Course Curricula for Course Curricula for Short Term Courses based on Short Term Courses based on Modular

Employable Skills (MES) Modular Employable Skills (MES) in in

Automotive Repair Sector

DIRECTORATE GENERAL OF EMPLOYMENT AND TRAINING DIRECTORATE GENERAL OF EMPLOYMENT AND TRAINING MINISTRY OF LABOUR & EMPLOYMENT MINISTRY OF LABOUR & EMPLOYMENT GOVERNMENT OF INDIA GOVERNMENT OF INDIA

Course Curricula for Short Term Courses based on Modular Employable Skills (MES) in the Automotive Repair Sector

CONTENTS

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 30.

Background ................................................................................................................2 Frame Work for Skill Development based on Modular Employable Skills ................2 Age of Participants .....................................................................................................3 Curriculum Development Process ..............................................................................3 Development of Core Competencies .........................................................................3 Duration of the Programmes ......................................................................................4 Pathways to acquire Qualification ..............................................................................4 Methodology ..............................................................................................................5 Instructional Media Packages ....................................................................................5 Assessment ...............................................................................................................5 Certificate ...................................................................................................................5 Course Matrix .............................................................................................................6 Modules ....................................................................................................................7 Basic Automobile Servicing of 2 & 3 Wheeler ............................................................7 Basic Automotive 4 wheeler servicing ........................................................................9 Repair & Overhauling of Mopeds ............................................................................ 11 Repair & Overhauling of Scooters ........................................................................... 13 Repair & Overhauling of Motor Cycles…………………… ..... ……………………….15 Repair & Overhauling of 3 Wheelers ...................................................................... .17 Repair & Overhauling of Engine Systems (Petrol / diesel) ...................................... .19 Repair & Overhauling of Chassis System (Light Vehicle) ....................................... 23 Repair & Overhauling of Chassis System (Heavy Vehicle) ..................................... 27 Repair of Auto Electrical & Electronics Systems ...................................................... 31 Repairing of Auto Air Conditioning System……………………… ...... …………......…34 Wheel alignment & balancing………………………...... …………………...…………..36 Minor repair of Auto body……………………………....... ………………………………38 Auto body Painting…………………………………… ..... …………………………..….41 Diesel Fuel Injection Technician ……………………… ...... ……………………….… 42 Bicycle and Tricycle repair………………………………………………………… .........45 Sun Control Film Fixing…………………………………………………………………..52 Driver cum Peon………………………………………………………………………….56. List of Expert/Trade Committee Members............ ………………………………….….51

1

Skill Development based on Modular Employable Skills (MES)

Background The need for giving emphasis on the Skill Development, especially for the less educated, poor and out of school youth has been highlighted in various forums. The skill level and educational attainment of the work force determines the productivity, income levels as well as the adaptability of the working class in changing environment. Large percentage of population in India is living below poverty line. One of the important causes is lower percentage of skilled persons in the workforce The skill development at present is taking place mostly in the informal way, i.e. persons acquire skill at the work-place when they help their parents, relatives and employers etc. Such persons do not have a formal certificate and thus earn lower wages and are exploited by employers. They have come through informal system due to socio-economic circumstances of the family and the compulsions of earning a livelihood rather than attending a formal course. While their productivity is low, their contribution to the national GDP cannot be ignored. If the country can create a system of certification which not only recognizes their skills but also provides education and training in a mode that suits their economic compulsions, it will not only benefit the workforce to earn a decent living but also contribute to the national economy by better productivity of this workforce. Another related problem to be tackled is large number of students drop outs (About 63% of the school students drop out at different stages before reaching Class-X).

Frame work for Skill Development based on ‘Modular Employable Skills (MES)’ Very few opportunities for skill development are available for the above referred groups (out of school youth & existing workers especially in the informal sector). Most of the existing Skill Development programmes are long term in nature. Poor and less educated persons can not afford long term training programmes due to higher entry qualifications, opportunity cost etc. Therefore, a new frame work for Skill Development for the Informal Sector has been evolved by the DGET to address to the above mentioned problems. The key features of the new frame work for skill development are:  Demand driven Short term training courses based on modular employable skills decided in consultation with Industry  Flexible delivery mechanism (part time, weekends, full time)  Different levels of programmes (Foundation level as well as skill upgradation) to meet demands of various target groups  Central Government will facilitate and promote training while Vocational Training (VT) Providers under the Govt. and Private Sector will provide training  Optimum utilisation of existing infrastructure to make training cost effective.  Testing of skills of trainees by independent assessing bodies who would not be involved in conduct of the training programme, to ensure that it is done impartially.  Testing & certification of prior learning (skills of persons acquired informally)

2

the performance of a person gets adversely affected. vocational training providers and other stake holders is ensured at each stages). It allows skills upgradation. Development of training modules corresponding to skills set identified so as to provide training for specific & fit for purpose Organization of modules in to a Course Matrix indicating vertical and horizontal mobility. Hence. Development of Core Competencies Possession of proper attitudes is one of the most important attribute of a competent person. State Governments. The trainees deal with men. Curriculum Development Process Following procedure is used for developing course curricula • • • • Identification of Employable Skills set in a sector based on division of work in the labour market. Positive attitudes have to be developed in the trainees by properly guiding 3 . They handle sophisticated tools and instruments. Courses could be available from level 1 to level 3 in different vocations depending upon the need of the employer organisations. systematic efforts will be made to develop attitudes during the training programme. multiskilling. The course matrix depicts pictorially relation among various modules. multi entry and exit. The modules in a sector when grouped together could lead to a qualification equivalent to National Trade Certificate or higher. Development of detailed curriculum and vetting by a trade committee and by the NCVT (Close involvement of Employers Organizations.The Short Term courses would be based on „Modular Employable Skills (MES)‟. materials and machines. MES would benefit different target groups like : o Workers seeking certification of their skills acquired informally o workers seeking skill upgradation o early school drop-outs and unemployed o previously child labour and their familly      Age of participants The minimum age limit for persons to take part in the scheme is 14 years but there is no upper age limit. pre requisites for higher level modules and how one can progress from one level to another. experts. It also allows recognition of prior learning (certification of skills acquired informally) effectively. Without proper attitudes. vertical mobility and life long learning opportunities in a flexible manner. The concept for the MES is :  Identification of „minimum skills set‟ which is sufficient to get an employment in the labour market.

Responsibility and accountability 10. Concern for environment and waste disposal Following competencies should also be developed during level-II and higher courses: 1. Ability to bear stress 5. Positive attitude and behavior 9. Concern for health and hygiene 7. Some important core competencies to be developed are: 1. discipline and honesty 4. However. Punctuality. organizing and coordinating 2. Negotiation Duration of the Programmes Time taken to gain the qualification will vary according to the pathway taken and will be kept very flexible for persons with different backgrounds and experience. Or The recognition of prior learning that provides evidence of the achievement of the competencies for the qualification.them and setting up examples of good attitudes by demonstrated behaviors and by the environment provided during training. Leadership 4. Pathways to acquire Qualification: Access to the qualification could be through:    An approved training programme. some persons may take more time than the prescribed time. Respect for rules and regulations 6. Or A combination of an approved training programme plus recognition of prior learning including credit transfer. Learn continously 11. Communication Skills 12. which are based on the content and requirements of a MES Module. They should be provided reasonable time to complete the course. Duration has been prescribed in hours in the curriculum of individual module. Cordial relationship and Cooperation with co-workers and team Work 8. Care of equipment and tools 3. problem solving and decision making 3. Ability for planning. Safety consciousness and safe working practices 2. Concern for quality 5. Creative thinking. 4 .

5 . Lecturing will be restricted to the minimum necessary and emphasis to be given for „hands on training‟. Assessment DGE&T will appoint assessing bodies to assess the competencies of the trained persons. The learning process will be continuously monitored and feedback will be provided on individual basis. will ensure quality of training and credibility of the scheme. more than one assessing bodies will be appointed for a sector or an area. Demonstrations using different models. Keeping in view the target of providing training/testing of one million persons through out the country and to avoid monopoly. This. The assessing body will be an independent agency. instructional media packages (IMPs) will be developed by the National Instructional Media Institute (NIMI). in turn. The training methods will be individual centered to make each person a competent one. Certificate Successful persons will be awarded certificates issued by National Council for Vocational Training (NCVT). The focus of the programme is on “performing” and not on “Knowing”. Opportunities for individual work will be provided. audio visual aids and equipment will be used intensively. Instructional Media Packages In order to maintain quality of training uniformly all over the country.Methodology The training methods to be used should be appropriate to the development of competencies. Chennai. which will not be involved in conducting the training programmes.

.Course Matrix Proposed Course Outline/ Pathway Certificate-II in Automotive Repair (Repair & Overhauling [R&O]) R&O of Engine Systems (petrol/ diesel) R&O of Chassis System (Light vehicle) R&O of Chassis System (Heavy vehicle) Repair of Auto Air conditionin g System Minor repair of Auto body Auto body Painting Repair of Auto Electrical & Electronics Systems Wheel balancin g& alignmen t Diesel Fuel Injection Technici an R&O of R&O of R&O of R&O of 2 2 2 3 wheelers wheelers wheelers wheelers moped Scooter (Motor cycles) Certificate-I in Automotive Repair (Fundamental s and Servicing) Sun Control Film Fixing AUR 117 Basic Automotive Servicing (4 wheelers) Bicycle & Tricycle repair Driver cum peon AUR 118 Basic Automotive Servicing (2-3 wheelers) .

Duration 7. Gearbox & brakes Tyre designation (size) Procedure for repairing the punctured tube 1. gear box & brakes General defects in clutch. do Wheel truing. adjust brake & top-up brake fluid  Adjust clutch play  Adjust. 7 . equipments & clothing safely  Practice 5S technic  Identify / Familiarize with the tools & equipments  Identify components of 2 & 3 wheeler from assembly drawings & diagrams  Water washing / cleaning of 2 & 3 wheelers  Clean/replace air cleaner. inflate. measure tread depth. Check and Adjust spark plug  Replace brake components. COURSE CONTENT: Practical Competencies  Practice Health & Safety – select. cleaning & assembling of major assemblies of vehicle Functions &Types of lubrication & cooling systems Fuel system layouts (Petrol. refit/replace – fuel tank. diesel & CNG) Functions of carburetor and adjustments Ignition system circuit & components Brief introduction on battery and its maintenance Purpose & types of clutch. Entry Qualification 5. Repair tyre puncture & Tuffe-up tube  Check and replace bulbs              Note: -Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle. clean. brake & accelerator cables – adjust clutch & brake plays  Charge the battery  Check pressure. 14 years of Age : Successful candidate would be able to carry out minor repairs and routine servicing of 2 & 3 Wheelers : 180 Hours Underpinning Knowledge (Theory General health & Safety precautions to be observed in the workshop / garage Over view on 5S technic (Sort. fuel pipes. Module name 2. . inspect for damage. Terminal competency 6. use. Code 4. check. Sector 3. fuel tap operation  Clean. maintain & store – tools. remove links & lubricate drive chain  Replace control cables – clutch. fuel strainers and oil filters  Drain & replenish lubricants  Remove.Basic Automobile Servicing of 2 & 3 Wheeler Modules Basic Automobile Servicing of 2 & 3 Wheeler : Basic Automobile Servicing of 2 & 3 Wheeler : Automotive Repair : AUR102 : Minimum 5th Std. Set in order. Standardise & Sustain)-advantages in implementation of 5S Working principle of 2 & 4 stroke engines Procedure for dismantling. Shine / Sweep.

75 mm Spanner.75 to 14.25 mm.75 mm.to read up to 5000 rpm Battery 12 V Vernier Caliper 250 or 200 mm inside. BSF American & metric with handle Drill Twist ( assorted ) Hand vice 37mm Hand reamer adjustable 10. BSW.) Feeler gauge 20 blades (metric) Steel tool box with lock & key (folding type) size 400x200x150mm Allen Key set of 12 pieces (2 mm to 14 mm) 28 29 30 31 32 33 34 35 36 37 38 39 40 Vice grip pliers Circlip pliers Expanding and contracting type 15 cm and 20 cm each Inspection lamp with guard Hollow punch set of seven pieces 6 to 15 mm Spanner off set double ended set of 7 pieces (6 mm -17 mm) Set of 12 nos. T bar and ratchet Oil can 0.8. Spanner for spark plugs 14 mm Spanners socket of 8 with handle. ring offset set of 6 (S A E) Spanner. Spanner D E set of 12 pieces (6mm to 32 mm) Pliers combination 15 cm Hand file 20 cm.18 v Torque wrench 0 – 50Nm Auto Rickshaw chassis of petrol & diesel Carburetors of 2 & 3 wheelers Spark plug cleaner and tester Water pump / Washer Fire Extinguisher Portable electric drill 6 mm Tyre dread depth gauge Tryre Pressure gauge Wheel truing machine Air compressor 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Prick punch 15 cm Scriber 15 cm with scribing block universal Hacksaw frame adjustable for 30 cm blade Taps and Dies complete set in a box BA. 12. Second cut Chisel cold flat 20 mm Ring spanner set of 12 pieces (6 to 32 mm.5 to 11. 11.5 liter cap Cleaning Tray 45 x 30 cm.25 to 15.no Item s. TOOLS & EQUIPMENT( Suggested ) s.25 mm and 14.75 kg Screw driver 20 cm.25 to 12. x 9 mm blade Screw driver 30 cm x 9 mm blade Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm Steel Rule 30 cm.no Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Hammer ball peen 0. adjustable 20 cm. Scooter. outside & depth Hydrometer Drilling machine bench to drill up to 12 mm dia Electric pedestal grinder Latest 2 Wheelers (Moped. Motor Cycle) of different makes along with workshop manuals and special maintenance tools Tyre repair kit Battery charger 6v. Centre punch 10 mm dia x 100 mm Tachometer . Work benches each 250 x 120x60 with 4 bench vices 12 cm jaw 41 42 43 44 45 46 47 48 49 50 51 52 53 8 .

Duration 7. rotate the tyres                      Note: -Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle.T. power steering hydraulic oil. 14 years of Age : Successful candidate would be able to carry out servicing and minor repairs of 4 Wheelers : 180 Hours Underpinning Knowledge (Theory General health & Safety precautions to be observed in the workshop / garage Over view on 5S technic (Sort. Ignition system circuit & components Brief introduction on ignition & injection systems Brief introduction on injectors Purpose of clutch. Shine. tread depth. Module name 2. wind screen wiper water. Check and Adjust spark plug  Adjust Hand brake and replace hand brake cable  Adjust clutch and brake pedal plays  Replace propeller shaft. maintain & store tools. reasons for general tyre defects Procedure for repairing the punctured tube Need & procedure for tyre rotation 6. inflate. manual gearbox Types of Brake & steering systems – working principle of drum and disc brakes General defects in brake systems Brief introduction on battery and its maintenance Tyre designation (size). equipments & clothing safely  Practice 5S technic  Identify / Familiarize with the tools & equipments  Water wash – before & after servicing  Check / replenish / top up – lubricating oil. Sector 3. oil filter & fuel filter  Apply Grease to parts / through greasing points  Remove & refit vehicle body parts (bonnet. Set in order. cables  Clean. brake fluid. front bumper & door)  Remove and refit head lamp assembly  Check power plug and inspect H. engine coolant.1. gear box & differential General defects in clutch. wheel hub bearings & brake pads  Charge the battery  Check Tyre pressure & for defects. 9 . Code 4. Terminal competency : Basic Automotive 4 wheeler servicing : Automotive Repair : AUR101 : Minimum 5th Std . use. battery electrolyte and transmission oil  Clean / replace – air cleaner. Standardise & Sustain)-advantages in implementation of 5S Nomenclature of different parts of vehicle and their locations Working principle of 4 stroke petrol & diesel engines Differences between petrol & diesel engines Lubrication and cooling system & types of lubricants Lay out of greasing points Torquing & detorquing technique / procedures Fuel supply layouts in both petrol & diesel engines Layout of power flow from Engine to wheels. Entry Qualification 5. COURSE CONTENT : Practical Competencies  Practice Health & Safety – select.

5 liter cap Cleaning Tray 45 x 30 cm.(6 mm -17 mm) Set of 12 nos. TOOLS & EQUIPMENTS ( Suggested ) s.75 kg Screw driver 20 cm. Second cut Centre punch 10 mm dia x 100 mm Chisel cold flat 20 mm Ring spanner set of 12 pieces (6 to 32 mm.no Item s. Hollow punch set of seven pieces 6 mm to 15 mm „V‟ Block 75 x 38 mm pair with Clamps Spanner off set double ended set of 7 pieces.) Feeler gauge 20 blades (metric) Steel tool box with lock & key (folding type) size 400x200x150mm .to read upto 5000 rpm Battery 12 V Hydrometer Air compressor Water pump / Washer Fire Extinguisher Tyre repair kit Torque wrench 0 – 50Nm Tryre Pressure gauge Tread depth gauge 10 . Allen Key set of 12 pieces (2 mm to 14 mm) Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm Steel Rule 30 cm. Work bench each 250 x 120x60 with 4 bench vices 12 cm jaw Pullers screw powered 2 mm with bearing puller attachment Vice grip pliers Circlip pliers Expanding and contracting type 15 cm and 20 cm each Inspection lamp with guard and wandering lead of 100 ft. Spark Plug Spanner Different types of Injectors Tachometer . Spanner for spark plugs 14 mm Socket Spanners with handle.no Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Hammer ball peen 0.8. English and metric Prick punch 15 cm Scriber 15 cm with scribing block universal Hacksaw frame adjustable for 30 cm blade Hand vice 37mm Drill Twist ( assorted ) Hand reamer adjustable Drilling machine Electric pedestal grinder with two wheel Portable electric drill 6 mm Spark plug cleaner and tester similar to Bosch / champion Battery charger 6v. T bar & ratchet Oil can 0.18 v Latest 4 Wheelers of different make (one LMV & one HCV) along with workshop manuals Grease gun 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 Mallets (wooden/plastic) Spanner. adjustable 20 cm. ring offset set of 6 (S A E) Spanner. x 9 mm blade Screw driver 30 cm x 9 mm blade Spanner D E set of 12 pieces (6 to 32 mm) Pliers combination 15 cm Hand file 20 cm.

Module name 2. use. checking. prepare electrolyte.  Check battery condition. Code 4. 14 years of Age MES Module on Basic Automobile Servicing of 2 & 3 Wheeler : Successful candidate would be able to carry out major repairs and overhauling of Mopeds : 210 Hours Underpinning Knowledge (Theory Knowledge on health & safety Procedure for checking compression pressure Procedure for dismantling engine Valve / port timing diagram of 2 stroke engine Air – fuel Ratio at different conditions. Entry Qualification : Repair & Overhauling of Mopeds : Automotive Repair : AUR203 : Minimum 5th Std . maintain & store tools. brake & suspension systems Emission norms. emission control components & their working principles Procedure for handling & using multi-meter Fundamental electrical principle . engine & transmission system (overhauling of an engine & transmission) Do & Don't during over hauling of engine Procedure for dismantling. inspecting/component checks. COURSE CONTENT: Practical Competencies  Practice Health & Safety – select. equipments & clothing safely. acids & asbestos safely  Identification of Tools. 11 . rectify/ replace and assemble engine & transmission  Measure cylinder bore-ovality. Sector 3. oils.1. lubricants. wear & take decision for next action  Check valve leak. assembling & adjustments of carburetor. taper. check & assemble wheel bearings & steering column bearing  Check & repair self starter and Starting system  Check & repair charging system components  Check voltage.Induction Working principle of Ignition system Procedure for checking & over hauling starting system Procedure for checking & over hauling charging system Procedure for checking & over hauling suspension system Procedure for testing the engine 5. continuity and resistance in electrical systems  Rectify defects in lightning system. find faults & rectify  Check compression pressure & take decision for next action  Dismantle.Series & Parallel resistance circuits. Knowledge on micrometer. Handle fuels. Duration 7. clean.Ohm's Law . Terminal competency 6. inspect components. . feeler gauge & dial gauges Procedure for dismantling. Procedure for overhauling transmission. top up & Maintain battery  Check speedometer & rectify the defect  Fine tune the Engine and road test the vehicle                   Note: -Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle. measuring instruments & equipments used for the trade  Measure any components by using the micrometer & dial gauge (practice)  Remove broken stud  Dismantle. assembling. assemble and adjust carburetor  Clean intake and exhaust system  Test Ignition system. sprocket & adjust chain tension  Dismantle. check. valve bend and valve lapping  Overhaul brake & suspension system  Replace chain/links.

25 mm. English and metric Prick punch 15 cm Scriber 15 cm with scribing block universal Hacksaw frame adjustable for 30 cm blade Hand vice 37mm Drill Twist ( assorted ) Taps and Dies complete set in a box BA.(6 mm -17 mm) Set of 12 nos.01 mm Circlip pliers Expanding and contracting type 15 cm and 20 cm each Piston Ring compressor & Ring Expander Tachometer .no Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Hammer ball peen 0. Allen Key set of 12 pieces (2 mm to 14 mm) Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm Steel Rule 30 cm.75 mm Dial indicator to read 0. TOOLS & EQUIPMENTS ( Suggested ) s.5 liter cap Cleaning Tray 45 x 30 cm.25 mm and 14. x 9 mm blade Screw driver 30 cm x 9 mm blade Spanner D E set of 12 pieces (6mm to 32 mm) Pliers combination 15 cm Hand file 20 cm. Spanner for spark plugs 14 mm Socket Spanners with handle.8. 25-50 mm.25 to 12. Work benches Hollow punch set of seven pieces 6 to15 mm Vice grip pliers DMM Auto range Inspection lamp with guard Spark plug cleaner and tester Valve spring Compressor Tool valve grinding. ring offset set of 6 (S A E) Spanner. BSF American & metric with handle Hand reamer adjustable 10.12.25 to 15. Outside Micrometer 0-25 mm.75 to 14. Mallets (wooden/plastic) Piston ring filer Spanner. suction type (consumable tool) Valve seat cutting tools complete with guides and pilot bar (all angles) in a box Cylinder bore gauge „V‟ Block 75 x 38 mm pair with Clamps Compression testing gauge to read 0 to 115 kg/sq cm Battery charger 6v. BSW.no Item s. Second cut Centre punch 10 mm dia x 100 mm Chisel cold flat 20 mm Ring spanner set of 12 pieces (6 to 32 mm. adjustable 20 cm.) Feeler gauge 20 blades (metric) Steel toolbox with lock & key (folding type) size 400x200x150mm.18 v 3 latest mopeds of different make along with workshop manuals and special maintenance tools Carburetors of mopeds Air compressor Water pump / Washer Fire Extinguisher Torque wrench 0 – 50Nm Tryre Pressure gauge 12 . outside & depth Hydrometer Drilling machine bench to drill up to 12 mm dia Electric pedestal grinder with two 18 cm wheel Portable electric drill 6 mm 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 Spanner off set double ended set of 7 pieces.75 kg Screw driver 20 cm.75 mm.to read upto 5000 rpm Battery 12 V Vernier Caliper 250 or 200 mm inside. 11.5 to 11. T bar & ratchet Oil can 0.

Procedure for dismantling. clean. repair/replace &  Procedure for dismantling. gases & asbestos safely  Procedure for dismantling. maintain &  Knowledge on health & safety store – tools. equipments & clothing safely. solvents. Terminal competency Repair & Overhauling of Scooters Automotive Repair AUR204 Minimum 5th Std . lubricants.  Dismantle wheel bearing.Working principle. inspecting & assembling assemble carburetor clutch & gear box  Dismantle. COURSE CONTENT: Practical Competencies Underpinning Knowledge (Theory  Practice Health & Safety – select. seals. use.Series & Parallel resistances circuits  Check & Overhaul starter motor & Starting system .  Reading of workshop manual Handle fuels. cleaning. inspect/check.1. Emission control components and their working principle 13 . inspect & assemble  Working principle & procedure for overhauling & testing Charging system components  Check the working condition of emission control devices  Procedure for dismantling & assembling of shock absorbers  Replacement of front fork oil / oil seals  Lighting system circuits & fault finding procedure Do fine tuning & Test Engine  Procedure for handling bearings  Emission norms. steering stem & ball inspecting & assembling of starter motor race. measuring instruments & an engine equipments used for the trade  Do's & Don‟ts during dismantling & assembling of an engine  Measure any components by using the micrometer & dial gauge (practice)  Measurement using micrometer. checking &  Check compression pressure & take decision for assembling a carburetor next action  Working principle of multi . acids. Module name 2. 14 years of Age MES Module on Basic Automobile Servicing of 2 & 3 Wheeler : Successful candidate would be able to carry out major repairs and overhauling of Scooters 6. clean. Entry Qualification : : : : 5. alkalis. continuity and find fault  Ignition system circuit and faults finding – procedure in electrical circuits  Working principle.  Check Battery. Duration : 240 Hours 7. checking & assembling of  Identification of Tools. dial gauges & feeler gauges  Remove broken stud  Construction & operation of carburetor  Clean intake and exhaust system  Procedure for dismantling.plate clutch & gear box  Dismantle.  Procedure for checking compression pressure adhesives. Sector 3. prepare electrolyte and charge  Wiring colour-code  Check voltage. application & checking of  Check charging system & rectify the defects transistors. oils. resistance.Ohm‟s Law  Overhaul clutch & gear box . Code 4. repair/replace &  Procedure for fine tuning & testing the engine assemble engine components (Overhauling of engine) of different models  Use of multimeter  Set ignition timing and find faults & rectify in the  Fundamental electrical principle ignition system . inspect/check.

75 mm. 8.25 mm and 14. outside & depth DMM Auto range Hydrometer Bench Drilling M/C to drill up to 12 mm dia Electric pedestal grinder with two 18 cm wheel 3 latest 2 Wheelers (Moped. Scooter) of different makes along with workshop manuals and special maintenance tools Battery charger 6v. BSW. English and metric Prick punch 15 cm Scriber 15 cm with scribing block universal Hacksaw frame adjustable for 30 cm blade Hand vice 37mm Drill Twist ( assorted ) Taps and Dies complete set in a box BA. Work bench each 250 x 120x60 with 4 bench vices 12 cm jaw 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 14 Mallets (wooden/plastic) Vice grip pliers Circlip pliers Expanding and contracting type 15 cm and 20 cm each Inspection lamp with guard Hollow punch set of seven pieces 6 mm to 15 mm Valve spring Compressor Tool valve grinding. Allen Key set of 12 pieces (2 mm to 14 mm) Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm Steel Rule 30 cm.*Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle.no Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Hammer ball peen 0. 5075mm.(6 mm -17 mm) Set of 12 nos. BSF American & metric with handle Hand reamer adjustable 10.75 kg Screw driver 20 cm.12.5 liter cap Cleaning Tray 45 x 30 cm. suction type (consumable tool) Valve seat cutting tools complete with guides and pilot bar(all angles) in a box Cylinder bore gauge „V‟ Block 75 x 38 mm pair with Clamps Spanner off set double ended set of 7 pieces. ring offset set of 6 (S A E) Spanner. Second cut Centre punch 10 mm dia x 100 mm Chisel cold flat 20 mm Ring spanner set of 12 pieces (6 to 32 mm.T bar & ratchet Oil can 0. 25-50 mm.25 to 15.25 to 12. Spanner for spark plugs 14 mm Socket Spanners with handle.01 mm Outside Micrometer 0-25 mm.25 mm. TOOLS & EQUIPMENTS ( Suggested ) s.no Item s.75 mm Dial indicator to read 0. Compression testing gauge to read 0 to 115 kg/sq cm Piston Ring compressor & Ring Expander Tachometer . 11. 75-100 mm Piston ring filer Spanner.75 to 14.5 to 11. adjustable 20 cm.18 v Spark plug cleaner and tester similar to Bosch / champion Portable electric drill 6 mm Carburetors of scooters Air compressor Water pump / Washer Fire Extinguisher Tyre repair kit Torque wrench 0 – 50Nm Tryre Pressure gauge . x 9 mm blade Screw driver 30 cm x 9 mm blade Spanner D E set of 12 pieces (6mm to 32 mm) Pliers combination 15 cm Hand file 20 cm.to read up to 7000 rpm Battery 12 V Vernier Caliper 250 or 200 mm inside.) Feeler gauge 20 blades (metric) Steel tool box with lock & key (folding type) size 400x200x150mm .

reset. handling.Working principal. oils. COURSE CONTENT : Practical Competencies  Practice Health & Safety – select. adhesives. Duration 7. application of transistors  Wiring colour-code  Working principle of starter motor & alternator  Electronic ignition system  Fault finding procedure in ignition system  Working principle of brakes (disc & drum brakes)  Procedure for handling bearings  Latest emission norms  Controls available to meet the norms & their working principle  Purpose & function of shock absorber  Procedure for overhauling a shock absorber  Bearing – Types (available in motor cycles). Sector 3. lubricants. check. equipments & clothing safely. steering stem & ball race. clean. repair and reassemble –charging system  Check voltage regulator  Set Ignition timing  Overhaul Disc & drum brakes system  Dismantle wheel bearing. gases & asbestos safely  Water wash & clean the vehicle  Remove broken stud  Check compression pressure  Clean Fuel tank  Dismantle. fit & fine tune carburetor  Dismantle. continuity and find fault in electrical circuits  Dismantle. checking components & assembling of engine & transmission   Usage of the multimeter  Fundamental electrical principle . check. Code 4. clean. resistance. repair and assemble – starter motor & starting system  Dismantle. clean. Terminal competency 6. seals. inspect & assemble  Replace front fork oil / oil seals  Check the working condition of emission control devices  Do fine tuning & Test the vehicle  Troubleshoot & rectify vehicle defects Repair & Overhauling of Motor Cycles Automotive Repair AUR205 Minimum 5th Std .Series & Parallel resistances circuits . solvents. clean.1. Entry Qualification : : : : 5.Ohm‟s Law . Handle fuels. check. acids.  Lubricate and grease the vehicle  Prepare electrolyte & charge the battery  Check voltage. 14 years of Age MES Module on Basic Automobile Servicing of 2 & 3 Wheeler : Successful candidate would be able to carry out major repairs and overhauling of Motor Cycles : 270 Hours Underpinning Knowledge (Theory           Knowledge on health & safety practices Reading of workshop manual Working principle of clutch Working principle of constant mesh gear box Valve timing of 4 stroke Petrol Engine Construction & operation of different circuits in a latest carburetor of motor cycle Procedure for dismantling & assembling a carburetor Procedure for checking compression pressure Procedure for reading micrometer & dial gauges Procedure for dismantling. clean. procedure for assembling & dismantling 15 . use. Module name 2. repair and refit clutch & gear box. alkalis. maintain & store – tools. check Engine components & assemble  Dismantle.

*Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle. 8. TOOLS & EQUIPMENTS ( Suggested )
s.no Item s.no Item

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Hammer ball peen 0.75 kg Screw driver 20 cm. x 9 mm blade Screw driver 30 cm x 9 mm blade Spanner D E set of 12 pieces (6mm to 32 mm) Pliers combination 15 cm Hand file 20 cm. Second cut Centre punch 10 mm dia x 100 mm Chisel cold flat 20 mm Ring spanner set of 12 pieces (6 to 32 mm.) Feeler gauge 20 blades (metric) Steel tool box with lock & key (folding type) size 400x200x150mm . Allen Key set of 12 pieces (2 mm to 14 mm) Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm Steel Rule 30 cm, English and metric Prick punch 15 cm Scriber 15 cm with scribing block universal Hacksaw frame adjustable for 30 cm blade Hand vice 37mm Stud remover Taps and Dies complete set in a box with handle (metric) Hand reamer adjustable 10.5 to 11.25 mm, 11.25 to 12.75 mm, 12.75 to 14.25 mm and 14.25 to 15.75 mm Dial indicator to read 0.01 mm Outside Micrometer 0-25 mm, 25-50 mm, 5075mm, 75-100 mm Mallets (wooden/plastic) Piston ring filer Spanner, ring offset set of 6 (Metric) Spanner, adjustable 20 cm. Spanner for spark plugs 14 mm Socket Spanners with handle, T bar & ratchet Oil can 0.5 liter cap Cleaning Tray 45 x 30 cm. Work bench each 250 x 120x60 with 4 bench

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 16

Pullers screw powered 2 mm with bearing puller attachment Vice grip pliers Circlip pliers Expanding and contracting type 15 cm and 20 cm each Inspection lamp with guard Hollow punch set of seven pieces 6 to 15 mm Valve spring Compressor Tool valve grinding, suction type (consumable tool) Valve seat cutting tools complete with guides and pilot bar (all angles) in a box Cylinder bore gauge capacity 50 to 150 mm Surface Plate 60 x 60 cm „V‟ Block 75 x 38 mm pair with Clamps Spanner off set double ended set of 7 pieces.(6 mm -17 mm) Set of 12 nos. Compression testing gauge to read 0 to 115 kg/sq cm Piston Ring compressor & Ring Expander Tachometer - to read up to 5000 rpm Battery 12 V Vernier Caliper 250 or 200 mm inside, outside & depth DMM Auto range Hydrometer Drilling machine bench to drill up to 12 mm dia Electric pedestal grinder with two 18 cm wheel 3 latest motor cycles of different make along with special tools, & workshop manuals Spark plug cleaner and tester Battery charger 6v- 18 v Portable electric drill 6 mm Carburetors of motor cycles Air compressor Water pump / Washer Fire Extinguisher Torque wrench 0 – 50Nm Tryre Pressure gauge Wheel truing machine

33

vices 12 cm jaw Ring ridge remover

17

1. Module name 2. Sector 3. Code 4. Entry Qualification

: : : :

5. Terminal competency

6. Duration 7. COURSE CONTENT : Practical Competencies  Practice Health & Safety – select, use, maintain & store – tools, equipments & clothing safely. Handle fuels, oils, lubricants, acids, alkalis, adhesives, seals, solvents, gases & asbestos safely  Water wash & clean the vehicle  Remove broken stud  Check compression pressure  Clean Fuel tank  Dismantle, clean, check Engine components & assemble  Dismantle, clean, reset, fit & fine tune carburetor  Overhaul and test Fuel Injection Pump  Test Injector & repair the defect  Set valve timing  Set Ignition / Injection timing  Dismantle, clean, check, repair and refit clutch & gear box.  Lubricate and grease the vehicle  Prepare electrolyte & charge the battery  Check voltage, resistance, continuity and find fault in electrical circuits & rectify  Dismantle, clean, check, repair and assemble – starter motor & starting system  Dismantle, clean, check, repair and reassemble – alternator / charging system  Check voltage regulator  Dismantle wheel bearing, steering stem & ball race, inspect & assemble  Overhaul Disc & drum brakes systems  Replace front fork oil / oil seals  Check the working condition of emission control devices  Do fine tuning, Test, rectify the vehicle defects

Repair & Overhauling of 3 Wheelers Automotive Repair AUR206 Minimum 5th Std ,14 years of Age MES Module on Basic Automobile Servicing of 2 & 3 Wheeler : Successful candidate would be able to carry out major repairs and overhauling of 3 Wheelers : 270 Hours Underpinning Knowledge (Theory Knowledge on safety practices Reading of workshop manual Procedure for checking compression pressure Do‟s & don‟ts during dismantling & assembling the engine Valve timing of 4 stroke Petrol Engine & Single Cylinder Diesel engine Working principle of diesel injection pump and injector of a single cylinder engine Procedure for reading micrometer & dial gauges Procedure for overhauling of an engine & transmission Usage of the multimeter Fundamental electrical principle - Ohm‟s Law - Series & Parallel resistances circuits - Working principle, application & checking of transistors. Wiring colour-code Fault finding procedure in ignition system Working principle of starter motor & alternator Working principle of constant mesh gear box Electronic ignition system Charging system circuit, system components overhauling & testing Working principle & procedure for overhauling of brakes Bearing – Types (available in 3 Wheelers cycles), procedure for handling, assembling & dismantling Purpose & function of shock absorber Procedure for overhauling a shock absorber Latest emission norms Latest emission controls available to meet the norms & their working principle

         

           

18

25 to 15.25 mm.) Feeler gauge 20 blades (metric) Steel toolbox with lock & key (folding type) size 400x200x150mm.25 mm and 14.*Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle. x 9 mm blade Screw driver 30 cm x 9 mm blade Spanner D E set of 12 pieces (6mm to 32 mm) Pliers combination 15 cm Hand file 20 cm. 8. 50-75mm. 25-50 mm.12. Allen Key set of 12 pieces (2 mm to 14 mm) Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm Steel Rule 30 cm.5 to 11. suction type Valve seat cutting tools complete with guides and pilot bar(all angles) in a box Surface Plate 60 x 60 cm „V‟ Block 75 x 38 mm pair with Clamps Spanner off set double ended set of 7 pieces.01 mm Piston ring filer Mallets (wooden/plastic) Outside Micrometer 0-25 mm. English and metric Prick punch 15 cm Scriber 15 cm with scribing block universal Hacksaw frame adjustable for 30 cm blade Hand vice 37mm Stud remover Taps and Dies complete set in a box with handle (metric) 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 Cleaning Tray 45 x 30 cm. 55 56 57 58 59 60 61 62 63 64 66 Single Cylinder Diesel Engine Electric pedestal grinder with two 18 cm wheel Portable electric drill 6 mm Spark plug cleaner and tester similar to Bosch / champion Injectors Single cylinder FIP Latest 3 Wheelers of different make along with workshop manual. Work bench each 250 x 120x60 with 4 bench vices 12 cm jaw Circlip pliers Expanding and contracting type 15 cm and 20 cm each Inspection lamp with guard and wandering lead of 100 ft.no Item s.18 v Air compressor 22 23 24 25 26 27 28 29 30 31 32 Spanner for spark plugs 14 mm Hand reamer adjustable 10. special maintenance tool & spares Carburetors of 3 Wheelers Water pump / Washer Fire Extinguisher Tyre repair kit 33 34 Socket Spanners with handle.5 liter cap 67 68 19 Torque wrench 0 – 50Nm Tryre Pressure gauge .75 mm.to read up to 5000 rpm Drilling machine bench to drill up to 12 mm dia Hydrometer DMM Auto range Straight edge gauge Battery charger 6v. ring offset set of 6 pieces Spanner. 75-100 mm Piston Ring compressor & Ring Expander Ring ridge remover Spanner.75 kg Screw driver 20 cm.75 mm Cylinder bore gauge Dial indicator to read 0. T bar and ratchet Oil can 0. Second cut Hollow punch set of seven pieces 6 to15mm Centre punch 10 mm dia x 100 mm Chisel cold flat 20 mm Ring spanner set of 12 pieces (6 to 32 mm. 11.75 to 14. Vice grip pliers Valve spring Compressor Tool valve grinding. adjustable 20 cm.25 to 12.no Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Hammer ball peen 0. TOOLS & EQUIPMENTS ( Suggested ) s. outside & depth Battery 12 V Tachometer . Compression testing gauge to read 0 to 115 kg/sq cm Vernier Caliper 250 or 200 mm inside.(6 mm -17 mm) Set of 12 nos.

Sector 3. Terminal competency 6. COURSE CONTENT: Practical Competencies Underpinning Knowledge (Theory 20 . Duration 6. & 14 years of Age+ MES module On ‘Basic Automotive servicing (4 wheelers) : Successful candidate would be able to Repair & Overhauling of Engine Systems : 320 Hours 5. Name 2. Code 4. Entry Qualification : Repair & Overhauling of Engine Systems (Petrol / diesel) : Automotive Repair : AUR207 : Minimum 5th Std.1.

bearing (oil) clearance. alternator. piston rings.Ohm‟s Law Dismantle completer engine and their . cylinder capacitors & transistors. valve leak.                         Knowledge on health & safety precautions to be observed in the workshop / garage Practice Health & Safety – familiarize. clean. assembling & proportion testing of petrol engines Start the engine and set idle rpm Find the fault on the given engine and rectify the  Procedure for – dismantling. shaft bend & valve timing valve drives. ring end gap & side clearance. Injectors. bore Do valve lapping & valve grinding measurement. checking. valve guide. bearings used on engines. equipments. charging. Torque wrenches /angle meter & multimeter Drain engine oil and coolant  Fundamental electrical principles Water wash engine / decrease . dial Remove engine from vehicle gauges.  Layout in diesel engine –fuel supply systems Identify differences between carburetor engine  Different valve operating mechanisms & Valve timing & MPFI Engines. ring end gap &  Working principle. cam & crank filters. fuel supply systems Select Locking devices and find their applications  Layout in MPFI engine –air induction. lubricating oil  Wiring colour-code. fuel pumps.  Familiarization of workshop manual use. liners. valves. ignition & fuel supply systems Identify differences between Petrol & diesel Engines. cam & crank shaft bend & valve timing Fill up oil & coolant after preparing in correct  Procedure for – dismantling. lubricating oil pressure. measure bore systems circuits & take decision for further action. head & block warpage. checking. ignition. bearing (oil) clearance.Working principle. FIPs. checking. inlet manifold Assemble the engine. reading of engine electrical pressure. clean.  Lubrication & cooling systems consumables & clothing safely Select proper materials for gaskets and packing  Layout in Carburetor engine – starting. 21 . engine. clean. MPFI system Service inlet and exhaust manifolds components Remove. cylinder head & block warpage. diagram Remove broken studs  Procedure for handling & reading – micrometers. fuel Overhaul piston and connecting rod assembly pressure regulator in MPFI engine. select. assembling & assemblies / components testing of starter motor & cooling fan motor Remove. checking. check & overhaul engine sub  Procedure for – dismantling. piston wrings pressure. assembling & testing of diesel engines defect  Latest emission norms  Controls available to meet the norms & their working principle Note: -Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle. vacuum. maintain & store – tools. inlet manifold vacuum. Different types & application of side clearance. fuel pressure regulator in MPFI starter motor. check & overhaul electrical  Procedure for – dismantling.Series & Parallel resistances circuits components . carburetor. starting. assemble and check injectors  Procedure for removing engines from the vehicle  Measure the bore and take the decision  Procedure for checking/testing – compression Replace – liner. assembling & components testing of alternator Dismantle. pistons. valve leak. types & application of – Check / test – compression pressure.

5051 Valve key inserter 1 no.75 to 14. 75-100 mm 17 Micrometer inside 25-50. suction type (consumable tool) 8 Hacksaw frame adjustable for 30 cm blade 43 Valve seat cutting tools complete with guides and pilot bar(all angles) in a box 9 Engineer‟s Stethoscope 04 Screw driver 30 cm 44 Cylinder bore gauge capacity 50 to 150 mm x 9 mm blade 10 Hand vice 37mm 45 Fuel feed pump 1 no. 75mm.25 mm.01 mm 50 Spanner off set double ended set of 7 pieces (6 mm -17 mm) 16 Micrometer outside 0-25 mm.75 mm 15 Dial indicator to read 0. 25-50 mm.8.12. 13 Taps and Dies complete set in a box (metric) 48 Surface Plate 60 x 60 cm with handle 14 Hand reamer adjustable 10. 11 File assorted (8 types ) 46 Bearing puller screw powered/hydraulic with attachments Max spread 80.25 to 12.75 mm.25 to 15.n Item s. English and metric 2 Screw driver 20 cm.25 mm and 14.5 kg 41 Valve spring Compressor 7 Scriber 15 cm with scribing block universal 42 Tool valve grinding. x 9 mm blade 3 Screw driver 30 cm x 9mm blade 4 Spanner D E set of 12 pieces (6mm to 32 mm) 5 6 7 Pliers combination Hand file 20 cm. 200 and 300 mm 12 Drill Twist ( assorted) 47 Hammer Copper 1 kg with handle 1 no. TOOLS & EQUIPMENT( Suggested ) s. Second cut Centre punch 10 mm dia x 100 mm 8 9 10 11 12 13 Chisel cold flat 20 mm Ring spanner set of 12 pieces (6mm to 32 mm.5 to 11. 75-150 mm 52 Compression testing gauge to read 0 to 115 with extension rod kg/sq cm 22 . 39 Hollow punch set of seven pieces 6 mm to 15 mm 1 set 5 Chisels Cross cut 200 mm x 6 mm 40 Cleaning tray.) Feeler gauge 20 blades (metric) Steel tool box with lock & key (folding type) size 400x200x150mm Allen Key set of 12 pieces (2 mm to 14 mm) Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm 04 Sets 34 Spanner. ring offset set MEASURING INSTRUMENTS AND GENERAL SHOP TOOLS 1 Steel Rule 30 cm. English and metric 36 Distributors 2 Engineer‟s square 15 cm blade 37 Carburetor (two different types) 3 Divider spring joint 15 cm 38 Crow bar 2 each 4 Prick punch 15 cm 2nos.50-75.Aluminum 45 x 30 cm 6 Ball peen Hammer 0. 49 „V‟ Block 75 x 38 mm pair with Clamps 11.n Item Trainees kit 1 Steel rule 15 cm.

50. (3nos. Governor Fuel feed pump Injectors of diesel engines Engine management system‟s Sensors & Actuators – 4 sets Vice grip pliers 67 Circlip pliers Expanding and contracting type 15 68 cm and 20 cm each 8 sets Inspection lamp with guard and wandering lead 69 of 100 ft. Torque wrench set of 3 Nos.450 mm Pliers water pump multifix 250 mm Long Battery 12 V Vernier Caliper 250 or 200 mm inside.V.18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Mallets (wooden/plastic) Piston ring filer Spanner.18 v Injector testing set (hand operated) Injector dismantling jig with mounting bench Engine cranker with 12V and 24 V Ac to DC Power supply system Engine scanner 23 .5-liter cap Cleaning Trays 45 x 30 cm. Stud remover 9 10 11 12 13 14 15 16 GENERAL INSTALLATION 1 Petrol engine ( 4 strokes.160. Multi Cylinder ) of different makes in running condition. Piston Ring compressor & Ring Expander Tachometer . Multi Cylinder) of different makes in running condition 4 Cut model of 4 stroke petrol engine on stand 5 Common Rail Diesel Injection vehicle on a stand with workshop manuals 6 Cut model of 4 stroke diesel engine on stand 7 Drilling machine bench to drill up to 12 mm dia 8 Electric pedestal grinder with two 18 cm wheel Nipple forming tool to form nipple on high pressure pipe lines 6. Work bench each 250 x 120x60 with 4 bench vices 12 cm jaw Pullers screw powered 2 mm with bearing puller attachment 53 54 55 56 57 58 59 60 61 62 63 64 65 66 Vacuum gauge to read 0 to 760 mm of Hg. with MPFI System & 1 Nos. outside & depth DMM Auto range Petrol Injector Petrol Fuel pump of MPFI system Hydrometer Piston Ring compressors Valve spring lifter Fuel injection pump one with pneumatic governor one with R Q governor and one with R. Spanner.to read up to 5000 rpm Triple leg grip puller with bearings attachment screw/ hydraulic powered max. Spread 80.8 and 10 mm dia Portable electric drill 6 mm Spark plug cleaner and tester similar to Bosch / champion Battery charger 6v.S. ring offset set of 6 (S A E) 2 sets. adjustable 20 cm Spanner for spark plugs 14 mm Spanners socket of 8 with handle. with Carburettor) 2 MPFI vehicle with workshop manuals 3 Diesel engine (4 stroke. T bar and ratchet Chain and Pulley block 3000 kg capacity Horses Screw jack 1 ton capacity double lift Oil can 0.

Power flow from engine to wheels Units & Definition of force. synchromesh gear boxes Gear selection mechanism Lubrication of transmission system Gear box faults Types of bearings. brake slip.                   Underpinning Knowledge (Theory Knowledge on health & safety precautions to be observed in the workshop / garage (health hazard of asbestos dust to be emphasized) Familiarization of workshop manual TRANSMISSION . & 14 years of Age. check. adjust all four-wheel brakes and test for brake concern. wheel drum  Bleed vacuum assisted hydraulic brakes  Remove & clean brake drums. Wheel cylinder & caliper pistons. Fit new cups and brake hoses –assemble. dismantle. Check disc/drum runout. fill lubricating oil & assemble  Align gear selector fork  Remove CV Joint.Repair & Overhauling of Chassis System (Light Vehicle) 1. COURSE CONTENT: Practical Competencies  Practice Health & Safety – familiarize. power. Check and adjust steering wheel play and backlash.manual & hydraulic Clutch faults Type of gears and their application-advantages and disadvantages-gear ratio Types of gear box Working principle of constant mesh. pinion and bearings. lubricate & refit  Remove crown wheel. Check tooth contact in the crown and pinion and adjust backlash & Assemble rear axle assembly  Check and adjust parking brake and service brakes. equipments. maintain & store – tools. checking and top-up oil in steering box. Entry Qualification : Repair & Overhauling of Chassis System (Light Vehicle) : Automotive Repair : AUR208 : Minimum 5th Std.  Check and correct the steering geometry with instruments  Remove and refit steering boxes from vehicle. time element of braking operation 24 . Functions of different parts of the clutch assembly. torque & pressure Description of single plate clutches. Dismantle. check for defects & rectify/replace & refit  Remove gear box from vehicle. braking force co-efficient. work. consumables & clothing safely  Identify different parts of chassis  Remove clutch plate from vehicle. MES module on ‘Basic Automotive Servicing ( 4 wheelers) : Successful candidate would be able to Repair & Overhauling Chassis System (Light Vehicle) : 320 Hours 5. rectify. Code 4. their characteristics & application Working principle of constant velocity joints Working principle of differential Faults in differential & C. Dismantle wheel brake assembly– remove old lining and fit new one  Remove and refit vacuum boosters  Overhaul – master cylinder. select. Clutch linings material. Power flow in clutch plate. use. Terminal competency 6. Joints BRAKE – Forces & moments acting on vehicle. maintenance. Name 2. Duration 7. Clutch operating mechanisms. clean parts. Sector 3.V.

wheel cylinder & different braking force control valves  Brake linings.  STEERING – Introduction. clutch. under steer & neutral steer) & steering linkage  Types of steering gear.  Usage of multimeter  Wiring colour-code. control valve & cylinder Remove and refit a leaf spring as an assembly in a vehicle. Re-camber the leaf spring Remove tyre.necessity. steering & suspension systems for their satisfactory working Note: -Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle. clutch. functions.Series & Parallel resistances circuits . basic types of steering. brake. designation & defects analysis  Procedure for tyre rotation  Fundamental electrical principles . 25 . reading of engine electrical systems circuits  Fault finding in electrical circuits  Final road test procedure – observation of Noise.        Overhaul hydraulic power assisted steering system – pump. requirement. shock absorber. inspect/check & assemble Rotate the tyres Remove and refit head lamp Check for electrical defects and rectify Do Final road test – observe for Noise. factors affecting the braking distance  Advantages of hydraulic brake system over pneumatic  Working principle of brake components – brake booster tandem master cylinder. brake. steering & suspension systems & rectify the defect  Classification of brake systems. types.Ohm‟s Law . steering characters (over steer. McPherson strut. changing rubber bushes of shock absorbers and independent front suspension. Lubricate suspension units. types & application of – capacitors & transistors. caliper assembly.Working principle.  Checks on suspension system and fault diagnosis  WHEELS & TYRES. power assisted steering (hydraulic & electronic)  Checks on steering system and fault diagnosis  SUSPENSION – Introduction. Vibration & harshness from different part of chassis – observe for problems in transmission. steering geometry (necessity. types & effects). Vibration & harshness from different part of chassis – observation of transmission. pads & fluid  Brake faults diagnostic  Introduction to anti-lock braking system (ABS).

ratchet and universal upto 32 mm set of 28 pieces with box Hand file 20 cm. 75. smooth triangular 12 Hand file 30 cm. X 9 mm Blade Spanner D. 50 – 75 Steel Rule 30 cm.round Hand file 20 cm.n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Item s. English and metric mm. cm 9 Torque wrench 5 to 35 Nm.75.50. X 9mm Blade Screw driver 30 cm. 12. 50. 25. 12 – 68 Nm & 50 – 225 Engineer‟s square 15 cm Blade Nm 10 Straight edge gauge 2 ft. 11.25 mm and 14. Second cut flat Item 28 29 30 31 15 16 17 s. E. T.25 to 15. bastard Steel tools box with lock and key (folding type) size400X200X150mm Circlip pliers 15 cm. set of 12 pieces (6mm to 32mm) Pliers combination 20 cm Pliers side cutting 15 cm Plier round nose 15 cm Plier flat nose 15 cm TOOL KIT 18 19 20 21 22 23 24 25 26 27 Hand file 20 cm.5kg Adjustable spanner (pipe wrench 350 mm) Spanner. ring set of 12 metric sizes 6 to 32 mm Spanner.25 mm. kg/ sq.75 mm Vice grip pliers Circlip pliers Expanding and contracting type 15cm and 20cm Circlip pliers 15 cm.25 mm.25 to 12. Feeler gauge 20 blades (metric) 26 . TOOLS & EQUIPMENT( Suggested ) s. Expanding type Chisel cold flat 20 mm Hand file 30 cm.5 to 11.8. 75 – 100 mm 8 Micrometer in side 25. Second cut half. round bastard Centre punch 10 cm Ball peen Hammer 0. English and metric Screw driver 20cm.50 mm. adjustable 15cm Spanner for spark plugs 14mm Hand reamers adjustable 10.150 mm with Compression testing gauge to read 0 to 50 extension rod.75 mm.n Item a) Steel rule 15 cm.n b) SHOP OUTFIT & MEASURING INSTRUMENTS 6 Cylinder bore gauge capacity 20 to 160 mm Dividers spring 15 cm 7 Micrometer out side 0.bar.n 1 2 3 4 5 32 33 34 s. Contracting type Item Hollow punch set of seven pieces 6mm to 15mm 1 Set Drift punch copper 15 cm Prick punch 15 cm Chisels cross cut 200 mm X 6mm Allen Key set of 12 pieces (2mm to 14mm) Philips Screw Driver set of 5 pieces (100 mm to 300 mm) Mallets wooden/ plastic Spanners socket with speed handle.75 to 14.

n Item 26 27 28 29 30 31 32 33 GENERAL INSTALLATION / MACHINERIES 34 Drill Twist (assorted) Taps and Dies complete sets (5 types) 35 Surface Plate 60 x 60cm 1 No.s. 450 mm 59 Marking out table 90X60X90 cm Spark plug testing machine 60 Cleaning tray 45x30 cm Crow bar 61 Valve spring lifter Petrol engine 4 stroke fitted with MPFI system for practice with manuals Bearing puller screw powered/ hydraulic powered with 62 Petrol engine 4 stroke fitted with carburetor attachments Max spread 80. length 42 Valve key inserter Fire extinguisher ABC type 5 kg capacity 43 Hand vice – 37 mm Fire Buckets (4 Nos. V.suction type Spark plug spanner 14mm x 18mm x Size 46 C. Capacity electric type 53 Petrol Engine of: latest model (CNG Engine) with workshop manuals 54 Hydraulic jack with trolley capacity 3 Ton Tubed tyre of cars 55 Electronic engine control modules Engineers stethoscope 56 Wheel alignment gauges 1 set Oil can 0. 250.n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Item s. 200 and 300mm for practice with manuals 63 Battery charger 6 – 24 V with 10 A rate Petrol Engine car of latest model with manuals 64 Synchromesh gear box of LCV 2 Nos.5/ 0.25 liter capacity 57 Cut model of 4 stroke Petrol engine on stand Smoke testing machine 58 Scriber with scribing black universal Triple leg grip puller with bearings attachment screw/hydraulic Powered max. Tyre pressure gauge with accessories 50 Wheel cylinder 4 Nos. Air compressor with accessories 49 Tandem master cylinder with booster 4 Nos. Diesel Engine car of latest model with manuals 65 Tyre remover pneumatic & mechanical Electric pedestal grinder with two 18cm. Wheel type C. 48 Engine analyzer Disk brake with caliper assembly 2 Nos. 100 Petrol Engine of: Piston ring expander and remover 50 mm & latest model ( CNG Engine ) with workshop manuals 100 mm 36 Hacksaw frame adjustable Piston Ring compressor 37 Distributor Piston Ring Groove cleaner 38 Carburetor Cylinder ridge remover/ cutter 39 Fuel feed pump Work bench 250 x 120 x 60 cm with 2 vices 40 4 Wheeler petrol vehicle fitted with MPFI system/ Pullers screw powered 2 mm gap with carburetor system with manuals bearing puller Valve seat cutting tools complete with guides and pilot 41 Inspection lamp with guard and wandering bar (all angles) lead of 100ft. 160. Vacuum gauge to read 0 to 760 mm of Hg 27 . Spread 80. 52 Screw jack one tone. Joint units of 3 different types 4 sets Cut model of 4 stroke Diesel engine on stand 47 Drilling machine bench to drill up to 12mm die Drum brake assembly 2 Nos. 51 Horses and wheel choke Lead acid battery 12 V 4 Nos.Aluminum 45 x 30 cm 45 Valve grinding tool.) with stand 44 V‟ Block 75 x 38mm pair with Clamps Cleaning tray. capacity double lift Speed counter / Tacho meter – pointed type to read up to 5000 RPM Chain and pulley block 3000 kg.

dismantle. clean parts. Code 4. torque & pressure Description of single plate clutch. Power flow in clutch plate. & 14 years of Age. brake slip. select. lubricate & refit Remove crown wheel. consumables & clothing safely Identify different parts of chassis Identify different tools & equipments Remove clutch plate from vehicle. Functions of different parts of the clutch assembly. check. Clutch operating mechanisms. adjust all wheel brakes and test for brake concern. equipments. Duration 7.Joints & drive shafts BRAKE – Forces & moments acting on vehicle. Check tooth contact in the crown and pinion and adjust backlash & Assemble rear axle assembly Check and adjust parking brake and service brakes. Clutch linings material. check for defects & rectify/replace & refit Remove gear box from vehicle. COURSE CONTENT: Practical Competencies               Practice Health & Safety – familiarize.Repair & Overhauling of Chassis System (Heavy Vehicle) 1.Power flow from engine to wheels Units & Definition of force. Entry Qualification : Repair & Overhauling of Chassis System (Heavy Vehicle) : Automotive Repair : AUR209 : Minimum 5th Std. time element of braking . . Terminal competency Vehicle) 6. use. Wheel cylinders & Drum brake/disc brakes Check fail safe system & rectify defects Remove & clean brake drums. fill lubricating oil & assemble Align gear selector fork Remove CV Joint. Dismantle wheel brake assembly– remove old lining and fit new one Overhaul – pneumatic valves. braking force co-efficient. rectify. work. Check and correct the steering geometry with instruments                   28 Underpinning Knowledge (Theory Knowledge on health & safety precautions to be observed in the workshop / garage (health hazard of asbestos dust to be emphasized) Familiarization of workshop manual Familiarization of different tools & equipments TRANSMISSION . their characteristics & application Working principle of constant velocity joints Working principle of differential Faults in differential. Dismantle. maintain & store – tools. MES module on ‘Basic Automotive Servicing ( 4 wheelers) : Successful candidate would be able to Repair & Overhauling Chassis System (Heavy : 320 Hours 5. Sector 3.V. Fit new cups and brake hoses/pipes –assemble. Check disc/drum runout. power. synchromesh gear boxes Gear selection mechanism Lubrication of transmission system Gear box faults Types of bearings. C.manual & hydraulic Clutch faults Type of gears and their application-advantages and disadvantages-gear ratio Types of gear box Working principle of constant mesh. pinion and bearings. maintenance. Name 2.

brake. pressure regulator. types. steering geometry (necessity. Check and adjusting steering wheel play and backlash. Usage of multimeter Wiring colour-code. steering & suspension systems for their satisfactory working Note: -Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle.         Remove and refit steering boxes from vehicle. Vibration & harshness from different part of chassis – observe for problems in transmission.necessity. 29 . STEERING – Introduction.Ohm‟s Law . Re-camber the leaf spring. reading of engine electrical systems circuits Fault finding in electrical circuits Final road test procedure – observation of Noise. steering & suspension systems & rectify the defect                   operation Classification of brake systems. Overhaul shackles Remove tyre. under steer & neutral steer) & steering linkage Types of steering gear. designation & defects analysis Procedure for tyre rotation Fundamental electrical principles . check and top-up oil in steering box. brake. Vibration & harshness from different part of chassis – observation of transmission. types & application of – capacitors & transistors. types & effects). control valve & cylinder Remove and refitting a leaf spring as an assembly in a vehicle. basic types of steering. wheel cylinder Brake linings & pads Brake faults diagnostics and adjustments Introduction to anti-lock braking system (ABS). requirement. clutch. Checks on suspension system and fault diagnosis WHEELS & TYRES. factors affecting the braking distance Advantages of pneumatic brake system over hydraulic Working principle of brake components – compressor. different pneumatic valves.Working principle. functions. power assisted steering (hydraulic) Checks on steering system and fault diagnosis SUSPENSION – Introduction. Lubricate suspension units. brake booster. steering characters (over steer. inspect/check & assemble Rotate the tyres Remove and refit head lamp Check for electrical defects and rectify Do Final road test – observe for Noise.Series & Parallel resistances circuits . changing rubber bushes of shock absorbers and independent front suspension. shock absorber. leaf spring. clutch. Overhaul hydraulic power assisted steering system – pump.

150 mm with Compression testing gauge to read 0 to 50 kg/ sq.50.75.25 mm. TOOLS & EQUIPMENT( Suggested ) s.25 mm) to 12.n Item 15 16 17 TOOL KIT 18 Steel rule 15 cm.25 to 15. 75.8. 12. 75 – 100 mm 8 Micrometer in side 25. 25.n Item b) SHOP OUTFIT & MEASURING INSTRUMENTS 6 Cylinder bore gauge capacity 20 to 160 mm Dividers spring 15 cm 7 Micrometer out side 0. English and metric Hand file 20 cm. extension rod. 12 – 68 Nm & 50 – 225 Engineer‟s square 15 cm Blade Nm 10 Straight edge gauge 2 ft. 50. bastard 21 Spanner D.50 mm.n 1 2 3 4 5 Item s.5 to 11. cm 9 Torque wrench 5 to 35 Nm. Contracting type a) s. X 9mm Blade Hand file 20 cm. smooth triangular 20 Screw driver 30 cm. ring set of 12 metric sizes 6 to 32 mm 29 Chisels cross cut 200 mm X 6mm Spanner.round 19 Screw driver 20cm. Expanding type 23 Pliers side cutting 15 cm Chisel cold flat 20 mm 24 Plier round nose 15 cm Hand file 30 cm. Second cut half. Feeler gauge 20 blades (metric) 30 . English and metric mm.n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Item s.bar. Second cut flat Circlip pliers 15 cm.25 mm. set of 12 pieces (6mm to 32mm) Steel tools box with lock and key (folding type) size400X200X150mm 22 Pliers combination 20 cm Circlip pliers 15 cm.75 to 14. E. ratchet Circlip pliers Expanding and contracting type 15cm and universal upto 32 mm set of 28 pieces with box and 20cm 34 Hand file 20 cm. X 9 mm Blade 12 Hand file 30 cm.25 mm and 14. adjustable 15cm 30 Allen Key set of 12 pieces (2mm to 14mm) Spanner for spark plugs 14mm 31 Philips Screw Driver set of 5 pieces (100 mm to 300 Hand reamers adjustable 10. T. round bastard 25 Plier flat nose 15 cm Centre punch 10 cm Hollow punch set of seven pieces 6mm to 15mm 1 Set 26 Ball peen Hammer 0.75 mm. 50 – 75 Steel Rule 30 cm. 11.5kg 27 Drift punch copper 15 cm Adjustable spanner (pipe wrench 350 mm) Prick punch 15 cm 28 Spanner.75 mm 32 Mallets wooden/ plastic Vice grip pliers 33 Spanners socket with speed handle.

51 Horses and wheel choke Lead acid battery 12 V 4 Nos.) with stand 44 V‟ Block 75 x 38mm pair with Clamps Cleaning tray. 65 Electric pedestal grinder with two 18cm. length 42 Valve key inserter Fire extinguisher ABC type 5 kg capacity 43 Hand vice – 37 mm Fire Buckets (4 Nos. Tyre pressure gauge with accessories 50 Wheel cylinder 4 Nos. GENERAL INSTALLATION / MACHINERIES 34 Drill Twist (assorted) Taps and Dies complete sets (5 types) 35 Surface Plate 60 x 60cm 1 No. Wheel Common Rail diesel engine on a stand 66 Pneumatic brake system on a bed board Injector tester 31 . 100 Petrol Engine of: Piston ring expander and remover 50 mm & 100 latest model ( CNG Engine ) with workshop manuals mm 36 Hacksaw frame adjustable Piston Ring compressor 37 Distributor Piston Ring Groove cleaner 38 Carburetor Cylinder ridge remover/ cutter 39 Fuel feed pump Work bench 250 x 120 x 60 cm with 2 vices 40 4 Wheeler petrol vehicle fitted with MPFI system/ Pullers screw powered 2 mm gap with bearing carburetor system with manuals puller Valve seat cutting tools complete with guides and pilot 41 Inspection lamp with guard and wandering lead of bar (all angles) 100ft. Spread 80. 450 mm 59 Marking out table 90X60X90 cm Crow bar 60 Cleaning tray 45x30 cm Diesel engine 61 Valve spring lifter HCV of latest model with manuals 62 Bearing puller screw powered/ hydraulic powered with Tyre remover pneumatic & mechanical type attachments Max spread 80.25 liter capacity Wheel alignment gauges 1 set 57 Cut model of 4 stroke Petrol engine on stand Smoke testing machine 58 Scriber with scribing black universal Triple leg grip puller with bearings attachment screw/hydraulic Powered max.Aluminum 45 x 30 cm 45 valve grinding tool. 52 Screw jack one tone. Capacity electric type 53 Diesel Engine of latest model (CNG Engine) with workshop manuals 54 Hydraulic jack with trolley capacity 3 Ton Tubed tyre of HCV 55 Engineers stethoscope Electronic control module 56 Oil can 0.suction type Spark plug spanner 14mm x 18mm x Size 46 C.1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 C. 250. 200 and 300mm 63 EGR cut out Battery charger 6 – 24 V with 10 A rate 64 Set of sensors & actuators Synchromesh gear box of LCV 2 Nos.5/ 0. Air compressor with accessories 49 Tandem master cylinder with booster 4 Nos. capacity double lift Speed counter / Tacho meter – pointed type to read up to 5000 RPM Chain and pulley block 3000 kg. 160. Joint units of 3 different types 4 sets Cut model of 4 stroke Diesel engine on stand 47 Drilling machine bench to drill up to 12mm die Drum brake assembly 2 Nos. 48 Engine analyzer Disk brake with caliper assembly 2 Nos. V.

maintain & store – tools. Sector 3. Care and maintenance of tools. etc. location. diodes. uses. Effects of resistance on the length and cross sectional area of a conductor. COURSE CONTENT: Practical Competencies  Practice Health & Safety – familiarize. assemble Underpinning Knowledge (Theory  Safety precautions and first aid. Identify marking on terminal joints. starter motor. Number systems and Truth table concept and application.. types. current flow in different line by connecting two or three resistors in parallel and series using a battery. Repair the faults. rotor winding insulation & rotor condition. & power supplies  Principles of Digital electronics.  Function. The parts of a simple electrical circuit  Ohm‟s law – Exercises on Ohm‟s law. location & checking of – switches. rectifier circuits. uses. and trouble shooting in a charging system. use.  Checking of circuit breakers and relays  Construct simple circuit by using relay  Test / check –alternator output voltage. Terminal competency 6. Thysistors. Measure conductor using wire gauge  Practice Soldering on wire joints. ICs.Repair of Auto Electrical & Electronics Systems 1. . resistors. Entry Qualification : Repair of Auto Electrical & Electronics Systems : Automotive Repair : AUR215 : Minimum 8th Std. maintenance & checking of various automobile electrical equipments – starter motor.  Solder and crimp of lugs with wire ends  Measure voltage drop. Circuit protectors. MES module on ‘Basic Automotive Servicing ( 4 wheelers) : Successful candidate would be able to Repair Auto Electrical & Electronics System : 320 Hours 5. dynamo control box etc. equipments. bulb / motor / resistors – reconcile Ohm‟s law. logic gates and 32 . horn & battery  Cables colour codes & sizes.  Signs and symbols used in Electrical & electronics  Voltage. Introduction to equipment used for soldering. circuit voltage drop. total resistance. wiper motor. Remove and repeat connections. connectors.  Introduction on Magnetism  Usage of multimeter.  Check blowing of fuse with wires short-circulated. Exercises on series and parallel circuits.e. uses. Code 4. solenoids. Follow up starting system wiring.  Description/working principles. & 14 years of Age. Method of using AVO meter  Semiconductor  Type of solder and flux required for soldering aluminum and copper conductor. Name 2. conductors and insulators  Cumulative resistance of parallel and series connected circuits. consumables & clothing safely  Identify different tools & equipments  Identify different electrical parts of a vehicle  Make joints on simple strapped conductors. Simple electronics circuits such as oscillators amplifiers. rotor condition. location & checking of – Basic electronics devices such as transistors. Triac. select.  Identify various electrical equipments on the mock up wiring board i.  Dismantling alternators and components tests –diodes. Current and Resistance and its units. sieving or taping with insulation tape. alternator.  Trace starter circuit in a vehicle Dismantle starter and check each components. types. relays. Diac. spark plugs (explain radio interference suppression) & condensers  Description / working principles. Duration 7. Do Similar practice on charging system wiring. types.

Check spark plugs. Camshaft and crank shaft position sensors (magnetic pick up type)  Construction and working principle of actuators –idle air control valve.0 x 1to 8x9 set of 5) 30 Prick punch 15 cm Spanner Clyburn 15 cm 31 Chisel cross cut 200mm x 6 mm Adjustable spanner 20 cm 32 Ball Peen Hammer 0. Reset keep alive memory/ ECA Check different wiring / circuits and rectify the defect their applications. top up battery with distilled water.5 mm –set of 7 nos. HT leads.measure outputs Construct simple logic circuits using digital trainer kit Check ignition coil of E-DIS (Electronic distributor less Ignition system) Check sensors & actuators using engine scanner / DMM Check the different modes/ strategies of Electronic Control Assembly.        and check starter motor on a test rig. injector & EGR cutout solenoid valve (explain duty cycle)  Basic structure and operation of a microcomputer Explanation of simple electronic circuits Different strategies/ modes available in the ECA Note: -Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle 8. ignition coil and condenser Test the batteries with Hydrometer and cell tester.n Item TRAINEES TOOL KIT 6 Steel rule 30mm 7 Plier combination 15cm 8 Steel tool box with lock & key ( folding type ) size 400x200x150mm 9 Insulated Screw driver 30 cm x 9mm blade Hand file 20 cm second cut 10 Insulated Screw driver 20 cm x 9mm blade Ring spanner set of 12mm b) SHOP OUTFIT & MEASURING INSTRUMENTS 25 Electric testing screwdrivers 12 Hand vice 37 mm 2 Stud extractors 26 Allen key set of 12 pieces ( 2mm – 14 mm) Poker 2 Nos 27 Circlip plier (External and Internal) 150mm & 200mm Double ended Spanner 6 to 32 mm . W) – 3 to 13. Engine coolant temperature.8.75 Kg Cold Flat Chiesel 19mm Centre Punch 10 mm dia x 100mm a) 33 .set of 12 nos Philips Screw Driver set of 5 pieces 100mm – 300mm 28 Double ended off. vehicle speed. Air temperature.5 Kg Spark plug spanner 14 mm 1 No. manifold absolute pressure (Piezo-Resistive & Piezo-electric type). Assemble and study rectifier circuits and power supplies.n 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11 Item s. Ball Peen Hammer 0.9.10 and 12 mm set Drift copper (10 mm x 150 mm) 1 No. Construct a simple electronic circuits using electronic trainer kit (to study the components functions). Air temperature (Thermistor).set Spanner (W. 29 Star Allen keys Double open ended ignition spanner set (of BA. 33 Hammer copper 1 Kg with handle Magneto spanner set with 8 spanners 1 set 34 Hack saw frame for 30 cm blade Socket spanner set with handle. T.  Demonstration of digital trainer kits  Demonstration on micro processor kits and familiarization with different related devices Demonstration and familiarization with automobile micro processor system  Working principle of instruments and gauges  Working principle of sensors – throttle position (Potentiometer).7.bar and ratchet 35 Hollow punch 6. Connect batteries for charging. prepare electrolyte (follow safety rules). TOOLS & EQUIPMENT( Suggested ) s. Simple digital circuits.

5mm x 18 mm set of four) 1 set Hydrometers Spring tension tester A. dynamo & cut out 2 each s. 25. V. pre. O.n Item 17 c) GENERAL INSTALLATION / MACHINERIES 18 Drilling Machine ( Bench) 12 mm dia Grease Gun 19 Growler Pulley set universal for bearing & bushes (set) 20 Battery charger 6V – 24 V Pulley puller 21 AC alternator slip ring puller Glow plug 22 AC alternator slip ring press tool Alternator 23 Executive Auto Electrical tool kit Glow plug tester 24 Electrical test bench Torque wrenches 5035 Nm. meters Alternator regulator tester Distributor tester Continuity meter Clip on meter Digital and Analog 1 each Tachometer Spark Plug tester “NEON” type High rate discharge tester Multimeter digital and Analog 1 each Starter motor. flocks for screwing up and up.25mm. alternator.engagement type & CoHorn and Horn relay axial type 1 each 29 Electrical horn( different types ) Air conditioned MPFI vehicle with accessories 30 Wiper motor assemblies Engine control sensors 8 types 31 Engine Scanner Five Point relays 4 nos 32 Anti theft devices Four Point relays 4 nos 33 Melting pot Bearing puller set ( 100.5mm x 12 mm.5 litres Smp (straight & bent) General purpose puller 36 37 38 39 40 41 42 43 44 45 46 47 48 Double open ended spanner set (10. 10.12 13 14 15 16 17 18 19 20 21 22 23 24 Flat File 35 cm bastard Flat File 25 cm second cut Micrometer Outside 0. 12.68 Nm 25 Car stereo 1 No Starter test bench 26 Battery 12V (Lead acid & Alkaline) Dynamo and voltage regulator 27 Electronic engine control module Alternator and inbuilt regulator 28 Starter motor axial type. capacity 80 and 160 mm (e) Slide hammer 2 sets Paraffin pressure Gun 34 .50mm Soldering iron 120 watts Nose Pliers (round and straight) 150 mm and 200mm Circlip pliers Thread pitch gauge Stud remover Spanner T.300mm for extracting both outer and inner races with box containing (a) 8 internal extractors (b) counter stays (c) Pulling chuck of capacity 5 x 32 mm (d) 2 arm cooler.screwing inaccessible positions Cleaning tray 45 x 30cm Oil cane 0.n 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Item s.

solenoids. Refrigeration cycle – high pressure side & low pressure side d.e. 35 . checking. crank shaft position / engine speed sensors (magnetic pick up type) – importance of these sensors for air conditioning system  Construction and working principle of actuators – coolant diversion valve(for heating the cabin) & idle air control valve (Electronic controlled engines ) & duty cycle  Description / Reading of wiring diagram  Description & operation of Main Functional parts–Compressor. condenser fan. heater-cooler independent system. 14 years of Age & MES Module on Basic Automotive Servicing (4 wheelers) : Successful candidate would be able to Repairing of Auto Air Conditioning System : 240 Hours Underpinning Knowledge (Theory Safety precautions and first aid. blower motor. resistance & continuity in different lines for air conditioning system (climate control)– reconcile Ohm‟s law. thermostat. Evaporator. types. switches. Brief on Magnetism. g. Resistance & their units. assemble & refit to the vehicle Remove expansion valve from the system. modules & sensors on vehicle Measure voltage. Engine coolant temperature (NTC type). rectify the defect. junction box. check. Potential difference. Use of multi-meter. reheat air condition system. finding the leak & charging the system  Procedure for Fault finding (Trouble shooting charts) & rectification in car air conditioning  Procedure for dismantling. consumables & clothing safely Identify various components of air condition system on the mockup board Identify various electrical equipments i. rectify the defect. Terminal competency 6. uses. Condenser. receiver/drier. & refit into the system Remove evaporator & heater cores from the vehicle. Air temperature (Thermistor).Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle. assemble & refit to the vehicle Check condenser on the vehicle. basic components & circuits (with fixed orifice tube & thermal expansion valve-Mechanical & Electrical circuits). Code 4. Definition of technical terms – pressure. quantity. dismantle. pressure switches & magnetic valve(for dual air conditioner) Repair  Procedure for evacuating / draining the system. semi air-mix type. Care and maintenance of tools & equipment  Signs and symbols used in Air conditioning system  Fundamentals of air conditioning: a. Sector 3. characteristics of R12 & R134a. check. maintain & store – tools. a/c systems – car air conditioning types & features(dash type. Handling of refrigerants. use of thermometer and pressure gauges. assembling different components of the system  Difference between manual & automatic air conditioning / climate control systems  Air distribution of air conditioning system & different types of actuation of distribution doors                 Note: . Circuit protectors. full air-mix type.  Semiconductor & application (only brief)  Description/working principles. ground connections.Repairing of Auto Air Conditioning System 1. select. basic operation of refrigeration cycle. all season type & dual air conditioner type). specific heat & heat transfer).Different types of above components  Description & operation of Other Functional parts – magnetic clutch. f. check. Introduction – purpose. Duration 7.. resistors. cooling load and capacity. use. dismantle. location & checking of – switches. b. relays. e. and Expansion Devise/valve . change of state & pressure temperature relation. heat(heat. rectify the defect. COURSE CONTENT: Practical Competencies  Practice Health & Safety – familiarize. dismantle. temperature. Humidity. Entry Qualification 5. & rectify the defect Check the drive system & adjust if required  Check Belt tension  Check Gap in electromagnetic clutch Remove & refit heater control module Test the system for leaks Evacuate/drain the system Charge / fill the system Find the Faults & rectify in the climate control system  : Repairing of Auto Air Conditioning System : Automotive Repair : AUR210 : Minimum 5th Std. lubrication. automatic temperature control systems  Electrical basics: Ohm‟s law – Current. Proper Use. equipments. Check of circuit breakers and relays Check sensors & actuators using engine scanner / DMM Check duty of idle air control valve with ac on & off with different engine RPM Remove compressor from the vehicle. diodes & Heater Control Module  Working principle of sensors – throttle position (Potentiometer). c. Name 2.

8. Pipe Wrench Screw Wrench Ring Spanner Set Hydraulic jack 2 Torque wrenches of different capacity Solder Iron Inspection lamp with guard and wandering lead of 100 ft Tripod axle stand adjustable 1500 kg capacity Vehicle with dual air conditioning system along with special tools for removing and refitting air conditioning system & work shop manuals 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 DMM 2 sets of accumulator / drier Mock-up board with semi-automatic air conditioning system Service units with set of Compound pressure gauges-Recovery Machine & charging Unit Leak detectors – electronic & UV lamp Drilling Machine 2 sets of condensers 2 sets of compressors of different types 2 sets of expansion valves of different types 2 sets of evaporators of different types 2 sets of air distribution doors of different types 2 sets of coolant control valves (heater control) 2 sets of A/C control assemblies of different types 2 sets of switches of different types (HP & LP Switches) 2 sets of Thermistors Heater control modules(E & C Unit) 2 sets of blower motor 2 sets of receiver/drier 34 35 . TOOLS & EQUIPMENT( Suggested ) s. 36 .n Item s.n Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Screw driver File Crimping Tool Hacksaw DE Spanner Set Vice Hammer Pliers.

use. bump steer. Code 4. fixed data & data to be fed to the machine  Procedure for balancing the tyre. vibration. castor. ride height. MES Module on Basic Automotive Servicing (4wheelers) : Successful candidate would be able to do wheel Alignment & wheel balancing : 120 Hours 5.Wheel alignment & balancing 1. 14 years of Age. excessive steering effort. steering shimmy. Terminal competency 6. COURSE CONTENT: Practical Competencies  Practice Health & Safety – familiarize. thrust angle & frame angle. function of each part. set back. Wheel balancing  Meaning of balance. dynamic balance. Sector 3. rim & assembly  Balancing tolerance values  Reasons for more imbalance         Note: -Do the practical works as per the manufacturer‟s recommendations mentioned in the service manual of the particular brand of vehicle 37 . causes & effects of imbalance. select.  Components. poor self centering and memory steer. shock absorbers & struts & power steering Set the aligner ready for wheel alignment tests Check and rectify steering geometry with wheel aligner – take a print out Wheel balancing Remove tyre from vehicle Check tyre & rim and also check for run out Do static balancing Fit the wheel assembly on the aligner and check for dynamic imbalance & rectify the defects Fit the tyre assembly to the vehicle Underpinning Knowledge (Theory)  Safety precautions and first aid. Name 2. turning angle. wobble & waddle  Brief on static balance. toe. brief working principle & operation of computerized wheel aligner  Procedure to make machine to check wheel alignment  Procedure for taking readings using wheel aligner. Care and maintenance of tools & equipment Wheel alignment  Layout of steering &suspension systems.. wheel bearings. control arms bushings and sway bars. equipments. ball joints.  Brief on suspension and its effects on steering  Steering geometry: Description and purposes of Ackerman steering.  Pre alignment inspection/checks  Two wheel & four wheel alignment  Reasons for Alignment problems – steering pull.  Procedures for test drive to confirm the repairs. transfer path & responder of vibration(can be felt & can be heard)  Analyzing & identifying complaint  Procedure for road tests(vibration diagnostic)  Steering wheel shake – shimmy. Identification of source. camber. interpreting alignment readings & repair the same. Mounting errors(radial & lateral) & excessive(Tyre & rim) run out-lateral & radial and mismatches  Brief description of wheel balancer(block diagram balancer). Entry Qualification : Wheel alignment & balancing : Automotive Repair : AUR211 : Minimum 5th Std. maintain & store – tools. king pin inclination/SAI(steering Axis Inclination). Duration 7. included angle. consumables & clothing safely Wheel alignment Check tyres. torque steer & steering harshness-alignment diagnostics chart & steering problem diagnostic chart. off-centre steering.

n Item 1 2 3 4 5 6 7 8 9 10 11 Screw drivers File DE Spanner Set Box spanner set Hacksaw blade with frame Tyre pressure gauge with accessories Hammer Vice Pliers Pipe Wrench Torque wrenches of different capacity 12 13 14 15 16 17 18 19 20 21 22 Inspection lamp with guard and wandering lead of 100 ft Horses and wheel chokes Screw Wrench Ring Spanner Set Wheel aligner bay/ramp/pit with rolling jack Computerized wheel aligner with all accessories along with manuals & diagnostic charts Wheel changer Computerized wheel balancing machine with all accessories Compressor with accessories FWD Vehicle with workshop manual & vehicle kit 38 . TOOLS & EQUIPMENT( Suggested ) s.n Item s.8.

seam and Butt welding. Fitment of repaired part and aligning to the original shape . description & Specification. Entry Qualification : Minor repair of Auto body : Automotive Repair : AUR212 : Minimum 5th Std.Gas Welding. gas brazing. floor wheel boxes & fenders Do gas welding. select. Procedure for inspection. Care and maintenance of tools & equipment Introduction on types & function of body & panels. Arc Welding procedure RESISTANCE WELDING: . proper use. make smooth surface by using different grade of sanders.Minor repair of Auto body 1. brazing & Soldering procedures Gas cutting practice ARC WELDING: . Terminal competency 6.Resistance welding process – spot. apply putty on affected area & primer (repair damaged body which is ready for final paint) Apply base coat painting Fit & Check the repaired components for alignment          Underpinning Knowledge (Theory Safety precautions and first aid. beat out of dents. Sector 3. 14 years of Age & MES Module on Basic Automotive Servicing (4 wheelers) : Successful candidate would be able to do minor repair of auto body : 210 Hours 5. beat out. doors & other body parts GAS WELDING : . removing & refitting of body components-panels.Basic Electricity and welding power source Electrodes – types. Proper Use. Remove and refit body panels. Name 2. stripping of old paints. seam & butt welding on vehicle body Do minor repair of auto body – cut open. strip out old paint. gas soldering & gas cutting on vehicle body Do arc welding on vehicle body Do Resistance spot. consumables & clothing safely Inspect & decide whether it can be repaired or replaced.. Code 4. COURSE CONTENT:          Practical Competencies Practice Health & Safety – familiarize. sanding at different stages. Duration 7. doors. smooth surface preparation at different stages. putty application & primer application at different stages of affected area (Chronological order for repair of auto body ). equipments. maintain & store – tools. Method of fixation of wind screen glass Procedure for cut open.

4mm &6mm Dia Centre Punch 100mm Gloves for Welding (Leather and Asbestos) Chisel cold flat 25mm x250mm Square File 2 Cut 250mm Hacksaw frame 300mm adjustable Hand Groover 3mm. 40. 18. 52. 4mm.25 Kg with handle Ball peen Hammer 0. 67. 22. 66.n Item 1 2 3 4 5 6 7 8 9 10 11 12 13. 32. 64. 50. 58. Steel Rule 300mm Steel Tape 2 meters Wing Divider 200mm Spring Dividers 150mm Ordinary Wooden Mallet 50mm Cross Peen Hammer 0. 59. 44. 55. Sher Tinmans 300mm 29. 38. 46. 69. 14. 42. TOOLS & EQUIPMENT( Suggested ) s. 72. 4mm. 53. 43. Snips straight 250mm 30. 62. 25. Right cut snips 250mm 31. Lead. 26. 23. 19. 56. 57.25 Kg Tin Man’s 450 mm x 600mm Sheet Metal Gauge Stake Round and Bottom Half Moon Stake Funnel Stake Anvil Face Stake Tinmans Horse Hammer Peaning with handle Hammer Creasing with handle Hammer Planshing with handle Hammer Block with handle Soft Hammers ( Brass. 51. 5mm Combination Plier Grip Wrench 200mm Soldering Copper Hatchet type 500gms Pneumatic riveting gun Trammel Point (with beam 600mm) Vernier Caliper (0mm-150mm) Micrometer outside (0 to 25mm) Raspcut file 250mm D. 47. 15. 60. 65.8. 54. 34. 48. 63. 61. 71. Close mouth and pick up (1 each) Portable Electric drill (Single phase) with drill bits Pillar type drilling machine 12mm with drill bits Crow bar 910 x25mm Pop rivet gun Lazy Tong Screw Driver 250mm ‘C’ Clamp 150mm 40 . 45. 17. Left cut snips 250mm Hand Shear Universal 250mm Punch Round 3mm. 39. 33. 6mm Leather Apron Tongs.2 Kg Goggles 37. 70. Spanner (6mm to 32mm) (set of 12 spanner) Scriber 150 mm Safety Glasses Hand vice 50mm Steel wire Brush 50mmx150mm Rivet sets snap and Dolly combined 3mm. 35. 27. Vernier bevel protractor Try square 200 mm Blade Ring spanner set at 12 metric 6 mm to 32 mm Adjustable Spanner 10 cm File flat 250mm second cut and smooth File flat 250mm smooth File flat 300mm bastard File half round 300mm smooth nd Round File 2 Cut 250mm Triangular File Smooth 250mm nd Gloves Apron Spark lighter Hammer Chipping 0.5 Kg with handle Protractor with blade 150mm Scriber 150mm x 3mm (Engineers) Soldering copper 0. 21. 41. 20.n Item s. 68. Copper. 49. 24. 36.E. 16. Rubber and Rawhide heads with handle) 28.

90.6mm 89. Portable Nibbler 85. Suitable Work Tables with vices Polishing cloth standard size LCV Condemned Consumables 41 . Buffing and Polishing Machine 83. Tin smiths bench folder 600 x 1. Spot Welding Machine with complete accessories 88. Welding Transformer ( 300 Amps) with accessories 86. Bench vice 82. Bench lever shears 250mm Blade x 3mm Capacity 75. Oxy-acetylene welding equipment with complete accessories (Low & high pressure) 79. D. 91.73. Air Compressor with accessories 76. 92. Liquified Petroleum Gas (LPG) Cylinder. Gas Welding Table 1220mm x760mm 87. Anvil 50 Kgs with Stand 81.E. Wooden Rule 450mm 84. Regulator and Torch with Burner 74. Spray Gun (Painting) 500ml 77. Guilltotine shearing Machine foot operation (1mt x 18G Capacity) 78. Grinder Pedestal motorized 200mm 80.

400G. Duration 7. Name 2.Auto body Painting 1. Entry Qualification : Auto body Painting : Automotive Repair : AUR213 : Minimum 5th Std.Application of body filler for surface preparation. Use. TOOLS & EQUIPMENT ( Suggested ) 1 2 3 4 5 6 7 General tools LCV Condemned vehicle body Air Compressor with accessories Spray Gun (Painting) 500ml Buffing and Polishing Machine Bench vice Consumables 8 9 10 11 12 13 14 Sanding emery 40G. selection of material.. 80G. equipments.  Application of Paint protection treatment / Anti-rust treatment  Procedure for Inspection of painting work & fixing the wind screen glass 8. Preparing affected surface for base coating. Terminal competency 6. Clear coat painting for metallic paints. Applying base coat painting. Primer coating on the affected area. 600G. Rubbing and polishing. 120G. select. proper use. Sector 3. Care and maintenance of tools & equipment  Selection of consumable for doing painting work  Procedure for doing painting( in chronological order). 14 years of Age & MES Module on Basic Automotive Servicing (4 wheelers) : Successful candidate would be able to do auto body Painting : 180 Hours 5. COURSE CONTENT: Practical Competencies  Practice Health & Safety – familiarize. tools & equipments . maintain & store – tools. 1500G. Hardener & thinner Paints Poly urethane body filler Rubbing & polishing compounds Polishing cloth standard size 42 . 220G. consumables & clothing safely  Prepare the damaged body for painting  Apply body filler on the affected area  Apply base coat  Apply clear coat  Do painting  Do rubbing & polishing  Apply anti-rust treatment  Fix wind screen glasses  Inspect the painting work Underpinning Knowledge (Theory  Safety precautions and first aid. Sanding on the affected area for smooth surface preparation. 2000G Primer. Code 4.

Terminal competency 6. maintain & store tools. Shine. 14 years of Age & MES Module on Basic Automotive Servicing (4 wheelers) : Successful candidate would be able to carry out repair and calibration of Diesel Fuel Injection pump & injectors : 180 Hours : Underpinning Knowledge (Theory General health & Safety precautions to be observed in the workshop / garage Over view on 5S technic (Sort. Code 4. Module name 2. Entry Qualification : Diesel Fuel Injection Technician : Automotive Repair : AUR214 : Minimum 5th Std. use. COURSE CONTENT              Practical Competencies Practice Health & Safety – select. construction & operation of Injectors and nozzles Procedure for testing the Injectors as per specification 5. Duration 7. Sector 3. Set in order.. types.Diesel Fuel Injection Technician 1. equipments & clothing safely Practice 5S technic Identify / Familiarize with the tools & equipments Wash / Clean FIP and Injectors Check the FIP on calibration bench and assess the condition Dismantle FIP using special tools Clean and inspect Parts of each components Replace defective components Assemble FIP using special tools Calibrate FIP using calibration test bench Test the Injectors using Injector Tester Replace defective nozzles using special tools Assemble injectors and test             Note: -Do the practical works as per the manufacturer’s recommendations mentioned in the service manual of the particular brand of vehicle 43 . Standardise & Sustain)-advantages in implementation of 5S Fuel supply layouts in diesel engines Nomenclature of different types of fuel injection pumps Working principle of FIP Components of an FIP and detailed functioning of each one of them Differences between different types of fuel injection pumps Working principle of Injection Timers and Governors Brief on the FIP Test rig & calibration charts Procedure for phasing & calibration of an FIP Purpose.

TOOLS & EQUIPMENTS ( Suggested ) s.(6 mm -17 mm) Set of 12 nos. x 9 mm blade Screw driver 30 cm x 9 mm blade Spanner D E set of 12 pieces (6 to 32 mm) Pliers combination 15 cm Hand file 20 cm. Hollow punch set of seven pieces 6 mm to 15 mm „V‟ Block 75 x 38 mm pair with Clamps Spanner off set double ended set of 7 pieces. T bar & ratchet Oil can 0. Different types of Fuel Injection Pumps Different types of Injectors FIP test Bench along with a set of special tools for repairing & Testing different types of FIPs Injector test bench along with a set of special tools for repairing different types injectors 44 .no Item s. ring offset set of 6 (S A E) Spanner.8. Allen Key set of 12 pieces (2 mm to 14 mm) Philips Screw Driver Type set of 5 pieces 100 mm to 300 mm Steel Rule 30 cm. English and metric Prick punch 15 cm Scriber 15 cm with scribing block universal Hacksaw frame adjustable for 30 cm blade Hand vice 37mm Drill Twist ( assorted ) Hand reamer adjustable Drilling machine Electric pedestal grinder with two wheel 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Portable electric drill 6 mm Latest Diesel 4 Wheelers of different make (one LMV & one HCV) along with workshop manuals Injector holders Mallets (wooden/plastic) Spanner.5 liter cap Cleaning Tray 45 x 30 cm with 6+1 compartments Work bench each 250 x 120x60 with 4 bench vices 12 cm jaw Pullers screw powered 2 mm with bearing puller attachment Vice grip pliers Circlip pliers Expanding and contracting type 15 cm and 20 cm each Inspection lamp with guard and wandering lead of 100 ft. Second cut Centre punch 10 mm dia x 100 mm Chisel cold flat 20 mm Ring spanner set of 12 pieces (6 to 32 mm. adjustable 20 cm.no Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Hammer ball peen 0.) Feeler gauge 20 blades (metric) Steel tool box with lock & key (folding type) size 400x200x150mm . Socket Spanners with handle.75 kg Screw driver 20 cm.

Competency Based Curricula Competency Based Curricula for for Short Term Courses based on Short Term Courses based on Modular Employable Skills (MES) Modular Employable Skills (MES) in in Bicycle & Tricycle Repair DIRECTORATE GENERAL OF EMPLOYMENT AND TRAINING MINISTRY OF LABOUR & EMPLOYMENT GOVERNMENT OF INDIA 45 .

clothing use of and protective materials used in Bicycle & Tricycle Repair  Apply good house keeping practices. Functions and uses of various tools and equipment. Reasons for carrying out good housekeeping practices disposal of waste. equipments and materials used in Bicycle & Tricycle repair in a safe manner.Bicycle & Tricycle Repair Name Sector Code Entry Qualification & Age Duration Terminal Competency : : : : : : Bicycle & Tricycle Repair Automotive Repair AUR116 Vth standard. 14 years & above 180 hours    Identify.  Store/lay materials at work in safe manner  Use and store tools and equipments in a safe manner  Select proper tools for a particular task   Care and use of tools. follow statutory regulations. Carry out repair of puncture Dismantle & assemble the Bi-cycle & Tricycle and troubleshoot the faults CONTENTS: Practical Competencies Underpinning Knowledge(Theory)   Use of protective clothing and boots Identify tools. equipment and materials used in Bicycle & Tricycle Repair Selection and correct use of tools 46 . equipments and  Safety precautions. select. proper handling of materials and   elementary first aid. use and store tools.

steering assembly. repair/ replace the defective parts  Functions of different parts of bicycle and tricycle  Assemble all the parts and check for sub-assembly‟s proper operations  Working steps on dismantling and assembling  Trouble shoot the various problems occur during running (Frequent loss of air pressure.  Maintenance of bicycle & tricycle (Cleaning. tyre tube valves)  List out the materials and spares required for the given repair work  Estimate cost of materials and spares required  Criteria for preparation of an estimate. handle bar shaking. pedal crank slipping. air pressure. Wheel assembly. wheels and drive system lubrication and oiling.Practical Competencies Underpinning Knowledge(Theory)      Drive bicycle safely Repair puncture in bicycle/ tricycle Check the correctness of fault rectified Change tyre and tube Dismantle the bicycle / tricycle (Sub-assemblies: Handle bar. brake failure. wheel wobbling. noise in running)  Method of aligning the wheel and balancing  Probable cause-effect – remedy of faults in brake systems. free wheel mal functioning. steering systems. drive system. bottom shell assembly)  Safety rules and traffic symbols for two wheelers     Procedure of Puncture repairing Method of testing for air leakage Tyre inflator and its uses Tube valve assembly and its function  Safety precautions in puncture repair  Clean and inspect parts. hard pedaling. fork assembly. drive system. brake . chain slipping. various types of costs 47  Maintenance schedule and procedure for bicycle and tricycle . brake system. if necessary. periodical checkup.

overheads and cost of utilities (Power.Practical Competencies Underpinning Knowledge(Theory)  Estimate man power and time required for completing the work (fixed and variable cost). water)  Prepare an estimate for the repair work including profit 48 . profit. calculation of total estimated cost  Estimate labour cost.

fork stem M25 Special spanner for bottom bracket. lock ring . fork stem M 35 All in one spanner Chain tensioner ratchet type and screw type 49 Quantity proposed for a batch of 20 trainees 5 sets 5 sets 5 sets 5 sets 10 Nos.LIST OF TOOLS AND EQUIPMENTS S. cup. 5 set 5 Nos 5 Nos 5 Nos 5 Nos 5 Nos 5 Nos 2 Nos 5 Nos 5 Nos 2 Nos 2 Nos 2 Nos 5 sets 2 Nos 5 Nos 5 Nos 5 Nos 5 Nos 5 Nos 5 Nos 2 Nos 2 Nos 2 Nos 2 Nos 2 Nos 2 Nos 2 Nos 2 Nos 2 Nos each . free wheel. free wheel body .No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Description of tools Double end spanner 6 – 27mm Double end spanner ¼” – 1 1/8” Ring spanner 6 – 27mm Ring spanner ¼” – 1 1/8” Screw driver heavy duty 12” Phillips screw driver Side Cutting plier 9” Flat Nose plier 6” Ball peen hammer 1 lb with handle Adjustable spanner 20cm long Pin punch 150 mm Cold flat chisel 19 mm Wheel balancing stand with rim bend remover Nipple key Adjustable tubular hacksaw frame Tyre inflator foot operated Tyre inflator hand operated Anvil 50 kg with stand Tyre levers Scissors 9 “ Rasp cut file 300 mm End Cutting plier 9” Box spanner 6 – 27mm Hook spanner Circlip plier 150 mm Face pin wrench for hub shell Grease gun 1 kg Oil can 250 ml Special spanner for fixed bottom race cup and for fork lock Special spanner for pedal shaft and wheel cone nut Special spanner for free wheel Special spanner for fork lock nut. rear cup adaptor.

8. 5. 6.No 36 37 38 39 40 41 42 43 45 46 47 48 49 50 51 Description of tools Water basin Tyre tube puncture repairing kit Slip joint multi grip plier Drift punch 150 mm Emery card Wire brush Old bicycle for spanner practice Old tricycle for spanner practice Wheel assembly Free wheel assembly Hub assembly Children cycle Sports cycle Handicapped cycle Gym cycle Quantity proposed for a batch of 20 trainees 5 Nos 5 Nos 2 Nos 2 Nos 2 Nos 5 Nos 2 Nos 2 Nos 5 nos 5 nos 5 nos 2 Nos 2 Nos 1 No 1 No Consumables 1. Kerosene Lubrication Oil Grease all purpose Cotton waste Soap Oil Multipurpose grease Wheel bearing grease Emery sheet (rough smooth sand paper) Wire brush 50 litres 10 litres 10 kgs 30 kgs 5 litres 50 kgs 50 kgs 1 dozen 5 Nos 50 . 3.S. 2. 7. 4. 9.

SivakumarRao 16.Sivakumar 17. Coimbatore G ITI .Guindy Kumaran ITC.Ambattur G ITI . Manager Guduvanchery. Raja 19.Pudukottai G ITI .M.Subbiah K. pP. 8. 4. Srinivasan 11. VVenkitesan 18.Mustafa T. Chennai G ITI . 9. K. 7. Chengalpet C E T. Guindy Deputy Director G I T I. 5. Vincent Raj Sanjay S.Kadirvelu B. K.Dharampuri G ITI .LIST OF MEMBERS OF TRADE COMMITTEE 1. T. Guindy Deputy Director C E T. Chennai Joint Director C E T. Trichy Secretary Principal Asst Training Officer Instructor Training Officer Asst Training Officer Asst Training Officer Asst Training Officer Jr Training Officer Asst Training Officer Jr Training Officer Asst Training Officer Technical Assistant G ITI .Jawaharlal G.Ambattur G ITI .Lakshminarayanan 13.John Bosco Prabahakaran Suganthan Employees Federation of Southern India „V‟ Care Ricess Technical Director – Tech Trg Academy Nandi motors. 14.Ambattur G ITI .N.Rudrakoti 12. Guindy Deputy Director C E T. G. CD Cell Member Member Member Chairman Member Member Member Member Member Member Member Member Member Member Member Member Member Member Member 10. Nirmal kumar D Justin Jebaraj 15. 2.Ambattur G ITI .Vijayamala 51 . 3.Ambattur G ITI . S S. 6.

#Detailed practice on different types of shrinking techniques and film fixing on car and residential windows. #Methods of taking the measurement of window glass right way and its practice #Identification of each tool used with its specific application #Demonstration of various Suncontrol film products. Safety. units & conversion #Construction. Quality control & Handling-Packing. #Understanding of Product coding used ( CH-Charcoal. . Reflective.Bronze.) #Demonstration on heat meter. # Tools used and their application # Standard Safety procedures during installation 52 Practical (45 Hours) # Demonstration on ideal work area cleanliness & its benefits . Privacy.MODULE Name of Course: Sun control Film Fixing Sector: Automotive Repair Entry qualification: 5th standard passed Age: 14 years completed Duration of course: 60 Hrs Code : AUR 117 Terminal Competency: On completion of course participant will be quality oriented Fixers with modern installation Techniques competent to fix the Suncontrol film on 4 wheelers. Storage and transportation of film #Types of Suncontrol film installation – Flat glass (Building/window) & automotive (door/window) # Different methods of Shrinking. and Decorative etc. High Performance. BR. G. properties & Benefits of products & their general coding #Product recommendations of various applications. #Basics of measurement: Methods. commercial and house hold glass panels Course Content: Under Pining knowledge (15 hrs) #Various Suncontrol film products: Non Reflective. BL-Blue etc …. #Demonstration on various areas where the accident occurs during installation & precautions for avoiding the same. #Product testing at Lab.Grey.

Low vision. Spray bottle 5. Flat glass residential window 9. Hearing impaired and Mild mentally retarded (I.Various product shade cards Note 1:This module is also found suitable for persons with disabilitities under the catagories of Locomotor (One arm/one leg). #Learning the techniques of easy way of removing the old film. # Use of Heat Meter. #Removal and Re-tinting / Re-fixing SunControl film for Auto and Flat Glasses. Side door windows OR different models of cars for practice 8.# Importance of cleaning.Measuring tape 2. #Flat Glass installation and special precautions. Front & Rear automobile glass 7.Q-50 to70) Note2: Item No 1 to 5 requires One for each student and Item 6 to 10 . 53 . #Recommendation customer #Film fixing practice on various car models and building windows ( Practice on minimum 10-15 standard of product to # Statutory requirements for Automobile Tinting & Dealing with Customer car windows & House / commercial windows ) #Soft skills and Dealing practice with customers Required Tools/Equipment for the course: 1. # Reverse Rolling Installation. Squeezee 3.Heat Meter 10. Hot air gun 6. Cutter 4.One for 5 students.

Mumbai DVET.co.in 9 rdatmum@nic. Organisation MIT College.com Dk12_dvet@yahoo. Joseph ITC Donbosco.Mumbai RDAT.List of members of Trade committee Sl No 1 Name S/Sh O. IR Bhilegaonkar Patil S A Zaidi R Senthil Kumar D K Pawagi D K Jatav Principal Astt App. Kurla .com 7 8 8 9892975454 9323456800 Szh_zaidi53e@yahoo. Advisor Instructor (MMV) Dy Director (Rehab) Regional Director 9892456368 9869673513 Amar_p77@yahoo.Mumbai RDAT.Mumbai Joint Director of Trg Assistant Director of Trg 9833563126 9867745863 dkpawagi@yahoo.com 54 . Mumbai VRC.com 5 Javed Pomatker Head-Customer Service 6 Amar P. Aurangabad431210 Garware Polyester Ltd.66 Cell 09850094317 9833856822 bsk@garwarepoly.in 10 11 RDAT. General Manager 4 Kaladharan Executive Director 02402485465.Mumbai Designation Director ( Poly) .Aurangabad 431005. Mumbai Madhuban Toyota LBS Marg Vidya Vihar Mumbai St.P. CIDCO. Town Center. Vaishya.Mumbai Govt ITI. Tel 02402341202 09325212387 02402488929/ 39 email 2 Arvind M. Aurangabad-431 201 Swaraj Mazda Lakozy Motors Pvt Ltd.in Devender_jatav@yahoo. Pathak Owner 3 B S Kulkarni. Maruti Authorized Service Station. Car Care. . Govandi .

Chennai-600 032 Ashwani Aggarwal Deputy Director of Training DGET AUTOMOTIVE REPAIR 02 03 04 05 06 07 55 . Chennai-600 035 Shri.Khivraj Motors (P) Ltd. Guindy. Guindy Chennai-600 032 Shri.Arivalagan.Sridhar Joint Director of Training Advanced Training Institute. Advanced Training Institute.M.G. Chirage Automobiles.Vincent Raj. Paul Wells Road. 13. St. Guindy. Assistant Director of Training. Service Engineer/Proprietor. Mount Road.P. 798. (Convenor) Assistant Director of Training. Chennai-600 016 Shri.Gandhi. “V” Care Bikes. Rajeswari Colony.Thomas Mount. (Chairman) Head – Training M/S.Ramakrishna Gowda.Subbarayudu.M. Advanced Training Institute. Chennai-600 032 Shri. Mount Road.List of Expert/Trade Committee Members CURRICULUM DEVELOPMENT FOR SHORT TERM COURSES BASED ON MODULAR EMPLOYABLE SKILLS SECTOR/AREA: 01 S.. Manager – Works M/S. Chennai-600 016 Shri.

 Filing of documents. Speed Post  Registering a letter & AD & Courier  Sending a Money Order  Sending mail/Speed Post/Courier Ways of sending money. permits. into the P. 180 hrs Duration: Note: On completion of the course the candidate has to obtain a valid Driving Licence as per RTO rules.  EMO The working of a Bank. General Office Work Understanding the importance of various  Making a photo-copy documents relating to the Vehicle namely  Buying office stationery insurance.  Sending mail Under Certification Different courier services and their operations of Posting  Depositing P.  Making of a DD. ------------------------------------------------------------------------------------------------------Syllabus ------------------------------------------------------------------------------------------------------Practical Competencies Underpinning Knowledge (Theory) Office work: ( 25hrs) Postal and Courier  Buying of postage. road-tax.  Telephone / Electric / Tax-bills  Paying the Tax & Insurance 56 . inland letters. post cards. etc The importance of registered post. Transport The documents used in road & rail transport.  Withdrawal of cash via cheques & withdrawal slip. cheques & drafts.Module-1 Name: Sector: Code: Entry Qualification: Age: Terminal Competency: DRIVER CUM PEON Automotive Repair AUR 118 8th pass Minimum 20 years. Banking The importance of a bearer cheque. Department.  Booking & sending a package by road & rail transport  Receiving goods from road Working of RTO/Motor Vehicle & transport. Driving licence & fitness. (Level-I) After completing the training the candidate will be able to drive the car and do the necessary peon work. The working of a Post-Office and a Courier.O. emission (PUC).F.  Depositing of cash.

Basic parts and working of a battery. How air is filtered. The different parts of a spark plug. The necessity of cleaning.  Replacing punctured tyres.  Replacing the points.  Checking the fuel pump. 57 . The need for distil water.  Cleaning the points.  Cleaning & washing the exterior. Petrol Smell:  Checking the fuel tank.  Replacing the spark plug. How a spark plug fails to function. The need for the cooling system.  Cleaning the spark plug. How a battery is charged and discharged.  Polishing the metal parts. The positioning of the fuel tank and fuel lines. The process of cleaning different materials. Oil & Filters:  Draining engine oil. Engine Overheating:  Checking the cooling system.  Checking the water pump. Spark Plug:  Removing the spark plug.  Rotating tyres. compression ignition & spark ignition.  Cleaning the radiator.Getting a PUC for the vehicle. The fan and its belts. Maintaining a Log -book Driving: ( 100hrs)   The importance of lubrication.  Changing fuel & air filters. The use of a spark plug. The difference between primary and secondary cells. When filters needs to be replaced. Awareness of LPG & CNG as fuel Simple testing of a battery.  Changing engine oil. The process of repairing a tyre.  Checking the spark-plug.  Flushing the cooling system. Cleaning & Polishing:  Cleaning the interior. The ignition system of a vehicle.  Checking the fuel lines.  Checking the charging. Battery Maintenance:  Cleaning and applying petroleum jelly.  Checking the HT leads. The relation of inflation with road grip The need for the rotation & alignment of tyres. How oil is cleaned. Curing Starting Problems:  Checking the battery. The purpose of different elements in the ignition system.  Topping up the distil water.  Application & Renewal Driving License Workshop Practice: (30hrs) Lubrication:  Checking & topping up oil  Lubricating moving parts  Greasing via nipples Tyres:  Jacking & supporting the car  Checking tyre inflation. The different types of lubrication used in vehicles.  Checking the distributor cap. Different parts of a tyre. The positioning of the different elements of the cooling system.  Checking the timing. Getting a Fitness Certificate of vehicle. The danger of a fuel fire. The timing mechanism.

2.  Driving on a highway.  Use of Speed.(Cardiopulmonary resuscitation) Global warming and tail pipe emissions.  Giving the correct signals. The dash-board instruments and their use.  The proper use of a horn. Knowledge of the different documents required for a vehicle. Tools & Equipment: 1. (when to use & when-not) Sensitivity to passenger needs. ………….  Negotiating roundabouts.  Negotiating junctions. 3. The necessity of good manners.    The different parts of a car.  Giving First-Aid.  Driving Away & Stopping.  Reversing. Identifying controls & Instruments. Road sign charts. Luggage and its positioning.  Turning the vehicle around.  Interacting with other traffic.  Dealing with a Road accident. First party & Third party insurance. The brakes and their application. The drive train. Etiquette & First Aid: ( 25hrs)  Learning Good Manners.  Pedestrian crossing. Road signs & signals with special stress on lane & highway driving. Filing an accident report.  Performing Eco-Driving & avoiding rash and negligence driving. The first-aid used in different situations.  Safe Positioning. CPR.  Parking.  Emergency stop. The working of the engine. Assorted hand tools. Loading and safety. One dedicated training car fitted with a dual brake & a dual clutch. The need and use of gears.Performing cockpit checks.  Driving at night.  Adjusting & using the mirrors.  Operation of Remote & Child lock. Performing safety checks. Proper use of a mobile by a driver.  Anticipating & Planning.  Personal Hygiene  Care of driving while carrying school children. The importance of the clutch. 58 .

RDAT. Asansol. Asansol. 14. CEO. Asansol. Raj Noronha S/s Tinku Kapoor S/s Sandip Samanta Organisation Regional Director. Eastern Region. H. 10 11.D.C. Asansol Secretarty. Kolkata Dy. Giri Br. Asansol Chamber of Commerce. CEO. Vincent’s ITC.. 13.College . Kolkata Superintendent. G. Asansol Manager. Yadav Farook Sayeed Carlton Dsouza Member Member Member Member Member Member Member Member Member \ 59 . The Technician. N. Asansol .Kapoor & Co.List of members attended the Trade Committee Meeting for designing the course curriculum under Skill Development Initiative Skill (SDIS) based on Modular Employable Skills (MES) on DRIVER CUM PERON Sr. Remark Chairman Member Member Member Member 6 7 8. No 1 2 3 4 5 Name S/s S. Advisor. Jupiter Services. 12. S/s Alok Kumar S/s Ranjan Kumar S/s Gour Chackraborty Prof. Asansol CEO. Eastern Region. Neha Multimedia. Steel City Courier.S. Asansol Maheswari Enterprises & Mining. Asansol Chamber Merchants Chamber of Commerce & Industry. Asansol CEO.do CEO. Asansol Ex-principal B. Asansol. 9. Director. Chackraborty S/s Navin Kumar Jain Khan Firoz Bhadur S/s R. (Service Station for Tata Motors). RDAT. Lahiri S/s G. Liliput. St.

Sign up to vote on this title
UsefulNot useful