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COMPETENCY STANDARDS
OF
AUTOMOBILE & DIESEL TECHNOLOGY
(DAE - Level- 5)
CONTENTS Sr. No
TABLE OF CONTENTS Pages
1. Introduction 8
2. Purpose of the qualification 8
3. Date of Validation 8
4. Date of Review 8
5. Code of Qualification 9
6. Qualification Development Committee 9
7. Qualification Validation Committee 11
8. Entry Requirements 12
9. Regulations for the Qualification and Schedule of Units
10. Packaging of the qualification
11. Summary of Competency Standards 12
12. Occupations of Automobile &Diesel Technology. 21
CORE COMPETENCIES
Internal Combustion Engine (AD-133) 30
CS1 Identify Engine Types Their Component and Interpret its Specifications
31
CS2 Identify Basic Engine Parts and Interpret Assembly Procedure
33
CS3 Understand Engine Cooling System Components and Their Relationship
35
CS4 Understand Engine Lubrication System and working of its Components
37
CS5 Understand Petrol Engine’s Fuel System Components and their Relations
38
CS6 Understand Diesel Engine’s Fuel System Components with their Relations
40
CS7 Understand the Engine Exhaust System Components 42
CS8 Diagnosing Engine Faults and fix them 43
CS9 Understand Spark Ignition System of Internal Combustion Engine
45
CS10 Perform Overhauling of Four Stroke Motor Cycle Engine 47
Automotive Electricity and Electronics (AD-143) 49
CS1 Perform Basic Electricity Measurements 50
CS2 Understand the Electromagnetism and its application 51
CS3 Perform Battery Service of Vehicle 52
CS4 Repair Engine Starting System 54
CS5 Repair Spark Ignition System of Internal Combustion Engine
56
CS6 Adjust Ignition Timing of Spark Ignition Engine 58
CS7 Repair Distributer-Less Ignition Systems of Spark Ignition Engine
59
CS8 Repair Battery Charging System 60
CS9 Repair Lightning System of Vehicle 62
CS10 Repair Vehicle Electrically Operated Accessories 63
Workshop Practice-1 (MT-164) 65
CS1 Perform Bench Work on Metallic Surfaces 66
CS2 Perform Shaper Machine Operations 69
CS3 Perform Lathe Turning Operations 71
CS4 Read and Interpret Manufacturing Drawings 73
CS5 Perform Welding Procedure Specifications (WPS) 75
CS6 Prepare Materials for Welding 77
CS7 Perform Shielded Metal Arc Welding (SMAW) in Vertical (3F, 3G) and Overhead (4F, 4G) Positions
79
CS8 Perform Forging Operations 81
Basic Engineering Drawing and CAD-I Mech-163 83
CS1 Perform Drawing, Sketch Making 84
CS2 Draw Pictorial Drawing 86
CS3 Perform Basic Dimensioning System in Working Drawing 87
CS4 Perform Sectioning and Pictorial Drawing 89
CS5 Draw Auxiliary Drawing 90
Problems in Internal Combustion Engines AD-203 91
CS1 Diagnose Engine Fault 92
CS2 Perform Engine Overhauling (Petrol/Diesel) 94
CS3 Diagnose Engine Cooling System Faults and Repair 96
CS4 Diagnose Faults in Engine Lubrication System 98
CS5 Diagnose Faults of Carburetor Fuel System 99
CS6 Diagnose Diesel Fuel System and Adjust 101
CS7 Diagnose Faults of Ignition System 103
Suspension, Steering & Brakes AD-213 105
CS1 Repair Vehicle Brake System 106
CS2 Repair Vehicle Steering System 108
CS3 Maintain Vehicle Suspension System 110
CS4 Carry out Wheel Alignment 112
CS5 Carry Out Wheel Balancing 114
CS6 Replace SRS System 116
Workshop Practice-II AD-224 117
CS1 Arrange Common Automotive Hand Tools and their Use 118
CS2 Carry Out Measurements with Automotive Measuring Tools
120
CS3 Perform Test on Vehicle with Automotive Workshop Equipment
122
CS4 Diagnose Faults by Computerized Performance Testing Equipment
124
CS5 Categorize Automotive Fasteners Types and their Uses 125
CS6 Specify Vehicle’s Lubricants Types 126
CS7 Differentiate Vehicle Oil Seals Types and Specifications Coding
127
CS8 Specify Vehicle Bearing’s Types and Coding 128
CS9 Read and Interpret Quality Control Standards and Certification
129
CS10 Plan and Organize Safe Workshop and Hazard Prevention Practices
130
Metrology MT-252 132
CS1 Recognize Graduated Instruments 133
CS2 Carry-Out Linear Measuring 134
CS3 Carry-out Precise Measuring 136
CS4 Perform Angular Measuring 138
CS5 Identify the Types of Gauges 140
CS6 Identify Comparators Instrument 142
Applied Thermodynamics AD-232 144
CS1 Analyses HVAC/R Systems Thermodynamic Performance
145
CS2 Carry-out Smooth Boiler Operation 147
CS3 Recognize Fundamentals of Thermodynamics Problems 149
CS4 Read and Interpret Perfect Gases Laws, Properties and Solve problems
150
CS5 Read and Derived Thermodynamics Processes and Cycles
151
CS6 Analyze Reciprocating & Rotary Air Compressors Performance
153
CS7 Solves Problems of Internal Combustion Engine 154
Motor Vehicle Driving AD-302 155
CS1 Inspect Vehicle Controls for pre Operational & Pre Starting
156
CS2 Read and Interpret Traffic Signals, Road Signs and Marking Lanes on Roads
159
CS3 Apply Power& Parking Brakes to Vehicle 161
CS4 Drive Car in Different Condition 162
CS5 Drive Vehicle with Manual& Automatic Transmission 164
CS6 Drive Motorcycle 166
CS7 Drive Vehicle on Economy Speed for Fuel Saving 168
CS8 Perform Safety Practices While Driving 170
Motor Vehicle Inspection AD-312 171
CS1 Inspect Tires& Wheels of Light & Heavy Duty Transport Vehicles (LTV& HTV)
172
CS2 Inspect Vehicle Suspension System 174
CS3 Inspect Vehicle Steering System and Wheel Alignment 176
CS4 Inspect Light & Heavy Duty Vehicle Brake System 178
CS5 Inspect Vehicle Light System 180
CS6 Inspect Vehicle Electric System 182
CS7 Inspect Vehicle Glazing System 184
CS8 Inspect Vehicle Fuel System 186
CS9 Inspect Vehicle Body Accessories 188
CS10 Inspect Vehicle Exhaust System 190
CS11 Prepare Comprehensive Vehicle Inspection Report 191
CS12 Prepare Vehicle Title Certificate 193
Fuel Injection and Carburetion AD-343 194
CS1 Diagnose Faults of Intake System 195
CS2 Diagnose Faults of Exhaust System 196
CS3 Diagnose Faults of Fuel Supply System 197
CS4 Diagnose Faults & Repair Hybrid System 200
CS5 Diagnose Faults & Repair Engine Valve Control System 202
Automotive Transmission AD-363 203
CS1 Diagnose Faults &Repair Clutch 204
CS2 Diagnose Faults &Repair Manual Gear Box 206
CS3 Diagnose Faults &Repair Automatic Gear Box 208
CS4 Diagnose Faults &Repair Final Drive 210
Auto Body Building & Finishing AD-383 212
CS1 Understand Vehicle Body Shell 213
CS2 Prepare Cost Estimate for Damaged Vehicle Body and Chassis
215
CS3 Perform Vehicle Body and Chassis Alignment and Repair
217
CS4 Perform Vehicle Body Repairs Work 219
CS5 Carryout Panel Repair with Washer Welder Machine 221
CS6 Repair Vehicle Body Fittings 224
CS7 Perform Welding Operations on Vehicle Body 226
CS8 Maintain Machinery, Tools and Equipment 228
CS9 Remove and Fix Glass Items 231
CS10 Perform Body Surface Cleaning by Mechanical Process 233
CS11 Perform Body Surface Cleaning with Chemical Process 235
CS12 Maintain Vehicle Body Repair Tools, Equipment and Machinery
237
CS13 Maintain Paint Booth and Stores 240
CS14 Apply Polyester Putty 243
CS15 Prepare Paint Booth and Vehicle 247
CS16 Apply Primer Surfacer 249
CS17 Perform Color Matching & Mixing 252
CS18 Apply Body Sealer 255
CS19 Perform Masking 257
CS20 Apply Under Coat 259
CS21 Apply Final Coats 263
CS22 Perform Polishing to Body Surface 266
CS23 Prepare Paint Work Estimation 269
Workshop Practice-III AD-324 271
CS1 Perform Engine Preventive Maintenance (Tune-Up) 272
CS2 Perform Periodic Maintenance 274
CS3 Arrange Workshop Equipment According to Lay-out 275
CS4 Prepare Documentation for Automotive workshop 276
CS5 Maintain Service Station Equipment 277
CS6 Maintain Emission control system 278
CS7 Perform Engine Overhauling 280
CS8 Maintain Climatic Control System 282
CS9 Perform Engine Output Testing 284
CS10 Read and Interpret Hydraulic and Pneumatic Code and Symbols
285
Generic Skills
CS1 Participate In Workplace Communication 287
CS2 Perform Work in Team Environment 289
CS3 Read and Develop Career Professionalism 291
CS4 Practice Occupational Health and Safety Procedures 293
CS5 Lead Small Teams 295
CS6 Develop Negotiation Skills 297
CS7 Solve Problems Related To Work Activities 299
CS8 Develop Communication Skill 301
CS9 Develop Administrative Skills 303
CS10 Work effectively in a customer service/ sales environment
304
CS11 Develop Professionalism 307
ENTREPRENEURSHIP SKILLS
CS1 Manage the Operations of Workshop Security Units 310
CS2 Organize Training On Multiple Workshop Units 313
CS3 Administer Multiple Commercial Units 315
CS4 Supervise performance of Technician 317
CS5 Plan Work to Meet Expected Outcomes 319
CS6 Work Effectively In a Team 320
CS7 Maintain Healthy, Safe and Secure Working Environment 321
CS8 Deal with Emergencies and Incidents at Workshop 323
CS9 Maintain Effective Communication with Companies 325
1. INTRODUCTION OF AUTOMOBILE TECHNOLOGY
Automobile engineering is the one of the stream of mechanical engineering. It deals with the various types of automobiles, their mechanism of transmission systems and its applications. Automobiles are the different types of vehicles used for transportation of passengers, goods, etc. Basically all the types of vehicles works on the principle of internal combustion processes or sometimes the engines are called as internal combustion engines. Different types of fuels are burnt inside the cylinder at higher temperature to get the transmission motion in the vehicles. Most of the automobiles are internal combustion engines vehicles only. Therefore, every mechanical and automobile engineer should have the knowledge of automobile engineering its mechanism and its various applications. Automobile engineering is a branch of engineering which deals with everything about automobiles and practices to propel them. Automobile is a vehicle driven by an internal combustion engine and it is used for transportation of passengers and goods on the ground. Automobile can also be defined as a vehicle which can move by itself, for example Car, jeep, bus, truck, scooter, etc. Therefore, industry expectations for skilled workforce are also dynamic which can only be managed through setting relevant competency standards in collaboration with the leading industries. Being cognizant of this fact, National Vocational & Technical Training Commission (NAVTTC) developed competency standards for Civil Technology under National Vocational Qualifications Framework (NVQF). These competency standards have been developed by a Qualifications Development Committee (QDC) and validated by the Qualifications Validation Committee (QVC) having representation from the Auto Mobile industry of the country.
2. PURPOSE OF THE QUALIFICATION
The purpose of these qualifications is to set high professional standards for automobile industry. The specific objectives of developing these qualifications are as under:
1. Improve the professional competence of the trainees 2. Provide opportunities for recognition of skills attained through non-formal or informal pathways 3. Improve the quality and effectiveness of training and assessment for automobile industry 4. Enable the existing workforce to capacitate themselves in new technologies and methods.
3. Date of Validation
These national qualifications have been validated by the Qualification Development Committee (QVC) on 27-29 May 2019.
4. Date of REVIEW
These national qualifications may be reviewed in May 2022.
5. Codes of Qualifications
The International Standard Classification of Education (ISCED) is a framework for assembling,
compiling and analyzing cross-nationally comparable statistics on education and training. ISCED codes
for these qualifications are assigned as follows:
ISCED Classification for DAE Auto Mobile Technology level-5
Code Description
000000000 1st Semester National Certificate of level-5, in “Auto Mobile Technology”
000000000 2nd Semester National Certificate of level-5, in “Auto Mobile Technology”
000000000 3rd Semester National Certificate of level-5, in “Auto Mobile Technology”
000000000 4th Semester National Certificate of level-5, in “Auto Mobile Technology”
000000000 5th Semester National Certificate of level-5, in “Auto Mobile Technology”
000000000 6th Semester National Certificate of level-5, in “Auto Mobile Technology”
6. Qualifications Development Committee
The following members participated in the qualifications development workshop 31st December 2018 to
4th January 2019 at Hospitality Inn, Lahore:
S. No. Name & Designation Organization
1. Ijaz Hamid, Chief Instructor Auto & Diesel/ DACUM Facilitator,
GCT, Railway Road, Lahore PTEVTA
2. Abdul Ateeq, CEO
Rehman Motors Workshop, Model Town, Lahore
S. No. Name & Designation Organization
3. Abdul Waheed,
CEO Honda Pitspot, Johar Town Motors, Lahore
4. Syed Kazim Hussain,
Technical Advisor Toyota Township Motors, Lahore
5. Adeel Ahmad, Assistant Manager (Tech)
Lahore Transport Company, Lahore
6. Abdul Basit, Technical Advisor
Toyota Garden Motors, Lahore
7. Adnan Siddique, Technician
Toyota Garden Motors, Lahore
8. Rehman Ali, Assistant Manager
Al-Haj Faw Motors (PVT) LTD; Lahore
9. Atif Mahmood,
Service Manager Suzuki Mini Motors, Lahore
10. Aamir Javed, Service Manager
Suzuki Khalid Motors, Lahore
11. Skindar Shahzad,
Sr. Instructor/ DACUM Facilitator Aman Tech, Karachi
12. Abdul Aleem,
Jr. Instructor GCT, Sahiwal, PTEVTA
13. Tanveer Abass,
Jr. Instructor GCT, Railway Road, Lahore PTEVTA
14. Shakeel Ahmad
Jr. Instructor GCT, Faisalabad, PTEVTA
15. Majid Khan,
Jr. Instructor GCT, Attock, PTEVTA
16. Shahbaz Ali,
Instructor GSPTC, Gujrat, PTEVTA
17. Bashir Hussain Arshad,
Sr. Instructor GCT, Sahiwal, PTEVTA
18. Muzamil Hussain,
Instructor GCT, Rawalpindi, PTEVTA
S. No. Name & Designation Organization
19. Muhammad Azhar Khan,
Instructor Auto & Farm GCT, Bahawalpur, PTEVTA
20. Muqeem-ul-Islam,
DG (SS&C) NAVTTC, HQ
21. Muhammad Ishaq,
Dy Director (TE) NAVTTC, HQ
7. Qualifications Validation Committee
The following members participated in the qualifications development and validation workshop on 11th
February 2019 to 15th February 2019 at Garvaish Hotel, Faisalabad:
S. No. Name & Designation Organization
1. Mr Sikandar Masood Director
NAVTTC HQ
2. Mr Ijaz Hameed Chief Instructor (DACUM )
GCT railway road Lahore
3. Mr Muzamil Hussain Sr Instructor
GCT Rwp (PTEVA representative)
4. Mr Sikandar Shahzad Sr Instructor
AMAN TECH Karachi
5. Mr Abid Iqbal Associate Professor
GCT Peshawar (KPK TEVTA Representative)
6. Mr Fiaz Ali Ujjan Regional Manager
Sindh TEVTA Representative
7. Mr Abdul Waheed CEO Johar Town Honda
Industry Representative
8. Mr Abdul rehman Research Assistant
PBTE representative
9. Mr Aamir Ali Khan Assistant Director
Regional Director General Office ICT, NAVTTC
8. Entry Requirements
The entry for D.A. E National Certificate level 5, in Auto Mobile Technology are
1. A person having National Vocational Certificate level 4, in Auto Mobile Technology.
2. A person having Matric certificate with Science subjects
9. Summary of Competency Standards
Code Competency Standards Level Credits Category
Internal Combustion Engine (AD-133)
CU-1: Identify Engine Types Their Component and Interpret its
Specifications
2 Technical
CU-2: Identify Basic Engine Parts and Interpret Assembly
Procedure
2 Technical
CU-3: Understand Engine Cooling System Components and
Their Relationship
2 Technical
CU-4: Understand Engine Lubrication System and working of its
Components
2 Technical
CU-5: Understand Petrol Engine’s Fuel System Components
and their Relations
2 Technical
CU-6: Understand Diesel Engine’s Fuel System Components
with their Relations
2 Technical
CU-7: Understand the Engine Exhaust System Components 2 Technical
CU-8: Diagnosing Engine Faults and fix them 2 Technical
CU-9: Understand Spark Ignition System of Internal Combustion
Engine
2 Technical
Code Competency Standards Level Credits Category
CU-10: Perform Overhauling of Four Stroke Motor Cycle Engine 2 Technical
Automotive Electricity and Electronics (AD-143)
CU-11: Perform Basic Electricity Measurements 2 Technical
CU-12: Understand the Electromagnetism and its application 2 Technical
CU-13: Perform Battery Service of Vehicle 2 Technical
CU-14: Repair Engine Starting System 2 Technical
CU-15: Repair Spark Ignition System of Internal Combustion
Engine 2 Technical
CU-16: Adjust Ignition Timing of Spark Ignition Engine 2 Technical
CU-17: Repair Distributer-Less Ignition Systems of Spark Ignition
Engine 2 Technical
CU-18: Repair Battery Charging System 2 Technical
CU-19: Repair Lightning System of Vehicle 2 Technical
CU-20: Repair Vehicle Electrically Operated Accessories 2 Technical
Workshop Practice-1 (MT-164)
CU-21: Perform Bench Work on Metallic Surfaces 2 Technical
CU-22: Perform Shaper Machine Operations 2 Technical
CU-23: Perform Lathe Turning Operations 2 Technical
CU-24: Read and Interpret Manufacturing Drawings 2 Technical
CU-25: Perform Welding Procedure Specifications (WPS) 2 Technical
CU-26: Prepare Materials for Welding 2 Technical
CU-27: Perform Shielded Metal Arc Welding (SMAW) in Vertical
(3F, 3G) and Overhead (4F, 4G) Positions 2 Technical
CU-28: Perform Forging Operations 2 Technical
Basic Engineering Drawing and CAD-I Mech-163
CU-29: Perform Basic Drawing, Sketch Making 2 Allied
CU-30: Draw Pictorial Drawing 2
2
Allied
CU-31: Perform Basic Dimensioning System in Working Drawing Allied
CU-32: Perform Sectioning and Pictorial Drawing 2 Allied
CU-33: Draw Auxiliary Drawing 2 Allied
Problems in Internal Combustion Engines AD-203
Code Competency Standards Level Credits Category
CU-34: Perform Engine Fault Diagnosing and Adjustment 3 Technical
CU-35: Perform Complete Engine Overhauling (Petrol/ Diesel) 3 Technical
CU-36: Diagnose Engine Cooling System Faults and Repair 3 Technical
CU-37: Diagnose Engine Lubrication System Faults and Repair 3 Technical
CU-38: Diagnose Faults of Engine Fuel System (Carburetor
Type) and Adjust 3 Technical
CU-39: Diagnose Diesel Engine Fuel System and Adjust 3 Technical
CU-40: Diagnose Faults of Spark Ignition System and Adjust 3 Technical
Suspension, Steering & Brakes AD-213
CU-41: Repair Vehicle Brake System. 3 Technical
CU-42: Repair Vehicle Steering System. 3 Technical
CU-43: Repair Vehicle Suspension System. 3 Technical
CU-44: Carry out Wheel Alignment 3 Technical
CU-45: Carry Out Wheel Balancing 3 Technical
CU-46: Repair SRS System 3 Technical
Workshop Practice-II AD-224
CU-47: Identify Common Automotive Hand Tools and their Use 3 Technical
CU-48: Carry Out Measurements With Automotive Measuring
Tools 3 Technical
CU-49: Perform Test on Vehicle with Automotive Workshop
Equipment 3 Technical
CU-50: Diagnosing Faults by Computerized Performance Testing
Equipment 3 Technical
CU-51: Identify Automotive Fasteners Types and their Uses 3 Technical
CU-52: Identify Vehicle’s Lubricants Types with Specifications 3 Technical
CU-53: Identify Different Types and Specifications Coding of
Vehicle Oil Seals 3 Technical
CU-54: Identify Vehicle Bearing’s Types with Specifications Cods 3 Technical
CU-55: Read and Interpret Quality Control Standards and
Certification 3 Technical
CU-56: Plan and Organize Safe Workshop and Hazard 3 Technical
Code Competency Standards Level Credits Category
Prevention Practices
Metrology MT-252
CU-57: Recognize Graduated Instruments 3 Functional
CU-58: Carry-Out Linear Measuring 3 Functional
CU-59: Carry-out Precise Measuring 3 Functional
CU-60: Perform Angular Measuring. 3 Functional
CU-61: Identify the Types of Gauges. 3 Functional
CU-62: Identify Comparators Instrument 3 Functional
Applied Thermodynamics AD-232
CU-63: Analyses HVAC/R Systems Thermodynamic
Performance 3 Functional
CU-64: Carry-out Smooth Boiler Operation 3 Functional
CU-65: Recognize Fundamentals of Thermodynamics Problems 3 Functional
CU-66: Read and Interpret Perfect Gases Laws, Properties and
Solve problems 3 Functional
CU-67: Read and Derived Thermodynamics Processes and
Cycles 3 Functional
CU-68: Analyze Performance of Air Compressors (Reciprocating
& Rotary) 3 Functional
CU-69: Solves Problems of Internal Combustion Engine 3 Functional
Motor Vehicle Driving AD-302
CU-70: Perform Inspections of Vehicle Controls for pre
Operational & Pre Starting 4 Technical
CU-71: Read and Interpret Traffic Signals, Road Signs and
Marking Lanes on Roads. 4 Technical
CU-72: Apply Power & Parking Brakes to Vehicle 4 Technical
CU-73: Drive Car in Different Condition 4 Technical
CU-74: Drive Vehicle with Manual & Automatic Transmission 4 Technical
CU-75: Drive Motorcycle 4 Technical
CU-76: Driving Vehicle on Economy Speed for Fuel Saving 4 Technical
CU-77: Perform Safety Practices While Driving 4 Technical
Code Competency Standards Level Credits Category
Motor Vehicle Inspection AD-312
CU-78: Inspect Tires & Wheels of Light & Heavy Duty Transport
Vehicles (LTV & HTV). 5 Technical
CU-79: Inspect Vehicle Suspension System. 5 Technical
CU-80: Inspect Vehicle Steering System and Wheel Alignment 5 Technical
CU-81: Inspect Light & Heavy Duty Vehicle Brake System 5 Technical
CU-82: Inspect Vehicle Lighting System. 5 Technical
CU-83: Inspect Vehicle Electric System 5 Technical
CU-84: Inspect Vehicle Glazing System 5 Technical
CU-85: Inspect Vehicle Fuel System 5 Technical
CU-86: Inspect Vehicle Body Accessories. 5 Technical
CU-87: Inspect Vehicle Exhaust System. 5 Technical
CU-88: Prepare Comprehensive Vehicle Inspection Report. 5 Technical
CU-89: Prepare Vehicle Title Certificate. 5 Technical
Fuel Injection and Carburetion AD-343
CU-90: Diagnose Faults & Repair Intake System. 5 Technical
CU-91: Diagnose Faults & Repair Exhaust System 5 Technical
CU-92: Diagnose Faults & Repair Fuel Supply System. 5 Technical
CU-93: Diagnose Faults & Repair Hybrid System 5 Technical
CU-94: Diagnose Faults & Repair Engine Valve Control System 5 Technical
Automotive Transmission AD-363
CU-95: Diagnose Faults & Repair Clutch. 5 Technical
CU-96: Diagnose Faults & Repair Manual Gear Box. 5 Technical
CU-97: Diagnose Faults & Repair Automatic Gear Box. 5 Technical
CU-98: Diagnose Faults & Repair Final Drive.
5 Technical
Auto Body Building & Finishing AD-383
CU-99: Understand Vehicle Body Shell 5 Technical
CU-100: Prepare Cost Estimate for Repairs Damaged Vehicle
Body and Chassis 5 Technical
CU-101: Perform Vehicle Body and Chassis Alignment and Repair 5 Technical
Code Competency Standards Level Credits Category
CU-102: Perform Vehicle Body Repairs Work 5 Technical
CU-103: Carryout Panel Repair with Washer Welder Machine 5 Technical
CU-104: Repair vehicle body fittings 5 Technical
CU-105: Perform Welding Operations on Vehicle Body 5 Technical
CU-106: Maintain Machinery, Tools and Equipment 5 Technical
CU-107: Remove and Fix Glass Items 5 Technical
CU-108: Perform Body Surface Cleaning by Mechanical Process 5 Technical
CU-109: Perform Body Surface Cleaning with Chemical Process 5 Technical
CU-110: Maintain Vehicle Body Repair Tools, Equipment and
Machinery 5 Technical
CU-111: Maintain Paint Booth and Stores 5 Technical
CU-112: Apply Polyester Putty 5 Technical
CU-113: Prepare Paint Booth and Vehicle 5 Technical
CU-114: Apply Primer Surfacer 5 Technical
CU-115: Perform Color Matching & Mixing 5 Technical
CU-116: Apply Body Sealer 5 Technical
CU-117: Perform Masking 5 Technical
CU-118: Apply Under Coat 5 Technical
CU-119: Apply Final Coats 5 Technical
CU-120: Perform Polishing to Body Surface 5 Technical
CU-121: Prepare Paint Work Estimation 5 Technical
Workshop Practice-III AD-324
CU-122: Perform Engine Preventive Maintenance (Tune-Up) 5 Technical
CU-123: Perform Periodic Maintenance 5 Technical
CU-124: Arrange Workshop Equipment According to Lay-out 5 Technical
CU-125: Prepare Documentation for Automotive workshop 5 Technical
CU-126: Maintain Service Station Equipment 5 Technical
CU-127: Maintain Emission control system 5 Technical
CU-128: Perform Engine Overhauling 5 Technical
CU-129: Maintain Climatic Control System. 5 Technical
CU-130: Perform Engine Output Testing 5 Technical
Code Competency Standards Level Credits Category
CU-131: Read and Interpret Hydraulic and Pneumatic Code and
Symbols 5 Technical
Generic
CU-132: Participate In Workplace Communication 2 Generic
CU-133: Practice Occupational Health and Safety Procedures 2 Generic
CU-134: Perform Work In Team Environment 3 Generic
CU-135: Read and Develop Career Professionalism 4 Generic
CU-136: Lead Small Teams 4 Generic
CU-137: Develop and Practice Negotiation Skills 5 Generic
CU-138: Solve Problems Related To Work Activities 5 Generic
CU-139: Develop Communication Skill 5 Generic
CU-140: Develop Administrative Skills 5 Generic
CU-141: Work effectively in a customer service/ sales environment 4 Generic
CU-142: Develop Professionalism 4 Generic
Entrepreneur
CU-143: Manage the Operations of Workshop Security Units 5 Entrepreneur
CU-144: Organize Training On Multiple Workshop Units 5 Entrepreneur
CU-145: Administer Multiple Commercial Units 5 Entrepreneur
CU-146: Supervise and Evaluate performance of Technician 5 Entrepreneur
CU-147: Plan and Organize Work to Meet Expected Outcomes 5 Entrepreneur
CU-148: Work Effectively In a Team 5 Entrepreneur
CU-149: Maintain Healthy, Safe and Secure Working Environment 5 Entrepreneur
CU-150: Deal with Emergencies and Incidents at Workshop 5 Entrepreneur
CU-151: Maintain Effective Communication with Companies 5 Entrepreneur
Automotive Maintenance Specialist
CU-152: Repair and Maintain the Process Control Systems 5 Technical
CU-153: Plan and Arrange for Installation of New Systems 5 Technical
Digital skills
CU-154: Use computer operating systems and hardware Digital Skills
CU-155: Operate digital media technology Digital Skills
CU-156: Perform computer operations Digital Skills
CU-157: Use computer applications Digital Skills
CU-158: Create user documentation Digital Skills
CU-159: Create technical documentation Digital Skills
CU-160: Create basic databases Digital Skills
CU-161: Use social media tools for collaboration and engagement Digital Skills
CU-162: E-Commerce- SEO (Search Engine Optimization) Digital Skills
CU-163: E-Commerce- SCM (Supply Chain Management) Digital Skills
CU-164: E-Commerce- Social Media Marketing Digital Skills
CU-165: Use digital devices Digital Skills
CU-166: Operate word-processing applications- Digital Skills
CU-167: Operate spreadsheet applications Digital Skills
CU-168: Operate presentation packages Digital Skills
CU-169: Perform writing and editing tasks Digital Skills
CU-170: Write and Edit Copy Digital Skills
CU-171: Build Java applets Digital Skills
CU-172: Build Java applets Digital Skills
CU-173: Manipulate Images (Illustrator) Digital Skills
CU-174: Manipulate Images (Photoshop) Digital Skills
CU-175: Design simple web page layouts Digital Skills
CU-176: Apply introductory programming techniques Digital Skills
Soft skills
CU-177: Develop workplace policy and procedures for
sustainability
Soft Skills
CU-178: Manage meetings Soft Skills
CU-179: Manage recruitment selection and induction processes Soft Skills
CU-180: Manage personal work priorities and professional
development
Soft Skills
CU-181: Manage workforce planning Soft Skills
CU-182: Undertake project work Soft Skills
CU-183: Identify and communicate trends in career development Soft Skills
CU-184: Apply specialist interpersonal and counseling interview
skills
Soft Skills
CU-185: Work safely in an office environment Soft Skills
CU-186: Develop workplace documents Soft Skills
CU-187: Prepare and implement negotiation Soft Skills
CU-188: Maintain professionalism in the workplace Soft Skills
CU-189: Maintain professional development and career
professionalism
Soft Skills
CU-190: Organize schedules Soft Skills
Entrepreneur
CU-191: Develop Entrepreneurial Skills Entrepreneur
CU-192: Apply project information management and
communications techniques
Entrepreneur
CU-193: Apply project human resources management approaches Entrepreneur
CU-194: Direct human resources management of a project
program
Entrepreneur
CU-195: Develop a project management plan Entrepreneur
CU-196: Maintain business resources Entrepreneur
CU-197: Develop a sales plan Entrepreneur
CU-198: Plan and implement business-to-business marketing Entrepreneur
CU-199: Address customer needs Entrepreneur
CU-200: Manage personal finances Entrepreneur
CU-201: Solve problems which jeopardize safety and security Entrepreneur
CU-202: Coordinate a work team Entrepreneur
CU-203: Lead small teams Entrepreneur
CU-204: Plan and organize work Entrepreneur
CU-205: Develop teams and individuals Entrepreneur
CU-206: Apply problem solving techniques in the workplace using
critical thinking
Entrepreneur
CU-207: Manage human resource services Entrepreneur
Suggested by DG (SS&C)
10. Occupations of Automobile & Diesel Technology
Level Name of Occupation/Nomenclature
Generic Competencies
Allied competencies require
Core /Technical Competencies required
1. Mechanical Service Department
Level-2 Pro Auto Mechanic 1, 2,3, 4, 5, 6, 7, 8, 9, 10,
Level-3 Auto Diagnostic Mechanic 29,30,32,33,34,42,43,44,45,46,47,48,49,50,51
Level-4 Vehicle Drive Test Technician 108,109,110,111, 112,113,114,115
Level-5 Master Technician 64,65,66,67,68,69,70,71,72
Level-5 Service Advisor 96,97,98,99,100, 101,102,103,104, 105
Level-5 Vehicle Examiner 52,53,54,55,56,57,58,59,60,61,62,63
2. Electrical Department
Level-2 Pro Auto Electrician 11, 12, 13, 14, 15, 16, 17, 18, 19, 20
Level-3 Diagnostic Auto Electrician 31,35
3. Chassis Department Level-3 Steering, Suspension and
Brake Mechanic 36,37,38
Level-3 Wheel Alignment Technician 39,40,41
4. Auto Body Shop Level-5 Auto Body Technician 73,74,75,76,77,78,
79,80,81
Level-5 Auto Paint Technician 82,83,84,85,86,87,88,89,90,91,92,93,94,95
5. Mechanical Works Level-2 Mill Wright Auto Mechanic 21,22,23,24
Level-2 Pro Welder 25, 26, 27, 28
Level-3 Boiler Supervisor (B-Class) 29,30,32,33,34,42,43,44,45,46,47,48,49,50,51
11. Leveling of the Competency Standards
(000000000)
1stSemester National Certificate of level-2 (Auto and Diesel Technology)
Code Name of Competency/ Duty/ Module Credit Category Courses
0000 Perform Basic Electricity Measurements Technical
y
0000 Repair Lightning System of Vehicle Technical
0000 Repair Vehicle Electrically Operated Accessories Technical
0000 Understand the Electromagnetism and its application Technical
0000 Perform Bench Work on Metallic Surfaces Technical
0000 Perform Shaper Machine Operations Technical
0000 Perform Lathe Turning Operations Technical
0000 Perform Basic Drawing, Sketch Making Functional
0000 Draw Pictorial Drawing Functional
0000 Perform Basic Dimensioning System in Working Drawing Functional
0000 Perform Sectioning and Pictorial Drawing Functional
0000 Draw Auxiliary Drawing Functional
0000 Manage the Operations of Workshop Security Units Generic
0000 Practice Occupational Health and Safety Procedures Generic
(000000000)
2nd Semester National Certificate of level-2, (Auto and Diesel Technology)
Code Name of Competency/ Duty/ Module Credit Category
000000000 Identify Engine Types Their Component and Interpret its Specifications
Technical
000000000 Identify Basic Engine Parts and Interpret Assembly Procedure
Technical
000000000 Understand Engine Cooling System Components and Their Relationship
Technical
000000000 Understand Engine Lubrication System and working of its Components
Technical
000000000 Understand Petrol Engine’s Fuel System Components and their Relations
Technical
000000000 Understand Diesel Engine’s Fuel System Components with their Relations
Technical
000000000 Understand the Engine Exhaust System Components Technical
000000000 Diagnosing Engine Faults and fix them Technical
000000000 Understand Spark Ignition System of Internal Combustion Engine
Technical
000000000 Perform Overhauling of Four Stroke Motor Cycle Engine Technical
000000000 Repair Engine Starting System Technical
000000000 Perform BatteryService of VePerform BatteryService of Vehicle hicle
Technical
000000000 Repair Battery Charging System Technical
000000000 Repair Spark Ignition System of Internal Combustion Engine
Technical
000000000 Adjust Ignition Timing of Spark Ignition Engine Technical
000000000 Repair Distributer-Less Ignition Systems of Spark Ignition Engine
Technical
000000000 Preform Welding Procedure Specifications (WPS) Technical
000000000 Prepare Materials for Welding Technical
000000000 Perform Shielded Metal Arc Welding (SMAW) in Vertical (3F, 3G) and Overhead (4F, 4G) Positions
Technical
000000000 Perform Forging Operations Technical
(000000000)
3rd Semester National Certificate of level-3 (Auto and Diesel Technology)
Code Name of Competency/ Duty/ Module Credit Category
000000000 Repair Vehicle Brake System
Technical
000000000 Repair Vehicle Steering System
Technical
000000000 Repair Vehicle Suspension System
Technical
000000000 Identify Common Automotive Hand Tools and their Use
Technical
000000000 Carry Out Measurements With Automotive Measuring Tools
Technical
000000000 Perform Test on Vehicle with Automotive Workshop Equipment
Technical
000000000 Diagnosing Faults by Computerized Performance Testing Equipment
Technical
000000000 Identify Automotive Fasteners Types and their Uses
Technical
000000000 Identify Vehicle’s Lubricants Types with Specifications Technical
000000000 Identify Different Types and Specifications Coding of Vehicle Oil Seals
Technical
000000000 Identify Vehicle Bearing’s Types with Specifications Cods
Technical
000000000 Read and Interpret Quality Control Standards and Certification
Technical
000000000 Plan and Organize Safe Workshop and Hazard Prevention Practices
Technical
000000000 Analyses HVAC/R Systems Thermodynamic Performance
Functional
000000000 Carry-out Smooth Boiler Operation
Functional
000000000 Recognize Fundamentals of Thermodynamics Problems
Functional
000000000 Read and Interpret Perfect Gases Laws, Properties and Solve problems
Functional
000000000 Read and Derived Thermodynamics Processes and Cycles
Functional
000000000 Analyze Performance of Air Compressors (Reciprocating & Rotary)
Functional
000000000 Solves Problems of Internal Combustion Engine
Functional
000000000 Perform Work In Team Environment
Generic
(000000000)
4th Semester National Certificate of level-3, (Auto and Diesel Technology)
Code Name of Competency/ Duty/ Module Credit Category
000000000 Perform Engine Fault Diagnosing and Adjustment Technical
000000000 Perform Complete Engine Overhauling (Petrol/ Diesel) Technical
000000000 Diagnose Engine Cooling System Faults and Repair Technical
000000000 Diagnose Engine Lubrication System Faults and Repair Technical
000000000 Diagnose Faults of Engine Fuel System (Carburetor Type) and Adjust
Technical
000000000 Diagnose Diesel Engine Fuel System and Adjust Technical
000000000 Diagnose Faults of Spark Ignition System and Adjust Technical
000000000 Carry out Wheel Alignment Technical
000000000 Carry Out Wheel Balancing Technical
000000000 Repair SRS System Technical
000000000 Recognize Graduated Instruments Functional
000000000 Carry-Out Linear Measuring Functional
000000000 Carry-out Precise Measuring Functional
000000000 Perform Angular Measuring Functional
000000000 Identify the Types of Gauges Functional
000000000 Identify Comparators Instrument Functional
000000000 Read and Develop Career Professionalism generic
000000000 Lead Small Teams generic
(000000000)
5th Semester National Certificate of level-4, (Auto and Diesel Technology)
Code Name of Competency/ Duty/ Module Credit Category
000000000 Diagnose Faults & Repair Clutch Technical
000000000 Diagnose Faults & Repair Manual Gear Box Technical
000000000 Diagnose Faults & Repair Automatic Gear Box Technical
000000000 Diagnose Faults & Repair Final Drive Technical
000000000 Perform Inspections of Vehicle Controls for pre Operational & Pre Starting
Functional
000000000 Read and Interpret Traffic Signals, Road Signs and Marking Lanes on Roads
Functional
000000000 Perform Inspections of Vehicle Controls for pre Operational & Pre Starting
Functional
000000000 Read and Interpret Traffic Signals, Road Signs and Marking Lanes on Roads
Functional
000000000 Perform Inspections of Vehicle Controls for pre Operational & Pre Starting
Functional
000000000 Read and Interpret Traffic Signals, Road Signs and Marking Lanes on Roads
Functional
000000000 Perform Inspections of Vehicle Controls for pre Operational & Pre Starting
Functional
000000000 Read and Interpret Traffic Signals, Road Signs and Marking Lanes on Roads
Functional
000000000 Work effectively in a customer service/ sales environment Generic
000000000 Develop Professionalism Generic
(000000000)
6th Semester National Certificate of level-5 (Auto and Diesel Technology)
Code Name of Competency/ Duty/ Module Credit Category
000000000 Inspect Tires & Wheels of Light & Heavy Duty Transport Vehicles (LTV & HTV)
Technical
000000000 Inspect Vehicle Suspension System Technical
000000000 Inspect Vehicle Steering System and Wheel Alignment Technical
000000000 Inspect Light & Heavy Duty Vehicle Brake System Technical
000000000 Inspect Vehicle Lighting System Technical
000000000 Inspect Vehicle Electric System Technical
000000000 Inspect Vehicle Glazing System Technical
000000000 Inspect Vehicle Fuel System Technical
000000000 Inspect Vehicle Body Accessories Technical
000000000 Inspect Vehicle Exhaust System Technical
000000000 Prepare Comprehensive Vehicle Inspection Report Technical
000000000 Prepare Vehicle Title Certificate Technical
000000000 Repair and Maintain the Process Control Systems Functional
000000000 Plan and Arrange for Installation of New Systems Functional
000000000 Develop and Practice Negotiation Skills Generic
000000000 Solve Problems Related To Work Activities Generic
000000000 Develop Communication Skill Generic
000000000 Develop Administrative Skills Generic
000000000 Manage the Operations of Workshop Security Units Entrepreneur
000000000 Organize Training On Multiple Workshop Units Entrepreneur
000000000 Administer Multiple Commercial Units Entrepreneur
000000000 Supervise and Evaluate performance of Technician Entrepreneur
000000000 Plan and Organize Work to Meet Expected Outcomes Entrepreneur
000000000 Work Effectively In a Team Entrepreneur
000000000 Maintain Healthy, Safe and Secure Working Environment Entrepreneur
000000000 Deal with Emergencies and Incidents at Workshop Entrepreneur
000000000 Maintain Effective Communication with Companies Entrepreneur
Internal Combustion Engine (AD-133)
1. Specify Engine Types and its Component
Overview:
This Learning Module is designed to provide skills and knowledge for different types of power producing units (engines) their understanding the working principles, construction, types, components and their relationship between different components, system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Identify Petrol Engine
P1. Observe vehicle systems, identify the typical petrol engines and function of their main components.
P2. Identify spark plugs and it functions P3. Identify distributor and its function P4. Identify ignition coil and its functions P5. Identify plug leads and its functions P6. Identify carburetor and its function P7. Identify EFI engine and its main components
2. Identify Diesel Engine
P1. Observe vehicle systems, identify the typical diesel engines and function of their main components.
P2. Identify fuel injectors and its function P3. Identify high pressure fuel pump and its functions P4. Identify heater plug and its function
Knowledge & Understanding
• Describe the vehicle engines in a variety of forms and locations as following: a. Types (Petrol four stroke, diesel four stroke, and rotary/Wankel). b. Aspirated (Natural, turbocharged, supercharged) c. Cylinder layout (single, multi, in-line, V shape, horizontally opposed). d. Locations(front, rear, mid, transverse, longitudinal)
Critical Evidences Required
• Capable to identify petrol/diesel engine.
• Capable to differentiate petrol EFI and carburetor engine.
• Capable to explain different parts in petrol/diesel engine.
List of Tools and Equipment
S. No. Description
1 Measuring tools (Verniercaliper, micrometer, Cylinder bore gauge)
2 Hand tools trolley
3 Special tools (ring compressor, belt tensioner, torque wrench)
4 Engine Petrol/ diesel
5 Vehicle
2. Identify Engine Parts and Interpret Assembly Procedure
Overview
These competency standards designed to provide skills and knowledge for engines their understanding the working principles, construction, types, components and their relationship between different components, system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Understand Engine block assembly procedure.
P1. Select appropriate tools and perform dismantling/assembly of the all engine components as specified procedure in the manual.
P2. Select appropriate tools and perform crankshaft assembly in the engine block with all related components.
P3. Select appropriate tools and perform piston ring assembly in the block under the specified procedure.
2. Understand Engine head assembly procedure.
P1. Select appropriate tools and perform dismantling/ assembly of engine head valve train as specified procedure in the manual.
P2. Select appropriate tools and perform dismantling/ assembly of rocker assembly on the engine head under the specified procedure in the manual.
P3. Set the camshaft on the engine head and fit bearing caps under the specified procedure.
Knowledge & Understanding
• Describe the engine terms as following: Top dead Centre (TDC), bottom dead Centre (BDC),bore, stroke, engine capacity, clearance volume, swept volume, compression ratio, single overhead cam, double overhead cam, overhead valve,
• Describe the main engine components and functions: Components: cylinder heads, cylinder blocks, liners(wet/dry), manifolds, valve operating mechanisms, timing, gears, camshafts, pistons, pushrods, connecting rods, crankshafts, flywheels, machined faces, securing devices, journals/bearings, seals.
• K-4describes the faults in engine as following: White smoke, black smoke, engine oil level decreasing, incorrect adjustment of tappets, incorrect adjustment of ignition timing, incorrect adjustment of engine timing.
Critical Evidences Required
• Capable to assemble the engine components
• Capable to adjust engine timing and ignition timing
• Capable to service air filter and spark plugs
List of Tools and Equipment
S. No. Description
1 Measuring tools (Verniercaliper, micrometer, Cylinder bore gauge)
2 Hand tools trolley
3 Special tools (ring compressor, belt tensioner, torque wrench)
4 Engine Petrol/ diesel
5 Vehicle
Consumable Items:
• Engine Oil, Gasket Set, Piston Rings, Oil Seals, Valve Seats, Silicon, Emery Paste and Stick, Cotton Waste.
3. Maintain Engine Cooling System Components
Overview
This Learning Module is designed to provide skills and knowledge for understanding the working principles, construction, types, components and their relationship between different components to service and repair air and water cooled engine cooling systems and to diagnose fault/s and other maintenance issues by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Identify Cooling system in the vehicle.
P1. Identify main components of cooling system their functions. P2. Identifies the water pump and understand the function of its
components. P3. Identify the thermostat and understand the function of its
components. P4. Identify the radiator, its types and understand the function of the
components. P5. Identify the radiator fan and understand its drive types.
2. Use Antifreeze/inhibitors
P1. Identify the antifreeze its compositions and types. P2. Identify the rust corrosion in the engine and preventions.
Knowledge & Understanding
• Describe the operating principles and terminologies of cooling system as following: Air cooled engine, liquid cooled engine, operating temperature, thermal efficiency, pressurized system, heat exchange method (conduction, radiation, and convection), corrosion, and inhibitors/antifreeze)
• Describe the functions and purpose of engine cooling system components as: Electrical motor operated fan with thermo switch, belt operated fan, temperature controlled/viscous coupling fan, pressure cap, water body/pump, drive belt, thermostat, radiator, core plug, hoses/clamps, and gasket/ seals.
Critical Evidence(s) Required
• Capable of diagnose, adjust and rectify the cooling system faults.
List of Tools and Equipment
S. No. Description
1 Hand tools trolley
2 Radiator leak tester
3 Vehicle/ simulator with a cooling system
5 Drive belt tensioner gauge
Consumable Items:
• Coolants, Sealant/gasket, Hose Pipe, Thermostat Valve
4. Maintain Engine Lubrication System
Overview
This Learning Module is designed to provide skills and knowledge for understanding the working principles, construction, types, components and their relationship between different components to repair different types of engine lubricating systems by Auto Mechanic, in accordance with the manufacturer’s Manual.
Units of Competency Performance Criteria
1. Identify the Lubrication system
P1. Identify the main components of engine lubrication system and understand its functions.
P2. Identify types of oil pumps and understand its function P3. Identify oil coolers for the high performance engine (air
cooled/Water cooled type)
2. Use different Lubricants in the vehicle
P1. Identify the types of engine oil used in the engine with respect to viscosity.
P2. Identify the function of oil filter and its components. P3. Identify the oil sump and its components.
Knowledge & Understanding
• The functions/operating principle and main components of engine lubrication system as following.
• Wet sump, dry sump, total loss, Oil pumps and its types, pressure relief valves, oil filter,oil cooler, ventilation/PCV Valve, hoses, and oil level indicators.
• Lubricant (oils viscosity, viscosity index, oil classifications, Reduction of frictional forces, cooling effect, cleaning effect, corrosion resistance, and noise reduction).
• The (Law of friction, static/dynamic friction (difference), coefficient of friction).
Critical Evidence(s) Required
• Capable of explain the lubrication system components.
• Capable to know the engine oil and filter.
List of Tools and Equipment
S. No. Description
1 Hand tools trolley
2 Car Lift
3 Vehicle/ simulator with a cooling system
4 Sealant/gasket
5. Retain Fuel System of Petrol Engine
Overview
This Learning Module is designed to provide skills and knowledge for understanding the working principles, construction, types, components and their relationship between different components to repair Carburetor type fuel system and basic EFI petrol engine by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Fuel system (carburetor type engine)
P1. Understand in the petrol engine function of Air Filter. P2. Understand in the petrol engine function of Fuel pump
(Mechanical and Electrical). P3. Understand the petrol engine (Carburetor type) main components
and function of Carburetor. P4. Understand the petrol engine (Carburetor type) main components
and function of Fuel filter. P5. Understand the petrol engine’s (Carburetor type) main
components and function of fuel lines/clips. P6. Understand the petrol engine’s (Carburetor type) main
components and function of fuel sending unit.
2. Fuel system (EFI type engine)
P1. Identifies the EFI main components and understand the working principle of main components.
P2. Identify the sensors in the vehicle and understand the function of each.
P3. Identify the actuators in the vehicle and understand the functions of each.
P4. Identify the ECU and engine malfunctioning light and understand its functions.
Knowledge & Understanding
• Describe the features of main components of engine fuel system as following: Fuel tanks, filler cap/ security, venting, fuel level sender, lines/ filters, carburetor, and fuel lift
pumps (mechanical/ electrical), fuel (octane rating, Octane number, cetane Number, cetane rating, leaded, unleaded fuel).
Critical Evidence(s) Required
• Capable understanding the petrol engine fuel system of carburetor type engine.
• Capable understanding the petrol engine fuel system of EFI type engine
List of Tools and Equipment
S. No. Description
1 Toll trolley (Complete set)
2 Test lamp/DMM (Digital multimeter)
4 Diesel injector pressure tester /Petrol Injector Tester
5 Safety wears
Consumable Items:
• Carburetor cleaner, Carburetor Gasket Set, Petrol, Injector seals/O ring,
6. Retain Fuel System of Diesel Engine
Overview
This Learning Module is designed to provide skills and knowledge for diesel engine fuel system their understanding the working principles, construction, types, components and their relationship between different components, system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Fuel system (diesel engine)
P1. Inspect diesel engine main components and understand the performance of heater plug.
P2. Inspect diesel engine main components and understand the performance of injectors.
P3. Inspect diesel engine main components and understand the performance of injection pump.
P4. Inspect diesel engine main components and understand the performance of sediment /filter.
2. Fuel system (EFI diesel engine)
P1. Identifies the EFI main components and understands the working principle.
P2. Identify the sensors in the diesel EFI engine and understand the functions of each.
P3. Identify the actuators in the diesel engine and understand the functions of each.
P4. Identify the ECU and engine malfunctioning light and understand the its functions.
Knowledge & Understanding
• Describe the features of main components of engine fuel system as following. Fuel tanks, filler cap/security, venting, fuel level sender, lines/filters, carburetor, and fuel lift pumps (mechanical/electrical),fuel (octane rating, Octane number , cetane Number ,cetane rating, leaded, unleaded).
• Describe the Diesel injection systems main components as following. Single/multi-hole injectors, inline fuel injection pump, rotary fuel injection pump, fuel injection pressure, bleed points, fuel cutoff switch, governor operation, in Combustion chamber types, main features of pressure/volume diagrams/effects of advanced/retarded/no fuel injection
• Describe the as following statements. Diesel fuel composition, effects of low temperature, viscosity, volatility, calorific value, cetane rating.
Critical Evidence(s) Required
• Capable understanding the diesel engine fuel system
• Capable understanding the diesel EFI engine fuel system
List of Tools and Equipment
S. No. Description
1 Toll trolley (Complete set)
2 Diesel engine vehicle or simulator
4 Safety wears
7. Maintain Engine Exhaust System
Overview
This Learning Module is designed to provide skills and knowledge for engine exhaust system their understanding the working principles, construction, types, components and their relationship between different components, system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Exhaust system components
P1. Inspect the performance of main components of exhaust manifold P2. Remove and assemble exhaust manifold from engine P3. Replace the muffler, resonator and catalytic converter under the
specified procedure. P4. Replace the gasket/packing of silencer under the specified procedure.
2. Emission control system
P1. Identify catalytic converter and understand the function. P2. Identify the positive crankcase ventilation (PCV) and understand the
function. P3. Identify and understand the functions of exhaust gas recirculation
system(EGR) P4. Identify the main components of Evaporative control system of fuel
system.
Knowledge & Understanding
• Describe the purpose of exhaust system and its functions.
• Describe the muffler assembly operation.
• Describe the catalytic converter operation
• Describe the positive crank case ventilation PCV system and it operation
• Describe the exhaust gas recirculation and its operation
Critical Evidence(s) Required
• Capable of understanding the exhaust system
• Capable of understanding EGR.
• Capable of understanding Catalytic converter.
List of Tools and Equipment
S. No. Description
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Gas analyzer
4 Vacuum pump
8. Diagnosing Engine Faults
Overview
This competency standard is developed to provide skills and knowledge to Overhaul Engine (Petrol and Diesel), in accordance with the Manufacturer Manual. You will be able to diagnose fault/s and other maintenance issues of automobile engines while ensuring safe use of tools equipment and materials
Unit of Competency Performance Criteria
1. Engine fault P1. Understand engine adjustment/setting faults of Engine Timing, Setting Distributor timing, tappet adjustment, drive belt/fan belt adjustment.
P2. Understand the faults of engine head gasket, Crank main oil seal, Engine timing belt, manifold packing, and exhaust muffler.
P3. Start the engine and identify the condition of engine missing, stalling, and lack of power, back fire, knocking, black smoke/heavy fuel consumption, excessive oil consumption, and leakages.
2. Engine assembly P1. Selects appropriate tools and perform dismantling/assembly of the all engine components as specified procedure in the manual.
P2. Assemble engine manifolds intake and exhaust.
Knowledge & Understanding
• Describe the following: Valve timing: lead, lag, overlap, timing diagrams, valve, clearances/adjustment/adjustment
methods. Terms: Top Dead Centre (TDC), Bottom Dead Centre (BDC),Bore, Stroke, Capacity, Clearance Volume, Swept Volume, Compression Ratio, Crank Throw, Torque at REVS/min, Brake power at revs/min, Specific Fuel Consumption (SFC),Volumetric efficiency, OHV, and OHC.
• Describe the possible causes of high fuel consumption as following: Overload the engine, excessive oil consumption, faulty air filter, carburetor poor setting, engine over cooled and hard/jam running of engine.
Critical Evidence(s) Required
• Capable of understand engine faults
List of Tools and Equipment
S. No. Description
1 Tools trolley (complete set of tools)
2 Compression tester
3 Measuring tools (Complete set for engine overhauling)
4 Fuel pressure Tester
5 Special Service Tools
Consumable Items:
Piston ring, Engine oil, Silicon, Oil sump Jain, oil filter, head Gaskit, grease, cotton waste.
9. Perform Ignition System of Petrol Engine
Overview:
These competency standards designed to diagnose and troubleshoot conventional spark ignition system as well as conceptualize the ignition system mechanism in the engine of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Repair Ignition System
P1. Identify the vehicle Ignition system and understand procedure of testing ignition coil under the specified procedure.
P2. Identify the vehicle Ignition system and understand procedure of testing fuse in fuse box under the specified procedure.
P3. Identify the vehicle Ignition system and understand procedure of testing the performance of plug cable and plugs under the specified procedure.
P4. Identify the vehicle Ignition system and understand procedure of inspecting distributor cap/rotor for the performance under the specified procedure.
P5. Identify the vehicle Ignition system and understand procedure of inspecting vacuum advancer, assess C.B Point condition/gap for the performance under the specified procedure.
P6. Identify the vehicle Ignition system and understand procedure of correct ignition timing under the specified procedure.
P7. Identify the vehicle Ignition system and understand the performance of CDI of distributor under the specified procedure.
2. Adjust ignition timing
P1. Installation of distributer assembly under specified procedure and start the engine, adjust ignition timing with the help of timing gun.
P2. Inspect/ Replace ignition switch, inspect/replace ignition coil, and Repair/ replace electrical connectors under specified procedure.
Knowledge & Understanding
• The Purpose and function of ignition system’s following parts. Spark ignition system contact breaker type, spark ignition system breaker less type.Ignition switch, Ignition coil, resister, plug cable, distributer cap, rotor arm, vacuum advancer, centrifugal advancer, contact breaker assembly, condenser, high tension leads/connectors, suppression, spark plug(construction, heat range type, size), Magnetic Reflector, hall effect trigger/amplifier, differentiate the performance of contact breaker and contact breaker less type.
• Describe primary circuit, secondary circuit of ignition system, identifies change in the spark timing in accordance to the load and speed of the engine.
• Explain Faradays law of mutual induction and calculate the primary and secondary voltages and current.
Critical Evidence(s) Required
• Troubleshot the vehicle ignition system (Non EFI engines)
• Capable to adjust the ignition timing
• Capable to service the ignition system.
List of Tools and Equipment
S. No. Description
1 vehicle/ simulator
2 Digital Multileter (DMM).
3 Tools box
4 test lamp
5 Timing gun
10. Perform Overhauling of Four Stroke Single Cylinder Engine
Overview:
This competency standard is designed to provide skills and knowledge to Overhauling Motorcycle Engine of motorcycle by Motorcycle Mechanic, in accordance with the Manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Overhauling Four stroke motorcycle engines
P1. Arrange proper tools and equipment’s to service cylinder head. P2. Disconnect cables, wires, and muffler from cylinder head for
dismantling cylinder head. P3. Remove cylinder head assembly and its components from the
engine to identify damage parts. P4. Replace/clean cylinder head and its components by using
appropriate tools as per shop manual P5. Refit cylinder head and its components; connect all the cables/
wires and muffler as per shop manual. P6. Test engine performance to verify servicing of cylinder head.
2. Service cylinder, Piston and Piston Rings
P1. Arrange proper tools and equipment to service cylinder and piston. P2. Remove cylinder head assembly from the cylinder block to service
cylinder block piston and piston Rings as per shop manual. P3. Remove cylinder block, piston and inspect its components to
identify the damage parts as per Shop manual. P4. Service/ clean cylinder block, piston and its components to remove
dust. P5. Refit Cylinder Block, piston, piston rings, cylinder head And
connect all the wires, cables to the engine as per shop manual. P6. Test engine performance to verify servicing of cylinder piston and
piston rings as per shop
Knowledge & Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out the tasks covered in this competency standard.
This includes the knowledge of:
• Knowledge about PPEs
• Different types of fire extinguishers
• Safe work environment
• Safety measures and precautions
• First Aid
• Proper use and handling of equipment
• Knowledge about securing measuring tools
• Types of engines
• Schedule of Motorcycle Maintenance
• Different parts of Motorcycle
• Working principles and comparison of 2 and 4 Stroke Engine
• Types and procedure of Oiling & greasing
• Inspections and Measurements
• Cleaning process of different Motorcycle parts / Components.
• Replacement of Motorcycle Parts / Components
• Adjustment of Motorcycle parts /Components
• Working principles of engine and its terminologies
• Different systems of engine
• Parts of engine
• Diagnostic procedure of Engine
• Engine dismantling procedure
• Engine inspection and repair procedure
• Engine assembling procedure
• Engine oil circuits
• Engine Timing
• Manufacturers and workshop manual of given vehicle
• Working principle Fuel system
• Exhaust system
• Euro standards
• Motorcycle driving tips and safety
Critical Evidence(s) Required
The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:
• Remove and install engine from motorcycle
List of Tools and Equipment
S. No. Description
1 Tools trolley (complete set of tools)
2 Compression tester
3 Measuring tools (Complete set for engine overhauling)
4 Fuel pressure Tester
5 Special Service Tools
Consumable Items:
Piston ring, Engine oil, Silicon, Oil sump Jain, oil filter, head Gaskit, grease, cotton waste.
Automotive Electricity and Electronics (AD-143)
1. Perform Electricity Measurements
Overview
These competency standards designed to enable the learner to perform electrical related calculations and measurements, as well as conceptualize different automotive functions related to the electrical operations.
Unit of Competency Performance Criteria
1. Basic Electricity P1. Prepare series circuit on work bench using appropriate tools. P2. Prepare parallel circuit on work bench using appropriate tools. P3. Prepare series parallel circuit on work bench using appropriate
tools.
2. Basic Electricity Measurement
P1. Measure/ record voltage by using Digital Multi METER (DMM) P2. Measure/ record current by using Digital Multi Meter (DMM) P3. Measure/ record resistance by using Digital Multi Meter. P4. Measure/ record continuity by using Digital Multi Meter.
Knowledge & Understanding
• Describe the following terms: Atom and its particles (electron, neutrons & protons), EMF, current, voltage, resistance, magnetism, electro magnetism, flux, inductance, mutual inductance, capacitance, and diode.
• Calculation of ohm law, (V= IR) calculation of power law (P= VI).
Critical Evidence(s) Required
• Calculation involving the series, parallel, and series parallel circuits
• Correct use of Digital multimeter (DMM)
• Point out electromagnets in the vehicle.
List of Tools and Equipment
S. No. Descriptions
1 Digital Multimeter (DMM).
2 Load (resistors)
3 Wires
4 Test bench (Complete accessories)
5 Lamps
Consumable Items:
• Wires, Bulb and Bulb Holder, Thimble (Male & Female),Circuit Board, Wire Clumps, Battery
2. Prepare Electromagnetism applications
Overview
These competency standards designed to enable the learner to perform electrical related calculations and measurements, as well as conceptualize different automotive functions related to the electrical operations.
Unit of Competency Performance Criteria
1. Basic Electricity P1. Prepare turn signal light circuit on work bench using appropriate tools.
P2. Prepare horn/ light circuits on work bench using appropriate tools.
P3. Prepare brake light circuit on work bench using appropriate tools.
2. Basic Electricity Measurement
P1. Measure/ record voltage by using Digital Multi Meter P2. Measure/ record current by using Digital Multi Meter P3. Measure/ record resistance by using Digital Multi Meter. P4. Measure/ record continuity by using Digital Multi Meter
Knowledge & Understanding
• Describe the following components: Electricity generation, storage, types of current, circuits (open/close), switches, relay, fuses, circuit breaker, motors(DC/AC), generator (DC/AC), and resistors/color coding.
Critical Evidence(s) Required
• Calculation involving the series, parallel, and series parallel circuits
• Correct use of Digital Multimeter (DMM)
• Point out electromagnets in the vehicle.
List of Tools and Equipment
S. No. Descriptions
1 Digital Multileter (DMM).
2 Load (resistors)
3 Wires
4 Test bench (Complete accessories)
5 Lamps
Consumable Items:
• Wires, Bulb and Bulb Holder, Thimble (Male & Female),Circuit Board, Wire Clumps, Battery
3. Perform Battery Service of Vehicle
Overview
These competency standards designed to enable the learner to diagnose the problem related to the battery and starting system and enable the learner to troubleshoot the system if not working, repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Service of battery P1. Perform the battery test by use of hydrometer, Terminal clean, tight, and insulated, secure with battery holder as per given specification.
P2. Inspect and change the Ground (Earth) cable from the vehicle body.
P3. Test battery by using the load tester/battery tester and assess the battery performance.
2. Battery replacement
P1. Perform Safe removal and installation of Battery from the vehicle Inspect/service the battery and assess safety fitting and correctness under specified procedure.
P2. Carry out safe procedure to charge the battery using an external charger.
Knowledge & Understanding
• Lead Acid battery and its internal components: Material, acid and water ratio, plates, cells, ampere hour rating, voltage drop, corroded/lose terminals, maintenance free batteries.
• Describe the chemical activities in Lead Acid Battery while charging and discharging.
Critical Evidence(s) Required
• Troubleshoot the problems related to the vehicle battery.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle or simulator.
2 Tool box
3 Safety goggles
4 Gloves
5 Battery External charger
6 Battery load tester
7 DMM
8 Wires
9 Hydrometer
4. Repair Engine Starting System
Overview
These competency standards designed to enable the learner to diagnose the problem related to the starting system and enable the learner to troubleshoot the system if not working,repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual
Unit of Competency Performance Criteria
1. Repair starting system
P1. Inspect the vehicle starting system and troubleshoot the following:
Low cranking speed/ not cranking, Ignition switch operation malfunctioning.
P2. Inspect the vehicle starting system and troubleshoot the following:
Unusual noise during operation, corrosive battery terminals, safety neutral switch, incorrect pinion engagement/ disengagement, blown fuse/ relay, lose/ corroded main starting wire.
2. Service Starter Motor. P1. Carryout safe procedure to replace the starter motor from the vehicle.
P2. Service/replace components of starter motor and perform bench testing.
Knowledge & Understanding
• Short circuits and battery related hazards.Wrong battery installation, touch the positive terminal with the body, un-insulated wire touches with the vehicle body, battery size not matches with the maker, battery acid injury (human eye/ body), disposal of faulty batteries.
• Describe the Wiring diagram associated with the electrical/electronic symbols. Circuit protection device (Fuse, fusible link, circuit breaker) Circuit switching device (manual switches, electromagnet switch/relay normal open and normal close, pressure switch, temperature switch) Resister (Rating, identification method, effect of change of temperature) Electronic devices (Diode, Zener diode, bipolar transistor, Thyristor, thermistor, heat sink, LED)
• Distinguish between increase/decrease cranking current consumption, voltage drop in a system, electrical load, and reason of high ampere draw from a system/overload.
• Describe the Lenz’s law of motor principle, single phase, three phase motor, AC Motor, DC Motor.
Critical Evidence(s) Required
• Troubleshoot the problems related to the vehicle battery.
• Capable to describe the fault related to the battery and take appropriate decisions.
• Capable to troubleshoot the vehicle starting system.
• Service the starter motor.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle or simulator.
2 Tool box
3 Safety goggles
4 Gloves
5 Battery External charger
6 Battery load tester
7 DMM
8 Wires
9 Hydrometer
5. Repair Ignition System of Petrol Engine
Overview
These competency standards designed to diagnose and troubleshoot conventional spark ignition system as well as conceptualize the ignition system mechanism in the engine, repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Repair Ignition System
P1. Inspect vehicle Ignition system and diagnose the following: Crank engine and test presence of spark in a system, identify faulty fuse in fuse box (Note: follow safe working procedure).
P2. Inspect vehicle Ignition system and diagnose following:
Test performance of plug cable (high tension leads) and plugs, inspect distributor cap/rotor for performance, assess correct ignition timing, inspect vacuum advancer, assess C.B. Point condition/gap and test condenser. (Note: follow safe working procedure).
2. Repair Ignition System (CDI System)
P1. Inspect the vehicle Ignition system and diagnose the ignition coil performance, (Note: follow safe working procedure).
P2. Inspect the vehicle Ignition system and diagnose the CDI of distributor. (Note: follow safe working procedure).
Knowledge & Understanding
• Describe the Purpose and function of ignition system’s following parts in Spark ignition system contact breaker type, spark ignition system breaker less type.Ignition switch, Ignition coil, resister, plug cable, distributer cap, rotor arm, vacuum advancer, centrifugal advancer, contact breaker assembly, condenser, high tension leads/connectors, suppression, spark plug(construction, heat range type, size), Magnetic Reflector, Hall Effect trigger/amplifier, differentiate the performance of contact breaker and contact breaker less type.
Critical Evidence(s) Required
• Troubleshot the vehicle ignition system (Non EFI engines)
• Capable to adjust the ignition timing
• Capable to service the ignition system.
List of Tools and Equipment
S. No. Descriptions
1. Vehicle/ Simulator
2. Digital Multileter (DMM).
3. Tools box
4. Test Lamp
5. Timing gun
6. Adjust Ignition Timing of Petrol Engine
Overview:
These competency standards designed to diagnose and troubleshoot conventional spark ignition system as well as conceptualize the ignition system mechanism in the engine, repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual
Unit of Competency Performance Criteria
1. Adjust Ignition Timing
P1. Installation of distributer assembly under specified procedure and start the engine, adjust ignition timing with the help of timing gun.
P2. Inspect/ Replace ignition switch, inspect/ replace ignition coil, and Repair/ replace electrical connectors under specified procedure.
2. Repair Ignition System
P1. Inspection of crank position sensor under specified procedure and starts the engine.
P2. Inspection/replace of ignition fuse under specified procedure and starts the engine.
Knowledge & Understanding
• Describe primary circuit, secondary circuit of ignition system, identifies change in the spark timing in accordance to the load and speed of the engine.
• Explain Faradays law of mutual induction and calculate the primary and secondary voltages and current.
Critical Evidence(s) Required
• Troubleshot the vehicle ignition system (Non EFI engines)
• Capable to adjust the ignition timing
• Capable to service the ignition system.
List of Tools and Equipment
S. No. Descriptions
1. Vehicle/ Simulator
2. Digital Multileter (DMM).
3. Tools Box
4. Test Lamp
5. Timing Gun
7. Repair Distributer-Less Ignition Systems of Petrol Engine
Overview
These competency standards designed to enable the learner to troubleshoot the electronic ignition related problems in the vehicle, repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Troubleshoot Distributer Less Systems
P1. Use of scanner and find out the fault related to the ignition coil and reset the trouble code by use of scanner.
P2. Use of scanner and find out the fault related to the crank sensor and reset the trouble code by use of scanner.
P3. Use of scanner and find out the fault related to the crank sensor and reset the trouble code by use of scanner.
2. Repair Distributor Less Systems
P1. Use test lamp and identify the faulty fuse in the fuse box under the specified procedure.
P2. Replace the faulty fuse with the same color and start the engine under the specified procedure.
P3. Replace the faulty ignition coil and faulty sensor under the specified procedure.
Knowledge & Understanding
Describe the following
• Ignition advance mechanism in Distributor less system, Dual coil system, Coil on plug system, crank sensor signals,
Critical Evidence(s) Required
• Capable to diagnose and troubleshoot the electronic ignition system.
• Capable to replace faulty parts of electronic ignition system.
List of Tools and Equipment
S. No. Descriptions
1 Tools trolley (Complete set of hand tools)
2 Scanner
3 Test lamp
4 DMM (Multimeter)
8. Repair Battery Charging System
Overview
These competency standards designed to enable the learner to troubleshoot battery charging related problems and conceptualize electronics used in the system.
Unit of Competency Performance Criteria
1. Repair charging system
P1. Inspect vehicle charging system and diagnose the following. Battery warning light indication on instrument panel, test output voltage of alternator, drive belt condition, alternator bearing noise, wire harness, fuse, and proper insulated wires.
P2. Dismantle/service of alternator as following;Repair connector, replace carbon brushes, Replace Rectifier Bridge, replace voltage regulator and replace stator winding.
2. Replace alternator P1. Perform safe working practice to remove the alternator from the vehicle and refit under the specified procedure.
P2. Perform test bench of alternator to confirm the operation.
Knowledge & Understanding
• Describe the Purpose and function of Alternator’s following parts. Rotor, stator windings, Voltage regulator, Rectifier Bridge, Internal cooling fan, Bearings, carbon brush, mounting/adjustment bolts), drive belt and its types, ratio alternator/ crank pulleys, RPM, Alternator input/ output voltages.
• Describe the functions and uses of the following. Semiconductor and its types, Rectification (Half wave/ full wave), transformer and its types, capacitor and its types.
Critical Evidence(s) Required
• Capable to troubleshoot the vehicle charging system
• Capable to describe the fault related to the alternator and take appropriate decisions.
• Capable to Service the alternator
List of Tools and Equipment
S. No. Descriptions
1 Vehicle/simulator
2 Test lamp
3 DMM
4 Tool kit
5 Ampere meter
6 Fuses
7 Relay
9. Repair Light System of Vehicle
Overview
These competency standards designed to enable the learner to rectify electrical related troubles in the vehicle and understand the Wiring of the vehicle, repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Troubleshoot The Lightening System
P1. Inspect vehicle lightening system and diagnose following; under specified testing instructions, Blown fuse finding from interior or exterior fuse box.(Note: follow safe working procedure).
P2. Inspect vehicle lightening system and diagnose following; under specified testing instructions, faulty relay and faulty flasher. (Note: follow safe working procedure).
2. Repair Lights P1. Inspect vehicle lightening system and diagnose following under specified testing instructions. Inspect/Replace head lamp, parking bulb and indicator bulb(Note: follow safe working procedure).
P2. Inspect vehicle lightening system and diagnose following under specified testing instructions. Back light bulb, reverse light bulb.(Note: follow safe working procedure).
Knowledge & Understanding
• Identify the terms used and calculations associated with the electricity. Definitions (magnetism, self/mutual induction). Laws (amperes rule, Fleming’s rule)Switch (manual, magnet, pressure, temperature)sender (fuel level, temperature)
Critical Evidence(s) Required
• Capable to troubleshoot the vehicle lightening system
10. Repair Vehicle Accessories
Overview
These competency standards designed to enable the learner to rectify electrical related troubles IN the vehicle and understand the Wiring of the vehicle, repair that system of vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Repair Cooling System and Vehicle Accessories
P1. Inspects the Radiator fan operation for correct operation under specified testing instructions.
P2. Inspects the thermal switch for correct operation under specified testing instructions.
P3. Inspects the temperature sender for correct operation under specified testing instructions.
2. Repair Electrical Accessories
P1. Inspects the oil warning switch operation for correct operation under specified testing instructions.
P2. Inspects fuse, relay operation for correct operation under specified testing instructions.
P3. Inspects the fuel sender operation for correct operation under specified testing instructions.
P4. Inspects the wiper motor, washer motor for correct operation under specified testing instructions.
P5. Inspects heating Elements for correct operation under specified testing instructions
Knowledge & Understanding
• Identify terms used and calculations associated with electricity. Definitions(magnetism, self/mutual induction).Laws (amperes rule, Fleming’s rule)
• Describe the use of following materials in vehicle with example. Conductor (Good/ bad), Insulator, semiconductors, electrical Cable (Color coding, ampere rating, wire harness, cross sectional area, cable identification method).
• Differentiates each in following. Switch (manual, magnet, pressure, temperature)sender (fuel level, temperature)
Critical Evidence(s) Required
• Capable to troubleshoot the vehicle lightening system
• Capable to describe fault related to electrical lights, cooling system, and take appropriate decision.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle/ simulator
2 Digital Multi Meter (DMM).
3 Tools box
4 test lamp
Workshop Practice-1 (MT-164)
1. Perform Bench Work on Metallic Surfaces
Overview:
These competency standards identify the competencies you need to perform bench work operations using different tools and equipment, in accordance with approved procedures. You will be expected to perform sawing, filing, threading and reaming using hand tools. You will be required to operate the tools and equipment safely by comply the organizational safety policy and approved procedures. Your underpinning knowledge will be sufficient to provide you the basis for your work.
Competency Units Performance Criteria
1. Carry-Out Sawing P1. Select appropriate blade and set in hacksaw frame according to the job requirement
P2. Select appropriate marking tool(s), mark the work piece and clamp it in the vice firmly as per standard practices
P3. Adopt sawing methods and techniques that are safe and suitable to cut the work-piece as required
P4. Follow marked line during sawing of work piece to ensure accuracy
2. File the Work-Piece P1. Select appropriate file and marking tool(s) according to the job requirement
P2. Mark the work-piece and clamp it in the vice firmly as per standard practices
P3. Adopt filing method and technique which is safe and suitable to produce the work-piece as per drawing
P4. Follow drawing dimensions and surface finish of field work-piece to ensure accuracy and precision
3. Carry out Drilling P1. Setup drill machine for producing hole in the work piece according to the job requirement
P2. Select drill bit and marking tools according to the material and job requirement, respectively
P3. Mark the work-piece according to the drawing and clamp it in the vice firmly as per standard practices
P4. Set the suitable RPM. P5. Adopt proper drilling method (manual/auto-feed, applying
coolants) which is safe and suitable to produce the hole in work-piece
P6. Follow drawing dimensions of drilled hole to ensure accuracy and precision
4. Produce Threads on Work-Piece
P1. Select tap and die according to the type of thread to be produced on work-piece as per drawing
Competency Units Performance Criteria
P2. Clamp the work-piece in the clamping device firmly as per standard practices
P3. Ensure the tap and die alignment as per prescribed standard P4. Make thread with die and follow appropriate sequence P5. Ensure the safety and dimensional accuracy of threads on work-
piece as per drawing
5. Perform Hand Reaming
P1. Select reamer according to the work-piece requirement P2. Clamp the work-piece in the clamping device firmly as per
standard practices P3. Ensure the reamer alignment as per prescribed standard P4. Produce reamed hole by following safety and prescribed method P5. Ensure the accuracy and size of reamed hole of work-piece
according to the drawing
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out the tasks covered in this competency standard. This includes the knowledge of:
• Mechanical Properties and strength of materials
• Combination of feed and speed settings according to the work-piece, and tools& materials
• Usage of bench-work tools and equipment
• Interpret basic drawings
• Measurement systems
• Use of measuring and marking tools
• Usage of bench working tools
• Procedure of safe clamping the work-piece
• Personal Protective Equipment (PPEs) and workplace safety
Critical Evidence(s) Required
The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:
• Utilization of tools (measuring, marking & cutting) equipment and their working method
• Produce a component containing the following operations marking, sawing & filing
• Produce a component containing operations with marking, drilling, threading & reaming
List of Tools and Equipment
S. No. Descriptions
1 Hacksaw
2 Drill set
3 Drill Machine
4 Shaper Machine
5 Lathe Machine
6 Milling Machine
7 Grinder
2. Perform Shaper Machine Operations
Overview:
This competency standard identifies the competencies you need to perform shaping operations on shaper machine in accordance with approved procedures. You will be expected to perform Facing, Step cutting, Squaring, Slotting, V-shape cutting with point cutting tool. You will be required to operate the shaper machine safely by complying the organizational safety policy and approved procedures. Your underpinning knowledge will be sufficient to provide you the basis for your work.
Competency Units Performance Criteria
1. Prepare Materials for Shaping Operations
P1. Interpret drawing and arrange the material accordingly P2. Prepare work-piece by required machining (sawing and filing
etc.) and get ready to clamp P3. Check and verify the dimensions of work-piece for shaping
according to the drawing
2. Select Tools and Equipment
P1. Select the material and shape of tool(s) according to the job requirements
P2. Arrange the measuring instruments and holding devices to attain accuracy of the work as per prescribed method
3. Set Shaper Machine for Operations
P1. Clamp the material of work-piece and tool into its holding devices as per standard practice
P2. Maintain safe distance between surface of work-piece and tooltip as per prescribed method
P3. Adjust the ram placement and stroke length according to the length of job
P4. Adjust the parameters of shaping (speed and feed) from control unit as per prescribed method
P5. Start shaping operation by locating the initial touching point and adjust the depth of cut according to the prescribed procedure
4. Perform Shaping Operations (Square Job)
P1. Ensure the proper clamping of work-piece and the tool according to the standard practice
P2. Start the shaping operation at top surface of work piece to get flatness as per initial requirements
P3. Re-clamp the work-piece by rotating 90° for next surface as per prescribed method
P4. Shape entire work-piece by following the above stated method for next surface to get square shaped work piece according to drawing
5. Perform Shaping Operations (Angular Job
P1. Ensure proper clamping of the work-piece and the tool according to standard practice
P2. Mark work-piece according to the drawing P3. Set and align the sliding degree of head according to required
angle P4. Start the angular shaping operation to get required angle as per
Competency Units Performance Criteria
marked line P5. Shape entire work-piece, by setting the required degree of head,
to get angle of work-piece according to the drawing
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out the tasks covered in this competency standard.
This includes the knowledge of:
• Interpret basic drawings
• Measurement systems
• Knowledge of shaping machines
• Types of shaping machines
• Ram and stroke settings
• Mechanical Properties and strength of materials
• Knowledge of shaping tools
• Feed and speed settings
• Working procedure of shaping
• Shaping tools and holding devices
• Housekeeping of tools and equipment
Critical Evidence(s) Required
The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:
• Produce a component containing the following operations with marking: o Square job as prescribed method o Angular job as prescribed method o Setting of machine, tool and stork per minute
Tools and equipment required
Sr. No. Items
1 Hacksaw
2 Shaper Machine
3 Flat File
4 Marking Tools
5 Chapping Tools
6 Measuring Tools
7 Tool Grinder
3. Perform Lathe Turning Operations
Overview:
This Competency Standard identifies the competencies required to perform lathe machine operations by a Machinist in accordance with the organization’s approved guidelines and procedures. You will be expected to perform facing, turning drilling/boring, taper turning, knurling and threading operations using lathe machine. Your underpinning knowledge will be sufficient to provide you the basis for your work.
Competency Units Performance Criteria
1. Prepare Materials for Lathe Operations
P1. Interpret drawing and arrange the material accordingly P2. Prepare work-piece by required machining (sawing and filing
etc.) and get it ready for clamping P3. Check and verify the dimensions of work-piece for lathe
operations as per drawing
2. Select Tools and Equipment
P1. Select the tool(s) according to material of job and shape of the job requirements
P2. Arrange the measuring instruments and holding devices to attain accuracy of the work as per prescribed method
3. Set Lathe Machine for Operations
P1. Clamp the material of work-piece and tool into its holding devices as per standard practice
P2. Maintain the safe distance between work-piece and tool tip as per prescribed method
P3. Adjust the revolution per minute (rpm) of chuck according to the specifications of work-piece.
P4. Adjust the parameters of speed and feed from control unit as per prescribed method
4. Carry-Out Lathe Operations
P1. Ensure the proper clamping of work-piece and the tool into the holding devices according to the required operation
P2. Maintain the alignment of work-piece and locate the tool tip at center position of the work-piece as per standard practice
P3. Start the lathe operations as required according to the drawing and replacing the required tool
P4. Check the work-piece by using appropriate measuring tools and instruments as per standard practice
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out the tasks covered in this competency standard.
This includes the knowledge of:
• Mechanical Properties and strength of materials
• Personal Protective Equipment and workplace safety
• Interpret basic drawings
• Measurement systems
• Use of measuring and marking tools
• Knowledge of Lathe machines and its types
• Knowledge of holding devices and lathe attachments
• Knowledge of lathe tools
• True running of job(s) and center alignment of tool tip
• Calculation of feed and speed according to the work-piece and tool materials
• Procedure of safe clamping the work-piece
• Importance and usage of coolants
Critical Evidence(s) Required
The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:
• Produce a component containing the following operations with marking as prescribed method:
• Facing
• Parallel Turning
• Step Turning
• Taper Turning
• Drilling
• Boring
• Threading (internal/external)
• Grooving
Tools and equipment required
Sr. No.
Items
1 Hacksaw
2 Drill set
3 Drill Machine
4 Lathe Machine
5 Tool Grinder
6 Lathe Cutting Tools
7 Measuring Tools
4. Read and Interpret Manufacturing Drawings
Overview
This competency standard is designed to gain basic knowledge and skills required to read and interpret manufacturing drawings and welding symbols. The standard covers specific knowledge related to reading and understanding manufacturing drawings, interpreting welding symbols, recognizing materials and specifications, and bill of material/s and manufacturing parts according to manufacturing drawings.
Competency Units Performance Criteria
1. Read and Understand Manufacturing Drawings
P1. Recognize basics of lines used in engineering drawings P2. Describe uses of lines in engineering drawings P3. Recognize and explain orthographic and isometric views of a
drawing P4. Identify manufacturing requirements according to drawings P5. Prepare job layout according to manufacturing requirements
2. Interpret Welding Symbols
P1. Understand basic and supplementary welding symbols used in manufacturing drawings
P2. Understand and differentiate between types of welds and joints P3. Identify welding requirements according to welding symbols given
in the manufacturing drawings
3. Recognize Material Specifications and Bill of Material (BOM)
P1. Identify material specifications according to manufacturing drawing
P2. Identify bill of material (BOM) according to manufacturing drawing
4. Manufacture Parts P1. Interpret dimensional tolerances according to manufacturing drawing
P2. Assemble and tack weld parts according to manufacturing drawing
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• Basic elements of engineering drawing
• Drawing symbols
• Dimensioning techniques
• Tolerances
• General tolerance
• Angular tolerance
• Geometric tolerance
• Drawing techniques
• Perspective
• Exploded view
• Hidden view technique
• Projections
• First angle projections
• Third angle projections
Critical Evidence(s) Required
The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:
• Prepare and interpret technical drawings and sketches based on provided specifications
Tools and Equipment Required
The tools and equipment required for this competency standard are given below:
S. No. Descriptions
1 Drawing or Sketch
2 Layout Tools
3 Measuring Devices
4 Handheld Calculator
5 Fabrication and Welding Equipment
6 Base Metals
7 Welding Consumables
5. Perform Welding Procedure Specifications (WPS)
Overview:
This competency standard is designed to gain basic knowledge and skills required to prepare Welding Procedure Specifications (WPS). The standard covers specific knowledge related to recognizing, interpreting and explaining and preparing Welding Procedure Specifications (WPS).
Competency Units Performance Criteria
1. Recognize Welding Procedure Specifications (WPS)
P1. Describe and understand contents of Welding Procedure Specifications (WPS)
P2. Recognize common acronyms used in Welding Procedure Specifications (WPS)
2. Interpret and Explain Welding Procedure Specifications (WPS
P1. Recognize materials specifications (base metals and fillers) according to Welding Procedure Specifications (WPS)
P2. Recognize weld type and joint design according to Welding Procedure Specifications (WPS)
P3. Recognize welding positions and parameters according to Welding Procedure Specifications (WPS)
3. Prepare a Welding Procedure Specifications (WPS)
P1. Prepare sample Welding Procedure Specifications (WPS) following a simple welding procedure
P2. Follow written Welding Procedure Specifications (WPS) to produce a production/sample weld
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• Written communication skills (reading and comprehension)
• Purpose of Welding Procedure Specifications
• Common contents of WPS
• Groupings of materials
• Thickness range
• Types of welds
• Joint design
• Welding processes
• Welding positions
• Welding consumables
• Electrical characteristics - volts, current, polarity
• Shielding gases
• Purge gas
• Gas flow rate
• Nozzle diameter
• Pre-heat/Post-heat
• Welding speed
Critical Evidence(s) Required
The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:
• Interpret a range of WPS documents.
Tools and equipment required
S. No. Descriptions
1 Hacksaw
2 Drill set
3 Drill Machine
4 Shaper Machine
5 Lathe Machine
6 Milling Machine
7 Cylindrical Grinder
8 Surface grinder
6. Prepare Materials for Welding
Overview:
This competency standard is designed to gain basic knowledge and skills required to prepare materials for a specific job. The standard covers specific knowledge of marking the material as per drawing/job requirement, setting up cutting equipment, cutting and preparing edges of base materials, cleaning surfaces and edges, preparing welding consumables and fitting up base materials.
Competency Units Performance Criteria
1. Select and Mark Material/s as per Drawing/Job Requirement
P1. Select and obtain required material/s as per job requirements P2. Select appropriate marking tools as per job requirements P3. Mark the area to be cut as per drawing/ job requirements
2. Cut and Prepare Edge/s of Base Materials
P1. Select appropriate cutting equipment as per job requirements P2. Set-up cutting equipment as per manufacturer’s instructions/job
requirements P3. Cut the base material as per job specifications and dimensions
provided in the drawing P4. Prepare edges of the base materials as per drawing/ WPS P5. Check dimensions of the prepared edges as per drawing/ WPS P6. Select proper tools and chemicals for cleaning P7. Clean the edges of the base materials as per job requirements
3. Prepare Welding Consumables
P1. Select relevant welding consumables as per job requirements/ WPS
P2. Prepare consumables in accordance with required specifications
4. Fit-up Base Materials
P1. Select proper tools and equipment to fit-up base materials P2. Tack weld joint/s as per drawing/ welding procedure
specifications (WPS) P3. Check root gap as per drawing/welding procedure specifications
(WPS) P4. Check alignment as per applicable code/standard
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• Interpretation of drawings and sketches
• Selection of appropriate method of edge preparation
• Selection of appropriate cutting equipment, accessories and supplies
• Operation of cutting equipment such as mechanical, gas and plasma
• Operation of grinding equipment
• Safety procedures for cutting and grinding
Critical Evidence(s) Required
The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:
• Perform edge preparation in accordance with WPS and safety procedures
Tools and equipment required
S. No. Descriptions 1 Hacksaw
2 Drill set
3 Drill Machine
4 Shaper Machine
5 Lathe Machine
6 Milling Machine
7 Cylindrical Grinder
8 Surface grinder
7. Perform Shielded Metal Arc Welding (SMAW) in Vertical (3F, 3G) and Overhead (4F, 4G) Positions
Overview:
This Competency Standard is designed to gain basic knowledge and skills required to perform Shielded Metal Arc Welding (SMAW) operations in Flat (1F, 1G) and Horizontal (2F, 2G) positions at workplace. The standard covers specific knowledge of performing Shielded Metal Arc Welding (SMAW) by selecting and setting up welding equipment, installing consumables, adjusting welding parameters and making fillet and groove welds in Flat (1F, 1G) and Horizontal (2F, 2G) positions of plate. The standard also covers post welding operations comprising cleaning, measuring, inspecting and repairing welds at workplace.
Competency Units Performance Criteria
1. Prepare Welding Machine and Accessories for SMAW
P1. Identify welding requirements from the job, welding procedure specifications and/or technical drawings
P2. Prepare SMAW welding machine in accordance with welding procedure specifications/ manufacturer instructions
P3. Set up welding machine accessories and consumables as per job requirements, welding procedure specifications and/or manufacturer’s instructions
P4. Connect welding machine to an independent power supply P5. Set polarity indicated in the welding procedure specifications
2. Make Fillet Welds on Carbon Steel Plate
P1. Adjust welding parameters (current, voltage etc.) as per welding procedure specifications/job requirements to produce acceptable weld
P2. Maintain gap between electrode and base metal as per standard practices
P3. Carry out welding in Flat (1F) and Horizontal (2F)positions following standard procedures
P4. Follow applicable manufacturing codes and standards for acceptance criteria of visual welding defects
3. Make Groove Welds on Carbon Steel Plate
P1. Adjust welding parameters (current, voltage etc.) as per welding procedure specifications/job requirements to produce acceptable weld
P2. Maintain gap between electrode and base metal as per standard practices
P3. Carry out welding in Flat (1G)and Horizontal (2G) positions following standard procedures
P4. Deposit root pass as per welding procedure specifications/ job requirements
P5. Deposit filling passes as per welding procedure specifications/job requirements
P6. Deposit capping pass as per welding procedure specifications/job requirements
P7. Check root, filling and capping passes for any visual discontinuities as per acceptance standards
Competency Units Performance Criteria
P8. Follow applicable manufacturing codes and standards for acceptance criteria of visual welding defects
4. Perform Post Welding Operations
P1. Carry out finishing work of welds following standard procedures P2. Inspect weld visually and mark any visual defects, as required P3. Carry out repair work in accordance with approved procedures,
as required P4. Clean work area in accordance with workplace safety practices P5. Maintain and store tools/ equipment/ consumable materials in
accordance with organization guidelines
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• Understanding of technical drawings
• Electrical supply AC and DC
• Polarity setting according to standard specifications
• Specifications/ classification of electrode/s required for the job
• Welding procedure specifications (WPS)
• Method of Pre- heating of base metal
• Electrical parameters like (voltage, current etc.) and their effects on weld
• Welding techniques as per WPS/instruction sheet
• Visual welding defects
• Welding codes and standards
Critical Evidence(s) Required
The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:
• Perform SMAW fillet weld at 1F, 2F positions, groove weld at 1G, 2G positions as per given job specification
Tools and equipment required
S. No. Descriptions
1 Hacksaw
2 Drill set
3 Drill Machine
4 Welding Machine
5 Lathe Machine
6 Milling Machine
8. Perform Forging Operations
Overview:
This Competency Standard is designed to gain basic knowledge and skills required to Perform main operation of forging (Drawing down and Swaging).The standard covers specific knowledge of performing of Forging in drawing down and swaging.
Competency Units Performance Criteria
1. Drawing down P1. Make fire in available forge furnace P2. Put the stock in forge furnace. P3. Heat the stock upto bright red condition ( Plastic State) P4. Grip the heated stock by tong and put on anvil. P5. Apply firm blows of sledge hammer on both sides of stock. P6. Put the stock again in forge furnace and repeat process P7. Always wear safety dress before start the performance.
2. Swaging P1. Make fire in forge furnace P2. Put the round stock in forge furnace. P3. Heat the stock upto bright red condition. P4. Fix the bottom swage in hardy hole. P5. Put the red hot round bar in the bottom swage. P6. Put the top swage over round bar with the help of handle. P7. Apply firm blows of sledge hammer and move round bar
longitudinally and circumferentially. P8. Always wear safety dress before start the performance.
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the Knowledge of:
• Understanding of techniques of drawing down
• Proper preparation and selection of stock.
• Understand the use of proper equipment.
• Using proper safety dress before starting performance.
• Complete the drawing down and swaging process rapidly.
Critical Evidence(s) Required
The candidate needs to produce following critical evidence(s) in order to be competent in
• Prepare the job through drawing down process.
• Prepare the job through Swaging process
Tools and equipment required
S. No. Descriptions
1 Hacksaw
2 Drill set
3 Drill Machine
4 Welding Machine
5 Lathe Machine
6 Milling Machine
Basic Engineering Drawing and CAD-I Mech-163
1. Perform Drawing, Sketch Making
Over View
This competency standard of manual drawing identifies the competencies to apply basic of drawing making sketches.
Competency Unit Performance Criteria
1. Draw Different Forms of Drawing
P1. Draw convention layout drawing P2. Draw convention electrical circuit drawing P3. Draw lines with different scale of measurement P4. Select the sheet format P5. Select the tool and equipment
2. Draw different lines for free hand sketching
P1. Draw horizontal lines P2. Draw vertical lines P3. Draw arcs P4. Draw circles P5. Draw ellipse P6. Draw all conic section P7. Draw projection of lines P8. Sketch different objects
3. Draw different lines with measurement
P1. Draw single Stroke lettering P2. Draw double stroke gothic letter P3. Draw different types of letter P4. Draw alphabet of lines in original scale P5. Apply alphabet of lines in drafting
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out the tasks covered in this competency standard.
This includes the knowledge of draw development by
• Draw mechanical drawing
• Draw electrical drawing
• Draw civil drawing
• Draw terms use in drawing
• Draw application of drawing forms
• Draw scales used in drawing
• Draw fundamentals units i.e. Arcs, circles and ellipse
• Draw single stroke and double stroke gothic letters
List of Tools and Equipment
S. No. Descriptions
1 T square
2 Set square
3 Compass
4 Eraser
5 Pencil
6 Sharpener
7 Drawing sheet
8 Paper tape
9 Drawing board
2. Draw Pictorial Drawing
Over View:-
This Competency standard of manual drawing identifies the competencies to draw pictorial drawings.
Competency unit Performance criteria
1. Draw different types of pictorial drawing
P1. Draw oblique drawing P2. Draw axonometric drawing P3. Draw perspective drawing P4. Draw Multiview drawing
2. Draw multi view projection
P1. Draw principle plane of projection P2. Draw projector / projection lines P3. Draw auxiliary view of objects P4. Draw Multiview drawing of machine components
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out the tasks covered in this competency standard. This includes the knowledge of:
Draw development by
• Draw oblique drawing
• Draw axonometric drawing
• Draw perspective drawing
• Draw multi view drawing
• Draw plan of projection
• Draw projection drawing
• Draw multi view drawing of machine equipment
List of Tools and Equipment
S. No. Descriptions
1 T square
2 Set square
3 Compass
4 Eraser
5 Pencil
6 Sharpener
7 Drawing sheet
8 Paper tape
9 Drawing board
3. Perform Basic Dimensioning System in Working Drawing
Over View
This Competency standard of manual drawing identifies the competencies to apply skills in having expertise in dimensioning systems and geometrical construction.
Competency Unit Performance Criteria
1. Draw dimensional geometrical constructions
P1. Draw the types of dimensioning ( size of dimension and location of dimension
P2. Draw system of dimensioning P3. Draw dimensioning of holes P4. Draw dimensioning of arc P5. Draw dimensioning circles P6. Draw dimensioning of angles P7. Draw all conic sections separately P8. Draw engineering involute curve of a circle
2. Draw working Drawing
P1. Draw preliminary designee sketching P2. Draw detail Drawing of an object P3. Draw Assembly Drawing of an object P4. Draw working drawing of machine component
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out the tasks covered in this competency standard. This includes the knowledge of:
Draw development by
• Draw types of dimensioning
• Draw system of dimensioning
• Draw dimensioning in size of holes
• Draw dimension in size of arc
• Draw dimensions in size of circle
• Draw all conic section separately
• Draw detail drawing of an object
• Draw assembly drawing of an object
• Draw working drawing of machine components
List of Tools and Equipment
S. No. Description
1 T square
2 Set square
3 Compass
4 Eraser
5 Pencil
6 Sharpener
7 Drawing sheet
8 Paper tape
9 Drawing board
4. Perform Sectioning and Pictorial Drawing
Over View:-
This Competency Standard of manual Drawing. Identifies the competencies to apply skill in sectioning and pictorial drawing.
Competency unit Performance criteria
1. Draw sectioning P1. Draw material symbols used in sectioning P2. Draw full section of an object P3. Draw half section of an object P4. Draw broken section of an object P5. Draw sectional view of machine components
2. Draw pictorial Drawing
P1. Draw isometric view of an object P2. Draw isometric view of arc P3. Draw isometric view of circle P4. Draw oblique view of a rectangular block P5. Draw isometric views of an object / components
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out the tasks covered in this competency standard. This includes the knowledge of:
Draw development by
• Draw material symbols used in engineering drawing
• Draw full section of an object
• Draw half section of an object
• Draw sectional views of machine components
• Draw oblique view of a rectangular block
• Draw isometric views of an object
List of Tools and Equipment
S. No. Descriptions
1 T square
2 Set square
3 Compass
4 Eraser
5 Pencil
6 Sharpener
7 Drawing sheet
5. Draw Auxiliary Drawing
Over view
This Competency Standard of manual Drawing. Identifies the competencies to apply skill in auxiliary drawing
Competency unit Performance criteria
1. Draw primary auxiliary view
P1. Draw Primary auxiliary view of frontal projection P2. Draw primary auxiliary view of horizontal projection P3. Draw primary auxiliary view of profile projection P4. Draw Example of all these
2. Draw true length line P1. Draw true length line in auxiliary view of different objects P2. Draw auxiliary view in different objects P3. Draw auxiliary view of objects P4. Draw auxiliary view of component part P5. Draw example of above two
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out the tasks covered in this competency standard. This includes the knowledge of:
Draw development by
• Apply auxiliary views
• Draw primary auxiliary views of frontal projection
• Draw primary auxiliary view in horizontal projection
• Draw primary auxiliary view in profile projection
• Draw true length line in the auxiliary view of different objects
• Draw secondary auxiliary view in different objects
List of Tools and Equipment
S. No. Descriptions
1 T square
2 Set square
3 Compass
4 Eraser
5 Pencil
6 Sharpener
7 Drawing sheet
Problems in Internal Combustion Engines AD-203
1. Diagnose Engine Fault
Overview
These competency standards designed to enable the learner to find out the faults and rectify accordingly, learner will be able to overhaul the engine under the specified format in the service manual.
Unit of Competency Performance Criteria
1. Engine fault adjustment
P1. Perform engine adjustment/setting of Engine Timing, Setting Distributor timing, tappet adjustment, drive belt/fan belt adjustment.
P2. Change the engine head gasket, Crank main oil seal, Engine timing belt, manifold packing, and exhaust muffler.
2. Engine fault diagnosing
P1. Use the compression tester and test engine compression to diagnose fault in piston rings or valve seats/burnt valve under specified procedure.
P2. Start the engine and identify the condition of engine missing, stalling, and lack of power, back fire, knocking, black smoke/heavy fuel consumption, excessive oil consumption, and leakages.
Knowledge & Understanding
• Describe the following;
Valve timing: lead, lag, overlap, timing diagrams, valve, clearances/adjustment/adjustment methods.
Terms: Top Dead Centre (TDC), Bottom Dead Centre (BDC),Bore, Stroke, Capacity, Clearance Volume, Swept Volume, Compression Ratio, Crank Throw, Torque at Revs/Min, Brake power at Revs/min, Specific fuel consumption (SFC),Volumetric Efficiency, OHV, and OHC.
Critical Evidence(s) Required
• Capable of adjustments.
• Capable of changing faulty components.
List of Tools and Equipment
S. No. Descriptions
1 Tools trolley (complete set of tools)
2 Compression tester, compression gauge)
3 Measuring tools (Verniercalliper, micrometre, bore gauge, dial gauge, Steel rule, filler gauge, try square)
4 Torque wrench
5 Impact gun
6 Oil can
7 Belt tensioner
8 Spray gun
9 Valve lapping tool
10 Timing gun
11 Engine analyzer
12 Tachometer
13 Scraper
Consumable Items:
S. No. Descriptions
1 Fuel (petrol/diesel)
2 Cotton rag
3 WD 40 spray
4 Carb cleaner spray
5 Kerosene oil
6 Engine oil
7 Engine coolant
8 fan belt
9 Timing belt
10 oil seals
11 Gasket
12 Silicone
13 Emery paste
2. Perform Engine Overhauling (Petrol/Diesel)
Overview
These competency standards designed to enable the learner to find out the faults and rectify accordingly, learner will be able to overhaul the engine under the specified format in the service manual.
Unit of Competency Performance Criteria
1. Engine sub-assemblies
P1. Make the engine sub-assemblies and inspect the performance for (setting piston rings, piston pin and connecting road),
P2. Make the engine sub-assemblies and inspect the performance for (valve train and test for the leakage from valve seats),
P3. Make the engine sub-assemblies and inspect the performance for (fitting crankshaft with main bearings and pistons with the big end bearings),
P4. Perform the straightness inspect of engine head and block straightness/warpage level and make decision for correctness.
2. Engine measurement P1. Use appropriate measuring tool and Measure piston bore, measure crankshaft main journals, crankshaft big end journals,
P2. Use appropriate measuring tool and Measure Camshaft main journals, Cam loops,
P3. Use appropriate measuring tool and Measure engine thrust washer, and piston connecting pin.
P4. Assemble the engine block with the engine head and adjust tappets, engine timing, and spark distributor of petrol engine under specified procedure.
Knowledge & Understanding
• The possible causes of high fuel consumption as following.
• Overload the engine, excessive oil reducing, faulty air filter, carburetor poor setting, engine over cooled and hard/jam running of engine, faulty fuel injectors, faulty fuel pump/fuel filter.
Critical Evidence(s) Required
• Capable to take decision for engine overhauling.
• Capable of knowing the engine faults
• Capable to assemble the engine.
• Capable to measure the engine components
List of Tools and Equipment
S. No. Description
1 Tools trolley (complete set of tools)
2 Compression tester, compression gauge)
3 Measuring tools (Verniercalliper, micrometre, bore gauge, dial gauge, Steel rule, filler gauge, try square)
4 Torque wrench
5 Impact gun
6 Oil can
7 Belt tensioner
8 Spray gun
9 Valve lapping tool
10 Timing gun
11 Engine analyzer
12 Tachometer
13 Scraper
Consumable Items:
S. No. Description
1 Fuel (petrol/diesel)
2 Cotton rag
3 WD 40 spray
4 Carb cleaner spray
5 Kerosene oil
6 Engine oil
7 Engine coolant
8 fan belt
9 Timing belt
10 oil seals
11 Gasket
12 Silicone
13 Emery paste
3. Diagnose Engine Cooling System Faults and Repair
Overview
These competency standards designed to enable the learner to diagnose the fault related to the vehicle cooling system and troubleshoot accordingly by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Cooling system service
P1. Inspect engine cooling system’s main components and diagnose the performance of (Radiator cap, water body/pump, drive belt/fan belt, thermostat Valve, radiator, Drain plug, hoses/clamps, and gasket/ seals)
P2. Inspect/service the radiator and top up with the coolant/antifreeze as per specified ratio in the manual.
2. Repair Cooling system P1. Change the water body under specified procedure and start the engine to confirm correct operation.
P2. Adjust fan belt tension under specified procedure and start the engine to confirm correct operation.
Knowledge & Understanding
• Describe the operating principles and terminologies of cooling system as following. Air cooled engine, liquid cooled engine, operating temperature, thermal efficiency, pressurized system, heat exchange method (conduction, radiation, and convection), corrosion, and inhibitors/antifreeze)
• Describe the functions and purpose of engine cooling system components as following. Electrical motor operated fan with thermo switch, belt operated fan, temperature controlled/viscous coupling fan, pressure cap, water body/pump, drive belt, thermostat, radiator, core plug, hoses/clamps, and gasket/ seals.
Critical Evidence(s) Required
• Capable of diagnose, adjust and rectify the cooling system faults.
List of Tools and Equipment
S. No. Description
1 Hand tools trolley
2 Radiator leak tester
3 Vehicle/ simulator with a cooling system
5 Drive belt
Consumable Items:
S. No. Description
10 Sealant
11 Hose pipe
12 Thermostat valve
4. Diagnose Faults in Engine Lubrication System
Overview
These competency standards designed to enable the learner to diagnose the fault related to the lubrication system and troubleshoot accordingly by Auto Mechanic, in accordance with the manufacturer’s Manual.
Units of Competency Performance Criteria
1. Lubrication system
P1. Inspect engine lubrication system’s main components and check (engine oil level)
P2. Inspect engine lubrication system’s main components and check (oil leakage)
P3. Inspect engine lubrication system’s main components and check (oil warning switch)
P4. Inspect engine lubrication system’s main components and check (and PCV valve)
2. Repair Lubrication system
P1. Inspect/replace of oil warning switch, PCV valve, oil sump, oil sump seal/gasket, and oil pump under the specified procedure.
P2. Carryout safe procedure to change the engine oil and oil filter.
Knowledge & Understanding
• Describe the functions/operating principle and main components of engine lubrication system as following. Wet sump, dry sump, total loss, Oil pumps and its types, pressure relief valves, oil filter, oil cooler, ventilation/PCV Valve, hoses, and oil level indicators. Lubricant (oils viscosity, viscosity index, oil classifications, Reduction of frictional forces, cooling effect, cleaning effect, corrosion resistance, and noise reduction).
• Describes the (Law of friction, static/dynamic friction (difference), coefficient of friction).
Critical Evidence(s) Required
• Capable of diagnose, adjust and rectify the lubrication system faults.
• Capable to change the engine oil and filter.
List of Tools and Equipment
S. No. Description
1 Hand tools trolley
2 Car Lift
3 Vehicle/ simulator with a cooling system
4 Sealant/gasket
5. Diagnose Faults of Carburetor Fuel System
Overview
These competency standards designed to enable the work on vehicle fuel system to diagnose and rectify the faults in petrol and diesel engines by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Service of Fuel system (carburetor type engine)
P1. Diagnose performance of petrol engine’s (Carburetor type) main components and Service/replace under the specified procedure of (Air Filter).
P2. Diagnose the performance of petrol engine’s (Carburetor type) main components and Service/replace under the specified procedure of (Fuel pump).
P3. Diagnose the performance of petrol engine’s (Carburetor type) main components and Service/replace under the specified procedure of (Carburetor and Fuel filter).
P4. Diagnose the performance of petrol engine’s (Carburetor type) main components and Service/replace under the specified procedure of (fuel lines/clips, fuel sending unit).
2. Repair of Fuel system (carburetor type engine)
P1. Start the engine and set air fuel mixture by adjusting required engine RPM at idling and at speed under specified procedure.
P2. Perform service of carburetor under specified procedure.
Knowledge & Understanding
• Describe the features of main components of engine fuel system as following: Fuel tanks, filler cap/security, venting, fuel level sender, lines/filters, carburetor, and fuel lift pumps (mechanical/electrical),Fuel (Octane Rating, Octane Number , CetaneNumber , Cetane Rating, Leaded, Unleaded).
Critical Evidence(s) Required
• Capable to diagnose and troubleshoot the petrol engine (Carburetor type)
• Capable to adjust air fuel ratio
• Capable to service of carburetor
List of Tools and Equipment
S. No. Descriptions
1 Toll trolley (Complete set)
2 Test lamp/DMM (Digital multimeter)
4 Diesel injector pressure tester /Petrol Injector Tester
5 Safety wears
Consumable Items:
• Carburetor cleaner, Carburetor Gasket Set, Petrol, Injector Rings,
6. Diagnose Diesel Fuel System and Adjust
Overview
These competency standards designed to enable the work on vehicle fuel system to diagnose and rectify the faults in petrol and diesel engines by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Service Fuel System (diesel engine)
P1. Use injector pressure tester machine and Service/set pressure of fuel injector as specified in the manual.
P2. Apply safety precautions and perform air bleeding from low pressure side and high pressure side under the specified procedure.
2. Repair Fuel System (diesel engine)
P1. Inspect diesel engine main components and diagnose the performance of (heater plug).
P2. Inspect diesel engine main components and diagnose the performance of (injectors).
P3. Inspect diesel engine main components and diagnose the performance of (injection pump, sediment /filter).
P4. Inspect diesel engine main components and diagnose the performance of (sediment /filter).
Knowledge & Understanding
• Describe the Diesel injection systems main components as following. Single/multi-hole injectors, inline fuel injection pump, rotary fuel injection pump, fuel injection
pressure, bleed points, fuel cutoff switch, governor operation, in Combustion chamber types, main features of pressure/volume diagrams/effects of advanced/retarded/no fuel injection
• Describe the as following statements. Diesel fuel composition, effects of low temperature, viscosity, volatility, calorific value, cetane
rating.
Critical Evidence(s) Required
• Capable to Check the fuel pressure with the help of pressure gauge
• Capable to diagnose and troubleshoot the diesel engine.
• Capable to service the injectors.
• Capable to bleed the air from the diesel fuel system.
List of Tools and Equipment
S. No. Descriptions
1 Toll trolley (Complete set)
2 Test lamp/DMM (Digital multimeter)
4 Diesel injector pressure tester /Petrol Injector Tester
5 Safety wears
Consumable Items:
• Carburetor cleaner, Carburetor Gasket Set, Petrol, Injector Rings,
7. Diagnose Faults of Ignition System
Overview
These competency standards designed to diagnose and troubleshoot conventional spark ignition system as well as conceptualize the ignition system mechanism in the engine.
Unit of Competency Performance Criteria
1. Repair Ignition System
P1. Inspect the vehicle Ignition system and diagnose the following (Note: follow safe working procedure).
P2. Crank the engine and test presence of spark in a system, identify faulty fuse in fuse box, test the performance of plug cable and plugs, inspect distributor cap/rotor for the performance, assess the correct ignition timing, inspect vacuum advancer, assess C.B Point condition/gap and test condenser, test ignition coil performance, and test CDI of distributor.
2. Adjust ignition timing
P1. Installation of distributer assembly under specified procedure and start the engine, adjust ignition timing with the help of timing gun.
P2. Inspect/Replace ignition switch, inspect/replace ignition coil, and Repair/replace electrical connectors under specified procedure.
Knowledge & Understanding
• Describe the Purpose and function of ignition system’s following parts. Spark ignition system contact breaker type, spark ignition system breaker less type. Ignition switch, Ignition coil, resister, plug cable, distributer cap, rotor arm, vacuum advancer,
centrifugal advancer, contact breaker assembly, condenser, high tension leads/connectors, suppression, spark plug(construction, heat range type, size), Magnetic Reflector, hall effect trigger/amplifier, differentiate the performance of contact breaker and contact breaker less type.
• Describe primary circuit, secondary circuit of ignition system, identifies change in the spark timing in accordance to the load and speed of the engine.
• Explain Faradays law of mutual induction and calculate the primary and secondary voltages and current.
Critical Evidence(s) Required
• Troubleshot the vehicle ignition system (Non EFI engines)
• Capable to adjust the ignition timing
• Capable to service the ignition system.
List of Tools and Equipment
S. No. Description
1 Vehicle/ Simulator
2 Digital Multi-meter (DMM).
3 Tools Box
4 Test Lamp
5 Timing Gun
Suspension, Steering & Brakes AD-213
1. Repair Vehicle Brake System
Overview:
These competency standards designed to enable the learner to work on vehicle brake system, and replacing the faulty parts. These competency standards designed to enable the learner to work on vehicle electronic features and troubleshoot on ABS system by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Brake system P1. Inspect the vehicle brake system for the brake fluid level, vacuum booster performance, master cylinder pressure, brake wheel cylinder for oil leakage, disc run out, brake pad/shoe fading/worn, and drum brake performance under the specified procedure.
P2. Service/Replace the Master cylinder, vacuum booster, wheel cylinder, brake disk, brake pad, and brake shoe under the specified procedure.
P3. Perform brake bleeding of the vehicle brake system under the specified procedure.
2. Brake system ABS
P-1. Check vehicle instrument panel and identify ABS mall functioning light.
P-2. Diagnose the vehicle ABS system with the use of scanner for wheel Sensors performance test, ABS Modular/actuator test under the specified procedure.
P-3. Change the wheel sensors, actuator and related fuse under the specified procedure.
Knowledge & Understanding
• Describe the purpose and function of the following. Disc brakes, drum brakes (reduce vehicle speed, stop vehicle), use of friction and friction
materials, hydraulic system in a vehicle brake system, vehicle mechanical/ hand bake, engine braking in the vehicle.
• Describe the brake main Components as following Master cylinder (single/tandem), wheel cylinder, calipers (single/tandem), pipes/flexible hoses,
brake shoes (leading/ trailing), brake pads, brake discs, brake drum, handbrake operating mechanism, pedal, limiting valves, adjusters, brake fluid, brake warning light, brake light, brake light switch, wear indicator.
• Describe the principles and functions of ABS system in a vehicle as following. ABS system, Traction control system, vehicle stability control system, Wheel sensors, ECU,
ABS modulator assembly, vehicle body (Honda G-CON) (Toyota GOA).
Critical Evidence(s) Required
• Capable of servicing brake system
• Capable of performing brake bleeding
• Capable to diagnose and rectify the ABS system.
List of Tools and Equipment
S. No. Description
1 Vehicle equipped with the ABS
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack /safety stand
4 Car lift
5 Automotive scanner
6 Vacuum gun
Consumable Items:
S. No. Description
1 Brake oil
2 Master cylinder kit
3 Wheel cylinder kit
2. Repair Vehicle Steering System
Overview
These competency standards designed to enable the learner to work on vehicle steering system, and replacing the faulty parts. These competency standards designed to enable the learner to work on vehicle power assisted steering system and troubleshoot accordingly by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Steering system P1. Inspect the vehicle steering system for rubber boots on (inner and outer ball joint), Tie road condition, and inner/outer ball joints play, steering rack and pinion box, mounting for the steering box under the specified procedure.
P2. Replace/service the Outer tie road, inner tie road, steering mountings, steering boots (inner and outer ball joint), under the specified procedure.
P3. Service the steering gear (Rack and pinion) box under the specified procedure.
2. Power steering system
P1. Inspect/replace power assisted steering system components for Pump, control valve, complete steering box.
P2. Replace the power steering oil and perform air bleeding from the system under the specified procedure.
Knowledge & Understanding
• Describe the purpose and function of the following: Steering systems (non-assisted/manual), power assisted system, electronic steering system
with a motor.
• Describe the main components and mechanism of the following: Ackerman principle, true rolling motion, steering ratio, toe in/out, camber, caster, steering axes
inclination, steering wheel/column, rack and pinion, steering gearboxes, steering ball joints, steering arm, front hubs, bearings/seals.
Critical Evidence(s) Required
• Capable of servicing steering system
• Capable of performing power steering bleeding
• Capable to diagnose and rectify the steering system problems.
List of Tools and Equipment
S. No. Description
1 Vehicle equipped with the power steering
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack /safety stand
4 Car lift
5 Automotive scanner
6 Ball joint removal
7 Grease gun
8 Steering fluid pressure tester
9 Oil can
Consumable Items:
S. No. Description
1 Grease
2 Steering oil
3 Seals
4 Kerosene Oil
5 Cotton rag
6 Spray gun
3. Maintain Vehicle Suspension System
Overview
These competency standards designed to enable the learner to work on vehicle electronic features and troubleshoot on ABS system, Electronic power steering, and Automatic gear in the vehicle while using the scanner where needed by Auto Mechanic, in accordance with the manufacturer’s Manual
Unit of Competency Performance Criteria
1. Inspect Suspension system
P1. Inspect the vehicle suspension system and diagnose the rubber bush for damage, Leaking the shock absorber oil, broken coil spring/ leaf spring,
P2. Inspect the vehicle suspension system and diagnose the rubber bush for lower arm ball joints under the specified procedure.
2. Repair Suspension System
P1. Replace the shock absorber, Coil spring, leaf spring, and rubber bushes under the specified procedure.
P2. Inspect the vehicle ride height, trim height, axle displaced under the specified procedure.
Knowledge & Understanding
• Describe the purpose and function of the following. Independent suspension system, non-independent suspension system, semi-independent
system, sprung weight, un-sprung weight.
• Describe the effect of road surface irregularities on passengers/vehicle/load, maintaining wheel contact with the road, supporting the sprung weight, minimizing un-sprung weight, absorbing torque reaction.
• Describe the Suspension main Components as following Beam axle, live axle, strut/McPherson strut, wishbone, trailing arm/semi trailing arm,
torsion beam, springs (Coil, leaf, torsion, air), antiroll bars, sub-frame assemblies, shackles, hangers, u bolt, damper bushes.
Critical Evidence(s) Required
• Capable of servicing suspension system
• Capable to diagnose and rectify the suspension system problems.
List of Tools and Equipment
S. No. Description
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack /safety stand
4 Car lift
5 Automotive scanner
6 Ball joint removal
7 Grease gun
8 Oil can
Consumable Items:
S. No. Description
1 Grease
2 Seals
3 Kerosene Oil
4 Cotton rag
5 Spray gun
4. Carry out Wheel Alignment
Overview
These competency standards designed to enable the learner to handle the wheel alignment machine and perform wheel alignment of the vehicle as well as the learner will be able to balance the wheel using the wheel balancing machine by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Pre alignments checks
P1. Check for the vehicle pre alignment for proper Tire pressure/inflation, and axle bushes under specified procedure.
P2. Check for the vehicle pre alignment for loose ball joints, wheel bearings, and tie road ends under specified procedure.
P3. Check for the vehicle pre alignment for faulty spring, tire deformation, and vehicle ride height under specified procedure.
P4. Check for the vehicle pre alignment for loose stabilizer bar under specified procedure.
2. Perform wheel alignment
P1. Drive the vehicle and load/offload it on wheel alignment machine following safety rules as specified in the manual.
P2. Perform wheel alignment using the wheel alignment machine as described procedure in the machine manual and adjust Toe, camber of front and rear wheels under specified procedure.
Knowledge & Understanding
• Describe the following functions/principles of wheel alignment. Ackerman principle for a true rolling motion, steering pull, steering center point, steering wheel
vibration causes.
• Describe the wheel alignment faults as following. Toe in, toe out, positive camber, negative camber, positive caster, steering axes inclination,
included angle, tire wear, ride height, trim height of vehicle.
Critical Evidence(s) Required
• Capable to perform wheel alignment of the vehicle.
List of Tools and Equipment
S. No. Description
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack
4 Wheel alignment machine
5 Wheel balancing / tire changing machine
6 Air pressure compressor and gauge
5. Carry Out Wheel Balancing
Overview
These competency standards designed to enable the learner to handle the wheel alignment machine and perform wheel alignment of the vehicle as well as the learner will be able to balance the wheel using the wheel balancing machine by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Use Tire changing machine.
P1. Use the tire changing machine and replace/inflate the tire as described in the machine manual under specified procedure.
P2. Replace the valve of the tire under the specified procedure.
2. Perform wheel balancing
P1. Use the wheel balancing machine and balance the wheel as described in the machine manual under the specified procedure.
P2. Keep the weights firmly with the rim
P3. Perform wheel balancing on allow rim under the specified procedure.
Knowledge & Understanding
• Describe the wheel balancing machine features as following. Setting procedure, Digital data setting procedure, cycle time, weight installation and removal
procedure, machine calibration.
Critical Evidence(s) Required
• Capable to perform wheel balancing
• Capable to perform tire changing.
List of Tools and Equipment
S. No. Description
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack
4 Wheel alignment machine
5 Wheel balancing / tire changing machine
6 Air pressure compressor and gauge
Consumable Items:
S. No. Description
1 Weights
2 Cotton rag
6. Replace SRS System
Overview
These competency standards designed to enable the learner to apply safe working practice and handle the SRS system of the vehicle as well as the learner will be able to use scanner apparatus by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Check the Supplementary Restrain System (SRS)
P1. Check for vehicle SRS sensor under the specified procedure. P2. Check for the vehicle SRS wiring under the specified
procedure.
2. Installation of new Supplementary Restrain System (SRS)
P1. Reinstall the SRS spiral cable under the specified procedure. P2. Start the vehicle and confirm the malfunctioning light is
removed.
Knowledge & Understanding
• Understand the purpose, construction and working of supplementary restrained systems (SRS) air bag control system. State the purpose of P2-Air Bag Control System.
• Enlist the Components of Air Bag Control system.
• Describe the construction & Working of Air Bag Control System.
Critical Evidence(s) Required
• Capable to troubleshoot the SRS System.
List of Tools and Equipment
S. No. Description
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack
4 Wheel alignment machine
5 Wheel balancing / tire changing machine
6 Air pressure compressor and gauge
Workshop Practice-II AD-224
1. Arrange Common Automotive Hand Tools and their Use
Overview:
These competency standards designed to enable the learner to handle appropriate hand tools and the importance of housekeeping in the workplace under the specified procedure of the vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Common Hand Tools P1. Demonstrate use of general hand tools under specified instructions and keep in secure location.
P2. Demonstrate service of general hand tools under specified instructions and keep in secure location.
2. Perform 5s at Workplace
P1. Demonstrate tools 5s (Sort, Set In Order, Shine, Standardize, Sustain)
Knowledge & Understanding
• Describe the types and use of the following automobile workshop hand tools. Screw driver, Hammers, Pliers, Lock pliers, Spanners, Wrenches, Socket sets, Torque
wrench, Pullers, Oil seal extractor/installer, Tube bender, Tube cutter, Flaring tool, Strap wrench, Automotive stethoscope, Valve spring compressor, piston ring expender, piston ring compressor, grease gun, flexible wire magnet, pop rivet plier, tin snap, hacksaw, punches, chisels, hollow punch set, spark plug spanner, Allen key
Critical Evidence(s) Required
• Capable to use and service the hand tools
List of Tools and Equipment
S. No. Descriptions
1 Screw driver set
2 Hammers
3 Pliers
4 Lock pliers
5 Spanners
6 Wrenches
7 Socket sets
8 Torque wrench
9 Pullers
10 Oil seal extractor/installer
11 Tube bender
12 Tube cutter
13 Flaring tool
14 Strap wrench/oil filter spanner
15 Valve spring compressor
16 piston ring expender
17 grease gun
18 flexible wire magnet
19 pop rivet plier
20 Punches
21 Chisels
22 spark plug spanner
23 Allen key set
24 Files
25 Steel foot rule
26 Vernier calliper
27 Micrometre (inside/Outside)
28 Dial gauge
29 Feeler gauge
30 Thread pitch gauge
2. Carry Out Measurements with Automotive Measuring Tools
Overview
These competency standards designed to enable the learner to handle appropriate measuring tools and the importance of housekeeping in the workplace under the specified procedure.
Unit of Competency Performance Criteria
1. Measuring tools P1. Demonstrate service of measuring tools under specified instructions and keep in secure location.
P2. Demonstrate use of measuring tools under specified instructions and keep in secure location.
2. Perform 5s at workplace
P1. Demonstrate measuring tools 5s (Sort, Set In Order, Shine, Standardize, Sustain)
Knowledge & Understanding
• Describe the types and use of the following automobile workshop measuring tools. Steel foot rule, Spring scale, Vernier caliper, Micrometer (inside/Outside), Dial gauge, Feeler
gauge, Thread pitch gauge, wire gauge, Belt tension gauge, Telescoping gauge, Tire pressure gauge.
Critical Evidence(s) Required
• Capable to measure with the measuring tools
List of Tools and Equipment
S. No. Descriptions
1 Screw driver set
2 Hammers
3 Pliers
4 Lock pliers
5 Spanners
6 Wrenches
7 Socket sets
8 Torque wrench
9 Pullers
10 Oil seal extractor/installer
11 Tube bender
12 Tube cutter
13 Flaring tool
14 Strap wrench/oil filter spanner
15 Valve spring compressor
16 piston ring expender
17 grease gun
18 flexible wire magnet
19 pop rivet plier
20 Punches
21 Chisels
22 spark plug spanner
23 Allen key set
24 Files
25 Steel foot rule
26 Verniercaliper
27 Micrometer (inside/Outside)
28 Dial gauge
29 Feeler gauge
30 Thread pitch gauge
3. Perform Test on Vehicle with Automotive Workshop Equipment
Overview
These competency standards designed to enable the learner to handle appropriate workshop equipment and the importance of housekeeping in the workplace under the specified procedure.
Unit of Competency Performance Criteria
1. Workshop Equipment
P1. Demonstrate of workshop equipment under specified instructions and keep in secure location.
P2. Demonstrate use of workshop equipment under specified instructions and keep in secure location.
2. Perform 5s at workplace
P1. Demonstrate equipment 5s (Sort, Set In Order, Shine, Standardize, Sustain)
Knowledge & Understanding
• Describe the types and use of the following automobile workshop equipment. Chain pulley block, Car lift, Crane, Spark plug cleaner machine, Tire changer, Electronic
injector testing machine, Tire inflator, Engine repairing stand/repair trolley, Compressor and pneumatic tools, Ramp and pits, Waste oil receptacle, Hydraulic press, Mechanical arbor press, Drill machine (bench and portable), Grinder (Bench and portable), Hydraulic jack, Mechanical jack, Radiator pressure cap tester, Safety floor stands, Creeper, Valve grinding and re facing machine, cleaning tank, Engine timing gun, Scanner
Critical Evidence(s) Required
• Capable to maintain workshop equipment
Tools and equipment required
S. No. Descriptions
1 Plug wire gauge
2 Tire pressure gauge
3 Car lift
4 Tire inflator
5 Engine repairing stand/repair table
6 Waste oil receptacle
7 Hydraulic jack
8 Mechanical jack
9 Radiator pressure cap tester
10 Safety floor stands
11 Creeper
12 Engine timing gun
13 OBD II Scanner
14 Compression tester
4. Diagnose Faults by Computerized Performance Testing Equipment
Overview
These competency standards designed to enable the learner to handle appropriate automotive testing and diagnosing instruments the importance of housekeeping in the workplace under the specified procedure.
Unit of Competency Performance Criteria
1. Engine Testing Equipment Mechanical
P1. Use of compression tester in the engine to diagnose condition of valve under the specified procedure
P2. Use of compression tester in the engine to diagnose condition of piston rings under the specified procedure.
P3. Use of vacuum tester to identify the intake manifold pressure to diagnose the engine condition.
P4. Use of engine leak tester in the engine to diagnose condition of valve, piston ring, and head gasket under the specified procedure
P5. Clean and service the equipment and place on safe location.
2. Engine testing Equipment Electronic
P1. Use of timing gun in the engine to identify correct engine timing under the specified procedure.
P2. Use of tachometer in the engine to identify correct engine RPM under the specified procedure
Knowledge & Understanding
• Describe the functions and operating principle of the following equipment: Tachometer, Compression Gauge, Vacuum Gauge, Engine Leakage Tester, Ignition Timing
Gun.
Critical Evidence(s) Required
• Capable to use the equipment and explain the operating principles.
Tools and Equipment
S. No. Descriptions
1 Tachometer
2 Compression Gauge
3 Vacuum Gauge
4 Engine Leakage Tester
5 Ignition Timing Gun
5. Categorize Automotive Fasteners Types and their Uses
Overview
These competency standards designed to enable the learner to Categorize Automotive Fasteners Types and their Uses the importance of housekeeping in the workplace under the specified procedure.
Unit of Competency Performance Criteria
1. Fastener Types P1. Inspect and understand the Types of permanents Fasteners.
P2. Inspect and understand the Types of Temporary Fasteners.
2. Fastener Uses P1. Perform application of permanents fasteners
P2. Perform application of Temporary fasteners
Knowledge & Understanding
• Describe the functions and operating principle of the following Permanents Fastener. Electric arc welding, Gas welding, spot welding, riveting, soldering and Brazing.
• Describe the functions and operating principle of the following Temporary Fastener. Nuts and bolts, screw and studs
Critical Evidence(s) Required
• Capable to use the Permanents and explain the operating principles.
• Capable to use the Temporary and explain the operating principles
Tools and Equipment
S. No. Descriptions
1 Permanents Fasteners
2 Temporary Fastener
6. Specify Vehicle’s Lubricants Types
Overview
These competency standards designed to enable the learner to handle lubricants and the importance of housekeeping in the workplace under the specified procedure of the vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Engine Lubricants P1. Identify different viscosity of engine oils and there different climate under the specification of SAE.
P2. Understand the viscosity index and select the appropriate engine oil under the weather condition.
P3. Understand the mineral oil formula oil and synthetic oil under the specification of manufacturer.
2. Vehicle lubricants P1. Identify the different kind of grease with respect to the use in the vehicle system under the specification.
P2. Identify the power steering fluid and understand its properties.
P3. Identify the ATF fluid and understand its properties.
P4. Identify the brake fluid and understand its properties
Knowledge & Understanding
• Describe the following: Lubricant (oils viscosity, viscosity index, oil classifications, Reduction of frictional forces,
cooling effect, cleaning effect, corrosion resistance, and noise reduction).Multipurpose grease, CV joint grease, brake oil (DOT standard), automatic transmission fluid
Critical Evidence(s) Required
• Capable to explain the lubricants use in engine
• Capable to explain the lubricants use in vehicle
Tools and equipment
S. No. Descriptions
1 Complete Tool trolley (Tools kit)
2 Workshop tools equipment
3 Special service tools
4 Measuring tools
7. Differentiate Vehicle Oil Seals Types and Specifications Coding
Overview
These competency standards designed to enable the learner to differentiate oil seals types and specifications and the coding specified procedure of the vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Identify Seals and Gasket
P1. Demonstrates oil seal replacement procedure under the specified procedure.
P2. Identify material and types of gaskets and seals
P3. Identify causes and remedies of seals and gasket failure.
2. Replace main oil seal
P1. Change engine main oil seal under specified procedure.
P2. Change gear main oil seal under specified procedure
Knowledge & Understanding
• Describe the head gasket types and thickness, main oil seal temperature resistant property.
• Problems in head gasket blown
Critical Evidence(s) Required
• Capable of replacing the head gasket
Tools and Equipment
S. No. Descriptions
1 Complete Tool trolley (Tools kit)
2 Workshop tools equipment
3 Special service tools
4 Measuring tools
5 Seals and Gas kit
8. Specify Vehicle Bearing’s Types and Coding
Overview
These competency standards designed to enable the learner understand purpose, types, materials and application of bearing on the vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual.
Unit of Competency Performance Criteria
1. Bearing P1. Demonstrate bearing replacement procedure under the specified procedure
P2. Identify material, types (Friction & Antifriction), size, and application of Bearings.
P3. Install Antifriction bearings in vehicle with special reference (load and size).
P4. Inspect antifriction Bearing.
2. Diagnose Bearing faults
P1. Change axle bearing under specified procedure.
P2. Change alternator under specified procedure.
Knowledge & Understanding
• Describe the different types of bearing, application of bearing.
• Describe the Problems in bearing during working.
Critical Evidence(s) Required
• Capable of replacing the bearings.
Tools and Equipment
S. No. Descriptions
1 Complete Tool trolley (Tools kit)
2 Workshop tools equipment
3 Special service tools (Bearing Puller)
4 Measuring tools
5 Bearing
9. Read and Interpret Quality Control Standards and Certification
Overview
These competency standards designed to enable the learner understand quality control standard and their certification of the vehicle by Auto Mechanic, in accordance with the manufacturer’s Manual..
Unit of Competency Performance Criteria
1. Quality Control Standards
P1. Elaborate the quality control standards
P2. Describe the quality control standard Application
2. Quality Control Certification
P1. Elaborate the quality control certification
P2. Describe the quality control certification Application
Knowledge & Understanding
• Describes the quality control standard and its importance.
• Describe the quality control certification and its importance.
Critical Evidence(s) Required
• Describe the quality control standard Application
• Describe the quality control certification Application
10. Plan and Organize Safe Workshop and Hazard Prevention Practices
Overview
These competency standards designed to enable the learner to follow the safety rules and know the first aid techniques at workplace as well as candidate will be able to response in any emergency situation.
Unit of Competency Performance Criteria
1. Safe Working Practice
P1. Use the appropriate personal protective equipment before starting the job to ensure the implementation of safety and health regulations.
P2. Identify the workshop associated hazards that can cause injury, burn, pinch, short circuit, and damages.
P3. Report to the supervision to analyze potential level of hazards that can cause damage.
P4. Demonstrate first aid procedure in case of minor injury and burn.
2. Fire, Preventions and Emergency.
P1. Extinguish the different kind of fires using the appropriate equipment and procedures.
P2. Identify the expiry date, filing level of fire extinguishers and report to the supervision.
P3. Demonstrate the Emergency situations and perform safe evacuations drill.
Knowledge & Understanding
• Describe the causes of accidents and preventions as following: Human (Carelessness, lake of training, improper behavior, and over confidence)
Environmental (untidy workplace, bad ventilation, unguarded/faulty machines, noise, and bad lighting).
• Describes the hazards at workplace as following. Vehicle battery handling, Rotating Pulleys and Belts, Jack and safety Stand, Venting the
Engine’s Exhaust
• Describe the flammable materials/liquids and toxic substance, safe disposal of used oil, asbestos, batteries, and recycling AC gas.
• Describes personal hygiene, care of eye, care of lungs, and allergy.
• Describe the fire triangle, types of fire, types of fire extinguishers, emergency situations (Earth quack, fire, terrorism)
Critical Evidence(s) Required
• Select and use appropriate PPE’s at workplace.
• Identify workplace hazards and its potential to harm.
• Perform First aid
• Use of fire extinguisher at different type of fire.
• Inspect the fire extinguisher for expiry and pressure.
• Execute emergency evacuation.
List of Tools and Equipment
S. No. Descriptions
1 Personal protective equipment
2 First aid box
3 Fire extinguisher
4 Emergency alarm
Metrology MT-252
1. Recognize Graduated Instruments
Overview
These competency standards designed to enable the learner identify and uses of graduated instrument as Steel Rule, Hook Rule, Folding Rule, and Measuring Tape.
Unit of Competency Performance Criteria
1. Steel Rule P1. Inspect and measure different kind of measurement (mm and inches) under the specified procedure.
P2. Conversion different kind of measurement under specified procedure
2. Hook Rule P1. Inspect and measure different kind of measurement (mm and inches) under the specified procedure.
P2. Conversion different kind of measurement under specified procedure
3. Folding Rule P1. Inspect and measure different kind of measurement (mm and inches) under the specified procedure.
P2. Conversion different kind of measurement under specified procedure
4. Measuring Tape P1. Inspect and measure different kind of measurement (mm and inches) under the specified procedure.
P2. Conversion different kind of measurement under specified procedure
Knowledge & Understanding
• Describes the main functions these tools. Steel Rule, Hook Rule, Folding Rule, Measuring Tape
• Describe the taking measuring method of these tools.
Critical Evidence(s) Required
• Capable to use steel rule.
• Capable to use Hook rule
• Capable to use Folding rule
• Capable to use Measuring Tape
• Capable to conversion method.
List of Tools and Equipment
S. No. Descriptions
1 Steel Rule, Hook Rule, Folding Rule, Measuring Tape
2 Object for measurement
2. Carry-Out Linear Measuring
Overview
These competency standards designed to enable the learner identify and uses of graduated instrument as Surface plate, Tool makers surface plate, Glass surface plate, Angle plate, Cast Iron cubes, Vee block, Straight Edge ,Spirit level, Engineer’s level, Engineer’s parallel
Unit of Competency Performance Criteria
1. Surface Plate P1. Perform different kind of measurement with surface plate.
P2. perform different kind of measuring tools adjust with surface plate
2. Toolmakers Surface Plate
P1. Perform different kind of measurement with Toolmaker surface plate.
P2. Perform different kind of measuring tools adjust with Toolmaker surface plate
3. Glass Surface Plate, P1. Perform different kind of measurement with Glass surface plate.
P2. Perform different kind of measuring tools adjust with Glass surface plate
4. Angle Plate P1. Perform different kind of measurement with Angle plate.
P2. Perform/adjust Angle plate with surface plate for measurement.
5. Cast Iron Cubes P1. Perform different kind of use OF cast iron Cubes.
P2. Perform/adjust Cast Iron cubes other measurement tools.
6. VeeBlock P1. Perform/uses of VeeBlocks.
P2. Perform/adjust Vee Block with U-Clamp and work piece with operation.
7. Straight Edge P1. Perform measurement different kind of Steel straight edge.
P2. Perform/ adjust straight edge with surface plate and sprit level..
8. Spirit Level P1. Perform / measure Horizontal surface with spirit level.
P2. Perform / measure Angle or inclination surface with spirit level.
P3. Perform / measure Vertical surface with spirit level.
9. Engineer’s level P1. Perform measurement with Engineer level.
10. Engineer's parallel P1. Perform measurement with engineer parallel.
Knowledge & Understanding
• Describe Linear Measurement instruments functions as following: o Surface plate 2-Tool makers surface plate 3-Glass surface plate 4-Angle plate
o Cast Iron cubes 6-Vee block 7-Straight Edge 8-Spirit level 9-Enginer's level 10-Engineer's parallel
Critical Evidence(s) Required
• Capable to use Surface plate
• Capable to use Tool makers surface plate
• Capable to use Glass surface plate
• Capable to use Angle plate
• Capable to use of Cast Iron cubes
• Capable to use Vee block
• Capable to use Straight Edge
• Capable to use Spirit level
• Capable to use Engineer’s level
• Capable to use Engineer's parallel
List of Tools and Equipment
S. No. Description
1 Surface plate
2 Tool makers surface plate
3 Glass surface plate
4 Angle plate
5 Cast Iron cubes
6 Vee block
7 Straight Edge
8 Spirit level
9 Engineer’s level
10 Engineer's parallel
3. Carry-out Precise Measuring
Overview
These competency standards designed to enable the learner identify and uses of Precise Measuring instruments. Micrometer, outside micrometer, inside micrometer, Depth Micrometer, Plug Micrometer, Vernier Micrometer. Vernier caliper, Vernier Height gauge, Vernier depth gauge,Dial Vernier caliper.
Unit of Competency Performance Criteria
1. Micrometer P1. Inspect and measure different kind of measurement with Outside micrometer (mm and inches) under the specified procedure.
P2. Inspect and measure different kind of measurement with Inside micrometer (mm and inches) under the specified procedure.
P3. Inspect and measure different kind of measurement with Depth Micrometer (mm and inches) under the specified procedure.
P4. Inspect and measure different kind of measurement with Plug Micrometer (mm and inches) under the specified procedure.
P5. Inspect and measure different kind of measurement with Vernier Micrometer (mm and inches) under the specified procedure.
P6. Conversion different kind of measurement under specified procedure
2. Vernier caliper P1. Inspect and measure different kind of measurement with Vernier caliper (mm and inches) under the specified procedure.
P2. Inspect and measure different kind of measurement with Vernier Height gauge (mm and inches) under the specified procedure.
P3. Inspect and measure different kind of measurement with Vernier depth gauge (mm and inches) under the specified procedure.
P4. Inspect and measure different kind of measurement with Dial Vernier caliper (mm and inches) under the specified procedure.
P5. Conversion different kind of measurement under specified procedure
Knowledge & Understanding
• Describe the different kind of measuring tools and its uses. Micrometer, Outside micrometer, Inside micrometer, Depth Micrometer, Plug Micrometer, Vernier Micrometer. Vernier caliper, Vernier Height gauge, Vernier depth gauge, Dial Vernier caliper.
Critical Evidence(s) required
• Capable to use Micrometer
• Capable to use Outside micrometer
• Capable to use Inside micrometer
• Capable to use Depth Micrometer
• Capable to use of Plug Micrometer
• Capable to use Vernier Micrometer.
• Capable to use Vernier caliper
• Capable to use Vernier Height gauge
• Capable to use Vernier depth gauge
• Capable to use Dial Vernier caliper
List of Tools and Equipment
S. No. Descriptions
1 Micrometer, Outside micrometer,Inside micrometer,Depth Micrometer,Plug Micrometer, Vernier Micrometer.
2 Vernier caliper,Vernier Height gauge,Vernier depth gauge,Dial Vernier caliper.
4. Perform Angular Measuring
Overview:
These competency standards designed to enable the learner Angular Measuring Instrument as Bevel protector, Bevel protector Vernier, and Single bar
Unit of Competency Performance Criteria
1. Bevel protector P1. Inspect and measure different kind of measurement with Bevel protector (Degree, Minute and second) under the specified procedure.
P2. Perform Adjustment of Bevel Protector
2. Bevel Protector Vernier
P1. Inspect and measure different kind of measurement with Bevel Vernier protector under the specified procedure.
P2. Perform Adjustment of Bevel Protector
3. Side bar
P1. Inspect and measure Known angle with the help of sine bar under the specified procedure.
P2. Measures the object with the help of formula of sine bar.
P3. Inspect and measure Unknown angle with the help of sine bar under the specified procedure.
P4. Measures the object with the help of formula of sine bar.
P5. Inspect and measure Unknown angle of Heavy workpiece with the help of sine bar under the specified procedure.
Knowledge & Understanding
• Describes the different kind of measuring tools and its uses. Bevel protector, Bevel protector Vernier and Sine bar
• Describe the operational principles of Bevel protector, Bevel protector Vernier and Sine bar
• Understand different kind of formulas use in sine bar measurement
Critical Evidence(s) Required
• Capable to measurement with Bevel protector.
• Capable to measurement with Bevel protector Vernier.
• Capable to measurement with Sine bar.
• Capable/ Understand different kind of formulas use in sine bar measurement.
List of Tools and Equipment
S. No. Descriptions
1 Bevel protector
2 Bevel protector Vernier
3 Side bar
4 Given Object
5. Identify the Types of Gauges
Overview
These competency standards designed to enable the learner Fixed gauges, Adjustable gauges, Indicating gauges, thread gauges
Unit of Competency Performance Criteria
1. Fixed Gauges Inspect and use following gauge under the specified procedure:
P1. Fixed Master gauge under the specified procedure.
P2. Fixed Limit gauge under the specified procedure.
P3. Fixed Plug gauge under the specified procedure.
P4. Fixed Ring gauge under the specified procedure.
P5. Fixed snap gauge under the specified procedure.
P6. Feeler gauge under the specified procedure.
P7. Sheet metal and wire gauge under the specified procedure.
2. Adjustable Gauges Inspect and use following gauge under the specified procedure:
P1. Surface gauge under the specified procedure.
P2. Depth gauge under the specified procedure.
P3. Height gauge under the specified procedure.
P4. Dial gauge under the specified procedure.
P5. Snap gauge under the specified procedure.
3. Indicating Gauges P1. Inspect run-out gauge under the specified procedure.
P2. Inspect back lash gauge under the specified procedure.
P3. Inspect end play under the specified procedure.
P4. Inspect cylinder bore under the specified procedure.
4. Thread Gauges P1. Inspect and use of thread gauge measure different kind of thread under the specified procedure.
5. Ziess Micrometer P1. Inspect and use of ziess micrometer under the specified procedure.
Knowledge & Understanding
• Describes the different kind of Gauges and its uses.
• Fixed gauges, Adjustable gauges, Indicating gauges, thread gauges
Critical Evidence(s) Required
• Capable to use of Fixed gauges.
• Capable to use of Adjustable gauges.
• Capable to use of Indicating gauges.
• Capable to use of thread gauges.
List of Tools and Equipment
S. No. Descriptions
1 Fixed gauges
2 Adjustable gauges
3 Indicating gauges
4 Thread gauges
6. Identify Comparators Instrument
Overview
These competency standards designed to enable the learner identify and uses of graduated instrument as Electrical/Electronic comparators, Pneumatic comparators, Optical/Projection comparators, Mechanical comparators, Automatic gauging comparators, Gauge block comparators, Microscope (Tool Maker microscope)
Unit of Competency Performance Criteria
1. Electrical/Electronic comparators
P1. Understand the parts and principle of Electrical/Electronic comparators
P2. Inspect and measurement with Electrical/Electronic comparators under the specified procedure.
P3. Performs the use of AC wheat stone bridge circuit incorporating a galvanometer.
2. Pneumatic comparators
P1. Understand the parts and principle Pneumatic comparators comparators
P2. Inspect and measurement with Pneumatic comparators under the specified procedure.
3. Optical/Projection comparators
P1. Inspect and measurement with Optical/Projection comparators under the specified procedure.
P2. Adjust Optical/Projection comparators according to job condition under the specified procedure.
4. Mechanical comparators
P1. Inspect and measurement with rack and pinion comparators under the specified procedure.
P2. Inspect and measurement with Cam and gear train comparators under the specified procedure.
P3. Inspect and measurement with lever and tooth sector comparators under the specified procedure.
P4. Inspect and measurement with compound comparators under the specified procedure.
P5. Inspect and measurement with Twisted taut strip comparators under the specified procedure.
5. Automatic gauging comparators
P1. Understand the parts and principle Automatic gauging comparators
P2. Inspect and measurement with Automatic gauging comparators under the specified procedure.
6. Gauge block comparators
P1. Inspect and measurement with Gauge block comparators under the specified procedure.
Unit of Competency Performance Criteria
7. Microscope (Tool Maker microscope)
P2. Understand the parts and principle Microscope (Tool Maker microscope).
P3. Inspect and measurement with Microscope (Tool Maker microscope).
Knowledge & Understanding
• Describes the different kind of measuring tools and its uses. 1-Electrical/Electronic comparators2- Pneumatic comparators 3-Optical/Projection comparators4-Mechanical comparators5-Automatic gauging comparators6-Gauge block comparator7-Microscope (Tool Maker microscope)
• Describe the different type attachment with above comparators.
Critical Evidence(s) Required
• Capable identify/ Measurement with the Electrical/Electronic comparators .
• Capable identify/Measurement with the Pneumatic comparators
• Capable identify/Measurement with the Optical/Projection comparators
• Capable identify/Measurement with the Mechanical comparators
• Capable identify/Measurement with the Automatic gauging comparators
• Capable identify/Measurement with the Gauge block comparator
• Capable identify/Measurement with the Microscope (Tool Maker microscope)
List of Tools and Equipment
S. No. Descriptions
1 Electrical/Electronic comparators
2 Pneumatic comparators
3 Optical/ Projection comparators
4 Mechanical comparators
5 Automatic gauging comparators Gauge block comparator
6 Microscope (Tool Maker microscope)
Applied Thermodynamics AD-232
1. Analyses HVAC/R Systems Thermodynamic Performance
Overview
This Competency Standard covers the analysis of heating, ventilating, air conditioning and refrigeration (HVAC/R) systems to provide solution to thermodynamic performance issues. It encompasses working safely, apply extensive knowledge of thermodynamic parameters, gathering and analyzing data, applying problem solving techniques, developing and documenting results and solutions for use in design work to provide you the basis for your work.
Competency Units Performance Criteria
1. Prepare to analyze the thermodynamic performance of HVAC/R systems
P1. Observe safe work practices and personal protective OHS processes and procedures for a given work area are identified, obtained and understood.
P2. Establish OHS risk control measures and procedures are followed in preparation for the work.
P3. Determine extent of the thermodynamic issues from performance specifications, situation reports and in consultations with relevant persons
P4. Plan activities to meet scheduled timelines in consultation with others involved in the work
P5. Form effective strategies to ensure solution development and implementation to carry out efficiently.
2. Analyze the thermodynamic performance of HVAC/R systems
P1. Apply thermodynamic principles to analytical solutions on refrigeration and air conditioning systems.
P2. Obtain Parameters, specifications and performance requirements in relation to refrigeration and air conditioning systems in accordance with established procedures.
P3. Carry out approaches to analyzing thermodynamic parameters to provide the most effective solution.
P4. Deal unplanned events with safely and effectively, consistent with regulatory requirements and enterprise policy.
P5. Monitor quality of work against personal performance agreement and/or establish organizational & professional standards
3. Report and action on the results of thermodynamic performance analysis
P1. Evaluate to determine their effectiveness of solutions for thermodynamic issues and modify where necessary. P2: Report the analysis including details of all findings, calculations and assumptions.
P2. Report analysis to appropriately personnel to establish appropriate action to be taken based on findings.
P3. Take actions regarding equipment, documented for inclusion in work/project or development records in accordance with professional standards and manufacturers specifications.
Knowledge and Understanding
This describes the essential skills and knowledge and their level, required for this unit. Evidence shall show that knowledge has been acquired of safe working practices and analyzing the thermodynamic performance of HVAC/R systems.
• Understanding the thermodynamic performance issues
• Forming effective strategies for analyzing refrigeration and air conditioning systems performance
• Obtaining thermodynamic performance parameters, specifications and performance requirements appropriate to each situation.
• Evaluating the results of the analysis
• Documenting analysis details of all findings, calculations and assumptions.
2. Carry-out Smooth Boiler Operation
Overview
This Competency Standard covers the competencies required to enable the student to prepare boiler for smooth operation. This unit covers the knowledge low pressure boiler, application of boiler in HVAC technology, its controls, chemical treatment of boiler/ water and feed water tanks to provide you the basis for your work.
Competency Units Performance Criteria
1. Prepare the Boiler for Operation
P1. Review operational order and where required check with appropriate personal
P2. Identify and report health and safety hazards / maintenance requirements to appropriate personnel according to workplace reporting procedures
P3. Identify and set quantity of steam to be generated for allocated Process
P4. Purge the boiler according to workplace procedure
P5. Perform pre-operational checks to confirm operational status of boiler and related equipment
2. Operate and Monitor Boiler
P1. Use equipment in line with organizational safety procedures, manufacturer’s instructions and environmental protection practices.
P2. Apply complete pre-operational safety and pre start-up checks to ensure operational effectiveness.
P3. Start boiler and bring safely on line; communicate recent performance to appropriate personnel.
P4. Monitor boiler operation, diagnose status and adjust to maintain safe and efficient operation.
3. Shut down and Store Boiler
P1. Shut down boiler according to workplace procedures and manufacturer's recommendations
P2. Clean boiler internally and externally according to workplace procedures and manufacturer's recommendations
P3. Remove valves and fittings in preparation for maintenance
P4. Store the boiler in the appropriate storage mode according to workplace procedures and manufacturer's recommendations
P5. Store and record boiler house chemicals, in line with safety procedures and environmental protection practices.
P6. Follow emergency shutdown procedures in cases of fire.
P7. Complete operating log, record fuel efficiency and report to appropriate personnel.
4. Analyze and Respond to Abnormal Performance (Trouble Shooting
P1. Analyze operating data and plant operating conditions to identify causes of abnormal performance
P2. Take action correctively in accordance with workplace procedures in response to Hazards, out-of-specification test results and/or plant performance
Competency Units Performance Criteria
of Boiler) P3. Implement emergency procedures as required according to workplace procedures and manufacturer's recommendations
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• Safe work procedures including awareness of health and safety hazards related to boiler operation and associated control measures. Hazards typically include working around hot surfaces, manual handling, fuel and steam leaks
• Purpose and limitations of protective clothing and equipment
• Hierarchy of hazard control measures
• Duty of care of the boiler operator
• Purpose and basic principles of combustion and boiler operation. This includes principles of heat transfer and properties of steam
• Boiler system layout and steam cycle
• The purpose of purging a boiler
• The effect of fuel quality on boiler operation
• Impact of ash removal on efficient boiler operation and impact of sluice water flow
• Relationship to other processes. This includes an understanding of the impact of sudden load changes on boiler pressure and plant operation
• Purpose and limitations of protective clothing and equipment
• Methods used to render equipment safe to inspect, maintain and/or clean including lock-out, tag-out and isolation procedures
3. Recognize Fundamentals of Thermodynamics Problems
Overview:
The user/ individual on the job needs to know and understand how to Solve problems of fundamentals of thermodynamics ,heat, mass & weight, force, work done and power. Develop skill, mathematical attitudes and logical perception in the use of mathematical instruments as required in the automobile fields.
Competency Units Performance Criteria
1. Perform the conversation of Temperature scales
P1. Measuring the temperature and convert to K to C.
P2. Solve the problem with the help formula.
P3. Measuring the temperature with appropriate tool.
2. Measuring the vacuum and pressure gauge
P1. Measure the vacuum use with vacuum gauge on engine.
P2. Measure the pressure use with the pressure gauge in different scales.
P3. Perform the conversation of vacuum and pressure in different scales.
P4. Solve the problems of mathematical attitudes and logical perception in the use of mathematical instruments
3. Understand and Solve the problems of Different Energies
P1. Solve the problems of following energies: a. Potential Energy b. Kinetic Energy c. Thermal Energy d. Chemical Energy
P2. Drive the law of a. Laws of thermodynamics
b. Law of conservation of energy
4. Derive the mathematical relations
P1. Drive the following laws: a. Boyles Law b. Charles Law c. Joules Law
P2. Solve the mathematical problems applying the laws
Knowledge and Understanding
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• Safe work.
4. Read and Interpret Perfect Gases Laws, Properties and Solve problems
Overview:
The user/ individual on the job needs to know and understand how to the knowledge of fundamentals of thermodynamics, laws and properties of gases, thermodynamic processes and cycles, steam and Gas turbines , I.C. Engines.
Competency Units Knowledge Criteria
1. Applying Gas Laws in problems
P1. Derive the following mathematical relations: a. General gas equation b. Characteristic Gas equation c. Universal Gas equation
P2. Understand the specific heats of a gas and derive its mathematical relations.
2. Derive the mathematical equation
P-1. Derive the mathematical equation of Enthalpy of a Gas.
Understanding and Knowledge:
• Perfect gas and its properties.
• Derive the mathematical relations. a. Boyle’s law. b. Charles’s law c. Joule’s law
• The mathematical relations.. a. General gas equation b. Characteristic Gas equation c. Universal Gas equation
• Describe the following. a. The two specific heats of a gas and derive its mathematical relations.
• State the following. a. Enthalpy of a Gas
5. Read and Derived Thermodynamics Processes and Cycles
Overview:
The user/ individual on the job needs to know and understand how to prepare the properties of steam, steam boilers and their performance , steam and Gas turbines , I.C. Engines, Air compressors and their problems.
Competency Units Knowledge Criteria
1. Draw the different Cycles
P1. Explain CARNOT CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation.
P2. OTTO CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation
P3. DIESEL CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation.
P4. Joule’s Cycle with the help of P-V diagram, also derive its mathematical relations for air standard efficiency during cycle of operation.
P5. DUAL COMBUSTION CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation.
2. Evaluate the performance of steam boilers
P1. Working and general construction of a boiler, Classification of boilers, Selection factors of a good steam boiler, Important terms used for steam boilers.
P2. The construction and working of Simple Vertical Boiler with the help of neat sketch.
P3. The construction and working of COCHRAN Boiler (Multi tubular boiler) with the help of neat sketch.
P4. The construction and working of Babcock and Wilcox Boiler with the help of neat sketch..
3. Derived and solved the mathematically problems of I.C engines
P1. Solve and Derived following a. Torque, and it’s unit in SI system. b. Mean effective pressure. c. Indicated power and its formula.. d. Brake Horse power and its formula. e. Measurement of Brake Horse power
P2. Solve and Derived following a. Friction Horse power. b. Mechanical efficiency. c. Thermal efficiency.
Understanding and Knowledge:
• Explain CARNOT CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation.
• Explain OTTO CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation.
• Explain DIESEL CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation..
• Explain DUAL COMBUSTION CYCLE with the help of P-V diagram; also derive its mathematical relations for Air Standard Efficiency during the cycle of operation.
• Solve the mathematical expressions of following: i. Performance of boiler ii. Equivalent evaporation of boiler iii. Efficiency of boiler
• Derived formula of Comparison between Water tube and Fire tube boilers.
6. Analyze Reciprocating & Rotary Air Compressors Performance
Overview:
This Competency standard identifies the competencies to transfer the knowledge of fundamentals of Air compressors its types and their performance.
Competency Units Knowledge Criteria
1. Inspect/Understand component of air compressor and their types
P1. Describe the introduction of Air Compressors, types of Air Compressors(Reciprocating & Rotary) a. And terms used for Air Compressors
P2. Describe the construction and working of single stage reciprocating air compressor with the help of PV diagram and sketch.
2. Derived the work done as per cycle.
P1. Derived and draw Describe the work done per cycle by a single stage reciprocating Air Compressor without and with clearance volume, considering the following laws of compression. a. Isothermal Compression. b. Isentropic compression. c. Polytrophic compression
P2. Solve the multistage compression and understand its advantages.
3. Derive mathematical expression two stage reciprocating air problems.
P1. Derive its mathematical Expression for the work done per cycle considering polytrophic law of compression
P2. Drive a single stage and two stages reciprocating Air compressors; also derive its formulae.
Knowledge & Understanding:
• Describe the work done per cycle by a single stage reciprocate Compressor without and with clearance volume, considering the following laws of compression. a. Isothermal Compression. b. Isentropic compression. c. Polytrophic compression.
• Describe the multistage compression and its advantages.
• Describe the two stage reciprocating air compressor with intercooler; also derive its mathematical Expression for the work done per cycle considering polytrophic law of compression.
7. Solves Problems of Internal Combustion Engine
Overview:
This Competency standard identifies the competencies required to develop and transfer the knowledge of fundamentals, types of, IC. engines and their performance.
Competency Units Knowledge Criteria
1. Understand and solve the IC. engine
P1. Perform the following. a. Torque, and it’s unit in SI system. b. Mean effective pressure. c. Indicated power and its formula.. d. Brake Horse power and its formula
2. Calculate the different powers/ Efficiency IC. Engine
P1. Perform the following. a. Measurement of Brake Horse power. b. Friction Horse power. c. Mechanical efficiency. d. Thermal efficiency e. Volumetric efficiency
Understand and Knowledge:
• Explain Torque, and it’s unit in SI system.
• Explain Mean effective pressure.
• Explain Indicated power and its formula.
• Explain Brake Horse power and its formula.
• Explain Measurement of Brake Horse power.
• Explain Friction Horse power.
• Explain Mechanical efficiency.
• Explain Thermal efficiency.
Motor Vehicle Driving AD-302
1. Inspect Vehicle Controls for pre Operational & Pre Starting
Overview
These competency standards designed to enable the learner to check performance of vehicle different controls and perform pre operational and pre starting inspection.
Unit of Competency Performance Criteria
1. Practice to use of Different Vehicle Controls
P1. Check the performance & Working of following controls. Dashboard instruments cluster lights and dials controls o Speedometer o Tachometer o Fuel gauge o Temperature gauge o Warning lights for fuel, oil, engine, water
P2. Steering Wheel control o Steering wheel o Windscreen wipers o Indicators o Headlights on full beam and dip o Horn
P3. Floor controls: o Accelerator pedal o Brake pedal o Clutch pedal (for manual cars) o Gear lever o Handbrake or park brake
2. Carry out Pre operational Inspection on Vehicle.
P1. Inspect the following o Vehicle tire pressure. o Fuel level. o Oil pressure. o Coolant level. o Battery Electrolyte level. o Brake Fluid level. o Head Lights, Turn Signal Lights, brake light and Horn working. o Brake Paddle Play, Accelerator Paddle Play, Clutch Paddle
Play. o Hand brake operation. o Steering operation.
P2. Check the working of different interiors and exteriors of a car.
3. Perform Basic Pre Starting inspection on Engine
P1. Perform following operations
• Set the position of choke on.
• Ignition Switch different Positions (Off, Acc, On, ST).
• Release of Ignition switch key just after the engine start.
• Engine Warm up Period.
• Glow of Oil pressure light, Battery charging light and Vehicle
Unit of Competency Performance Criteria
Malfunction Indication Light just after Starting the engine.
• Abnormal engine noises.
• Engine Stopping.
Knowledge & Understanding
• Describes the performance & Working of following controls. Dashboard instruments cluster lights and dials controls o Speedometer o Tachometer o Fuel gauge o Temperature gauge o Warning lights for fuel, oil, engine, water
• Explain Steering Wheel control o Steering wheel o Windscreen wipers o Indicators o Headlights on full beam and dip o Horn
• Explain Floor controls o Accelerator pedal o Brake pedal o Clutch pedal (for manual cars) o Gear lever o Handbrake or park brake.
• Explain the following o Vehicle tire pressure. o Fuel level. o Oil pressure. o Coolant level. o Battery Electrolyte level. o Brake Fluid level. o Head Lights, Turn Signal Lights, brake light and Horn working. o Brake Paddle Play, Accelerator Paddle Play, Clutch Paddle Play. o Hand brake operation. o Steering operation.
• Explain following operations o Set the position of choke on. o Ignition Switch different Positions (Off, Acc, On, ST). o Release of Ignition switch key just after the engine start. o Engine Warm up Period. o Glow of Oil pressure light, Battery charging light and Vehicle Malfunction Indication Light just
after Starting the engine. o Abnormal engine noises. o Engine Stopping.
Critical Evidence(s) Required
• Capable to Practice to use of Different Vehicle Controls
• Capable to Carry out Pre operational Inspection on Vehicle.
• Capable to Perform Basic Pre Starting inspection on Engine
List of Tools and Equipment
S. No. Descriptions
1 Vehicle Equipped with manual transmission
2. Read and Interpret Traffic Signals, Road Signs and Marking Lanes on Roads
Overview
These competency standards designed to enable the learner to Identify Traffic Signals, Road signs, marking Lanes on Roads.
Unit of Competency Performance Criteria
1. Identify and follow Traffic signals.
P1. Follow the following traffic signals, o Red signals. o Yellow signals. o Green signals. o Traffic signal blackout.
2. Identify and follow different Road signs.
P1. Follow the following road signs. o Regulatory signs o Guidance signs o Warning signs o Information signs o Octagonal stop sign o Triangular yield sign o Diamond-shaped pedestrian priority sign
3. Identify and follow Marking lanes on roads.
P1. Follow the following marking lanes on roads
o Regulatory markings o Warning markings o Guidance markings
Knowledge & Understanding
• Describe the following traffic signals, o Red signals. o Yellow signals. o Green signals. o Traffic signal blackout.
• Describe the following road signs. o Regulatory signs o Guidance signs o Warning signs
• Explain the following marking lanes on roads
o Regulatory markings o Warning markings o Guidance markings
Critical Evidence(s) Required
• Capable to Identify and follow Traffic signals
• Capable to Identify and follow different Road signs.
• Capable to Identify and follow marking lanes on roads.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
2 Driving charts
3. Apply Power& Parking Brakes to Vehicle
Overview
These competency standards designed to enable the learner to use of brake & parking brake of vehicle and park the vehicle in proper place Under the specified procedure.
Unit of Competency Performance Criteria
1. Perform brake operation on road.
P1. Brake controls on vehicle
P2. Start driving and apply brake in different condition and situation
P3. Check and observe breaking distance
2. Properly park the car at proper place.
P1. Drive car and take to proper parking place
P2. Observe road signs and road lanes and marking on roads
P3. Park the vehicle at proper place
P4. Apply parking brake
Knowledge & Understanding
This competency standard will provide knowledge related to:
• Purpose of Brake and parking brake.
• Factors effecting Vehicle Stopping.
• Types of road surfaces and their effects on braking.
• Vehicle Skidding.
• Road Resistance / Road Grip.
• Over Speeding and its Disadvantages.
• Vehicle tires wear & tear and its limits.
• Car Speed / Vehicle inertia to Braking
Critical Evidence(s) required
The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:
• Capable to apply braking in different situations
• Capable to drive a car in accordance to breaking distance.
• Capable to park vehicle in proper place and observe rules while parking.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
4. Drive Car in Different Condition
Overview
These competency standards designed to enable the learner to work on vehicle final drive and repair or replace the faulty components as directed in the manual.
Unit of Competency Performance Criteria
1. Drive Car on Straight Road
P1. Driving on straight Road
• Proper use of indicators
• Proper use Road lanes.
• Proper use of horn
• Understanding road signs
• Proper use of brake.
2. Driving In Hilly Area
P1. Driving in Hilly area
• Proper use of Clutch
• Proper gear shifting
• Understanding Warning Signs.
• Observing Speed limits.
3. Vehicle Overtaking
P1. Vehicle Overtaking
• Proper use indicators
• Proper use of Road lanes.
• Check oncoming lanes
• Check mirrors
• Go back to own lane after overtaking by using indicators.
Knowledge & Understanding
• Describe the Driving on straight Road o Proper use of indicators o Proper use Road lanes. o Proper use of horn o Understanding road signs o Proper use of brake.
• Describe the Driving in Hilly area o Proper use of brake o Proper use of Clutch o Proper gear shifting o Understanding Warning Signs. o Observing Speed limits.
• Describe Vehicle Overtaking o Proper use indicators o Proper use of Road lanes.
o Check oncoming lanes o Check mirrors o Go back to own lane after overtaking by using indicators.
Critical Evidence(s) Required
• Capable to Drive Car on Straight Road
• Capable to Driving In Hilly Area
• Capable to Vehicle Overtaking
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
5. Drive Vehicle with Manual& Automatic Transmission
Overview
These competency standards designed to enable the learner to driving of manual, automatic vehicle & motorcycle
Unit of Competency Performance Criteria
1. Drive Car With Manual Transmission
P1. Drive Car With Manual Transmission and follow the following
• Adjust mirrors
• Adjust seats
• Adjust Steering
• Know the Different pedals & their uses.
• Proper using of Clutch.
• Use proper gear Shifting & Gear position.
• Proper use of indicator.
• Know the Different pedals & their uses.
• Parking in proper place.
2. Drive Car With Manual Transmission
P1. Drive Car With Manual Transmission and follow the following
• Adjust mirrors
• Adjust seats
• Adjust Steering
• Know the use of Brake & Accelerator.
• Shifting of gear lever in proper position
• Proper use of indicator.
• Parking in proper place.
3. Drive Four Stroke Motorcycle
P1. Drive Four Stroke Motorcycle and follow the following
• Adjust back view mirror
• Start motorcycle in proper sequence.
• Proper use of front wheel brake
• Proper use of rear wheel brake
• Proper use of clutch
• Proper use of indicator while turning
• Proper use of horn
• Park in proper place
• Wear helmet before driving motorcycle
Knowledge & Understanding
Describes the following
• Adjustment of mirrors
• Adjustment of seats
• Adjustment of Steering
• Different pedals & their uses.
• Proper using of Clutch.
• Gear Shifting & Gear position.
• Proper use of indicator.
• Parking in proper place.
Explain the following
• Adjust back view mirror
• Starting of motorcycle in proper sequence.
• Proper use of front wheel brake
• Proper use of rear wheel brake
• Proper use of clutch
• proper use of indicator while turning
• Proper use of horn
• Park in proper place
Critical Evidence(s) Required
• Capable to drive car with manual transmission
• Capable to drive car with manual transmission
• Capable to drive four stroke motorcycle
List of Tools and Equipment
S. No. Descriptions
1 Vehicle Equipped with manual transmission
2 Vehicle Equipped with Automatic transmission
3 Motorcycle 125cc
6. Drive Motorcycle
Overview
These competency standards designed to enable the learner to driving of manual, automatic vehicle & motorcycle
Unit of Competency Performance Criteria
1. Drive Four Stroke Motorcycle
P1. Drive Four Stroke Motorcycle and follow the following
• Adjust back view mirror
• Start motorcycle in proper sequence.
• Proper use of front wheel brake
• Proper use of rear wheel brake
• Proper use of clutch
• Proper use of indicator while turning
• Proper use of horn
• Park in proper place
2. Safe driving techniques
P1. Drive Motorcycle and monitor the following:
• Wear helmet before driving motorcycle
• Understand motor vehicle act , traffic regulations
• Safe Overtaking
• Safe driving in different situations
• Parking at side stand
• Parking at double stand
Knowledge & Understanding
• Describes the following
• Adjustment of back view mirrors
• Different grips, pedals & their uses.
• Proper using of Clutch.
• Gear Shifting & Gear position.
• Proper use of indicator.
• Explain the following
• Starting of motorcycle in proper sequence.
• Proper use of front wheel brake
• Proper use of rear wheel brake
• Proper use of clutch
• proper use of indicator while turning
• Proper use of horn
• Park at single & double stand
Critical Evidence(s) Required
• Capable to drive four stroke motorcycle
List of Tools and Equipment
S. No. Descriptions
1 Motorcycle 125cc
7. Drive Vehicle on Economy Speed for Fuel Saving
Overview
These competency standards designed to enable the learner to drive the vehicle on economy speed for fuel saving
Unit of Competency Performance Criteria
1. Perform pre starting
P1. Perform following operations
• Set the position of choke on.
• Ignition Switch different Positions (Off, Acc, On, ST).
• Release of Ignition switch key just after the engine start.
• Engine Warm up Period.
• Glow of Oil pressure light, Battery charging light and Vehicle Malfunction Indication Light just after Starting the engine
• Warm up the engine to normal temperature.
2. Drive the vehicle at economic speed for fuel saving
P1. Perform following operations
• Avoid Aggressive Driving
• Drive Steadily at Posted Speed Limits
• Avoid over Speeding
• Avoid Idling Your Vehicle in Both Summer and Winter
• Make Sure Your Tires Are Proper
• Select the Right Gear
• Use Your Air Conditioner Sparingly on Older Cars
• Use the Cruise Control
• Choose the Octane Fuel Which Best Suits Your Car
• Avoid Putting Your Car in Neutral When Idling
Knowledge & Understanding
• Describe the Aggressive Driving.
• Describe the steadily driving at Posted Speed Limits
• Explain the over Speeding
• Explain proper gear shifting
Critical Evidence(s) Required
• Capable to Drive the vehicle at economic speed for fuel saving
• Capable to Drive Steadily at Posted Speed Limits
• Capable to use proper gear shifting
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
8. Perform Safety Practices While Driving
Overview
These competency standards designed to enable the learner driving safety and first aid procedures.
Unit of Competency Performance Criteria
1. First aid given according to accepted medical regulations in case of road Accident to Treat minor injuries
P1. First aid cut injury
P2. First aid eye injury
P3. First aid burn injury
P4. Provide artificial respiration
2. Perform rescue drill and training exercise in case of accidents to treat life saving
P1. Provide artificial respiration.
P2. Support head & neck to avoid them twisting
P3. Do not cover her eyes.
P4. Keep talking to them.
P5. Keep checking that they are still breathing.
P6. Keep the patient away from vehicle.
P7. Call the Ambulance
Knowledge & Understanding
This competency standard will provide knowledge related to:
• Explain First Aid (according to accepted medical regulations in case of road Accident to Treat minor injuries)
• Describe rescue drill and training exercise in case of accidents to treat life saving
Critical Evidence(s) required
The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:
• Capable to give first aid according to accepted medical regulations in case of road accident to treat minor injuries
• Capable to Perform rescue drill and training exercise in case of accidents to treat life saving
List of Tools and Equipment
S. No. Descriptions
1 First Aid Box
Motor Vehicle Inspection AD-312
1. Inspect Tires& Wheels of Light & Heavy Duty Transport Vehicles (LTV& HTV)
Overview
These competency standards designed to enable the learner to inspect tires & wheels of HTV and LTV vehicles According to specifications under the specified procedure.
Unit of Competency Performance Criteria
1. Check the condition & quality of Light vehicle (LTV) tires and wheels.
P1. Check And Inspect the following in tire,
• Tire inflation
• Tire tread
• Side wall
• Pledge on tire
• Tire type
• Retreading
• Broken fabrics
• Broken wires
P2. Check And Inspect the following in wheels,
• Welded wheel
• Broken wheel
• Broken stud and nut.
• Missing nut
• Damage wheel
• Oval hole in Wheel
2. Check the condition & quality of Heavy vehicle (HTV) tires and wheels
P1. Check And Inspect the following in heavy tire,
• Tire inflation
• Tire tread
• Side wall
• Pledge on tire
• Tire type
• Retreading
• Broken fabrics
• Broken wires
• Re-grooved
• Restriction mark on tire
• Same size of all tires
P2. Check And Inspect the following in wheels,
• Welded wheel
• Broken wheel
• Broken stud and nut.
• Missing nut
• Damage wheel
• Oval hole in Wheel
• Check stem
Unit of Competency Performance Criteria
• Check cap
Knowledge & Understanding
• Describes the following in Heavy and Light vehicle tire,
• Tire inflation
• Tire tread
• Side wall
• Pledge on tire
• Tire type
• Retreading
• Broken fabrics
• Broken wires
• Explain the following in Heavy and Light vehicle wheels,
• Welded wheel
• Broken wheel
• Broken stud and nut.
• Missing nut
• Damage wheel
• Oval hole in Wheel
Critical Evidence(s) Required
• Capable to check the condition & quality of Light vehicle (LTV) tires and wheels.
• Capable to check the condition & quality of Heavy vehicle (HTV) tires and wheels.
List of Tools and Equipment
S. No. Descriptions
1 Light vehicles tires
2 Light vehicles wheel/rim
3 Heavy vehicle tires
4 Heavy vehicle wheel/rim
5 Tool kit complete
2. Inspect Vehicle Suspension System
Overview
These competency standards designed to enable the learner to Inspect vehicle suspension system According to specification. Under the specified procedure.
Unit of Competency Performance Criteria
1. Check performance of spring, shock-absorber and tracking
P1. Coil spring inspection
• Breakage
• Height
P2. Leaf spring inspection
• Center bolt
• U bolt
• Leaves
• Bushes
P3. Shock absorber inspection o Leakage o Bushes o Attachments o Tracking inspection o By tracking gauge. o By wet road test.
2. Check performance of the electronic control suspension system.
P1. Check & verify the following,
• Height sensor • Actuator • Shock Absorber • Compressor • Switch
• Fuses
• Wring & relays
Knowledge & Understanding
• Describe the inspection of following o Shock absorber inspection o Shock absorber inspection
• Describe the following in electronic suspension system o Height sensor o Actuator o Shock Absorber o Compressor o Switch o Fuses o Wring & relays
Critical Evidence(s) Required
• Capable to Identify Faults of spring, shock-absorber and tracking and rectify it
• Capable to check performance of the electronic control suspension system
• Capable to Identify Faults of electronic control system and rectify it.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle equipped with electronic suspension system
2 Vehicle equipped with Manual suspension system
3 Tool kit complete
3. Inspect Vehicle Steering System and Wheel Alignment
Overview
These competency standards designed to enable the learner to inspect vehicle steering system and wheel alignment under the specified procedure.
Unit of Competency Performance Criteria
1. Inspect and check the performance of steering system and wheel alignment
P1. Inspect the vehicle steering system for rubber boots on (inner and outer ball joint), Tie road condition, and inner/outer ball joints play, steering rack and pinion box, Mounting for the steering box under the specified procedure.
P2. Replace/service the Outer tie road, inner tie road, steering mountings, steering boots (inner and outer ball joint), under the specified procedure.
P3. Service the steering gear (Rack and pinion) box under the specified procedure.
P4. Inspect and check the following components of steering system
• Lose steering Column
• Defective energy absorbing steering column
• Steering wheel play
• Steering linkage play
• Steering gear lash
• Steering wheel Hardness
• Lose Ball joint
• Front wheel bearing
2. Inspect and check the wheel alignment
P1. Check for the vehicle pre alignment for proper Tire pressure/inflation, loose ball joints, wheel bearings, tie road ends, axle bushes, faulty spring, tire deformation, vehicle ride height, and loose stabilizer bar under specified procedure.
P2. Drive the vehicle and load/offload it on wheel alignment machine following safety rules as specified in the manual.
P3. Perform wheel alignment using the wheel alignment machine as described procedure in the machine manual and adjusts Toe, camber of front and rear wheels under specified procedure.
Knowledge & Understanding
• Describe the purpose and function of the following. Steering systems (non-assisted/manual), power assisted system, electronic steering system
with a motor.
• Describe the main components and mechanism of the following. Ackerman principle, true rolling motion, steering ratio, toe in/out, camber, caster, steering axes
inclination, steering wheel/column, rack and pinion, steering gearboxes, steering ball joints, steering arm, front hubs, bearings/seals.
• Describe the following functions/principles of wheel alignment. Ackerman principle for a true rolling motion, steering pull, steering center point, steering wheel
vibration causes.
• Describe the wheel alignment faults as following. Toe in, toe out, positive camber, negative camber, positive caster, steering axes inclination,
included angle, tire wear, ride height, trim height of vehicle.
Critical Evidence(s) Required
The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:
• Capable of servicing steering system
• Capable of performing power steering bleeding
• Capable to diagnose and rectify the steering system problems.
• Capable to perform wheel alignment of the vehicle.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle equipped with the power steering
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack /safety stand
4 Car lift
5 Automotive scanner
6 Ball joint removal
7 Grease gun
8 Steering fluid pressure tester
9 Oil can
4. Inspect Light & Heavy Duty Vehicle Brake System
Overview
These competency standards designed to enable the learner to Inspect Light & heavy Duty Vehicle Brake system as directed in the manual.
Unit of Competency Performance Criteria
1. Inspect Light Vehicle (LTV) Brake system.
P1. Check brake performance test on road
P2. Check brake performance at inspection station on brake tester
P3. Check The following
• Master cylinder
• Brake fluid leve
• Brake fluid leakage
• Gas kit
• Brake servo
• Wheel cylinder leakage
• Break line damage
• Disk brake lining
• Drum lining
P4. Check vehicle instrument panel and identify ABS mall functioning light.
P5. Diagnose the vehicle ABS system with the use of scanner for wheel Sensors performance test, ABS Modular/actuator test under the specified procedure.
P6. Change the wheel sensors, actuator and related fuse under the specified procedure.
2. Inspect heavy Vehicle (HTV) Brake system.
P1. Check brake performance test on road
P2. Check brake performance at inspection station on brake tester
P3. Check The following
• Master cylinder
• Brake fluid leve
• Brake fluid leakage
• Gas kit
• Brake servo
• Wheel cylinder leakage
• Break line damage
• Disk brake lining
• Drum lining
• Brake drum diameter.
• Drum thickness.
• Paddle reservoir
P4. Check performance of brake booster.
Knowledge & Understanding
• Describe the purpose and function of the following. Disc brakes, drum brakes (reduce vehicle speed, stop vehicle), use of friction and friction
materials, hydraulic system in a vehicle brake system, vehicle mechanical/ hand bake, engine braking in the vehicle.
• Describe the brake main Components as following Master cylinder (single/tandem), wheel cylinder, calipers (single/tandem), pipes/flexible hoses,
brake shoes (leading/ trailing), brake pads, brake discs, brake drum, handbrake operating mechanism, pedal, limiting valves, adjusters, brake fluid, brake warning light, brake light, brake light switch, wear indicator.
• Describe the principles and functions of ABS system in a vehicle as following. ABS system, Traction control system, vehicle stability control system, Wheel sensors, ECU,
ABS modulator assembly, vehicle body (Honda G-CON) (Toyota GOA).
Critical Evidence(s) Required
• Capable of servicing brake system
• Capable of performing brake bleeding
• Capable to diagnose and rectify the ABS system.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle equipped with the ABS
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack /safety stand
4 Car lift
5 Automotive scanner
6 Vacuum gun
5. Inspect Vehicle Light System
Overview
These competency standards designed to enable the learner Inspect vehicle Lighting System as directed in the manual.
Unit of Competency Performance Criteria
1. Check The Performance Of LTV Vehicle Lighting System
P1. Check Head Light Aiming Through Head Light Aimer.
P2. Check The Beam of head light
P3. Check Head light DIM and FULL Light Position
P4. Check The Presence and working of Fog Lights
P5. Check Parking Lights
P6. Check Left Right Indicators
P7. Check the double indicate switch
P8. Check Brake lights
P9. Check Reverse indication light.
P10. Check Number plate lights
P11. Check Warning lights present in dash board.
P12. Check door lights
P13. Check all interior lights.
2. Check The Performance Of HTV Vehicle Lighting System
P1. Check Warning lights present in dash board
P2. Check door lights
P3. Check all interior lights.
P4. Check Brake lights
P5. Check Reverse indication light.
P6. Check Number plate lights
P7. Check Parking Lights
P8. Check Left Right Indicators
P9. Check the double indicate switch
P10. Check Head Light Aiming Through Head Light Aimer.
P11. Check The Beam of head light
P12. Check Head light DIM and FULL Light Position
P13. Check The Presence and working of Fog Lights
Knowledge & Understanding
• Describes the following
• Head Light Aiming Through Head Light Aimer.
• Beam of head light
• Head light DIM and FULL Light Position
• Fog Lights
• Parking Lights
• Indicators
• Brake lights
• Reverse indication light.
• Warning lights present in dash board.
• Door lights
Critical Evidence(s) Required
• Capable to check the performance of LTV vehicle lighting system
• Capable to Check the performance of HTV vehicle lighting system
List of Tools and Equipment
S. No. Descriptions
1 Head light aimer
2 Tool kit
3 12 Volt tester
6. Inspect Vehicle Electric System
Overview
These competency standards designed to enable the learner to Inspect Vehicle Electric System as directed in the manual.
Unit of Competency Performance Criteria
1. Check and Inspect the Performance of Light Vehicle Electric system.
P1. Check Wiring Condition
P2. Check Wiring Color coding
P3. Check alternator condition and its performance
P4. Check ignition switch condition and working
P5. Check safety starting switch performance
P6. Check fuse box Inspect all fuses
P7. Check horn circuit and its performance
P8. Check wind screen wiper motor circuit and its performance
P9. Check and inspect wind screen washer motor circuit and check its performance.
P10. Inspect vehicle defogger system performance
P11. In case of key less ignition check push starting button.
P12. Check and inspect the performance of starting motor of vehicle.
2. Repair charging system
P1. Inspect the vehicle charging system and diagnose the following.
P2. Battery warning light indication on instrument panel, test output voltage of alternator, drive belt condition, alternator bearing noise, wire harness, fuse, and proper insulated wires.
P3. Dismantle/service of alternator as following.
P4. Repair connector, replace carbon brushes, replace Rectifier Bridge, replace voltage regulator, and replace stator winding.
Knowledge & Understanding
Describe the following
• Check Wiring Condition
• Check Wiring Color coding
• Check alternator condition and its performance
• Check ignition switch condition and working
• Check safety starting switch performance
• Check fuse box Inspect all fuses
• Check horn circuit and its performance
• Check wind screen wiper motor circuit and its performance
• Check and inspect wind screen washer motor circuit and check its performance.
• Inspect vehicle defogger system performance
• In case of key less ignition check push starting button.
• Check and inspect the performance of starting motor of vehicle.
• Describe the Purpose and function of Alternator’s following parts. Rotor, stator windings, Voltage regulator, Rectifier Bridge, Internal cooling fan, Bearings, carbon brush, mounting/adjustment bolts), drive belt and its types, ratio alternator/crank pulleys, RPM, Alternator input/output voltages.
Critical Evidence(s) Required
• Capable to Check and Inspect the Performance of Light Vehicle Electric system.
• Capable to troubleshoot the vehicle charging system
List of Tools and Equipment
S. No. Descriptions
1 Vehicle/simulator
2 Test lamp
3 DMM
4 Tool kit
5 Ampere meter
6 Fuses
7 Relay
7. Inspect Vehicle Glazing System
Overview
These competency standards designed to enable the learner to Inspect Vehicle glazing System as directed in the manual.
Unit of Competency Performance Criteria
1. Check and inspect Front Screen
P1. Check and inspect front screen for breakage.
P2. Check the type of glass used
P3. Check that glass is according to automotive safety glazing.
P4. Check for electric defogger system present on screen
P5. Check the installation of front screen
2. Check and inspect Rear screen
P-1. Check and inspect Rear screen for breakage.
P-2. Check the type of glass used for rear screen
P-3. Check that Rear screen glass is according to automotive safety glazing.
P-4. Check the installation of Rear screen
3. Check and inspect Side glasses
P1. Check and inspect all side glasses for breakage
P2. Check that all glasses are properly installed and operate able.
P3. Check all glasses are according to automotive safety glazing,
Knowledge & Understanding
This competency standard will provide knowledge related to explain the following
• Check and inspect front screen for breakage.
• Check the type of glass used
• Check that glass is according to automotive safety glazing.
• Check for electric defogger system present on screen
• Check the installation of front screen
• Describe the following
• Check and inspect Rear screen for breakage.
• Check the type of glass used for rear screen
• Check that Rear screen glass is according to automotive safety glazing.
• Check the installation of Rear screen
• Check and inspect all side glasses for breakage
• Check that all glasses are properly installed and operate able.
• Check all glasses are according to automotive safety glazing,
Critical Evidence(s) Required
The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:
• Capable to Check and inspect Front Screen
• Capable to Check and inspect Rear screen
• Capable to Check and inspect Side glasses
List of Tools and Equipment
S. No. Descriptions
1 Tempered glass
2 Laminated glass
3 Front screen with defogger
4 Rear screen with defogger
8. Inspect Vehicle Fuel System
Overview
These competency standards designed to enable the learner to inspect vehicle fuel system According to specification Under the specified procedure.
Unit of Competency Performance Criteria
1. Check and Inspect Petrol Engine Fuel System
P1. For inspection of Petrol engine fuel system check the performance of following,
• Fuel tank
• Fuel gauge unit
• Fuel pump
• Fuel lines
• Fuel filter
• Charcoal canister
• Carburetor
P2. For EFI system Also Check
• Electric Fuel Pump
• Fuel rail
• Fuel injectors
• Pressure regulator Valve
2. Check and Inspect Diesel Engine Fuel System
P1. For inspection of Diesel engine fuel system check the performance of following,
• Fuel tank
• Fuel gauge unit
• Fuel Pump
• Diesel Fuel Filter
• Fuel Lines
• Fuel Injection Pump
• Fuel injectors
Knowledge & Understanding
Describes the following petrol components
• Fuel tank
• Fuel gauge unit
• Fuel pump
• Fuel lines
• Fuel filter
• Charcoal canister
• carburetor
For EFI system Also Check
• Electric Fuel Pump
• Fuel rail
• Fuel injectors
• Pressure regulator Valve
Explain the following diesel components
• Fuel tank
• Fuel gauge unit
• Fuel Pump
• Diesel Fuel Filter
• Fuel Lines
• Fuel Injection Pump
• Fuel injectors
Critical Evidence(s) Required
• Capable to check and Inspect Petrol Engine Fuel System.
• Capable to check and Inspect Diesel Engine Fuel System.
List of Tools and Equipment
S. No. Descriptions
1 Diesel engine
2 Petrol engine
3 Tool kit
4 Automotive scanner
5 Engine analyzer
9. Inspect Vehicle Body Accessories
Overview
These competency standards designed to enable the learner to Inspect vehicle body accessories According to specification under the specified procedure.
Unit of Competency Performance Criteria
1. Check and Inspect the Performance of Vehicle Body Accessories exterior
Check and inspect the following
P1. Front and rear bumper (car)
P2. Side skirts
P3. Bumper lips
P4. Bumper canards
P5. Bumper diffusers
P6. Bumper splitters
P7. Bumper grilles
P8. Fenders with vents
P9. Fender flares
P10. Wide body fenders and quarter panels
P11. Spoilers
P12. Custom hoods
P13. Hood Scoops
P14. Roof scoops
P15. Side scoops
2. Check and Inspect the Performance of Vehicle Body Accessories interior.
Check and inspect the following
P1. Dashboard
P2. Console box
P3. Seats
P4. Trims
P5. Roof
P6. Seat belts
P7. Interior lights
P8. Rear view mirror
Knowledge & Understanding
Describe the following Interiors
• Front and rear bumper (car)
• Side skirts
• Bumper lips
• Bumper canards
• Bumper diffusers
• Bumper splitters
• Bumper grilles
• Fenders with vents
• Fender flares
• Wide body fenders and quarter panels
• Spoilers
• Custom hoods
• Hood Scoops
• Roof scoops
• Side scoops Describe the following exteriors
• Dashboard
• Console box
• Seats
• Trims
• Roof
• Seat belts
• Interior lights
• Rear view mirror
Critical Evidence(s) Required
• Capable to check and Inspect the Performance of Vehicle Body Accessories exterior
• Capable to check and Inspect the Performance of Vehicle Body Accessories interior.
List of Tools and Equipment
S. No. Descriptions
1 Tool kit complete
10. Inspect Vehicle Exhaust System
Overview
These competency standards designed to enable the learner to inspect vehicle exhaust according to the specified procedure.
Unit of Competency Performance Criteria
1. Exhaust system components
P1. Inspect the performance of main components of exhaust manifold
P2. Remove and assemble exhaust manifold from engine
P3. Inspect the performance of Muffler.
P4. Dismantle and assemble the Muffler from pipe.
2. Emission control system
P1. Identify catalytic converter and understand the function.
P2. Identify the positive crankcase ventilation (PCV)and understand the function.
P3. Identify and understand the functions of exhaust gas recirculation system(EGR)
Knowledge & Understanding
• Describe the exhaust manifold types and its functions.
• Describe the muffler assembly operation.
• Describe the catalytic converter operation
• Describe the positive crank case ventilation PCV system and it operation
• Describe the exhaust gas recirculation and its operation
List of Tools and Equipment
S. No. Descriptions
1 Vehicle equipped with the power steering
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack /safety stand
4 Car lift
5 Automotive scanner
6 Ball joint removal
7 Grease gun
8 Steering fluid pressure tester
9 Oil can
11. Prepare Comprehensive Vehicle Inspection Report
Overview
These competency standards designed to enable the learner to Inspect Light & heavy Duty Vehicle Brake system as directed in the manual.
Unit of Competency Performance Criteria
1. Make Vehicle inspection report
Vehicle inspection report consist of following system inspection,
P1. Complete lighting system of vehicle conditions
P2. Complete mirrors and glasses condition
P3. Engine condition
P4. Fuel system condition
P5. Exhaust system condition
P6. Brake system condition
P7. Vehicle interior conditions
P8. Vehicle body condition
P9. Vehicle suspension system condition
P10. Vehicle steering system condition
P11. Vehicle all lubricants condition
P12. Vehicle power train condition
P13. Vehicle tires and wheels condition
P14. Vehicle alignment condition
P15. Cooling system condition
P16. Vehicle heating and A/C system condition.
P17. SRS system condition
Knowledge & Understanding
Describe the following
• Complete lighting system of vehicle conditions
• Complete mirrors and glasses condition
• Engine condition
• Fuel system condition
• Exhaust system condition
• Brake system condition
• Vehicle interior conditions
• Vehicle body condition
• Vehicle suspension system condition
• Vehicle steering system condition
• Vehicle all lubricants condition
• Vehicle power train condition
• Vehicle tires and wheels condition
• Vehicle alignment condition
• Cooling system condition
• Vehicle heating and A/C system condition.
• SRS system condition
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack /safety stand
4 Car lift
5 Automotive scanner
6
12. Prepare Vehicle Title Certificate
Overview
These competency standards designed to enable the learner to prepare certificate of title for a vehicle.
Unit of Competency Performance Criteria
1. Make a Certificate of title
The certificate of title Includes the following,
P1. Vehicle owners name
P2. Vehicle owners address
P3. Vehicle owners contact
P4. Vehicle registration no
P5. Vehicle chassis. No.
P6. Vehicle engine no
P7. Vehicle maker detail
P8. Vehicle year of manufacture
P9. Vehicle Body type
P10. Vehicle loading capacity
P11. Vehicle seating capacity
P12. Color of vehicle
P13. Vehicle body type
P14. Vehicle tax detail
P15. Vehicle fitness certification
Knowledge & Understanding
Describe the following
• Vehicle owners name
• Vehicle owners address
• Vehicle owners contact
• Vehicle registration no
• Vehicle chassis. No.
• Vehicle engine no
• Vehicle maker detail
• Vehicle year of manufacture
• Vehicle Body type
• Vehicle loading capacity
• Vehicle seating capacity
• Color of vehicle
• Vehicle body type
• Vehicle tax detail
• Vehicle fitness certification
Fuel Injection and Carburetion AD-343
1. Diagnose Faults of Intake System
Overview
These competency standards designed to enable the learner intake system, adjust and service the intake related problems as well under the specified procedure in the manual.
Unit of Competency Performance Criteria
1. Intake system P1. Inspect the main components intake system.
P2. Change/service the intake manifold specified procedure.
P3. Change/service air cleaner.
P4. Replace throttle body/carburetor from intake manifold
P5. Remove and dismantle turbocharger from intake manifold
2. Exhaust system P1. Inspect the main components turbocharger system
P2. Dismantle and assemble turbocharger/supercharger
P3. Fault trace of Turbo charger/super charger
Knowledge & Understanding
• Describes the intake system main components and their functions as following.
• Plenum, Runner, Tuned intake manifold, motor, resonator, pipe.
• Describe the operational principles of intake system systems.
• Describe the operation of turbocharger/super charger
• Describe the components of turbocharger/super charger
Critical Evidence(s) Required
• Capable to service intake system.
• Capable to change intake system.
• Capable to change Tuned intake motor vehicle.
• Capable to replace faulty components for intake manifold system.
• Capable to check tuned intake manifold motor
• Capable to check fault turbocharger/super charger
• Capable to service turbocharger/super charger
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
2 Tools trolley (Complete set of Hand Tools)
3 Multi-meter
4 Special Service tools
2. Diagnose Faults of Exhaust System
Overview
These competency standards designed to enable the learner to inspect and service of exhaust system under the specified procedure in the manual.
Unit of Competency Performance Criteria
1. Service exhaust system
P1. Inspect the performance of main components of exhaust manifold
P2. Remove and assemble exhaust manifold from engine
P3. Inspect the performance of Muffler.
P4. Dismantle and assemble the Muffler from pipe.
2. Emission control system
P1. Inspects catalytic converter under the specified procedure.
P2. Inspect and perform service of positive crankcase ventilation (PCV) P-1. Inspect and perform service of exhaust gas recirculation
system(EGR)
Knowledge & Understanding
• Describe the exhaust manifold types and its functions.
• Describe the muffler assembly operation.
• Describe the catalytic converter operation
• Describe the positive crank case ventilation PCV system and it operation
• Describe the exhaust gas recirculation and its operation
Critical Evidence(s) Required
• Capable identify/service the Muffler assembly.
• Capable to service catalytic converter.
• Capable to service PCV System.
• Capable to service EGR system.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Gas analyzer
4 Vacuum pump
3. Diagnose Faults of Fuel Supply System
Overview
These competency standards designed to enable the learner to inspect and fuel supply system faulty parts or repairable parts to be changed under the specified procedure in the manual.
Unit of Competency Performance Criteria
1. Conventional Fuel Supply System of Petrol Engine
P1. Inspect fuel, fuel tank, filter and lines and identify fault/s according to set standards.
P2. Inspect Fuel pump and identify fault/s in fuel supply to Carburetor according to set standards.
P3. Inspect Fuel pump operating function by camshaft
P4. Check and identify fault/s to ensure the proper functioning of Carburetor.
2. Conventional Fuel Supply System of Diesel Engine
P1. Inspect fuel, fuel tank, primary fuel pump, Fuel injection pump, filter and lines and identify fault/s according to set standards.
P2. Inspect Fuel pump and identify fault/s in fuel supply to Fuel injection pump, according to set standards.
P3. Inspect Primary Fuel pump operating function by camshaft
P4. Check and identify fault/s to ensure the proper functioning of Fuel injection.
P5. Adjust the procedure of phasing and calibration of diesel fuel injection pumps.
P6. Adjust the procedure of setting of timing of diesel fuel injection pump.
P7. Inspect and replace diesel engine glow plug.
3. Electronic Fuel injection system of petrol engine
P1. Inspect the components of EFI system Fuel pump, fuel line, fuel filter, pressure regulator, common rail, injector
P2. Inspect and replace fuel pump
P3. Inspect and replace pressure regulator
P4. Inspect and replace fuel filter
P5. Inspect and replace fuel gallery
P6. Inspect and replace injector
P7. Inspect and replace fuel line
4. Electronic Fuel injection system of Diesel engine
P1. Inspect the components of EFI system Fuel pump, fuel line ,fuel filter, pressure regulator, common rail, injector
P2. Inspect and replace fuel pump
P3. Inspect and replace pressure regulator
P4. Inspect and replace fuel filter
P5. Inspect and replace injector
P6. Inspect and replace fuel line
Unit of Competency Performance Criteria
5. Sensors P1. Inspect the of EFI system sensors Air Flow meter ,Map sensor ,Air temperature sensor, Water temperature sensor, Throttle position sensor, , Knock sensor, RPM sensor, Oxygen sensor.
P2. Inspect and replace Air Flow meter
P3. Inspect and replace Map sensor
P4. Inspect and replace Air temperature sensor
P5. Inspect and replace Water temperature sensor
P6. Inspect and replace Throttle position sensor
P7. Inspect and replace Knock sensor
P8. Inspect and replace Knock sensor
P9. Inspect and replace Oxygen sensor
6. Compressed Natural Gas
P1. Inspect the components of CNG system Cylinder, line, filler cap, Mechanical gauge, change over switch, converter, petrol and CNG solenoid.
P2. Inspect and replace cylinder
P3. Inspect and replace filler valve
P4. Inspect and replace gauge
P5. Inspect and replace change over switch
P6. Inspect and service convertor
P7. Inspect and replace petrol and CNG solenoid
P8. Inspect , install and repair CNG wiring
P9. Diagnose the CNG system problem
7. Liquid petroleum gas
P1. Inspect the components of LPG system Cylinder, line, filler cap, Mechanical gauge, change over switch, converter, petrol and LPG solenoid.
P2. Inspect and replace cylinder
P3. Inspect and replace filler valve
P4. Inspect and replace gauge
P5. Inspect and replace change over switch
P6. Inspect and service convertor
P7. Inspect and replace petrol and LPG solenoid
P8. Inspect , install and repair LPG wiring
P9. Diagnose the LPG system problem
Knowledge & Understanding
This competency standard will provide knowledge related to:
• Describe construction of fuel tank
• Describe construction and working of fuel gauge and its circuit
• State the function of fuel pump, it’s types
• Adjustment the ideal Air / Fuel ratio of different fuels
• Describe air-fuel ratio for different engine working conditions.
• Describe air-fuel mixture adjustment at idle speed
• Describe Carburetor types according to No of barrels, No of Venturies, Air draft and fix & variable Venturies.
• Methods of Carburetor troubleshooting and remedies for the faults i.e.
o Excessive Fuel Consumption. o Engine Dieseling. o Engine Missing. o Fuel Blockage. o Engine starving o Carburetor over flow
• Describe Fuel injection pump according to operation.
• Describe the components of EFI system
• Describe the function of EFI system sensors Air Flow meter ,Map sensor ,Air temperature sensor, Water temperature sensor, Throttle position sensor, , Knock sensor, RPM sensor, Oxygen sensor.
• Describe the components of CNG system
• Describe the components of LPG system
Critical Evidence(s) required
Capable identify/service the Petrol Engine.
• Capable to service Diesel engine.
• Capable to service LPG System.
• Capable to service CNG system.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle (petrol and Diesel)
2 Tools trolley (Complete set of hand tools)
3 Complete CNG kit and LPG kit
4 Special service tool for EFI System
4. Diagnose Faults & Repair Hybrid System
Overview
These competency standards designed to enable the learner to work on vehicle Hybrid system and repair or replace the faulty components as directed in the manual.
Unit of Competency Performance Criteria
1. Perform Inspection.
P1. Identify the type of system
P2. Check the components:
• Cable
• Switches
• Modules
• Cooling devices
• Protective devices
P3. Identify the components.
• Missing
• Damage
• Leak
• Loose
• Worn
• Defective components
2. Repair Hybrid system
P1. Diagnose complex system faults
P2. Diagnose and repair high voltage rechargeable energy storage systems in battery electric vehicles
P3. Diagnose and repair traction motor speed control systems in battery electric vehicles
P4. Diagnose and repair traction motor speed control systems in battery electric vehicles
P5. Diagnose and repair auxiliary motors and associated components in battery electric vehicles
3. Diagnose Hybrid system
P1. Diagnose and repair system instrumentation and safety interlocks in battery
P2. Diagnose and repair HVAC and rechargeable energy storage cooling systems in battery electric vehicle
P3. Diagnose and repair DC to DC converters in battery electric vehicles
P4. Diagnose and repair high voltage rechargeable energy storage systems in hybrid electric vehicles
P5. Diagnose complex faults in light vehicle safety systems
4. Verify Repair of hybrid Systems and Components
P1. Use testing tools manually
P2. Verify through computerized system.
P3. Evaluate performance of the components through test drive
P4. Verify the codes pressure, vibration , noise and leak points
P5. Ensure all the devices affix properly.
Knowledge & Understanding
• Describe the final drive main components and functions as following Battery, generator, inverter, Motor, wiring(Harness)
• Describe the function of hybrid Battery
• Describe the function of Generator.
• Describe the function of inverter.
Critical Evidence(s) Required
• Capable identify the faults in Hybrid system.
• Capable to check and replace battery.
• Capable to replace Motor generator.
• Capable to replace the motor.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Hybrid system repair kit
4 Scanner
5. Diagnose Faults & Repair Engine Valve Control System
Overview
These competency standards designed to enable the learner to work engine valve control system and repair or replace the faulty components as directed in the manual.
Unit of Competency Performance Criteria
1. Engine Valve control system
P1. Inspect, adjust and replace components of variable valve timing Intelligence (VVT-i).
P2. Inspect, adjust and replace components of variable valve timing and electric lift control systems (VTEC).
P3. Inspect ,adjust and replace the components VANOS
Knowledge & Understanding
• State the Purpose of Variable valve timing control systems (VVT-I,VTEC ,VANOS)
• Enlist the components of Variable valve timing control systems (VVTI,VTEC ,VANOS)
• Describe the working principles of Variable valve timing control systems (VVT-I,VTEC,VANOS)
Critical Evidence(s) Required
• Capable identify the faults valve control system.
• Capable to check and replace Variable valve timing control systems (VVT-I, VTEC,VANOS).
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Special service kit
4 Scanner
Automotive Transmission AD-363
1. Diagnose Faults &Repair Clutch
Overview
These competency standards designed to enable the learner to adjust and service the clutch related problems of mechanical and hydraulic system as well under the specified procedure in the manual.
Unit of Competency Performance Criteria
1. Repair Clutch System (Manual)
P1. Inspect the main components of clutch for paddle free play, smooth gear changing, clutch cable, drive the can and check pickup, release bearing abnormal noise under the specified safe procedure.
P2. Change/service the clutch cable under specified procedure.
P3. Change the clutch plate while inspecting the release bearing, pilot bearing, clutch pressure plate, fork operation under specified procedure.
2. Repair Clutch System (Hydraulic)
P1. Service/replace clutch master cylinder, slave cylinder under the specified procedure in the manual.
P2. Perform clutch oil bleeding and top up the clutch oil reservoir under specified procedure.
Knowledge & Understanding
• Describes the clutch main components and their functions as following. Clutch cables, self-adjusting mechanisms, master/slave cylinders, pressure plate/cover, clutch
plates, release bearings, gear input shaft front support bearings (pilot),release bearing carriers, fluid, fluid/hydraulic pipes.
• Describe the operational principles of clutch systems. Transmitting torque (turning moment), gradual drive, take-up, neutral gear (at park), drive path
(flywheel/gearbox input).
Critical Evidence(s) Required
• Capable to service/adjust clutch system.
• Capable to change clutch cable.
• Capable to change clutch plate from the vehicle.
• Capable to replace faulty components for hydraulic clutch system.
• Capable to perform clutch bleeding
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack
4 Clutch special tools
Consumable Items:
S. No. Descriptions
1 Master cylinder kit
2 Clutch Fluid
3 Cotton Waste
2. Diagnose Faults &Repair Manual Gear Box
Overview
These competency standards designed to enable the learner to inspect and repair faulty gearbox parts. No repairable parts to be changed under the specified procedure in the manual.
Unit of Competency Performance Criteria
1. Inspect Gearbox (Manual)
P1. Inspect the performance of main components of gear box for lake of drive, noisy operation, difficulty engaging/disengaging gears, jumping out of gears, oil leakage, vibration, excessive movement of gear lever, speedometer inoperative under the specified procedure.
2. Service Gearbox (Manual)
P1. Change the gear shift lever foundation to correct excessive movement of gear lever under the specified procedure.
P2. Change and top up the gear oil under the specified procedure.
P3. Service the gearbox while repairing the faults under the specified procedure.
3. Over Drive Units P1. Inspect the performance of main components of over drive units for lake of drive, noisy operation, difficulty engaging/disengaging gears, oil leakage, vibration, under the specified procedure.
P2. Service of over drive unit under the specified procedure.
P3. Change and top up the gear oil under the specified procedure.
Knowledge & Understanding
• Describe the gearbox main types and there functions as following. Types of gear (Spur, Bevel, Helical) used in gearbox, difference between transaxle and
transmission, front wheel drive and rear wheel drive, difference between all-wheel drive and 4X4
• Describe main components and functions gearbox as following. Input shaft, output shaft, gear selector shaft, reverse gear, synchronizer, gear ratios, reverse
switch, differential, and speedometer sender in the transaxle. Inputs shaft, counter/lay shaft, output shaft, gear ratio, reverse switch, speedometer sender,
synchronizer, and selector shafts in the Transmission.
• Describe the main components and function overdrive as following Input shaft, planetary gear, locking device, output shaft,
Critical Evidence(s) Required
• Capable identify the faults in the gear system.
• Capable to service the gear system.
• Capable to replace gear shift lever foundation.
• Capable to replace the gear oil.
• Capable identify the faults in the over drive system.
• Capable to service the over drive system.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack
4 Gear service special tools
3. Diagnose Faults &Repair Automatic Gear Box
Overview
These competency standards designed to enable the learner to inspect and repair no the gearbox faulty parts or repairable parts to be changed under the specified procedure in the manual.
Unit of Competency Performance Criteria
1. Diagnose Faults in Automatic Transmission System
P1. out road test at different speeds for smooth operations of torque converter and gear shifting according to Manufacturer standard
P2. Check automatic transmission mounting for faults.
P3. Check automatic transmission fluid (ATF) level, according to standard specification and identify leaks if any
P4. Check automatic transmission solenoid by using automotive scanner and identify faults if any
P5. Check electrical controls and Hydraulic pressure of automatic transmission for faults if any
2. Disassemble Automatic Transmission System and Ancillary Components
P1. Remove automatic transmission and disassemble it to check for worn-out/ faulty parts and replace them as per Manufacturer Repair Manual
P2. Check automatic transmission performance by ensuring proper linkages and controls as per standards
P3. Reassemble automatic transmission and refit to the vehicle according to standards
Knowledge & Understanding
This competency standard will provide knowledge related to:
• Occupational Health & Safety (OHS) precautions
• Describe the function of Manual gear box(input shaft, idler shaft, counter shaft, reverse shaft)
• Describe the importance mechanical transmission fluid.
• Describe the function/operation Automatic transmission(Torque converter, pump, clutches, brake band, planetary gear, valve body)
• Describe the function of Automatic transmission fluid.
Critical Evidence(s) required
The candidate needs to produce following critical evidence(s) in order to be competent in this competency standard:
• Capable to service of Manual gear box.
• Capable to service and adjust shift cable.
• Capable to check and replace the gear box oil.
• Capable to service automatic transmission.
• Capable to service and adjust shift cable.
• Capable to replace the Automatic transmission fluid.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack
4 Gear service special tools
4. Diagnose Faults &Repair Final Drive
Overview
These competency standards designed to enable the learner to work on vehicle final drive and repair or replace the faulty components as directed in the manual.
Unit of Competency Performance Criteria
1. Repair propeller shaft
P1. Inspect the performance of main components of propeller shaft like as slip joint, Universal joint, Central bearing, Flexible coupling.
P2. Replace/service the propeller shaft like as slip joint, Universal joint, Central bearing under the specified procedure in the manual.
2. Repair Axle P1. Inspect the performance of main components of final drive for Axle noise during turning of a vehicle, axle rubber boots conditions on CV joints under the specified procedure.
P2. Replace/service the Axle CV Joints outer and inner under the specified procedure in the manual.
3. Repair differential
P1. Inspect the performance of main components of differential for uneven noise during the acceleration, propeller shaft free play, oil leakage, and breather valve assembly under the specified procedure in the manual.
P2. Service/adjust differential assembly under the specified procedure.
Knowledge & Understanding
• Describe the Propeller shaft and main components functions as following Slip joint, Universal joint, Central bearing, Flexible coupling.
• Describe the function dead and live axle, CV joint.
• Describe the operational principles of final drive and differential systems. Final drive, final gear reduction and ratio, differential unit (torque equalizer), torque reaction on
a live rear axle, driving/braking conditions, pinion location in relation to crown wheel.
Critical Evidence(s) Required
• Capable to service of propeller shaft (slip joint, Universal joint, Central bearing, Flexible coupling).
• Capable to service the axle CV Joints.
• Capable to replace differential system.
• Capable to replace the differential oil.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Hydraulic jack
4 special tools
Auto Body Building & Finishing AD-383
1. Understand Vehicle Body Shell
Overview
This unit covers the competencies required to identify external body parts internal body parts, and welded parts, bolted parts and fundamental construction of car body ensuring safe working in such operations and also in the use of related tools and equipment.
Unit of Competency Performance Criteria
1. Identify the body construction
P1. Inspect and identify the external body parts.
P2. Inspect and identify the external body parts.
P3. Identify welded body parts
P4. Identify bolted body parts
P5. Identify the classification of vehicle by shape
2. Identification of Monocoque and Frame type vehicle
P1. Identify the engine support method
P2. Identify center member method
P3. Identify direct mounted method.
P4. Identify fundamental construction of passenger car body
P5. Identify the vehicle classification by space
P6. Identify the crash impact absorbing front & rear area
3. Identification Characteristic of Monocoque & frame type vehicle.
P1. Identify FF type vehicle
P2. P-2 Identify FR type vehicle
P3. P-3 Identification MR type vehicle
P4. P-4 Identification 4WD type vehicle
Knowledge & Understanding
• Basic knowledge of passenger vehicle and commercial vehicle construction.
• Basic Knowledge of Monocoque and Frame type vehicle
• Basic knowledge of FF type vehicle
• Basic knowledge of FR type vehicle
• Basic knowledge of side body FF and FR type vehicle
• Basic knowledge of welded parts
• Basic knowledge of bolted parts
• Basic knowledge of fundamental construction of car body
• Knowledge of various types of car body shape
List of Tools and Equipment
S. No. Descriptions
1 Marker
2 Pen/ Pencil
3 Cotton gloves (PPE)
4 Goggles (PPE)
5 Safety Helmet (PPE)
2. Prepare Cost Estimate for Damaged Vehicle Body and Chassis
Overview
This unit covers the competencies required to inspect a damaged automobile, generate a job sheet, estimate the cost of damage, prepare a quotation and cost a job. In the process of preparing an estimate for repairs, safe working in such operations as well as in the use of related tools and equipment shall be ensured.
Unit of Competency Performance Criteria
1. Assess extent of necessary repair/replacement and identify work to be done
P1. Inspect the vehicle body to ascertain the extent of damage
P2. Identify body work and chassis work to be done
P3. Measurements taken to quantify damage
P4. Identify vehicle body fittings that need to be replaced
P5. Prepare Job sheet for the necessary repairs
2. Obtain quotations and calculate the cost of spare parts/components to be replaced
P1. Prepare Quotations for the necessary replacement parts/components obtained
P2. Prepare Quotations evaluated and the most reasonable quotation based on the price, quality and the choice of the customer,
P3. Calculated Total cost of replacement parts
3. Prepare an estimate of the total cost to the client/insurance company
P1. Calculated Total material cost by getting quotations for materials necessary for the repair
P2. Calculated Total cost of labor by estimating the number of man hours necessary in each category of craftsmen
P3. Calculated Total machinery running and equipment usage cost by listing out the machinery and equipment necessary to carry out the identified load of repair work
P4. Calculated Individual or total overhead cost according to company Policy
P5. Calculated Profit margin in accordance with company policy
P6. Calculated Total cost of repair estimated
P7. Provided Estimate to client / insurance company
Knowledge & Understanding
• Knowledge of body repair & basic of automobile working principles and arithmetic.
• Basic geometry including angular measurements and longitudinal measurements.
• Techniques of measuring body repair work areas, for estimation purposes.
• Safety precautions connected with inspection of damaged vehicles.
• Conversion of measurements from imperial to metric units.
• Knowledge of body layouts.
• Use of current industrial norms in estimation.
• Estimation procedures according to company principles.
• Awareness of current insurance requirements.
• Estimation of current rates for labor material
• Replacement and repair of parts.
• Knowledge of simple metal working practices.
• Knowledge of dismantling procedures.
• Care and maintenance of tools.
List of Tools and Equipment
S. No. Descriptions
1 Measuring Tape
2 Measuring Tools
3 General Hand Tools
4 Calculator
5 Pen/ Pencil
3. Perform Vehicle Body and Chassis Alignment and Repair
Overview:
This unit covers the competencies required to inspect a damaged vehicle body, diagnose the chassis damage, prepare and align the chassis, and reassemble the automobile chassis and body parts ensuring safe working in such operations, and also in the use of related tools and equipment.
Unit of Competency Performance Criteria
1. Inspect a damaged automobile and diagnose the chassis damage
P1. Inspected to identify the total extent of chassis damage.
P2. Assess direct and indirect damage estimated in order to commence repairs / replacements.
P3. Identify the types of metal replacements required to repair the chassis identified.
P4. Identify the Chassis repairs and alignment required determined according to manufacturer’s specifications and company policies.
2. Select tools and equipment and align the chassis
P1. Select Tools and equipment for aligning the chassis to restore the vehicle to original condition
P2. Remove body parts and fittings to facilitate the repair and stored in such a manner as to facilitate retrieval for reassembly.
P3. Protect Electrical/electronic systems to avoid damage during repair.
P4. Carried out Necessary repairs to the chassis follow the safety practices.
P5. Chassis aligned using jigs according to manufacturer’s specifications.
P6. Components welded to complete repair according to manufacturer’s specifications, follow the safety practices.
P7. Verified Chassis measurements according to manufacturer’s specifications.
P8. Prepared and repaired metal areas and painted with primer / prescribed anticorrosive paints according to manufacturer’s specifications.
3. Reassemble chassis and body parts and complete the job
P1. Replaced Chassis parts, aligned and refitted according to manufacturer’s specifications.
P2. Interpreted Wheel alignment report and adjustments made, if necessary, according to manufacturer’s specifications.
P3. Replaced Body parts, aligned and refitted according to manufacturer’s specifications.
P4. Removed all accessories from the automobile, reassembled and fixed to meet original specifications.
P5. All repairs and replacements done recorded for the purpose of costing the job to the customer, according to company policies.
P6. Keep clean work place, tools & equipment properly
Knowledge & Understanding
• Knowledge of body repair & basic knowledge of automobile working principles
• Basic arithmetic
• Basic geometry including angular measurements and longitudinal measurements
• Techniques of interpreting measurements of body work areas listed in estimates
• Safety precautions connected with working with metal sheets and in welding
• Conversion of measurements from imperial to metric units
• Knowledge of body layouts
• Repair procedures according to company principles based on estimate provided.
• Types of chassis and chassis frame construction
• Interpretation of wheel alignment report & diagnosis of chassis defects
• Stiffening of thin sheet metal by mechanical methods such as edging, seaming and flanging
• Knowledge of preventing rust and scale formation
• Basic knowledge of welding consumables.
• Knowledge of reducing warping and distortion of sheet metal during welding
• Use of different types of fire extinguishers.
List of Tools and Equipment
S. No. Descriptions
1 Measuring Tape
2 Measuring Tools
3 Universal Measuring Systems
4 General Hand Tools
5 Body Repair Tools
6 Wire Brush
7 Hydraulic, Pneumatic And Mechanical Pullers
8 Cotton Gloves
9 Welding Unit
10 MIG Welding Wire
11 Welding Gloves
12 Centering Gauges
13 Industry Approved Body Frame Aligner Equipment
14 Drill Machine
15 Grinding Disc
16 Cutting Disc
17 Safety Shoes
18 Safety Helmet
19 Calculator
20 Pen/ Pencil
21 Body Repair Manual
4. Perform Vehicle Body Repairs Work
Overview
This unit covers the competencies required to inspect a damaged automobile, diagnose the body damage, prepare and align the bodywork and reassemble body parts of all types of automobiles, ensuring safe working in such operations and also in the use of related tools and equipment and compliance with government regulation.
Unit of Competency Performance Criteria
1. Diagnose body Damage
P1. Inspect & identify damage body work
P2. Amount of direct and indirect damage identified in order to commence repairs / replacements
P3. Types of metal required to repair the vehicle, determined
P4. Misaligned and damaged parts identified for repair / replacement Any chassis repairs and alignment required, identified
2. Align and repair Bodywork
P1. Tools and equipment required to align and repair the body according to manufacturer’s specifications
P2. All serviceable components that are obstructing the repair removed and stored in such a manner as to facilitate retrieval for reassembly
P3. Electrical/electronic systems protected to ensure that they are not damaged during repair
P4. Necessary repairs to the bodywork carried out and body aligned as necessary to regain the original shape
P5. Bodywork aligned according to manufacturer’s specifications Components welded and sealants applied to complete repair according to manufacturer’s specifications.
P6. Body measurements verified according to manufacturer’s specifications
P7. Parts and fittings checked during repair for damage caused and rectified as necessary
3. Finish body work by preparing the surface for painting
P-1. Repaired metal areas cleaned and primer and under coating applied according to manufacturer’s specifications
P-2. Repaired areas leveled by applying metal filler to restore the body shape so that excessive putty application is not required
P-3. All accessories removed for the repair, refitted in original positions Linings, sound deadener pads and sealers fixed according to manufacturer’s specifications
P-4. Tools and equipment cleaned and returned to appropriate places and work area cleaned
Knowledge & Understanding
• Knowledge of body repair &basic knowledge of automobile working principles
• Basic arithmetic
• Basic geometry including angular measurements and longitudinal measurements
• Techniques of interpreting measurements of body repair work areas listed in estimates
• Safety precautions connected with working with metal sheets and in welding
• Conversion of measurements from imperial to metric units
• Knowledge of body layouts
• Repair procedures according to company principles based on estimate provided.
• Removal of rust and de-rusting mechanically and chemically
• Application procedures of anticorrosive paints & body primer
• Interpretation of wheel alignment report & diagnosis of chassis defects affecting body work
• Use of different types of fire extinguishers
• Government regulations applicable to vehicle specification
List of Tools and Equipment
S. No. Descriptions
1 Measuring Tape
2 Measuring Tools
3 Universal Measuring Systems
4 General Hand Tools
5 Body Repair Tools
6 Wire Brush
7 Hydraulic, Pneumatic And Mechanical Pullers
8 Cotton Gloves
9 Welding Unit (MIG Welder)
10 Washer Welder
11 MIG Welding Wire
12 Welding Gloves
13 Welding Goggle
14 Welding Apron
15 Centering Gauges
16 Industry Approved Body Frame Aligner Equipment
17 Drill Machine
18 Grinder Machine
19 Sealant Gun
20 C-Clamps
21 Equipment For Painting
22 Body Jack
23 Grinding Disc
24 Cutting Disc
25 Safety Shoes
26 Safety Helmet
27 Calculator
28 Pen/ Pencil
29 Body Repair Manual
5. Carryout Panel Repair with Washer Welder Machine
Overview
After successful completion of this module the trainee will be able to perform each task of the following according to the relevant standards and specifications
1. Assessing the range of damage. 2. Repair using hammer and dolly technique. 3. Repair using washer welder. 4. Repair using shrinking method. 5. Assess the repaired panel. 6. Apply anti rust agent in back side of repaired sheet.
Unit of Competency Performance Criteria
1. Assess the range of damage.
P1. Visual inspect and Asses the range of damage
P2. Apply inspection rules –Observe-Touch-Press and compare.
P3. Mark the damage area with marker.
2. Repair using hammer and dolly.
P1. Inspect complete panel and mark the damage area.
P2. Select the hammer and dolly according to required area.
P3. Hold hammer and dolly with S.O.P.
P4. Apply method hammer and dolly technique at damage area.
P5. Time to time check damage surface with undamaged surface.
P6. After completion of repair process it must be compare with undamaged surface.
P7. Clean work place.
P8. Clean tools and equipment’s and store safe place.
3. Repair using washer welder.
P1. Select tool and equipment which is required.
P2. Prepare the panel before repair.
P3. Mark assess the range of damage.
P4. Remove old paint with appropriate method.
P5. Weld the washer for earthling.
P6. Sliding hammer attached with washer welding gun with star bit.
P7. Set the parameter of washer welder first.
P8. Apply washer welder at damage area for removing dents.
P9. Apply copper electrode for removing the burrs.
P10. Check damage area to undamaged area.
P11. Off the washer welder after the completion the work.
P12. Keep the tools and equipment neat and clean and safe condition.
4. Repair using shrinking method.
P1. Select tools and equipment according to the job.
P2. Set the parameter of washer welder.
P3. Attach copper electrode with washer welder gun.
P4. Apply shrinking method.
P5. Cool the surface with air blow gun.
P6. Check the strength of surface from undamaged area.
P7. All tools and equipment cleaned and stored in appropriate places.
Unit of Competency Performance Criteria
5. Assess the repaired area after the completion of panel repair
P1. Inspect all damage area
P2. Apply straight ruler according the S.O.P
P3. Compare damage and undamaged area
P4. The damage area should be lower than the undamaged surface
P5. Apply anti rust agent in back side of repaired sheet
Knowledge & Understanding
• Guideline for Inspection criteria and asses the range of damage
• Knowledge about repairing technique for damage panel
• Knowledge about Remove old paint film according to standard
• Knowledge about hammer and dolly technique with respect to job
• Operation method of washer welder
• Shrinking method application process.
• Washer welder parameter setting procedure
• Assess the repaired area after when work finish to undamaged surface
• Anti-rust application
List of Tools and Equipment
S. No. Descriptions
1 Measuring Tape
2 Measuring Tools
3 Universal Measuring Systems
4 General Hand Tools
5 Body Repair Tools
6 Wire Brush
7 Hydraulic, Pneumatic And Mechanical Pullers
8 Cotton Gloves
9 Welding Unit (MIG Welder)
10 Washer Welder
11 MIG Welding Wire
12 Welding Gloves
13 Welding Goggle
14 Welding Apron
15 Centring Gauges
16 Industry Approved Body Frame Aligner Equipment
17 Drill Machine
18 Grinder Machine
19 Sealant Gun
20 C-Clamps
21 Equipment For Painting
22 Body Jack
23 Grinding Disc
24 Cutting Disc
25 Safety Shoes
26 Safety Helmet
27 Calculator
28 Pen/ Pencil
29 Body Repair Manual
6. Repair Vehicle Body Fittings
Overview
This unit covers the competencies required to inspect a damaged automobile, diagnose the body damage, prepare and align the bodywork and reassemble body parts of all types of automobiles, ensuring safe working in such operations and also in the use of related tools and equipment and compliance with government regulation.
Unit of Competency Performance Criteria
1. preparations for the repair of automobile fittings
P1. Identified Damaged and missing fittings by inspecting vehicle body
P2. Remove Wire harness and all other fittings including which are obstructing the repair, using specified tools and methods.
P3. Undamaged fittings labeled and stored to be retrieved when re-fixing them.
P4. Damaged fittings dismantled for repair or replacement.
P5. Fittings that are irreparable, including missing fittings, identified.
P6. Misalignments and damage caused to repairable fittings identified and the necessary repairs assessed.
P7. Orders placed for the replacement fittings to be received, before Commencement of re-assembly.
P8. Job orders to repair damaged and misaligned fittings by straightening, welding and leveling initiated.
2. Repair fittings and refit them
P1. Tools and equipment required to carry out the repair according to manufacturer’s specifications and government regulations selected.
P2. Necessary repairs to the fittings carried out and shaping done to restore them to original condition.
P3. Fittings aligned according to manufacturer’s specifications.
P4. Fittings welded and leveled to complete repair according to manufacturer’s specifications and government regulations.
P5. Other fittings / parts checked for any damage caused during repairs and rectified as necessary.
P6. Surface protection provided to all repaired fittings as necessary.
P7. Remove other fittings and accessories from the vehicle, refitted.
P8. Arrange Wire harness and re-fixed in original position.
P9. Clean work place, tools & equipment and stored in appropriate places.
Knowledge & Understanding
• Knowledge of body repairing & basic knowledge of automobile working principles
• Basic arithmetic
• Basic geometry including angular measurements and longitudinal measurements
• Techniques of interpreting measurements of work areas listed in estimates
• Safety precautions connected with working with metal sheets and in reverting, soldering and welding
• Conversion of measurements from imperial to metric units
• Knowledge of body layouts
• Repair procedures and company policies
• Use of different types of fire extinguishers.
• Removing methods of upholstery
List of Tools and Equipment
S. No. Descriptions
1 Measuring Tape
2 Measuring Tools
3 Universal Measuring Systems
4 General Hand Tools
5 Body Repair Tools
6 Wire Brush
7 Hydraulic, Pneumatic And Mechanical Pullers
8 Cotton Gloves
9 Welding Unit (MIG Welder)
10 Washer Welder
11 MIG Welding Wire
12 Welding Gloves
13 Welding Goggle
14 Welding Apron
15 Centring Gauges
16 Industry Approved Body Frame Aligner Equipment
17 Drill Machine
18 Grinder Machine
19 Sealant Gun
20 C-Clamps
21 Equipment For Painting
22 Body Jack
23 Grinding Disc
24 Cutting Disc
25 Safety Shoes
26 Safety Helmet
27 Calculator
28 Pen/ Pencil
29 Body Repair Manual
7. Perform Welding Operations on Vehicle Body
Overview
This unit covers the competencies required to perform welding operations in the body repair work of automobiles, ensuring safe working in such operations and also in the use of related tools and equipment.
Unit of Competency Performance Criteria
1. Preparations for welding of automobile body, chassis and other components.
P1. Inspected and identify the body for welding work
P2. Disconnected battery, wire harness and all other components which are obstructing the repair removed, and the serviceable ones labeled and stored to be retrieved when reassembling after welding.
P3. Dismantle damaged components that are to be welded
P4. Select Tools and equipment for leveling, aligning and clamping the components to enable the repair to be carried out according to manufacturer’s specifications.
P5. Surfaces to be welded prepared by grinding, facing and aligning.
2. Weld automobile Chassis, body and other components.
P1. Tools and equipment required for welding the components to enable the repair to be carried out according to manufacturer’s specifications selected.
P2. The type of welding to be carried out on the item determined.
P3. Body and components arranged for welding.
P4. Set the parameter of MIG welding machine according repair
P5. Components aligned according to manufacturer’s specifications.
P6. Components welded and leveled to complete repair according to manufacturer’s specifications.
P7. Quality of fabrication checked by visual inspection.
P8. All components and accessories removed from the automobile before the repair.
P9. Component measurements verified according to manufacturer’s specifications.
P10. Surface protection provided to all repaired components.
P11. Wire harness arranged and re-fixed in original position.
P12. Clean work place, body repair tools, welding equipment and store them in appropriate places
Knowledge & Understanding
• Knowledge of body repairing & basic knowledge of automobile working principles
• Basic arithmetic
• Basic geometry including angular and longitudinal measurements
• Techniques of interpreting measurements of body work areas, listed in estimates
• Safety precautions connected with working with metal sheets and in welding
• Conversion of measurements from imperial to metric units
• Knowledge of welding with gas, arc, spot, TIG, MIG/MAG and polymer welding equipment in respect to automobile
• Knowledge of minimizing warping, distortion and stress formation in sheet metal while welding
• Safe handling and care of various types of welding equipment
• Repair procedures according to S.O.P
• Interpretation of the wheel alignment report & diagnosis of chassis defects affecting the bodywork
• Knowledge of visual inspection / non-destructive testing methods.
List of Tools and Equipment
S. No. Descriptions
1 Measuring Tape
2 Measuring Tools
3 Universal Measuring Systems
4 General Hand Tools
5 Body Repair Tools
6 Wire Brush
7 Hydraulic, Pneumatic And Mechanical Pullers
8 Cotton Gloves
9 Welding Unit (MIG Welder)
10 Washer Welder
11 MIG Welding Wire
12 Welding Gloves
13 Welding Goggle
14 Welding Apron
15 Centring Gauges
16 Industry Approved Body Frame Aligner Equipment
17 Drill Machine
18 Grinder Machine
19 Sealant Gun
20 C-Clamps
21 Equipment For Painting
22 Body Jack
23 Grinding Disc
24 Cutting Disc
25 Safety Shoes
26 Safety Helmet
27 Calculator
28 Pen/ Pencil
29 Body Repair Manual
8. Maintain Machinery, Tools and Equipment
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications.
1. Label tools and equipment for easy identification and store safely. 2. Maintain MIG welder 3. Prepare a monthly plan for maintenance of hand tools 4. Maintain washer welder 5. Maintain frame aligner 6. Inform relevant sections about malfunctioning equipment 7. Use of welding equipment 8. Maintain plasma & gas cutter 9. Maintain pneumatic and power tools
Unit of Competency Performance Criteria
1. Maintain MIG welder
P1. Remove all dirt, dust or debris from the machine and its accessories
P2. MIG welder is to keep covered when not in use
P3. Check all electrical component of MIG welder machine
P4. Drive rolls should be clean & settled properly
P5. Adjust the driver rolls tension properly
P6. Clean gun & nozzle regularly
2. Maintain Washer welder machine
P1. Remove all dirt, dust or debris from the machine and its accessories
P2. Washer welder is to keep covered when not in use
P3. Clean earth cable with dry sand paper
P4. Clean the sliding hammer properly
P5. Service at the proper time
P6. Check all electrical component of washer welder machine
3. Maintain spot welder machine
P1. Remove all dirt, dust or debris from the machine and its accessories
P2. Spot welder is to keep covered when not in use
P3. Check all electrical component of spot welder machine
P4. Clean the air filter of machine
P5. service at the proper time
P6. Clean spot gun properly
P7. Clean & replace welding tools
4. Maintain Grinder P1. Check all bolts and screws for tightness
P2. Check condition of hub or drum assembly and replace flaps, cutters or axles if required
P3. Check the security of all hoses clamps and fittings,
P4. Clean air filter lubricator
P5. Check the vibration of grinder
Unit of Competency Performance Criteria
5. Maintain frame aligner
P1. Remove any dirt or sealer from all pulling clamp of body aligner
P2. Check the leakage of hydraulic oil from pump
P3. Clean all accessories of frame aligner
P4. Check whether there were leaks at the places where the hose was fixed
P5. Check & clean all safety cable of frame aligner
6. Maintain pneumatic tools
P1. Check that all screws on tool are tight.
P2. Keep magazine and feeder mechanism clean.
P3. Lubricate "O" rings that are replaced.
P4. Clean filter element-then blow air through filter in direction opposite to normal flow.
P5. Drain airline filter(daily) and Keep lubricator filled
7. Top up oil level of compressor
P1. Check the oil level of the compressor every day in the morning
P2. Select the type of oil according to that given by the manufacturer
P3. If the oil level has dropped, fill oil up to the marked level
8. Drain water in the air tank of compressor
P1. Check whether there was water in the air tank of the compressor every day in the morning
P2. Drain water by opening the drain tap
P3. Close the tap to prevent air leakage
P4. If there was water while painting, drain the water collected in the air tank following Steps 2 and 3 above
9. Replace air filter of compressor
P1. Decide whether a filter has to be fixed to the compressor or not
P2. Decides a suitable type of filter?
P3. Collect necessary raw materials and equipment after replacing the filter, and operate the compressor again and check whether the air produced was free from water clean and store the equipment
10. Drain water in air regulator
P1. Decide whether water had to be drained from the regulator
P2. Drain the water by activating the knob or the switch key of the regulator
P3. Check a number of times whether the air coming through the regulator was free from water
Knowledge & Understanding
• Guidelines on maintenance of tools and equipment
• Guidelines to be followed and matters to be considered when storing of equipment
• Guidelines to be considered in storage
• Documents used in storing and their maintenance
• Guidelines to be considered in maintaining the frame aligner
• Maintain MIG welder, washer welder, spot welder
• Aspects to be considered in using welding machine.
• Functioning of the welding machine and guidelines to be considered in its maintenance
• Aspects to be considered in updating maintenance register
• Knowledge about the components of the air compressor and pneumatic tools
• Knowledge about guidelines for maintaining air compressors and pneumatic tools
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Cotton Gloves
3 Cutting Disc
4 Safety Shoes
5 Safety Helmet
6 Compressor oil
7 Lubrication oil
8 Cleaning thinner
9. Remove and Fix Glass Items
Overview
This unit covers the competencies required to remove glass items from automobiles before body repairing and painting, and re-fixing after repairs, ensuring safe working in such operations and also in the use of related tools and equipment.
Unit of Competency Performance Criteria
1. Determine the scope of the task in removing specified glass items from frame and re-fixing them
P1. Inspected and identify the specified glass items.
P2. Identify any uneven surfaces, cracks / corrosion on the frames of the specified glass items.
P3. Remove glass without any damages wit specified procedure
P4. Fixing the glass without damages with specified procedure
2. Remove glass items from automobiles and re-fix them
P1. Select Tools and equipment to remove and re-fix glass items from the automobile selected.
P2. Operations to be carried out on the glass frame and beading for removal and fixing without damage
P3. Remove Glass carefully without damaging either the glass or the frame.
P4. Cleaned glass with kerosene, water, detergents etc. as appropriate and stored carefully in a safe place for easy retrieval when re-fixing.
P5. Frame cleaned with kerosene, water, detergents and cutting compound as necessary to produce a smooth surface.
P6. Condition of the prepared frame surfaces checked by visual inspection or by any method using measuring instruments if applicable, to ensure compatibility with the respective glass items.
P7. Any specified paints or other appropriate material applied on the frame surfaces for the prevention of corrosion
P8. Appropriate sealing material applied as required, to ensure a proper fit.
P9. Glass fixed carefully into the frame, ensuring that it is correctly fitted.
P10. Leak test carried out with water to ensure that the joint is leak proof.
P11. Glass and surrounding area cleaned to complete the job.
P12. All glass fixing tools cleaned and stored in appropriate places.
Knowledge & Understanding
• Basic knowledge about different type of glass
• Basic geometry including angular and longitudinal measurements
• Techniques of interpreting measurements of body repair work areas listed in estimates
• Safety precautions connected with working with glass items and frames
• Conversion of measurements
• Knowledge of glass removal and fixing
• Repair procedures according to company standard
• Interpretation of the alignment report & diagnosis of glass frame defects due to accidents and corrosion in the bodywork
• Knowledge of various types of safety glass such as laminated, tempered, reflective, and polymer types such as flexi glass polycarbonates
• Knowledge of various types of paints, sealants and adhesives, and their uses
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Cotton Gloves
3 Goggles
4 Safety Shoes
5 Measuring Tape
6 Mallets in Rubber
7 Cutting Disc
8 Grinders
9 Wire Brushes
10 Sealant Gun
11 Files
12 Glass cleaning equipment
13 Glass primer
14 Glass Sealant
15 Special equipment for fixing glass
16 Suction type glass holders
17 Hand Drills
18 Sealant cutting tool
19 Safety Shoes
20 Safety Helmet
21 Compressor oil
22 Lubrication oil
23 Cleaning thinner
10. Perform Body Surface Cleaning by Mechanical Process
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications.
1. Use power operated wire brush and normal grinder 2. Use double action sander 3. Remove paint on aluminum panels using single action sander 4. Remove rust on vehicle body parts using wire brush and Sandpaper
Unit of Competency Performance Criteria
1. Remove paint in aluminum body using single action sander
P1. Select the areas from which Paint had to be removed.
P2. Take necessary tools and equipment
P3. Prepare the single action sander for removing paint
P4. Removes existing paint using the single action sander.
P5. Smoothen the body surface by applying dry sandpaper
P6. Clean the body surface
P7. Clean the work place and tools and store them properly
2. Surface preparation
P1. Examine the areas marked for removing rust
P2. Take necessary tools and equipment, check their workability.
P3. Prepare the single action sander for removing rust
P4. Remove rust using the single action sander check whether all the rust had been removed
P5. Clean the body using dry sandpaper
P6. Clean the workplace and tools and store them
3. Remove rust using power wire brush
P1. Determine the areas to be clean
P2. Using a power wire brush
P3. Take necessary tools and equipment
P4. Prepare the power wire brush appropriately for relevant job
P5. Remove rust from the determined areas using the power wire brush
P6. Apply dry sandpaper only on places cleaned using the power wire brush
P7. Clean the de-rusted vehicle body parts
P8. Clean the workplace and tools and store them properly
4. Remove rust using Dry sandpaper
P1. Mark the areas from where rust had to be removed.
P2. Select dry sandpaper according to the extent of rusting.
P3. Remove the rust completely using dry sand paper.
P4. Cleans the vehicle body parts and keeps in a suitable place.
P5. Clean the work place and tools and store them properly.
Knowledge & Understanding
• Rusting and steps to be taken to prevent it
• Instructions for removing rust
• Use of double action sander, normal grinder, power wire brush and sand paper and hints on maintaining the above mentioned equipment
• Aspects to be considered when using double action grinder
• Types of double action sander and their functioning
• Aspects to be considered for proper operation of sanders
• Distinguishing properties of aluminum metal
• Dry sandpaper and distinguishing properties of different types, methods and situations of using them
• Hints for selecting required sandpaper
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Cotton Gloves
3 Dust mask
4 Goggles
5 Safety Shoes
6 Measuring Tape
7 Mallets in Rubber
8 Cutting Disc
9 Grinders
10 Single Action Sander
11 Double action sander
12 Wire Brushes
13 Power Wire Brush
14 Files
15 Sand papers
16 Shop Cloth
17 Glass Sealant
18 Safety Shoes
19 Safety Helmet
11. Perform Body Surface Cleaning with Chemical Process
Overview:
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications.
1. Remove rust from corroded vehicle body / body parts using chemicals. 2. Remove existing paint from body parts of vehicles using chemicals. 3. Remove oil and grease on vehicle body / body parts using chemicals. 4. Remove dampness in vehicle body parts using chemicals. 5. Remove silicon in vehicle parts using chemicals.
Unit of Competency Performance Criteria
1. Remove rust using chemicals
P1. Mark the areas from which rust had to be removed
P2. Prepare the necessary tools and chemicals
P3. Wear PPE according to instruction
P4. Mask the areas where rust removing chemicals were not applied
P5. Remove rust by applying the rust removing chemical
P6. Check whether all the rust was removed
P7. Clean vehicle body, tools and equipment and workplace using detergents.
2. Remove existing paint using chemicals
P1. Determine the areas on the body parts from which paint had to be removed
P2. Collect required chemicals and other materials
P3. Wear PPE according to instruction
P4. Remove paint only from areas where paint had to be removed using chemicals
P5. Examine whether all paint had been removed
P6. Perform work in well-ventilated area
P7. Clean the tools, vehicle body parts and the workplaces after finishing work
3. Remove oil and grease using chemicals
P1. Mark the areas covered with oil and grease
P2. Collect the chemicals to be applied and tools
P3. Apply chemicals in relevant areas and remove oil and grease
P4. Examine whether all the oil and grease were removed
P5. Perform work in well-ventilated area
P6. Clean the tools and the workplace after finishing work
4. Remove dampness of body surface
P1. Select the areas with oil and grease on the vehicle body
P2. Prepare necessary tools and chemicals
P3. Wear PPE according to instruction
P4. Apply chemicals on the damp areas and remove oil and grease
P5. Check whether vehicle body was fully dry
P6. Clean the tools and the workplace after finishing work
5. Remove silicon using chemicals
P1. Examine well and identify the area from which silicon had to be removed
Unit of Competency Performance Criteria
P2. Prepare the required chemicals and tools
P3. Apply chemicals on areas coated with silicon
P4. Remove silicon using chemicals according to the instructions of the manufacturer
P5. Check whether silicon had been removed
P6. Clean the tools and the workplace after finishing work
Knowledge & Understanding
• Types of chemicals used to remove existing paint, rust, oil and Grease, dampness and silicon from vehicle body parts and their qualities.
• Guidelines and safety measures to be followed in the use of chemicals.
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Chemical resistance gloves
3 Respirator
4 Goggles
5 Safety Shoes
6 Paint Remover
7 Rust Remover
8 Degreaser
9 Shop Cloth
10 Masking Tape
11 Masking Paper
12 Sealant cutting tool
13 Safety Shoes
14 Safety Helmet
15 Cleaning thinner
12. Maintain Vehicle Body Repair Tools, Equipment and Machinery
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications.
1. Label tools and equipment for easy identification and store safely. 2. Maintain polisher 3. Prepare a monthly plan for maintenance of hand tools 4. Make a sanding block 5. Maintain sanding machine 6. Inform relevant sections about malfunctioning equipment 7. Dismantle spray gun and record its performance 8. Use spray gun cleaner 9. Connect the spray gun to the air compressor and activate the air compressor.
Unit of Competency Performance Criteria
1. Maintain polisher P1. Remove, wash, dry and store the pads of the polisher
P2. Clean the polisher with compressed air and store
P3. Service the polisher at the proper time
2. Maintain sanding machine
P1. Clean the dust extraction bag
P2. Check the amount of oil required for the machine
P3. Control air current obtained from the compressor
P4. Clean the sanding machine with compressed air and store it
P5. Service at the proper time
3. Clean spray gun manually
P1. Dismantle separately the spray gun, the nozzle, the bottle and the cap after applying one kind of paint
P2. Wash each of them separately using cleaning thinner kerosene
P3. Cleaning the nozzle, did you insert a thin wire and remove the paint in the vent
P4. Place the nozzle inside the bottle of spray gun and store all the parts securely
4. Clean spray gun using gun cleaner
P1. Dismantle the spray gun into separate parts
P2. Prepare spray gun cleaning liquid and pour it into the gun cleaner
P3. Place in the cleaning machine the parts dismantled from the spray gun(nozzle, bottle, cap, control lever (trigger)
P4. Activate the machine and wash the parts twice or more number of times(until all the paint was removed)
P5. Put thinner to the washed and cleaned parts and assemble again
P6. Store the spray gun in a secure place
5. Replace compressor air hose
P1. Take the tools needed to fix the hose to the air compressor to the relevant place
P2. Select the hose to be fixed to the air compressor according to the instructions of the manufacturer
P3. Fix the hose to the compressor using couplings
P4. Check whether there were leaks at the places where the hose was
Unit of Competency Performance Criteria
fixed by activating the compressor
P5. Clean and store the tools and equipment
6. Replace spray gun repair kit
P1. Dismantle parts of the spray gun separately according to the instructions of the manufacturer
P2. Select the repair kit of the spray gun according to the part number of the manufacturer
P3. Assemble the spray gun again using the repair kit according to the instructions of the manufacturer
P4. Check whether there were air leaks by connecting the spray gun to the air compressor
P5. Clean and store securely the spray gun
7. Top up oil level of compressor
P1. Check the oil level of the compressor every day in the morning
P2. Select the type of oil according to that given by the manufacturer
P3. If the oil level has dropped, fill oil up to the marked level
8. Drain water in the air tank of compressor
P1. Check whether there was water in the air tank of the compressor every day in the morning
P2. Drain water by opening the drain tap
P3. Close the tap to prevent air leakage
P4. If there was water while painting, drain the water collected in the air tank following Steps 2 and 3 above
9. Replace air filter of compressor
P1. Decide whether a filter has to be fixed to the compressor or not
P2. Decides a suitable type of filter?
P3. Collect necessary raw materials and equipment after replacing the filter, and operate the compressor again and check whether the air produced was free from water clean and store the equipment
10. Drain water in air regulator
P1. Decide whether water had to be drained from the regulator
P2. Drain the water by activating the knob or the switch key of the regulator
P3. Check a number of times whether the air coming through the regulator was free from water
Knowledge & Understanding
• Guidelines on maintenance of tools and equipment
• Guidelines to be followed and matters to be considered when storing finishing equipment
• Guidelines to be considered in storage
• Documents used in storing and their maintenance
• Guidelines to be considered in maintaining the polisher
• Maintain single action and double action sander and their functions
• Aspects to be considered in using sanding machine.
• Functioning of the sanding machine and guidelines to be considered in its maintenance
• Aspects to be considered in updating maintenance register
• Knowledge about the components of the air compressor and the spray gun
• Knowledge about guidelines for maintaining air compressors and spray gun
•
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Cotton Gloves
3 Compressor Oil
4 Lubrication Oil
5 Cleaning Thinner
13. Maintain Paint Booth and Stores
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications.
1. Maintain paint booth Sealing filters, Floor filter, pre filter 2. Replacement of paint booth filter 3. Fuel filling in fuel tank of paint booth burner 4. Store material in order position 5. Update the documents relevant to stores when raw materials and chemical 6. Understanding of 5S and ISO method
Unit of Competency Performance Criteria
1. Maintain paint booth filters
P1. Take the air filter out and blow air into it
P2. Cleans the inside of paint booth using an air hose
P3. Fixes the air filter blowing air to clean it
P4. Operate air filter in the paint booth for at least half an hour
P5. Air filter was more than 18 month old replace it with a new one
2. Maintain cleanliness of paint booth
P1. Decide on the parts to be cleaned
P2. Gather the tools / equipment and materials
P3. Test the functioning of tools /equipment
P4. Remove the vehicle, paint and other material
P5. Clean the interior of the paint booth using a vacuum cleaner
P6. Close doors to prevent the entry of dust
P7. Store the tools / equipment properly
3. Replace paint booth filter
P1. Decide on the task to be performed
P2. Gather tools and equipment
P3. Test the condition of tools and equipment If paint dust remains inside often after painting about 100 vehicles,
P4. Remove filters from their attachments
P5. Clean the places where filters and their supports were fixed using a vacuum cleaner
P6. Select filter according to the accessory number of paint booth manufacturer
P7. Fix that filter according to the instructions of manufacturer
P8. Test the functioning of the filter
P9. Store the tools / equipment properly after completion the work.
4. Fill fuel in paint booth furnace / burner
P1. Identify the fuel tanks of the paint booth
P2. Examine the fuel tanks of the paint booth
P3. Fill the fuel tanks with not more than the required quantity of fuel
P4. Remove electric wires and inflammable materials
P5. Fix fire extinguishing equipment
P6. Fix alarm sign
5. Store materials P1. Separate raw materials (types of chemical paints), inflammable materials and poisonous materials
Unit of Competency Performance Criteria
P2. label all the materials for easy identification (using suitable diagrams or names) and store them in the correct places
P3. Store inflammable materials separately from other materials
P4. Store these materials under environmental conditions as stated by the manufacturer of such materials
P5. Keep records of receipts and issues of materials
6. Maintain paint stores
P1. label paint and other chemicals and store them separately
P2. Store tools and equipment enabling easy access
P3. Note down places where fans and blowers required for raw materials are fixed
P4. Update the documents relevant to stores when raw materials and chemical substances get spilled inside the stores,
P5. Mention how they should be removed without catching fire
P6. Remove unusable materials from the stores
7. Store tools and equipment
P1. Separate tools and equipment according to their use and value
P2. Provide numbers / labels to identify every tool and equipment
P3. Decide on the place for storing each tool and equipment
P4. Decide about safe places for storing valuable tools and equipment
P5. Label such places
P6. Store tools and equipment at the relevant places
P7. Enter information about tools and equipment in the stock-book
P8. Sort out the malfunctioning tools and equipment and store them separately
P9. Maintain data about malfunctioning tools and equipment
Knowledge & Understanding
• Different materials used in painting and their properties
• Types of filters and their properties, their applications and manufacturer’s instructions
• The guidelines to be considered in maintaining filters
• A brief introduction about the 5S method and ISO 14000
• Fuel tanks and their maintenance
• Guidelines regarding stores and maintenance of materials stored
• Techniques of cleaning
• Classification of paints, cost of painting materials and distinguishing inflammable materials
• Aspects to be considered in storing paint
• Safety precautions to be adopted in maintaining stores
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Cotton Gloves
3 Dust Mask
4 Air Compressor
5 Air blow Gun
6 Shop cloth
14. Apply Polyester Putty
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications.
1. Assessment the range of damage 2. Surface preparation 3. Putty application 4. Putty shaping 5. Putty sanding 6. Filler application
Unit of Competency Performance Criteria
1. Assessment the range of damage
P1. Collect the necessary tools & equipment
P2. wear the necessary safety gear.
P3. Clean the panel so aS. No.t to overlook damage
P4. Assess damaged area by (observe, Touch, Press, Compare )
P5. Mark the top, bottom, left and right limits and define the range of damage.
P6. Assess the dent and bump on the surface.
P7. Check the tension of the damage panel
P8. Assess the differences by comparing damaged area to undamaged area
P9. Define the range of damage
2. Surface preparation
P1. Identify the areas to be prepare
P2. Collect the necessary tools, equipment and materials
P3. Prepare the areas to be protected
P4. Prepare the panel for putty application
P5. Remove old paint coat and rust to within the marked area.
P6. Sand the surface with a single-action sander using 60 to 80 grit sandpaper
P7. Smooth out the step between the bare metal and original paint film
P8. Attach 120 grit sandpaper to the dual action sander for sanding
P9. Remove dirt, dust and grease from the surface to prevent irregularities.
P10. Wipe off the area with a shop cloth
P11. Blow air after removing any dirt or dust with a shop cloth
P12. Apply primer to exposed bare metal
3. Apply polyester putty manually
P1. Identify the areas for applying the putty
P2. Collect the tools & equipment and materials
P3. Wear PPE according to instruction
P4. Mix the putty and the hardener
P5. Mix the putty by moving the mixing stick up and down while turning the can.
P6. Tighten the cap of tube and massage the entire tube to mix the
Unit of Competency Performance Criteria
hardener
P7. Combine the putty and hardener for mixing ratio follow the manufacturer instruction.
P8. Apply putty thinly within 10mm of the outer edge of the scuffed area.
P9. Apply putty higher than the undamaged surface overlaps 1/3 of the previously applied putty.
P10. Clean the workplace tools & equipment and store them properly.
4. Putty sanding by Dry sanding machine
P1. Identify the areas to be sanded
P2. Collect the tools equipment and materials
P3. Wear PPE according to instruction
P4. Identify the parts to be protected
P5. Adjust the tools and equipment for sanding
P6. Stand in a position where the sander can reach both ends of the putty application area easily
P7. Start sanding when the putty and panel reach room temperature
P8. Use a sander with 80 grit sandpaper to remove dent or bump from putty surface
P9. Sand the putty surface to 80% of the correct surface with 120 grit sand paper
P10. Sand the putty surface to 90% of the correct surface with 180 to 220 grit sand paper
P11. Sand with 320 grit sandpaper for surface finishing
P12. Check the finish of putty surface remove all abrasion mark
P13. Clean the work place tools & equipment and store them properly
5. Putty sanding by Hand sanding block
P1. Identify the areas to be sanded
P2. Collect the tools equipment and materials
P3. Wear PPE according to instruction
P4. Identify the parts to be protected
P5. Attached the hand sanding block with dust extraction machine
P6. Stand in a position where the hand sanding block can reach both ends of the putty application area easily
P7. Start sanding when the putty and panel reach room temperature
P8. Use a hand sanding block with 80 grit sandpaper to remove dent or bump from putty surface
P9. Sand the putty surface to 80% of the correct surface with 120 grit sand paper
P10. Sand the putty surface to 90% of the correct surface with 180 to 220 grit sand paper
P11. Sand with 320 grit sandpaper for surface finishing
P12. Check the finish of putty surface remove all abrasion mark
P13. Clean the work place tools & equipment and store them properly
6. Apply one pack nitrocellulose primer filler
P1. Take a decision regarding the weather
P2. Decide on the areas for application of NC filler
P3. Decide on the areas to be protected
Unit of Competency Performance Criteria
P4. COLLECT the tools, equipment and materials
P5. Check the workability of tools and equipment
P6. Wear PPE according to instruction
P7. Mix NC paint using weighing scale according to ( MSDS )
P8. Filter the paint and pour in to the spray gun
P9. Adjust the pressure of air
P10. Adjust the spray gun according repair area
P11. Clean the surface with cleaning thinner
P12. Air blowing on surface to remove dirt particle on surface
P13. Apply tack cloth
P14. Apply paint on surface according to paint spraying method
P15. Clean the spray gun after work finish
P16. Clean the work place, tools & equipment and store them properly
7. Apply 2 pack Urethane type filler
P1. Take a decision regarding the weather
P2. Decide on the areas for application of urethane type filler
P3. Decide on the areas to be protected
P4. Collect the tools, equipment and materials
P5. Check the workability of tools and equipment
P6. Wear PPE according to instruction
P7. Mix urethane primer and hardener using weighing scale according to ( MSDS)
P8. Filter the primer and pour in to the spray gun
P9. Adjust the pressure of air
P10. Adjust the spray gun according repair area
P11. Clean the surface with cleaning thinner
P12. Air blowing on surface to remove dirt particle on surface
P13. Apply tack cloth
P14. Apply paint on surface according to paint spraying method
P15. Clean the spray gun after work finish
P16. Clean the work place, tools & equipment and store them properly
8. Apply nitrocellulose putty
P1. Make a decision about the weather
P2. Determine the areas to be filled
P3. Identify the areas to be protected
P4. Collect the tools, equipment and materials
P5. Wear PPE according to instruction
P6. Test the workability of the rubber pad
P7. apply putty between 900- 600 for small holes / defects
P8. apply again using reduced pressure
P9. Clean the workplace and the tools / equipment and store the tools /equipment
P10. Allow to dry for 1 hours
Knowledge & Understanding
• Types of metal filler, high filler, and one pack nitrocellulose primer filler, nitrocellulose putty; their qualities and information on using them
• Guidance to be followed in the use of above material
• Hints on leveling metal filler by wet method and dry method
• Hints for deciding areas that do not require any application
• Hints for deciding the suitable weather for applications
• Properties of raw materials used for application and their usage
• Types of metal fillers and their properties
• Instructions to be followed during applications
• Hints for leveling using a machine
• Hints on detecting defects of the vehicle body by touch and observation
• Information about sand papers
• Types of high fillers and instructions on using them
• Instructions to be followed polyester putty & filler
• Types of nitrocellulose; their use and properties
• Information on polyester putty and its use
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Solvent Resistance Gloves
3 Apron
4 Google
5 Respirator
6 Dry Sanding Machine
7 Sanders
8 Hand Sanding Block
9 Weighing Scale
10 Paint Mixing Stick
11 Putty Spatula
12 Air Compressor
13 Spray Gun
14 Air blow Gun
15 Shop cloth
16 Polyester Putty
17 NC Putty
18 NC Primer
19 Urethane Primer
20 Orbital Sand Papers
21 Sand Paper for Hand Block
15. Prepare Paint Booth and Vehicle
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications.
Unit of Competency Performance Criteria
1. Mask required body parts
P1. Decide what coating to be applied
P2. Decide what body parts do not need the particular coating
P3. Select materials and tools required to mask those body parts
P4. Cover such body parts with masking tape or some other material to prevent paint dripping on to them when applying
P5. Clean tools and equipment and store them
2. Remove dust on painted surface
P1. Identify the areas to be painted
P2. Select the required equipment and material
P3. Use suitable water sand paper
P4. Scrub off the dust layer
P5. Check whether parts covered with dust were scrubbed off
P6. Clean the place where the task was performed and store equipment and material
3. Adjust paint booth temperature
P1. Determine the weather condition in making the decision
P2. Check whether the sensors in the paint booth were kept in the places mentioned by the manufacturer
P3. Adjust the temperature regulator in the room to the required temperature
P4. Measure the internal temperature.
P5. Determine correctly the task at hand and the relevant temperature
P6. Check whether the machines and equipment operated as stated by manufacturer
4. Fix water separating filter
P1. Examine whether there was a defect in the water separating filter
P2. Prepare the required tools and equipment
P3. Unfix and remove the water separating filter
P4. Select water separating filter of the particular type
P5. Fix it at the correct location
P6. Clean and store tools and equipment
5. Adjust paint booth burner / furnace
P1. Mask the parts that needed to be protected
P2. Gather the tools / equipment and the materials
P3. Check whether there was fuel / electricity leakage in the vehicle that was painted
P4. Remove paint / thinner from the paint booth
P5. Check whether the burners were in working order
P6. Locate the vehicle at the center of the paint booth
P7. Close all the doors of paint booth
P8. Check whether the fire extinguishing equipment was functioning
P9. Adjust both / all the plugs in the burners to emit a high temperature
P10. Operate all the burners
Unit of Competency Performance Criteria
P11. Prepare for the next task until the green bulb in the thermometer turned red and stopped automatically
6. Adjust paint booth heating timer
P1. Decide the time required for heating according to the intended paint
P2. application and the job
P3. Adjust both / all the timers as to indicate the same time
P4. Adjust the relevant timers according to the required time
7. Operate paint booth ventilator feed air fan
P1. Gather the tools / equipment and material
P2. Check whether they were functioning properly
P3. Prepare the vehicle to be painted/ paint and were you ready
P4. Check whether the feed / exhaust air fan in paint booth was functioning
P5. Switch on the fan
P6. Switch off the feed / exhaust fan in the paint booth after painting
Knowledge & Understanding
• Instructions for removing dust on the body parts before painting
• Aspects to be taken into consideration in removing dust (safety)
• Instruction for controlling the internal temperature of the paint booth
• Instruction for safety precautions to be adopted when adjusting the internal temperature
• Instruction for functioning of a water separating filter
• Reasons for draining water from the air system
• Aspects to be taken into consideration in adjusting the heating furnace in the paint booth
• Instruction for safety precautions to be adopted in adjusting the heating furnace
• Instruction the necessity of adjusting the heating timer in the paint booth
• Aspects to be considered in adjusting the heating timer
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Cotton Gloves
3 DustMask
4 Air Compressor
5 Air blow Gun
6 Shop cloth
7 Masking tape
8 Masking Paper
9 Sand Paper
16. Apply Primer Surfacer
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications.
Unit of Competency Performance Criteria
1. Scuffing for primer Surfacer with sanding machine
P1. Determine the areas for scuffing primer Surfacer
P2. Determine the areas that need to be masking
P3. Collect tools, equipment and material
P4. Check functioning of equipment
P5. Wear PPE according to instruction
P6. Attached 320 grit sand paper with dual action sander
P7. Adjust the revolution speed of dual action sander
P8. Scuff the surface to a distance of 100mm from the edge
P9. Bring the sander into contact with the panel before starting the sander
P10. Scuffing the act of finely scratching a surface with sandpaper
P11. Clean the work place
P12. Clean tools & equipment and store them properly
2. Scuffing for primer Surfacer with hand sanding block
P1. Determine the areas for scuffing primer Surfacer
P2. Determine the areas that need to be masking
P3. Collect tools, equipment and material
P4. Check the pad of sanding block
P5. Wear PPE according to instruction
P6. Attached 320 grit sand paper with hand sanding block
P7. Attached hand sanding block with dust extraction machine
P8. Scuff the surface to a distance of 100mm from the edge
P9. Hold the sanding block at 45degrees to direction of sanding
P10. Scuffing the act of finely scratching a surface with sandpaper
P11. Clean the work place
P12. Clean tools & equipment and store them properly
3. Cleaning °reasing before primer Surfacer application
P1. Determine the area for cleaning & degreasing
P2. Collect the necessary tools / equipment and materials
P3. Wear PPE according to instruction
P4. Wipe the area with shop cloth which is socked in degreaser
P5. Blow air on the surface to dry the degreaser
P6. Wipe away any dirt or dust with a tack cloth Without applying pressure
P7. Clean work area
P8. Clean tools & equipment and store them properly
4. Masking before primer Surfacer application
P1. Determine the parts & body for masking
P2. Gather tools / equipment and materials
P3. Protect all body for over spray use masking foil
P4. Mask the openings after remove fittings.
Unit of Competency Performance Criteria
P5. Mask the gaps between the panel
P6. Use reverse masking to avoid creating a step around the edge of the repainted area
P7. Clean the work place
P8. Clean Tools & equipment and store them properly
5. Mixing of primer Surfacer
P1. Decide the area where primer Surfacer is to be applied
P2. Calculate the amount of primer to be Mixed
P3. Collect tools / equipment and materials
P4. Mix it primer Surfacer & hardener according to manufacturer’s instructions
P5. Calibrate the weighing scale at zero
P6. Pour the primer Surfacer in to the mixing container according to job
P7. Pour the hardener in to the container according to manufacture instruction
P8. Mix all component properly using a mixing stick
P9. Clean work place
P10. Clean tools / equipment and store them properly
6. Primer Surfacer application
P1. Determine the areas Primer Surfacer to the applied
P2. Mask the body that need to be protected
P3. COLLECT tools / equipment and materials
P4. Check whether the tools / equipment are functioning
P5. Strain the primer Surfacer using a strainer according to instruction
P6. Pour the primer Surfacer in to the spray gun
P7. Adjust the air pressure according to instruction
P8. Adjust the spray gun
P9. Apply primer Surfacer according to specified method
P10. Clean the spray gun after work finish
P11. Clean the work place tools & equipment and store them properly
7. Drying of primer Surfacer From infrared heater
P1. Determine the area for drying of primer Surfacer
P2. Collect tools / equipment and materials
P3. Wear PPE according to instruction
P4. Connect the power cable securely
P5. Adjust the distance of infrared heater between panel
P6. Adjust the timer of infrared heater according to standard
P7. Dry the primer Surfacer according to manufacturer instruction
P8. Clean and store tools/ equipment and store them securely
Knowledge & Understanding
• Types of primer Surfacer
• Mixing of primer Surfacer
• Types of anticorrosive paints and their properties
• Instructions to be followed when using anticorrosive paints
• Types of infrared heater and drying procedure
• Types of foam and properties
• Instructions for mixing of hardener
• Types of mixing thinner and there use according to temperature
• Instructions on determining application condition
• Types of hardener and there use
• Instructions related to application of primer Surfacer
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Solvent Resistance Gloves
3 Spray Suit
4 Spray Gun
5 Respirator
6 Air Compressor
7 Air blow Gun
8 Paint Booth
9 Weighing Scale
10 Mixing Stick
11 Shop cloth
12 Masking tape
13 Masking Paper
14 Sand Paper P-300
15 Primer Surfacer
16 Hardener
17 Mixing Thinner
17. Perform Color Matching & Mixing
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications
Unit of Competency Performance Criteria
1. Decide type of paint to be applied
P1. Discuss to decide the customers requirement
P2. Decide on different types of paint to be applied
P3. Prepare approximate estimates
P4. Decide on the type of color
P5. Decide on the price based on agreement with the customer
2. Measure existing color of vehicle body
P1. Decide the area where paint is to be applied
P2. Select the required tools and equipment
P3. Take the vehicle to a place with suitable lighting condition
P4. Keep the color gauge on the vehicle and obtain data
P5. Get paint prepared and examined from a color matching
3. Match colors to be applied
P1. Obtain information about the color to be applied by discussing with the customer
P2. Compare the required color with the color card
P3. Prepare colors by mixing primary colors in different ratios
P4. Apply paint on a part of the vehicle and compare (by looking at 450 )
4. Mix paint colors
P1. Select primary color mixtures
P2. Prepare necessary weighing scale and measuring instruments for matching colors
P3. Get color volumes from the computer for matching color
P4. Mix colors according to volumes to get the required color
P5. Match colors by applying on another metal sheet before applying it on the vehicle
P6. Compare either with color code or with the color of vehicle to check whether the required color was obtained
P7. Calculate the volumes of paints to be used Accordingly
P8. Prepare the required quantities (liters) of paint
P9. Clean and store the tools and equipment used for mixing
5. Mix component colors using computer
P1. Operate color mixing computer at color matching room
P2. Obtains the available color code or color catalogue number according to customer’s request
P3. Enter the color code in the computer and obtain primary colors ratios
P4. Measure volume ratios using an electronic weighing machine
P5. Pour the measured volumes of paint into a clean vessel and stir it
P6. Compare the prepared mixture with the color to be applied
P7. Clean and store the tools and equipment
P8. Shut down the computer after getting the relevant information
6. Decide basic color ratios
P1. Identify clearly the given colors
Unit of Competency Performance Criteria
P2. Decide the primary colors of which the particular color is made of
P3. Mix primary colors in different ratios to find the ratio of primary colors
P4. Calculate the primary color ratios after it was matched
P5. Clean and store the tools and equipment
7. Adjust paint viscosity
P1. Mix paint to be applied using a mixing stick
P2. Measure the paint using ICI measuring ruler and pour into a clean vessel
P3. Measure an equal volume of thinner with the same measuring rulerand pour into the vessel
P4. Mix paint and thinner According to manufacture instruction
P5. Check the viscosity of the mixture using measured volumes ofpaint and thinner until the required viscosity was obtained
P6. clean the used equipment with thinner after obtaining the required viscosity
Knowledge & Understanding
• Guideline for shade card, formula chart, color tint guide
• Guide lines to use the color gauge
• Techniques used to match colors
• Guide lines to mix colors manually
• Paint colors and their characteristics
• Guide line to select basic colors and ratios
• Decide quality of paints
• Effects of light conditions in matching colors and color matching light
• Understand basic color, secondary color, and complimentary color
• Identify types of paints using different methods
• Factors to be considered in comparing colors
• Calculate the quantity of paint
• Hints on obtaining the required colors mixing quickly by identifying new colors
• Use of computers for mixing ratio
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Solvent Resistance Gloves
3 Google
4 Spray Suit
5 Spray Gun
6 Respirator
7 Air Compressor
8 Air blow Gun
9 Paint Booth
10 Weighing Scale
11 Mixing Stick
12 Shop cloth
13 Computer with formula software
14 Mixing color with mixing rack
15 Mixing Container
16 Mixing Thinner
17 Mixing Stick
18 Sand Paper P-300
19 Primer Surfacer
20 Hardener
21 Mixing Thinner
18. Apply Body Sealer
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications
Unit of Competency Performance Criteria
1. Scuffing for body sealing
P1. Collect tools & equipment for scuffing
P2. Wear PPE according to instruction
P3. Scuff the area with double action sander use 600 grit sand paper
P4. Scuff with 600 grit scuffing material in locations where it is impossible to use a dual action sander
P5. Scuff the area, as it will be difficult to scuff after applying body sealer the paint manufacturer
P6. Clean the work place tools & equipment and store them properly
2. Nozzle processing
P1. Collect tools & equipment for nozzle processing
P2. Wear PPE according to instruction
P3. Cut the tip of nozzle according to required shape of the sealer
P4. Cutting both size to form a peak shape
P5. Cutting one side of a peak shape
P6. Press with pliers
P7. Cut the other side so that it is flat
P8. Clean the work place tools & equipment and store them properly
3. Cleaning & degreasing
P1. Decide on the areas to be clean
P2. Collect necessary tools & material
P3. Clean and degrease the surface where body sealer is to be applied
P4. Blow air across the surface to remove dirt and dust
P5. Wipe the surface with a shop cloth soaked id degreaser
P6. Wipe away any dirt or dust with a tack cloth
P7. Clean the work place
P8. Clean tools & equipment and store them properly
4. Application of body sealer
P-1. Wear PPE according to instruction P-2. Collect the essential equipment and materials P-3. Grasp the lever with your dominant hand, and hold your other in the
vicinity of the nozzle P-4. Adjust the air pressure Use low air pressure to apply the sealer in
a narrow and thin manner P-5. Adjust the air pressure Use high air pressure to apply the sealer in
a wide and thick manner P-6. Adjust the angle of sealing gun P-7. Adjust speed and movement of sealer gun P-8. Find a position that allows you to stand in one place and apply the
sealer from start to finish without moving P-9. Use a rubber spatula to shape the body sealer P-10. Clean the work place tools & equipment and store them properly
Knowledge & Understanding
• Types and composition of body sealer
• Preparation for body sealer
• Purpose of body sealer application
• Instructions on preparation for application of body sealer
• Relevant details of body sealer
• Guidelines and safety precautions to be followed in the application of body sealer
• Understanding of location and shape of body sealer
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Solvent Resistance Gloves
3 Google
4 Body Sealing Gun
5 Spatula
6 Respirator
7 Air Compressor
8 Air blow Gun
9 Knife Cutter
10 Weighing Scale
11 Mixing Stick
12 Shop cloth
13 Mixing Thinner
14 Mixing Stick
15 Body Sealer
16 Cleaning Thinner
19. Perform Masking
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications
Unit of Competency Performance Criteria
1. Preparation before masking
P1. Determine the area for cleaning & degreasing
P2. Collect the necessary tools / equipment and materials
P3. Wear PPE according to instruction
P4. Wipe the area with shop cloth which is socked in degreaser
P5. Blow air on the surface to dry the degreaser
P6. Wipe away any dirt or dust with a tack cloth Without applying pressure
P7. Clean work area
P8. Clean tools & equipment and store them properly
2. Masking on opening area
P1. Collect tools & equipment for masking
P2. Wear PPE according to instruction
P3. Insert your middle finger into the hole in the roll, pull out the desired length of tape
P4. Mask the openings left after fittings are removed
P5. Make sure that masking tape will not be peeled off by the air pressure
3. Masking on gaps P1. Collect tools & equipment for masking
P2. Wear PPE according to instruction
P3. Mask the gaps between the panels use gap tape
P4. Pay extra attention to the upper and lower edges when masking the front and rear door gaps
4. Masking on fitting & glass
P1. Collect tools & equipment for masking
P2. Wear PPE according to instruction
P3. Mask the borders of the fittings last using 18mm masking tape
P4. Leave a gap the thickness of the paint coat between the panel surface and the masking tape
P5. Mask the areas that require fine line tape first
P6. Mask the glass moldings that come into direct contact with the paint surface
P7. After painting, remove the masking tape at a 90-degree angle to the vehicle’s surface.
Knowledge & Understanding
• Purpose of masking
• Types of masking tape and masking paper and masking foil
• Use of masking material
• Instructions on preparation for masking
• Relevant details of masking equipment
• Guidelines and safety precautions to be followed in masking procedure
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Cotton Gloves
3 Masking Dispenser
4 Knife Cutter
5 Masking Tape
6 Shop cloth
7 Masking Papers
8 Masking Foil
9 Cleaning Thinner
20. Apply Under Coat
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications
Unit of Competency Performance Criteria
1. Apply undercoats
P1. Collect necessary tools & equipment
P2. Wear PPE according to instruction
P3. Mask all the body parts of the vehicle except those that were to be painted
P4. Mix filler or primer with thinner according to the instructions of the paint manufacturer
P5. Measure the viscosity of the mixture According to instruction of the paint manufacture
P6. Fill the spray gun with the prepared mixture and start the air compressor
P7. Adjust the nozzle of the spray gun and test the uniformity of the spray
P8. Start the spray gun and apply the undercoat uniformly follow the method of application
P9. Check the under coat was uniformly applied covering all the areas
P10. Allow it to dry for 15 minutes
P11. Wash the vessels and equipment used with thinner
2. Apply one pack solid color paint
P1. Collect necessary tools & equipment
P2. Wear PPE according to instruction
P3. Obtain paints and thinner
P4. Open the can, safely and mix the paint to have a uniform color
P5. Measure the quantity of paint by putting it into a separate vessel
P6. Close the can with the remaining paint and keep it air tight
P7. Mix paint and thinner according to MSDS
P8. Adjust the air pressure to the required level
P9. Add paint to the spray gun (to 3/4 of its volume)
P10. Spray paint by holding the spray gun at the appropriate distance in accordance with the prescribed method
P11. Allowing it to dry for the required period
P12. Clean and store the tools and equipment
3. Apply two pack metallic pearl color paint
P1. obtain the required brands and quantities of 2K metallic pearl color paint and thinner
P2. Collect the essential equipment and materials
P3. Obtain the spray gun 1.2 mm or 1.3 mm nozzle
P4. Mix the paint homogeneously
P5. Measure the required quantity of paint with the gauge and put into a clean vessel
P6. Measure hardener with the gauge in the required proportion, add to the vessel of paint and mix
Unit of Competency Performance Criteria
P7. Measure thinner with the gauge in the required proportion, add it to the vessel containing paint and hardener and mix
P8. Prepare the paint mixture according to the instructions of the paint manufacturer (4 parts of paint, 1 part of hardener and 10% of thinner).
P9. Adjust the temperature of the paint booth to the required level
P10. Fill 3/4 of the spray gun with the paint mixture
P11. Adjust air pressure to the prescribed level and draw air in through the air filter
P12. Apply paint on the vehicle body follow the prescribed method
P13. Allow to dry the paint
P14. Clean and store the tools and equipment
P15. Keep the painted body/body parts safely for drying
4. Apply two pack solid color paint
P1. Prepare the surface to be applied with 2K solid color paint
P2. Arrange required quantities of paint and thinner
P3. Collect essential equipment and materials
P4. Select 1.2 mm or 1.5 mm nozzle spray gun
P5. Mix the paint well till it was homogeneous
P6. Measure the required amount of paint with the gauge and put into a clean vessel
P7. Measure hardener with the gauge in the required proportion, add to the vessel of paint and mix
P8. Measure thinner with the gauge in the required proportion, add it to the Vessel containing paint and hardener and mix (Viscometer may be used).
P9. Maintain the required temperature in the paint booth
P10. Draw air through the air filter under the prescribed pressure
P11. Add the required amount of paint mixture to the spray gun (about 3/4).Did you adjust the flame of the spray gun to the required level
P12. Apply paint on the vehicle body follow the prescribed method
P13. Check that the painting was in good condition
P14. Bake the body after bringing the painting booth temperature to the prescribed level
P15. Clean and store the tools and equipment
5. Apply transparent colored silver paint
P1. Check the areas well prepared
P2. Obtain the necessary products
P3. Collect essential tools and equipment
P4. Read and understand the instructions/data in the manufacturer’s information leaflet
P5. Mix the silver paint well to the first application
P6. Add the mixed paint to another vessel
P7. Measure with the gauge the required quantity of thinner and add
P8. Take the ambient temperature into consideration
P9. Get air through the air filter under the prescribed pressure
P10. Add the required amount of paint (about 3/4) to the spray gun
P11. Adjust the flame of the spray gun(about 3/4)
Unit of Competency Performance Criteria
P12. Make the spray at the correct distance
P13. Allow the parts to stand for the required time to dry
P14. Select the color for the second coat
P15. Apply the second paint color follow the above steps
P16. Clean and store tools and equipment
6. Apply one pack metallic pearl color paint
P1. Take weather conditions into consideration
P2. Decide on the areas to be painted
P3. Collect the necessary equipment
P4. Obtains paint and thinner.
P5. Mix paint well after opening the can
P6. Measure the required quantity of paint with the gauge and add it to a clean vessel
P7. Add and mix thinner according to the standard proportion
P8. Draw the required amount of air in through filters
P9. Filter the mixed one pack metallic pearl color paint
P10. Add the required quantity of paint (about 3/4) to the spray gun
P11. Wear the safety gear
P12. Apply paint in the paint booth,
P13. Adjust the temperature to suit the paint
P14. Adjust the flame of the spray gun as required
P15. Perform spraying by holding the spray gun at the appropriate distance
P16. Allow the body to dry for an appropriate period
P17. Bake the vehicle body well in the paint booth
P18. Clean and store the tools and equipment
Knowledge & Understanding
• The types of fillers and primers used for the binding layer and how they are used
• Preparation of paint for the spray gun
• Types of one pack solid color paints and their qualities
• Instructions on preparation for application of one pack solid color paint
• Relevant details of application method
• Guidelines and safety precautions to be followed in the application of type of paint
• Types of two pack metallic pearl color paints and their basic qualities
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Solvent Resistance Gloves
3 Masking Dispenser
4 Spray Suit
5 Respirator
6 Air Compressor
7 Spray Gun
8 Air Blow Gun
9 Mixing Stick
10 Weighing Scale
11 Paint Booth
12 Shop cloth
13 Masking Papers
14 Masking Foil
15 Masking Tape
16 Sand Paper
17 Under Coat Paint
18 Hardener
19 Mixing Thinner
20 Cleaning Thinner
21. Apply Final Coats
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications
Unit of Competency Performance Criteria
1. Perform two tone painting
P1. Find out the customers need
P2. Wear PPE according to instruction
P3. Determine the color to be painted
P4. Collect necessary equipment and raw material,
P5. Other sections were covered with masking
P6. Pour paint into the spray gun and adjust the spray gun & air pressure
P7. Apply the main color that had to be applied
P8. Allow to dry for 24 hours,
P9. Check again whether the components and areas that need to be covered were fully covered
P10. Apply the second color
P11. Open the top coat tin and mix until a uniform mixture was obtained
P12. Obtain required thinner
P13. Measure with a scale and pour top coat into a clean vessel
P14. Pour thinner to standard ratio and mix
P15. Obtain standard air of required amount through filters
P16. Strain (though strainer) the mixed paint
P17. Pour required amount of top coat into the spray gun
P18. Wear safety gear
P19. Adjust the required flame of the spray gun
P20. Applying the basic colors, cover both colors with top coat
P21. Clean the used equipment, and surroundings
P22. Store equipment properly
2. Perform touch up work
P1. Discus about special requirements with the customer
P2. Determine the sections to be newly painted
P3. Measure the condition and color of the applied paint
P4. Gather the necessary raw materials tools and equipment
P5. Clean the surface of the applied paint in sections that had to be newly painted
P6. Prepare the required paint mixture
P7. Pour paint into the spray gun, provide the necessary air pressure and adjust the spray gun
P8. Paint the sections that need to be painted follow safety procedure
P9. Clean & store tools and equipment at the end of the task
3. Apply one pack paint with retarder
P1. Collect necessary equipment and raw materials
P2. Use retarder type of paint selected for painting according to weather condition
P3. Add only 10% of the retarder to the quantity of paint used for
Unit of Competency Performance Criteria
painting and prepare the mixture
P4. Pour paint into the spray gun, provide necessary air pressure and adjust the spray gun
P5. Apply paint with retarder mixture
P6. Clean and store the used tools and equipment
4. Apply one pack solid color paint with lacquer
P1. Decide that there was a suitable weather condition
P2. Collect necessary tools & equipment and raw materials
P3. Use lacquer relevant type of paint
P4. Mix paint and lacquer (1/4 liter of lacquer to be added to 1 liter of paint)
P5. Fill paint to 3/4 of spray gun
P6. Provide required air pressure and adjust the flame
P7. Apply the mixed paint
P8. Clean the used tools and equipment and the surroundings
5. Apply mat finish paint
P1. Determine the type of mat finish paint to be painted
P2. Decide that there was a suitable weather condition
P3. Collect necessary equipment and raw materials
P4. Mix paint with mat finish until it was uniform
P5. Add lacquer and other raw materials to paint according tospecified instructions
P6. Take required quantity of paint and keep the balance securely closed
P7. Fill paint to 3/4th of the spray gun
P8. Adjust required air pressure and adjust the flame
P9. Clean the used tools and equipment and the surroundings
Knowledge & Understanding
• Instructions to be followed when using chemicals
• Points to consider when storing paint, chemicals and equipment
• Aspects to consider in two tone painting
• Hints to identify places with lapses after color painting
• Points to follow when touching up
• Distinguishing characteristics of paints that require use of retarder
• Distinguishing characteristics of paints and retarder
• Points to consider when applying one pack paint with retarder
• Safety required when applying one pack paint with retarder
• Reactions that take place when mixing paints (chemical ratios)
• Characteristics of lacquer and one pack paint and their use
• Points to consider when applying paint and lacquer
• Basic characteristics of mat finish paint
• Point to consider when applying mat finish paint
• Instructions regarding mixing of paints
• Properties of one pack clear lacquer
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Solvent Resistance Gloves
3 Spray Suit
4 Respirator
5 Air Compressor
6 Spray Gun
7 Air Blow Gun
8 Mixing Stick
9 Weighing Scale
10 Paint Booth
11 Shop cloth
12 Masking Papers
13 Masking Foil
14 Masking Tape
15 Sand Paper
16 Under Coat Paint
17 Top coat paints
18 Hardener
19 Retarder
20 Mixing Thinner
21 Cleaning Thinner
22. Perform Polishing to Body Surface
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications.
Unit of Competency Performance Criteria
1. Assess and repair the paint surface
P1. Identify the areas to be cut using compound
P2. Gather the required tools & equipment and materials
P3. Wear PPE according to instruction
P4. Press the paint coat with a finger to determine whether the surface is dry enough for compound polishing.
P5. Use the reflection of a fluorescent light to check the surface
P6. Wipe any dirt and dust off the panel with a clean shop cloth
P7. Correcting dirt particle & paint run using a rubber sanding block
P8. Sand the surface with P1500 – P3000 grit sand paper to produce a texture with slightly higher depressions and ridges than the original texture
P9. Clean the work place tools & equipment and store them properly
2. Perform compound polishing
P1. Collect tools & equipment and material
P2. Wear PPE according to instruction
P3. Select suitable materials for cutting
P4. Mask the fittings on the bordering section and panel edges
P5. Wipe any dirt and dust off the panel with a clean shop cloth
P6. Attach the buff pad in the center of the polisher
P7. Clean the buff pad to remove any foreign particles before use
P8. Spread the compound without spinning the polisher to prevent spattering
P9. Move the polisher so that each pass of the polisher overlaps the previous pass by 2/3
P10. Polish the surface using the polishing compounds in order from fine to ultra-fine
P11. Eliminate any swirl marks made during the rough polishing process to produce gloss.
P12. Use a polisher with a sponge buff pad to perform finish polishing with ultra-fine polishing compound
P13. Use the color matching light to check whether there are any remaining swirl marks
P14. Clean work place tools & equipment and store them properly
3. Paste body stickers
P1. Decide what to do after consulting the customer
P2. Decide the parts where stickers have to be pasted
P3. Gather the required tools, equipment and material
P4. Cut the relevant parts according to required shapes
P5. Clean those parts with a mixture of water and a kind of shampoo
Unit of Competency Performance Criteria
using a manual spray gun
P6. Spray shampoo on the side where the sticker was pasted
P7. Place it / them to fit into the required part
P8. Spray shampoo outside the sticker
P9. Removing shampoo, and check the sticker past systematically without trapping air bubbles
P10. Clean and store tools and equipment
4. Apply wax P1. Decide the parts to be waxed
P2. Whether the weather condition was suitable
P3. Gather the required raw materials
P4. Remove dust in areas where wax was to be applied
P5. Apply wax on the required parts
P6. Use a clean piece of cloth to scrub the wax applied
P7. Clean the surroundings and store raw materials properly
5. Clean body moldings
P1. Decide the type of beadings to be cleaned
P2. Gather raw materials used for cleaning
P3. Clean the beadings with water only or with any detergent (shampoo) that iS. No.t harmful to them
P4. Clean the beadings and other components without damaging them
P5. Clean the working area and store raw materials and equipment properly
6. Clean buffers and tires
P1. Obtain the required raw materials for cleaning
P2. Wash the buffers and tires to be painted with a detergent (a kind of shampoo) and clean them
P3. Remove the stains and dirt using another chemical substance (if necessary)
P4. Clean the working area and store materials and equipment
7. Re-fix emblem & logo
P1. Select special points to fix badges
P2. Gather the required tools / equipment and materials
P3. Mark the points where the badges were to be fixed
P4. Bore the relevant points as required
P5. Paste double side tape on the inner sides of the badges
P6. Paste the inner sides of the badges with excess tape
P7. Apply primer paint on the bored holes
P8. Paste / fix the badges as required
P9. Tighten the relevant nuts and bolts
P10. Clean and store the equipment
Knowledge & Understanding
• The types of detergents used in washing vehicles and the aspects to be considered in using them
• The Types of polishing compound and polishing method, the aspects to be considered in following each of these methods and the safety procedures to be adopted
• Different types of wax and their properties
• Aspects to be considered in applying wax
• Different types of stickers and the aspects to be considered in pasting them
• Aspects to be considered in cleaning upholstery, windscreen, glass, body moldings, buffers and tires
• Aspects to be considered in fixing badges
List of Tools and Equipment
S. No. Descriptions
1 General Hand Tools
2 Cotton Gloves
3 Safety Glass
4 Dust mask
5 Polisher
6 Dual Action Polisher
7 Polishing compound
8 Fine Polishing Compound
9 Ultra-Fine Polishing Compound
10 Weighing Scale
11 Shop cloth
12 Masking Tape
13 Cleaning Thinner
23. Prepare Paint Work Estimation
Overview
After successful completion of this module the trainee will be able to perform each of the tasks according to the relevant standards and specifications
Unit of Competency Performance Criteria
1. Decide work to be done
P1. Determine the customer’s requirements
P2. Inspect the parts to be repaired
P3. Determine the amount of work to be done
P4. Prepare the technical report (job card)
2. Study gathered information related to market
P1. Collect information on price lists for different parts / raw materials from the market
P2. Find out work done related to vehicles in the market
P3. Collect information about present charges for such work
P4. Collect information about existing charges / payments for essential services
P5. Collect information about number of workers employed and level of work for relevant work in the market
P6. Study this information in preparing estimates and determine the cost
3. Calculate overheads
P1. Determine the amount to be spent on electricity
P2. Determine the amount to be spent on water
P3. Determine the amount of stationary to be used
P4. Determine the amount to be spent on equipment and machinery
P5. Determine the expenditure on buildings and paint booth
P6. Determine the factory insurance cost
P7. Determine the expenditure on telephone, computer, typewriter etc.
P8. Determine the cost of specific tools and equipment
P9. Determine the cost of floor area of establishment
P10. Determine the amount spent for dependent workers who do not participate in the relevant job
P11. Determine the expenditure on insurance services
P12. Determine the expenditure on vehicles of the establishment
P13. Determine the total expenditure Accordingly, did you determine/Calculate a percentage to be added
4. Calculate material cost
P1. Obtain relevant information from the customer
P2. Identify the jobs to be done
P3. Determine the nature / type of raw materials of correct standard
P4. Determines the raw materials to be expended? (Thinner, paint, filler tape, Lacquer, water and dry sandpaper etc.)
P5. Calculate the total cost of raw materials
5. Calculate labor P1. Check the job
Unit of Competency Performance Criteria
cost P2. Determine the extent of work relevant to the job
P3. Determine the time to be spent on the job
P4. Determine whether specialist assistance was necessary
P5. Allocate time according to type of workers
P6. Calculate the cost of an hour according to level of workers
P7. Calculate the cost of time according to level of workers
P8. Determine the total cost
6. Calculate cost of body parts
P-1. Determine customer’s preferences P-2. Examine the job P-3. Determine the parts to be newly fixed P-4. Obtain the parts of specific standard at the lowest quotation P-5. Obtain information about part number and manufacturing type of
parts P-6. obtain information about cost of partsIf the body part is to be
imported, calculate the expenditure cost
7. Calculate gross amount
P-1. Obtain correct and current data for calculation P-2. Calculate by adding together overheads, raw material cost, labor
costand cost of body parts (if any) P-3. Calculate expenditure on wastage P-4. Calculate government taxes and other charges relevant to above
basicexpenses P-5. get the percentage for profit used in the establishment P-6. Calculate the profit according to the percentage P-7. Calculate the gross amount follow the above steps
Knowledge & Understanding
• Methods to be used for collecting data
• Methods of analyzing data
• Determination of cost of raw material
• Deployment of labor according to jobs
• Calculation of cost of labor per hour
• Financial and institutional rules and regulations
• Salient features about import market
• Methodology about estimation
• Points to consider when preparing a technical report
List of Tools and Equipment
S. No. Descriptions
1 Calculator
2 Pen Writing Pad
Workshop Practice-III AD-324
1. Perform Engine Preventive Maintenance (Tune-Up)
Overview
These competency standards designed to enable the learner perform engine tune-up Petrol or Gasoline Engine, Diesel Engine under the specified procedure in the manual.
Unit of Competency Performance Criteria
1. Tune-up Petrol or Gasoline “Conventional Carburetor” Engine
P1. Inspect the main components of Engine system
P2. Service/Replace the air cleaner
P3. Change/service the spark plug specified procedure.
P4. Adjust valve clearance
P5. Inspect/Replace/adjust CB Point gap from distributer.
P6. Adjust/service carburetor specified procedure.
2. Tune-up Petrol or Gasoline “Electronic Fuel injection” Engine
P1. Inspect the main components of EFI system.
P2. Service/ Replace the air cleaner
P3. Change/ service the spark plug specified procedure.
P4. Inspect fuel pressure.
P5. Use the scanner specified procedure.
3. Service of Mechanical Fuel injection Diesel Engine
P1. Inspect the main components of mechanical fuel injection diesel engine system.
P2. Service/Replace the air cleaner
P3. Change/ service the Glow plug specified procedure.
P4. Inspect/adjust fuel from fuel injection pump
4. Service of Electronic Fuel injection Diesel Engine
P1. Inspect the main components of EFI system.
P2. Service/ Replace the air cleaner.
P3. Use the scanner specified procedure.
Knowledge & Understanding
• Describes the main components of engine and their functions as following: Air cleaner, spark plug, Distributer, HT Leads, Carburetor.
• Describe the operational principles of Mechanical and Electrical Fuel pump.
• Describe the operation of different types Fuel injection pump.
• Describe the different types of smoke.
Critical Evidence(s) Required
• Capable to tune-up petrol engine.
• Capable to tune-up FFI Engine.
• Capable to Tune-up diesel engine.
• Capable to Tune-up EFI Diesel engine.
• Capable to check different types of smoke
• Capable to check fault Fuel injection pump
List of Tools and Equipment
S. No. Descriptions
1 Vehicle (Diesel and petrol)
2 Tools trolley (Complete set of hand tools)
3 Multi-meter
4 Special service tools (Scanner)
2. Perform Periodic Maintenance
Overview
These competency standards designed to enable the learner to understand for periodic maintenance under the specified procedure in the manual.
Unit of Competency Performance Criteria
1. Service of petrol Vehicle
P1. Inspect the performance of main components of vehicle.
P2. Perform the periodic service of engine according to shop manual.
2. Service of diesel vehicle
P3. Inspect the performance of main components of vehicle.
P4. Perform the periodic service of engine according to shop manual.
Knowledge & Understanding
• Describe the periodic maintenance schedule of petrol vehicle.
• Describe the periodic maintenance schedule of diesel engine.
Critical Evidence(s) Required
• Capable to periodic maintenance of petrol vehicle. .
• Capable to periodic maintenance of diesel engine.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle(petrol and diesel)
2 Tools trolley (Complete set of hand tools)
3 Gas analyzer
4 Scanner
3. Arrange Workshop Equipment According to Lay-out
Overview
These competency standards designed to enable the learner understand lay-out of workshop and use workshop equipment under the specified procedure in the manual.
Unit of Competency Performance Criteria
1. Lay-out of work shop
P1. Marks the bay/pit different works.
P2. Mark the area for storage used oil.
P3. Mark the area for salvage.
2. Workshop equipment
P1. Mark the place hand tools
P2. Mark the place of measuring tools
P3. Mark the place of power tools and equipment
Knowledge & Understanding
• Describe the lay out function of work shop.
• Describe the importance of lay-out of workshop.
• Describe the importance of lay-out for workshop tools and equipment
Critical Evidence(s) Required
• Capable prepare layout of workshop bay/pit.
• Capable prepare lay-out work shop tools and equipment.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
2 Hand tools ,Power Tools ,Measuring Tools
3 Workshop
4. Prepare Documentation for Automotive workshop
Overview
These competency standards designed to enable the learner understand the documentation of workshop under the specified procedure.
Unit of Competency Performance Criteria
1. Service department documentation
P1. Prepare the job card and time sheet.
P2. Read the shop manual
P3. Read the service bulletin
P4. Read the parts catalog(Manual and e-catalog).
P5. Prepare the technical report
2. Parts Department documentation
P1. Prepare the main stock register
P2. Prepare the sub store register
P3. Order the parts through online.
Knowledge & Understanding
• Describe the importance of shop manual.
• Describe the importance of service bulletin.
• Describe the importance of inventory register.
Critical Evidence(s) Required
• Capable read the shop manual.
• Capable read parts catalog.
• Capable to prepare inventory register.
• Capable to prepare technical report.
List of Tools and Equipment
S. No. Descriptions
1 Shop manual
2 Parts catalogue
3 Inventory register
5. Maintain Service Station Equipment
Overview
These competency standards designed to enable the learner maintain the service station equipment under the specified procedure.
Unit of Competency Performance Criteria
1. Working with equipment
P1. Operate the hydraulic jack.
P2. Operate the crane
P3. Operate the car lift
2. Maintain the equipment
P1. Maintain the hydraulic jack.
P2. Maintain the crane
P3. Maintain the car lift
Knowledge & Understanding
• Describe the importance and operation of hydraulic jack.
• Describe the importance and operation crane.
• Describe the importance and operation of car lift.
Critical Evidence(s) Required
• Capable operate the hydraulic jack.
• Capable operate the crane.
• Capable to operate the car lift.
List of Tools and Equipment
S. No. Descriptions
1 Hydraulic jack.
2 crane
3 car lift
6. Maintain Emission control system
Overview
These competency standards designed to enable the learner understand and service emission control system under the specified procedure in the manual.
Unit of Competency Performance Criteria
1. Service of exhaust manifold
P1. Inspect performance of main components of exhaust manifold
P2. Remove and assemble exhaust manifold from engine
P3. Inspect and perform service of positive crankcase ventilation (PCV)
P4. Inspect and perform service of exhaust gas recirculation system(EGR)
2. Service of Muffler
P1. Inspect the performance of Muffler.
P2. Dismantle and assemble the Muffler from pipe.
3. Service of catalytic convertor
P1. Inspects catalytic converter under the specified procedure.
P2. Replace the catalytic convertor
4. Service of PCV P1. Inspect and perform service of positive crankcase ventilation (PCV)
P2. Inspect the PCV through vacuum pump
P3. Remove and assemble PCV through engine
P4. Inspect and perform service of exhaust gas recirculation system(EGR)
5. Service of EGR Valve
P1. inspect and identify location of exhaust gas recirculation system(EGR)
P2. Check the EGR valve operation(vacuum and electric controlled)
Knowledge & Understanding
• Describe the exhaust manifold types and its functions.
• Describe the muffler assembly operation.
• Describe the catalytic converter operation
• Describe the positive crank case ventilation PCV system and it operation
• Describe the exhaust gas recirculation and its operation
Critical Evidence(s) Required
• Capable identify/service Muffler assembly.
• Capable to service catalytic converter.
• Capable to service PCV System.
• Capable to service EGR system.
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Gas analyzer
4 Vacuum pump
7. Perform Engine Overhauling
Overview
These competency standards designed to enable the learner understand and service emission control system under the specified procedure in the manual.
Unit of Competency Performance Criteria
1. Petrol engine P1. Remove Engine from Vehicle.
P2. Remove Auxiliary components from Engine.
P3. Remove Cylinder Head.
P4. Dismantle engine block.
P5. Dismantle cylinder head.
P6. Clean dismantled parts
P7. Inspect engine block
P8. Repair Connecting rod and piston assembly
P9. Repair valve mechanism
P10. Repair cylinder Head
P11. Assembled Cylinder Head
P12. Assembled Crank Shaft to cylinder block
P13. Assembled Piston assembly
P14. Fix piston assembly to the cylinder block
P15. Mount Cylinder head to the cylinder block
P16. Set Valve Timing
P17. Fix Auxiliary Accessories
P18. Place to the engine vehicle
P19. Ready to start the engine
P20. Check performance
2. Diesel engine P1. Remove Engine from Vehicle.
P2. Remove Auxiliary components from Engine.
P3. Remove Cylinder Head.
P4. Dismantle engine block.
P5. Dismantle cylinder head.
P6. Clean dismantled parts
P7. Inspect engine block
P8. Repair Connecting rod and piston assembly
P9. Repair valve mechanism
P10. Repair cylinder Head
P11. Assembled Cylinder Head
P12. Assembled Crank Shaft to cylinder block
P13. Assembled Piston assembly
P14. Fix piston assembly to the cylinder block
P15. Mount Cylinder head to the cylinder block
P16. Set Valve Timing
P17. Fix Auxiliary Accessories
P18. Place to the engine vehicle
Unit of Competency Performance Criteria
P19. Ready to start the engine
P20. Check performance
3. Motor cycle Engine
P1. Remove Engine from Motorcycle.
P2. Remove Auxiliary components from Engine.
P3. Remove Cylinder Head.
P4. Dismantle engine block.
P5. Dismantle cylinder head.
P6. Clean dismantled parts
P7. Inspect engine block
P8. Repair Connecting rod and piston assembly
P9. Repair valve mechanism
P10. Repair cylinder Head
P11. Assembled Cylinder Head
P12. Assembled Crank Shaft to cylinder block
P13. Assembled Piston assembly
P14. Fix piston assembly to the cylinder block
P15. Mount Cylinder head to the cylinder block
P16. Set Valve Timing
P17. Fix Auxiliary Accessories
P18. Place to the engine vehicle
P19. Ready to start the engine
P20. Check performance
Knowledge & Understanding
• Describe the importance of engine overhauling.
• Describe the process of engine overhauling.
Critical Evidence(s) Required
• Capable to petrol engine overhauling.
• Capable to diesel engine overhauling.
• Capable to Motor cycle engine overhauling.
List of Tools and Equipment
S. No. Descriptions
1 Petrol engine ,diesel engine ,Motorcycle engine
2 Tools trolley (Complete set of hand tools)
3 Engine overhauling kit
4 Gas analyzer
8. Maintain Climatic Control System
Overview
These competency standards designed to enable the learner to inspect Heating ventilation and air conditioning system and faulty parts to be changed under the specified procedure in the manual.
Unit of Competency Performance Criteria
1. Check and identify defects / or need for servicing of the Automobile Air Conditioner
P1. Job card/ estimate traced and vehicle located, and repair/ servicing initiated.
P2. Air conditioner switched on and checked the extent of repair/ or servicing ascertained, according to standard procedures.
P3. Defects localized and identified using specified test instrument as per manufacturer’s instructions and standard procedures.
P4. Equipment / items, material and accessories required for job
2. Repair / or service refrigerant system of the Automobile Air conditioner
P1. Refrigerant in the system recovered where necessary using specified recovery equipment following safety procedures.
P2. Condition of the compressor checked for defects and defective parts serviced / or replaced, oil level checked and topped up where necessary according to specifications and manufactures instructions.
P3. Evaporator checked visually and pressure tested for leaks / clogs and serviced / or replaced where necessary.
P4. Expansion valve checked for proper operation and serviced / or replaced as necessary.
P5. Condenser checked visually and pressure tested for leaks / clogs and serviced / or replaced as necessary using specified test equipment, adhering to safety practices.
P6. Cooling / blower fans checked for performance, tested and serviced/ or replaced as necessary according to manufacturer’s instructions, adhering to safety practices.
P7. Filter/receiver driers inspected and replaced as necessary according to manufacturers specifications.
P8. Refrigerant liquid lines and hoses pressure tested using specified test equipment adhering to safety practices and leaks repaired, and pressure tested after repair of leaks.
P9. Sight glass, oil separator, gas accumulator checked and replaced as necessary.
P10. Refrigerant circuit flushed with specified flushing agent.
P11. System pressure tested using dry nitrogen and evacuated using vacuum pump and tested according to specifications
P12. The recovered refrigerant and the cylinder weighed, and recorded.
P13. The recovered refrigerant cylinder coupled to the empty cylinder and to the recycling machine observing standard procedure and safety practices.
P14. The recycling machine started up, the process monitored and proper operation ensured.
P15. All refrigerant recycled, hoses disconnected and cylinder reweighed
Unit of Competency Performance Criteria
to determine the weight of refrigerant recovered.
P16. Recycling of all recovered refrigerant ensured.
Knowledge & Understanding
This competency standard will provide knowledge related to:
• Describe construction air condition system.
• Describe construction and working of AC compressor
• State the function of evaporator
• State the function of dryer
• Describe the function condenser.
• Understand and trace the fault of AC system
Critical Evidence(s) required
• Capable identify/ service of AC system.
• Capable to service of gas charging
List of Tools and Equipment
S. No. Descriptions
1 Vehicle
2 Tools trolley (Complete set of hand tools)
3 Complete AC service kit
9. Perform Engine Output Testing
Overview
These competency standards designed to enable the learner use dynamometer and other equipment for testing engine under the specified procedure.
Unit of Competency Performance Criteria
1. Use of dynamometer
P1. Inspect the dynamometer condition
P2. Attach the dynamometer with engine
P3. Operate the engine and check its condition.
P4. Record the data during testing
2. Measure volumetric efficiency
P1. Calculate the engine volume
P2. Measure vacuum pressure
P3. Measure Air volume
P4. Induction time
Knowledge & Understanding
• Describe the dynamometer
• Describe the function of dynamometer.
• Describe the importance engine testing with dynamometer.
Critical Evidence(s) Required
• Capable to attach the dynamometer with engine.
• Capable to record data.
• Capable to analyze engine condition.
List of Tools and Equipment
S. No. Descriptions
1 E engine
2 Tools trolley (Complete set of hand tools)
3 Dynamometer
10. Read and Interpret Hydraulic and Pneumatic Code and Symbols
Overview
These competency standards designed to enable the learner to understand International Hydraulic and Pneumatic Code and Symbols.
Unit of Competency Performance Criteria
1. Hydraulic symbol P1. Identify the hydraulic symbol.
P2. Identify the Hydro pneumatic symbol
P3. Inspect and read different hydraulic circuit diagram.
2. Pneumatic Symbol
P1. Identify the pneumatic symbol.
P2. Identify the Electro pneumatic symbol
P3. Inspect and read different pneumatic circuit diagram
Knowledge & Understanding
• Describe the different hydraulic symbol
• Describe the different hydro pneumatic symbol.
• Describe the pneumatic symbol.
• Describe the different electro pneumatic symbols.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
Generic
1 Participate In Workplace Communication
Overview
This unit covers the knowledge, skills and attitudes required to gather, interpret and convey information in response to workplace requirements
Unit of Competency Performance Criteria
1. Obtain and convey Workplace information
P1. Assess the Specific and relevant information from the appropriate sources
P2. Convey and gather the information of Effective questioning, active listening and speaking skills.
P3. Transfer the information using the appropriate medium and ideas.
P4. Use appropriate non- verbal communication.
P5. Identify and follow appropriate lines of communication with supervisors and colleagues.
P6. Use the defined workplace procedures for the location and storage of information.
P7. Carry out Personal interaction clearly and concisely.
2. Participate in workplace meetings and discussions
P1. Attend the team meetings on time
P2. Clearly express your own opinions and listen other’s point of view without interruption.
P3. Established the protocols in the courteous manner of meeting inputs with the meeting purpose and Workplace interactions.
P4. Questions about simple routine workplace procedures and matters concerning working conditions of employment are asked and responded to Meetings outcomes are interpreted and implemented
3. Complete relevant work related documents
P1. Range of forms relating to conditions of employment are completed accurately and legibly
P2. Workplace data is recorded on standard workplace forms and documents
P3. Perform the basic mathematical processes that are used for routine calculations
P4. Identify the errors in recording information on forms/ documents and properly acted upon
P5. Reporting requirements to supervisor are completed according to organizational guidelines
Knowledge & Understanding
Describe the following.
• Appropriate sources: Team members, Suppliers, Trade personnel, Local government, Industry bodies
• Medium: Memorandum, Circular, Notice, Information discussion, Follow-up or verbal, instructions, Face to face communication.
• Storage: Manual filing system, Computer-based filing system.
• Forms: Personnel forms, telephone message forms, safety reports.
• Workplace interactions: Face to face, Telephone, Electronic and two way radio, Written including electronic, memos, instruction, and forms, non-verbal including gestures, signals, signs and diagrams
• Protocols: Observing meeting, Compliance with meeting decisions, Obeying meeting instructions
Knowledge & Understanding
• Describe the different hydraulic symbol
• Describe the different hydro pneumatic symbol.
• Describe the pneumatic symbol.
• Describe the different electro pneumatic symbols.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
2 Perform Work In Team Environment
Overview
This unit covers the skills, knowledge and attitudes to identify role and responsibility as a member of a team
Unit of Competency Performance Criteria
1. Describe team role and scope
P1. Identify the role and objective of the team from available sources of information.
P2. Identify team parameters, reporting relationships and responsibilities from team discussions and appropriate external sources.
2. Identify own role and responsibility within team
P1. Identify the individual role and responsibilities within the team environment.
P2. Identify and recognize the roles and responsibility of other team members.
P3. Reporting relationships within team and external to team are identified
3. Work as a team member
P1. Effective and appropriate forms of communications used and interactions undertaken with team members who contribute to known team activities and objectives
P2. Effective and appropriate contributions made to complement team activities and objectives, based on individual skills and competencies and workplace context
P3. Observed protocols in reporting using standard operating procedures
P4. Contribute to the development of team work plans based on an understanding of team’s role and objectives and
Knowledge & Understanding:
• Role and objective of team: Work activities in a team environment with enterprise or specific sector, Limited discretion, initiative and judgment maybe demonstrated on the job, either individually or in a team environment.
• Sources of information: Standard operating and/or other workplace procedures, Job procedures, Machine/equipment manufacturer’s specifications and instructions, Organizational or external personnel, Client/supplier instructions, Quality standards, OHS and environmental standards.
• Workplace context: Work procedures and practices, Conditions of work environments, Legislation and industrial agreements, Standard work practice including the storage, safe handling and disposal of chemicals, Safety, environmental, housekeeping and quality guidelines.
Knowledge & Understanding
• Describe the different hydraulic symbol
• Describe the different hydro pneumatic symbol.
• Describe the pneumatic symbol.
• Describe the different electro pneumatic symbols.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
3 Read and Develop Career Professionalism
Overview
This unit covers the knowledge, skills and attitudes in promoting career growth and advancement.
Unit of Competency Performance Criteria
1. Integrate personal objectives with organizational goals
P1. Personal growth and work plans are pursued towards improving the qualifications set for the profession
P2. Maintain the Intra- and interpersonal relationships in the course of managing oneself based on performance evaluation.
P3. Demonstrate the commitment to the organization and its goal in the performance of duties.
2. Set and meet work priorities
P1. Competing demands are prioritized to achieve personal, team and organizational goals and objectives.
P2. Manage work priorities and commitments in order to utilize the resources efficiently and effectively.
P3. Practices along economic use and maintenance of equipment and facilities are followed as per established procedures
3. Maintain professional growth and development
P1. Identify the trainings and career opportunities and avail on the bases of job requirements.
P2. Recognitions are sought/received and demonstrated as proof of career advancement
P3. Obtained and renewed the licenses and/or certifications relevant to job and career.
Knowledge & Understanding
• Evaluation: Performance Appraisal, Psychological Profile, Aptitude Tests.
• Resources: Human, Financial, Technology, Hardware, Software
• Trainings and career opportunities: Participation in training programs, Technical, Supervisory, Managerial, Continuing Education, Serving as Resource Persons in conferences and workshops.
• Recognitions: Recommendations, Citations, Certificate of Appreciations, Commendations, Awards, Tangible and Intangible Rewards.
• Licenses and/or certifications: National Certificates, Certificate of Competency, Support Level Licenses, Professional Licenses
Knowledge & Understanding
• Describe the different hydraulic symbol
• Describe the different hydro pneumatic symbol.
• Describe the pneumatic symbol.
• Describe the different electro pneumatic symbols.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
4 Practice Occupational Health and Safety Procedures
Overview
This unit covers the outcomes required to comply with regulatory and organizational requirements for occupational health and safety
Unit of Competency Performance Criteria
1. Identify hazards and risks
P1. Identify the safety regulations and workplace safety and hazard control practices and procedures are clarified and explained based on organization procedures
P2. Identify the hazards/risks in the workplace and their corresponding indicators to minimize or eliminate risk to co-workers, workplace and environment in accordance with organization procedures.
P3. Contingency measures during workplace accidents, fire and other emergencies are recognized and established in accordance with organization procedures
2. Evaluate hazards and risks
P1. Identify the terms of maximum tolerable limits which when exceeded will result in harm or damage are identified based on threshold limit values (TLV)
P2. Identify the effects of the hazards.
P3. Identify the OHS issues and/or concerns and safety hazards are reported to designated personnel in accordance with workplace requirements and relevant workplace OHS legislation.
3. Control hazards and risks
P1. Identify the occupational Health and Safety (OHS) procedures for controlling hazards/risks in workplace are consistently followed
P2. Procedures for dealing with workplace accidents, fire and emergencies are followed in accordance with organization OHS policies
P3. Use of Personal protective equipment (PPE) in accordance with organization OHS procedures and practices.
P4. Provide the appropriate assistance in the event of a workplace emergency in accordance with established organization protocol.
4. Maintain OHS awareness
P1. Practice the emergency-related drills and trainings as per established organization guidelines and procedures.
P2. Update and complete the OHS personal records in accordance with workplace requirements.
Knowledge & Understanding
• Safety regulations: May include but are not limited to: Clean Air Act, Building code, National Electrical and Fire Safety Codes, Waste management statutes and rules, Philippine Occupational Safety and Health Standards, DOLE regulations on safety legal requirements, ECC regulations.
• Hazards/Risks: May include but are not limited to: Physical hazards – impact, illumination, pressure, noise, vibration, temperature, radiation, Biological hazards- bacteria, viruses, plants,
parasites, mites, molds, fungi, insects, Chemical hazards – dusts, fibers, mists, fumes, smoke, gasses, vapors Ergonomics, Psychological factors – over exertion/ excessive force, awkward/static positions, fatigue, direct pressure, varying metabolic cycles Physiological factors – monotony, personal, relationship, work out cycle.
• Contingency measures: May include but are not limited to: Evacuation, Isolation, Decontamination, (Calling designed) emergency personnel.
• PPE: May include but are not limited to: Mask, Gloves, Goggles, Hair Net/cap/bonnet, Face mask/shield, Ear muffs, Apron/Gown/coverall/jump suit, Anti-static suits.
• Emergency-related drills and training: Fire drill, Earthquake drill, Basic life support/CPR, First aid, Spillage control, Decontamination of chemical and toxic, Disaster, preparedness/management.
• OHS personal records: Medical/Health records, Incident reports, Accident reports, OHS-related training completed.
Knowledge & Understanding
• Describe the different hydraulic symbol
• Describe the different hydro pneumatic symbol.
• Describe the pneumatic symbol.
• Describe the different electro pneumatic symbols.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
5 Lead Small Teams
Overview
This unit covers the knowledge, skills and attitudes to lead small teams including setting and maintaining team and individual performance standards.
Unit of Competency Performance Criteria
1. Provide team leadership
P1. Identify the work requirements and present it to team members
P2. Communicate the reasons for instructions and requirements to team members.
P3. Deal with the team members and discuss the queries and concerns.
2. Assign responsibilities
P1. Identify the duties, and responsibilities are allocated having regard to the skills, knowledge and aptitude required to properly undertake the assigned task and according to company policy
P2. Identify the duties are allocated having regard to individual preference, domestic and personal considerations, whenever possible
3. Set performance expectations for team members
P1. Understand the performance expectations are established based on client needs and according to assignment requirements
P2. Demonstrate the Performance expectations are based on individual team members duties and area of responsibility
P3. Demonstrate Performance expectations are discussed and disseminated to individual team members
4. Supervised team performance
P1. Demonstrate the monitoring of performance takes place against defined Performance Criteria and/or assignment instructions and corrective action taken.
P2. Provide a feedback by the Team members, positive support and advice on strategies to overcome any deficiencies
P3. Identify the performance issues which cannot be rectified or addressed within the team are referenced to appropriate personnel according to employer policy
P4. Inform the team members and keep informed of any changes in the priority allocated to assignments or tasks which might impact on client/customer needs and
P5. satisfaction
P6. identify the team operations are monitored to ensure that employer/client needs and requirements are met
P7. Follow-up communication is provided on all issues affecting the team
P8. Identify the all relevant documentation is completed in accordance with company procedures
Knowledge & Understanding
• Work requirements: Client Profile, Assignment instructions.
• Team member’s concerns: Roster/shift details.
• Monitor performance: Formal process, Informal process.
• Feedback: Formal process, Informal process.
• Performance issues: Work output, Work quality, Team participation, Compliance with workplace protocols, Safety, Customer service.
Knowledge & Understanding
• Describe the different hydraulic symbol
• Describe the different hydro pneumatic symbol.
• Describe the pneumatic symbol.
• Describe the different electro pneumatic symbols.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
6 Develop Negotiation Skills
Overview
This unit covers the skills, knowledge and attitudes required to collect information in order to negotiate to a desired outcome and participate in the negotiation.
Unit of Competency Performance Criteria
1. Plan negotiations P1. Identify the Information on preparing for negotiation and included in the plan.
P2. Perform positive negotiating and create Information of nonverbal environments and included in the plan.
P3. Identify the information on active listening is identified and included in the plan
P4. Identify the information on different questioning techniques and included in the plan
P5. Check the Information to ensure it is correct and up-to- date.
2. Participate in negotiations
P1. Identify the criteria for successful outcome are agreed upon by all parties
P2. Considered Appropriate language is used on desired outcome of all parties throughout the negotiation.
P3. Use a variety of questioning techniques are used The issues and processes are documented and agreed upon by all parties
P4. Assess possible solutions that are discussed and their viability.
P5. Identify the areas for agreement is confirmed and recorded Follow-up action is agreed upon by all parties.
Knowledge & Understanding
• Preparing for negotiation: Background information on other parties to the
• Negotiation: Good understanding of topic to be negotiated, Clear understanding of desired outcome/s,
• Personal attributes, (self-awareness, self-esteem, objectivity, empathy, respect for others)
• Interpersonal skills, (listening/reflecting, nonverbal communication, assertiveness, behavior labeling, testing understanding, seeking information, self-disclosing
• Analytic skills (observing differences between content and process, identifying bargaining information, applying strategies to manage process, applying steps in negotiating process, strategies to manage conflict, steps in negotiating process, options within organization and externally for resolving conflict.
• Nonverbal environments: Friendly reception, Warm and welcoming room, Refreshments offered, Lead in conversation before negotiation begins.
• Active listening: Attentive, Don’t interrupt, Good posture, Maintain eye contact, Reflective listening.
• Questioning techniques: Direct, Indirect, Open-ended
Knowledge & Understanding
• Describe the different hydraulic symbol
• Describe the different hydro pneumatic symbol.
• Describe the pneumatic symbol.
• Describe the different electro pneumatic symbols.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
7 Solve Problems Related To Work Activities
Overview
This unit covers the skills, knowledge and attitudes required to collect information in order to solve problems to a desired outcome and participate in the work activities.
Unit of Competency Performance Criteria
1. Identify the problem
P1. Identify the Variances from normal operating parameters; and product quality Extent,
P2. Identify the cause and nature are of the problem are defined through observation, investigation and analytical techniques
P3. Demonstrate the Problems are clearly stated and specified
2. Determine fundamental causes of the problem
P1. Identify the Possible causes that are based on experience and the use of problem solving tools / analytical techniques.
P2. Develop possible cause statements based on findings
P3. Identify the fundamental causes as per results of investigation conducted.
3. Determine corrective action
P1. Report on recommendations are prepared
P2. Recommendations are presented to appropriate personnel.
P3. Recommendations are followed-up, if required
Knowledge & Understanding
• Analytical techniques: Brainstorming, Intuitions/Logic, Cause and effect diagrams, Pareto analysis, SWOT analysis, Gant chart, Pert CPM and graphs, Scatter grams.
• Problem: Non – routine process and quality problems, Equipment selection, availability and failure, Teamwork and work allocation problem, Safety and emergency situations and incidents.
• Action plans: Priority requirements, Measurable objectives, Resource requirements, Timelines, Co-ordination and feedback requirements, Safety requirements, Risk assessment, Environmental requirements
Knowledge & Understanding
• Describe the different hydraulic symbol
• Describe the different hydro pneumatic symbol.
• Describe the pneumatic symbol.
• Describe the different electro pneumatic symbols.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
8 Develop Communication Skill
Overview:
The user/ individual on the job needs to know and understand how to writing skills, reading skills and oral communications skills (Listening and speaking)
Unit of Competency Performance Criteria
1. Writing Skills The user/ individual on job needs to know and understand how to:
P1. Document instructions, itinerary and task lists
P2. Maintain documents and reports pertaining to security operations, emergency response, personnel and equipment
P3. Document activities and incidents in a chronological order
P4. Write letters/ memos, feedback and reports
P5. Use computers to generate Management Information System (MIS), emails and other reports
P6. Write in English and at least in one vernacular language proficiently
2. Speaking and Listening Skills
The user/ individual on job needs to know and understand how to:
P1. Read and assimilate organizational procedures, site and security instructions, and correspondence, as applicable
P2. Read security registers, documents, feedback, reports and applications Oral Communication (Listening and Speaking skills)The user/individual on the job needs to know and understand how to:
P3. Speak clearly and emphatically
P4. Receive briefings and instructions from superiors and ask queries
P5. Brief and instruct subordinates and receive debriefings
P6. Reply to the queries from stakeholders
P7. Ask questions from visitors
P8. Raise alarm/ make announcements/ speak over phone/ radio
3. Professional Skills
Decision Making The user/individual on job needs to know and understand how to: SB1 take decisions pertaining to security operations, training, administration and emergency situations Plan and Organize. The user/individual on the job needs to know and understand how to:
P1. Plan security operations as per site instructions and resources available assess and assign tasks to teams and individuals
P2. Conduct training, rehearsals and mock drills Customer Centricity The user/individual on the job needs to know and understand how to:
P3. Manage relationships with stakeholders and visitors Problem Solving The user/individual on the job needs to know and understand how to:
P4. Think through the problem, evaluate the possible solution(s) and adopt a best possible solution(s)
P5. Handle disruption in security operations Analytical Thinking The user/individual on the job needs to know and understand how to:
Unit of Competency Performance Criteria
P6. Anticipate and identify potential risk and threats and take suitable actions
P7. Observe people, activities and movements keenly Critical Thinking The user/individual on the job needs to know and understand how to:
P8. Analyze and evaluate a situation and available information to take appropriate action
Knowledge & Understanding
• Analytical techniques: Brainstorming, Intuitions/Logic, Cause and effect diagrams, Pareto analysis, SWOT analysis, Gant chart, Pert CPM and graphs, Scatter grams.
• Problem: Non – routine process and quality problems, Equipment selection, availability and failure, Teamwork and work allocation problem, Safety and emergency situations and incidents.
• Action plans: Priority requirements, Measurable objectives, Resource requirements, Timelines, Co-ordination and feedback requirements, Safety requirements, Risk assessment, Environmental requirements
Knowledge & Understanding
• Describe the different hydraulic symbol
• Describe the different hydro pneumatic symbol.
• Describe the pneumatic symbol.
• Describe the different electro pneumatic symbols.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
• Capable to
9 Develop Administrative Skills
Overview:
The user/ individual on the job need to know and understand how to develop administrative skills.
Unit of Competency Performance Criteria
1. Decision making P1. Perform decisions pertaining to security operations, training and administration
P2. Perform emergency situations
2. Make Plan and Organize the workshop
The user/individual on job needs to know and understand how to:
P1. Plan security operations as per site instructions and resources available assess and assign tasks to teams and individuals
P2. Conduct training, rehearsals and mock drills
P3. Manage relationships with stakeholders and visitors
3. Evaluate the possible solution
P1. Think through the problem, evaluate the possible solution(s) and adopt a best possible solution(s)
P2. Handle disruption in security operations
P3. Anticipate and identify potential risk and threats and take suitable actions
P4. Observe people, activities and movements keenly
P5. Analyze and evaluate a situation and available information to take appropriate action
Knowledge & Understanding
• Analytical techniques: Brainstorming, Intuitions/Logic, Cause and effect diagrams, Pareto analysis, SWOT analysis, Gant chart, Pert CPM and graphs, Scatter grams.
• Problem: Non – routine process and quality problems, Equipment selection, availability and failure, Teamwork and work allocation problem, Safety and emergency situations and incidents.
• Action plans: Priority requirements, Measurable objectives, Resource requirements, Timelines, Co-ordination and feedback requirements, Safety requirements, Risk assessment, Environmental requirements
Knowledge & Understanding
• Describe the different hydraulic symbol
• Describe the different hydro pneumatic symbol.
• Describe the pneumatic symbol.
• Describe the different electro pneumatic symbols.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
10 Work effectively in a customer service/ sales environment
Overview:
This Competency standard identifies the competencies required Work Effectively in a Customer Service/Sales Environment as per Organization’s approved guidelines and procedures. You will be expected to work within organizational requirements, support the work team, maintain personal presentation, develop effective work habits, portray ethical behavior and acquire up to date product / service knowledge. You’re underpinning knowledge about Work Effectively in a Customer Service/Sales Environment will be sufficient for you to provide the basics of the work.
Unit of Competency Performance Criteria
1. Work within organizational requirements.
You must be able to:
P1. Identify and read organization’s requirements and responsibilities and seek advice from appropriate people where necessary.
P2. Interpret staff rosters and provide sufficient notice of unavailability for rostered hours according to workplace policy and procedures.
P3. Develop and use a current working knowledge and understanding of employee and employer rights and responsibilities.
P4. Comply with relevant duty of care and legal responsibilities, and support organizational culture.
P5. Identify roles and responsibilities of colleagues and immediate supervisors.
P6. Identify standards and values considered to be detrimental to the Organization and communicate this through appropriate channels.
P7. Identify, recognize and follow behaviour that contributes to a safe and sustainable work environment.
2. Support the work team.
You must be able to:
P1. Display courteous and helpful behavior at all times.
P2. Take opportunities to enhance the level of assistance offered to colleagues and meet all reasonable requests for assistance within acceptable workplace timeframes.
P3. Complete allocated tasks as required.
P4. Seek assistance when difficulties arise.
P5. Use questioning techniques to clarify instructions or responsibilities.
P6. Identify and display a non-discriminatory attitude in all contacts with customers and other staff members.
3. Maintain personal Presentation.
You must be able to:
P1. Observe appropriate dress code and presentation as required by the workplace, job role and level of customer contact.
P2. Follow personal hygiene procedures according to organizational policy and relevant legislation.
4. Develop effective work habits.
You must be able to:
P1. Interpret, confirm and act on work place information, instructions and procedures relevant to the particular task.
P2. Ask questions to seek and clarify workplace information.
P3. Plan and organize daily work routine within the scope of the job
Unit of Competency Performance Criteria
role.
P4. Priorities and complete tasks according to required timeframes.
P5. Identify work and personal priorities and achieve a balance between competing priorities
5. Portray ethical behavior
You must be able to:
P1. Follow ethical code of conduct.
P2. Understand your costumer’s code of ethics.
P3. Declare conflict of interest.
P4. Maintain confidentiality.
P5. Honor your commitments (timeframe, deliverables etc.)
P6. Use internet for business only on company time.
6. Acquire up to date product / service Knowledge
You must be able to:
P1. Gather information about your product / services.
P2. Identify the components of your product and services.
P3. Recognize the essential selling features of your products and services.
P4. Translate all essential features of your product and services.
P5. Analyze product success.
P6. Identify your market position.
P7. Familiar with all product promotions, sales manuals and product Literature.
P8. Keep information of latest technology advances and seek ways to use these technologies in your work.
Knowledge & Understanding:
• Define industry awards and agreements that relate to personal job role and terms and conditions of employment.
• Differentiate between employer and employee responsibilities.
• Explain different relevant legislation and statutory requirements.
• Explain the importance of team work
• Define workplace relations
• Explain workplace policies, plans and procedures, including, Dealing with Grievances, Discriminatory, behavior, Equal opportunity, issues, Staff rosters and notification of shift Availability or nonattendance Providing customer service to colleagues and customers.
• Explain hygiene and personal presentation
• Explain the importance of workplace ethics.
• Explain staff counseling and disciplinary procedures
• Describe workplace organizational structure
• Explain the importance of ethical behavior.
• Explain the importance of commitment in sales and customer services
• Explain: a. Price per product. b. Profit per product /service. c. Price flections
d. Product strengths e. Product weaknesses. f. Warranty / guarantee policies. g. Packaging facilities and potential.
• Explain how your product/service fits into your customers overall operations, business plan, sales success, operation cost etc.
Knowledge & Understanding
• Analytical techniques: Brainstorming, Intuitions/Logic, Cause and effect diagrams, Pareto analysis, SWOT analysis, Gant chart, Pert CPM and graphs, Scatter grams.
• Problem: Non – routine process and quality problems, Equipment selection, availability and failure, Teamwork and work allocation problem, Safety and emergency situations and incidents.
• Action plans: Priority requirements, Measurable objectives, Resource requirements, Timelines, Co-ordination and feedback requirements, Safety requirements, Risk assessment, Environmental requirements
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
11 Develop Professionalism
Overview:
This Competency standard identifies the competencies required to Develop Professionalism as per Organization’s approved guidelines and procedures. You will be expected to create a personal vision / mission, manage your attitude, practice self-discipline, manage time, manage your professional development, and participate in trainings and performance review. Your underpinning knowledge about Develop Professionalism will be sufficient for you to provide the basics of the work.
Unit of Competency Performance Criteria
1. Create a personal vision / mission
You must be able to:
P1. Clarify / prioritize self-values and consider the value of others.
P2. Clarify expectations of yourself and expectations others have of you.
P3. Identify what you need to do to be successful (personal standards, targets, goals, principals)
P4. Set specific short and long term goals.
P5. Translate the vision into actionable steps.
P6. Integrate the vision into daily practice.
P7. Recount frequently with your vision and change accordingly.
2. Manage your attitude
You must be able to:
P1. Challenge yourself, break old habits, and move out of your comfort zone.
P2. Practice innovative techniques for out of the box creative thinking.
P3. Seek out support and feedback from others on the team, in the organization / community etc.
P4. Identify daily, weekly accomplishments.
P5. Read inspirational material, audiotapes etc.
3. Practice self-discipline
You must be able to:
P1. Accountable for your performance.
P2. Identify what you need to do to be successful.
P3. Communicate your priorities to others.
P4. Make and honor appointments with yourself and others.
P5. Practice relaxation and energizing techniques.
4. Manage time You must be able to:
P1. Isolate key success activities and prioritize them.
P2. Breakdown large tasks down into manageable action steps (set time frame).
P3. Create or adopt action plans and follow it.
P4. Set aside appropriate blocks of time for goal related activities.
P5. Make the best possible use of support people / recourses to
accomplish tasks.
5. Manage your professional development
You must be able to:
P1. Take inventory of your personal interests, abilities, skills, knowledge etc.
P2. Identify and prioritize the strengths and gaps.
P3. Use available assessment tools.
P4. Create a personal growth strategy / career path.
P5. Set personal goals and timeframe for achieving them.
P6. Learn from your mistakes.
6. Participate in trainings and performance review
You must be able to:
P1. Analyze, evaluate and improve performance, and report significant issues/problems to senior management
P2. Demonstrate to-do attitude in profession
P3. Demonstrate understanding of skills requirements
P4. Use the competences acquired in trainings
Understand and Knowledge:
• Explain long and short term goals.
• Explain why personal vision and mission is important for success.
• Describe the advantages of personal vision and mission.
• Explain the importance of personal and professional motivation
• Identify your positive attitude.
• Explain the advantages of innovative ideas and techniques during job.
• Explain the importance of communication.
• Explain the advantages of self-discipline.
• Explain the importance of time management to achieve different tasks.
• Explain the importance and need of professional development.
• Define concept about performance standards.
• Explain policies, procedures and regulations regarding human resources of the organization.
• Explain self-planning and management techniques.
• Define goals and strategies of self- development.
• Explain relevant knowledge about training / job requirements.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
Entrepreneur
1. Manage the Operations of Workshop Security Units
Overview
This Competency Standard identifies the competencies required to prepare for managing the operations, manage resources of a security unit, organize guarding operations, control entry to and exit from premises, control screening and search operations and organize traffic control and parking. Your underpinning knowledge regarding workshop security units will be sufficient to provide the basis for this task.
Competency Units Performance Criteria
1. Prepare to manage the operations
P1. Observe organizational procedures related to security operations Security Operations: Access control, screening & search, escort, duties by unarmed & armed security guards and personal security officers (PSO), observation & surveillance, control room operations, traffic control, parking management, information gathering, key-control, dealing with emergencies, investigations, security equipment operation, documentation and reporting
P2. Plan operations as per site instructions and availability of resources Site Instructions: Instructions covering the details of deployment and operations at a particular site
P3. Develop personnel and resources in an efficient and economical manner
P4. Review functioning of teams and shifts and carry out improvements P5. Assess training and performance standards of security unit
Training Requirements P6. Check and report functioning of provided security equipment to
facilitate access control, search and screening, parking, surveillance and smoke & fire detection
P7. Check and report functioning of personal protection equipment P8. Initiate actions to rectify faulty equipment P9. Organize security operations manually in the event of equipment
malfunction P10. Check and carry out periodic / surprise inspections P11. Communicate effectively with team members and stakeholders P12. Take report and feedback from team members P13. Coordinate, organize, train and rehearse emergency response
teams (ERT) P14. Respond to emergencies and irregular situations Emergencies by
security unit members P15. Take preventive actions and call for assistance to control irregular
situations
2. Manage resources of a security unit
P1. Plan and organize required personnel and equipment as per site instructions
P2. Assess and report suitability of provided personnel and equipment P3. Carry out adjustments in deployment to cover deficiency of
personnel and equipment
Competency Units Performance Criteria
P4. Record and report status and issues related to personnel and equipment
3. Organize guarding Operations
P1. Organize security and guarding operations against likely threats and risks
P2. Organize briefing of guards and supervisors between the shifts P3. Carry out periodic review of the deployment and operations P4. Control functioning and operations of CCTV control room, if
provided P5. Follow the laid down procedure of key control P6. Prepare, issue and monitor patrolling plan P7. Debrief guards/ patrols/ supervisors after the tasks P8. Take feedback P9. Deal with lost and found property
4. Control entry to and exit from premises
P1. Identify likely threats and risks to premises from outside P2. Summarize access control procedure and functioning of the
equipment in use P3. Train team members in operation of the equipment P4. Brief team members regarding people/ vehicles/ material
authorized to enter/ leave premises P5. Identify papers, passes, permission and documentation to facilitate
entry and exit of people/ vehicles/ material to and from the premises
P6. Organize receipt of postal mail and couriers, if assigned
5. Control screening and search operations
P1. Identify procedure of screening and search operations and the functioning of equipment in use
P2. Train team members in operation of the equipment P3. Sensitize subordinates to respect persons’ right to dignity, privacy
and gender/ religious/ cultural sensitivity P4. Deal with persons and vehicles violating laid down procedures P5. Identify presence of prohibited/ unauthorized items P6. Segregate material containing prohibited/ unauthorized items
Knowledge and Understanding Units:
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• Reporting procedures
• Category of authorized people/ people debarred entry
• Types of identity/ authorization documents in use
• Areas within the premises having restricted/ controlled entry
• Details of unauthorized/ prohibited items
• Action to be taken in case of recovery of unauthorized/ prohibited items
• Procedure for receipt of postal mail and couriers
• Action to be taken in case of delivery of a suspicious package
• Method of securing and storing letters and packages
• Methods and techniques adopted by miscreants to defeat security measures and equipment
• Knowledge of security equipment installed in the premises
• Capability and limitations of the security equipment in use
• Understanding of signals emanating from equipment
• Common faults occurring in the equipment
• Procedure re for carrying out operations manually, in case of equipment failure
• Indications regarding suspicious packages
• Items that cannot be put through screening and search equipment
• Procedure for vehicle search
• Personal protective gear required for security operations
• Layout of the parking areas and traffic plan in the premises
• Suitability of prevailing conditions for parking
• Traffic signals, signage and markings
• Category of vehicles
• Untoward situations faced during security operations
• Procedure for dealing with untoward situations
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
2. Organize Training On Multiple Workshop Units
Overview
This Competency Standard identifies the competencies required to organize training on multiple workshop units. Your underpinning knowledge regarding organize training will be sufficient to provide the basis for this task.
Competency Units Performance Criteria
1. Assess the training Requirements
P-1. Identify relevant legislation/ regulations, organizational requirements relating to standards of training in the automobile sector.
P-2. Assess site-specific training requirements for technician and experts.
P-3. Report to superiors on existing training standards and additional training required
P-4. Assess time required for conduct of training P-5. Decide on learning objectives of the training P-6. Maintain environmental and situational awareness to upgrade
training Standards
2. Plan and Schedule training for technicians
P-1. Keep in view availability of time on the type and method of training and resources
P-2. Chalk out training program(s) P-3. Arrange for required trainers and training infrastructure i.e.
Training areas, trainers, curriculum/ course content, classrooms, equipment, aids and simulators
P-4. Brief security unit on training schedule P-5. Carry out/ facilitate pre-induction training P-6. Carry out/ facilitate on-the-job training P-7. Train team members in the operation of security and
communication equipment P-8. Carry out routine checks to assess training efficacy P-9. Assess and report on standards of training and performance
Knowledge and Understanding Units:
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• Category of authorized people/ people debarred entry
• Types of identity/ authorization documents in use
• Areas within the premises having restricted/ controlled entry
• Details of unauthorized/ prohibited items
• Action to be taken in case of recovery of unauthorized/ prohibited items
• Procedure for receipt of postal mail and couriers
• Action to be taken in case of delivery of a suspicious package
• Method of securing and storing letters and packages
• Methods and techniques adopted by miscreants to defeat security measures and equipment
• Knowledge of security equipment installed in the premises
• Capability and limitations of the security equipment in use
• Understanding of signals emanating from equipment
• Common faults occurring in the equipment
• Procedure re for carrying out operations manually, in case of equipment failure
• Indications regarding suspicious packages
• Items that cannot be put through screening and search equipment
• Procedure for vehicle search
• Personal protective gear required for security operations
• Layout of the parking areas and traffic plan in the premises
• Suitability of prevailing conditions for parking
• Traffic signals, signage and markings
• Category of vehicles
• Untoward situations faced during security operations
• Procedure for dealing with untoward situations
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
3. Administer Multiple Commercial Units
Overview
This Competency Standard identifies the competencies required to administer multiple commercial units. Your underpinning knowledge regarding Implementation of SOP Process and administer multiple bay units will be sufficient to provide the basis for this task.
Competency Units Knowledge Criteria
1. Control the operations of workshop
P1. Commence operations at a new or existing site, as per site instructions
P2. Assess site-specific administrative requirements i.e. accommodation, transportation, food, medical, hygiene & sanitation, support staff, shift timings, working hours, rest, leave, entitlement of salary/ allowances, payment to staff, documentation, addressing grievances, welfare, security of female guards and handling of petty cash
P3. Inform superiors about the requirements P4. Issue identity cards to team members P5. Inform superior about complaints/ suggestion received from
principal employer P6. Interact with team members frequently P7. Resolve grievances of staff P8. Maintain confidentiality of information P9. Receive/ issue/ account for stores meant for security unit P10. Prepare attendance sheet, overtime details and MIS reports P11. Document new entrants/ those leaving the site Documents i.e.
Master roll, attendance sheet, pay roll, site assignment document, individual’s verification & identification documents, personnel movement control documents, duty roster, leave & absence register, medical register
P12. Handle and account for petty cash P13. Pursue pending issues of security unit and agency with principal
employer
2. Administer a workshop/bayUnit
P1. Identify and address important administrative concerns P2. Arrange for accommodation, transportation and food for the unit P3. Enforce dress code P4. Maintain discipline P5. coordinate with own agency/ principal employer to resolve issues P6. Ensure privacy and personal safety of the unit, especially of female
staff P7. Motivate team through personal example and concern P8. Assess performance and standards of team members P9. Counsel team members on their performance and conduct P10. Recommend deserving personnel for promotion and reward
Knowledge and Understanding Units:
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• The site instruction
• Details of personnel and equipment required
• Channel of reporting and communication with stakeholders Stake holders: Principal employer, superior, own management, subordinates, visitors and residents/tenants
• Contact details of stakeholders, superiors and team members
• Documentation formats
• Reporting procedure
• Organizational standards on grooming, conduct, behavior and performance
• Leadership and management fundamentals Leadership: Administration, discipline, motivation, impartiality, punctuality, concern for subordinates, welfare and leading by example
• Organizational protocol for resolution of concerns/ grievances
• Management information system
• Performance management system
• Compensation management
• Accounting and issue procedure for stores, material and equipment
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
4. Supervise performance of Technician
Overview
ThisCompetencyStandardidentifiesthecompetenciesrequiredtosupervise and evaluate performance of technician. Your underpinning knowledge regarding supervision and evaluation the performance of subordinates ensure higher levels of motivation will be sufficient to provide the basis for this task.
Competency Units Knowledge Criteria
1. Supervise the staff P1. Ensure and implement strict adherence of all activities performed by subordinates to organizational guidelines
P2. Monitor and supervise all the activities performed by subordinates and ensure optimization to achieve the set goals
P3. Document all performance indicators and metrics of subordinates in the prescribed format of organization
P4. Ensure and implement proper process flow for feedbacks and queries received from subordinates
2. Evaluate performance of all subordinates and reporting executives
P1. Set goals and targets as per organizational directives for all reporting executives
P2. Create quantified measures and metrics to analyze the performance delivered by subordinates
P3. Set tangible and achievable incentives for subordinates as per the goals and targets assigned
P4. Assist and support reporting executives whenever necessary or applicable
P5. Evaluate performance of subordinates and reporting executives on the designed measures and metrics as per the guidelines of the organization
P6. Perform all appraisal related process flow for subordinates, as per respective performance documents
P7. Handover all the documents and appropriate support measures to human resources department for official records
Knowledge and Understanding Units:
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• Standard operating procedures of the organization for appraisals, incentives, promotions and performance evaluation.
• Standard operating procedures for query and problem reporting and their redressal in the organization
• Framework and guidelines prescribed by the organization for query and problem redressal
• Framework and guidelines prescribed by the organization for performance evaluations and based appraisals out of it
• Documentation requirements for each procedure carried out as part of roles and responsibilities
• Institutional and professional code of ethics and standards of practice
• Safety and health policies and regulations for the workplace.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
5. Plan Work to Meet Expected Outcomes
Overview
This Competency Standard identifies the competencies required to plan and organize work to meet expected outcomes. Your underpinning knowledge regarding planning and organizing individual’s work in order to complete it to the required standards, on time and within budget in terms of cost and material will be sufficient to provide the basis for this task.
Competency Units Knowledge Criteria
1. Set quality standards for Work requirements including various activities within the given time
P1. Keep immediate work area clean and tidy P2. Treat confidential information as per the organization’s guidelines P3. Work in line with organization’s policies and procedures P4. Work within the limits of job role P5. Obtain guidance from appropriate people, where necessary P6. Ensure work meets the agreed requirements
2. Use Appropriate resources
P1. Establish and agree on work requirements with appropriate people
P2. Manage time, materials and cost effectively P3. Use resources in a responsible manner
Knowledge and Understanding Units:
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• The organization’s policies, procedures and priorities for area of work, role and responsibilities in carrying out that work
• The limits of responsibilities and when to involve others
• Specific work requirements and who these must be agreed with
• The importance of having a tidy work area and how to do this
• How to prioritize workload according to urgency and importance and the benefits of this
• The organization’s policies and procedures for dealing with confidential information and the importance of complying with these
• The purpose of keeping others updated with the progress of work
• Who to obtain guidance from and the typical circumstances when this may be required
• The purpose and value of being flexible and adapting work plans
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
6. Work Effectively In a Team
Overview
This Competency Standard identifies the competencies required to work effectively in a team. Your underpinning knowledge regarding working effectively with colleagues, either in own work group or in other work groups within organization will be sufficient to provide the basis for this task.
Competency Units Knowledge Criteria
1. Interact and communicate effectively with colleagues
P1. Maintain clear communication with colleagues (by all means including face-to-face, telephonic as well as written)
P2. Support colleagues to integrate work P3. Pass on information to colleagues in line with organizational
requirements both through verbal as well aS. No.n-verbal means P4. Accomplish work in ways that show respect for colleagues P5. Carry out commitments made to colleagues P6. Identify problems in working with colleagues and take the initiative
to solve these problems
2. Interact & communicate with other stack holders.
P1. Maintain clear communication with stockholder (by all means including face-to-face, telephonic as well as written)
P2. Follow the automobile sector policies and procedures for working with stockholders.
P3. Present all types of information to stack holders when it is required. P4. Obey the rules and regulations as per govt. policy.
Knowledge and Understanding Units:
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• The organization’s policies and procedures for working with colleagues, role and responsibilities in relation to this
• The importance of effective communication and establishing good working relationships with colleagues
• Different methods of communication and the circumstances in which it is appropriate to use these
• The importance of creating an environment of trust and mutual respect
• The implications of own work on the work and schedule of others.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
7. Maintain Healthy, Safe and Secure Working Environment
Overview
This Competency Standard identifies the competencies required to maintain healthy, safe and secure working environment. Your underpinning knowledge regarding monitoring work place practices and making sure they meet requirements for health, safety, security and environmental concerns will be sufficient to provide the basis for this task.
Competency Units Knowledge Criteria
1. Need Resources to maintain a safe, secure working environment
P1. Comply with organization’s current health, safety and security policies and procedures
P2. Report any identified breaches in health, safety, and security policies and procedures to the designated person
P3. Coordinate with other resources at the workplace to achieve the healthy, safe and secure environment for all incorporating all government norms esp. for emergency situations like fires, earthquakes etc.
P4. Identify and correct any hazards like illness, accidents, fires or any other natural calamity safely and within the limits of individual’ authority
P5. Report any hazards outside the individual’s authority to the relevant person in line with organizational procedures and warn other people who may be affected
P6. Follow organization’s emergency procedures for accidents, fires or any other natural calamity
P7. Identify and recommend opportunities for improving health, safety, and security to the designated person
P8. Complete all health and safety records are updates and procedures well defined
Knowledge and Understanding Units:
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• The organization’s policies and procedures for working with colleagues, role and responsibilities in relation to this
• The importance of effective communication and establishing good working relationships with colleagues
• Different methods of communication and the circumstances in which it is appropriate to use these
• The importance of creating an environment of trust and mutual respect
• The implications of own work on the work and schedule of others.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
8. Deal with Emergencies and Incidents at Workshop
Overview
This Competency Standard identifies the competencies required to deal with emergencies and incidents at work shop. Your underpinning knowledge regarding to deal with emergencies and incidents at workshop will be sufficient to provide the basis for this task.
Competency Units Knowledge Criteria
1. Deal with emergencies and incidents at workshop
P1. Follow organizational procedures while responding to emergencies and incidents at workshop.(SOP)
P2. Review organizational procedure periodically Procedures: Laid down SOPs for dealing with accidents, emergency or untoward security situation
P3. Train and prepare Staff to respond to emergencies and incidents at workshop.
P4. Take appropriate action Appropriate Actions: Respond with equipment/ aid at hand, Request for qualified assistance, Evacuate people; isolate area; inform and brief relevant authorities and maintain order, Maintain safety of self and others
P5. Identify and investigate causes of alarms Alarm and Sensors: Against intrusion & forced entry, for heat, smoke & fire, SOS from residents, medical emergencies, elevator/ escalator crisis, gas leak, electrical short circuit, other alarms from building management system, environmental hazards, and CCTV
P6. Communicate information and seek assistance P7. Ensure health and safety while responding to risks and threats
2. Reduce risks to health and safety at the workplace
P1. Carry out security operations in line with workplace health and safety norms
P2. Identify the main safety and health related threat/ risks within the premises i.e. Fires, Electric short circuit; electric shock and electrocution, Medical emergency, Inflammable & toxic chemicals gases, Falls; trips and slips, Natural calamities, Equipment malfunction, Poor ventilation and suffocation, Improper use of personal safety gear and no adherence to safety norms, Ergonomic risks pertaining to long and static postures; prolonged use of computer and viewing of monitor, Poor hygiene and sanitation conditions, Extreme temperature conditions
P3. Participate in discussions/ training on safety and health issues P4. Implement health and safety related procedures P5. Enforce the use of personal protective equipment (PPE) by stake-
holders P6. Ensure safety of self and others while carrying out duties P7. Identify key people for anchoring safety and health related roles P8. Organize required equipment/ resources P9. Organize awareness training for stakeholders P10. Organize and train emergency response teams (ERT) P11. Maintain the desired state of readiness for dealing with
Competency Units Knowledge Criteria
emergencies P12. Ensure placement of equipment and signage as per plan P13. Organize periodic mock drills/ rehearsals P14. Deal with hazards and report based on operational procedures P15. Report and record safety and health incidents.
Knowledge and Understanding Units:
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• Policy/ procedures/ guidelines related to workplace health and safety
• Responsibilities of the security function related to health and safety
• Limits and responsibilities of the security unit
• Organizational procedure for handling different levels of risks
• Reporting protocol for health and safety matters
• Communication protocol
• Documentation formats and reports to be maintained The seer/individual on the job needs to know and understand:
• Organizational procedures relating to communication
• Details of stakeholders/ concerned agencies
• Means of available communication
• Details of security functions that need employers’ approval
• Format and process for obtaining feedback Format: Written and electronic
• Organization’s standards of communication, behavior and courtesy
• Resolution process for queries/ complaints of stakeholders
• Communication etiquette to be followed by the security unit
• Gender, cultural, religious and other sensitivities
• Organizational procedure for recording and sharing of information
• Timelines and periodicity for submission of reports/ documentation. Documentation: Relating to operations, training and administration
• Frequency for reviewing records maintained by security unit
• Storage and archival policy/ processes followed by the organization
• Details of stakeholders/ agencies authorized to receive information
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.
9. Maintain Effective Communication with Companies
Overview
This Competency Standard identifies the competencies required to maintain effective communication with HVAC companies. Your underpinning knowledge regarding effective communication with HVAC companies/ dealers and also carry out the review role-related documentation will be sufficient to provide the basis for this task.
Competency Units Knowledge Criteria
1. Communicate effectively with Stakeholders
P1. Communicate effectively with stakeholders on security functions i.e. residents, residents welfare association members, visitors, workers, staff, vendors, facility management, service providers and maintenance staff
P2. Establish a system of receiving feedback from stakeholders P3. Enforce organization’s standards of communication, behavior
and courtesy within the security unit Operate communication equipment effectively Communication Equipment: Walkie-talkie, telephone, intercom, mobile phone, signage, whistle, light signals, hand signals, field signals
P4. Communicate security-related protocol to stakeholders P5. Interact with stakeholders to understand their requirements P6. Interact with media on instructions P7. Resolve queries/ complaints of stakeholders as per
procedure P8. Train the security personnel in required communication
etiquettes P9. Educate security staff on gender, cultural and religious
sensitivities P10. Intervene and resolve instances of aggressive and unruly
behavior
2. Carry out and review role-related documentation
P1. Identify essential documents to be completed and maintained by the security unit
P2. Finalize the format for recording information/ incidents as per organizational procedure
P3. Decide on timelines and frequency for submission of reports P4. Use computers and other equipment to facilitate
documentation P5. Record and store documents as per organizational
procedure P6. Forward report/ feedback to designated superior P7. Store and handle information/ media generated by the
security equipment(s) P8. Handle electronic media and archive to store information/
documents safely Information: Written, verbal, electronic, and public-address system
P9. Share information with authorized stakeholders on a ‘need-to-know’ basis
Competency Units Knowledge Criteria
P10. Maintain security and confidentiality of information
Knowledge and Understanding Units:
The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of:
• Organizational procedures relating to communication
• Details of stakeholders/ concerned agencies
• Means of available communication
• Details of security functions that need employers’ approval
• Format and process for obtaining feedback Format: Written and electronic
• Organization’s standards of communication, behavior and courtesy
• Resolution process for queries/ complaints of stakeholders
• Communication etiquette to be followed by the security unit
• Gender, cultural, religious and other sensitivities
• Organizational procedure for recording and sharing of information
• Timelines and periodicity for submission of reports/ documentation. Documentation: Relating to operations, training and administration
• Frequency for reviewing records maintained by security unit
• Storage and archival policy/ processes followed by the organization
• Details of stakeholders/ agencies authorized to receive information.
Critical Evidence(s) Required
• Capable to identify the hydraulic symbol.
• Capable to identify the pneumatic symbol.