association members, visitors, workers, staff, vendors, facility management, service providers and maintenance staff

P2. Establish a system of receiving feedback from stakeholders P3. Enforce organization’s standards of communication, behavior

and courtesy within the security unit Operate communication equipment effectively Communication Equipment: Walkie-talkie, telephone, intercom, mobile phone, signage, whistle, light signals, hand signals, field signals

P4. Communicate security-related protocol to stakeholders P5. Interact with stakeholders to understand their requirements P6. Interact with media on instructions P7. Resolve queries/ complaints of stakeholders as per

procedure P8. Train the security personnel in required communication

etiquettes P9. Educate security staff on gender, cultural and religious

sensitivities P10. Intervene and resolve instances of aggressive and unruly

behavior

2. Carry out and review role-related documentation

P1. Identify essential documents to be completed and maintained by the security unit

P2. Finalize the format for recording information/ incidents as per organizational procedure

P3. Decide on timelines and frequency for submission of reports P4. Use computers and other equipment to facilitate

documentation P5. Record and store documents as per organizational

procedure P6. Forward report/ feedback to designated superior P7. Store and handle information/ media generated by the

security equipment(s) P8. Handle electronic media and archive to store information/

documents safely Information: Written, verbal, electronic, and public-address system

P9. Share information with authorized stakeholders on a ‘need-to-know’ basis


P10. Maintain security and confidentiality of information



• Organizational procedures relating to communication

• Details of stakeholders/ concerned agencies

• Means of available communication

• Details of security functions that need employers’ approval

• Format and process for obtaining feedback Format: Written and electronic

• Organization’s standards of communication, behavior and courtesy

• Resolution process for queries/ complaints of stakeholders

• Communication etiquette to be followed by the security unit

• Gender, cultural, religious and other sensitivities

• Organizational procedure for recording and sharing of information

• Timelines and periodicity for submission of reports/ documentation. Documentation: Relating to operations, training and administration

• Frequency for reviewing records maintained by security unit

• Storage and archival policy/ processes followed by the organization

• Details of stakeholders/ agencies authorized to receive information.


