Course Objectives

1. Safety, health and environmental policies and regulations for the workplace as well as for automotive trade in general (e.g. safe working practices inside pits/ under vehicles).

2. Understand the auto component manufacturer specifications related to the various components/ aggregates in the two/ three wheeler vehicle.

3. Follow standard operating procedures for using workshop tools and equipment for service and minor aggregate repairs in the two/ three wheeler vehicle.

4. Conduct test drives to assess need for repairs, calibration or any other adjustments in the electrical/ mechanical aggregates in the two/ three wheeler vehicle.

5. Ensure OEM recommended procedure and checklist is followed for routine servicing in case of non-routine service or repair, confirm tasks to be carried out with superior.

6. calibrate, align and adjust settings, alignment, pressures, tension, speeds and levels relevant to:

• Engine and aggregates.

• Transmission system.

• Electrical and electronic components.

• Scooter (two-stroke engine).

• Scooter (four-stroke engine).

• Motorcycle (two-stroke engine),

• Motorcycle (four-stroke engine).

• Disc & drum brakes system.

• Other components (including to valves, ignition, fuel and emissions, transmission, lights, tyres, steering and body fittings).

Learning Outcomes

1. Carry out routine service and minor repairs of Vehicles and aggregates of two and three-wheelers understand auto component specifications, correctly use workshop tools, assess the need for repairs, and understand contents of service manuals.

2. Plan and organize work to meet expected outcomes, plan & understand work content and output required in a given time, maintain set quality standards, identify and manage organizational resources efficiently and effectively.

3. Work Effectively in a Team:-know and follow organizational policies and procedures for working with colleagues.

4. Maintain a healthy, safe, and secure working environment: - know prevailing environmental norms, government policies, and work to eliminate common breaches in health &safety.

Course Syllabus

Module 1:safety and job role model.

1. Introduction.

2. Industrial in-house practice platform as per the customer complaint.

Module 2: Specification parameters of 2 & 3 wheelers.

1. Different companies specification variation along with models.

2. Basics of automobile terms.

Video tutorial – 01

Module 3: Overview construction of 2 & 3 wheelers.

1. Introduction.

2. Component identification.

• Update technology adoption.

1. Engine electrical system.

Practice: - Demonstration and identification of all attachment components.

Practice: - Complete dismantle and assemble the engine with the procedure by following the respective service manual.

Practice: - Use of engine special tools.

Practice: - Precision measurement of all components.

Practice: - Engine electrical fault finding.

Video tutorial - 01

 Video tutorial – 02

Project -Phase 1 (3HRS).

Measure engine components.

(Piston, Crankshaft, connecting rod, gudgeon pin, camshaft, valve guide, block deck test, engine cylinder, oil clearance between main journal bearing and crank throw shaft, valve adjustment, crankshaft endplay) etc.

Module 4: Anatomy (aggregate) of an automobile.

1. Introduction.

2. Components of an automobile.

• Tools and equipment.

1. Engine basics.

2. System of an engine.

Practice: - Overview demonstration of the different companies' engines and comparisons.

Practice: - Use of special tools.

Practice: - Overhauling procedure of an engine.

Practice: -Engine assembling and dismantling procedure.

Practice:- Carburettor and its cleaning process.

Video tutorial - 01

 Video tutorial - 02

Project -Phase 2 (3HRS).

Overhauling of a live engine. (Overhauling needed).

Module 5: Electrical and electronics system.

1. Introduction.

2. Basics of automobile electrical components.

• ISO symbols (International standardization for organization).

1. Wiring diagram.

Practice-identification of electrical components (Fuse, relay, Battery, Relay, Fuse, Diode, Resistor, Capacitor, Switch, Transistor, Solenoid, Harness connector, Sensors.

Practice: - Troubleshooting in the starting and charging system.

Practice: - Electrical components troubleshooting and its repair process.

Practice: -Use of multimeter, Thermometer.

Practice: - Interpretation of schematic wiring diagram.

Video tutorial - 01

 Video tutorial - 02

Project -Phase 3 (3HRS).

Diagnose the fuel meter. (Fuel meter defective).

Module 6: Braking and steering system.

1. Introduction.

2. Principle of the braking system.

• Types of the braking system.

1. Repairing of mechanical and disc brake.

2. Brake bleeding process.

3. Basics of the steering system.

• Components identification of steering system.

Practice: -Demonstration of different types of braking systems.

Practice: -Brake bleeding process.

Practice: - Demonstration of the steering system.

Practice: -Repair process of the steering system.

 Video tutorial - 01

 Video tutorial - 02

 Video tutorial - 03

Module 7: Propeller shaft, suspension system, and tire wheel.

1. Introduction.

2. Different types of the suspension system.

• Servicing of the suspension system.

1. Dismantle and assemble procedure of suspension system.

2. Struts and shocks absorber.

3. Demonstration of propeller shaft or drive shaft.

Practice: -Demonstration of the suspension system.

Practice: -Dismantling and assembling of the suspension system.

Practice: -Servicing of the suspension system.

Practice: -Demonstration of propeller or drive shaft.

Practice: -Assemble and dismantle the procedure of propeller shaft.

Practice: - Wheel balancing.

Video tutorial - 01

 Video tutorial - 02

Module 8: Interval schedule maintenance.

1. Introduction.

2. Need for servicing.

• Items change in interval service maintenance as per the respective service manual.

Practice: -Identification of changeable items.

Practice: -Full maintenance practice.

Video tutorial - 01

 Video tutorial - 02

Project -Phase 4 (3HRS).

Interval servicing maintenance of the 2 & 3 wheeler as per the company’s maintenance chat with a report.

Session Plan

Session Plane:(T-THEORY,P- PRACTICAL)

Session – 1. (T-45Min)

LECTURE - safety and job role model.

DEMO– Industrial workshop practice model procedure.

Video tutorial-2.

Session – 2. (T-1.5HRS)

LECTURE –Overview construction of 2 & 3 wheelers.

DEMO– Different company's specification variation along with the models.

   Basic terminology of an automobile.

Video tutorial-1

Session – 3. (T-45Min)

LECTURE – Overview construction of 2 & 3 wheelers.

DEMO–Demonstration and identification of all attachment components.

Video tutorial-1

Session – 4. (P–3HRS)

PRACTICE – Complete dismantle and assemble the engine with the procedure by following the respective manual.

PRACTICE –Use of engine special tools.

Video tutorial 1.

Video tutorial 2.

Session – 5. (T-45Min)

LECTURE – Actual valve timing diagram of SI and CI engine.

DEMO–Variable valve timing.

Video tutorial 1.

Session – 6.(P–3HRS)

PRACTICE – Valveadjustment practice.

PRACTICE – Fuel injection pump FIP advance setting.

Session – 7. (T-45Min)

LECTURE –Engine wiring installation.

DEMO –Understanding of engine wiring and the electrical component.

Video tutorial 1.

Session – 8.(T-45Min)

LECTURE –Engine electrical monitoring system ECM description.

DEMO – Engine sensor monitoring value and error codes (active & reactive) function.

Video tutorial 1.

Session – 9.(P–6HRS)

PRACTICE – Precision measurement of all components.

PRACTICE – Engine electrical fault finding.

Video tutorial 1.

Video tutorial 2.

Session – 10. (T-45Min)

LECTURE – Anatomy (aggregate) of an automobile.

DEMO –Overview demonstration of the different company’s engine and comparison.

Session – 11.(P-6HRS)

PRACTICE –Use of special tools.

PRACTICE - Overhauling procedure of an engine.

Video tutorial 1.

Session – 12. (T-45Min)

LECTURE –Types of automobile layout.

DEMO –Anatomy (aggregate) of an automobile.

Video tutorial 1.

Session – 13.(P-6HRS)

PRACTICE –Engine assembling and dismantling procedure.

PRACTICE – Carburettor and its cleaning process.

Video tutorial 1.

Session – 14.(P-3HRS)

PRACTICE – Study of fuel injection of a diesel engines.

PRACTICE – Advance setting of fuel injection pump FIP.

Video tutorial 1.

Session – 15.(P-6HRS)

PRACTICE – The model study of the air cooling system.

PRACTICE – The model study of the liquid cooling system.

Session – 16. (T-45Min)

LECTURE –Electrical and electronics system.

DEMO –Understanding of starting and charging system.

Video tutorial 1.

Session – 17. (T-45Min)

LECTURE - Electrical and electronics system.

DEMO –ISO symbol identification of a schematic diagram.

Session – 18.(P-3HRS)

PRACTICE –Use of multimeter, Thermometer.

PRACTICE – Interpretation of schematic wiring diagram.

Video tutorial 1.

Video tutorial 2.

Session – 19. (T-45Min)

LECTURE - Braking and steering system.

DEMO - Demonstration of different types of braking and steering system.

Session – 20. (P-6HRS)

PRACTICE –Brake bleeding process.

PRACTICE - Demonstration of steering system.

PRACTICE - Repair process of steering system.

Video tutorial 1.

Session – 21. (T-45Min)

LECTURE – Steering geometry (caster, camber, toe in, toe out and king pin inclination).

DEMO – Types of steering gear boxes and their construction and working principle.

Video tutorial 1.

Session – 22. (T-45Min)

LECTURE - Propeller shaft, suspension system, and tire wheel.

DEMO –briefing and describe the purpose and mounting location of the propeller shaft.

Understanding different types of suspension systems.

Video tutorial 1.

Session – 23.(T-45Min)

LECTURE – Construction features and working of air suspension system & telescopic suspension system.

DEMO – Demonstration of different aggregates of the suspension system as per the various of 2 & 3 wheelers vehicle model.

Session – 24.(P-3HRS)

PRACTICE - Dismantling and assembling of suspension system.

PRACTICE - Servicing of suspension system.

Video tutorial 1.

Video tutorial 2.

Session – 25. (T-45Min)

LECTURE - Propeller shaft, suspension system and tyre wheel.

DEMO – Briefing the wheel balancing and vehicle placing procedure (service position) .

Video tutorial 1.

Session – 26. (P-3HRS)

PRACTICE - Assemble and dismantle procedure of propeller shaft.

PRACTICE - Wheel balancing.

Video tutorial 1.

Video tutorial 1.

Session – 27. (T-45Min)

LECTURE - Interval schedule maintenance.

DEMO –Demonstration of maintenance chat table.

Video tutorial 1.

Session – 28. (P-6HRS)

PRACTICE –Identification of changeable items

PRACTICE – Full interval servicing maintenance practice.

Video tutorial 1.

Video tutorial 1.

Session – 29. (P-3HRS)

PRACTICE – Preparation of service inquiry form and service report.

PROJECT:

1. Measure engine components.

2. Overhauling of a live engine. (Overhauling needed).

3. Diagnose the fuel meter. (Fuel meter defective).

4. Interval servicing maintenance of the 2 & 3 wheeler as per the company’s maintenance chat with the report.

Case Studies

Case Studies