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MES COURSE MODULES In AUTOMOTIVE REPAIR GENERAL INFORMATION FOR BASIC AUTOMOTIVE SERVICING 2W&3W Name of Sector AUTOMOTIVE REPAIR Name of Module BASIC AUTOMOTIVE SERVICING OF 2&3W MES Code AUR701 Competency as per N C O Code Duration of Course 500 Hrs th Entry Qualification of Trainee 5 Pass + 14 yrs of age Unit size (No. Of trainees) 20 Power Norms 3 KW Space Norms (Workshop and Class Room) 80 sqm +30 sqm parking area Job Profile Two wheeler / three wheeler Mechanic Helper for garage boy Objective 1. Produce Two wheeler / three wheeler Mechanic Helper for Garage Boy in automotive workshop by pinning with following Employability skills: (i) Safety awareness about work safety, tools, Equipments & Machinery safety, Personal safety and Environmental safety. (ii) Quality awareness. (iv) Skills to do general servicing and maintenance of 2 Wheelers & 3 Wheelers. (v) Skills to do minor repair works in 2 & 3 wheelers. 2. Self Employment in the area of Vehicle washing and Tyre Repair. Terminal competency 1. Safe practice on Work 2. First Aid 3. Handling of General Tools, Special tools, equipments and Machineries available in the Automobile Garage 4.Identifying vehicle components 5.Use of fasteners 6.Able to check engine condition 7.Able to do general maintenance of 2 & 3 wheeler 8. Able to do minor repair works of 2 & 3 wheeler 9.Washing of vehicle 10. Tyre repair work Instructors Qualification Degree in automobile Engineering with one year relevant Experience OR Diploma in automobile Engineering with two year relevant Experience OR NTC/ NAC in automobile Trade Group with three years of relevant Experience Desirable Qualification Craft Instructor Certificate (CIC) Course Contents for Module BASIC AUTOMOTIVE SERVICING OF 2&3 WHEELERS PRACTICAL COMPETENCIES UNDERPINNING KNOWLEDGE (THEORY) BASICS General service information Reading and understanding of service General safety manual Handling of vehicle components Vehicle identification(VIN) Handling of fuels Practice on different types of fastening Types of fasteners devices Effects of exhaust smoke Measuring threads Fire extinguishers Practice 5S techniques Threads and its types Handling of fire extinquishers Reading and Understanding service manuals Practice on different types of hand tools 5S techniques Handling of workshop equipments Handling and Disposal of consumables Hand tools-types-description Study about various workshop equipments Using sand paper-grades of sand paper ENGINE 4s&2s engines Checking engine compression Petrol, diesel and LPG engines-principle Checking engine vacuum Effects of engine compression Removing timing chain Effects of engine vacuum Dismantling cylinder head Constructional details of valve mechanism Decarbonizing Importance of correct valve clearance Testing valve, valve seat and valve guide Types of cylinder head Reassembling cylinder head Effects of carbon deposits in the cylinder Adjusting valve clearance Precautions to be taken while decarbonizing Using torque wrenches EXHAUST SYSTEM Emissions of exhaust smoke and its effects Testing exhaust smoke Principle of secondary air injection system Cleaning secondary air injection system Importance of clean silencer Silencer cleaning in 2stroke engine vehicles Principle of catalytic converter FUEL SYSTEM Description of fuel tank Cleaning fuel tank Air cleaner – types- effects of clogged air Servicing air cleaner cleaner Cleaning carburetor Carburetor principles-types-importance of Tuning carburetor carburetor adjustments-do’s and don’ts Bleeding diesel fuel system in 3wheelers while servicing carburetor Changing fuel filters Diesel fuel system in 3wheelers LUBRICATING SYSTEM Lubricants-types-properties of lubricants Draining and measuring engine oil level Lubrication system-lubricating circuit- Replacing/cleaning oil filter functions of engine oil-engine oil grade- Cleaning the engine with flushing oil importance of correct quality and quantity Replacing engine oil of engine oil-troubles and causes for lubricating system COOLING SYSTEM Cooling system-basic parts and its functions Replacing coolant Coolant –types- different coolant mixture cleaning radiator ratios- troubles and causes in cooling Adjusting fan belt tension system TRANSMISSION Clutch-types-constructional details Adjusting clutch play Constructional details of Chain and sprocket Removing chain and sprocket Details of variable transmission assembly Lubricating chain Troubles and causes for transmission Reassembling chain and sprocket Servicing variable transmission BRAKE SYSTEM Brake-types-principle-constructional details Dismantling the brake assembly Brake fluid-types Inspecting brake drum, brake shoes and Troubles and causes for brake system brake pads Care to be taken while handling brake shoes Reassembling brake assembly Replacing brake fluid Bleeding the hydraulic brake system Adjusting brake STEERING AND SUSPENSION SYSTEM Constructional details of steering-reasons Adjusting steering play for steering play Changing front fork oil Effects of stiff steering Adjusting shock absorbers Description of front fork assy Shock absorbers–types –constructional details ELECTRICAL Electrical basics Practice on use of multimeter AC & DC
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