national competency standards level 5 in automobile …navttc.gov.pk/nvqs/diploma...

National Competency Standards Level- 5 in Automobile Technology

National Competency Standards level 5 in Automobile Technology

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National Vocational and Technical Training Commission (NAVTTC),

Government of Pakistan

ACKNOWLEDGEMENTS

National Vocational and Technical Training Commission (NAVTTC) extends its gratitude and

appreciation to many representatives of business, industry, academia, government

agencies, Provincial TEVTAs, Sector Skill Councils and trade associations who speared

their time and expertise to the development and validation of these National Vocational

Qualifications (Competency Standards, Curricula, Assessments Packs and related material).

This work would not have been possible without the financial and technical support of the

TVET Sector Support Programme co-funded by European Union, Norwegian and German

Governments implemented by GIZ Pakistan. NAVTTC is especially indebted to Dr. Muqeem

ul Islam, who lead the project from the front. The core team was comprised on:

● Dr. Muqeem ul Islam, Director General (Skills,Standards and Curricula) NAVTTC

● Mr. Muhammad Naeem Akhtar, Senior Technical Advisor TSSP-GIZ,

● Mr. Muhammad Yasir, Deputy Director (SS&C Wing) NAVTTC

● Mr. Muhammad Ishaq, Deputy Director (SS&C Wing) NAVTTC

● Mr. Fayaz A. Soomro, Deputy Director (SS&C Wing) NAVTTC

NAVTTC team under the leadership of Dr. Muqeem ul Islam initiated development of CBT &

A based qualifications of diploma level-5 as a reform project of TVET sector in November

2018 and completed 27 NVQF diplomas of Level-5 in September, 2019. It seems worth

highlighting that during this endeavor apart from developing competency standards/curricula

in conventional trades new dimensions containing high-tech trades in TVET sector in the

context of generation IR 4.0 trades have also been developed which inter alia includes

Robotics, Mechatronics, artificial intelligence, industrial automation, instrumentation and

process control. Moreover, trades like entrepreneurship, green/environmental skills and

variety of soft/digital skill have also been developed to equip the Pakistani youth with skills

set as per requirement of the global trends. These skills have been made integral part of all

the 27 diplomas.

Nobody has been more important in the pursuit of this project than Dr. Nasir Khan, Executive

Director, NAVTTC, whose patronage and support remain there throughout the development

process and lastly to thanks specially to Syed Javed Hassan, Chairman NAVTTC and Raja

Saad Khan, Deputy Team Lead TSSP-GIZ who made it happened in this challenging time.

1. Introduction .................................................................................................................11

2. Purpose of the Qualification .......................................................................................11

3. Date of Validation ........................................................................................................12

4. Date of Review .............................................................................................................12

5. Codes of Qualifications...............................................................................................12

6. Members of Qualifications Development Committee................................................14

7. Members of Qualification Validation Committee .......................................................16

8. Entry Requirements ....................................................................................................17

9. Summary of Competency Standards .........................................................................18

10. Leveling of the Competency Standards .....................................................................25

11. Packaging of the Qualification ...................................................................................34

12. Internal Combustion Engine (AD-133) .......................................................................44

0716MS&A1. Specify Engine Types and its Component .....................................................45

0716MS&A2. Identify Engine Parts and Interpret Assembly Procedure ...............................47

0716MS&A3. Maintain Engine Cooling System Components ..............................................49

0716MS&A4. Maintain Engine Lubrication System ..............................................................51

0716MS&A5. Retain Fuel System of Petrol Engine .............................................................53

0716MS&A6. Retain Fuel System of Diesel Engine .............................................................55

0716MS&A7. Maintain Engine Exhaust System ..................................................................57

0716MS&A8. Diagnosing Engine Faults ..............................................................................59

0716MS&A9. Perform Ignition System of Petrol Engine ......................................................61

0716MS&A10. Perform Overhauling of Four Stroke Single Cylinder Engine ..........................63

13. Automotive Electricity and Electronics (AD-143) ......................................................66

0716MS&A11. Perform Electrical Measurements ..................................................................66

0716MS&A12. Prepare Electromagnetism applications .........................................................68

0716MS&A13. Perform Battery Service of Vehicle ................................................................70

0716MS&A14. Repair Engine Starting System ......................................................................72

0716MS&A15. Repair Ignition System of Petrol Engine ........................................................74

0716MS&A16. Adjust Ignition Timing of Petrol Engine ..........................................................76

0716MS&A17. Repair Distributer-Less Ignition Systems of Petrol Engine .............................78

0716MS&A18. Repair Battery Charging System ...................................................................80

0716MS&A19. Repair Light System of Vehicle ......................................................................82

0716MS&A20. Repair Vehicle Accessories ...........................................................................84

14. Workshop Practice-1 (MT-164) ...................................................................................86

0716MS&A21. Perform Bench Work on Metallic Surfaces .....................................................87

0716MS&A22. Perform Shaper Machine Operations .............................................................90

0716MS&A23. Perform Lathe Turning Operations.................................................................93

0716MS&A24. Read and Interpret Manufacturing Drawings ..................................................96

0716MS&A25. Preform Welding Procedure Specifications (WPS) ........................................99

0716MS&A26. Prepare Materials for Welding ..................................................................... 101

0716MS&A27. Perform Shielded Metal Arc Welding (SMAW) in Vertical (3F, 3G) and

Overhead (4F, 4G) Positions ....................................................................... 103

0716MS&A28. Perform Forging Operations ........................................................................ 106

15. Basic Engineering Drawing and CAD-I Mech-163 ................................................... 108

0716MS&A29. Perform Drawing, Sketch Making ................................................................ 109

0716MS&A30. Draw Pictorial Drawing ................................................................................ 111

0716MS&A31. Perform Basic Dimensioning System in Working Drawing ........................... 113

0716MS&A32. Perform Sectioning and Pictorial Drawing .................................................... 115

0716MS&A33. Draw Auxiliary Drawing ................................................................................ 117

Problems in Internal Combustion Engines AD-203 ............................................................ 119

0716MS&A34. Diagnose Engine Fault ................................................................................ 120

0716MS&A35. Perform Engine Overhauling (Petrol/Diesel) ................................................ 123

0716MS&A36. Diagnose Engine Cooling System Faults and Repair ................................... 126

0716MS&A37. Diagnose Faults in Engine Lubrication System ............................................ 128

0716MS&A38. Diagnose Faults of Carburetor Fuel System ................................................ 130

0716MS&A39. Diagnose Diesel Fuel System and Adjust .................................................... 132

0716MS&A40. Diagnose Faults of Ignition System .............................................................. 134

16. Suspension, Steering & Brakes AD-213 .................................................................. 135

0716MS&A41. Repair Vehicle Brake System. ..................................................................... 135

0716MS&A42. Repair Vehicle Steering System. ................................................................. 138

0716MS&A43. Maintain Vehicle Suspension System. ......................................................... 139

0716MS&A44. Carry out Wheel Alignment .......................................................................... 142

0716MS&A45. Carry Out Wheel Balancing ......................................................................... 144

0716MS&A46. Replace SRS System .................................................................................. 146

17. Workshop Practice-II AD-224 .................................................................................... 148

0716MS&A47. Arrange Common Automotive Hand Tools and their Use ............................. 149

0716MS&A48. Carry Out Measurements with Automotive Measuring Tools........................ 151

0716MS&A49. Perform Test on Vehicle with Automotive Workshop Equipment .................. 153

0716MS&A50. Diagnose Faults by Computerized Performance Testing Equipment ........... 155

0716MS&A51. Categorize Automotive Fasteners Types and their Uses ............................. 157

0716MS&A52. Specify Vehicle’s Lubricants Types .............................................................. 158

0716MS&A53. Differentiate Vehicle Oil Seals Types and Specifications Coding ................. 160

0716MS&A54. Specify Vehicle Bearing’s Types and Coding ............................................... 161

0716MS&A55. Read and Interpret Quality Control Standards and Certification ................... 162

0716MS&A56. Plan and Organize Safe Workshop and Hazard Prevention Practices ......... 163

18. Metrology MT-252 ...................................................................................................... 165

0716MS&A57. Recognize Graduated Instruments .............................................................. 165

0716MS&A58. Carry-Out Linear Measuring ........................................................................ 167

0716MS&A59. Carry-out Precise Measuring ....................................................................... 170

0716MS&A60. Perform Angular Measuring. ........................................................................ 172

0716MS&A61. Identify the Types of Gauges. ...................................................................... 174

0716MS&A62. Identify Comparators Instrument ................................................................... 176

19. Applied Thermodynamics AD-232 ............................................................................ 178

0716MS&A63. Analyses HVAC/R Systems Thermodynamic Performance ......................... 178

0716MS&A64. Carry-out Smooth Boiler Operation .............................................................. 180

0716MS&A65. Recognize Fundamentals of Thermodynamics Problems ............................ 182

0716MS&A66. Read and Interpret Perfect Gases Laws, Properties and Solve problems .... 184

0716MS&A67. Read and Derived Thermodynamics Processes and Cycles ........................ 185

0716MS&A68. Analyze Reciprocating & Rotary Air Compressors Performance .................. 188

0716MS&A69. Solves Problems of Internal Combustion Engine ......................................... 190

20. Motor Vehicle Driving AD-302................................................................................... 191

0716MS&A70. Inspect Vehicle Controls for pre Operational & Pre Starting ......................... 192

0716MS&A71. Read and Interpret Traffic Signals, Road Signs and Marking Lanes on

Roads. ......................................................................................................... 196

0716MS&A72. Apply Power & Parking Brakes to Vehicle .................................................... 198

0716MS&A73. Drive Car in Different Condition ................................................................... 200

0716MS&A74. Drive Vehicle with Manual& Automatic Transmission................................... 202

0716MS&A75. Drive Motorcycle .......................................................................................... 204

0716MS&A76. Drive Vehicle on Economy Speed for Fuel Saving ....................................... 206

0716MS&A77. Perform Safety Practices While Driving ....................................................... 208

21. Motor Vehicle Inspection AD-312 ............................................................................. 209

0716MS&A78. Inspect Tires & Wheels of Light & Heavy Duty Transport Vehicles (LTV

& HTV). ....................................................................................................... 210

0716MS&A79. Inspect Vehicle Suspension System. ........................................................... 212

0716MS&A80. Inspect Vehicle Steering System and Wheel Alignment ............................... 214

0716MS&A81. Inspect Light & Heavy Duty Vehicle Brake System ...................................... 216

0716MS&A82. Inspect Vehicle Light System. ...................................................................... 219

0716MS&A83. Inspect Vehicle Electric System ................................................................... 221

0716MS&A84. Inspect Vehicle Glazing System .................................................................. 222

0716MS&A85. Inspect Vehicle Fuel System........................................................................ 225

0716MS&A86. Inspect Vehicle Body Accessories. .............................................................. 227

0716MS&A87. Inspect Vehicle Exhaust System. ................................................................. 230

0716MS&A88. Prepare Comprehensive Vehicle Inspection Report. .................................... 232

0716MS&A89. Prepare Vehicle Title Certificate. ................................................................. 234

22. Fuel Injection and Carburetion AD-343 .................................................................... 236

0716MS&A90. Diagnose Faults of Intake System. .............................................................. 236

0716MS&A91. Diagnose Faults of Exhaust System ............................................................ 238

0716MS&A92. Diagnose Faults of Fuel Supply System. ..................................................... 240

0716MS&A93. Diagnose Faults & Repair Hybrid System .................................................... 244

0716MS&A94. Diagnose Faults & Repair Engine Valve Control System ............................. 246

23. Automotive Transmission AD-363 ........................................................................... 247

0716MS&A95. Diagnose Faults & Repair Clutch. ................................................................ 247

0716MS&A96. Diagnose Faults &Repair Manual Gear Box. ............................................... 249

0716MS&A97. Diagnose Faults & Repair Automatic Gear Box. .......................................... 251

0716MS&A98. Diagnose Faults & Repair Final Drive. ......................................................... 253

24. Auto Body Building & Finishing AD-383 .................................................................. 255

0716MS&A99. Understand Vehicle Body Shell ................................................................... 255

0716MS&A100. Prepare Cost Estimate for Damaged Vehicle Body and Chassis ................. 257

0716MS&A101. Perform Vehicle Body and Chassis Alignment and Repair ........................... 258

0716MS&A102. Perform Vehicle Body Repairs Work ............................................................ 260

0716MS&A103. Carryout Panel Repair with Washer Welder Machine .................................. 264

0716MS&A104. Repair Vehicle Body Fittings ........................................................................ 267

0716MS&A105. Perform Welding Operations on Vehicle Body ............................................. 270

0716MS&A106. Maintain Machinery, Tools and Equipment .................................................. 273

0716MS&A107. Remove and Fix Glass Items ....................................................................... 276

0716MS&A108. Perform Body Surface Cleaning by Mechanical Process ............................. 279

0716MS&A109. Perform Body Surface Cleaning with Chemical Process .............................. 282

0716MS&A110. Maintain Vehicle Body Repair Tools, Equipment and Machinery ................. 285

0716MS&A111. Maintain Paint Booth and Stores ................................................................. 288

0716MS&A112. Apply Polyester Putty................................................................................... 291

0716MS&A113. Prepare Paint Booth and Vehicle ................................................................. 295

0716MS&A114. Apply Primer Surface ................................................................................... 299

0716MS&A115. Preform Color Matching & Mixing ................................................................ 302

0716MS&A116. Apply Body Sealer ....................................................................................... 305

0716MS&A117. Perform Masking ......................................................................................... 308

0716MS&A118. Apply Under Coat ........................................................................................ 311

0716MS&A119. Apply Final Coats ........................................................................................ 316

0716MS&A120. Perform Polishing to Body Surface .............................................................. 320

0716MS&A121. Prepare Paint Work Estimation .................................................................... 322

25. Workshop Practice-III AD-324 ................................................................................... 325

0716MS&A122. Perform Engine Preventive Maintenance (Tune-Up) .................................... 326

0716MS&A123. Perform Periodic Maintenance ..................................................................... 328

0716MS&A124. Arrange Workshop Equipment According to Lay-out ................................... 329

0716MS&A125. Prepare Documentation for Automotive workshop ....................................... 330

0716MS&A126. Maintain Service Station Equipment ............................................................ 330

0716MS&A127. Maintain Emission control system ................................................................ 332

0716MS&A128. Perform Engine Overhauling........................................................................ 334

0716MS&A129. Maintain Climatic Control System. ............................................................... 337

0716MS&A130. Perform Engine Output Testing ................................................................... 339

0716MS&A131. Read and Interpret Hydraulic and Pneumatic Code and Symbols ................ 341

26. Generic ....................................................................................................................... 342

0716MS&A132. Participate In Workplace Communication .................................................... 343

0716MS&A133. Perform Work In Team Environment ............................................................ 345

0716MS&A134. Read and Develop Career Professionalism ................................................. 347

0716MS&A135. Practice Occupational Health and Safety Procedures .................................. 348

0716MS&A136. Lead Small Teams ....................................................................................... 350

0716MS&A137. Develop Negotiation Skills ........................................................................... 352

0716MS&A138. Solve Problems Related To Work Activities ................................................. 354

0716MS&A139. Develop Communication Skill ...................................................................... 355

0716MS&A140. Develop Administrative Skills ....................................................................... 357

0716MS&A141. Work effectively in a customer service/ sales environment .......................... 358

0716MS&A142. Develop Professionalism ............................................................................. 361

27. Entrepreneur .............................................................................................................. 363

0716MS&A143. Manage the Operations of Workshop Security Units .................................... 364

0716MS&A144. Organize Training On Multiple Workshop Units ........................................... 367

0716MS&A145. Administer Multiple Commercial Units ......................................................... 369

0716MS&A146. Supervise performance of Technician .......................................................... 371

0716MS&A147. Plan Work to Meet Expected Outcomes ...................................................... 373

0716MS&A148. Work Effectively In a Team .......................................................................... 375

0716MS&A149. Maintain Healthy, Safe and Secure Working Environment ........................... 377

0716MS&A150. Deal with Emergencies and Incidents at Workshop ..................................... 379

0716MS&A151. Maintain Effective Communication with Companies ..................................... 382

0716MS&A152. Compliance and certifications (IATF/ISO 16949, ISO 9001:2015, ISO

50001) ......................................................................................................... 384

1. Introduction

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

The level 5 of National DAE qualification on Electrical has been validated by the

Qualifications Validation Committee (QVC) members on 23-25 May, 2019 and will remain

valid for ten years i.e 25 May, 2029

4. Date of Review

The level 5 of National DAE qualification on Electrical has been validated by the

Qualifications Validation Committee (QVC) members on 23-25 May, 2019 and shall be

reviewed after three years i.e 26 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

0716MS&A(1) 1st Level National Certificate of level-5, in “AutoMobile Technology”

0716MS&A(2) 2nd Level National Certificate of level-5, in “AutoMobile Technology”

0716MS&A(3) 3rd Level National Certificate of level-5, in “AutoMobile Technology”

0716MS&A(4) 4th Level National Certificate of level-5, in “AutoMobile Technology”

0716MS&A(5) 5th Level National Certificate of level-5, in “AutoMobile Technology”

6. Members of 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. Muzammal Hussain,

Instructor ( Auto & Diesel )

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. Members of Qualification Validation Committee

The following members participated in the qualifications development and validation

workshop on 20th May 2019 to 22nd May 2019 at Park Lane Hotel, Lahore

Sr.

No.

Name & Designation Organization

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

GCT, Railway Road, Lahore

PTEVTA

2. Skindar Shahzad,

Sr. Instructor/ DACUM Facilitator

Aman Tech, Karachi

3. Muzammal Hussain,

Instructor ( Auto & Diesel )

GCT, Rawalpindi, PTEVTA

4. Mr. Abid Iqbal

GCT, Peshawar

Representative from KP-TEVTA

5. Mr. Muhammad Memon,

GCT, Hyderabad

Representative from Sindh-TEVTA

6. Mr. Muhammad Hafeez, Deputy Secretary PBTE, Lahore

7. Mr. Sikandar Masood, Director, NAVTTC ( Coordinator)

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

AD-133 Internal Combustion Engine

0716MS&A1:

Specify Engine Types and its Component 2 5 Technical

0716MS&A2:

Identify Engine Parts and Interpret Assembly Procedure

2 5 Technical

0716MS&A3:

Maintain Engine Cooling System Components 2 4 Technical

0716MS&A4:

Maintain Engine Lubrication System 2 5 Technical

0716MS&A5:

Retain Fuel System of Petrol Engine 2 5 Technical

0716MS&A6:

Retain Fuel System of Diesel Engine 2 5 Technical

0716MS&A7:

Maintain Engine Exhaust System 2 3 Technical

0716MS&A8:

Diagnosing Engine Faults 2 4 Technical

0716MS&A9:

Perform Ignition System of Petrol Engine 2 4 Technical

0716MS&A10:

Perform Overhauling of Four Stroke Single Cylinder Engine

2 4 Technical

AD-143 Automotive Electricity and Electronics 2

0716MS&A11:

Perform Electrical Measurements 2 5 Technical

0716MS&A12:

Prepare Electromagnetism applications 2 4 Technical

0716MS&A13:

Perform Battery Service of Vehicle 2 5 Technical

0716MS&A14:

Repair Engine Starting System 2 5 Technical

0716MS&A15:

Repair Ignition System of Petrol Engine 2 5 Technical

0716MS&A16:

Adjust Ignition Timing of Petrol Engine 2 4 Technical

0716MS&A17:

Repair Distributer-Less Ignition Systems of Petrol Engine

2 3 Technical

0716MS&A18:

Repair Battery Charging System 2 4 Technical

0716MS&A19:

Repair Light System of Vehicle 2 4 Technical

0716MS&A20:

Repair Vehicle Accessories 2 5 Technical

MT-164 Workshop Practice-1 2

0716MS&A21:

Perform Bench Work on Metallic Surfaces 2 4 Technical

0716MS&A22:

Perform Shaper Machine Operations 2 3 Technical

0716MS&A23:

Perform Lathe Turning Operations 2 5 Technical

0716MS&A24:

Read and Interpret Manufacturing Drawings 2 5 Technical

0716MS&A25:

Preform Welding Procedure Specifications (WPS) 2 4 Technical

0716MS&A26:

Prepare Materials for Welding 2 4 Technical

0716MS&A27:

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

2 5 Technical

0716MS&A28:

Perform Forging Operations 2 3 Technical

Mech-163

Basic Engineering Drawing and CAD-I 2

0716MS&A29:

Perform Drawing, Sketch Making 2 5 Allied

0716MS&A30:

Draw Pictorial Drawing 2 5 Allied

0716MS&A31:

Perform Basic Dimensioning System in Working Drawing

2 5 Allied

0716MS&A32:

Perform Sectioning and Pictorial Drawing 2 6 Allied

0716MS&A33:

Draw Auxiliary Drawing 2 6 Allied

AD-203 Problems in Internal Combustion Engines 3

0716MS&A34:

Diagnose Engine Fault 3 3 Technical

0716MS&A35:

Perform Engine Overhauling (Petrol/Diesel) 3 5 Technical

0716MS&A36:

Diagnose Engine Cooling System Faults and Repair

3 4 Technical

0716MS&A37:

Diagnose Faults in Engine Lubrication System 3 3 Technical

0716MS&A38:

Diagnose Faults of Carburetor Fuel System 3 4 Technical

0716MS&A39:

Diagnose Diesel Fuel System and Adjust 3 3 Technical

0716MS&A40:

Diagnose Faults of Ignition System 3 4 Technical

AD-213 Suspension, Steering & Brakes 3

0716MS&A41:

Repair Vehicle Brake System. 3 3 Technical

0716MS&A42:

Repair Vehicle Steering System. 3 3 Technical

0716MS&A43:

Maintain Vehicle Suspension System. 3 3 Technical

0716MS&A44:

Carry out Wheel Alignment 3 3 Technical

0716MS&A45:

Carry Out Wheel Balancing 3 3 Technical

0716MS&A46:

Replace SRS System 3 3 Technical

AD-224 Workshop Practice-II 3

0716MS&A47:

Arrange Common Automotive Hand Tools and their Use

3 4 Technical

0716MS&A48:

Carry Out Measurements with Automotive Measuring Tools

3 4 Technical

0716MS&A49:

Perform Test on Vehicle with Automotive Workshop Equipment

3 4 Technical

0716MS&A50:

Diagnose Faults by Computerized Performance Testing Equipment

3 4 Technical

0716MS&A51:

Categorize Automotive Fasteners Types and their Uses

3 4 Technical

0716MS&A52:

Specify Vehicle's Lubricants Types 3 4 Technical

0716MS&A53:

Differentiate Vehicle Oil Seals Types and Specifications Coding

3 3 Technical

0716MS&A54:

Specify Vehicle Bearing's Types and Coding 3 4 Technical

0716MS&A55:

Read and Interpret Quality Control Standards and Certification

3 3 Technical

0716MS&A56:

Plan and Organize Safe Workshop and Hazard Prevention Practices

3 3 Technical

MT-252 Metrology 3

0716MS&A57:

Recognize Graduated Instruments 3 3 Functional

0716MS&A58:

Carry-Out Linear Measuring 3 2 Functional

0716MS&A59:

Carry-out Precise Measuring 3 2 Functional

0716MS&A60:

Perform Angular Measuring. 3 2 Functional

0716MS&A61:

Identify the Types of Gauges. 3 2 Functional

0716MS&A62:

Identify Comparators Instrument 3 2 Functional

AD-232 Applied Thermodynamics 4

0716MS&A63:

Analyses HVAC/R Systems Thermodynamic Performance

3 3 Functional

0716MS&A64:

Carry-out Smooth Boiler Operation 3 3 Functional

0716MS&A65:

Recognize Fundamentals of Thermodynamics Problems

3 3 Functional

0716MS&A66:

Read and Interpret Perfect Gases Laws, Properties and Solve problems

3 4 Functional

0716MS&A67:

Read and Derived Thermodynamics Processes and Cycles

3 4 Functional

0716MS&A68:

Analyze Reciprocating & Rotary Air Compressors Performance

3 3 Functional

0716MS&A69:

Solves Problems of Internal Combustion Engine 3 3 Functional

AD-302 Motor Vehicle Driving 4

0716MS&A70:

Inspect Vehicle Controls for pre Operational & Pre Starting

4 3 Technical

0716MS&A71:

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

4 3 Technical

0716MS&A72:

Apply Power & Parking Brakes to Vehicle 4 3 Technical

0716MS&A73:

Drive Car in Different Condition 4 4 Technical

0716MS&A74:

Drive Vehicle with Manual& Automatic Transmission

4 4 Technical

0716MS&A75:

Drive Motorcycle 4 3 Technical

0716MS&A76:

Drive Vehicle on Economy Speed for Fuel Saving 4 3 Technical

0716MS&A77:

Perform Safety Practices While Driving 4 3 Technical

AD-312 Motor Vehicle Inspection 5

0716MS&A78:

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

5 4 Technical

0716MS&A79:

Inspect Vehicle Suspension System. 5 4 Technical

0716MS&A80:

Inspect Vehicle Steering System and Wheel Alignment

5 4 Technical

0716MS&A81:

Inspect Light & Heavy Duty Vehicle Brake System

5 4 Technical

0716MS&A82:

Inspect Vehicle Light System. 5 4 Technical

0716MS&A83:

Inspect Vehicle Electric System 5 4 Technical

0716MS&A84:

Inspect Vehicle Glazing System 5 4 Technical

0716MS&A85:

Inspect Vehicle Fuel System 5 4 Technical

0716MS&A86:

Inspect Vehicle Body Accessories. 5 3 Technical

0716MS&A87:

Inspect Vehicle Exhaust System. 5 4 Technical

0716MS&A88:

Prepare Comprehensive Vehicle Inspection Report.

5 4 Technical

0716MS&A89:

Prepare Vehicle Title Certificate. 5 4 Technical

AD-343 Fuel Injection and Carburetion 5

0716MS&A90:

Diagnose Faults of Intake System. 5 3 Technical

0716MS&A91:

Diagnose Faults of Exhaust System 5 3 Technical

0716MS&A92:

Diagnose Faults of Fuel Supply System. 5 2 Technical

0716MS&A93:

Diagnose Faults & Repair Hybrid System 5 2 Technical

0716MS&A94:

Diagnose Faults & Repair Engine Valve Control System

5 2 Technical

AD-363 Automotive Transmission 5

0716MS&A95:

Diagnose Faults & Repair Clutch. 5 6 Technical

0716MS&A96:

Diagnose Faults &Repair Manual Gear Box. 5 6 Technical

0716MS&A97:

Diagnose Faults & Repair Automatic Gear Box. 5 6 Technical

0716MS&A98:

Diagnose Faults & Repair Final Drive. 5 6 Technical

AD-383 Auto Body Building & Finishing 5

0716MS&A99:

Understand Vehicle Body Shell 5 2 Technical

0716MS&A100:

Prepare Cost Estimate for Damaged Vehicle Body and Chassis

5 2 Technical

0716MS&A101:

Perform Vehicle Body and Chassis Alignment and Repair

5 2 Technical

0716MS&A102:

Perform Vehicle Body Repairs Work 5 2 Technical

0716MS&A103:

Carryout Panel Repair with Washer Welder Machine

5 2 Technical

0716MS&A104:

Repair Vehicle Body Fittings 5 2 Technical

0716MS&A105:

Perform Welding Operations on Vehicle Body 5 2 Technical

0716MS&A106:

Maintain Machinery, Tools and Equipment 5 2 Technical

0716MS&A107:

Remove and Fix Glass Items 5 2 Technical

0716MS&A108:

Perform Body Surface Cleaning by Mechanical Process

5 2 Technical

0716MS&A109:

Perform Body Surface Cleaning with Chemical Process

5 2 Technical

0716MS&A110:

Maintain Vehicle Body Repair Tools, Equipment and Machinery

5 2 Technical

0716MS&A111:

Maintain Paint Booth and Stores 5 1 Technical

0716MS&A112:

Apply Polyester Putty 5 1 Technical

0716MS&A113:

Prepare Paint Booth and Vehicle 5 1 Technical

0716MS&A114:

Apply Primer Surface 5 1 Technical

0716MS&A115:

Preform Color Matching & Mixing 5 1 Technical

0716MS&A116:

Apply Body Sealer 5 1 Technical

0716MS&A117:

Perform Masking 5 1 Technical

0716MS&A118:

Apply Under Coat 5 1 Technical

0716MS&A119:

Apply Final Coats 5 1 Technical

0716MS&A120:

Perform Polishing to Body Surface 5 1 Technical

0716MS&A121:

Prepare Paint Work Estimation 5 1 Technical

AD-324 Workshop Practice-III 4

0716MS&A122:

Perform Engine Preventive Maintenance (Tune-Up)

5 2 Technical

0716MS&A123:

Perform Periodic Maintenance 5 2 Technical

0716MS&A124:

Arrange Workshop Equipment According to Lay-out

5 2 Technical

0716MS&A125:

Prepare Documentation for Automotive workshop 5 2 Technical

0716MS&A126:

Maintain Service Station Equipment 5 2 Technical

0716MS&A127:

Maintain Emission control system 5 2 Technical

0716MS&A128:

Perform Engine Overhauling 5 2 Technical

0716MS&A129:

Maintain Climatic Control System. 5 2 Technical

0716MS&A130:

Perform Engine Output Testing 5 2 Technical

0716MS&A131:

Read and Interpret Hydraulic and Pneumatic Code and Symbols

5 2 Technical

Generic

0716MS&A132:

Participate In Workplace Communication 2 2 Generic

0716MS&A133:

Perform Work In Team Environment 2 2 Generic

0716MS&A134:

Read and Develop Career Professionalism 2 2 Generic

0716MS&A135:

Practice Occupational Health and Safety Procedures

2 2 Generic

0716MS&A136:

Lead Small Teams 3 2 Generic

0716MS&A137:

Develop Negotiation Skills 3 2 Generic

0716MS&A138:

Solve Problems Related To Work Activities 3 2 Generic

0716MS&A139:

Develop Communication Skill 5 2 Generic

0716MS&A140:

Develop Administrative Skills 5 2 Generic

0716MS&A141:

Work effectively in a customer service/ sales environment

4 2 Generic

0716MS&A142:

Develop Professionalism 4 2 Generic

Entrepreneur 5

0716MS&A143:

Manage the Operations of Workshop Security Units

5 3 Entrepreneur

0716MS&A144:

Organize Training On Multiple Workshop Units 5 3 Entrepreneur

0716MS&A145:

Administer Multiple Commercial Units 5 4 Entrepreneur

0716MS&A146:

Supervise performance of Technician 5 4 Entrepreneur

0716MS&A147:

Plan Work to Meet Expected Outcomes 5 3 Entrepreneur

0716MS&A148:

Work Effectively In a Team 5 3 Entrepreneur

0716MS&A149:

Maintain Healthy, Safe and Secure Working Environment

5 4 Entrepreneur

0716MS&A150:

Deal with Emergencies and Incidents at Workshop

5 3 Entrepreneur

0716MS&A151:

Maintain Effective Communication with Companies

5 3 Entrepreneur

0716MS&A152:

Compliance and certifications (IATF/ISO 16949, ISO 9001:2015, ISO 50001)

5 3 Entrepreneur

10. Leveling of the Competency Standards

Level 2

Code Competency Standards Level TH PR TL Credits Category


0716MS&A1: Specify Engine Types and its Component

2 14 36 50 5 Technical

0716MS&A2: Identify Engine Parts and Interpret Assembly Procedure


0716MS&A3: Maintain Engine Cooling System Components


0716MS&A4: Maintain Engine Lubrication System


0716MS&A5: Retain Fuel System of Petrol Engine


0716MS&A6: Retain Fuel System of Diesel Engine


0716MS&A7: Maintain Engine Exhaust System 2 10 20 30 3 Technical

0716MS&A8: Diagnosing Engine Faults 2 15 25 40 4 Technical

0716MS&A9: Perform Ignition System of Petrol Engine


0716MS&A10: Perform Overhauling of Four Stroke Single Cylinder Engine


MT-164 Workshop Practice-1

0716MS&A21: Perform Bench Work on Metallic Surfaces


0716MS&A22: Perform Shaper Machine Operations


0716MS&A23: Perform Lathe Turning Operations 2 15 35 50 5 Technical

0716MS&A24: Read and Interpret Manufacturing Drawings


0716MS&A25: Preform Welding Procedure Specifications (WPS)


0716MS&A26: Prepare Materials for Welding 2 10 30 40 4 Technical

0716MS&A27: Perform Shielded Metal Arc Welding (SMAW) in Vertical (3F, 3G) and Overhead (4F, 4G) Positions


0716MS&A28: Perform Forging Operations 2 10 20 30 3 Technical

Generic

0716MS&A134: Read and Develop Career Professionalism

2 10 10 20 2 Generic

Level 2


AD-143 Automotive Electricity and Electronics

0716MS&A11: Perform Electrical Measurements 2 15 35 50 5 Technical

0716MS&A12: Prepare Electromagnetism applications


0716MS&A13: Perform Battery Service of Vehicle


0716MS&A14: Repair Engine Starting System 2 15 35 50 5 Technical

0716MS&A15: Repair Ignition System of Petrol Engine


0716MS&A16: Adjust Ignition Timing of Petrol Engine


0716MS&A17: Repair Distributer-Less Ignition Systems of Petrol Engine


0716MS&A18: Repair Battery Charging System 2 15 25 40 4 Technical

0716MS&A19: Repair Light System of Vehicle 2 15 25 40 4 Technical

0716MS&A20: Repair Vehicle Accessories 2 15 35 50 5 Technical

Mech-163 Basic Engineering Drawing and CAD-I

0716MS&A29: Perform Drawing, Sketch Making 2 16 34 50 5 Allied

0716MS&A30: Draw Pictorial Drawing 2 15 35 50 5 Allied

0716MS&A31: Perform Basic Dimensioning System in Working Drawing

2 15 35 50 5 Allied

0716MS&A32: Perform Sectioning and Pictorial Drawing

2 15 45 60 6 Allied

0716MS&A33: Draw Auxiliary Drawing 2 16 44 60 6 Allied

Generic

0716MS&A132: Participate In Workplace Communication

2 8 12 20 2 Generic

0716MS&A133: Perform Work In Team Environment

2 8 12 20 2 Generic

0716MS&A135: Practice Occupational Health and Safety Procedures

2 10 10 20 2 Generic

Level 3

Code Competency Standards Level

TH PR TL Credits

Category

AD-203 Problems in Internal Combustion Engines

0716MS&A34:

Diagnose Engine Fault 3 10

20

30 3 Technical

0716MS&A35:

Perform Engine Overhauling (Petrol/Diesel)

3 10

40

50 5 Technical

0716MS&A36:


3 10

30

40 4 Technical

0716MS&A37:

Diagnose Faults in Engine Lubrication System

3 10

20

30 3 Technical

0716MS&A38:

Diagnose Faults of Carburetor Fuel System

3 15

25

40 4 Technical

0716MS&A39:

Diagnose Diesel Fuel System and Adjust

3 10

20

30 3 Technical

0716MS&A40:

Diagnose Faults of Ignition System 3 15

25

40 4 Technical

AD-224 Workshop Practice-II

0716MS&A47:


3 15

25

40 4 Technical

0716MS&A48:


3 15

25

40 4 Technical

0716MS&A49:


3 15

25

40 4 Technical

0716MS&A50:


3 15

25

40 4 Technical

0716MS&A51:


3 14

26

40 4 Technical

0716MS&A52:

Specify Vehicle's Lubricants Types 3 15

25

40 4 Technical

0716MS&A53:


3 10

20

30 3 Technical

0716MS&A54:

Specify Vehicle Bearing's Types and Coding

3 15

25

40 4 Technical

0716MS&A55:


3 10

20

30 3 Technical

0716MS&A56:


3 10

20

30 3 Technical

MT-252 Metrology

0716MS&A57:

Recognize Graduated Instruments 3 10

20

30 3 Functional

0716MS&A58:

Carry-Out Linear Measuring 3 8 12

20 2 Functional

0716MS&A59:

Carry-out Precise Measuring 3 8 12

20 2 Functional

0716MS&A60:

Perform Angular Measuring. 3 8 12

20 2 Functional

0716MS&A61:

Identify the Types of Gauges. 3 8 12

20 2 Functional

0716MS&A62:

Identify Comparators Instrument 3 8 12

20 2 Functional

Generic

0716MS&A136:

Lead Small Teams 3 10

10

20 2 Generic

0716MS&A13 Develop Negotiation Skills 3 1 1 20 2 Generic

7: 0 0

0716MS&A138:

Solve Problems Related To Work Activities

3 10

10

20 2 Generic

Level 4


TH

PR

TL

Credits

Category

AD-213 Suspension, Steering & Brakes

0716MS&A41:

Repair Vehicle Brake System. 3 10

20

30

3 Technical

0716MS&A42:

Repair Vehicle Steering System. 3 10

20

30

3 Technical

0716MS&A43:

Maintain Vehicle Suspension System. 3 10

20

30

3 Technical

0716MS&A44:

Carry out Wheel Alignment 3 8 22

30

3 Technical

0716MS&A45:

Carry Out Wheel Balancing 3 10

20

30

3 Technical

0716MS&A46:

Replace SRS System 3 10

20

30

3 Technical

AD-232 Applied Thermodynamics

0716MS&A63:


3 10

20

30

3 Functional

0716MS&A64:

Carry-out Smooth Boiler Operation 3 10

20

30

3 Functional

0716MS&A65:


3 10

20

30

3 Functional

0716MS&A66:


3 15

25

40

4 Functional

0716MS&A67:


3 15

25

40

4 Functional

0716MS&A68:


3 10

20

30

3 Functional

0716MS&A69:

Solves Problems of Internal Combustion Engine

3 10

20

30

3 Functional

AD-383 Auto Body Building & Finishing

0716MS&A99:

Understand Vehicle Body Shell 5 10

10

20

2 Technical

0716MS&A100:


5 8 12

20

2 Technical

0716MS&A101:


5 8 12

20

2 Technical

0716MS&A102:

Perform Vehicle Body Repairs Work 5 10

10

20

2 Technical

0716MS&A103:


5 10

10

20

2 Technical

0716MS&A104:

Repair Vehicle Body Fittings 5 8 12

20

2 Technical

0716MS&A105:

Perform Welding Operations on Vehicle Body 5 8 12

20

2 Technical

0716MS&A106:

Maintain Machinery, Tools and Equipment 5 10

10

20

2 Technical

0716MS&A107:

Remove and Fix Glass Items 5 8 12

20

2 Technical

0716MS&A108:


5 8 12

20

2 Technical

0716MS&A109:


5 5 15

20

2 Technical

0716MS&A110:


5 8 12

20

2 Technical

0716MS&A111:

Maintain Paint Booth and Stores 5 2 8 10

1 Technical

0716MS&A112:

Apply Polyester Putty 5 2 8 10

1 Technical

0716MS&A113:

Prepare Paint Booth and Vehicle 5 2 8 10

1 Technical

0716MS&A114:

Apply Primer Surface 5 2 8 10

1 Technical

0716MS&A115:

Preform Color Matching & Mixing 5 2 8 10

1 Technical

0716MS&A116:

Apply Body Sealer 5 2 8 10

1 Technical

0716MS&A117:

Perform Masking 5 2 8 10

1 Technical

0716MS&A118:

Apply Under Coat 5 2 8 10

1 Technical

0716MS&A119:

Apply Final Coats 5 2 8 10

1 Technical

0716MS&A120:

Perform Polishing to Body Surface 5 2 8 10

1 Technical

0716MS&A121:

Prepare Paint Work Estimation 5 2 8 10

1 Technical

Generic

0716MS&A139:

Develop Communication Skill 5 10

10

20

2 Generic

0716MS&A140:

Develop Administrative Skills 5 10

10

20

2 Generic

Level 5


TH

PR

TL

Credits

Category

AD-312 Motor Vehicle Inspection

0716MS&A78:


5 10

30

40

4 Technical

0716MS&A79:

Inspect Vehicle Suspension System. 5 10

30

40

4 Technical

0716MS&A80:


5 10

30

40

4 Technical

0716MS&A81:


5 14

26

40

4 Technical

0716MS&A82:

Inspect Vehicle Light System. 5 10

30

40

4 Technical

0716MS&A83:

Inspect Vehicle Electric System 5 15

25

40

4 Technical

0716MS&A84:

Inspect Vehicle Glazing System 5 15

25

40

4 Technical

0716MS&A85:

Inspect Vehicle Fuel System 5 15

25

40

4 Technical

0716MS&A86:

Inspect Vehicle Body Accessories. 5 10

20

30

3 Technical

0716MS&A87:

Inspect Vehicle Exhaust System. 5 15

25

40

4 Technical

0716MS&A88:


5 15

25

40

4 Technical

0716MS&A89:

Prepare Vehicle Title Certificate. 5 15

25

40

4 Technical

AD-343 Fuel Injection and Carburetion

0716MS&A90:

Diagnose Faults of Intake System. 5 10

20

30

3 Technical

0716MS&A91:

Diagnose Faults of Exhaust System 5 10

20

30

3 Technical

0716MS&A92:

Diagnose Faults of Fuel Supply System. 5 8 12

20

2 Technical

0716MS&A93:

Diagnose Faults & Repair Hybrid System 5 8 12

20

2 Technical

0716MS&A94:


5 8 12

20

2 Technical

AD-324 Workshop Practice-III

0716MS&A122:


5 8 12

20

2 Technical

0716MS&A123:

Perform Periodic Maintenance 5 8 12

20

2 Technical

0716MS&A124:


5 8 12

20

2 Technical

0716MS&A125:

Prepare Documentation for Automotive workshop

5 8 12

20

2 Technical

0716MS&A126:

Maintain Service Station Equipment 5 8 12

20

2 Technical

0716MS&A127:

Maintain Emission control system 5 8 12

20

2 Technical

0716MS&A128:

Perform Engine Overhauling 5 8 12

20

2 Technical

0716MS&A129:

Maintain Climatic Control System. 5 8 12

20

2 Technical

0716MS&A130:

Perform Engine Output Testing 5 8 12

20

2 Technical

0716MS&A131:


5 8 12

20

2 Technical

Generic

0716MS&A141:


4 8 12

20

2 Generic

0716MS&A142:

Develop Professionalism 4 8 12

20

2 Generic

Level 5


AD-363 Automotive Transmission

0716MS&A95: Diagnose Faults & Repair Clutch.


0716MS&A96: Diagnose Faults &Repair Manual Gear Box.


0716MS&A97: Diagnose Faults & Repair Automatic Gear Box.


0716MS&A98: Diagnose Faults & Repair Final Drive.


AD-302 Motor Vehicle Driving

0716MS&A70: Inspect Vehicle Controls for pre Operational & Pre Starting


0716MS&A71: Read and Interpret Traffic Signals, Road Signs and Marking Lanes on Roads.


0716MS&A72: Apply Power & Parking Brakes to Vehicle


0716MS&A73: Drive Car in Different Condition


0716MS&A74: Drive Vehicle with Manual& Automatic Transmission


0716MS&A75: Drive Motorcycle -4 10 20 30 3 Technical

0716MS&A76: Drive Vehicle on Economy Speed for Fuel Saving


0716MS&A77: Perform Safety Practices While Driving


Entrepreneur

0716MS&A143: Manage the Operations of Workshop Security Units

5 10 20 30 3 Entrepreneur

0716MS&A144: Organize Training On Multiple Workshop Units


0716MS&A145: Administer Multiple Commercial Units


0716MS&A146: Supervise performance of Technician


0716MS&A147: Plan Work to Meet Expected Outcomes


0716MS&A148: Work Effectively In a Team


0716MS&A149: Maintain Healthy, Safe and Secure Working Environment


0716MS&A150: Deal with Emergencies and Incidents at Workshop


0716MS&A151: Maintain Effective Communication with Companies


0716MS&A152: Compliance and certifications (IATF/ISO 16949, ISO 9001:2015, ISO 50001)


11. Packaging of the Qualification

1. Auto Service Department


000000 Pro Auto Mechanic


0716MS&A1: Specify Engine Types and its Component


0716MS&A2: Identify Engine Parts and Interpret Assembly Procedure


0716MS&A3: Maintain Engine Cooling System Components


0716MS&A4: Maintain Engine Lubrication System


0716MS&A5: Retain Fuel System of Petrol Engine


0716MS&A6: Retain Fuel System of Diesel Engine


0716MS&A7: Maintain Engine Exhaust System 2 10 20 30 3 Technical

0716MS&A8: Diagnosing Engine Faults 2 15 25 40 4 Technical

0716MS&A9: Perform Ignition System of Petrol Engine


0716MS&A10: Perform Overhauling of Four Stroke Single Cylinder Engine


000000 Auto Diagnostic Mechanic


0716MS&A34: Diagnose Engine Fault 3 10 20 30 3 Technical

0716MS&A35: Perform Engine Overhauling (Petrol/Diesel)


0716MS&A36: Diagnose Engine Cooling System Faults and Repair


0716MS&A37: Diagnose Faults in Engine Lubrication System


0716MS&A38: Diagnose Faults of Carburetor Fuel System


0716MS&A39: Diagnose Diesel Fuel System and Adjust


0716MS&A40: Diagnose Faults of Ignition System


AD-224 Workshop Practice-II

0716MS&A47: Arrange Common Automotive Hand Tools and their Use


0716MS&A48: Carry Out Measurements with Automotive Measuring Tools


0716MS&A49: Perform Test on Vehicle with Automotive Workshop Equipment


0716MS&A50: Diagnose Faults by Computerized Performance Testing Equipment


0716MS&A51: Categorize Automotive Fasteners Types and their Uses


0716MS&A52: Specify Vehicle's Lubricants Types


0716MS&A53: Differentiate Vehicle Oil Seals Types and Specifications Coding


0716MS&A54: Specify Vehicle Bearing's Types and Coding


0716MS&A55: Read and Interpret Quality Control Standards and Certification


0716MS&A56: Plan and Organize Safe Workshop and Hazard Prevention Practices


000000 Vehicle Drive Test Technician

0716MS&A70: Inspect Vehicle Controls for pre Operational & Pre Starting


0716MS&A71: Read and Interpret Traffic Signals, Road Signs and Marking Lanes on Roads.


0716MS&A72: Apply Power & Parking Brakes to Vehicle


0716MS&A73: Drive Car in Different Condition 4 15 25 40 4 Technical

0716MS&A74: Drive Vehicle with Manual& Automatic Transmission


0716MS&A75: Drive Motorcycle 4 10 20 30 3 Technical

0716MS&A76: Drive Vehicle on Economy Speed for Fuel Saving


0716MS&A77: Perform Safety Practices While Driving


000000 Master Technician

AD-343 Fuel Injection and Carburetion

0716MS&A90: Diagnose Faults of Intake System.


0716MS&A91: Diagnose Faults of Exhaust System


0716MS&A92: Diagnose Faults of Fuel Supply System.


0716MS&A93: Diagnose Faults & Repair Hybrid System


0716MS&A94: Diagnose Faults & Repair Engine Valve Control System


AD-363 Automotive Transmission

0716MS&A95: Diagnose Faults & Repair Clutch.


0716MS&A96: Diagnose Faults &Repair Manual Gear Box.


0716MS&A97: Diagnose Faults & Repair Automatic Gear Box.


0716MS&A98: Diagnose Faults & Repair Final Drive.


000000 Service Advisor

AD-324 Workshop Practice-III

0716MS&A122: Perform Engine Preventive Maintenance (Tune-Up)


0716MS&A123: Perform Periodic Maintenance 5 8 12 20 2 Technical

0716MS&A124: Arrange Workshop Equipment According to Lay-out


0716MS&A125: Prepare Documentation for Automotive workshop


0716MS&A126: Maintain Service Station Equipment


0716MS&A127: Maintain Emission control system


0716MS&A128: Perform Engine Overhauling 5 8 12 20 2 Technical

0716MS&A129: Maintain Climatic Control System.


0716MS&A130: Perform Engine Output Testing 5 8 12 20 2 Technical

0716MS&A131: Read and Interpret Hydraulic and Pneumatic Code and Symbols


000000 Vehicle Examiner

AD-312 Motor Vehicle Inspection

0716MS&A78: Inspect Tires & Wheels of Light & Heavy Duty Transport Vehicles (LTV & HTV).


0716MS&A79: Inspect Vehicle Suspension System.


0716MS&A80: Inspect Vehicle Steering System and Wheel Alignment


0716MS&A81: Inspect Light & Heavy Duty Vehicle Brake System


0716MS&A82: Inspect Vehicle Light System. 5 10 30 40 4 Technical

0716MS&A83: Inspect Vehicle Electric System 5 15 25 40 4 Technical

0716MS&A84: Inspect Vehicle Glazing System 5 15 25 40 4 Technical

0716MS&A85: Inspect Vehicle Fuel System 5 15 25 40 4 Technical

0716MS&A86: Inspect Vehicle Body Accessories.


0716MS&A87: Inspect Vehicle Exhaust System. 5 15 25 40 4 Technical

0716MS&A88: Prepare Comprehensive Vehicle Inspection Report.


0716MS&A89: Prepare Vehicle Title Certificate. 5 15 25 40 4 Technical

2. Electrical Department


000000 Pro Auto Electrician


0716MS&A11: Perform Electricity Measurements 2 15 35 50 5 Technical















000000 Diagnostic Auto Electrician


0716MS&A11: Perform Electricity Measurements 2 15 35 50 5 Technical
















0716MS&A34: Diagnose Engine Fault 3 10 20 30 3 Technical

0716MS&A36: Diagnose Engine Cooling System Faults and Repair


0716MS&A37: Diagnose Faults in Engine Lubrication System


0716MS&A40: Diagnose Faults of Ignition System


3. Chassis Department


000000 Steering, Suspension and Brake Mechanic

AD-213 Suspension, Steering & Brakes

0716MS&A41: Repair Vehicle Brake System. 3 10 20 30 3 Technical

0716MS&A42: Repair Vehicle Steering System.


0716MS&A43: Maintain Vehicle Suspension System.


000000 Wheel Alignment Technician

0716MS&A44: Carry out Wheel Alignment 3 8 22 30 3 Technical

0716MS&A45: Carry Out Wheel Balancing 3 10 20 30 3 Technical

0716MS&A46: Replace SRS System 3 10 20 30 3 Technical

4. Auto Body Shop


000000 Auto Body Technician


0716MS&A99: Understand Vehicle Body Shell 5 10 10 20 2 Technical

0716MS&A100: Prepare Cost Estimate for Damaged Vehicle Body and Chassis


0716MS&A101: Perform Vehicle Body and Chassis Alignment and Repair


0716MS&A102: Perform Vehicle Body Repairs Work


0716MS&A103: Carryout Panel Repair with Washer Welder Machine


0716MS&A104: Repair Vehicle Body Fittings 5 8 12 20 2 Technical

0716MS&A105: Perform Welding Operations on Vehicle Body


0716MS&A106: Maintain Machinery, Tools and Equipment


0716MS&A107: Remove and Fix Glass Items 5 8 12 20 2 Technical

0716MS&A108: Perform Body Surface Cleaning by Mechanical Process


0716MS&A109: Perform Body Surface Cleaning with Chemical Process


0716MS&A110: Maintain Vehicle Body Repair Tools, Equipment and Machinery


000000 Auto Paint Technician


0716MS&A111: Maintain Paint Booth and Stores 5 2 8 10 1 Technical

0716MS&A112: Apply Polyester Putty 5 2 8 10 1 Technical

0716MS&A113: Prepare Paint Booth and Vehicle 5 2 8 10 1 Technical

0716MS&A114: Apply Primer Surface 5 2 8 10 1 Technical

0716MS&A115: Preform Color Matching & Mixing


0716MS&A116: Apply Body Sealer 5 2 8 10 1 Technical

0716MS&A117: Perform Masking 5 2 8 10 1 Technical

0716MS&A118: Apply Under Coat 5 2 8 10 1 Technical

0716MS&A119: Apply Final Coats 5 2 8 10 1 Technical

0716MS&A120: Perform Polishing to Body Surface


0716MS&A121: Prepare Paint Work Estimation 5 2 8 10 1 Technical

5. Mechanical Works


000000 Mill Wright Auto Mechanic


0716MS&A21: Perform Bench Work on Metallic Surfaces


0716MS&A22: Perform Shaper Machine Operations


0716MS&A23: Perform Lathe Turning Operations


0716MS&A24: Read and Interpret Manufacturing Drawings


000000 Pro Welder


0716MS&A25: Preform Welding Procedure Specifications (WPS)


0716MS&A26: Prepare Materials for Welding


0716MS&A27: Perform Shielded Metal Arc Welding (SMAW) in Vertical (3F, 3G) and Overhead (4F, 4G) Positions


0716MS&A28: Perform Forging Operations 2 10 20 30 3 Technical

000000 Boiler Supervisor (B-Class)

AD-232 Applied Thermodynamics

0716MS&A63: Analyses HVAC/R Systems Thermodynamic Performance

3 10 20 30 3 Functional

0716MS&A64: Carry-out Smooth Boiler Operation


0716MS&A65: Recognize Fundamentals of Thermodynamics Problems


0716MS&A66: Read and Interpret Perfect Gases Laws, Properties and Solve problems


0716MS&A67: Read and Derived Thermodynamics Processes and Cycles


0716MS&A68: Analyze Reciprocating & Rotary Air Compressors Performance


0716MS&A69: Solves Problems of Internal Combustion Engine


12. Internal Combustion Engine (AD-133)

Specify Engine Types and its Component

Overview:

This Competency Standard 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

CU-1: Identify Petrol

Engine

P-1. Observe vehicle systems, identify the typical petrol

engines and function of their main components.

P-2. Identify spark plugs and it functions

P-3. Identify distributor and its function

P-4. Identify ignition coil and its functions

P-5. Identify plug leads and its functions

P-6. Identify carburetor and its function

P-7. Identify EFI engine and its main components

CU-2: Identify Diesel

Engine

P-1. Observe vehicle systems, identify the typical diesel

engines and function of their main components.

P-2. Identify fuel injectors and its function

P-3. Identify high pressure fuel pump and its functions

P-4. Identify heater plug and its function

Knowledge & Understanding

K-1. 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 (Vernier calliper, micrometre, Cylinder bore gauge)

2 Hand tools trolley

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

4 Engine Petrol/ diesel

5 Vehicle

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.


CU-1: Understand Engine

block assembly

procedure.

P-1. Select appropriate tools and perform

dismantling/assembly of the all engine components as

specified procedure in the manual.

P-2. Select appropriate tools and perform crankshaft

assembly in the engine block with all related

components.

P-3. Select appropriate tools and perform piston ring

assembly in the block under the specified procedure.

CU-2: Understand Engine

head assembly

procedure.

P-1. Select appropriate tools and perform dismantling/

assembly of engine head valve train as specified

procedure in the manual.

P-2. Select appropriate tools and perform dismantling/

assembly of rocker assembly on the engine head under

the specified procedure in the manual.

P-3. Set the camshaft on the engine head and fit bearing

caps under the specified procedure.


K-1. 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,

K-2. 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-3. 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 (Vernier calliper, micrometre, 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.

Maintain Engine Cooling System Components

Overview

This Competency Standard 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



CU-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.

CU-2: Use Antifreeze/

inhibitors

P1. Identify the antifreeze its compositions and types.

P2. Identify the rust corrosion in the engine and preventions.


K-1. 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)

K-2. 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 the cooling system faults

Capable to identify the cooling system main components.


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

Maintain Engine Lubrication System

Overview



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

CU-1: Identify the

Lubrication

system

P-1. Identify the main components of engine lubrication

system and understand its functions.

P-2. Identify types of oil pumps and understand its function

P-3. Identify oil coolers for the high performance engine (air

cooled/Water cooled type)

CU-2: Use different

Lubricants in the

vehicle

P-1. Identify the types of engine oil used in the engine with

respect to viscosity.

P-2. Identify the function of oil filter and its components.

P-3. Identify the oil sump and its components.


K-1. The functions/operating principle and main components of engine lubrication

system as following.

K-2. 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.

K-3. Lubricant (oils viscosity, viscosity index, oil classifications, Reduction of frictional

forces, cooling effect, cleaning effect, corrosion resistance, and noise reduction).

K-4. 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

Retain Fuel System of Petrol Engine

Overview



different components to repair Carburetor type fuel system and basic EFI petrol engine by

Auto Mechanic, in accordance with the manufacturer’s Manual.


CU-1: Fuel system

(carburetor type

engine)

P-1. Understand in the petrol engine function of Air Filter.

P-2. Understand in the petrol engine function of Fuel pump

(Mechanical and Electrical).

P-3. Understand the petrol engine (Carburetor type) main

components and function of Carburetor.

P-4. Understand the petrol engine (Carburetor type) main

components and function of Fuel filter.

P-5. Understand the petrol engine’s (Carburetor type) main

components and function of fuel lines/clips.

P-6. Understand the petrol engine’s (Carburetor type) main

components and function of fuel sending unit.

CU-2: Fuel system (EFI

type engine)

P-1. Identifies the EFI main components and understand the

working principle of main components.

P-2. Identify the sensors in the vehicle and understand the

function of each.

P-3. Identify the actuators in the vehicle and understand the

functions of each.

P-4. Identify the ECU and engine malfunctioning light and

understand its functions.


K-1. 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 main components of petrol engine fuel system of

carburetor type engine.

Capable understanding the main components of petrol engine fuel system of EFI

type engine


S No. Description

1 Toll trolley (Complete set)

2 Test lamp/DMM (Digital MultiMate)

4 Diesel injector pressure tester /Petrol Injector Tester

5 Safety wears

Consumable Items:

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

Retain Fuel System of Diesel Engine

Overview

This Competency Standard 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.


CU-1: Fuel system (diesel

engine)

P-1. Inspect diesel engine main components and understand

the performance of heater plug.


the performance of injectors.


the performance of injection pump.


the performance of sediment /filter.

CU-2: Fuel system (EFI

diesel engine)

P-1. Identifies the EFI main components and understands the

working principle.

P-2. Identify the sensors in the diesel EFI engine and

understand the functions of each.

P-3. Identify the actuators in the diesel engine and understand

the functions of each.

P-4. Identify the Ecu and engine malfunctioning light and

understand the its functions.


K-1. 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).

K-2. 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

K-3. Describe the as following statements.

Diesel fuel composition, effects of low temperature, viscosity, volatility, calorific

value, cetane rating.


Capable understanding the main components of diesel engine fuel system

Capable understanding the main components of diesel EFI engine fuel system


S No. Description


2 Diesel engine vehicle or simulator

4 Safety wears

Maintain Engine Exhaust System

Overview

This Competency Standard 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



CU-1: Exhaust system

components

P-1. Inspect the performance of main components of exhaust

manifold

P-2. Remove and assemble exhaust manifold from engine

P-3. Replace the muffler, resonator and catalytic converter under

the specified procedure.

P-4. Replace the gasket/packing of silencer under the specified

procedure.

CU-2: Emission control

system

P-1. Identify catalytic converter and understand the function.

P-2. Identify the positive crankcase ventilation (PCV) and

understand the function.

P-3. Identify and understand the functions of exhaust gas

recirculation system(EGR)

P-4. Identify the main components of Evaporative control system

of fuel system.


K-1. Describe the purpose of exhaust system and its functions.

K-2. Describe the muffler assembly operation.

K-3. Describe the catalytic converter operation

K-4. Describe the positive crank case ventilation PCV system and it operation

K-5. Describe the exhaust gas recirculation and its operation


Capable of understanding the exhaust system main components

Capable of understanding EGR function.

Capable of understanding Catalytic converter function.


S No. Description

1 Vehicle

2 Tools trolley (Complete set of hand tools)

3 Gas analyser

4 Vacuum pump

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


CU-1: Engine fault P-1. Understand engine adjustment/setting faults of Engine

Timing, Setting Distributor timing, tappet adjustment, drive

belt/fan belt adjustment.

P-2. Understand the faults of engine head gasket, Crank main

oil seal, Engine timing belt, manifold packing, and exhaust

muffler.

P-3. 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.

CU-2: Engine assembly P-1. Selects appropriate tools and perform

dismantling/assembly of the all engine components as


P-2. Assemble engine manifolds intake and exhaust.


K-1. 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.

K-2. 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

Capable to refit the all components of the engine.


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 Gasket, grease, cotton waste.

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.


CU-1: Repair Ignition

System

P-1. Identify the vehicle Ignition system and understand

procedure of testing ignition coil under the specified

procedure.


procedure of testing fuse in fuse box under the specified

procedure.


procedure of testing the performance of plug cable and

plugs under the specified procedure.


procedure of inspecting distributor cap/rotor for the

performance under the specified procedure.


procedure of inspecting vacuum advancer, assess C.B

Point condition/gap for the performance under the

specified procedure.


procedure of correct ignition timing under the specified

procedure.

P-7. Identify the vehicle Ignition system and understand the

performance of CDI of distributor under the specified

procedure.

CU-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



K-1. 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.

K-2. Describe primary circuit, secondary circuit of ignition system, identifies change in

the spark timing in accordance to the load and speed of the engine.

K-3. Explain Faradays law of mutual induction and calculate the primary and secondary

voltages and current.


Capable to understand the ignition timing

Capable to understand the procedure of servicing the ignition system.


S No. Description

1 vehicle/ simulator

2 Digital Multileter (DMM).

3 Tools box

4 test lamp

5 Timing gun

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.


CU-1: Overhauling Four

stroke motorcycle

engines

P-1. Arrange proper tools and equipment’s to service cylinder

head.

P-2. Disconnect cables, wires, and muffler from cylinder head

for dismantling cylinder head.

P-3. Remove cylinder head assembly and its components

from the engine to identify damage parts.

P-4. Replace/clean cylinder head and its components by

using appropriate tools as per shop manual

P-5. Refit cylinder head and its components; connect all the

cables/ wires and muffler as per shop manual.

P-6. Test engine performance to verify servicing of cylinder

head.

CU-2: Service cylinder,

Piston and Piston

Rings

P-1. Arrange proper tools and equipment to service cylinder

and piston.

P-2. Remove cylinder head assembly from the cylinder block

to service cylinder block piston and piston Rings as per

shop manual.

P-3. Remove cylinder block, piston and inspect its

components to identify the damage parts as per Shop

manual.

P-4. Service/ clean cylinder block, piston and its components

to remove dust.

P-5. Refit Cylinder Block, piston, piston rings, and cylinder

head and connect all the wires, cables to the engine as

per shop manual.

P-6. 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:

K-1. Knowledge about PPEs

K-2. Different types of fire extinguishers

K-3. Safe work environment

K-4. Safety measures and precautions

K-5. First Aid

K-6. Proper use and handling of equipment

K-7. Knowledge about securing measuring tools

K-8. Types of engines

K-9. Schedule of Motorcycle Maintenance

K-10. Different parts of Motorcycle

K-11. Working principles and comparison of 2 and 4 Stroke Engine

K-12. Types and procedure of Oiling & greasing

K-13. Inspections and Measurements

K-14. Cleaning process of different Motorcycle parts / Components.

K-15. Replacement of Motorcycle Parts / Components

K-16. Adjustment of Motorcycle parts /Components

K-17. Working principles of engine and its terminologies

K-18. Different systems of engine

K-19. Parts of engine

K-20. Diagnostic procedure of Engine

K-21. Engine dismantling procedure

K-22. Engine inspection and repair procedure

K-23. Engine assembling procedure

K-24. Engine oil circuits

K-25. Engine Timing

K-26. Manufacturers and workshop manual of given vehicle

K-27. Working principle Fuel system

K-28. Exhaust system

K-29. Euro standards

K-30. 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

Capable to overhaul the engine


S No. Description


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 Gasket, grease, cotton waste.

13. Automotive Electricity and Electronics (AD-143)

Perform Electrical 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.


CU-1: Prepare Basic

Electric Circuits

P-1. Prepare series circuit on work bench using appropriate

tools.

P-2. Prepare parallel circuit on work bench using appropriate

tools.

P-3. Prepare series parallel circuit on work bench using

appropriate tools.

P-4. Prepare Head and Tail Light Circuit on work bench

using appropriate tools.

P-5. Prepare indicator circuit on work bench using

appropriate tools.

P-6. Prepare brake light circuit on work bench using

appropriate tools.

CU-2: Perform Basic

Electrical

Measurement

P-1. Measure/ record voltage by using Digital Multi METER

(DMM)

P-2. Measure/ record current by using Digital Multi Meter

(DMM)

P-3. Measure/ record resistance by using Digital Multi Meter.

P-4. Measure/ record continuity by using Digital Multi Meter.


K-1. 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.

K-2. 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 millimeter (DMM)

Point out electromagnets in the vehicle.


S No. Descriptions

1 Digital MultiMate (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

Prepare Electromagnetism applications

Overview

These competency standards designed to enable the learner to perform electromagnetism

related calculations and measurements, as well as conceptualize different automotive

functions related to the electrical operations.


CU-1: Prepare basic

Electromagnetic

circuits.

P-1. Prepare basic electromagnet with the help of iron core

and copper wire.

P-2. Prepare horn circuit on work bench using appropriate

tools.

P-3. Prepare self-starter circuit on work bench using

appropriate tools.

CU-2: Basic

Electromagnetic

circuits

Measurement

P-1. Test winding resistance of DC motor by using Digital

Multi Meter

P-2. Test Relay function by switching relay coil points and

measure / record continuity between contact points by

using Digital Multi Meter

P-3. Measure/ record voltage drop during self-starter cranking

by using Digital Multi Meter.


K-1. 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.


Capable to measure the current and voltage drop in self-starter circuits

Capable to use the Digital MultiMeter (DMM)

Capable to make the electromagnets


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

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



CU-1: Perform Service of

battery

P-1. Perform the battery test by use of hydrometer, Clean

Terminals, tight and insulate, secure with battery holder

as per given specification.

P-2. Inspect and change the Ground (Earth) cable from the

vehicle body.

P-3. Test battery by using the load tester/battery tester and

assess the battery performance.

CU-2: Perform Battery

replacement

P-1. Perform Safe removal and installation of Battery from the

vehicle Inspect/service the battery and assess safety

fitting and correctness under specified procedure.

P-2. Carry out safe procedure to charge the battery using an

external charger.


K-1. 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.

K-2. Describe the chemical activities in Lead Acid Battery while charging and

discharging.


Troubleshoot the problems related to the vehicle battery.

Service the 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

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


CU-1: Repair starting system P-1. Inspect the vehicle starting system and troubleshoot the

following:

Low cranking speed/ not cranking, Ignition switch

operation malfunctioning.

P-2. 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.

CU-2: Service Starter Motor. P-1. Carryout safe procedure to replace the starter motor

from the vehicle.

P-2. Service/replace components of starter motor and

perform bench testing.


K-1. 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.

K-2. 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)

K-3. Distinguish between increase/decrease cranking current consumption, voltage drop

in a system, electrical load, and reason of high ampere draw from a system/overload.

K-4. Describe the Lenz’s law of motor principle, single phase, three phase motor, AC

Motor, DC Motor.


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

Repair Ignition System of Petrol Engine

Overview


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.



System

P-1. Follow safe working procedure.

P-2. Inspect vehicle Ignition system and diagnose the following:

Crank engine and test presence of spark in a system,

identify faulty fuse in fuse box.

P-3. Inspect vehicle Ignition system.

P-4. Test performance of plug cable (high tension leads) and

plugs.

P-5. Inspect distributor cap/rotor for performance, assess

correct ignition timing.

P-6. Inspect vacuum advancer, assess C.B. Point condition/gap

and test condenser.


System (CDI

System)

P-1. Follow safe working procedure.

P-2. Inspect the vehicle Ignition system and diagnose the

ignition coil performance.

P-3. Inspect the vehicle Ignition system and diagnose the CDI

of distributor.


K-1. Describe the Purpose, function and Types of ignition system.

K-2. Describe the following parts of ignition system contact breaker point, 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.

K-3. Differentiate the performance of contact breaker point and Electronic Ignition system.


Troubleshot the vehicle ignition system (Non EFI engines)

Capable to adjust the ignition timing (Set distributer)

Capable to refit the plug cables according to the firing order


S No. Descriptions

1. Vehicle/ Simulator

2. Digital Multileter (DMM).

3. Tools box

4. Test Lamp

5. Timing gun

6. Battery

7. C.B Point

8. Electronic Distributor

9. CDI Unit

10. HT Cable

11. Distributor Cables

12. Conventional Distributor

13. Ignition Tester

Adjust Ignition Timing of Petrol Engine

Overview:


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


CU-1: Adjust Ignition

Timing

P-1. Installation of distributer assembly under specified



P-2. Inspect/ Replace ignition switch, inspect/ replace ignition

coil, and Repair/ replace electrical connectors under


CU-2: Repair Electronic

Ignition System

(EIS)

P-1. Inspection of crank position sensor under specified

procedure and starts the engine.

P-2. Inspection/replace of ignition fuse under specified

procedure and starts the engine.


K-1. Describe primary circuit, secondary circuit of ignition system, identifies change in the

spark timing in accordance to the load and speed of the engine.




Capable to adjust CB point

Capable to change the condenser on the distributor


S No. Descriptions

1. Vehicle/ Simulator

2. Digital Multileter (DMM).

3. Tools Box

4. Test Lamp

5. Timing Gun

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



CU-1: Troubleshoot

Distributer Less

Systems

P-1. Use scanner and find out the fault related to the ignition

coil and reset the trouble code by use of scanner.

P-2. Use scanner and find out the fault related to the Cam

Angle sensor and reset the trouble code by use of

scanner.

P-3. Use scanner and find out the fault related to the crank

sensor and reset the trouble code by use of scanner.

CU-2: Repair Distributor

Less Systems

P-1. Use test lamp and identify the faulty fuse in the fuse box

under the specified procedure.

P-2. Replace the faulty fuse with the same color and start the

engine under the specified procedure.

P-3. Replace the faulty ignition coil and faulty sensor under



Describe the following

K-1. Ignition advance mechanism in Distributor less system, Intelligent Dual and

Sequential Ignition System, Coil on plug system, crank Position sensor signals.


Capable to diagnose and troubleshoot the electronic ignition system.

Capable to identify and replace faulty fuse of electronic ignition system.


S No. Descriptions


2 Scanner

3 Test lamp

4 DMM (Multimeter)

5 Crank Position Sensor

6 Cam Angle Sensor

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.


CU-1: Repair charging

system

P-1. Inspect vehicle charging system and diagnose the

following. Battery warning light indication on instrument

panel.

P-2. Test output voltage of alternator.

P-3. Test drives belt condition and Tension, alternator bearing

noise.

P-4. Test wire harness, fuse, and proper insulated wires.

P-5. Dismantle/service of alternator as following; Repair

connector, replace carbon brushes, Replace Rectifier

Bridge, replace voltage regulator and replace stator

winding.

CU-2: Replace alternator P-1. Perform safe working practice to remove the alternator

from the vehicle and refit under the specified procedure.

P-2. Perform test of alternator to confirm the operation on test

bench.


K-1. 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.

K-2. 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

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



CU-1: Troubleshoot The

Light System

P-1. Follow safe working procedure

P-2. Inspect vehicle lightening system and diagnose following;

under specified testing instructions, Blown fuse finding

from interior or exterior fuse box.

P-3. Inspect vehicle lightening system and diagnose following;

under specified testing instructions, faulty relay and faulty

flasher.

CU-2: Repair Lights P-1. follow safe working procedure

P-2. Inspect vehicle lightening system and diagnose following

under specified testing instructions. Inspect/Replace

head lamp, parking bulb and indicator bulb.

P-3. Inspect vehicle lightening system and diagnose following

under specified testing instructions. Back light bulb,

reverse light bulb.


K-1. 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

Capable to replace faulty relay and flashers

Tools and Material Required:

1. Test lamp

2. Digital Multimeter DMM

3. Insulated wires

4. Indicator lamps

5. Head light lamps

6. Tail Light Lamps

7. Battery

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



CU-1: Repair Cooling

System and

Vehicle

Accessories

P-1. Inspects the Radiator fan for correct operation under

specified testing instructions.

P-2. Inspects the thermal switch for correct operation under


P-3. Inspects the temperature sender for correct operation

under specified testing instructions.

CU-2: Repair Electrical

Accessories

P-1. Inspects the oil warning switch operation for correct

operation under specified testing instructions.

P-2. Inspects fuse, relay operation for correct operation under


P-3. Inspects the fuel sender operation for correct operation

under specified testing instructions.

P-4. Inspects the wiper motor, washer motor for correct

operation under specified testing instructions.

P-5. Inspects heating Elements for correct operation under

specified testing instructions


K-1. Identify terms used and calculations associated with electricity. Definitions

(magnetism, self/mutual induction). Laws (amperes rule, Fleming’s rule)

K-2. 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).

K-3. 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, lubrication

system and take appropriate decision.


S No. Descriptions

1 Vehicle/ simulator

2 Digital Multi Meter (DMM).

3 Tools box

4 test lamp

14. Workshop Practice-1 (MT-164)

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

CU-1: Carry-Out Sawing P-1. Select appropriate blade and set in hacksaw frame

according to the job requirement

P-2. Select appropriate marking tool(s), mark the work piece

and clamp it in the vice firmly as per standard practices

P-3. Adopt sawing methods and techniques that are safe and

suitable to cut the work-piece as required

P-4. Follow marked line during sawing of work piece to ensure

accuracy

CU-2: File the Work-

Piece

P-1. Select appropriate file and marking tool(s) according to

the job requirement

P-2. Mark the work-piece and clamp it in the vice firmly as per

standard practices

P-3. Adopt filing method and technique which is safe and

suitable to produce the work-piece as per drawing

P-4. Follow drawing dimensions and surface finish of filed

work-piece to ensure accuracy and precision

CU-3: Carry out Drilling P-1. Setup drill machine for producing hole in the work piece

according to the job requirement

P-2. Select drill bit and marking tools according to the material

and job requirement, respectively

P-3. Mark the work-piece according to the drawing and clamp

it in the vice firmly as per standard practices

P-4. Set the suitable RPM.

P-5. Adopt proper drilling method (manual/auto-feed, applying

coolants) which is safe and suitable to produce the hole

in work-piece

P-6. Follow drawing dimensions of drilled hole to ensure

accuracy and precision

CU-4: Produce Threads

on Work-Piece

P-1. Select tap and die according to the type of thread to be

produced on work-piece as per drawing

P-2. Clamp the work-piece in the clamping device firmly as

per standard practices

P-3. Ensure the tap and die alignment as per prescribed

standard

P-4. Make thread with die and follow appropriate sequence

P-5. Ensure the safety and dimensional accuracy of threads

on work-piece as per drawing

CU-5: Perform Hand

Reaming

P-1. Select reamer according to the work-piece requirement

P-2. Clamp the work-piece in the clamping device firmly as

per standard practices

P-3. Ensure the reamer alignment as per prescribed standard

P-4. Produce reamed hole by following safety and prescribed

method

P-5. Ensure the accuracy and size of reamed hole of work-

piece according to the drawing

Knowledge and Understanding


required to carry out the tasks covered in this competency standard. This includes the

knowledge of:

K-1. Mechanical Properties and strength of materials

K-2. Combination of feed and speed settings according to the work-piece, and tools&

materials

K-3. Usage of bench-work tools and equipment

K-4. Interpret basic drawings

K-5. Measurement systems

K-6. Use of measuring and marking tools

K-7. Usage of bench working tools

K-8. Procedure of safe clamping the work-piece

K-9. 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

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.


CU-1: Prepare Materials

for Shaping

Operations

P-1. Interpret drawing and arrange the material accordingly

P-2. Prepare work-piece by required machining (sawing and

filing etc.) and get ready to clamp

P-3. Check and verify the dimensions of work-piece for

shaping according to the drawing

CU-2: Select Tools and

Equipment

P-1. Select the material and shape of tool(s) according to the

job requirements

P-2. Arrange the measuring instruments and holding devices

to attain accuracy of the work as per prescribed method

CU-3: Set Shaper

Machine for

Operations

P-1. Clamp the material of work-piece and tool into its holding

devices as per standard practice

P-2. Maintain safe distance between surface of work-piece

and tooltip as per prescribed method

P-3. Adjust the ram placement and stroke length according to

the length of job

P-4. Adjust the parameters of shaping (speed and feed) from

control unit as per prescribed method

P-5. Start shaping operation by locating the initial touching

point and adjust the depth of cut according to the

prescribed procedure

CU-4: Perform Shaping

Operations

(Square Job)

P-1. Ensure the proper clamping of work-piece and the tool

according to the standard practice

P-2. Start the shaping operation at top surface of work piece

to get flatness as per initial requirements

P-3. Re-clamp the work-piece by rotating 90° for next surface

as per prescribed method

P-4. Shape entire work-piece by following the above stated

method for next surface to get square shaped work

piece according to drawing

CU-5: Perform Shaping

Operations

(Angular Job

P-1. Ensure proper clamping of the work-piece and the tool

according to standard practice

P-2. Mark work-piece according to the drawing

P-3. Set and align the sliding degree of head according to

required angle

P-4. Start the angular shaping operation to get required angle

as per marked line

P-5. Shape entire work-piece, by setting the required degree

of head, to get angle of work-piece according to the

drawing







K-3. Knowledge of shaping machines

K-4. Types of shaping machines

K-5. Ram and stroke settings


K-7. Knowledge of shaping tools

K-8. Feed and speed settings

K-9. Working procedure of shaping

K-10. Shaping tools and holding devices

K-11. 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

S No. Descriptions

1 Hacksaw

2 Shaper Machine

3 Flat File

4 Marking Tools

5 Chapping Tools

6 Measuring Tools

7 Tool Grinder

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.


CU-1: Prepare Materials

for Lathe

Operations

P-1. Interpret drawing and arrange the material accordingly

P-2. Prepare work-piece by required machining (sawing and

filing etc.) and get it ready for clamping

P-3. Check and verify the dimensions of work-piece for lathe

operations as per drawing

CU-2: Select Tools and

Equipment

P-1. Select the tool(s) according to material of job and shape

of the job requirements

P-2. Arrange the measuring instruments and holding devices

to attain accuracy of the work as per prescribed method

CU-3: Set Lathe

Machine for

Operations

P-1. Clamp the material of work-piece and tool into its holding

devices as per standard practice

P-2. Maintain the safe distance between work-piece and tool

tip as per prescribed method

P-3. Adjust the revolution per minute (rpm) of chuck

according to the specifications of work-piece.

P-4. Adjust the parameters of speed and feed from control

unit as per prescribed method

CU-4: Carry-Out Lathe

Operations

P-1. Ensure the proper clamping of work-piece and the tool

into the holding devices according to the required

operation

P-2. Maintain the alignment of work-piece and locate the tool

tip at center position of the work-piece as per standard

practice

P-3. Start the lathe operations as required according to the

drawing and replacing the required tool

P-4. Check the work-piece by using appropriate measuring

tools and instruments as per standard practice






K-2. Personal Protective Equipment and workplace safety



K-5. Use of measuring and marking tools

K-6. Knowledge of Lathe machines and its types

K-7. Knowledge of holding devices and lathe attachments

K-8. Knowledge of lathe tools

K-9. True running of job(s) and center alignment of tool tip

K-10. Calculation of feed and speed according to the work-piece and tool materials

K-11. Procedure of safe clamping the work-piece

K-12. 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


S No. Descriptions

1 Hacksaw

2 Drill set

3 Drill Machine

4 Lathe Machine

5 Tool Grinder

6 Lathe cutting Tools

7 Measuring Tools

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.


CU-1: Read and

Understand

Manufacturing

Drawings

P-1. Recognize basics of lines used in engineering drawings

P-2. Describe uses of lines in engineering drawings

P-3. Recognize and explain orthographic and isometric views

of a drawing

P-4. Identify manufacturing requirements according to

drawings

P-5. Prepare job layout according to manufacturing

requirements

CU-2: Interpret Welding

Symbols

P-1. Understand basic and supplementary welding symbols

used in manufacturing drawings

P-2. Understand and differentiate between types of welds

and joints

P-3. Identify welding requirements according to welding

symbols given in the manufacturing drawings

CU-3: Recognize

Material

Specifications and

Bill of Material

(BOM)

P-1. Identify material specifications according to

manufacturing drawing

P-2. Identify bill of material (BOM) according to


CU-4: Manufacture Parts P-1. Interpret dimensional tolerances according to


P-2. Assemble and tack weld parts according to




required to carry out tasks covered in this competency standard. This includes the

knowledge of:

K-1. Basic elements of engineering drawing

K-2. Drawing symbols

K-3. Dimensioning techniques

K-4. Tolerances

K-5. General tolerance

K-6. Angular tolerance

K-7. Geometric tolerance

K-8. Drawing techniques

K-9. Perspective

K-10. Exploded view

K-11. Hidden view technique

K-12. Projections

K-13. First angle projections

K-14. 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

Preform 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).


CU-5: Recognize

Welding

Procedure

Specifications

(WPS)

P-3. Describe and understand contents of Welding Procedure

Specifications (WPS)

P-4. Recognize common acronyms used in Welding

Procedure Specifications (WPS)

CU-6: Interpret and

Explain Welding

Procedure

Specifications

(WPS

P-1. Recognize materials specifications (base metals and

fillers) according to Welding Procedure Specifications

(WPS)

P-2. Recognize weld type and joint design according to

Welding Procedure Specifications (WPS)

P-3. Recognize welding positions and parameters according

to Welding Procedure Specifications (WPS)

CU-7: Prepare a Welding

Procedure

Specifications

(WPS

P-1. Prepare sample Welding Procedure Specifications

(WPS) following a simple welding procedure

P-2. Follow written Welding Procedure Specifications (WPS)

to produce a production/sample weld




knowledge of:

K-1. Written communication skills (reading and comprehension)

K-2. Purpose of Welding Procedure Specifications

K-3. Common contents of WPS

K-4. Groupings of materials

K-5. Thickness range

K-6. Types of welds

K-7. Joint design

K-8. Welding processes

K-9. Welding positions

K-10. Welding consumables

K-11. Electrical characteristics - volts, current, polarity

K-12. Shielding gases

K-13. Purge gas

K-14. Gas flow rate

K-15. Nozzle diameter

K-16. Pre-heat/Post-heat

K-17. 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

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.


CU-1: Select and Mark

Material/s as per

Drawing/Job

Requirement

P-1. Select and obtain required material/s as per job

requirements

P-2. Select appropriate marking tools as per job requirements

P-3. Mark the area to be cut as per drawing/ job requirements

CU-2: cut and Prepare

Edge/s of Base

Materials

P-1. Select appropriate cutting equipment as per job

requirements

P-2. Set-up cutting equipment as per manufacturer’s

instructions/job requirements

P-3. cut the base material as per job specifications and

dimensions provided in the drawing

P-4. Prepare edges of the base materials as per drawing/

WPS

P-5. Check dimensions of the prepared edges as per drawing/

WPS

P-6. Select proper tools and chemicals for cleaning

P-7. Clean the edges of the base materials as per job

requirements

CU-3: Prepare Welding

Consumables

P-1. Select relevant welding consumables as per job

requirements/ WPS

P-2. Prepare consumables in accordance with required

specifications

CU-4: Fit-up Base

Materials

P-1. Select proper tools and equipment to fit-up base

materials

P-2. Tack weld joint/s as per drawing/ welding procedure

specifications (WPS)

P-3. Check root gap as per drawing/welding procedure

specifications (WPS)

P-4. Check alignment as per applicable code/standard




knowledge of:

K-1. Interpretation of drawings and sketches

K-2. Selection of appropriate method of edge preparation

K-3. Selection of appropriate cutting equipment, accessories and supplies

K-4. Operation of cutting equipment such as mechanical, gas and plasma

K-5. Operation of grinding equipment

K-6. 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

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.


CU-1: Prepare Welding

Machine and

Accessories for

SMAW

P-1. Identify welding requirements from the job, welding

procedure specifications and/or technical drawings

P-2. Prepare SMAW welding machine in accordance with

welding procedure specifications/ manufacturer

instructions

P-3. Set up welding machine accessories and consumables

as per job requirements, welding procedure

specifications and/or manufacturer’s instructions

P-4. Connect welding machine to an independent power

supply

P-5. Set polarity indicated in the welding procedure

specifications

CU-2: Make Fillet Welds

on Carbon Steel

Plate

P-1. Adjust welding parameters (current, voltage etc.) as per

welding procedure specifications/job requirements to

produce acceptable weld

P-2. Maintain gap between electrode and base metal as per

standard practices

P-3. Carry out welding in Flat (1F) and Horizontal

(2F)positions following standard procedures

P-4. Follow applicable manufacturing codes and standards for

acceptance criteria of visual welding defects

CU-3: Make Groove P-1. Adjust welding parameters (current, voltage etc.) as per

Welds on Carbon

Steel Plate

welding procedure specifications/job requirements to

produce acceptable weld

P-2. Maintain gap between electrode and base metal as per

standard practices

P-3. Carry out welding in Flat (1G)and Horizontal (2G)

positions following standard procedures

P-4. Deposit root pass as per welding procedure

specifications/ job requirements

P-5. Deposit filling passes as per welding procedure

specifications/job requirements

P-6. Deposit capping pass as per welding procedure

specifications/job requirements

P-7. Check root, filling and capping passes for any visual

discontinuities as per acceptance standards

P-8. Follow applicable manufacturing codes and standards for

acceptance criteria of visual welding defects

CU-4: Perform Post

Welding

Operations

P-1. Carry out finishing work of welds following standard

procedures

P-2. Inspect weld visually and mark any visual defects, as

required

P-3. Carry out repair work in accordance with approved

procedures, as required

P-4. Clean work area in accordance with workplace safety

practices

P-5. Maintain and store tools/ equipment/ consumable

materials in accordance with organization guidelines




knowledge of:

K-1. Understanding of technical drawings

K-2. Electrical supply AC and DC

K-3. Polarity setting according to standard specifications

K-4. Specifications/ classification of electrode/s required for the job

K-5. Welding procedure specifications (WPS)

K-6. Method of Pre- heating of base metal

K-7. Electrical parameters like (voltage, current etc.) and their effects on weld

K-8. Welding techniques as per WPS/instruction sheet

K-9. Visual welding defects

K-10. 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

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 0f Forging in drawing down and swaging.


CU-1: Draw down P-1. Make fire in available forge furnace

P-2. Put the stock in forge furnace.

P-3. Heat the stock upto bright red condition ( Plastic State)

P-4. Grip the heated stock by tong and put on anvil.

P-5. Apply firm blows of sledge hammer on both sides of

stock.

P-6. Put the stock again in forge furnace and repeat process

P-7. Always wear safety dress before start the performance.

CU-2: Perform

Swaging

P-1. Make fire in forge furnace

P-2. Put the round stock in forge furnace.

P-3. Heat the stock upto bright red condition.

P-4. Fix the bottom swage in hardy hole.

P-5. Put the red hot round bar in the bottom swage.

P-6. Put the top swage over round bar with the help of

handle.

P-7. Apply firm blows of sledge hammer and move round bar

longitudinally and circumferentially.

P-8. Always wear safety dress before start the performance.




Knowledge of:

K-1. Understanding of techniques of drawing down

K-2. Proper preparation and selection of stock.

K-3. Understand the use of proper equipment.

K-4. Using proper safety dress before starting performance.

K-5. Complete the drawing down and swaging process rapidly.



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

15. Basic Engineering Drawing and CAD-I Mech-163

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

CU-1. Draw Different

Forms of Drawing

P-1. Draw convention layout drawing

P-2. Draw convention electrical circuit drawing

P-3. Draw lines with different scale of measurement

P-4. Select the sheet format

P-5. Select the tool and equipment

CU-2. Draw different

lines for free hand

sketching

P-1. Draw horizontal lines

P-2. Draw vertical lines

P-3. Draw arcs

P-4. Draw circles

P-5. Draw ellipse

P-6. Draw all conic section

P-7. Draw projection of lines

P-8. Sketch different objects

CU-3. Draw different

lines with

measurement

P-1. Draw single Stroke lettering

P-2. Draw double stroke gothic letter

P-3. Draw different types of letter

P-4. Draw alphabet of lines in original scale

P-5. Apply alphabet of lines in drafting




This includes the knowledge of draw development by

K-1. Draw mechanical drawing

K-2. Draw electrical drawing

K-3. Draw civil drawing

K-4. Draw terms use in drawing

K-5. Draw application of drawing forms

K-6. Draw scales used in drawing

K-7. Draw fundamentals units i.e. Arcs, circles and ellipse

K-8. Draw single stroke and double stroke gothic letters


Capable to draw different king of drawings

Capable to draw different kinds of lines


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

Draw Pictorial Drawing

Over View:-

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

drawings.

Competency unit Performance criteria

CU-1: Draw different

types of pictorial

drawing

P-1. Draw oblique drawing

P-2. Draw axonometric drawing

P-3. Draw perspective drawing

P-4. Draw Multi view drawing

CU-2: Draw multi view

projection

P-1. Draw principle plane of projection

P-2. Draw projector / projection lines

P-3. Draw auxiliary view of objects

P-4. Draw Multi view drawing of machine components




knowledge of:

Draw development by

K-1. Draw oblique drawing

K-2. Draw axonometric drawing

K-3. Draw perspective drawing

K-4. Draw multi view drawing

K-5. Draw plan of projection

K-6. Draw projection drawing

K-7. Draw multi view drawing of machine equipment


Capable to draw pictorial drawings

Capable to draw multi view projections


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

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

CU-1: Draw dimensional

geometrical

constructions

P-1. Draw the types of dimensioning ( size of dimension and

location of dimension

P-2. Draw system of dimensioning

P-3. Draw dimensioning of holes

P-4. Draw dimensioning of arc

P-5. Draw dimensioning circles

P-6. Draw dimensioning of angles

P-7. Draw all conic sections separately

P-8. Draw engineering involute curve of a circle

CU-2: Draw working

Drawing

P-1. Draw preliminary designee sketching

P-2. Draw detail Drawing of an object

P-3. Draw Assembly Drawing of an object

P-4. Draw working drawing of machine component




knowledge of:

Draw development by

K-1. Draw types of dimensioning

K-2. Draw system of dimensioning

K-3. Draw dimensioning in size of holes

K-4. Draw dimension in size of arc

K-5. Draw dimensions in size of circle

K-6. Draw all conic section separately

K-7. Draw detail drawing of an object

K-8. Draw assembly drawing of an object

K-9. Draw working drawing of machine components


Capable to draw dimensions

Capable to draw work drawing


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

Perform Sectioning and Pictorial Drawing

Over View:-

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

sectioning and pictorial drawing.


CU-1: Draw sectioning P-1. Draw material symbols used in sectioning

P-2. Draw full section of an object

P-3. Draw half section of an object

P-4. Draw broken section of an object

P-5. Draw sectional view of machine components

CU-2: Draw pictorial

Drawing

P-1. Draw isometric view of an object

P-2. Draw isometric view of arc

P-3. Draw isometric view of circle

P-4. Draw oblique view of a rectangular block

P-5. Draw isometric views of an object / components




knowledge of:

Draw development by

K-1. Draw material symbols used in engineering drawing

K-2. Draw full section of an object

K-3. Draw half section of an object

K-4. Draw sectional views of machine components

K-5. Draw oblique view of a rectangular block

K-6. Draw isometric views of an object


Capable to draw sectioning drawing

Capable to create cutting plan in the drawing


S No Descriptions

1. T square

2. Set square

3. Compass

4. Eraser

5. Pencil

6. Sharpener

7. Drawing sheet

Draw Auxiliary Drawing

Over view

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

auxiliary drawing, projection and any component of part.


CU-1: Draw primary

auxiliary view

P-1. Draw Primary auxiliary view of frontal projection

P-2. Draw primary auxiliary view of horizontal projection

P-3. Draw primary auxiliary view of profile projection

P-4. Draw Example of all these

CU-2: Draw true length

line

P-1. Draw true length line in auxiliary view of different objects

P-2. Draw auxiliary view in different objects

P-3. Draw auxiliary view of objects

P-4. Draw auxiliary view of component part

P-5. Draw example of above two




knowledge of:

Draw development by

K-1. Apply auxiliary views

K-2. Draw primary auxiliary views of frontal projection

K-3. Draw primary auxiliary view in horizontal projection

K-4. Draw primary auxiliary view in profile projection

K-5. Draw true length line in the auxiliary view of different objects

K-6. Draw secondary auxiliary view in different objects


Capable to draw different views

Capable to draw true length line


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

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.


CU-1: Engine fault

adjustment

P-1. Perform engine adjustment/setting of Engine Timing,

Setting Distributor timing, tappet adjustment, drive

belt/fan belt adjustment.

P-2. Change the engine head gasket, Crank main oil seal,

Engine timing belt, manifold packing, and exhaust

muffler.

CU-2: Engine fault

diagnosing

P-1. Use the compression tester and test engine compression

to diagnose fault in piston rings or valve seats/burnt valve

under specified procedure.

P-2. 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.


K-1. 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 setting and adjustment the engine timing, tappet, drive belt tension.

Capable to replace the head gasket.

Capable of changing faulty components in the engine.


S No. Descriptions


2 Compression tester, compression gauge)

3 Measuring tools (Vernier calliper, 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

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.


CU-1: Engine sub-

assemblies

P-1. Make the engine sub-assemblies and inspect the

performance for (setting piston rings, piston pin and

connecting road),


performance for (valve train and test for the leakage from

valve seats),


performance for (fitting crankshaft with main bearings

and pistons with the big end bearings),

P-4. Perform the straightness inspect of engine head and

block straightness/war page level and make decision for

correctness.

CU-2: Engine

measurement

P-1. Use appropriate measuring tool and Measure piston

bore, measure crankshaft main journals, crankshaft big

end journals,

P-2. Use appropriate measuring tool and Measure Camshaft

main journals, Cam loops,

P-3. Use appropriate measuring tool and Measure engine

thrust washer, and piston connecting pin.

P-4. Assemble the engine block with the engine head and

adjust tappets, engine timing, and spark distributor of

petrol engine under specified procedure.


K-1. The possible causes of high fuel consumption as following.

K-2. 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 (Vernier calliper, 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


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.


CU-1: Cooling system

service

P-1. 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)

P-2. Inspect/service the radiator and top up with the

coolant/antifreeze as per specified ratio in the manual.

CU-2: Repair Cooling

system

P-1. Change the water body under specified procedure and

start the engine to confirm correct operation.

P-2. Adjust fan belt tension under specified procedure and

start the engine to confirm correct operation.


K-1. 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)

K-2. 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.

Capable to replace the water body (Pump) under the specified method.

Capable to replace the hoses.


S No. Description


2 Radiator leak tester


5 Drive belt

Consumable Items:

S No. Description

Sealant

Hose pipe

Thermostat valve

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

CU-1: Lubrication

system

P-1. Inspect engine lubrication system’s main components and

check (engine oil level)


check (oil leakage)


check (oil warning switch)


check (and PCV valve)

CU-2: Repair

Lubrication

system

P-1. Inspect/replace of oil warning switch, PCV valve, oil

sump, oil sump seal/gasket, and oil pump under the


P-2. Carryout safe procedure to change the engine oil and oil

filter.


K-1. 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).

K-2. 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.

Capable to diagnose the PCV valve.


S No. Description


2 Car Lift


4 Sealant/gasket

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



CU-1: Service of Fuel

system (carburetor

type engine)

P-1. Diagnose performance of petrol engine’s (Carburetor

type) main components and Service/replace under the

specified procedure of (Air Filter).

P-2. Diagnose the performance of petrol engine’s (Carburetor


specified procedure of (Fuel pump).



specified procedure of (Carburetor and Fuel filter).



specified procedure of (fuel lines/clips, fuel sending unit).

CU-2: Repair of Fuel

system (carburetor

type engine)

P-1. Start the engine and set air fuel mixture by adjusting

required engine RPM at idling and at speed under


P-2. Perform service of carburetor under specified procedure.


K-1. 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).


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

Capable to adjust air fuel ratio

Capable to service of carburetor

Capable to replace the fuel pump.



2 Test lamp/DMM (Digital multimeter)


5 Safety wears

Consumable Items:

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

Diagnose Diesel Fuel System and Adjust

Overview

These competency standards designed to enable the learner to work on vehicle diesel fuel

system and diagnose, rectify the faults in diesel engines by Auto Mechanic, in accordance



CU-1: Service Fuel

System (diesel

engine)

P-1. Use injector pressure tester machine and Service/set

pressure of fuel injector as specified in the manual.

P-2. Apply safety precautions and perform air bleeding from

low pressure side and high pressure side under the


CU-2: Repair Fuel

System (diesel

engine)

P-1. Inspect diesel engine main components and diagnose

the performance of (heater plug).


the performance of (injectors).


the performance of (injection pump, sediment /filter).


the performance of (sediment /filter).


K-1. 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

K-2. Describe the as following statements.

Diesel fuel composition, effects of low temperature, viscosity, volatility, calorific

value, cetane rating.


Capable to diagnose and troubleshoot the not starting condition of diesel engine.

Capable to service the injectors.

Capable to test the diesel injector pressure by use of pressure tester.

Capable to bleed the air from the diesel fuel system.


S No. Descriptions


2 Test lamp/DMM (Digital multimeter)


5 Safety wears

Consumable Items:

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

Diagnose Faults of Ignition System

Overview


ignition system as well as conceptualize the ignition system mechanism in the engine.



System

P-1. Inspect the vehicle Ignition system and diagnose the

following (Note: follow safe working procedure).

P-2. 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.

CU-2: Adjust ignition

timing

P-1. Installation of distributer assembly under specified



P-2. Inspect/Replace ignition switch, inspect/replace ignition

coil, and Repair/replace electrical connectors under



K-1. 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.

K-2. Describe primary circuit, secondary circuit of ignition system, identifies change in

the spark timing in accordance to the load and speed of the engine.




Troubleshot the vehicle ignition system (Non EFI engines)

Capable to adjust the ignition timing

Capable to service (Tuning) the ignition system.


S No. Description

1 Vehicle/ Simulator

2 Digital Multi-meter (DMM).

3 Tools Box

4 Test Lamp

5 Timing Gun

16. Suspension, Steering & Brakes AD-213

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.


CU-1: Brake system P-1. 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


P-2. Service/Replace the Master cylinder, vacuum booster,

wheel cylinder, brake disk, brake pad, and brake shoe


P-3. Perform brake bleeding of the vehicle brake system


CU-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



K-1. 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.

K-2. 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.

K-3. 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 Disk and drum brake assembly.

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

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.


CU-1: Steering system P-1. 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.

P-2. Replace/service the Outer tie road, inner tie road,

steering mountings, steering boots (inner and outer ball

joint), under the specified procedure.

P-3. Service the steering gear (Rack and pinion) box under


CU-2: Power steering

system

P-1. Inspect/replace power assisted steering system

components for Pump, control valve, complete steering

box.

P-2. Replace the power steering oil and perform air bleeding

from the system under the specified procedure.


K-1. Describe the purpose and function of the following:

Steering systems (non-assisted/manual), power assisted system, electronic

steering system with a motor.

K-2. 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 (Rack and pinion) system

Capable of performing power steering air bleeding.

Capable to replace the power steering pump.

Capable to replace the steering box.


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

Maintain Vehicle Suspension System.

Overview

These competency standards designed to enable the learner to work on vehicle suspension

system and the learner will be able to replace the main components of suspension system


CU-1: Inspect

Suspension system

P-1. Inspect the vehicle suspension system and diagnose the

rubber bush for damage, Leaking the shock absorber oil,

broken coil spring/ leaf spring,

P-2. Inspect the vehicle suspension system and diagnose the

rubber bush for lower arm ball joints under the specified

procedure.

CU-2: Repair Suspension

System

P-1. Replace the shock absorber, Coil spring, leaf spring, and

rubber bushes under the specified procedure.

P-2. Inspect the vehicle ride height, trim height, axle displaced




Independent suspension system, non-independent suspension system, semi-

independent system, sprung weight, un-sprung weight.

K-2. 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.

K-3. 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 diagnosing the faulty suspension components.

Capable to replace the spring, shock absorber and suspension bushes..


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

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



CU-1: Pre alignments

checks

P-1. Check for the vehicle pre alignment for proper Tire

pressure/inflation, and axle bushes under specified

procedure.

P-2. Check for the vehicle pre alignment for loose ball joints,

wheel bearings, and tie road ends under specified

procedure.

P-3. Check for the vehicle pre alignment for faulty spring, tire

deformation, and vehicle ride height under specified

procedure.

P-4. Check for the vehicle pre alignment for loose stabilizer

bar under specified procedure.

CU-2: Perform wheel

alignment

P-1. Drive the vehicle and load/offload it on wheel alignment

machine following safety rules as specified in the manual.

P-2. 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



K-1. Describe the following functions/principles of wheel alignment.

Ackerman principle for a true rolling motion, steering pull, steering center point,

steering wheel vibration causes.

K-2. 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.

Capable to check the pre alignment checks.


S No. Description

1 Vehicle


3 Hydraulic jack

4 Wheel alignment machine

5 Wheel balancing / tire changing machine

6 Air pressure compressor and gauge

Carry Out Wheel Balancing

Overview

These competency standards designed to enable the learner to work on tire changing

machine to replace the tire 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.


CU-1: Use Tire changing

machine.

P-1. Use the tire changing machine and replace/inflate the tire

as described in the machine manual under specified

procedure.

P-2. Replace the valve of the tire under the specified

procedure.

CU-2: Perform wheel

balancing

P-1. Use the wheel balancing machine and balance the wheel

as described in the machine manual under the specified

procedure.

P-2. Keep the weights firmly with the rim

P-3. Perform wheel balancing on allow rim under the specified

procedure.


K-1. 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

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.


CU-1: Check the

Supplementary

Restrain System

(SRS)

P-1. Check for vehicle SRS sensor under the specified

procedure.

P-2. Check for the vehicle SRS wiring under the specified

procedure.

CU-2: Installation of

new

Supplementary

Restrain System

(SRS)

P-1. Reinstall the SRS spiral cable under the specified

procedure.

P-2. Start the vehicle and confirm the malfunctioning light is

removed.


K-1. Understand the purpose, construction and working of supplementary restrained

systems (SRS) air bag control system. State the purpose of P2-Air Bag Control

System.

K-2. Enlist the Components of Air Bag Control system.

K-3. Describe the construction & Working of Air Bag Control System.


Capable to reset the SRS System warning light by use of scanner


S No. Description

1 Vehicle


3 Hydraulic jack




17. Workshop Practice-II AD-224


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.


CU-1: Demonstrate

Common Hand

Tools

P-1. Demonstrate use of general hand tools under specified

instructions and keep in secure location.

P-2. Demonstrate service of general hand tools under

specified instructions and keep in secure location.

CU-2: Perform 5s at

Workplace

P-1. Demonstrate tools 5s (Sort, Set In Order, Shine,

Standardize, Sustain)


K-1. 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

Capable to implement the 5s at workplace.


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


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.


CU-1: Demonstrate

Measuring tools

P-1. Demonstrate service of measuring tools under specified


P-2. Demonstrate use of measuring tools under specified


CU-2: Perform 5s at

workplace

P-1. Demonstrate measuring tools 5s (Sort, Set In Order,

Shine, Standardize, Sustain)


K-1. 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 vernier caliper, micrometer and dial

gauge.


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 caliper

27. Micrometer (inside/Outside)

28. Dial gauge

29. Feeler gauge

30. Thread pitch gauge


Overview


workshop equipment and the importance of housekeeping in the workplace under the



CU-1: Demonstrate

Workshop

Equipment

P-1. Demonstrate of workshop equipment under specified


P-2. Demonstrate use of workshop equipment under specified


CU-2: Perform 5s at

workplace

P-1. Demonstrate equipment 5s (Sort, Set In Order, Shine,

Standardize, Sustain)


K-1. 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

14. Compression tester


Overview


automotive testing and diagnosing instruments the importance of housekeeping in the

workplace under the specified procedure.


CU-1: Perform

Mechanical

Efficiency Test by

Engine Testing

Equipment.

P-1. Use of compression tester in the engine to diagnose

condition of valve under the specified procedure

P-2. Use of compression tester in the engine to diagnose

condition of piston rings under the specified procedure.

P-3. Use of vacuum tester to identify the intake manifold

pressure to diagnose the engine condition.

P-4. Use of engine leak tester in the engine to diagnose

condition of valve, piston ring, and head gasket under

the specified procedure

P-5. Clean and service the equipment and place on safe

location.

CU-2: Perform Electronic

Efficiency Test by

Engine testing

Equipment.

P-1. Use of timing gun in the engine to identify correct engine

timing under the specified procedure.

P-2. Use of tachometer in the engine to identify correct engine

RPM under the specified procedure


K-1. 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.

Capable to maintain the tools and equipment in good condition.

Tools and Equipment

S No. Descriptions

1 Tachometer

2 Compression Gauge

3 Vacuum Gauge

4 Engine Leakage Tester

5 Ignition Timing Gun


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



CU-1: Identify Fastener

by their Types

P-1. Inspect and understand the Types of permanents

Fasteners.

P-2. Inspect and understand the Types of Temporary

Fasteners.

CU-2: Carry out

Fastening

P-1. Perform application of permanents fasteners

P-2. Perform application of Temporary fasteners


K-1. Describe the functions and operating principle of the following Permanents

Fastener. Electric arc welding, Gas welding, spot welding, riveting,

soldering and Brazing.

K-2. Describe the functions and operating principle of the following Temporary

Fastener. Nuts and bolts, screw and studs


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

Capable to use the Temporary fasteners and explain the operating principles

Tools and Equipment

S No. Descriptions

1 Permanents Fasteners

2 Temporary Fastener

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



CU-1: Identify Engine

Lubricants

P-1. Identify different viscosity of engine oils and there

different climate under the specification of SAE.

P-2. Understand the viscosity index and select the appropriate

engine oil under the weather condition.

P-3. Understand the mineral oil formula oil and synthetic oil

under the specification of manufacturer.

CU-2: Identify Vehicle

lubricants

P-1. Identify the different kind of grease with respect to the

use in the vehicle system under the specification.

P-2. Identify the power steering fluid and understand its

properties.

P-3. Identify the ATF fluid and understand its properties.

P-4. Identify the brake fluid and understand its properties


K-1. 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 select the appropriate lubricants use in the vehicle

Capable to explain the lubricants use in vehicle

Capable to explain the oil viscosity index.

Tools and equipment

S No. Descriptions

1. Complete Tool trolley (Tools kit)

2. Workshop tools equipment

3. Special service tools

4. Measuring tools


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



CU-1: Identify Seals and

Gasket

P-1. Demonstrates oil seal replacement procedure under the


P-2. Identify material and types of gaskets and seals

P-3. Identify causes and remedies of seals and gasket failure.

CU-2: Replace main oil

seal

P-1. Change engine main oil seal under specified procedure.

P-2. Change gear main oil seal under specified procedure


K-1. Describe the head gasket types and thickness, main oil seal temperature resistant

property.

K-2. Problems in head gasket blown


Capable of replacing the head gasket

Capable to replace engine main oil seals (Crank and Cam)

Tools and Equipment

S No. Descriptions

1 Complete Tool trolley (Tools kit)

2 Workshop tools equipment

3 Special service tools

4 Measuring tools

5 Seals and Gas kit

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



CU-1: Service Bearing P-1. Demonstrate bearing replacement procedure under the

specified procedure

P-2. Identify material, types (Friction & Antifriction), size, and

application of Bearings.

P-3. Install Antifriction bearings in vehicle with special

reference (load and size).

P-4. Inspect antifriction Bearing.

CU-2: Diagnose Bearing

Faults

P-1. Change axle bearing under specified procedure.

P-2. Change alternator under specified procedure.


K-1. Describe the different types of bearing, application of bearing.

K-2. Describe the Problems in bearing during working.


Capable of replacing the axle bearings.

Tools and Equipment

S No. Descriptions

1. Complete Tool trolley (Tools kit)

2. Workshop tools equipment

3. Special service tools (Bearing Puller)

4. Measuring tools

5. Bearing


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



CU-1: Describe Quality

Control Standards

P-1. Elaborate the quality control standards

P-2. Describe the quality control standard Application

CU-2: Describe Quality

Control

Certification

P-1. Elaborate the quality control certification

P-2. Describe the quality control certification Application


K-1. Describes the quality control standard and its importance.

K-2. Describe the quality control certification and its importance.


Describe the quality control standard Application

Describe the quality control certification Application


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.


CU-1: Safe Working

Practice

P-1. Use the appropriate personal protective equipment

before starting the job to ensure the implementation of

safety and health regulations.

P-2. Identify the workshop associated hazards that can cause

injury, burn, pinch, short circuit, and damages.

P-3. Report to the supervision to analyze potential level of

hazards that can cause damage.

P-4. Demonstrate first aid procedure in case of minor injury

and burn.

CU-2: Fire, Preventions

and Emergency.

P-1. Extinguish the different kind of fires using the appropriate

equipment and procedures.

P-2. Identify the expiry date, filing level of fire extinguishers

and report to the supervision.

P-3. Demonstrate the Emergency situations and perform safe

evacuations drill.


K-1. 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).

K-2. Describes the hazards at workplace as following.

Vehicle battery handling, Rotating Pulleys and Belts, Jack and safety Stand,

Venting the Engine’s Exhaust

K-3. Describe the flammable materials/liquids and toxic substance, safe disposal of used

oil, asbestos, batteries, and recycling AC gas.

K-4. Describes personal hygiene, care of eye, care of lungs, and allergy.

K-5. 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

18. Metrology MT-252

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.


CU-1: Steel Rule P-1. Inspect and measure different kind of measurement (mm

and inches) under the specified procedure.

P-2. Conversion different kind of measurement under

specified procedure

CU-2: Hook Rule P-1. Inspect and measure different kind of measurement (mm



specified procedure

CU-3: Folding Rule P-1. Inspect and measure different kind of measurement (mm



specified procedure

CU-4: Measuring Tape P-1. Inspect and measure different kind of measurement (mm



specified procedure


K-1. Describes the main functions these tools. Steel Rule, Hook Rule, Folding Rule,

Measuring Tape

K-2. 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

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, V- block, Straight Edge, Spirit level, Engineer’s level, Engineer’s parallel


CU-1: Surface Plate P-1. Perform different kind of measurement with surface plate.

P-2. perform different kind of measuring tools adjust with

surface plate

CU-2: Toolmakers

Surface Plate

P-1. Perform different kind of measurement with Toolmaker

surface plate.

P-2. Perform different kind of measuring tools adjust with

Toolmaker surface plate

CU-3: Glass Surface

Plate,

P-1. Perform different kind of measurement with Glass surface

plate.

P-2. Perform different kind of measuring tools adjust with

Glass surface plate

CU-4: Angle Plate P-1. Perform different kind of measurement with Angle plate.

P-2. Perform/adjust Angle plate with surface plate for

measurement.

CU-5: Cast Iron cubes P-1. Perform different kind of use OF cast iron cubes.

P-2. Perform/adjust Cast Iron cubes other measurement tools.

CU-6: Vee Block P-1. Perform/uses of Vee Blocks.

P-2. Perform/adjust Vee Block with U-Clamp and work piece

with operation.

CU-7: Straight Edge P-1. Perform measurement different kind of Steel straight

edge.

P-2. Perform/ adjust straight edge with surface plate and sprit

level..

CU-8: Spirit Level P-1. Perform / measure Horizontal surface with spirit level.

P-2. Perform / measure Angle or inclination surface with spirit

level.

P-3. Perform / measure Vertical surface with spirit level.

CU-9: Engineer’s level P-1. Perform measurement with Engineer level.

CU-10: Engineer's parallel P-1. Perform measurement with engineer parallel.


K-1. Describe Linear Measurement instruments functions as following:

a- Surface plate 2-Tool makers surface plate 3-Glass surface plate 4-Angle plate

b- 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

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.


CU-1: Micrometer P-1. Inspect and measure different kind of measurement with

Outside micrometer (mm and inches) under the specified

procedure.

P-2. Inspect and measure different kind of measurement with

Inside micrometer (mm and inches) under the specified

procedure.


Depth Micrometer (mm and inches) under the specified

procedure.


Plug Micrometer (mm and inches) under the specified

procedure.


Vernier Micrometer (mm and inches) under the specified

procedure.


specified procedure

CU-2: Vernier caliper P-1. Inspect and measure different kind of measurement with

Vernier caliper (mm and inches) under the specified

procedure.


Vernier Height gauge (mm and inches) under the



Vernier depth gauge (mm and inches) under the



Dial Vernier caliper (mm and inches) under the specified

procedure.


specified procedure


K-1. 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

National Competency Standards Level- 5 in Automobile Technology

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 u 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.

Perform Angular Measuring.

Overview

These competency standards designed to enable the learner Angular Measuring Instrument as Bevel

protector, Bevel protector Vernier, and Single bar


CU-1: Bevel protector P-1. Inspect and measure different kind of measurement with Bevel

protector (Degree, Minute and second) under the specified

procedure.

P-2. Perform Adjustment of Bevel Protector

CU-2: Bevel Protector Vernier P-1. Inspect and measure different kind of measurement with Bevel

Vernier protector under the specified procedure.

P-2. Perform Adjustment of Bevel Protector

CU-3: Side bar

P-1. Inspect and measure Known angle with the help of sine bar under


P-2. Measures the object with the help of formula of sine bar.

P-3. Inspect and measure Unknown angle with the help of sine bar


P-4. Measures the object with the help of formula of sine bar.

P-5. Inspect and measure Unknown angle of Heavy workpiece with the

help of sine bar under the specified procedure.


K-1. Describes the different kind of measuring tools and its uses. Bevel protector, Bevel protector Vernier

and Sine bar

K-2. Describe the operational principles of Bevel protector, Bevel protector Vernier and Sine bar

K-3. 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

Identify the Types of Gauges.

Overview

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

gauges, thread gauges


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

P-1. Fixed Master gauge under the specified procedure.

P-2. Fixed Limit gauge under the specified procedure.

P-3. Fixed Plug gauge under the specified procedure.

P-4. Fixed Ring gauge under the specified procedure.

P-5. Fixed snap gauge under the specified procedure.

P-6. Feeler gauge under the specified procedure.

P-7. Sheet metal and wire gauge under the specified procedure.

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

P-1. Surface gauge under the specified procedure.

P-2. Depth gauge under the specified procedure.

P-3. Height gauge under the specified procedure.

P-4. Dial gauge under the specified procedure.

P-5. Snap gauge under the specified procedure.

CU-3: Indicating Gauges P-1. Inspect run-out gauge under the specified procedure.

P-2. Inspect back lash gauge under the specified procedure.

P-3. Inspect end play under the specified procedure.

P-4. Inspect cylinder bore under the specified procedure.

CU-4: Thread Gauges P-1. Inspect and use of thread gauge measure different kind of thread


CU-5: Ziess Micrometer P-1. Inspect and use of ziess micrometer under the specified

procedure.


K-1. Describes the different kind of Gauges and its uses.

K-2. Fixed gauges, Adjustable gauges, Indicating gauges, thread gauges


Capable to measure with the Fixed gauges.

Capable to measure with the Adjustable gauges.

Capable to measure with the Indicating gauges.

Capable to measure with the thread gauges.


S No Descriptions

1. Fixed gauges

2. Adjustable gauges

3. Indicating gauges

4. Thread gauges

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)


CU-1: Electrical/ Electronic

comparators

P-1. Understand the parts and principle of Electrical/Electronic

comparators

P-2. Inspect and measurement with Electrical/Electronic comparators


P-3. Performs the use of AC wheat stone bridge circuit incorporating a

galvanometer.

CU-2: Pneumatic comparators

P-1. Understand the parts and principle Pneumatic comparators

P-2. Inspect and measurement with Pneumatic comparators under the


CU-3: Optical/Projection

comparators

P-1. Inspect and measurement with Optical/Projection comparators


P-2. Adjust Optical/Projection comparators according to job condition


CU-4: Mechanical

comparators

P-1. Inspect and measurement with rack and pinion comparators under


P-2. Inspect and measurement with Cam and gear train comparators


P-3. Inspect and measurement with lever and tooth sector comparators


P-4. Inspect and measurement with compound comparators under the


P-5. Inspect and measurement with Twisted taut strip comparators


CU-5: Automatic gauging

comparators

P-1. Understand the parts and principle Automatic gauging comparators

P-2. Inspect and measurement with Automatic gauging comparators


CU-6: Gauge block

comparators

P-1. Inspect and measurement with Gauge block comparators under the


CU-7: Microscope (Tool Maker

microscope)

P-2. Understand the parts and principle Microscope (Tool Maker

microscope).

P-3. Inspect and measurement with Microscope (Tool Maker

microscope).


K-1. 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)

K-2. 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)

19. Applied Thermodynamics AD-232


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.


CU-1: Prepare to analyze the

thermodynamic

performance of

HVAC/R systems

P-1. Observe safe work practices and personal protective OHS

processes and procedures for a given work area are identified,

obtained and understood.

P-2. Establish OHS risk control measures and procedures are followed

in preparation for the work.

P-3. Determine extent of the thermodynamic issues from performance

specifications, situation reports and in consultations with relevant

persons

P-4. Plan activities to meet scheduled timelines in consultation with

others involved in the work

P-5. Form effective strategies to ensure solution development and

implementation to carry out efficiently.

CU-2: Analyze the

thermodynamic

performance of

HVAC/R systems

P-1. Apply thermodynamic principles to analytical solutions on

refrigeration and air conditioning systems.

P-2. Obtain Parameters, specifications and performance requirements

in relation to refrigeration and air conditioning systems in

accordance with established procedures.

P-3. Carry out approaches to analyzing thermodynamic parameters to

provide the most effective solution.

P-4. Deal unplanned events with safely and effectively, consistent with

regulatory requirements and enterprise policy.

P-5. Monitor quality of work against personal performance agreement

and/or establish organizational & professional standards

CU-3: Report and action on P-1. Evaluate to determine their effectiveness of solutions for

the results of

thermodynamic

performance analysis

thermodynamic issues and modify where necessary. P2: Report

the analysis including details of all findings, calculations and

assumptions.

P-2. Report analysis to appropriately personnel to establish appropriate

action to be taken based on findings.

P-3. 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.

K-1. Understanding the thermodynamic performance issues

K-2. Forming effective strategies for analyzing refrigeration and air conditioning systems performance

K-3. Obtaining thermodynamic performance parameters, specifications and performance requirements

appropriate to each situation.

K-4. Evaluating the results of the analysis

K-5. Documenting analysis details of all findings, calculations and assumptions.


Capable to solve the thermodynamics related problems

Capable to explain the thermodynamic diagrams.

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.


CU-1: Prepare the Boiler for

Operation

P-1. Review operational order and where required check with

appropriate personal

P-2. Identify and report health and safety hazards / maintenance

requirements to appropriate personnel according to workplace

reporting procedures

P-3. Identify and set quantity of steam to be generated for allocated

Process

P-4. Purge the boiler according to workplace procedure

P-5. Perform pre-operational checks to confirm operational status of

boiler and related equipment

CU-2: Operate and Monitor

Boiler

P-1. Use equipment in line with organizational safety procedures,

manufacturer’s instructions and environmental protection practices.

P-2. Apply complete pre-operational safety and pre start-up checks to

ensure operational effectiveness.

P-3. Start boiler and bring safely on line; communicate recent

performance to appropriate personnel.

P-4. Monitor boiler operation, diagnose status and adjust to maintain

safe and efficient operation.

CU-3: Shut down and Store

Boiler

P-1. Shut down boiler according to workplace procedures and

manufacturer's recommendations

P-2. Clean boiler internally and externally according to workplace

procedures and manufacturer's recommendations

P-3. Remove valves and fittings in preparation for maintenance

P-4. Store the boiler in the appropriate storage mode according to

workplace procedures and manufacturer's recommendations

P-5. Store and record boiler house chemicals, in line with safety

procedures and environmental protection practices.

P-6. Follow emergency shutdown procedures in cases of fire.

P-7. Complete operating log, record fuel efficiency and report to

appropriate personnel.

CU-4: Analyze and Respond

to Abnormal

Performance (Trouble

Shooting of Boiler)

P-1. Analyze operating data and plant operating conditions to identify

causes of abnormal performance

P-2. Take action correctively in accordance with workplace procedures

in response to Hazards, out-of-specification test results and/or

plant performance

P-3. Implement emergency procedures as required according to

workplace procedures and manufacturer's recommendations


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:

K-1. 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

K-2. Purpose and limitations of protective clothing and equipment

K-3. Hierarchy of hazard control measures

K-4. Duty of care of the boiler operator

K-5. Purpose and basic principles of combustion and boiler operation. This includes principles of heat

transfer and properties of steam

K-6. Boiler system layout and steam cycle

K-7. The purpose of purging a boiler

K-8. The effect of fuel quality on boiler operation

K-9. Impact of ash removal on efficient boiler operation and impact of sluice water flow

K-10. Relationship to other processes. This includes an understanding of the impact of sudden load

changes on boiler pressure and plant operation

K-11. Purpose and limitations of protective clothing and equipment

K-12. Methods used to render equipment safe to inspect, maintain and/or clean including lock-out, tag-

out and isolation procedures


Capable to explain the boiler system

Capable to solve the boiler related 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.


CU-1: Preform the

conversation of

Temperature scales

P-1. Measuring the temperature and convert to K to C.

P-2. Solve the problem with the help formula.

P-3. Measuring the temperature with appropriate tool.

CU-2: Measuring the vacuum

and pressure gauge

P-1. Measure the vacuum use with vacuum gauge on engine.

P-2. Measure the pressure use with the pressure gauge in different

scales.

P-3. Perform the conversation of vacuum and pressure in different

scales.

P-4. Solve the problems of mathematical attitudes and logical

perception in the use of mathematical instruments

CU-3: Understand and Solve

the problems of

Different Energies

P-1. Solve the problems of following energies:

a. Potential Energy

b. Kinetic Energy

c. Thermal Energy

d. Chemical Energy

P-2. Drive the law of

a. Laws of thermodynamics

b. Law of conservation of energy

CU-4: Derive the

mathematical relations

P-1. Drive the following laws:

a. Boyles Law

b. Charles Law

c. Joules Law

P-2. Solve the mathematical problems applying the laws




K-1. Safe work.


Capable to solve the problems related to the heat, mass & weight, force.


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

CU-1: Applying Gas Laws in

problems

P-1. Derive the following mathematical relations:

a. General gas equation

b. Characteristic Gas equation

c. Universal Gas equation

P-2. Understand the specific heats of a gas and derive its mathematical

relations.

CU-2: Derive the

mathematical

equation

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

Understanding and Knowledge:

K-1. Perfect gas and its properties.

K-2. Derive the mathematical relations.

a. Boyle’s law.

b. Charles’s law

c. Joule’s law

K-3. The mathematical relations..

a. General gas equation

b. Characteristic Gas equation

c. Universal Gas equation

K-4. Describe the following.

a. The two specific heats of a gas and derive its mathematical relations.

K-5. State the following.

a. Enthalpy of a Gas


Capable to drive the gas equations

Capable to drive the enthalpy gas equation


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.


CU-1: Draw the different

Cycles

P-1. Explain CARNOT CYCLE with the help of P-V diagram; also derive

its mathematical relations for Air Standard Efficiency during the

cycle of operation.

P-2. OTTO CYCLE with the help of P-V diagram; also derive its

mathematical relations for Air Standard Efficiency during the cycle

of operation

P-3. DIESEL CYCLE with the help of P-V diagram; also derive its

mathematical relations for Air Standard Efficiency during the cycle

of operation.

P-4. Joule’s Cycle with the help of P-V diagram, also derive its

mathematical relations for air standard efficiency during cycle of

operation.

P-5. DUAL COMBUSTION CYCLE with the help of P-V diagram; also

derive its mathematical relations for Air Standard Efficiency during

the cycle of operation.

CU-2: Evaluate the

performance of steam

boilers

P-1. Working and general construction of a boiler, Classification of

boilers, Selection factors of a good steam boiler, Important terms

used for steam boilers.

P-2. The construction and working of Simple Vertical Boiler with the help

of neat sketch.

P-3. The construction and working of COCHRAN Boiler (Multi tubular

boiler) with the help of neat sketch.

P-4. The construction and working of Babcock and Wilcox Boiler with

the help of neat sketch.

CU-3: Derived and solved

the mathematically

problems of I.C

engines

P-1. 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

P-2. Solve and Derived following

a. Friction Horse power.

b. Mechanical efficiency.

c. Thermal efficiency.

Understanding and Knowledge:

K-1. Explain CARNOT CYCLE with the help of P-V diagram; also derive its mathematical relations for Air

Standard Efficiency during the cycle of operation.

K-2. Explain OTTO CYCLE with the help of P-V diagram; also derive its mathematical relations for Air

Standard Efficiency during the cycle of operation.

K-3. Explain DIESEL CYCLE with the help of P-V diagram; also derive its mathematical relations for Air

Standard Efficiency during the cycle of operation..

K-4. 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.

K-5. Solve the mathematical expressions of following:

i. Performance of boiler

ii. Equivalent evaporation of boiler

iii. Efficiency of boiler

K-6. Derived formula of Comparison between Water tube and Fire tube boilers.


Capable to explain the PV cycle

Capable to explain the Otto cycle, diesel cycle

Capable to explain the thermal efficiency and sole the related problems


Overview:

This Competency standard identifies the competencies to transfer the knowledge of fundamentals of Air

compressors its types and their performance.


CU-1: Inspect/Understand

component of air

compressor and their

types

P-1. Describe the introduction of Air Compressors, types of Air

Compressors(Reciprocating & Rotary)

a. And terms used for Air Compressors

P-2. Describe the construction and working of single stage

reciprocating air compressor with the help of PV diagram and

sketch.

CU-2: Derived the work done

as per cycle.

P-1. 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

P-2. Solve the multistage compression and understand its advantages.

CU-3: Derive mathematical

expression two stage

reciprocating air

problems.

P-1. Derive its mathematical Expression for the work done per cycle

considering polytrophic law of compression

P-2. Drive a single stage and two stages reciprocating Air

compressors; also derive its formulae.

Knowledge & Understanding:

K-1. 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.

K-2. Describe the multistage compression and its advantages.

K-3. 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.


Capable to explain the Air compressor and its types

Capable to drive the work done as per cycle

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.


CU-1: Understand and solve

the IC. engine

P-1. 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

CU-2: Calculate the different

powers/ Efficiency IC.

Engine

P-1. 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:

K-1. Explain Torque, and its unit in SI system.

K-2. Explain Mean effective pressure.

K-3. Explain Indicated power and its formula.

K-4. Explain Brake Horse power and its formula.

K-5. Explain Measurement of Brake Horse power.

K-6. Explain Friction Horse power.

K-7. Explain Mechanical efficiency.

K-8. Explain Thermal efficiency.


Capable to explain mean effective pressure

Capable to explain the brake horse power

20. Motor Vehicle Driving AD-302

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.


CU-1: Practice to use of

Different Vehicle

Controls

P-1. Check the performance & Working of following controls. Dashboard

instruments cluster lights and dials controls

Speedometer

Tachometer

Fuel gauge

Temperature gauge

Warning lights for fuel, oil, engine, water

P-2. Steering Wheel control

Steering wheel

Windscreen wipers

Indicators

Headlights on full beam and dip

Horn

P-3. Floor controls:

Accelerator pedal

Brake pedal

Clutch pedal (for manual cars)

Gear lever

Handbrake or park brake

CU-2: Carry out Pre

operational Inspection

on Vehicle.

P-1. Inspect the following

Vehicle tire pressure.

Fuel level.

Oil pressure.

Coolant level.

Battery Electrolyte level.

Brake Fluid level.

Head Lights, Turn Signal Lights, brake light and Horn working.

Brake Paddle Play, Accelerator Paddle Play, Clutch Paddle

Play.

Hand brake operation.

Steering operation.

P-2. Check the working of different interiors and exteriors of a car.

CU-3: Perform Basic Pre

Starting inspection on

Engine

P-1. 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.


K-1. Describes the performance & Working of following controls. Dashboard instruments cluster lights

and dials controls

Speedometer

Tachometer

Fuel gauge

Temperature gauge

Warning lights for fuel, oil, engine, water

K-2. Explain Steering Wheel control

Steering wheel

Windscreen wipers

Indicators

Headlights on full beam and dip

Horn

K-3. Explain Floor controls

Accelerator pedal

Brake pedal

Clutch pedal (for manual cars)

Gear lever

Handbrake or park brake.

K-4. Explain the following

Vehicle tire pressure.

Fuel level.

Oil pressure.

Coolant level.

Battery Electrolyte level.

Brake Fluid level.

Head Lights, Turn Signal Lights, brake light and Horn working.

Brake Paddle Play, Accelerator Paddle Play, Clutch Paddle Play.

Hand brake operation.

Steering operation.

K-5. Explain following operations





Glow of Oil pressure light, Battery charging light and Vehicle Malfunction Indication Light just

after Starting the engine.

Abnormal engine noises.

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

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.


CU-1: Identify and follow

Traffic signals.

P-1. Follow the following traffic signals,

Red signals.

Yellow signals.

Green signals.

Traffic signal blackout.


different Road signs.

P-1. Follow the following road signs.

Regulatory signs

Guidance signs

Warning signs

Information signs

Octagonal stop sign

Triangular yield sign

Diamond-shaped pedestrian priority sign


Marking lanes on roads.

P-1. Follow the following marking lanes on roads

Regulatory markings

Warning markings

Guidance markings


K-1. Describe the following traffic signals,

Red signals.

Yellow signals.

Green signals.

Traffic signal blackout.

K-2. Describe the following road signs.

Regulatory signs

Guidance signs

Warning signs

K-3. Explain the following marking lanes on roads

Regulatory markings

Warning markings

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

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.


CU-1: Perform brake

operation on road.

P-1. Brake controls on vehicle

P-2. Start driving and apply brake in different condition and situation

P-3. Check and observe breaking distance

CU-2: Properly park the car at

proper place.

P-1. Drive car and take to proper parking place

P-2. Observe road signs and road lanes and marking on roads

P-3. Park the vehicle at proper place

P-4. Apply parking brake


This competency standard will provide knowledge related to:

K-1. Purpose of Brake and parking brake.

K-2. Factors effecting Vehicle Stopping.

K-3. Types of road surfaces and their effects on braking.

K-4. Vehicle Skidding.

K-5. Road Resistance / Road Grip.

K-6. Over Speeding and its Disadvantages.

K-7. Vehicle tires wear & tear and its limits.

K-8. 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

Drive Car in Different Condition

Overview

These competency standards designed to enable the learner to work on vehicle final drive the car in

different road conditions.


CU-1: Drive Car on Straight

Road

P-1. Driving on straight Road

Proper use of indicators

Proper use Road lanes.

Proper use of horn

Understanding road signs

Proper use of brake.

CU-2: Driving In Hilly Area

P-1. Driving in Hilly area

Proper use of brake

Proper use of Clutch

Proper gear shifting

Understanding Warning Signs.

Observing Speed limits.

CU-3: Vehicle Overtaking P-1. 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.


K-1. Describe the Driving on straight Road

Proper use of indicators

Proper use Road lanes.

Proper use of horn

Understanding road signs

Proper use of brake.

K-2. Describe the Driving in Hilly area

Proper use of brake

Proper use of Clutch

Proper gear shifting

Understanding Warning Signs.

Observing Speed limits.

K-3. Describe 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.


Capable to Drive Car on Straight Road

Capable to Driving In Hilly Area

Capable to Vehicle Overtaking


S No Descriptions

1 Vehicle

Drive Vehicle with Manual& Automatic Transmission

Overview

These competency standards designed to enable the learner to driving of manual, and automatic vehicle.


CU-1: Drive Car With Manual

Transmission

P-1. 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.

CU-2: Drive Car With Manual

Transmission

P-1. 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



CU-3: Drive Four Stroke

Motorcycle

P-1. 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

Proper use of horn

Park in proper place

Wear helmet before driving motorcycle


K-1 Describes the following

Adjustment of mirrors

Adjustment of seats

Adjustment of Steering

Different pedals & their uses.


Gear Shifting & Gear position.



K-2 Explain the following


Starting of motorcycle in proper sequence.




proper use of indicator while turning

Proper use of horn



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

Drive Motorcycle

Overview

These competency standards designed to enable the learner to driving of manual, automatic vehicle &

motorcycle


CU-1: Drive Four Stroke

Motorcycle

P-1. Drive Four Stroke Motorcycle and follow the following


Start motorcycle in proper sequence.




Proper use of indicator while turning

Proper use of horn


CU-2: Safe driving techniques P-1. 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


K-1. Describes the following

Adjustment of back view mirrors

Different grips, pedals & their uses.


Gear Shifting & Gear position.


K-2. Explain the following

Starting of motorcycle in proper sequence.




proper use of indicator while turning

Proper use of horn

Park at single & double stand


Capable to drive four stroke motorcycle


S No. Descriptions

1. Motorcycle 125cc

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


CU-1: Perform pre starting






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.

CU-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


K-1. Describe the Aggressive Driving.

K-2. Describe the steadily driving at Posted Speed Limits

K-3. Explain the over Speeding

K-4. 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

Perform Safety Practices While Driving

Overview

These competency standards designed to enable the learner driving safety and first aid procedures.


CU-1: First aid given

according to accepted

medical regulations in

case of road Accident

to Treat minor injuries

P-1. First aid cut injury

P-2. First aid eye injury

P-3. First aid burn injury

P-4. Provide artificial respiration

CU-2: Perform rescue drill and

training exercise in

case of accidents to

treat life saving

P-1. Provide artificial respiration.

P-2. Support head & neck to avoid them twisting

P-3. Do not cover her eyes.

P-4. Keep talking to them.

P-5. Keep checking that they are still breathing.

P-6. Keep the patient away from vehicle.

P-7. Call the Ambulance



K-1. Explain First Aid (according to accepted medical regulations in case of road Accident to Treat

minor injuries)

K-2. Describe rescue drill and training exercise in case of accidents to treat life saving


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

standard:

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

21. Motor Vehicle Inspection AD-312


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.


CU-1: Check the condition &

quality of Light vehicle

(LTV) tires and wheels.

1. Check And Inspect the following in tire,

2. Tire inflation

3. Tire tread

4. Side wall

5. Pledge on tire

6. Tire type

7. Retreading

8. Broken fabrics

9. Broken wires

10. Check And Inspect the following in wheels,

11. Welded wheel

12. Broken wheel

13. Broken stud and nut.

14. Missing nut

15. Damage wheel

16. Oval hole in Wheel

17. Check the condition &

quality of Heavy vehicle

(HTV) tires and wheels

18. Check And Inspect the following in heavy tire,

19. Tire inflation

20. Tire tread

21. Side wall

22. Pledge on tire

23. Tire type

24. Retreading

25. Broken fabrics

26. Broken wires

27. Re-grooved

28. Restriction mark on tire

29. Same size of all tires

30. Check And Inspect the following in wheels,

31. Welded wheel

32. Broken wheel

33. Broken stud and nut.

34. Missing nut

35. Damage wheel

36. Oval hole in Wheel

37. Check stem

38. Check cap


K-1. 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

K-2. Explain the following in Heavy and Light vehicle wheels,

Welded wheel

Broken wheel

Broken stud and nut.

Missing nut

Damage wheel

Oval hole in 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

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.


CU-1: Check performance of

spring, shock-absorber

and tracking

P-1. Coil spring inspection

Breakage

Height

P-2. Leaf spring inspection

Center bolt

U bolt

Leaves

Bushes

P-3. Shock absorber inspection

Leakage

Bushes

Attachments

Tracking inspection

By tracking gauge.

By wet road test.

CU-2: Check performance of

the electronic control

suspension system.

P-1. Check & verify the following,

Height sensor

Actuator

Shock Absorber

Compressor

Switch

Fuses

Wring & relays


K-1. Describe the inspection of following

Shock absorber inspection

Shock absorber inspection

K-2. Describe the following in electronic suspension system

Height sensor

Actuator

Shock Absorber

Compressor

Switch

Fuses

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


Overview

These competency standards designed to enable the learner to inspect vehicle steering system and wheel

alignment under the specified procedure.


CU-1: Inspect and check the

performance of steering

system and wheel

alignment

P-1. 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


P-2. Replace/service the Outer tie road, inner tie road, steering

mountings, steering boots (inner and outer ball joint), under the


P-3. Service the steering gear (Rack and pinion) box under the specified

procedure.

P-4. 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

CU-2: Inspect and check the

wheel alignment

P-1. 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.

P-2. Drive the vehicle and load/offload it on wheel alignment machine

following safety rules as specified in the manual.

P-3. 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.



Steering systems (non-assisted/manual), power assisted system, electronic steering system with a

motor.

K-2. 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.

K-3. Describe the following functions/ principles of wheel alignment.

Ackerman principle for a true rolling motion, steering pull, steering center point, steering wheel

vibration causes.

K-4. 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

8 Steering fluid pressure tester

9 Oil can


Overview

These competency standards designed to enable the learner to inspect light & heavy Duty Vehicle Brake

system as directed in the manual.


CU-1: Inspect Light Vehicle

(LTV) Brake system.

P-1. Check brake performance test on road

P-2. Check brake performance at inspection station on brake tester

P-3. 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

P-4. Check vehicle instrument panel and identify ABS mall functioning

light.

P-5. Diagnose the vehicle ABS system with the use of scanner for wheel

Sensors performance test, ABS Modular/actuator test under the


P-6. Change the wheel sensors, actuator and related fuse under the


CU-2: Inspect heavy Vehicle

(HTV) Brake system.

P-1. Check brake performance test on road

P-2. Check brake performance at inspection station on brake tester

P-3. 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

P-4. Check performance of brake booster.



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.

K-2. 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.

K-3. 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


S No. Descriptions

1 Vehicle equipped with the ABS



4 Car lift


6 Vacuum gun

Inspect Vehicle Light System.

Overview

These competency standards designed to enable the learner Inspect vehicle Lighting System as directed in

the manual.


CU-1: Check The

Performance Of LTV

Vehicle Lighting System

P-1. Check Head Light Aiming Through Head Light Aimer.

P-2. Check The Beam of head light

P-3. Check Head light DIM and FULL Light Position

P-4. Check The Presence and working of Fog Lights

P-5. Check Parking Lights

P-6. Check Left Right Indicators

P-7. Check the double indicate switch

P-8. Check Brake lights

P-9. Check Reverse indication light.

P-10. Check Number plate lights

P-11. Check Warning lights present in dash board.

P-12. Check door lights

P-13. Check all interior lights.

CU-2: Check The

Performance Of HTV

Vehicle Lighting System

P-1. Check Warning lights present in dash board

P-2. Check door lights

P-3. Check all interior lights.

P-4. Check Brake lights

P-5. Check Reverse indication light.

P-6. Check Number plate lights

P-7. Check Parking Lights

P-8. Check Left Right Indicators

P-9. Check the double indicate switch

P-10. Check Head Light Aiming Through Head Light Aimer.

P-11. Check The Beam of head light

P-12. Check Head light DIM and FULL Light Position

P-13. Check The Presence and working of Fog Lights


K-1. Describes the following

K-2. Head Light Aiming Through Head Light Aimer.

K-3. Beam of head light

K-4. Head light DIM and FULL Light Position

K-5. Fog Lights

K-6. Parking Lights

K-7. Indicators

K-8. Brake lights

K-9. Reverse indication light.

K-10. Warning lights present in dash board.

K-11. 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

Inspect Vehicle Electric System

Overview

These competency standards designed to enable the learner to Inspect Vehicle Electric System as

directed in the manual.


CU-1: Check and Inspect the

Performance of Light

Vehicle Electric system.

P-1. Check Wiring Condition

P-2. Check Wiring Color coding

P-3. Check alternator condition and its performance

P-4. Check ignition switch condition and working

P-5. Check safety starting switch performance

P-6. Check fuse box Inspect all fuses

P-7. Check horn circuit and its performance

P-8. Check wind screen wiper motor circuit and its performance

P-9. Check and inspect wind screen washer motor circuit and check its

performance.

P-10. Inspect vehicle defogger system performance

P-11. In case of key less ignition check push starting button.

P-12. Check and inspect the performance of starting motor of vehicle.

CU-2: Repair charging system P-1. Inspect the vehicle charging system and diagnose the following.

P-2. 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.

P-3. Dismantle/service of alternator as following.

P-4. Repair connector, replace carbon brushes, replace Rectifier Bridge,

replace voltage regulator, and replace stator winding.



K-1. Check Wiring Condition

K-2. Check Wiring Color coding

K-3. Check alternator condition and its performance

K-4. Check ignition switch condition and working

K-5. Check safety starting switch performance

K-6. Check fuse box Inspect all fuses

K-7. Check horn circuit and its performance

K-8. Check wind screen wiper motor circuit and its performance

K-9. Check and inspect wind screen washer motor circuit and check its performance.

K-10. Inspect vehicle defogger system performance

K-11. In case of key less ignition check push starting button.

K-12. Check and inspect the performance of starting motor of vehicle.

K-13. 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

Inspect Vehicle Glazing System

Overview

These competency standards designed to enable the learner to Inspect Vehicle glazing System as directed

in the manual.


CU-1: Check and inspect

Front Screen

P-1. Check and inspect front screen for breakage.

P-2. Check the type of glass used

P-3. Check that glass is according to automotive safety glazing.

P-4. Check for electric defogger system present on screen

P-5. Check the installation of front screen

CU-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

CU-3: Check and inspect

Side glasses

P-1. Check and inspect all side glasses for breakage

P-2. Check that all glasses are properly installed and operate able.

P-3. Check all glasses are according to automotive safety glazing,


This competency standard will provide knowledge related toexplain the following

K-1. Check and inspect front screen for breakage.

K-2. Check the type of glass used

K-3. Check that glass is according to automotive safety glazing.

K-4. Check for electric defogger system present on screen

K-5. Check the installation of front screen

K-6. Describe the following

K-7. Check and inspect Rear screen for breakage.

K-8. Check the type of glass used for rear screen

K-9. Check that Rear screen glass is according to automotive safety glazing.

K-10. Check the installation of Rear screen

K-11. Check and inspect all side glasses for breakage

K-12. Check that all glasses are properly installed and operate able.

K-13. Check all glasses are according to automotive safety glazing,


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

standard:

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

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.

.Unit of Competency Performance Criteria

CU-1: Check and Inspect

Petrol Engine Fuel

System

P-1. 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

P-2. For EFI system Also Check

Electric Fuel Pump

Fuel rail

Fuel injectors

Pressure regulator Valve

CU-2: Check and Inspect

Diesel Engine Fuel

System

P-1. 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

K-1. Fuel tank

K-2. Fuel gauge unit

K-3. Fuel pump

K-4. Fuel lines

K-5. Fuel filter

K-6. Charcoal canister

K-7. carburetor

For EFI system Also Check

K-8. Electric Fuel Pump

K-9. Fuel rail

K-10. Fuel injectors

K-11. Pressure regulator Valve

Explain the following diesel components

K-12. Fuel tank

K-13. Fuel gauge unit

K-14. Fuel Pump

K-15. Diesel Fuel Filter

K-16. Fuel Lines

K-17. Fuel Injection Pump

K-18. 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 analyser

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.



Performance of Vehicle

Body Accessories

exterior

Check and inspect the following

P-1. Front and rear bumper (car)

P-2. Side skirts

P-3. Bumper lips

P-4. Bumper canards

P-5. Bumper diffusers

P-6. Bumper splitters

P-7. Bumper grilles

P-8. Fenders with vents

P-9. Fender flares

P-10. Wide body fenders and quarter panels

P-11. Spoilers

P-12. custom hoods

P-13. Hood Scoops

P-14. Roof scoops

P-15. Side scoops


Performance of Vehicle

Body Accessories

interior.

Check and inspect the following

P-1. Dashboard

P-2. Console box

P-3. Seats

P-4. Trims

P-5. Roof

P-6. Seat belts

P-7. Interior lights

P-8. Rear view mirror


Describe the following Interiors

K-1. Front and rear bumper (car)

K-2. Side skirts

K-3. Bumper lips

K-4. Bumper canards

K-5. Bumper diffusers

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

K-6. Bumper splitters

K-7. Bumper grilles

K-8. Fenders with vents

K-9. Fender flares

K-10. Wide body fenders and quarter panels

K-11. Spoilers

K-12. custom hoods

K-13. Hood Scoops

K-14. Roof scoops

K-15. Side scoops

Describe the following exteriors

K-16. Dashboard

K-17. Console box

K-18. Seats

K-19. Trims

K-20. Roof

K-21. Seat belts

K-22. Interior lights

K-23. 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

Inspect Vehicle Exhaust System.

Overview

These competency standards designed to enable the learner to inspect vehicle exhaust according to the



CU-1: Exhaust system

components

P-1. Inspect the performance of main components of exhaust manifold


P-3. Inspect the performance of Muffler.

P-4. Dismantle and assemble the Muffler from pipe.


system

P-1. Identify catalytic converter and understand the function.

P-2. Identify the positive crankcase ventilation (PCV)and understand the

function.

P-3. Identify and understand the functions of exhaust gas recirculation

system(EGR)


K-1. Describe the exhaust manifold types and its functions.






Capable to check and Inspect vehicle exhaust system components

Capable to analyze the emission control system


S No. Descriptions




4 Car lift


Overview

These competency standards designed to enable the learner to inspect Light & heavy Duty Vehicle with

the consideration of performance as directed in the manual.


CU-1: Make Vehicle

inspection report Vehicle inspection report consist of following system inspection,

P-1. Complete lighting system of vehicle conditions

P-2. Complete mirrors and glasses condition

P-3. Engine condition

P-4. Fuel system condition

P-5. Exhaust system condition

P-6. Brake system condition

P-7. Vehicle interior conditions

P-8. Vehicle body condition

P-9. Vehicle suspension system condition

P-10. Vehicle steering system condition

P-11. Vehicle all lubricants condition

P-12. Vehicle power train condition

P-13. Vehicle tires and wheels condition

P-14. Vehicle alignment condition

P-15. Cooling system condition

P-16. Vehicle heating and A/C system condition.

P-17. SRS system condition



K-1. Complete lighting system of vehicle conditions

K-2. Complete mirrors and glasses condition

K-3. Engine condition

K-4. Fuel system condition

K-5. Exhaust system condition

K-6. Brake system condition

K-7. Vehicle interior conditions

K-8. Vehicle body condition

K-9. Vehicle suspension system condition

K-10. Vehicle steering system condition

K-11. Vehicle all lubricants condition

K-12. Vehicle power train condition

K-13. Vehicle tires and wheels condition

K-14. Vehicle alignment condition

K-15. Cooling system condition

K-16. Vehicle heating and A/C system condition.

K-17. SRS system condition


Capable to inspect vehicle performance and main components

Capable to analyze performance report of the vehicle


S No. Descriptions

1 Vehicle



4 Car lift


6

Prepare Vehicle Title Certificate.

Overview

These competency standards designed to enable the learner to prepare certificate of title for a vehicle.


CU-1: Make a Certificate of

title

The certificate of title Includes the following,

P-1. Vehicle owners name

P-2. Vehicle owners address

P-3. Vehicle owners contact

P-4. Vehicle registration no

P-5. Vehicle chassis no

P-6. Vehicle engine no

P-7. Vehicle maker detail

P-8. Vehicle year of manufacture

P-9. Vehicle Body type

P-10. Vehicle loading capacity

P-11. Vehicle seating capacity

P-12. Color of vehicle

P-13. Vehicle body type

P-14. Vehicle tax detail

P-15. Vehicle fitness certification



K-1. Vehicle owners name

K-2. Vehicle owners address

K-3. Vehicle owners contact

K-4. Vehicle registration no

K-5. Vehicle chassis no

K-6. Vehicle engine no

K-7. Vehicle maker detail

K-8. Vehicle year of manufacture

K-9. Vehicle Body type

K-10. Vehicle loading capacity

K-11. Vehicle seating capacity

K-12. Color of vehicle

K-13. Vehicle body type

K-14. Vehicle tax detail

K-15. Vehicle fitness certification


Capable to check all related documents of the vehicle

Capable to read the document of vehicle record


Vehicle

22. Fuel Injection and Carburetion AD-343

Diagnose Faults of Intake System.

Overview

These competency standards designed to enable the learner intake and exhaust system, adjust and

service the problems as well under the specified procedure in the manual.


CU-1: Service Intake system P-1. Inspect the main components intake system.

P-2. Change/service the intake manifold specified procedure.

P-3. Change/service air cleaner.

P-4. Replace throttle body/carburetor from intake manifold

P-5. Remove and dismantle turbocharger from intake manifold

CU-2: Service Turbo charger/

super charger system

P-1. Inspect the main components turbocharger system

P-2. Dismantle and assemble turbocharger/supercharger

P-3. Fault trace of Turbo charger/super charger


K-1. Describes the intake system main components and their functions as following.

K-2. Plenum, Runner, Tuned intake manifold, motor, resonator, pipe.

K-3. Describe the operational principles of intake system systems.

K-4. Describe the operation of turbocharger/super charger

K-5. 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

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.


CU-1: Service exhaust system P-1. Inspect the performance of main components of exhaust manifold


P-3. Inspect the performance of Muffler.



system

P-1. Inspects catalytic converter under the specified procedure.

P-2. 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

Diagnose Faults of Fuel Supply System.

Overview

These competency standards designed to enable the learner to inspect and fuel supply system faulty

parts nor repairable parts to be changed under the specified procedure in the manual.


CU-1: Conventional Fuel

Supply System of Petrol

Engine

P-1. Inspect fuel, fuel tank, filter and lines and identify fault/s according

to set standards.

P-2. Inspect Fuel pump and identify fault/s in fuel supply to Carburetor

according to set standards.

P-3. Inspect Fuel pump operating function by camshaft

P-4. Check and identify fault/s to ensure the proper functioning of

Carburetor.

CU-2: Conventional Fuel

Supply System of

Diesel Engine

P-1. Inspect fuel, fuel tank, primary fuel pump, Fuel injection pump, filter

and lines and identify fault/s according to set standards.

P-2. Inspect Fuel pump and identify fault/s in fuel supply to Fuel injection

pump, according to set standards.

P-3. Inspect Primary Fuel pump operating function by camshaft

P-4. Check and identify fault/s to ensure the proper functioning of Fuel

injection.

P-5. Adjust the procedure of phasing and calibration of diesel fuel

injection pumps.

P-6. Adjust the procedure of setting of timing of diesel fuel injection

pump.

P-7. Inspect and replace diesel engine glow plug.

CU-3: Electronic Fuel injection

system of petrol engine

P-1. Inspect the components of EFI system Fuel pump, fuel line, fuel

filter, pressure regulator, common rail, injector

P-2. Inspect and replace fuel pump

P-3. Inspect and replace pressure regulator

P-4. Inspect and replace fuel filter

P-5. Inspect and replace fuel gallery

P-6. Inspect and replace injector

P-7. Inspect and replace fuel line

CU-4: Electronic Fuel injection

system of Diesel engine

P-1. Inspect the components of EFI system Fuel pump, fuel line ,fuel

filter, pressure regulator, common rail, injector

P-2. Inspect and replace fuel pump

P-3. Inspect and replace pressure regulator

P-4. Inspect and replace fuel filter

P-5. Inspect and replace injector

P-6. Inspect and replace fuel line

CU-5: Sensors P-1. 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.

P-2. Inspect and replace Air Flow meter

P-3. Inspect and replace Map sensor

P-4. Inspect and replace Air temperature sensor

P-5. Inspect and replace Water temperature sensor

P-6. Inspect and replace Throttle position sensor

P-7. Inspect and replace Knock sensor

P-8. Inspect and replace Knock sensor

P-9. Inspect and replace Oxygen sensor

CU-6: Compressed Natural

Gas

P-1. Inspect the components of CNG system Cylinder, line, filler cap,

Mechanical gauge, change over switch, converter, petrol and CNG

solenoid.

P-2. Inspect and replace cylinder

P-3. Inspect and replace filler valve

P-4. Inspect and replace gauge

P-5. Inspect and replace change over switch

P-6. Inspect and service convertor

P-7. Inspect and replace petrol and CNG solenoid

P-8. Inspect , install and repair CNG wiring

P-9. Diagnose the CNG system problem

CU-7: Liquid petroleum gas P-1. Inspect the components of LPG system Cylinder, line, filler cap,

Mechanical gauge, change over switch, converter, petrol and LPG

solenoid.

P-2. Inspect and replace cylinder

P-3. Inspect and replace filler valve

P-4. Inspect and replace gauge

P-5. Inspect and replace change over switch

P-6. Inspect and service convertor

P-7. Inspect and replace petrol and LPG solenoid

P-8. Inspect , install and repair LPG wiring

P-9. Diagnose the LPG system problem



K-1. Describe construction of fuel tank

K-2. Describe construction and working of fuel gauge and its circuit

K-3. State the function of fuel pump, it’s types

K-4. Adjustment the ideal Air / Fuel ratio of different fuels

K-5. Describe air-fuel ratio for different engine working conditions.

K-6. Describe air-fuel mixture adjustment at idle speed

K-7. Describe Carburetor types according to No of barrels, No of Venturies, Air draft and fix & variable

Venturies.

K-8. Methods of Carburetor troubleshooting and remedies for the faults i.e.

a. Excessive Fuel Consumption.

b. Engine Dieseling.

c. Engine Missing.

d. Fuel Blockage.

e. Engine starving

f. Carburetor over flow

K-9. Describe Fuel injection pump according to operation.

K-10. Describe the components of EFI system

K-11. 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.

K-12. Describe the components of CNG system

K-13. Describe the components of LPG system


Capable identify/service the Petrol Engine.

Capable to service the EFI system

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

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.


CU-1: Perform Inspection. P-1. Identify the type of system

P-2. Check the components:

Cable

Switches

Modules

Cooling devices

Protective devices

P-3. Identify the components.

Missing

Damage

Leak

Loose

Worn

P-4. Defective components

CU-2: Repair Hybrid system P-1. Diagnose complex system faults

P-2. Diagnose and repair high voltage rechargeable energy storage

systems in battery electric vehicles

P-3. Diagnose and repair traction motor speed control systems in

battery electric vehicles

P-4. Diagnose and repair traction motor speed control systems in

battery electric vehicles

P-5. Diagnose and repair auxiliary motors and associated

components in battery electric vehicles

CU-3: Diagnose Hybrid

system

P-1. Diagnose and repair system instrumentation and safety

interlocks in battery

P-2. Diagnose and repair HVAC and rechargeable energy storage

cooling systems in battery electric vehicle

P-3. Diagnose and repair DC to DC converters in battery electric

vehicles

P-4. Diagnose and repair high voltage rechargeable energy storage

systems in hybrid electric vehicles

P-5. Diagnose complex faults in light vehicle safety systems

CU-4: Verify Repair of hybrid

Systems and

Components

P-1. Use testing tools manually

P-2. Verify through computerized system.

P-3. Evaluate performance of the components through test drive

P-4. Verify the codes pressure, vibration , noise and leak points

P-5. Ensure all the devices affix properly.


K-1. Describe the final drive main components and functions as following

Battery, generator, invertor, Motor, wiring (Harness)

K-2. Describe the function of hybrid Battery

K-3. Describe the function of Generator.

K-4. Describe the function of invertor.


Capable identify the faults in Hybrid system.

Capable to check and replace battery.

Capable to replace Motor generator.


S No. Descriptions

1 Vehicle


3 Hybrid system repair kit

4 Scanner


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.


CU-1: Engine Valve control

system

P-1. Inspect, adjust and replace components of variable valve timing

Intelligence (VVT-i).

P-2. Inspect, adjust and replace components of variable valve timing

and electric lift control systems (VTEC).

P-3. Inspect ,adjust and replace the components VANOS


K-1. State the Purpose of Variable valve timing control systems (VVT-I, VTEC ,VANOS)

K-2. Enlist the components of Variable valve timing control systems (VVTI, VTEC ,VANOS)

K-3. 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

23. Automotive Transmission AD-363

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.


CU-1: Repair Clutch System

(Manual)

P-1. 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.

P-2. Change/service the clutch cable under specified procedure.

P-3. Change the clutch plate while inspecting the release bearing, pilot

bearing, clutch pressure plate, fork operation under specified

procedure.

CU-2: Repair Clutch System

(Hydraulic)

P-1. Service/replace clutch master cylinder, slave cylinder under the


P-2. Perform clutch oil bleeding and top up the clutch oil reservoir under



K-1. 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.

K-2. 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

Diagnose Faults &Repair Manual Gear Box.

Overview

These competency standards designed to enable the learner to inspect and repair faulty gearbox parts

nor repairable parts to be changed under the specified procedure in the manual.


CU-1: Inspect Gearbox

(Manual)

P-1. 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.

CU-2: Service Gearbox

(Manual)

P-1. Change the gear shift lever foundation to correct excessive

movement of gear lever under the specified procedure.

P-2. Change and top up the gear oil under the specified procedure.

P-3. Service the gearbox while repairing the faults under the specified

procedure.

CU-3: Over Drive Units P-1. 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.

P-2. Service of over drive unit under the specified procedure.

P-3. Change and top up the gear oil under the specified procedure.


K-1. 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

K-2. 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.

K-3. 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

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.


CU-1: Diagnose Faults in

Automatic Transmission

System

P-1. out road test at different speeds for smooth operations of torque

converter and gear shifting according to Manufacturer standard

P-2. Check automatic transmission mounting for faults.

P-3. Check automatic transmission fluid (ATF) level, according to

standard specification and identify leaks if any

P-4. Check automatic transmission solenoid by using automotive

scanner and identify faults if any

P-5. Check electrical controls and Hydraulic pressure of automatic

transmission for faults if any

CU-2: Disassemble Automatic

Transmission System

and

Ancillary Components

P-1. Remove automatic transmission and disassemble it to check for

worn-out/ faulty parts and replace them as per Manufacturer

Repair Manual

P-2. Check automatic transmission performance by ensuring proper

linkages and controls as per standards

P-3. Reassemble automatic transmission and refit to the vehicle

according to standards



K-1. Occupational Health & Safety (OHS) precautions

K-2. Describe the function of Manual gear box(input shaft, idler shaft, counter shaft, reverse shaft)

K-3. Describe the importance mechanical transmission fluid.

K-4. Describe the function/operation Automatic transmission(Torque converter, pump, clutches, brake

band, planetary gear, valve body)

K-5. 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

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.


CU-1: Repair propeller shaft P-1. Inspect the performance of main components of propeller shaft like

as slip joint, Universal joint, Central bearing, and Flexible coupling.

P-2. Replace/service the propeller shaft like as slip joint, Universal joint,

Central bearing under the specified procedure in the manual.

CU-2: Repair Axle P-1. 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.

P-2. Replace/service the Axle CV Joints outer and inner under the


CU-3: Repair differential P-1. 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.

P-2. Service/adjust differential assembly under the specified procedure.


K-1. Describe the Propeller shaft and main components functions as following

Slip joint, Universal joint, Central bearing,Flexible coupling.

K-2. Describe the function dead and live axle, CV joint.

K-3. 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

5

24. Auto Body Building & Finishing AD-383

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.


CU-1: Identify the body

construction

P-1. Inspect and identify the external body parts.

P-2. Inspect and identify the external body parts.

P-3. Identify welded body parts

P-4. Identify bolted body parts

P-5. Identify the classification of vehicle by shape

CU-2: Identification of

Monocoque and Frame

type vehicle

P-1. Identify the engine support method

P-2. Identify center member method

P-3. Identify direct mounted method.

P-4. Identify fundamental construction of passenger car body

P-5. Identify the vehicle classification by space

P-6. Identify the crash impact absorbing front & rear area

CU-3: Identification

Characteristic of

Monocoque & frame

type vehicle.

P-1. Identify FF type vehicle

P-2. P-2 Identify FR type vehicle

P-3. P-3 Identification MR type vehicle

P-4. P-4 Identification 4WD type vehicle


K-1. Basic knowledge of passenger vehicle and commercial vehicle construction.

K-2. Basic Knowledge of Monocoque and Frame type vehicle

K-3. Basic knowledge of FF type vehicle

K-4. Basic knowledge of FR type vehicle

K-5. Basic knowledge of side body FF and FR type vehicle

K-6. Basic knowledge of welded parts

K-7. Basic knowledge of bolted parts

K-8. Basic knowledge of fundamental construction of car body

K-9. Knowledge of various types of car body shape


Capable to identify the vehicle body parts

Capable to know monocoque construction and name the parts


S No. Descriptions

Marker

Pen/ Pencil

Cotton gloves (PPE)

Goggles (PPE)

Safety Helmet (PPE)


Overview

This unit covers the competencies required to inspect a damaged automobile, generatea job sheet,

estimate the cost of damage, prepare a quotation and cost a job. Inthe process of preparing an estimate for

repairs, safe working in such operations aswell as in the use of related tools and equipment shall be

ensured.


CU-1: Assess extent of

necessary

repair/replacement and

identify work to be done

P-1. Inspect the vehicle body to ascertain the extent of damage

P-2. Identify body work and chassis work to be done

P-3. Measurements taken to quantify damage

P-4. Identify vehicle body fittings that need to be replaced

P-5. Prepare Job sheet for the necessary repairs

CU-2: Obtain quotations and

calculate the cost of

spare

parts/components to be

replaced

P-1. Prepare Quotations for the necessary replacement

parts/components obtained

P-2. Prepare Quotations evaluated and the most reasonable quotation

based on the price, quality and the choice of the customer,

P-3. Calculated Total cost of replacement parts

CU-3: Prepare an estimate of

the total cost to the

client/ insurance

company

P-1. Calculated Total material cost by getting quotations for materials

necessary for the repair

P-2. Calculated Total cost of labor by estimating the number of man

hours necessary in each category of craftsmen

P-3. 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

P-4. Calculated Individual or total overhead cost according to company

Policy

P-5. Calculated Profit margin in accordance with company policy

P-6. Calculated Total cost of repair estimated

P-7. Provided Estimate to client / insurance company


K-1. Knowledge of body repair & basic of automobile working principles and arithmetic.

K-2. Basic geometry including angular measurements and longitudinal measurements.

K-3. Techniques of measuring body repair work areas, for estimation purposes.

K-4. Safety precautions connected with inspection of damaged vehicles.

K-5. Conversion of measurements from imperial to metric units.

K-6. Knowledge of body layouts.

K-7. Use of current industrial norms in estimation.

K-8. Estimation procedures according to company principles.

K-9. Awareness of current insurance requirements.

K-10. Estimation of current rates for labor material

K-11. Replacement and repair of parts.

K-12. Knowledge of simple metal working practices.

K-13. Knowledge of dismantling procedures.

K-14. Care and maintenance of tools.


Capable to assess the damage of body

Capable to calculate the damage cost


S No. Descriptions

1. Measuring Tape

2. Measuring Tools

3. General Hand Tools

4. Calculator

5. Pen/ Pencil


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.


CU-1: Inspect a damaged

automobile and

diagnose the chassis

damage

P-1. Inspected to identify the total extent of chassis damage.

P-2. Assess direct and indirect damage estimated in order to commence

repairs / replacements.

P-3. Identify the types of metal replacements required to repair the

chassis identified.

P-4. Identify the Chassis repairs and alignment required determined

according to manufacturer’s specifications and company policies.

CU-2: Select tools and

equipment and align

the chassis

P-1. Select Tools and equipment for aligning the chassis to restore the

vehicle to original condition

P-2. Remove body parts and fittings to facilitate the repair and stored in

such a manner as to facilitate retrieval for reassembly.

P-3. Protect Electrical/electronic systems to avoid damage during repair.

P-4. Carried out Necessary repairs to the chassis follow the safety

practices.

P-5. Chassis aligned using jigs according to manufacturer’s

specifications.

P-6. Components welded to complete repair according to manufacturer’s

specifications, follow the safety practices.

P-7. Verified Chassis measurements according to manufacturer’s

specifications.

P-8. Prepared and repaired metal areas and painted with primer /

prescribed anticorrosive paints according to manufacturer’s

specifications.

CU-3: Reassemble chassis

and body parts and

complete the job

P-1. Replaced Chassis parts, aligned and refitted according to

manufacturer’s specifications.

P-2. Interpreted Wheel alignment report and adjustments made, if

necessary, according to manufacturer’s specifications.

P-3. Replaced Body parts, aligned and refitted according to


P-4. Removed all accessories from the automobile, reassembled and

fixed to meet original specifications.

P-5. All repairs and replacements done recorded for the purpose of

costing the job to the customer, according to company policies.

P-6. Keep clean work place, tools & equipment properly


K-1. Knowledge of body repair & basic knowledge of automobile working principles

K-2. Basic arithmetic

K-3. Basic geometry including angular measurements and longitudinal measurements

K-4. Techniques of interpreting measurements of body work areas listed in estimates

K-5. Safety precautions connected with working with metal sheets and in welding

K-6. Conversion of measurements from imperial to metric units

K-7. Knowledge of body layouts

K-8. Repair procedures according to company principles based on estimate provided.

K-9. Types of chassis and chassis frame construction

K-10. Interpretation of wheel alignment report & diagnosis of chassis defects

K-11. Stiffening of thin sheet metal by mechanical methods such as edging, seaming and flanging

K-12. Knowledge of preventing rust and scale formation

K-13. Basic knowledge of welding consumables.

K-14. Knowledge of reducing warping and distortion of sheet metal during welding

K-15. Use of different types of fire extinguishers.


Capable to use the body alignment tools

Capable to align the chasses


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

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.


CU-1: Diagnose body

Damage

P-1. Inspect & identify damage body work

P-2. Amount of direct and indirect damage identified in order to commence

repairs / replacements

P-3. Types of metal required to repair the vehicle, determined

P-4. Misaligned and damaged parts identified for repair / replacement Any

chassis repairs and alignment required, identified

CU-2: Align and repair

Body work

P-1. Tools and equipment required to align and repair the body according to

manufacturer’s specifications

P-2. All serviceable components that are obstructing the repair removed

and stored in such a manner as to facilitate retrieval for reassembly

P-3. Electrical/electronic systems protected to ensure that they are not

damaged during repair

P-4. Necessary repairs to the bodywork carried out and body aligned as

necessary to regain the original shape

P-5. Bodywork aligned according to manufacturer’s specifications

Components welded and sealants applied to complete repair according

to manufacturer’s specifications.

P-6. Body measurements verified according to manufacturer’s

specifications

P-7. Parts and fittings checked during repair for damage caused and

rectified as necessary

CU-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


K-1. Knowledge of body repair & basic knowledge of automobile working principles



K-4. Techniques of interpreting measurements of body repair work areas listed in estimates




K-8. Repair procedures according to company principles based on estimate provided.

K-9. Removal of rust and de-rusting mechanically and chemically

K-10. Application procedures of anticorrosive paints & body primer

K-11. Interpretation of wheel alignment report & diagnosis of chassis defects affecting body work

K-12. Use of different types of fire extinguishers

K-13. Government regulations applicable to vehicle specification


Capable to repair the vehicle body

Capable to prepare for body finishing work


S No. Descriptions

1. Measuring Tape

2. Measuring Tools




6. Wire Brush

7. Hydraulic, Pneumatic And Mechanical

Pullers

8. Cotton Gloves

9. Welding Unit (MIG Welder)

10. Washer Welder


12. Welding Gloves

13. Welding Goggle

14. Welding Apron

15. Centering Gauges

16. Industry Approved Body Frame Aligner

Equipment

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



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.


CU-1: Assess the range of

damage.

P-1. Visual inspect and Asses the range of damage

P-2. Apply inspection rules –Observe-Touch-Press and compare.

P-3. Mark the damage area with marker.

CU-2: Repair using hammer

and dolly.

P-1. Inspect complete panel and mark the damage area.

P-2. Select the hammer and dolly according to required area.

P-3. Hold hammer and dolly with S.O.P.

P-4. Apply method hammer and dolly technique at damage area.

P-5. Time to time check damage surface with undamaged surface.

P-6. After completion of repair process it must be compare with

undamaged surface.

P-7. Clean work place.

P-8. Clean tools and equipment’s and store safe place.

CU-3: Repair using washer

welder.

P-1. Select tool and equipment which is required.

P-2. Prepare the panel before repair.

P-3. Mark assess the range of damage.

P-4. Remove old paint with appropriate method.

P-5. Weld the washer for earthling.

P-6. Sliding hammer attached with washer welding gun with star bit.

P-7. Set the parameter of washer welder first.

P-8. Apply washer welder at damage area for removing dents.

P-9. Apply copper electrode for removing the burrs.

P-10. Check damage area to undamaged area.

P-11. Off the washer welder after the completion the work.

P-12. Keep the tools and equipment neat and clean and safe condition.

CU-4: Repair using shrinking

method.

P-1. Select tools and equipment according to the job.

P-2. Set the parameter of washer welder.

P-3. Attach copper electrode with washer welder gun.

P-4. Apply shrinking method.

P-5. Cool the surface with air blow gun.

P-6. Check the strength of surface from undamaged area.

P-7. All tools and equipment cleaned and stored in appropriate places.

CU-5: Assess the repaired

area after the

completion of panel

repair

P-1. Inspect all damage area

P-2. Apply straight ruler according the S.O.P

P-3. Compare damage and undamaged area

P-4. The damage area should be lower than the undamaged surface

P-5. Apply anti rust agent in back side of repaired sheet


K-1. Guideline for Inspection criteria and asses the range of damage

K-2. Knowledge about repairing technique for damage panel

K-3. Knowledge about Remove old paint film according to standard

K-4. Knowledge about hammer and dolly technique with respect to job

K-5. Operation method of washer welder

K-6. Shrinking method application process.

K-7. Washer welder parameter setting procedure

K-8. Assess the repaired area after when work finish to undamaged surface

K-9. Anti-rust application


Capable to Assessing the range of damage.

Capable to Repair using hammer and dolly technique.

Capable to Repair using washer welder.

Capable to Repair using shrinking method.

Capable to assess the repaired panel.

Apply anti rust agent in back side of repaired sheet


S No. Descriptions

1. Measuring Tape

2. Measuring Tools




6. Wire Brush

7. Hydraulic, Pneumatic And Mechanical Pullers

8. Cotton Gloves


10. Washer Welder


12. Welding Gloves

13. Welding Goggle

14. Welding Apron

15. Centring Gauges

16. Industry Approved Body Frame Aligner Equipment

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


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.


CU-1: preparations for the

repair of automobile

fittings

P-1. Identified Damaged and missing fittings by inspecting vehicle body

P-2. Remove Wire harness and all other fittings including which are

obstructing the repair, using specified tools and methods.

P-3. Undamaged fittings labeled and stored to be retrieved when re-

fixing Them.

P-4. Damaged fittings dismantled for repair or replacement.

P-5. Fittings that are irreparable, including missing fittings, identified.

P-6. Misalignments and damage caused to repairable fittings identified

and the necessary repairs assessed.

P-7. Orders placed for the replacement fittings to be received, before

Commencement of re-assembly.

P-8. Job orders to repair damaged and misaligned fittings by

straightening, welding and leveling initiated.

CU-2: Repair fittings and refit

them

P-1. Tools and equipment required to carry out the repair according to

manufacturer’s specifications and government regulations selected.

P-2. Necessary repairs to the fittings carried out and shaping done to

restore them to original condition.

P-3. Fittings aligned according to manufacturer’s specifications.

P-4. Fittings welded and leveled to complete repair according to

manufacturer’s specifications and government regulations.

P-5. Other fittings / parts checked for any damage caused during repairs

and rectified as necessary.

P-6. Surface protection provided to all repaired fittings as necessary.

P-7. Remove other fittings and accessories from the vehicle, refitted.

P-8. Arrange Wire harness and re-fixed in original position.

P-9. Clean work place, tools & equipment and stored in appropriate

places.


K-1. Knowledge of body repairing & basic knowledge of automobile working principles



K-4. Techniques of interpreting measurements of work areas listed in estimates

K-5. Safety precautions connected with working with metal sheets and in reverting, soldering and

welding



K-8. Repair procedures and company policies

K-9. Use of different types of fire extinguishers.

K-10. Removing methods of upholstery


Capable to refit the components on the vehicle.

Capable to Repair using hammer and dolly technique


S No. Descriptions

1. Measuring Tape

2. Measuring Tools




6. Wire Brush


Pullers

8. Cotton Gloves


10. Washer Welder


12. Welding Gloves

13. Welding Goggle

14. Welding Apron

15. Centring Gauges


Equipment

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


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.


CU-1: Preparations for welding of

automobile body, chassis

and other components.

P-1. Inspected and identify the body for welding work

P-2. 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.

P-3. Dismantle damaged components that are to be welded

P-4. Select Tools and equipment for leveling, aligning and clamping

the components to enable the repair to be carried out according

to manufacturer’s specifications.

P-5. Surfaces to be welded prepared by grinding, facing and aligning.

CU-2: Weld automobile Chassis,

body and other

components.

P-1. Tools and equipment required for welding the components to

enable the repair to be carried out according to manufacturer’s

specifications selected.

P-2. The type of welding to be carried out on the item determined.

P-3. Body and components arranged for welding.

P-4. Set the parameter of MIG welding machine according repair

P-5. Components aligned according to manufacturer’s specifications.

P-6. Components welded and leveled to complete repair according to


P-7. Quality of fabrication checked by visual inspection.

P-8. All components and accessories removed from the automobile

before the repair.

P-9. Component measurements verified according to manufacturer’s

specifications.

P-10. Surface protection provided to all repaired components.

P-11. Wire harness arranged and re-fixed in original position.

P-12. Clean work place, body repair tools, welding equipment and

store them in appropriate places


K-1. Knowledge of body repairing & basic knowledge of automobile working principles


K-3. Basic geometry including angular and longitudinal measurements

K-4. Techniques of interpreting measurements of body work areas, listed in estimates



K-7. Knowledge of welding with gas, arc, spot, TIG, MIG/ MAG and polymer welding equipment in

respect to automobile

K-8. Knowledge of minimizing warping, distortion and stress formation in sheet metal while welding

K-9. Safe handling and care of various types of welding equipment

K-10. Repair procedures according to S.O.P

K-11. Interpretation of the wheel alignment report & diagnosis of chassis defects affecting the bodywork

K-12. Knowledge of visual inspection / non-destructive testing methods.


Capable to weld the vehicle body.



S No. Descriptions

1. Measuring Tape

2. Measuring Tools




6. Wire Brush


Pullers

8. Cotton Gloves


10. Washer Welder


12. Welding Gloves

13. Welding Goggle

14. Welding Apron

15. Centring Gauges


Equipment

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


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


CU-1: Maintain MIG welder P-1. Remove all dirt, dust or debris from the machine and its

accessories

P-2. MIG welder is to keep covered when not in use

P-3. Check all electrical component of MIG welder machine

P-4. Drive rolls should be clean & settled properly

P-5. Adjust the driver rolls tension properly

P-6. Clean gun & nozzle regularly

CU-2: Maintain Washer

welder machine

P-1. Remove all dirt, dust or debris from the machine and its

accessories

P-2. Washer welder is to keep covered when not in use

P-3. Clean earth cable with dry sand paper

P-4. Clean the sliding hammer properly

P-5. Service at the proper time

P-6. Check all electrical component of washer welder machine

CU-3: Maintain spot welder

machine

P-1. Remove all dirt, dust or debris from the machine and its

accessories

P-2. Spot welder is to keep covered when not in use

P-3. Check all electrical component of spot welder machine

P-4. Clean the air filter of machine

P-5. service at the proper time

P-6. Clean spot gun properly

P-7. Clean & replace welding tools

CU-4: Maintain Grinder P-1. Check all bolts and screws for tightness

P-2. Check condition of hub or drum assembly and replace flaps, cutters

or axles if required

P-3. Check the security of all hoses clamps and fittings,

P-4. Clean air filter lubricator

P-5. Check the vibration of grinder

CU-5: Maintain frame aligner P-1. Remove any dirt or sealer from all pulling clamp of body aligner

P-2. Check the leakage of hydraulic oil from pump

P-3. Clean all accessories of frame aligner

P-4. Check whether there were leaks at the places where the hose was

fixed

P-5. Check & clean all safety cable of frame aligner

CU-6: Maintain pneumatic

tools

P-1. Check that all screws on tool are tight.

P-2. Keep magazine and feeder mechanism clean.

P-3. Lubricate "O" rings that are replaced.

P-4. Clean filter element-then blow air through filter in direction opposite

to normal flow.

P-5. Drain airline filter(daily) and Keep lubricator filled

CU-7: Top up oil level of

compressor

P-1. Check the oil level of the compressor every day in the morning

P-2. Select the type of oil according to that given by the manufacturer

P-3. If the oil level has dropped, fill oil up to the marked level

CU-8: Drain water in the air

tank of compressor

P-1. Check whether there was water in the air tank of the compressor

every day in the morning

P-2. Drain water by opening the drain tap

P-3. Close the tap to prevent air leakage

P-4. If there was water while painting, drain the water collected in the air

tank following Steps 2 and 3 above

CU-9: Replace air filter of

compressor

P-1. Decide whether a filter has to be fixed to the compressor or not

P-2. Decides a suitable type of filter?

P-3. 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

CU-10: Drain water in air

regulator

P-1. Decide whether water had to be drained from the regulator

P-2. Drain the water by activating the knob or the switch key of the

regulator

P-3. Check a number of times whether the air coming through the

regulator was free from water


K-1. Guidelines on maintenance of tools and equipment

K-2. Guidelines to be followed and matters to be considered when storing of equipment

K-3. Guidelines to be considered in storage

K-4. Documents used in storing and their maintenance

K-5. Guidelines to be considered in maintaining the frame aligner

K-6. Maintain MIG welder, washer welder, spot welder

K-7. Aspects to be considered in using welding machine.

K-8. Functioning of the welding machine and guidelines to be considered in its maintenance

K-9. Aspects to be considered in updating maintenance register

K-10. Knowledge about the components of the air compressor and pneumatic tools

K-11. Knowledge about guidelines for maintaining air compressors and pneumatic tools


Capable of Label tools and equipment for easy identification and store safely.

Capable of Maintain MIG welder

Capable of Prepare a monthly plan for maintenance of hand tools

Capable of Maintain washer welder

Capable of Maintain frame aligner

Capable of Inform relevant sections about malfunctioning equipment

Capable of Use of welding equipment

Capable of Maintain plasma & gas cutter

Capable of Maintain pneumatic and power 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

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.


CU-1: Determine the

scope of the task in

removing specified

glass items from

frame and re-fixing

them

P-1. Inspected and identify the specified glass items.

P-2. Identify Any uneven surfaces, cracks / corrosion on the frames of the

specified glass items.

P-3. Remove glass without any damages wit specified procedure

P-4. Fixing the glass without damages with specified procedure

CU-2: Remove glass items

from automobiles

and re-fix them

P-1. Select Tools and equipment to remove and re-fix glass items from the

automobile selected.

P-2. Operations to be carried out on the glass frame and beading for

removal and fixing without damage

P-3. Remove Glass carefully without damaging either the glass or the

frame.

P-4. Cleaned glass with kerosene, water, detergents etc. as appropriate

and stored carefully in a safe place for easy retrieval when re-fixing.

P-5. Frame cleaned with kerosene, water, detergents and cutting

compound as necessary to produce a smooth surface.

P-6. 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.

P-7. Any specified paints or other appropriate material applied on the frame

surfaces for the prevention of corrosion

P-8. Appropriate sealing material applied as required, to ensure a proper fit.

P-9. Glass fixed carefully into the frame, ensuring that it is correctly fitted.

P-10. Leak test carried out with water to ensure that the joint is leak proof.

P-11. Glass and surrounding area cleaned to complete the job.

P-12. All glass fixing tools cleaned and stored in appropriate places.


K-1. Basic knowledge about different type of glass

K-2. Basic geometry including angular and longitudinal measurements

K-3. Techniques of interpreting measurements of body repair work areas listed in estimates

K-4. Safety precautions connected with working with glass items and frames

K-5. Conversion of measurements

K-6. Knowledge of glass removal and fixing

K-7. Repair procedures according to company standard

K-8. Interpretation of the alignment report & diagnosis of glass frame defects due to accidents and

corrosion in the bodywork

K-9. Knowledge of various types of safety glass such as laminated, tempered, reflective, and polymer

types such as flexi glass polycarbonates

K-10. Knowledge of various types of paints, sealants and adhesives, and their uses


Capable of fixing the door glass

Capable of fixing the front and rear screen of the vehicle.

Capable of Maintain MIG welder


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


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


CU-1: Remove paint in

aluminum body using

single action sander

P-1. Select the areas from which Paint had to be removed.

P-2. Take necessary tools and equipment

P-3. Prepare the single action sander for removing paint

P-4. Removes existing paint using the single action sander.

P-5. Smoothen the body surface by applying dry sandpaper

P-6. Clean the body surface

P-7. Clean the work place and tools and store them properly

CU-2: Surface preparation P-1. Examine the areas marked for removing rust

P-2. Take necessary tools and equipment, check their workability.

P-3. Prepare the single action sander for removing rust

P-4. Remove rust using the single action sander check whether all the

rust had been removed

P-5. Clean the body using dry sandpaper

P-6. Clean the workplace and tools and store them

CU-3: Remove rust using

power wire brush

P-1. Determine the areas to be clean

P-2. Using a power wire brush

P-3. Take necessary tools and equipment

P-4. Prepare the power wire brush appropriately for relevant job

P-5. Remove rust from the determined areas using the power wire brush

P-6. Apply dry sandpaper only on places cleaned using the power wire

brush

P-7. Clean the de-rusted vehicle body parts

P-8. Clean the workplace and tools and store them properly

CU-4: Remove rust using Dry

sandpaper

P-1. Mark the areas from where rust had to be removed.

P-2. Select dry sandpaper according to the extent of rusting.

P-3. Remove the rust completely using dry sand paper.

P-4. Cleans the vehicle body parts and keeps in a suitable place.

P-5. Clean the work place and tools and store them properly.


K-1. Rusting and steps to be taken to prevent it

K-2. Instructions for removing rust

K-3. Use of double action sander, normal grinder, power wire brush and sand paper and hints on

maintaining the above mentioned equipment

K-4. Aspects to be considered when using double action grinder

K-5. Types of double action sander and their functioning

K-6. Aspects to be considered for proper operation of sanders

K-7. Distinguishing properties of aluminum metal

K-8. Dry sandpaper and distinguishing properties of different types, methods and situations of using

them

K-9. Hints for selecting required sandpaper


Capable of Use power operated wire brush and normal grinder

Capable of Use double action sander

Capable of Remove paint on aluminum panels using single action sander

Capable of Remove rust on vehicle body parts using wire brush and 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


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.


CU-1: Remove rust using

chemicals

P-1. Mark the areas from which rust had to be removed

P-2. Prepare the necessary tools and chemicals

P-3. Wear PPE according to instruction

P-4. Mask the areas where rust removing chemicals were not applied

P-5. Remove rust by applying the rust removing chemical

P-6. Check whether all the rust was removed

P-7. Clean vehicle body, tools and equipment and workplace using

detergents.

CU-2: Remove existing paint

using chemicals

P-1. Determine the areas on the body parts from which paint had to

beremoved

P-2. Collect required chemicals and other materials


P-4. Remove paint only from areas where paint had to be removed

usingchemicals

P-5. Examine whether all paint had been removed

P-6. Perform work in well-ventilated area

P-7. Clean the tools, vehicle body parts and the workplaces after

finishing work

CU-3: Remove oil and grease

using chemicals

P-1. Mark the areas covered with oil and grease

P-2. Collect the chemicals to be applied and tools

P-3. Apply chemicals in relevant areas and remove oil and grease

P-4. Examine whether all the oil and grease were removed

P-5. Perform work in well-ventilated area

P-6. Clean the tools and the workplace after finishing work

CU-4: Remove dampness of

body surface

P-1. Select the areas with oil and grease on the vehicle body

P-2. Prepare necessary tools and chemicals


P-4. Apply chemicals on the damp areas and remove oil and grease

P-5. Check whether vehicle body was fully dry


CU-5: Remove silicon using

chemicals

P-1. Examine well and identify the area from which silicon had to

beremoved

P-2. Prepare the required chemicals and tools

P-3. Apply chemicals on areas coated with silicon

P-4. Remove silicon using chemicals according to the instructions of the

manufacturer

P-5. Check whether silicon had been removed



K-1. Types of chemicals used to remove existing paint, rust, oil andGrease, dampness and silicon from

vehicle body parts and their qualities.

K-2. Guidelines and safety measures to be followed in the use of chemicals.


Capable of Remove rust from corroded vehicle body / body parts using chemicals.

Capable of Remove existing paint from body parts of vehicles using chemicals.

Capable of Remove oil and grease on vehicle body / body parts using chemicals.

Capable of Remove dampness in vehicle body parts using chemicals.

Capable of Remove silicon in vehicle parts using 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


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.


CU-1: Maintain polisher P-1. Remove, wash, dry and store the pads of the polisher

P-2. Clean the polisher with compressed air and store

P-3. Service the polisher at the proper time

CU-2: Maintain sanding

machine

P-1. Clean the dust extraction bag

P-2. Check the amount of oil required for the machine

P-3. Control air current obtained from the compressor

P-4. Clean the sanding machine with compressed air and store it

P-5. Service at the proper time

CU-3: Clean spray gun

manually

P-1. Dismantle separately the spray gun, the nozzle, the bottle and the

cap after applying one kind of paint

P-2. Wash each of them separately using cleaning thinner kerosene

P-3. Cleaning the nozzle, did you insert a thin wire and remove the paint

in the vent

P-4. Place the nozzle inside the bottle of spray gun and store all the

parts securely

CU-4: Clean spray gun using

gun cleaner

P-1. Dismantle the spray gun into separate parts

P-2. Prepare spray gun cleaning liquid and pour it into the gun cleaner

P-3. Place in the cleaning machine the parts dismantled from the spray

gun(nozzle, bottle, cap, control lever (trigger)

P-4. Activate the machine and wash the parts twice or more number of

times(until all the paint was removed)

P-5. Put thinner to the washed and cleaned parts and assemble again

P-6. Store the spray gun in a secure place

CU-5: Replace compressor air

hose

P-1. Take the tools needed to fix the hose to the air compressor to the

relevant place

P-2. Select the hose to be fixed to the air compressor according to the

instructions of the manufacturer

P-3. Fix the hose to the compressor using couplings

P-4. Check whether there were leaks at the places where the hose was

fixed by activating the compressor

P-5. Clean and store the tools and equipment

CU-6: Replace spray gun

repair kit

P-1. Dismantle parts of the spray gun separately according to the


P-2. Select the repair kit of the spray gun according to the part number

of the manufacturer

P-3. Assemble the spray gun again using the repair kit according to the


P-4. Check whether there were air leaks by connecting the spray gun to

the air compressor

P-5. Clean and store securely the spray gun

CU-7: Top up oil level of

compressor

P-1. Check the oil level of the compressor every day in the morning

P-2. Select the type of oil according to that given by the manufacturer

P-3. If the oil level has dropped, fill oil up to the marked level

CU-8: Drain water in the air

tank of compressor

P-1. Check whether there was water in the air tank of the compressor

every day in the morning

P-2. Drain water by opening the drain tap

P-3. Close the tap to prevent air leakage

P-4. If there was water while painting, drain the water collected in the air

tank following Steps 2 and 3 above

CU-9: Replace air filter of

compressor

P-1. Decide whether a filter has to be fixed to the compressor or not

P-2. Decides a suitable type of filter?

P-3. 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

CU-10: Drain water in air

regulator

P-1. Decide whether water had to be drained from the regulator

P-2. Drain the water by activating the knob or the switch key of the

regulator

P-3. Check a number of times whether the air coming through the

regulator was free from water


K-1. Guidelines on maintenance of tools and equipment

K-2. Guidelines to be followed and matters to be considered when storing finishing equipment

K-3. Guidelines to be considered in storage

K-4. Documents used in storing and their maintenance

K-5. Guidelines to be considered in maintaining the polisher

K-6. Maintain single action and double action sander and their functions

K-7. Aspects to be considered in using sanding machine.

K-8. Functioning of the sanding machine and guidelines to be considered in its maintenance

K-9. Aspects to be considered in updating maintenance register

K-10. Knowledge about the components of the air compressor and the spray gun

K-11. Knowledge about guidelines for maintaining air compressors and spray gun


Capable of Label tools and equipment for easy identification and store safely.

Capable of Maintain polisher

Capable of Prepare a monthly plan for maintenance of hand tools

Capable of Make a sanding block

Capable of Maintain sanding machine

Capable of Inform relevant sections about malfunctioning equipment

Capable of Dismantle spray gun and record its performance

Capable of Use spray gun cleaner

Capable of Connect the spray gun to the air compressor and activate the air compressor.


S No. Descriptions


2. Cotton Gloves

3. Compressor Oil

4. Lubrication Oil

5. Cleaning Thinner

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


CU-1: Maintain paint booth

filters

P-1. Take the air filter out and blow air into it

P-2. Cleans the inside of paint booth using an air hose

P-3. Fixes the air filter blowing air to clean it

P-4. Operate air filter in the paint booth for at least half an hour

P-5. Air filter was more than 18 month old replace it with a new one

CU-2: Maintain cleanliness of

paint booth

P-1. Decide on the parts to be cleaned

P-2. Gather the tools / equipment and materials

P-3. Test the functioning of tools /equipment

P-4. Remove the vehicle, paint and other material

P-5. Clean the interior of the paint booth using a vacuum cleaner

P-6. Close doors to prevent the entry of dust

P-7. Store the tools / equipment properly

CU-3: Replace paint booth

filter

P-1. Decide on the task to be performed

P-2. Gather tools and equipment

P-3. Test the condition of tools and equipment If paint dust remains

inside often after painting about 100 vehicles,

P-4. Remove filters from their attachments

P-5. Clean the places where filters and their supports were fixed using a

vacuum cleaner

P-6. Select filter according to the accessory number of paint booth

manufacturer

P-7. Fix that filter according to the instructions of manufacturer

P-8. Test the functioning of the filter

P-9. Store the tools / equipment properly after completion the work.

CU-4: Fill fuel in paint booth

furnace / burner

P-1. Identify the fuel tanks of the paint booth

P-2. Examine the fuel tanks of the paint booth

P-3. Fill the fuel tanks with not more than the required quantity of fuel

P-4. Remove electric wires and inflammable materials

P-5. Fix fire extinguishing equipment

P-6. Fix alarm sign

CU-5: Store materials P-1. Separate raw materials (types of chemical paints), inflammable

materials and poisonous materials

P-2. label all the materials for easy identification (using suitable

diagrams or names) and store them in the correct places

P-3. Store inflammable materials separately from other materials

P-4. Store these materials under environmental conditions as stated by

the manufacturer of such materials

P-5. Keep records of receipts and issues of materials

CU-6: Maintain paint stores P-1. label paint and other chemicals and store them separately

P-2. Store tools and equipment enabling easy access

P-3. Note down places where fans and blowers required for raw

materials are fixed

P-4. Update the documents relevant to stores when raw materials and

chemical substances get spilled inside the stores,

P-5. Mention how they should be removed without catching fire

P-6. Remove unusable materials from the stores

CU-7: Store tools and

equipment

P-1. Separate tools and equipment according to their use and value

P-2. Provide numbers / labels to identify every tool and equipment

P-3. Decide on the place for storing each tool and equipment

P-4. Decide about safe places for storing valuable tools and equipment

P-5. Label such places

P-6. Store tools and equipment at the relevant places

P-7. Enter information about tools and equipment in the stock-book

P-8. Sort out the malfunctioning tools and equipment and store them

separately

P-9. Maintain data about malfunctioning tools and equipment


K-1. Different materials used in painting and their properties

K-2. Types of filters and their properties, their applications and manufacturer’s instructions

K-3. The guidelines to be considered in maintaining filters

K-4. A brief introduction about the 5S method and ISO 14000

K-5. Fuel tanks and their maintenance

K-6. Guidelines regarding stores and maintenance of materials stored

K-7. Techniques of cleaning

K-8. Classification of paints, cost of painting materials and distinguishing inflammable materials

K-9. Aspects to be considered in storing paint

K-10. Safety precautions to be adopted in maintaining stores


Capable of Maintain paint booth Sealing filters, Floor filter, pre filter

Capable of Replacement of paint booth filter

Capable of Fuel filling in fuel tank of paint booth burner

Capable of Store material in order position

Capable of Update the documents relevant to stores when raw materials and chemical

Capable of Understanding of 5S and ISO method


S No. Descriptions


2. Cotton Gloves

3. Dust Mask

4. Air Compressor

5. Air blow Gun

6. Shop cloth

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


CU-1: Assessment the range

of damage

P-1. Collect the necessary tools & equipment

P-2. wear the necessary safety gear.

P-3. Clean the panel so as not to overlook damage

P-4. Assess damaged area by (observe, Touch, Press, Compare )

P-5. Mark the top, bottom, left and right limits and define the range of

damage.

P-6. Assess the dent and bump on the surface.

P-7. Check the tension of the damage panel

P-8. Assess the differences by comparing damaged area to undamaged

area

P-9. Define the range of damage

CU-2: Surface preparation P-1. Identify the areas to be prepare

P-2. Collect the necessary tools, equipment and materials

P-3. Prepare the areas to be protected

P-4. Prepare the panel for putty application

P-5. Remove old paint coat and rust to within the marked area.

P-6. Sand the surface with a single-action sander using 60 to 80 grit

sandpaper

P-7. Smooth out the step between the bare metal and original paint film

P-8. Attach 120 grit sandpaper to the dual action sander for sanding

P-9. Remove dirt, dust and grease from the surface to prevent

irregularities.

P-10. Wipe off the area with a shop cloth

P-11. Blow air after removing any dirt or dust with a shop cloth

P-12. Apply primer to exposed bare metal

CU-3: Apply polyester putty P-1. Identify the areas for applying the putty

manually P-2. Collect the tools & equipment and materials


P-4. Mix the putty and the hardener

P-5. Mix the putty by moving the mixing stick up and down while turning

the can.

P-6. Tighten the cap of tube and massage the entire tube to mix the

hardener

P-7. Combine the putty and hardener for mixing ratio follow the

manufacturer instruction.

P-8. Apply putty thinly with in 10mm of the outer edge of the scuffed

area.

P-9. Apply putty higher than the undamaged surface overlaps 1/3 of the

previously applied putty.

P-10. Clean the workplace tools & equipment and store them properly.

CU-4: Putty sanding by Dry

sanding machine

P-1. Identify the areas to be sanded

P-2. Collect the tools equipment and materials


P-4. Identify the parts to be protected

P-5. Adjust the tools and equipment for sanding

P-6. Stand in a position where the sander can reach both ends of the

putty application area easily

P-7. Start sanding when the putty and panel reach room temperature

P-8. Use a sander with 80 grit sandpaper to remove dent or bump from

putty surface

P-9. Sand the putty surface to 80% of the correct surface with 120 grit

sand paper

P-10. Sand the putty surface to 90% of the correct surface with 180 to

220 grit sand paper

P-11. Sand with 320 grit sandpaper for surface finishing

P-12. Check the finish of putty surface remove all abrasion mark

P-13. Clean the work place tools & equipment and store them properly

CU-5: Putty sanding by Hand

sanding block

P-1. Identify the areas to be sanded

P-2. Collect the tools equipment and materials


P-4. Identify the parts to be protected

P-5. Attached the hand sanding block with dust extraction machine

P-6. Stand in a position where the hand sanding block can reach both

ends of the putty application area easily

P-7. Start sanding when the putty and panel reach room temperature

P-8. Use a hand sanding block with 80 grit sandpaper to remove dent or

bump from putty surface

P-9. Sand the putty surface to 80% of the correct surface with 120 grit

sand paper

P-10. Sand the putty surface to 90% of the correct surface with 180 to

220 grit sand paper

P-11. Sand with 320 grit sandpaper for surface finishing

P-12. Check the finish of putty surface remove all abrasion mark


CU-6: Apply one pack

nitrocellulose primer

filler

P-1. Take a decision regarding the weather

P-2. Decide on the areas for application of NC filler

P-3. Decide on the areas to be protected

P-4. COLLECT the tools, equipment and materials

P-5. Check the workability of tools and equipment


P-7. Mix NC paint using weighing scale according to ( MSDS )

P-8. Filter the paint and pour in to the spray gun

P-9. Adjust the pressure of air

P-10. Adjust the spray gun according repair area

P-11. Clean the surface with cleaning thinner

P-12. Air blowing on surface to remove dirt particle on surface

P-13. Apply tack cloth

P-14. Apply paint on surface according to paint spraying method

P-15. Clean the spray gun after work finish

P-16. Clean the work place, tools & equipment and store them properly

CU-7: Apply 2 pack Urethane

type filler

P-1. Take a decision regarding the weather

P-2. Decide on the areas for application of urethane type filler

P-3. Decide on the areas to be protected

P-4. Collect the tools, equipment and materials

P-5. Check the workability of tools and equipment


P-7. Mix urethane primer and hardener using weighing scale according

to ( MSDS)

P-8. Filter the primer and pour in to the spray gun

P-9. Adjust the pressure of air

P-10. Adjust the spray gun according repair area

P-11. Clean the surface with cleaning thinner

P-12. Air blowing on surface to remove dirt particle on surface

P-13. Apply tack cloth

P-14. Apply paint on surface according to paint spraying method


P-16. Clean the work place, tools & equipment and store them properly

CU-8: Apply nitrocellulose

putty

P-1. Make a decision about the weather

P-2. Determine the areas to be filled

P-3. Identify the areas to be protected

P-4. Collect the tools, equipment and materials


P-6. Test the workability of the rubber pad

P-7. apply putty between 900- 600 for small holes / defects

P-8. apply again using reduced pressure

P-9. Clean the workplace and the tools / equipment and store the tools

/equipment

P-10. Allow to dry for 1 hours


K-1. Types of metal filler, high filler, and one pack nitrocellulose primer filler, nitrocellulose putty; their

qualities and information on using them

K-2. Guidance to be followed in the use of above material

K-3. Hints on leveling metal filler by wet method and dry method

K-4. Hints for deciding areas that do not require any application

K-5. Hints for deciding the suitable weather for applications

K-6. Properties of raw materials used for application and their usage

K-7. Types of metal fillers and their properties

K-8. Instructions to be followed during applications

K-9. Hints for leveling using a machine

K-10. Hints on detecting defects of the vehicle body by touch and observation

K-11. Information about sand papers

K-12. Types of high fillers and instructions on using them

K-13. Instructions to be followed polyester putty & filler

K-14. Types of nitrocellulose; their use and properties

K-15. Information on polyester putty and its use


Capable of Assessment the range of damage

Capable of Surface preparation

Capable of Putty application

Capable of Putty shaping

Capable of Putty sanding

Capable of Filler application


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

Prepare Paint Booth and Vehicle

Overview




CU-1: Mask required body

parts

P-1. Decide what coating to be applied

P-2. Decide what body parts do not need the particular coating

P-3. Select materials and tools required to mask those body parts

P-4. Cover such body parts with masking tape or some other material to

prevent paint dripping on to them when applying

P-5. Clean tools and equipment and store them

CU-2: Remove dust on

painted surface

P-1. Identify the areas to be painted

P-2. Select the required equipment and material

P-3. Use suitable water sand paper

P-4. Scrub off the dust layer

P-5. Check whether parts covered with dust were scrubbed off

P-6. Clean the place where the task was performed and store equipment

and material

CU-3: Adjust paint booth

temperature

P-1. Determine the weather condition in making the decision

P-2. Check whether the sensors in the paint booth were kept in the

places mentioned by the manufacturer

P-3. Adjust the temperature regulator in the room to the required

temperature

P-4. Measure the internal temperature.

P-5. Determine correctly the task at hand and the relevant temperature

P-6. Check whether the machines and equipment operated as stated by

manufacturer

CU-4: Fix water separating

filter

P-1. Examine whether there was a defect in the water separating filter

P-2. Prepare the required tools and equipment

P-3. Unfix and remove the water separating filter

P-4. Select water separating filter of the particular type

P-5. Fix it at the correct location

P-6. Clean and store tools and equipment


burner / furnace

P-1. Mask the parts that needed to be protected

P-2. Gather the tools / equipment and the materials

P-3. Check whether there was fuel / electricity leakage in the vehicle that

was painted

P-4. Remove paint / thinner from the paint booth

P-5. Check whether the burners were in working order

P-6. Locate the vehicle at the center of the paint booth

P-7. Close all the doors of paint booth

P-8. Check whether the fire extinguishing equipment was functioning

P-9. Adjust both / all the plugs in the burners to emit a high temperature

P-10. Operate all the burners

P-11. Prepare for the next task until the green bulb in the thermometer

turned red and stopped automatically


heating timer

P-1. Decide the time required for heating according to the intended paint

P-2. application and the job

P-3. Adjust both / all the timers as to indicate the same time

P-4. Adjust the relevant timers according to the required time

CU-7: Operate paint booth

ventilator feed air fan

P-1. Gather the tools / equipment and material

P-2. Check whether they were functioning properly

P-3. Prepare the vehicle to be painted/ paint and were you ready

P-4. Check whether the feed / exhaust air fan in paint booth was

functioning

P-5. Switch on the fan

P-6. Switch off the feed / exhaust fan in the paint booth after painting


K-1. Instructions for removing dust on the body parts before painting

K-2. Aspects to be taken into consideration in removing dust (safety)

K-3. Instruction for controlling the internal temperature of the paint booth

K-4. Instruction for safety precautions to be adopted when adjusting the internal temperature

K-5. Instruction for functioning of a water separating filter

K-6. Reasons for draining water from the air system

K-7. Aspects to be taken into consideration in adjusting the heating furnace in the paint booth

K-8. Instruction for safety precautions to be adopted in adjusting the heating furnace

K-9. Instruction the necessity of adjusting the heating timer in the paint booth

K-10. Aspects to be considered in adjusting the heating timer


Capable of adjust the paint booth temperature

Capable to adjust water spreading filter


S No. Descriptions


2. Cotton Gloves

3. Dust Mask

4. Air Compressor

5. Air blow Gun

6. Shop cloth

7. Masking tape

8. Masking Paper

9. Sand Paper

Apply Primer Surface

Overview




CU-1: Scuffing for primer

Surface with sanding

machine

P-1. Determine the areas for scuffing primer Surface

P-2. Determine the areas that need to be masking

P-3. Collect tools, equipment and material

P-4. Check functioning of equipment


P-6. Attached 320 grit sand paper with dual action sander

P-7. Adjust the revolution speed of dual action sander

P-8. Scuff the surface to a distance of 100mm from the edge

P-9. Bring the sander into contact with the panel before starting the

sander

P-10. Scuffing the act of finely scratching a surface with sandpaper

P-11. Clean the work place

P-12. Clean tools & equipment and store them properly

CU-2: Scuffing for primer

Surface with hand

sanding block

P-1. Determine the areas for scuffing primer Surface

P-2. Determine the areas that need to be masking

P-3. Collect tools, equipment and material

P-4. Check the pad of sanding block


P-6. Attached 320 grit sand paper with hand sanding block

P-7. Attached hand sanding block with dust extraction machine

P-8. Scuff the surface to a distance of 100mm from the edge

P-9. Hold the sanding block at 45degrees to direction of sanding

P-10. Scuffing the act of finely scratching a surface with sandpaper



CU-3: Cleaning & degreasing

before primer Surface

application

P-1. Determine the area for cleaning & degreasing

P-2. Collect the necessary tools / equipment and materials


P-4. Wipe the area with shop cloth which is socked in degreaser

P-5. Blow air on the surface to dry the degreaser

P-6. Wipe away any dirt or dust with a tack cloth Without applying

pressure

P-7. Clean work area


CU-4: Masking before primer

Surface application

P-1. Determine the parts & body for masking

P-2. Gather tools / equipment and materials

P-3. Protect all body for over spray use masking foil

P-4. Mask the openings after remove fittings.

P-5. Mask the gaps between the panel

P-6. Use reverse masking to avoid creating a step around the edge of

the repainted area


P-8. Clean Tools & equipment and store them properly

CU-5: Mixing of primer

Surface

P-1. Decide the area where primer Surface is to be applied

P-2. Calculate the amount of primer to be Mixed

P-3. Collect tools / equipment and materials

P-4. Mix it primer Surface & hardener according to manufacturer’s

instructions

P-5. Calibrate the weighing scale at zero

P-6. Pour the primer Surface in to the mixing container according to job

P-7. Pour the hardener in to the container according to manufacture

instruction

P-8. Mix all component properly using a mixing stick

P-9. Clean work place

P-10. Clean tools / equipment and store them properly

CU-6: Primer Surface

application

P-1. Determine the areas Primer Surface to the applied

P-2. Mask the body that need to be protected

P-3. COLLECT tools / equipment and materials

P-4. Check whether the tools / equipment are functioning

P-5. Strain the primer Surface using a strainer according to instruction

P-6. Pour the primer Surface in to the spray gun

P-7. Adjust the air pressure according to instruction

P-8. Adjust the spray gun

P-9. Apply primer Surface according to specified method



CU-7: Drying of primer

Surface From infrared

heater

P-1. Determine the area for drying of primer Surface

P-2. Collect tools / equipment and materials


P-4. Connect the power cable securely

P-5. Adjust the distance of infrared heater between panel

P-6. Adjust the timer of infrared heater according to standard

P-7. Dry the primer Surface according to manufacturer instruction

P-8. Clean and store tools/ equipment and store them securely


K-1. Types of primer Surface

K-2. Mixing of primer Surface

K-3. Types of anticorrosive paints and their properties

K-4. Instructions to be followed when using anticorrosive paints

K-5. Types of infrared heater and drying procedure

K-6. Types of foam and properties

K-7. Instructions for mixing of hardener

K-8. Types of mixing thinner and there use according to temperature

K-9. Instructions on determining application condition

K-10. Types of hardener and there use

K-11. Instructions related to application of primer Surface


Capable of application of scuffing for primer

Capable of decreasing the surface

Capable of applying the paint on the surface


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 Surface

16. Hardener

17. Mixing Thinner

Preform Color Matching & Mixing

Overview


the relevant standards and specifications


CU-1: Decide type of paint to

be applied

P-1. Discuss to decide the customers requirement

P-2. Decide on different types of paint to be applied

P-3. Prepare approximate estimates

P-4. Decide on the type of color

P-5. Decide on the price based on agreement with the customer

CU-2: Measure existing color

of vehicle body

P-1. Decide the area where paint is to be applied

P-2. Select the required tools and equipment

P-3. Take the vehicle to a place with suitable lighting condition

P-4. Keep the color gauge on the vehicle and obtain data

P-5. Get paint prepared and examined from a color matching

CU-3: Match colors to be

applied

P-1. Obtain information about the color to be applied by discussing with

the customer

P-2. Compare the required color with the color card

P-3. Prepare colors by mixing primary colors in different ratios

P-4. Apply paint on a part of the vehicle and compare (by looking at 450

)

CU-4: Mix paint colors

P-1. Select primary color mixtures

P-2. Prepare necessary weighing scale and measuring instruments for

matching colors

P-3. Get color volumes from the computer for matching color

P-4. Mix colors according to volumes to get the required color

P-5. Match colors by applying on another metal sheet before applying it

on the vehicle

P-6. Compare either with color code or with the color of vehicle to check

whether the required color was obtained

P-7. Calculate the volumes of paints to be used Accordingly

P-8. Prepare the required quantities (liters) of paint

P-9. Clean and store the tools and equipment used for mixing

CU-5: Mix component colors

using computer

P-1. Operate color mixing computer at color matching room

P-2. Obtains the available color code or color catalogue number

according to customer’s request

P-3. Enter the color code in the computer and obtain primary colors

ratios

P-4. Measure volume ratios using an electronic weighing machine

P-5. Pour the measured volumes of paint into a clean vessel and stir it

P-6. Compare the prepared mixture with the color to be applied


P-8. Shut down the computer after getting the relevant information

CU-6: Decide basic color

ratios

P-1. Identify clearly the given colors

P-2. Decide the primary colors of which the particular color is made of

P-3. Mix primary colors in different ratios to find the ratio of primary

colors

P-4. Calculate the primary color ratios after it was matched


CU-7: Adjust paint viscosity P-1. Mix paint to be applied using a mixing stick

P-2. Measure the paint using ICI measuring ruler and pour into a clean

vessel

P-3. Measure an equal volume of thinner with the same measuring ruler

and pour into the vessel

P-4. Mix paint and thinner According to manufacture instruction

P-5. Check the viscosity of the mixture using measured volumes of paint

and thinner until the required viscosity was obtained

P-6. clean the used equipment with thinner after obtaining the required

viscosity


K-1. Guideline for shade card, formula chart, color tint guide

K-2. Guide lines to use the color gauge

K-3. Techniques used to match colors

K-4. Guide lines to mix colors manually

K-5. Paint colors and their characteristics

K-6. Guide line to select basic colors and ratios

K-7. Decide quality of paints

K-8. Effects of light conditions in matching colors and color matching light

K-9. Understand basic color, secondary color, and complimentary color

K-10. Identify types of paints using different methods

K-11. Factors to be considered in comparing colors

K-12. Calculate the quantity of paint

K-13. Hints on obtaining the required colors mixing quickly by identifying new colors

K-14. Use of computers for mixing ratio


Capable of decide the paint to be applied

Capable to decide the color ratio

Capable to set paint viscosity


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 Surface

20. Hardener

21. Mixing Thinner

Apply Body Sealer

Overview




CU-1: Scuffing for body

sealing

P-1. Collect tools & equipment for scuffing


P-3. Scuff the area with double action sander use 600 grit sand paper

P-4. Scuff with 600 grit scuffing material in locations where it is

impossible to use a dual action sander

P-5. Scuff the area, as it will be difficult to scuff after applying body

sealer the paint manufacturer


CU-2: Nozzle processing P-1. Collect tools & equipment for nozzle processing


P-3. cut the tip of nozzle according to required shape of the sealer

P-4. cutting both size to form a peak shape

P-5. cutting one side of a peak shape

P-6. Press with pliers

P-7. cut the other side so that it is flat


CU-3: Cleaning & degreasing P-1. Decide on the areas to be clean

P-2. Collect necessary tools & material

P-3. Clean and degrease the surface where body sealer is to be applied

P-4. Blow air across the surface to remove dirt and dust

P-5. Wipe the surface with a shop cloth soaked id degreaser

P-6. Wipe away any dirt or dust with a tack cloth



CU-4: Application of body

sealer


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



K-1. Types and composition of body sealer

K-2. Preparation for body sealer

K-3. Purpose of body sealer application

K-4. Instructions on preparation for application of body sealer

K-5. Relevant details of body sealer

K-6. Guidelines and safety precautions to be followed in the application of body sealer

K-7. Understanding of location and shape of body sealer


Capable of application of body sealer

Capable to process the nozzle


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

Perform Masking

Overview




CU-1: Preparation before

masking

P-1. Determine the area for cleaning & degreasing

P-2. Collect the necessary tools / equipment and materials


P-4. Wipe the area with shop cloth which is socked in degreaser

P-5. Blow air on the surface to dry the degreaser

P-6. Wipe away any dirt or dust with a tack cloth Without applying

pressure

P-7. Clean work area


CU-2: Masking on opening

area

P-1. Collect tools & equipment for masking


P-3. Insert your middle finger into the hole in the roll, pull out the desired

length of tape

P-4. Mask the openings left after fittings are removed

P-5. Make sure that masking tape will not be peeled off by the air

pressure

CU-3: Masking on gaps P-1. Collect tools & equipment for masking


P-3. Mask the gaps between the panels use gap tape

P-4. Pay extra attention to the upper and lower edges when masking the

front and rear door gaps

CU-4: Masking on fitting &

glass

P-1. Collect tools & equipment for masking


P-3. Mask the borders of the fittings last using 18mm masking tape

P-4. Leave a gap the thickness of the paint coat between the panel

surface and the masking tape

P-5. Mask the areas that require fine line tape first

P-6. Mask the glass moldings that come into direct contact with the paint

surface

P-7. After painting, remove the masking tape at a 90-degree angle to the

vehicle’s surface.


K-1. Purpose of masking

K-2. Types of masking tape and masking paper and masking foil

K-3. Use of masking material

K-4. Instructions on preparation for masking

K-5. Relevant details of masking equipment

K-6. Guidelines and safety precautions to be followed in masking procedure


Capable of Appling the masking in different conditions

Capable to Appling the masking on fitting glass


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

Apply Under Coat

Overview




CU-1: Apply undercoats P-1. Collect necessary tools & equipment


P-3. Mask all the body parts of the vehicle except those that were to be

painted

P-4. Mix filler or primer with thinner according to the instructions of the

paint manufacturer

P-5. Measure the viscosity of the mixture According to instruction of the

paint manufacture

P-6. Fill the spray gun with the prepared mixture and start the air

compressor

P-7. Adjust the nozzle of the spray gun and test the uniformity of the

spray

P-8. Start the spray gun and apply the undercoat uniformly follow the

method of application

P-9. Check the under coat was uniformly applied covering all the areas

P-10. Allow it to dry for 15 minutes

P-11. Wash the vessels and equipment used with thinner

CU-2: Apply one pack solid

color paint

P-1. Collect necessary tools & equipment


P-3. Obtain paints and thinner

P-4. Open the can, safely and mix the paint to have a uniform color

P-5. Measure the quantity of paint by putting it into a separate vessel

P-6. Close the can with the remaining paint and keep it air tight

P-7. Mix paint and thinner according to MSDS

P-8. Adjust the air pressure to the required level

P-9. Add paint to the spray gun (to 3/4 of its volume)

P-10. Spray paint by holding the spray gun at the appropriate distance in

accordance with the prescribed method

P-11. Allowing it to dry for the required period


CU-3: Apply two pack metallic

pearl color paint

P-1. obtain the required brands and quantities of 2K metallic pearl color

paint and thinner

P-2. Collect the essential equipment and materials

P-3. Obtain the spray gun 1.2 mm or 1.3 mm nozzle

P-4. Mix the paint homogeneously

P-5. Measure the required quantity of paint with the gauge and put into a

clean vessel

P-6. Measure hardener with the gauge in the required proportion, add to

the vessel of paint and mix

P-7. Measure thinner with the gauge in the required proportion, add it to

the vessel containing paint and hardener and mix

P-8. Prepare the paint mixture according to the instructions of the paint

manufacturer (4 parts of paint, 1 part of hardener and 10% of

thinner).

P-9. Adjust the temperature of the paint booth to the required level

P-10. Fill 3/4 of the spray gun with the paint mixture

P-11. Adjust air pressure to the prescribed level and draw air in through

the air filter

P-12. Apply paint on the vehicle body follow the prescribed method

P-13. Allow to dry the paint


P-15. Keep the painted body/body parts safely for drying

CU-4: Apply two pack solid

color paint

P-1. Prepare the surface to be applied with 2K solid color paint

P-2. Arrange required quantities of paint and thinner

P-3. Collect essential equipment and materials

P-4. Select 1.2 mm or 1.5 mm nozzle spray gun

P-5. Mix the paint well till it was homogeneous

P-6. Measure the required amount of paint with the gauge and put into a

clean vessel

P-7. Measure hardener with the gauge in the required proportion, add to

the vessel of paint and mix

P-8. Measure thinner with the gauge in the required proportion, add it to

the Vessel containing paint and hardener and mix (Viscometer may

be used).

P-9. Maintain the required temperature in the paint booth

P-10. Draw air through the air filter under the prescribed pressure

P-11. 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

P-12. Apply paint on the vehicle body follow the prescribed method

P-13. Check that the painting was in good condition

P-14. Bake the body after bringing the painting booth temperature to the

prescribed level


CU-5: Apply transparent

colored silver paint

P-1. Check the areas well prepared

P-2. Obtain the necessary products

P-3. Collect essential tools and equipment

P-4. Read and understand the instructions/data in the manufacturer’s

information leaflet

P-5. Mix the silver paint well to the first application

P-6. Add the mixed paint to another vessel

P-7. Measure with the gauge the required quantity of thinner and add

P-8. Take the ambient temperature into consideration

P-9. Get air through the air filter under the prescribed pressure

P-10. Add the required amount of paint (about 3/4) to the spray gun

P-11. Adjust the flame of the spray gun(about 3/4)

P-12. Make the spray at the correct distance

P-13. Allow the parts to stand for the required time to dry

P-14. Select the color for the second coat

P-15. Apply the second paint color follow the above steps


CU-6: Apply one pack metallic

pearl color paint

P-1. Take weather conditions into consideration

P-2. Decide on the areas to be painted

P-3. Collect the necessary equipment

P-4. Obtains paint and thinner.

P-5. Mix paint well after opening the can

P-6. Measure the required quantity of paint with the gauge and add it to

aclean vessel

P-7. Add and mix thinner according to the standard proportion

P-8. Draw the required amount of air in through filters

P-9. Filter the mixed one pack metallic pearl color paint

P-10. Add the required quantity of paint (about 3/4) to the spray gun

P-11. Wear the safety gear

P-12. Apply paint in the paint booth,

P-13. Adjust the temperature to suit the paint

P-14. Adjust the flame of the spray gun as required

P-15. Perform spraying by holding the spray gun at the appropriate

distance

P-16. Allow the body to dry for an appropriate period

P-17. Bake the vehicle body well in the paint booth



K-1. The types of fillers and primers used for the binding layer and how they are used

K-2. Preparation of paint for the spray gun

K-3. Types of one pack solid color paints and their qualities

K-4. Instructions on preparation for application of one pack solid color paint

K-5. Relevant details of application method

K-6. Guidelines and safety precautions to be followed in the application of type of paint

K-7. Types of two pack metallic pearl color paints and their basic qualities


Capable of Appling the undercote

Capable to applying one pack solid color paint


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


Apply Final Coats

Overview




CU-1: Perform two tone

painting

P-1. Find out the customers need


P-3. Determine the color to be painted

P-4. Collect necessary equipment and raw material,

P-5. Other sections were covered with masking

P-6. Pour paint into the spray gun and adjust the spray gun & air

pressure

P-7. Apply the main color that had to be applied

P-8. Allow to dry for 24 hours,

P-9. Check again whether the components and areas that need to be

covered were fully covered

P-10. Apply the second color

P-11. Open the top coat tin and mix until a uniform mixture was obtained

P-12. Obtain required thinner

P-13. Measure with a scale and pour top coat into a clean vessel

P-14. Pour thinner to standard ratio and mix

P-15. Obtain standard air of required amount through filters

P-16. Strain (though strainer) the mixed paint

P-17. Pour required amount of top coat into the spray gun

P-18. Wear safety gear

P-19. Adjust the required flame of the spray gun

P-20. Applying the basic colors, cover both colors with top coat

P-21. Clean the used equipment, and surroundings

P-22. Store equipment properly

CU-2: Perform touch up work P-1. Discus about special requirements with the customer

P-2. Determine the sections to be newly painted

P-3. Measure the condition and color of the applied paint

P-4. Gather the necessary raw materials tools and equipment

P-5. Clean the surface of the applied paint in sections that had to be

newly painted

P-6. Prepare the required paint mixture

P-7. Pour paint into the spray gun, provide the necessary air pressure

and adjust the spray gun

P-8. Paint the sections that need to be painted follow safety procedure

P-9. Clean & store tools and equipment at the end of the task

CU-3: Apply one pack paint

with retarder

P-1. Collect necessary equipment and raw materials

P-2. Use retarder type of paint selected for painting according to

weather condition

P-3. Add only 10% of the retarder to the quantity of paint used for

painting and prepare the mixture

P-4. Pour paint into the spray gun, provide necessary air pressure and

adjust the spray gun

P-5. Apply paint with retarder mixture

P-6. Clean and store the used tools and equipment

CU-4: Apply one pack solid

color paint with lacquer

P-1. Decide that there was a suitable weather condition

P-2. Collect necessary tools & equipment and raw materials

P-3. Use lacquer relevant type of paint

P-4. Mix paint and lacquer (1/4 liter of lacquer to be added to 1 liter of

paint)

P-5. Fill paint to 3/4 of spray gun

P-6. Provide required air pressure and adjust the flame

P-7. Apply the mixed paint

P-8. Clean the used tools and equipment and the surroundings

CU-5: Apply mat finish paint P-1. Determine the type of mat finish paint to be painted

P-2. Decide that there was a suitable weather condition

P-3. Collect necessary equipment and raw materials

P-4. Mix paint with mat finish until it was uniform

P-5. Add lacquer and other raw materials to paint according to specified

instructions

P-6. Take required quantity of paint and keep the balance securely

closed

P-7. Fill paint to 3/4th of the spray gun

P-8. Adjust required air pressure and adjust the flame

P-9. Clean the used tools and equipment and the surroundings


K-1. Instructions to be followed when using chemicals

K-2. Points to consider when storing paint, chemicals and equipment

K-3. Aspects to consider in two tone painting

K-4. Hints to identify places with lapses after color painting

K-5. Points to follow when touching up

K-6. Distinguishing characteristics of paints that require use of retarder

K-7. Distinguishing characteristics of paints and retarder

K-8. Points to consider when applying one pack paint with retarder

K-9. Safety required when applying one pack paint with retarder

K-10. Reactions that take place when mixing paints (chemical ratios)

K-11. Characteristics of lacquer and one pack paint and their use

K-12. Points to consider when applying paint and lacquer

K-13. Basic characteristics of mat finish paint

K-14. Point to consider when applying mat finish paint

K-15. Instructions regarding mixing of paints

K-16. Properties of one pack clear lacquer


Capable of performing touchup work

Capable to apply solid color with 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


Perform Polishing to Body Surface

Overview




CU-1: Assess and repair the

paint surface

P-1. Identify the areas to be cut using compound

P-2. Gather the required tools & equipment and materials


P-4. Press the paint coat with a finger to determine whether the surface

is dry enough for compound polishing.

P-5. Use the reflection of a fluorescent light to check the surface

P-6. Wipe any dirt and dust off the panel with a clean shop cloth

P-7. Correcting dirt particle & paint run using a rubber sanding block

P-8. Sand the surface with P1500 – P3000 grit sand paper to produce a

texture with slightly higher depressions and ridges than the original

texture


CU-2: Perform compound

polishing

P-1. Collect tools & equipment and material


P-3. Select suitable materials for cutting

P-4. Mask the fittings on the bordering section and panel edges

P-5. Wipe any dirt and dust off the panel with a clean shop cloth

P-6. Attach the buff pad in the center of the polisher

P-7. Clean the buff pad to remove any foreign particles before use

P-8. Spread the compound without spinning the polisher to prevent

spattering

P-9. Move the polisher so that each pass of the polisher overlaps the

previous pass by 2/3

P-10. Polish the surface using the polishing compounds in order from fine

to ultra-fine

P-11. Eliminate any swirl marks made during the rough polishing process

to produce gloss.

P-12. Use a polisher with a sponge buff pad to perform finish polishing

with ultra-fine polishing compound

P-13. Use the color matching light to check whether there are any

remaining swirl marks

P-14. Clean work place tools & equipment and store them properly

CU-3: Paste body stickers P-1. Decide what to do after consulting the customer

P-2. Decide the parts where stickers have to be pasted

P-3. Gather the required tools, equipment and material

P-4. cut the relevant parts according to required shapes

P-5. Clean those parts with a mixture of water and a kind of shampoo

using a manual spray gun

P-6. Spray shampoo on the side where the sticker was pasted

P-7. Place it / them to fit into the required part

P-8. Spray shampoo outside the sticker

P-9. Removing shampoo, and check the sticker past systematically

without trapping air bubbles


CU-4: Apply wax P-1. Decide the parts to be waxed

P-2. Whether the weather condition was suitable

P-3. Gather the required raw materials

P-4. Remove dust in areas where wax was to be applied

P-5. Apply wax on the required parts

P-6. Use a clean piece of cloth to scrub the wax applied

P-7. Clean the surroundings and store raw materials properly

CU-5: Clean body moldings P-1. Decide the type of beadings to be cleaned

P-2. Gather raw materials used for cleaning

P-3. Clean the beadings with water only or with any detergent

(shampoo)that is not harmful to them

P-4. Clean the beadings and other components without damaging them

P-5. Clean the working area and store raw materials and equipment

properly

CU-6: Clean buffers and tires P-1. Obtain the required raw materials for cleaning

P-2. Wash the buffers and tires to be painted with a detergent (a kind of

shampoo) and clean them

P-3. Remove the stains and dirt using another chemical substance (if

necessary)

P-4. Clean the working area and store materials and equipment

CU-7: Re-fix emblem & logo P-1. Select special points to fix badges

P-2. Gather the required tools / equipment and materials

P-3. Mark the points where the badges were to be fixed

P-4. Bore the relevant points as required

P-5. Paste double side tape on the inner sides of the badges

P-6. Paste the inner sides of the badges with excess tape

P-7. Apply primer paint on the bored holes

P-8. Paste / fix the badges as required

P-9. Tighten the relevant nuts and bolts

P-10. Clean and store the equipment


K-1. The types of detergents used in washing vehicles and the aspects to be considered in using them

K-2. 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

K-3. Different types of wax and their properties

K-4. Aspects to be considered in applying wax

K-5. Different types of stickers and the aspects to be considered in pasting them

K-6. Aspects to be considered in cleaning upholstery, windscreen, glass, body moldings, buffers and

tires

K-7. Aspects to be considered in fixing badges


Capable of applying the wax

Capable to paste body stickers


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


Prepare Paint Work Estimation

Overview




CU-1: Decide work to be done P-1. Determine the customer’s requirements

P-2. Inspect the parts to be repaired

P-3. Determine the amount of work to be done

P-4. Prepare the technical report (job card)

CU-2: Study gathered

information related to

market

P-1. Collect information on price lists for different parts / raw materials

from the market

P-2. Find out work done related to vehicles in the market

P-3. Collect information about present charges for such work

P-4. Collect information about existing charges / payments for essential

services

P-5. Collect information about number of workers employed and level of

work for relevant work in the market

P-6. Study this information in preparing estimates and determine the

cost

CU-3: Calculate overheads P-1. Determine the amount to be spent on electricity

P-2. Determine the amount to be spent on water

P-3. Determine the amount of stationary to be used

P-4. Determine the amount to be spent on equipment and machinery

P-5. Determine the expenditure on buildings and paint booth

P-6. Determine the factory insurance cost

P-7. Determine the expenditure on telephone, computer, typewriter etc.

P-8. Determine the cost of specific tools and equipment

P-9. Determine the cost of floor area of establishment

P-10. Determine the amount spent for dependent workers who do not

participate in the relevant job

P-11. Determine the expenditure on insurance services

P-12. Determine the expenditure on vehicles of the establishment

P-13. Determine the total expenditure Accordingly, did you

determine/Calculate a percentage to be added

CU-4: Calculate material cost P-1. Obtain relevant information from the customer

P-2. Identify the jobs to be done

P-3. Determine the nature / type of raw materials of correct standard

P-4. Determines the raw materials to be expended? (Thinner, paint, filler

tape, Lacquer, water and dry sandpaper etc.)

P-5. Calculate the total cost of raw materials

CU-5: Calculate labor cost P-1. Check the job

P-2. Determine the extent of work relevant to the job

P-3. Determine the time to be spent on the job

P-4. Determine whether specialist assistance was necessary

P-5. Allocate time according to type of workers

P-6. Calculate the cost of an hour according to level of workers

P-7. Calculate the cost of time according to level of workers

P-8. Determine the total cost

CU-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 parts If the body part is to be

imported, calculate the expenditure cost

CU-7: Calculate gross amount P-1. Obtain correct and current data for calculation

P-2. Calculate by adding together overheads, raw material cost, labor

cost and cost of body parts (if any)

P-3. Calculate expenditure on wastage

P-4. Calculate government taxes and other charges relevant to above

basic expenses

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


K-1. Methods to be used for collecting data

K-2. Methods of analyzing data

K-3. Determination of cost of raw material

K-4. Deployment of labor according to jobs

K-5. Calculation of cost of labor per hour

K-6. Financial and institutional rules and regulations

K-7. Salient features about import market

K-8. Methodology about estimation

K-9. Points to consider when preparing a technical report


Capable of calculating the cost of body repair work

Capable to estimate the time consumed in body repair work


S No. Descriptions

1. Calculator

2. Pen Writing Pad

25. Workshop Practice-III AD-324


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.


CU-1: Tune-up Petrol or

Gasoline

“Conventional

Carburetor” Engine

P-1. Inspect the main components of Engine system

P-2. Service/Replace the air cleaner

P-3. Change/service the spark plug specified procedure.

P-4. Adjust valve clearance

P-5. Inspect/Replace/adjust CB Point gap from distributer.

P-6. Adjust/service carburetor specified procedure.

CU-2: Tune-up Petrol or

Gasoline “Electronic

Fuel injection” Engine

P-1. Inspect the main components of EFI system.

P-2. Service/ Replace the air cleaner

P-3. Change/ service the spark plug specified procedure.

P-4. Inspect fuel pressure.

P-5. Use the scanner specified procedure.

CU-3: Service of Mechanical

Fuel injection Diesel

Engine

P-1. Inspect the main components of mechanical fuel injection diesel

engine system.

P-2. Service/Replace the air cleaner

P-3. Change/ service the Glow plug specified procedure.

P-4. Inspect/adjust fuel from fuel injection pump

CU-4: Service of Electronic

Fuel injection Diesel

Engine

P-1. Inspect the main components of EFI system.

P-2. Service/ Replace the air cleaner.

P-3. Use the scanner specified procedure.


K-1. Describes the main components of engine and their functions as following:

Air cleaner, spark plug, Distributer, HT Leads, Carburetor.

K-2. Describe the operational principles of Mechanical and Electrical Fuel pump.

K-3. Describe the operation of different types Fuel injection pump.

K-4. 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)

Perform Periodic Maintenance

Overview

These competency standards designed to enable the learner to understand for periodic maintenance under

the specified procedure in the manual.


CU-1: Service of petrol

Vehicle

P-1. Inspect the performance of main components of vehicle.

P-2. Perform the periodic service of engine according to shop manual.

CU-2: Service of diesel

vehicle

P-3. Inspect the performance of main components of vehicle.

P-4. Perform the periodic service of engine according to shop manual.


K-1. Describe the periodic maintenance schedule of petrol vehicle.

K-2. Describe the periodic maintenance schedule of diesel engine.


Capable to follow the periodic maintenance work of petrol/diesel vehicle.

Capable to locate the non-routine work in the vehicle


S No. Descriptions

1 Vehicle(petrol and diesel)


3 Gas analyzer

4 Scanner


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.


CU-1: Lay-out of work shop P-1. Marks the bay/pit different works.

P-2. Mark the area for storage used oil.

P-3. Mark the area for salvage.

CU-2: Workshop equipment P-1. Mark the place hand tools

P-2. Mark the place of measuring tools

P-3. Mark the place of power tools and equipment


K-1. Describe the lay out function of work shop.

K-2. Describe the importance of lay-out of workshop.

K-3. Describe the importance of lay-out for workshop tools and equipment


Capable prepare layout of workshop bay/pit.

Capable to display the workshop shop tools and equipment.


S No. Descriptions

1 Vehicle

2 Hand tools ,Power Tools ,Measuring Tools

3 Workshop

Prepare Documentation for Automotive workshop

Overview

These competency standards designed to enable the learner understand the documentation of workshop



CU-1: Service department

documentation

P-1. Prepare the job card and time sheet.

P-2. Read the shop manual

P-3. Read the service bulletin

P-4. Read the parts catalog (Manual and e-catalog).

P-5. Prepare the technical report

CU-2: Parts Department

documentation

P-1. Prepare the main stock register

P-2. Prepare the sub store register

P-3. Order the parts through online.


K-1. Describe the importance of shop manual.

K-2. Describe the importance of service bulletin.

K-3. Describe the importance of inventory register.


Capable to read and interpret the shop manual.

Capable to update the inventory control register.

Capable to prepare technical report.


S No. Descriptions

1 Shop manual

2 Parts catalogue

3 Inventory register

Maintain Service Station Equipment

Overview

These competency standards designed to enable the learner to maintain the service station equipment



CU-1: Working with equipment P-1. Operate the hydraulic jack.

P-2. Operate the crane

P-3. Operate the car lift

CU-2: Maintain the equipment P-1. Maintain the hydraulic jack.

P-2. Maintain the crane

P-3. Maintain the car lift


K-1. Describe the importance and operation of hydraulic jack.

K-2. Describe the importance and operation crane.

K-3. Describe the importance and operation of car lift.


Capable to work with the hydraulic jack.

Capable handle the lifting crane.

Capable to operate the toe post car lift.


S No. Descriptions

1 Hydraulic jack.

2 crane

3 car lift

Maintain Emission control system

Overview

These competency standards designed to enable the learner to inspect and replace the components

related to the emission control system under the specified procedure in the manual.


CU-1: Service of exhaust

manifold

P-1. Inspect performance of main components of exhaust manifold


CU-2: Service of Muffler P-1. Inspect the performance of Muffler.


CU-3: Service of catalytic

convertor

P-1. Inspects catalytic converter under the specified procedure.

P-2. Replace the catalytic convertor

CU-4: Service of PCV P-1. Inspect and perform service of positive crankcase ventilation (PCV)

P-2. Inspect the PCV through vacuum pump

P-3. Remove and assemble PCV through engine

P-4. Inspect and perform service of exhaust gas recirculation

system(EGR)

CU-5: Service of EGR Valve P-1. inspect and identify location of exhaust gas recirculation

system(EGR)

P-2. Check the EGR valve operation(vacuum and electric controlled)








Capable identify/service Muffler assembly.

Capable to inspect and replace the catalytic converter.

Capable to inspect and replace the PCV valve.

Capable to inspect and replace the EGR valve.


S No. Descriptions

1 Vehicle


3 Gas analyzer

4 Vacuum pump

Perform Engine Overhauling

Overview

These competency standards designed to enable the learner to perform the engine overhauling of the

petrol diesel engine under the specified procedure.


CU-1: Petrol engine P-1. Remove Engine from Vehicle.

P-2. Remove Auxiliary components from Engine.

P-3. Remove Cylinder Head.

P-4. Dismantle engine block.

P-5. Dismantle cylinder head.

P-6. Clean dismantled parts

P-7. Inspect engine block

P-8. Repair Connecting rod and piston assembly

P-9. Repair valve mechanism

P-10. Repair cylinder Head

P-11. Assembled Cylinder Head

P-12. Assembled Crank Shaft to cylinder block

P-13. Assembled Piston assembly

P-14. Fix piston assembly to the cylinder block

P-15. Mount Cylinder head to the cylinder block

P-16. Set Valve Timing

P-17. Fix Auxiliary Accessories

P-18. Place to the engine vehicle

P-19. Ready to start the engine

P-20. Check performance

CU-2: Diesel engine P-1. Remove Engine from Vehicle.




















CU-3: Motor cycle Engine P-1. Remove Engine from Motorcycle.





















K-1. Describe the importance of engine overhauling.

K-2. Describe the process of engine overhauling.


Capable to overhaul the petrol engine.

Capable to overhaul the diesel engine.

Capable to overhaul the Motor cycle engine.


S No. Descriptions

1 Petrol engine ,diesel engine ,Motorcycle engine


3 Engine overhauling kit

4 Gas analyzer

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.


CU-1: Check and identify

defects / or need for

servicing of the

Automobile Air

Conditioner

P-1. Job card/ estimate traced and vehicle located, and repair/ servicing

initiated.

P-2. Air conditioner switched on and checked the extent of repair/ or

servicing ascertained, according to standard procedures.

P-3. Defects localized and identified using specified test instrument

asper manufacturer’s instructions and standard procedures.

P-4. Equipment / items, material and accessories required for job

CU-2: Repair / or service

refrigerant system of

the Automobile Air

conditioner

P-1. Refrigerant in the system recovered where necessary using

specified recovery equipment following safety procedures.

P-2. 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.

P-3. Evaporator checked visually and pressure tested for leaks / clogs

and serviced / or replaced where necessary.

P-4. Expansion valve checked for proper operation and serviced / or

replaced as necessary.

P-5. Condenser checked visually and pressure tested for leaks / clogs

and serviced / or replaced as necessary using specified test

equipment, adhering to safety practices.

P-6. Cooling / blower fans checked for performance, tested and

serviced/ or replaced as necessary according to manufacturer’s

instructions, adhering to safety practices.

P-7. Filter/receiver driers inspected and replaced as necessary

according to manufacturer’s specifications.

P-8. 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.

P-9. Sight glass, oil separator, gas accumulator checked and replaced

as necessary.

P-10. Refrigerant circuit flushed with specified flushing agent.

P-11. System pressure tested using dry nitrogen and evacuated using

vacuum pump and tested according to specifications

P-12. The recovered refrigerant and the cylinder weighed, and recorded.

P-13. The recovered refrigerant cylinder coupled to the empty cylinder

and to the recycling machine observing standard procedure and

safety practices.

P-14. The recycling machine started up, the process monitored and

proper operation ensured.

P-15. All refrigerant recycled, hoses disconnected and cylinder reweighed

to determine the weight of refrigerant recovered.

P-16. Recycling of all recovered refrigerant ensured.



K-1. Describe construction air condition system.

K-2. Describe construction and working of AC compressor

K-3. State the function of evaporator

K-4. State the function of dryer

K-5. Describe the function condenser.

K-6. Understand and trace the fault of AC system


Capable to service of Car AC.

Perform gas charging and recovery in the Car Ac.


S No Descriptions

1 Vehicle


3 Complete AC service kit

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.


CU-1: Use of dynamometer P-1. Inspect the dynamometer condition

P-2. Attach the dynamometer with engine

P-3. Operate the engine and check its condition.

P-4. Record the data during testing

CU-2: Measure volumetric

efficiency

P-1. Calculate the engine volume

P-2. Measure vacuum pressure

P-3. Measure Air volume

P-4. Induction time


K-1. Describe the dynamometer

K-2. Describe the function of dynamometer.

K-3. 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 Engine


3 Dynamometer


Overview

These competency standards designed to enable the learner to understand International Hydraulic and

Pneumatic Code and Symbols.


CU-1: Hydraulic symbol P-1. Identify the hydraulic symbol.

P-2. Identify the Hydro pneumatic symbol

P-3. Inspect and read different hydraulic circuit diagram.

CU-2: Pneumatic Symbol P-1. Identify the pneumatic symbol.

P-2. Identify the Electro pneumatic symbol

P-3. Inspect and read different pneumatic circuit diagram


K-1. Describe the different hydraulic symbol

K-2. Describe the different hydro pneumatic symbol.

K-3. Describe the pneumatic symbol.

K-4. Describe the different electro pneumatic symbols.


Capable to identify the hydraulic symbol.

Capable to identify the pneumatic symbol.

26. Generic

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


CU-1: Obtain and convey

Workplace information

P-1 Assess the Specific and relevant information from the appropriate

sources

P-2 Convey and gather the information of Effective questioning, active

listening and speaking skills.

P-3 Transfer the information using the appropriate medium and ideas.

P-4 Use appropriate nonverbal communication.

P-5 Identify and follow appropriate lines of communication with

supervisors and colleagues.

P-6 Use the defined workplace procedures for the location and storage

of information.

P-7 Carry out Personal interaction clearly and concisely.

CU-2: Participate in workplace

meetings and

discussions

P-1 Attend the team meetings on time

P-2 Clearly express your own opinions and listen other’s point of view

without interruption.

P-3 Established the protocols in the courteous manner of meeting

inputs with the meeting purpose and Workplace interactions.

P-4 Questions about simple routine workplace procedures and maters

concerning working conditions of employment are asked and

responded to Meetings outcomes are interpreted and implemented

CU-3: Complete relevant work

related documents

P-1 Range of forms relating to conditions of employment are completed

accurately and legibly

P-2 Workplace data is recorded on standard workplace forms and

documents

P-3 Perform the basic mathematical processes that are used for

routine calculations

P-4 Identify the errors in recording information on forms/ documents

and properly acted upon

P-5 Reporting requirements to supervisor are completed according to

organizational guidelines


Describe the following.

K-1 Appropriate sources: Team members, Suppliers, Trade personnel, Local government, Industry

bodies

K-2 Medium: Memorandum, Circular, Notice, Information discussion, Follow-up or verbal, instructions,

Face to face communication.

K-3 Storage: Manual filing system, Computer-based filing system.

K-4 Forms: Personnel forms, telephone message forms, safety reports.

K-5 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

K-6 Protocols: Observing meeting, Compliance with meeting decisions, Obeying meeting instructions

.


Capable convey the message in the specified format.

Capable to record minutes of the meeting

Capable to interpret the work related documents

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


CU-1: Describe team role and

scope

P-1 Identify the role and objective of the team from available sources of

information.

P-2 Identify team parameters, reporting relationships and

responsibilities from team discussions and appropriate external

sources.

CU-2: Identify own role and

responsibility within

team

P-1 Identify the individual role and responsibilities within the team

environment.

P-2 Identify and recognize the roles and responsibility of other team

members.

P-3 Reporting relationships within team and external to team are

identified

CU-3: Work as a team

member

P-1 Effective and appropriate forms of communications used and

interactions undertaken with team members who contribute to

known team activities and objectives

P-2 Effective and appropriate contributions made to complement team

activities and objectives, based on individual skills and

competencies and workplace context

P-3 Observed protocols in reporting using standard operating

procedures

P-4 Contribute to the development of team work plans based on an

understanding of team’s role and objectives and


K-1 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.

K-2 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.

K-3 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.


Capable to demonstrate the team work.

Capable to identify team role and individual task.

Read and Develop Career Professionalism

Overview

This unit covers the knowledge, skills and positive attitudes in promoting career growth and advancement


CU-1: Integrate personal

objectives with

organizational goals

P-1 Personal growth and work plans are pursued towards improving the

qualifications set for the profession

P-2 Maintain the Intra- and interpersonal relationships in the course of

managing oneself based on performance evaluation.

P-3 Demonstrate the commitment to the organization and its goal in the

performance of duties.

CU-2: Set and meet work

priorities

P-1 Competing demands are prioritized to achieve personal, team and

organizational goals and objectives.

P-2 Manage work priorities and commitments in order to utilize the

resources efficiently and effectively.

P-3 Practices along economic use and maintenance of equipment and

facilities are followed as per established procedures

CU-3: Maintain professional

growth and

development

P-1 Identify the trainings and career opportunities and avail on the

bases of job requirements.

P-2 Recognitions are sought/received and demonstrated as proof of

career advancement

P-3 Obtained and renewed the licenses and/or certifications relevant to

job and career.


K-1 Evaluation: Performance Appraisal, Psychological Profile, Aptitude Tests.

K-2 Resources: Human, Financial, Technology, Hardware, Software

K-3 Trainings and career opportunities: Participation in training programs, Technical, Supervisory,

Managerial, Continuing Education, Serving as Resource Persons in conferences and workshops.

K-4 Recognitions: Recommendations, Citations, Certificate of Appreciations, Commendations,

Awards, Tangible and Intangible Rewards.

K-5 Licenses and/or certifications: National Certificates, Certificate of Competency, Support Level

Licenses, Professional Licenses


Capable to identify the personal objective

Capable to demonstrate the positive attitude towards work.

Capable to identify the professional growth

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


CU-1: Identify hazards and

risks

P-1 Identify the safety regulations and workplace safety and hazard

control practices and procedures are clarified and explained based

on organization procedures

P-2 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.

P-3 Contingency measures during workplace accidents, fire and other

emergencies are recognized and established in accordance with

organization procedures

CU-2: Evaluate hazards and

risks

P-1 Identify the terms of maximum tolerable limits which when

exceeded will result in harm or damage are identified based on

threshold limit values (TLV)

P-2 Identify the effects of the hazards.

P-3 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.

CU-3: Control hazards and

risks

P-1 Identify the occupational Health and Safety (OHS) procedures for

controlling hazards/risks in workplace are consistently followed

P-2 Procedures for dealing with workplace accidents, fire and

emergencies are followed in accordance with organization OHS

policies

P-3 Use of Personal protective equipment (PPE) in accordance with

organization OHS procedures and practices.

P-4 Provide the appropriate assistance in the event of a workplace

emergency in accordance with established organization protocol.

CU-4: Maintain OHS

awareness

P-1 Practice the emergency-related drills and trainings as per

established organization guidelines and procedures.

P-2 Update and complete the OHS personal records in accordance with

workplace requirements.


K-1 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.

K-2 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.

K-3 Contingency measures: May include but are not limited to: Evacuation, Isolation,

Decontamination, (Calling designed) emergency personnel.

K-4 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.

K-5 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.

K-6 OHS personal records: Medical/Health records, Incident reports, Accident reports, OHS-related

training completed..


Capable to identify the workplace hazards.

Capable to control the hazards

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.


CU-1: Provide team

leadership

P-1 Identify the work requirements and present it to team members

P-2 Communicate the reasons for instructions and requirements to

team members.

P-3 Deal with the team members and discuss the queries and

concerns.

CU-2: Assign responsibilities P-1 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

P-2 Identify the duties are allocated having regard to individual

preference, domestic and personal considerations, whenever

possible

CU-3: Set performance

expectations for team

members

P-1 Understand the performance expectations are established based

on client needs and according to assignment requirements

P-2 Demonstrate the Performance expectations are based on individual

team members duties and area of responsibility

P-3 Demonstrate Performance expectations are discussed and

disseminated to individual team members

CU-4: Supervised team

performance

P-1 Demonstrate the monitoring of performance takes place against

defined Performance Criteria and/or assignment instructions and

corrective action taken.

P-2 Provide a feedback by the Team members, positive support and

advice on strategies to overcome any deficiencies

P-3 Identify the performance issues which cannot be rectified or

addressed within the team are referenced to appropriate personnel

according to employer policy

P-4 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

P-5 satisfaction

P-6 identify the team operations are monitored to ensure that

employer/client needs and requirements are met

P-7 Follow-up communication is provided on all issues affecting the

team

P-8 Identify the all relevant documentation is completed in accordance

with company procedures


K-1 Work requirements: Client Profile, Assignment instructions.

K-2 Team member’s concerns: Roster/shift details.

K-3 Monitor performance: Formal process, Informal process.

K-4 Feedback: Formal process, Informal process.

K-5 Performance issues: Work output, Work quality, Team participation, Compliance with workplace

protocols, Safety, customer service.


Capable to demonstrate the leadership qualities.

Capable to set the expectations of the team

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.


CU-1: Plan negotiations P-1 Identify the Information on preparing for negotiation and included in

the plan.

P-2 Perform positive negotiating and create Information of nonverbal

environments and included in the plan.

P-3 Identify the information on active listening is identified and included

in the plan

P-4 Identify the information on different questioning techniques and

included in the plan

P-5 Check the Information to ensure it is correct and up-to- date.

CU-2: Participate in

negotiations

P-1 Identify the criteria for successful outcome are agreed upon by all

parties

P-2 Considered Appropriate language is used on desired outcome of all

parties throughout the negotiation.

P-3 Use a variety of questioning techniques are used The issues and

processes are documented and agreed upon by all parties

P-4 Assess possible solutions that are discussed and their viability.

P-5 Identify the areas for agreement is confirmed and recorded Follow-

up action is agreed upon by all parties.


K-1 Preparing for negotiation: Background information on other parties to the

K-2 Negotiation: Good understanding of topic to be negotiated, Clear understanding of desired

outcome/s,

K-3 Personal attributes, (self-awareness, self-esteem, objectivity, empathy, respect for others)

K-4 Interpersonal skills, (listening/reflecting, nonverbal communication, assertiveness, behavior

labeling, testing understanding, seeking information, self-disclosing

K-5 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.

K-6 Nonverbal environments: Friendly reception, Warm and welcoming room, Refreshments offered,

Lead in conversation before negotiation begins.

K-7 Active listening: Attentive, Don’t interrupt, Good posture, Maintain eye contact, Reflective

listening.

K-8 Questioning techniques: Direct, Indirect, Open-ended


Capable to negotiate.

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.


CU-1: Identify the problem P-1 Identify the Variances from normal operating parameters; and

product quality Extent,

P-2 Identify the cause and nature are of the problem are defined

through observation, investigation and analytical techniques

P-3 Demonstrate the Problems are clearly stated and specified

CU-2: Determine fundamental

causes of the problem

P-1 Identify the Possible causes that are based on experience and the

use of problem solving tools / analytical techniques.

P-2 Develop possible cause statements based on findings

P-3 Identify the fundamental causes as per results of investigation

conducted.

CU-3: Determine corrective

action

P-1 Report on recommendations are prepared

P-2 Recommendations are presented to appropriate personnel.

P-3 Recommendations are followed-up, if required


K-1 Analytical techniques: Brainstorming, Intuitions/Logic, Cause and effect diagrams, Pareto

analysis, SWOT analysis, Gant chart, Pert CPM and graphs, Scatter grams.

K-2 Problem: Non – routine process and quality problems, Equipment selection, availability and

failure, Teamwork and work allocation problem, Safety and emergency situations and incidents.

K-3 Action plans: Priority requirements, Measurable objectives, Resource requirements, Timelines,

Co-ordination and feedback requirements, Safety requirements, Risk assessment, Environmental

requirements

.


Capable to identify the work related problems

Capable to determine the corrective action.

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)


CU-1: Writing Skills The user/ individual on job needs to know and understand how to:

P-1. Document instructions, itinerary and task lists

P-2. Maintain documents and reports pertaining to security operations,

emergency response, personnel and equipment

P-3. Document activities and incidents in a chronological order

P-4. Write letters/ memos, feedback and reports

P-5. Use computers to generate Management Information System

(MIS), emails and other reports

P-6. Write in English and at least in one vernacular language

proficiently

CU-2: Speaking and

Listening Skills

The user/ individual on job needs to know and understand how to:

P-1. Read and assimilate organizational procedures, site and security

instructions, and correspondence, as applicable

P-2. 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:

P-3. Speak clearly and emphatically

P-4. Receive briefings and instructions from superiors and ask queries

P-5. Brief and instruct subordinates and receive debriefings

P-6. Reply to the queries from stakeholders

P-7. Ask questions from visitors

P-8. Raise alarm/ make announcements/ speak over phone/ radio

CU-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:

P-1. Plan security operations as per site instructions and resources

available assess and assign tasks to teams and individuals

P-2. Conduct training, rehearsals and mock drills customer Centricity

The user/individual on the job needs to know and understand how

to:

P-3. Manage relationships with stakeholders and visitors Problem

Solving The user/individual on the job needs to know and

understand how to:

P-4. Think through the problem, evaluate the possible solution(s) and

adopt a best possible solution(s)

P-5. Handle disruption in security operations Analytical Thinking The

user/individual on the job needs to know and understand how to:

P-6. Anticipate and identify potential risk and threats and take suitable

actions

P-7. Observe people, activities and movements keenly Critical

Thinking The user/individual on the job needs to know and

understand how to:

P-8. Analyze and evaluate a situation and available information to take

appropriate action








requirements


Capable to know the writing skills

Capable to know the speaking skills.

Capable to know the professional skills

Develop Administrative Skills

Overview:

The user/ individual on the job need to know and understand how to develop administrative skills.


CU-1: Decision making P-1. Perform decisions pertaining to security operations, training and

administration

P-2. Perform emergency situations

CU-2: Make Plan and

Organize the

workshop

The user/individual on job needs to know and understand how to:

P-1. Plan security operations as per site instructions and resources

available assess and assign tasks to teams and individuals

P-2. Conduct training, rehearsals and mock drills

P-3. Manage relationships with stakeholders and visitors

CU-3: Evaluate the possible

solution

P-1. Think through the problem, evaluate the possible solution(s) and

adopt a best possible solution(s)

P-2. Handle disruption in security operations

P-3. Anticipate and identify potential risk and threats and take suitable

actions

P-4. Observe people, activities and movements keenly

P-5. Analyze and evaluate a situation and available information to take

appropriate action








requirements

.


Capable to make a decision pertaining to the security operations

Capable to observe the people and evaluate the possible solution


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.


CU-1: Work within

organizational

requirements.

You must be able to:

P-1. Identify and read organization’s requirements and responsibilities

and seek advice from appropriate people where necessary.

P-2. Interpret staff rosters and provide sufficient notice of unavailability

for rostered hours according to workplace policy and procedures.

P-3. Develop and use a current working knowledge and understanding

of employee and employer rights and responsibilities.

P-4. Comply with relevant duty of care and legal responsibilities, and

support organizational culture.

P-5. Identify roles and responsibilities of colleagues and immediate

supervisors.

P-6. Identify standards and values considered to be detrimental to the

Organisation and communicate this through appropriate channels.

P-7. Identify, recognise and follow behaviour that contributes to a safe

and sustainable work environment.

CU-2: Support the work

team.


P-1. Display courteous and helpful behaviour at all times.

P-2. Take opportunities to enhance the level of assistance offered to

colleagues and meet all reasonable requests for assistance within

acceptable workplace timeframes.

P-3. Complete allocated tasks as required.

P-4. Seek assistance when difficulties arise.

P-5. Use questioning techniques to clarify instructions or responsibilities.

P-6. Identify and display a non-discriminatory attitude in all contacts with

customers and other staff members.

CU-3: Maintain personal

Presentation.


P-1. Observe appropriate dress code and presentation as required by

the workplace, job role and level of customer contact.

P-2. Follow personal hygiene procedures according to organizational

policy and relevant legislation.

CU-4: Develop effective

work habits.


P-1. Interpret, confirm and act on workplace information, instructions

and procedures relevant to the particular task.

P-2. Ask questions to seek and clarify workplace information.

P-3. Plan and organize daily work routine within the scope of the job

role.

P-4. Priorities and complete tasks according to required timeframes.

P-5. Identify work and personal priorities and achieve a balance

between competing priorities

CU-5: Portray ethical

behavior


P-1. Follow ethical code of conduct.

P-2. Understand your costumer’s code of ethics.

P-3. Declare conflict of interest.

P-4. Maintain confidentiality.

P-5. Honour your commitments (timeframe, deliverables etc.)

P-6. Use internet for business only on company time.

CU-6: Acquire up to date

product / service

Knowledge


P-1. Gather information about your product / services.

P-2. Identify the components of your product and services.

P-3. Recognize the essential selling features of your products and

services.

P-4. Translate all essential features of your product and services.

P-5. Analyze product success.

P-6. Identify your market position.

P-7. Familiar with all product promotions, sales manuals and product

Literature.

P-8. Keep information of latest technology advances and seek ways to

use these technologies in your work.


K-1. Define industry awards and agreements that relate to personal job role and terms and conditions of

employment.

K-2. Differentiate between employer and employee responsibilities.

K-3. Explain different relevant legislation and statutory requirements.

K-4. Explain the importance of team work

K-5. Define workplace relations

K-6. 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.

K-7. Explain hygiene and personal presentation

K-8. Explain the importance of workplace ethics.

K-9. Explain staff counseling and disciplinary procedures

K-10. Describe workplace organizational structure

K-11. Explain the importance of ethical behavior.

K-12. Explain the importance of commitment in sales and customer services

K-13. Explain:

a. Price per product.

b. Profit per product /service.

c. Price flection

d. Product strengths

e. Product weaknesses.

f. Warranty / guarantee policies.

g. Packaging facilities and potential.

K-14. Explain how your product/service fits into your customers overall operations, business plan, sales

success, operation cost etc.








requirements


Capable to present oneself effectively in front of audience.

Capable to portray the ethical behavior

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.


CU-1: Create a personal

vision / mission You must be able to:

P-1. Clarify / prioritize self-values and consider the value of others.

P-2. Clarify expectations of yourself and expectations others have of you.

P-3. Identify what you need to do to be successful (personal standards,

targets, goals, principals)

P-4. Set specific short and long term goals.

P-5. Translate the vision into actionable steps.

P-6. Integrate the vision into daily practice.

P-7. Recount frequently with your vision and change accordingly.

CU-2: Manage your

attitude You must be able to:

P-1. Challenge yourself, break old habits, and move out of your comfort

zone.

P-2. Practice innovative techniques for out of the box creative thinking.

P-3. Seek out support and feedback from others on the team, in the

organization / community etc.

P-4. Identify daily, weekly accomplishments.

P-5. Read inspirational material, audiotapes etc.

CU-3: Practice self-

discipline You must be able to:

P-1. Accountable for your performance.

P-2. Identify what you need to do to be successful.

P-3. Communicate your priorities to others.

P-4. Make and honour appointments with yourself and others.

P-5. Practice relaxation and energizing techniques.

CU-4: Manage time You must be able to:

P-1. Isolate key success activities and prioritize them.

P-2. Breakdown large tasks down into manageable action steps (set time

frame).

P-3. Create or adopt action plans and follow it.

P-4. Set aside appropriate blocks of time for goal related activities.

P-5. Make the best possible use of support people / recourses to

accomplish tasks.

CU-5: Manage your

professional

development


P-1. Take inventory of your personal interests, abilities, skills, knowledge

etc.

P-2. Identify and prioritize the strengths and gaps.

P-3. Use available assessment tools.

P-4. Create a personal growth strategy / career path.

P-5. Set personal goals and timeframe for achieving them.

P-6. Learn from your mistakes.

CU-6: Participate in

trainings and

performance review


P-1. Analyze, evaluate and improve performance, and report significant

issues/problems to senior management

P-2. Demonstrate to-do attitude in profession

P-3. Demonstrate understanding of skills requirements

P-4. Use the competences acquired in trainings

Understand and Knowledge:

K-1. Explain long and short term goals.

K-2. Explain why personal vision and mission is important for success.

K-3. Describe the advantages of personal vision and mission.

K-4. Explain the importance of personal and professional motivation

K-5. Identify your positive attitude.

K-6. Explain the advantages of innovative ideas and techniques during job.

K-7. Explain the importance of communication.

K-8. Explain the advantages of self-discipline.

K-9. Explain the importance of time management to achieve different tasks.

K-10. Explain the importance and need of professional development.

K-11. Define concept about performance standards.

K-12. Explain policies, procedures and regulations regarding human resources of the organization.

K-13. Explain self-planning and management techniques.

K-14. Define goals and strategies of self- development.

K-15. Explain relevant knowledge about training / job requirements.


Capable to identify the personal vision in the professional career.

Capable to identify the mission statement in the professional career.

Capable to adopt the positive attitude.

27. Entrepreneur

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.


CU-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

CU-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

CU-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

CU-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

CU-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:



K-1. Reporting procedures

K-2. Category of authorized people/ people debarred entry

K-3. Types of identity/ authorization documents in use

K-4. Areas within the premises having restricted/ controlled entry

K-5. Details of unauthorized/ prohibited items

K-6. Action to be taken in case of recovery of unauthorized/ prohibited items

K-7. Procedure for receipt of postal mail and couriers

K-8. Action to be taken in case of delivery of a suspicious package

K-9. Method of securing and storing letters and packages

K-10. Methods and techniques adopted by miscreants to defeat security measures and equipment

K-11. Knowledge of security equipment installed in the premises

K-12. Capability and limitations of the security equipment in use

K-13. Understanding of signals emanating from equipment

K-14. Common faults occurring in the equipment

K-15. Procedure re for carrying out operations manually, in case of equipment failure

K-16. Indications regarding suspicious packages

K-17. Items that cannot be put through screening and search equipment

K-18. Procedure for vehicle search

K-19. Personal protective gear required for security operations

K-20. Layout of the parking areas and traffic plan in the premises

K-21. Suitability of prevailing conditions for parking

K-22. Traffic signals, signage and markings

K-23. Category of vehicles

K-24. Untoward situations faced during security operations

K-25. Procedure for dealing with untoward situations


Capable to identify the resources.

Capable to assess the risk.

Capable to control entry and exit record from the firm.

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.


CU-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

CU-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




K-1. Category of authorized people/ people debarred entry

K-2. Types of identity/ authorization documents in use

K-3. Areas within the premises having restricted/ controlled entry

K-4. Details of unauthorized/ prohibited items

K-5. Action to be taken in case of recovery of unauthorized/ prohibited items

K-6. Procedure for receipt of postal mail and couriers

K-7. Action to be taken in case of delivery of a suspicious package

K-8. Method of securing and storing letters and packages

K-9. Methods and techniques adopted by miscreants to defeat security measures and equipment

K-10. Knowledge of security equipment installed in the premises

K-11. Capability and limitations of the security equipment in use

K-12. Understanding of signals emanating from equipment

K-13. Common faults occurring in the equipment

K-14. Procedure re for carrying out operations manually, in case of equipment failure

K-15. Indications regarding suspicious packages

K-16. Items that cannot be put through screening and search equipment

K-17. Procedure for vehicle search

K-18. Personal protective gear required for security operations

K-19. Layout of the parking areas and traffic plan in the premises

K-20. Suitability of prevailing conditions for parking

K-21. Traffic signals, signage and markings

K-22. Category of vehicles

K-23. Untoward situations faced during security operations

K-24. Procedure for dealing with untoward situations


Capable to identify the training requirement for self-grooming

Capable to plan the trainings schedule.

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.


CU-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

CU-2: Administer a

workshop/bay Unit

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




K-1. The site instruction

K-2. Details of personnel and equipment required

K-3. Channel of reporting and communication with stakeholders Stake holders: Principal employer,

superior, own management, subordinates, visitors and residents/tenants

K-4. Contact details of stakeholders, superiors and team members

K-5. Documentation formats

K-6. Reporting procedure

K-7. Organizational standards on grooming, conduct, behavior and performance

K-8. Leadership and management fundamentals Leadership: Administration, discipline, motivation,

impartiality, punctuality, concern for subordinates, welfare and leading by example

K-9. Organizational protocol for resolution of concerns/ grievances

K-10. Management information system

K-11. Performance management system

K-12. Compensation management

K-13. Accounting and issue procedure for stores, material and equipment


Capable to control the workshop operations.

Capable to follow the administrative SOP’s

Capable to handle the administrative issues.

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.


CU-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

CU-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




K-1. Standard operating procedures of the organization for appraisals, incentives, promotions and

performance evaluation.

K-2. Standard operating procedures for query and problem reporting and their redressal in the

organization

K-3. Framework and guidelines prescribed by the organization for query and problem redressal

K-4. Framework and guidelines prescribed by the organization for performance evaluations and based

appraisals out of it

K-5. Documentation requirements for each procedure carried out as part of roles and responsibilities

K-6. Institutional and professional code of ethics and standards of practice

K-7. Safety and health policies and regulations for the workplace.


Capable to supervise the team members.

Capable to evaluate the performance of employee.

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.


CU-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

CU-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




K-1. The organization’s policies, procedures and priorities for area of work, role and responsibilities in

carrying out that work

K-2. The limits of responsibilities and when to involve others

K-3. Specific work requirements and who these must be agreed with

K-4. The importance of having a tidy work area and how to do this

K-5. How to prioritize workload according to urgency and importance and the benefits of this

K-6. The organization’s policies and procedures for dealing with confidential information and the

importance of complying with these

K-7. The purpose of keeping others updated with the progress of work

K-8. Who to obtain guidance from and the typical circumstances when this may be required

K-9. The purpose and value of being flexible and adapting work plans


Capable to set the quality standards.

Capable to implement on the quality standards.

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.


CU-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 non-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

CU-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.




K-1. The organization’s policies and procedures for working with colleagues, role and responsibilities in

relation to this

K-2. The importance of effective communication and establishing good working relationships with

colleagues

K-3. Different methods of communication and the circumstances in which it is appropriate to use these

K-4. The importance of creating an environment of trust and mutual respect

K-5. The implications of own work on the work and schedule of others.


Capable to interact with the team effectively.

Capable to communicate with other stake holders

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.


CU-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




K-1. The organization’s policies and procedures for working with colleagues, role and responsibilities in

relation to this

K-2. The importance of effective communication and establishing good working relationships with

colleagues

K-3. Different methods of communication and the circumstances in which it is appropriate to use these

K-4. The importance of creating an environment of trust and mutual respect

K-5. The implications of own work on the work and schedule of others.


Capable work under the safe working environment.

Deal with Emergencies and Incidents at Workshop

Overview

This Competency Standard identifies the competencies required to deal with emergencies and incidents at

workshop. You’re underpinning knowledge regarding to deal with emergencies and incidents at workshop

will be sufficient to provide the basis for this task.


CU-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

CU-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.




K-1. Policy/ procedures/ guidelines related to workplace health and safety

K-2. Responsibilities of the security function related to health and safety

K-3. Limits and responsibilities of the security unit

K-4. Organizational procedure for handling different levels of risks

K-5. Reporting protocol for health and safety matters

K-6. Communication protocol

K-7. Documentation formats and reports to be maintained The seer/individual on the job needs to know

and understand:

K-8. Organizational procedures relating to communication

K-9. Details of stakeholders/ concerned agencies

K-10. Means of available communication

K-11. Details of security functions that need employers’ approval

K-12. Format and process for obtaining feedback Format: Written and electronic

K-13. Organization’s standards of communication, behavior and courtesy

K-14. Resolution process for queries/ complaints of stakeholders

K-15. Communication etiquette to be followed by the security unit

K-16. Gender, cultural, religious and other sensitivities

K-17. Organizational procedure for recording and sharing of information

K-18. Timelines and periodicity for submission of reports/ documentation. Documentation: Relating to

operations, training and administration

K-19. Frequency for reviewing records maintained by security unit

K-20. Storage and archival policy/ processes followed by the organization

K-21. Details of stakeholders/ agencies authorized to receive information


Capable to deal in the emergency condition.

Capable to maintain the safe working condition

Maintain Effective Communication with Companies

Overview

This Competency Standard identifies the competencies required to maintain effective communication with

the companies. Your underpinning knowledge regarding effective communication with the companies/

dealers and also carry out the review role-related documentation will be sufficient to provide the basis for

this task.


CU-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

CU-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




K-1. Organizational procedures relating to communication



K-4. Details of security functions that need employers’ approval



K-7. Resolution process for queries/ complaints of stakeholders

K-8. Communication etiquette to be followed by the security unit





K-12. Frequency for reviewing records maintained by security unit


K-14. Details of stakeholders/ agencies authorized to receive information.


Capable to communicate effectively with the other stakeholders.

Capable to communicate effectively with in the departments

Compliance and certifications (IATF/ISO 16949, ISO 9001:2015, ISO 50001)

Overview

This Competency Standard identifies the competencies required to identify and understand the local and

international compliance regime for automotive component manufacturing supply chain. Your underpinning

knowledge regarding effective communication with the auto parts manufacturers and also carry out the

review role-related documentation will be sufficient to provide the basis for this task.


CU-1. Identify sector specific

compliance requirements

(national/international)

(e.g. IATF/ISO 1649, ISO

9001:2015, ISO 50001)

P1. Identify sector specific certifications (national/international)

P2. Identify business development service providers to acquire

sector specific certifications (local/international)

CU-2. Understand requirements for

compliances

(local/international)

P1. Understand requirements to acquire certifications (HR,

material, equipment, etc)

P2. Plan under supervision of management/experts for

acquisition of certifications (local/international)

P3. Implement planned activities to acquire certifications

P4. Forward report/ feedback to designated superior

P5. Share information with authorized stakeholders on a ‘need-

to-know’ basis

P6. Maintain security and confidentiality of information




K-1. Identify sector specific compliances certifications/standards (local/international)





K-6. Able to plan for acquisition of compliances






K-11. Details of stakeholders/ agencies authorized to receive information.


Capable to identify the compliance regime (local/international).

Capable to understand and implement the activities to acquire certifications/standards

(local/international)

Islamabad 31st May, 2019

NOTIFICATION

No. F. 5(13)/2018-DD (TE): In pursuance of sub-section (d) of section-6" Functions of the Commission"

National Vocational & Technical Training Commission (NAVTTC) Act-2011, NAVTTC is pleased to

approve and notify following qualifications in twenty (20) trades for Level 1-5 under National

Vocational Qualification Framework (NVQF), which have been developed in compatibility with latest

global trends in the fields and fulfilling requirements of competency based training and assessment

(CBT&A) system. The qualifications have been developed and validated in collaboration with

TEVTAs, QABs, industry and other relevant stakeholders: -

S# National Vocational Qualifications

1. National Qualification Level-5 diploma in Automobile Technology

2. National Qualification Level-5 diploma in Civil Technology

3. National Qualification Level-5 diploma in Construction Technology

4. National Qualification Level-5 diploma in Information & Commutation Technology (ICT)

5. National Qualification Level-5 diploma in Garment Manufacturing Technology

6. National Qualification Level-5 diploma in Electrical Technology

7. National Qualification Level-5 diploma in Electronics Technology

8. National Qualification Level-5 diploma in Instrumentation Technology

9. National Qualification Level-5 diploma in Computer Aided Design & Manufacturing (CAD /CAM)

10. National Qualification Level-5 diploma in Mechanical Technology

11. National Qualification Level-5 diploma in Graphics Designing

12. National Qualification Level-5 diploma in Heating, Ventilation, Air-conditioning & Refrigeration

(HVACR) Technology

13. National Qualification Level-5 diploma in Media Production

14. National Qualification Level-5 diploma in Hotel Management

15. National Qualification Level-5 diploma in Professional Chef

16. National Qualification Level-5 diploma in Tourism Management

17. National Qualification Level-5 diploma in Hair & Beauty Services

18. National Qualification Level-5 diploma in Fashion Designing

19. National Qualification Level-5 diploma in Ceramics Technology

20. National Qualification Level-5 diploma in Telecom Technology

2. All the TVET related institutions / organizations are required to implement aforementioned

qualifications so that a uniform and standardized TVET qualification system is established in

Pakistan and efforts are made for international equivalence / recognition of these qualifications.

3. Competency Standards of the above enlisted qualifications can be accessed at NAVTTC's website

(www.navttc.org).

(Muqeem Islam)

Director General (Skill Standards & Curricula)

Phone: 051-9215385

Distribution:

1. Federal Secretary, Ministry of Federal Education & Professional Training, Govt of Pakistan

2. Federal Secretary, Ministry of Overseas Pakistanis and Human Resource Development, Govt of

Pakistan, Islamabad

3. Federal Secretary, Ministry of Industry and Production, Govt of Pakistan, Islamabad

4. Federal Secretary, Ministry of Textile Industry, Govt of Pakistan, Islamabad

5. Federal Secretary, Ministry of Commerce, Govt of Pakistan, Islamabad

6. Federal Secretary, Ministry of Railway, Govt of Pakistan, Islamabad

7. Federal Secretary, Ministry of Climate Change, Govt of Pakistan, Islamabad

8. Federal Secretary, Ministry of Religious Affairs, Govt of Pakistan, Islamabad

9. Federal Secretary, Ministry of Communication, Govt of Pakistan, Islamabad

10. Federal Secretary, Ministry of Aviation Division, Govt of Pakistan, Islamabad

11. Federal Secretary, Ministry of Science & Technology, Govt of Pakistan, Islamabad

12. Chairperson, Punjab Technical Education and Vocational Training Authority (P-TEVTA), Lahore

13. Managing Director, Khyber Pakhtunkhwa Technical Education and Vocational Training Authority (KP-

TEVTA),

14. Managing Director, Sindh Technical Education and Vocational Training Authority (S-TEVTA), Karachi

15. Chairman, Azad Jammu & Kashmir, Technical Education and Vocational Training Authority (AJ&K

TEVTA), Muzafarabad

16. Director TVET Cell, Gilgit Baltistan, Gilgit

17. Director General, Punjab Vocational Training Council (PVTC), Punjab

18. Managing Director, Technology Upgradation and Skill Development Company (TUSDEC) Lahore

19. Project Director, Punjab Skill Development Program (PSDP) Lahore

20. CEO, Punjab Skill Development Fund, Lahore

21. Rector, UNTECH University Islamabad

22. National Deputy Leader, GIZ Islamabad

23. PS to Minister of Federal Education & Professional Training, Govt of Pakistan

24. PS to Special Adviser to the Prime Minister on Youth Affairs, Prime Minister's Office, Islamabad

25. Chairperson, Federal of Pakistan Chamber of Commerce and Industry (FPCCI), Karachi

26. Conveyor, Sector Skills Council (Textile/ Construction/ Renewable Energy/ Hospitality and Tourism)

27. Director Technical Education and Vocational Training Authorities (TEVTA), Balochistan

28. Chairman, Pakistan Tourism Development Corporation, Lahore

29. Chairman, PCSIR Headquarters, Islamabad

30. Director General, Pakistan Forest Institute, Peshawar

31. Chairman, Wafaq ul Madaris, Multan

32. Director General, Staff Welfare, Islamabad

33. Director General, NISTE Capital Administration and Development Division, Islamabad

34. Director General, National Training Bureau, Islamabad

35. Chairmen, Provincial Technical Education Boards

36. Chairmen, Provincial Trade Testing Boards

37. Secretary, IBCC, Islamabad: with the request that National qualifications of Level 5 diploma in the

aforementioned trades may be considered equivalent to Diploma of Associate Engineer/HSSC after

inclusion of compulsory courses in the light of IBCC general requirement.

Copy for information to: -

http://tusdec.org.pk/

1. DG (P&D)/(A&F)/ (A&C) (S&C) NAVTTC

2. Director General(s), NAVTTC Regional Office(s).

3. Sr. Technical Advisor, TSSP-GIZ

4. Staff Officer to Chairman, NAVTTC

5. PS to Executive Director, NAVTTC Islamabad

6. Concerned File/ Office Copy