Lab Specifications. Automotive 4 Wheeler Repair

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1 Lab Specifications Automotive 4 Wheeler Repair An initiative of Ministry of Skill Development & Entrepreneurship, Govt. of India and National Skill Development Corporation

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3 If we have to promote the development of our country then our mission has to be skill development and skilled India. Shri Narendra Modi Honourable Prime Minister 03

4 OVERVIEW The lab standardization guidelines envisions to standardize the lab infrastructure for automotive 4 wheeler repair trades across sectors. The document intends to ensure industry linked training with state-of-art infrastructure. 04

3D Representation of Automotive 4 Wheeler Repair 4.

5 AUTOMOTIVE 4 WHEELER REPAIR SECTOR 1. Description of Lab 2. List of Tools & Equipment - Automotive 4 Wheeler Repair 3. 3D Representation of Automotive 4 Wheeler Repair 4. Illustrative Architectural Layout of Lab 5. Illustrative Pricing of Tools & Equipment 6. Safety Instructions 05

1 DESCRIPTION OF LAB Lab Specifications for the Listed Sectors / Job Roles Proposed Batch Size Machine - Man Ratio 1. 4 Wheeler Service Technician Level 4 2. AC Specialist 3. Brake Specialist 4.

6 1 DESCRIPTION OF LAB Lab Specifications for the Listed Sectors / Job Roles Proposed Batch Size Machine - Man Ratio 1. 4 Wheeler Service Technician Level 4 2. AC Specialist 3. Brake Specialist 4. Automotive Electrician Level Clutch Specialist 6. Chauffeur-cum-Taxi Driver 7. Automotive Sales Head (Retail) 8. Sales Representative 9. Showroom Hostess 10. Service Office Executive Wheeler Service Technician Level 3 Some of the above mentioned job roles may be done with planning and delivery methodology. 25 1:5 06

7 2 LIST OF TOOLS & EQUIPMENT - AUTOMOTIVE 4 WHEELER REPAIR S. No. Equipment Name Qty Unit Type 1 Service Technician Tool Kit 15 Set 2 Drive Socket Set 2 Set 3 Lever Type Grease Gun 2 Nos 4 Chisel - Drop Forge 16 x 22 x Nos 5 Oil Can - Wesco Type 4 Nos 6 Centre Punches 10 Nos 7 Two Leg Puller 1 Nos 8 Hammer Ball Pin 15 Nos 9 Single - Arm Torque Wrench Covering 1-7 mkg 1 Nos 10 Single - Arm Torque Wrench Covering 3-14 mkg 1 Nos 11 Single - Arm Torque Wrench Covering 5-23 mkg 1 Nos 12 Cross Wheel Spanner (17 x x 21 mm) 5 Nos 13 Bench Vice (100 mm x 4") 2 Nos 14 Working Bench Wooden 2 Nos 15 Vernier Callipers 4 Nos 16 Micrometer (Size: 0 to 25 mm) 4 Nos 17 Digital Multimeter with Various Lead Sets 2 Nos 18 Work Bench Wooden (Two) Size: 4*3*2.5" in Feet 2 Nos 19 Hacksaw (300 mm) with Blade 15 Nos 20 Tyre Pressure Gauge 2 Nos 21 Steel Rule 15 Nos 22 Tape Measure 15 Nos 23 Depth Gauge 2 Nos 24 Hydro Meter 2 Nos 07

8 2 LIST OF TOOLS & EQUIPMENT - AUTOMOTIVE 4 WHEELER REPAIR S. No. Equipment Name Qty Unit Type 25 Tyre Pressure Gauge 2 Nos 26 Plastic Hammer 5 Nos 27 Filter Adjustable Remover 1 Nos 28 Spark Plug Sockets 67 mm Drive Size 16/21 mm 2 Nos 29 Magnetic Pickup Tool (Bar) 2 Nos 30 Dial Gauge (Mahr 10 mm Range) 5 Nos 31 Wire Brush 5 Nos 32 Hydraulic Jacks 3 Ton 1 Nos 33 Air Compressor and Hoses 1 Nos 34 Tyre Inflator 1 Nos 35 Battery Charger 1 Nos 36 Universal Battery Tester and Probe 2 Nos 37 Creeper 2 Nos 38 Drain Pans / Engine Tray 12" x 18", 18" x 24" 6 Nos 39 Screw Extractor Set 2 Nos 40 Temperature Sensing Device 2 Nos 41 Wheel Chocks 6 Nos 42 Measuring Can 2 Nos 43 Two Post Lift 1 Nos 44 Neon Timing Light 3 Nos 45 Battery & Charging System Tester 1 Nos 46 Injector Tester and Cleaner 1 Nos 47 Air Tester Filter Machine 1 Nos 48 A/C Leakage Tester 1 Nos 08

9 2 LIST OF TOOLS & EQUIPMENT - AUTOMOTIVE 4 WHEELER REPAIR S. No. Equipment Name Qty Unit Type 49 Diagnostic Tool 1 Nos 50 Brake Bleeder, Pressure or Vacuum 1 Nos 51 Wheel Balancer (Optima D ) 1 Nos 52 Tyre Changer (Trufit) 1 Nos 53 Head Light Focusing 1 Set 54 Pneumatic Tools 1 Set 55 Wheel Aligner 1 Nos 56 Goggles 15 Nos 57 Ear Plugs 15 Nos 58 Gloves 15 Nos 59 First Aid 2 Nos 59 Powder - Based Fire Extinguisher Class ABC, 500 gms 4 Nos 60 Water Stored Pressure Fire - Extinguisher Class A, 9 ltr 2 Nos 61 Safety Sign 1 Nos 62 Complete Car Cut Section 1 Nos 63 Petrol Vehicle - Minimum Maruti Alto 1 Nos 64 Diesel Vehicle - Minimum Indica / Indigo 1 Nos 64 Aggregate Car Petrol ( Engine, Transmission System, Brake System, Suspension System, Steering System, Electrical System, etc. Mounted on Chassis) - 1 Set Minimum Maruti Alto 65 Special Maintenance Tool for Maruti Suzuki Alto 1 Set Diesel Engine Mounted on Stand Four Cylinder Inline Engine 1200 CC 66 1 Nos Tata Sumo (Preferred) 67 Clutch System Gypsy or Tata Sumo 1 Nos 09

10 2 LIST OF TOOLS & EQUIPMENT - AUTOMOTIVE 4 WHEELER REPAIR S. No. Equipment Name Qty Unit Type 68 Gear - Box Mounted on Stand Gypsy or Tata Sumo (Synchromesh) 1 Nos 69 Propeller Shaft - Gypsy or Tata Sumo (Preferred) 1 Nos 70 Differential Mounted on Stand - Gypsy or Tata Sumo (Preferred) 1 Nos 71 Starter Motor - Lucas or Equivalent 12 Volt / 1 kw 1 Nos 72 Alternator Lucas or Equivalent 12 Volt / 70 amp 1 Nos 73 Steering System Rack Travel 136 mm Rane Male or Equivalent 1 Nos 74 Air Assisted Brake System 1 Nos 75 Brake System Hydraulic any 4 - Wheeler 1 Nos 76 Fuel Pump (12 V Electrical Fuel Pump) - Maruti or Tata Motor Preferred 3 Nos 77 Water Pump 3 Nos 78 Radiator for 4 - Wheeler 3 Nos 79 Fuel Filter 3 Nos 80 Oil Filter 3 Nos 81 Almirah for Keeping Tools 6'' Height x 3'' Width x 1.75'' Depth and 18 Gauge 2 Nos 82 Tool Board 1 Nos 10

Equipment Chassis with Gear Box and Steering Section Vehicle Service Area Store Room Auto

11 3 3D REPRESENTATION OF AUTOMOTIVE 4 WHEELER REPAIR LAB List of Equipment Entry Engine Cut Section and Aggregates Vertical Hydraulic Hoist Work Benches for Observers Diagosnistic Equipment Chassis with Gear Box and Steering Section Vehicle Service Area Store Room Auto Electrician Cut Section and Work Area Service Area Classrooms Transmission Cut Section Area Air Compressor 11

12 4 ILLUSTRATIVE ARCHITECTURAL LAYOUT OF LAB 12

13 5 ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT S. No. Equipment Name Qty Unit Unit Price* Amount Brands** Type (INR) (INR) 1 Service Technician Tool Kit 15 Set 10,000 1,50,000 Multi Branded 2 Drive Socket Set 2 Set 4,000 8,000 Multi Branded 3 Lever Type Grease Gun 2 Nos Non Branded 4 Chisel - Drop Forge 16 x 22 x Nos 140 1,400 Non Branded 5 Oil Can - Wesco Type 4 Nos Non Branded 6 Centre Punches 10 Nos Non Branded 7 Two - Leg Puller 1 Nos 1,798 1,798 Non Branded 8 Hammer Ball Pin 15 Nos 171 2,565 Non Branded 9 Single Arm Torque Wrench Covering 1-7 mkg 1 Nos 3,700 3,700 Taparia or Equivalent 10 Single Arm Torque Wrench Covering 3-14 mkg 1 Nos 4,200 4,200 Taparia or Equivalent 11 Single Arm Torque Wrench Covering 5-23 mkg 1 Nos 4,600 4,600 Taparia or Equivalent 12 Cross Wheel Spanner (17 x x 21 mm) 5 Nos 320 1,600 Taparia or Equivalent 13 Bench Vice (100 mm x 4") 2 Nos 3,000 6,000 Multi Brands 14 Working Bench Wooden 2 Nos 8,000 16,000 Fabricated 15 Vernier Callipers 4 Nos 900 3,600 Mitutoyo or Equivalent 16 Micrometre (Size: 0 to 25 mm) 4 Nos 1,200 4,800 Mitutoyo or Equivalent 17 Digital Multimeter with Various Lead Sets 2 Nos Mitutoyo or Equivalent 18 Work Bench Wooden (Two) Size: 4*3*2.5" in Feet 2 Nos 7,500 15,000 Fabricated 19 Hacksaw (300 mm) with Blade 15 Nos 300 4,500 Non Branded 20 Tyre Pressure Gauge 2 Nos Multi Branded 21 Steel Rule 15 Nos 75 1,125 Non Branded 22 Tape Measure 15 Nos 75 1,125 Multi Branded 23 Depth Gauge 2 Nos Mitutoyo or Equivalent 24 Hydrometer 2 Nos Multi Branded *Price is indicative for the major brands, similar tools/equipment may be used **Brands are illustrative, other brands with same specifications may be used 13

14 5 ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT S. No. Equipment Name Qty Unit Unit Price* Amount Brands** Type (INR) (INR) 25 Tyre Pressure Gauge 2 Nos Multi Branded 26 Plastic Hammer 5 Nos 326 1,630 Non Branded 27 Filter Adjustable Remover 1 Nos Non Branded 28 Spark Plug Sockets 67 mm Drive Size 16/21 mm 2 Nos Non Branded 29 Magnetic Pickup Tool (Bar) 2 Nos 545 1,090 Non Branded 30 Dial Gauge (Mahr 10 mm Range ) 5 Nos 385 1,925 Mitutoyo or Equivalent 31 Wire Brush 5 Nos Non Branded 32 Hydraulic Jacks 3 Ton 1 Nos 1,13,000 1,13,000 Multi Branded 33 Air Compressor and Hoses 1 Nos 1,50,000 1,50,000 Atlas Capco or Equivalent 34 Tyre Inflator 1 Nos 18,000 18,000 Multi Branded 35 Battery Charger 1 Nos 3,825 3,825 Multi Branded 36 Universal Battery Tester and Probe 2 Nos 899 1,798 Multi Branded 37 Creeper 2 Nos 3,000 6,000 Non Branded 38 Drain Pans / Engine Tray 12" x 18", 18'' x 24" 6 Nos 1,000 6,000 Non Branded 39 Screw Extractor Set 2 Nos Non Branded 40 Temperature Sensing Device 2 Nos Multi Branded 41 Wheel Chocks 6 Nos 445 2,670 Non Branded 42 Measuring Can 2 Nos Non Branded 43 Two Post Lift 1 Nos 1,65,000 1,65,000 Multi Branded 44 Neon Timing Light 3 Nos 4,200 12,600 Multi Branded 45 Battery & Charging System Tester 1 Nos 13,500 13,500 Non Branded 46 Injector Tester and Cleaner 1 Nos 19,500 19,500 Bosch or Equivalent 47 Air Tester Filter Machine 1 Nos 12,490 12,490 Bosch or Equivalent *Price is indicative for the major brands, similar tools/equipment may be used **Brands are illustrative, other brands with same specifications may be used 14

15 5 ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT S. No. Equipment Name Qty Unit Unit Price* Amount Brands** Type (INR) (INR) 48 A/c Leakage Tester 1 Nos 4,490 4,490 Bosch or Equivalent 49 Wheel Balancer (Optima D ) 1 Nos 1,14,000 1,14,000 Multi Branded 50 Tyre Changer (Trufit) 1 Nos 1,08,000 1,08,000 Multi Branded 51 Head Light Focusing 1 Set 34,950 34,950 Multi Branded 52 Pneumatic Tools 1 Set 35,320 35,320 Taparia or Equivalent 53 Wheel Aligner 1 Nos 5,61,000 5,61,000 Multi Branded 54 Goggles 15 Nos 119 1,785 3 m or Equivalent 55 Ear Plugs 15 Nos 132 1,980 3 m or Equivalent 56 Gloves 15 Nos 71 1,065 3 m or Equivalent 57 First Aid 2 Nos 2,000 4,000 Non Branded 58 Powder Based Fire Extinguisher Class ABC, 500 gm 4 Nos 2,500 10, Water Stored Pressure Fire Extinguisher Class A, 9 ltr 2 Nos 2,500 5,000 Cease Fire or Equivalent Cease Fire or Equivalent 60 Safety Sign 1 Nos 5,000 5,000 Non Branded 61 Complete Car Cut Section 1 50,000 50,000 Multi Branded 62 Petrol Vehicle - Minimum Maruti Alto 1 Nos 1,00,000 1,00, Diesel Vehicle - Minimum Indica / Indigo 1 Nos 1,50,000 1,50, Aggregate Car Petrol (Engine, Transmission System, Brake System, Suspension System, Steering System, Electrical System, etc. Mounted on Chassis) - Minimum Maruti Alto Maruti Alto or Equivalent Indica / Indigo or Equivalent 1 Set 1,00,000 1,00,000 Non Branded 65 Special Maintenance Tool for Maruti Suzuki Alto 1 Set 15,000 15,000 Taparia or Equivalent 66 Diesel Engine Mounted on Stand Four Cylinder Inline Engine 1200 CC Tata Sumo (Preferred) 1 Nos 20,000 20,000 Gypsy or Tata Sumo *Price is indicative for the major brands, similar tools/equipment may be used **Brands are illustrative, other brands with same specifications may be used 15

16 5 ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT S. No. Equipment Name Qty Unit Unit Price* Amount Brands** Type (INR) (INR) 67 Clutch System Gypsy or Tata Sumo 1 Nos 4,000 4,000 Gypsy or Tata Sumo Gear Box Mounted on Stand Gypsy 1 Nos 4,500 4,500 Gypsy or Tata Sumo 68 or Tata Sumo (Synchromesh) 69 Propeller Shaft - Gypsy or Tata Sumo (Preferred) 1 Nos 2,500 2,500 Gypsy or Tata Sumo 70 Differential Mounted on Stand - Gypsy 1 Nos 4,500 4,500 Gypsy or Tata Sumo or Tata Sumo (Preferred) 71 Starter Motor - Lucas or Equivalent 12 Volt / 1kW 1 Nos 3,000 3,000 Lucas or Equivalent 72 Alternator Lucas or Equivalent 12 Volt / 70 amp 1 Nos 2,500 2,500 Lucas or Equivalent 73 Steering System Rack Travel 136 mm 1 Nos 3,000 3,000 Rane or Equivalent Rane Male or Equivalent 74 Air Assisted Brake System 1 Nos 2,590 2,590 Bosch or Equivalent 75 Brake System Hydraulic any 4-Wheeler 1 Nos 3,500 3,500 Bosch or Equivalent Fuel Pump (12 V Electrical Fuel Pump) - 3 Nos 1,800 5,400 Multi Branded 76 Maruti or Tata Motor Preferred 77 Water Pump 3 Nos 1,500 4,500 Multi Branded 78 Radiator for 4-Wheeler 3 Nos 3,000 9,000 Multi Branded 79 Fuel Filter 3 Nos 500 1,500 Bosch or Equivalent 80 Oil Filter 3 Nos 600 1,800 Multi Branded Almirah for Keeping Tools 6' Height x 3' Width x 1.75' 81 2 Nos 10,000 20,000 Fabricated Depth and 18 Gauge 82 Tool Board 1 Nos 2,750 2,750 Fabricated Total 22,92,509 *Price is indicative for the major brands, similar tools/equipment may be used **Brands are illustrative, other brands with same specifications may be used 16

17 6 SAFETY INSTRUCTIONS Given below Safety Instruction posters should be placed at appropriate places in the lab. The posters should be digitally printed and pasted on sun board. Power Tools Precaution CAUTION SLIPPERY When in Fire Situation, Please Remember PASS PULL... the pin. Some extinguishers may require releasing of a lock latch, pressing a puncture lever or other motion AIM... low, pointing the extinguisher nozzle (or it's horn or hose) towards the base of the fire SQUEEZE... the handle. This releases the extinguishing agent FLOOR SWEEP... from side to side at the base of the fire until it appears to be out. Watch the fire area in case fire breaks out again and repeat use of extinguisher, if necessary 17

18 6 SAFETY INSTRUCTIONS Electrical Hazards Do not work in wet work areas or cramped up work spaces Do not leave naked or loose wires in the lab Electrical exposure may lead to falls, fractures and other accidents. A small shock can cause brain damage while death can occur from large shocks. ELECTRICAL HAZARDS Electrical Safety Use dry gloves Wear rubber soled shoes Protect yourself from surfaces that conduct electricity Keep insulation on all equipment Components must be dry and in good condition Do not do wiring with bare hands, wet gloves or while standing on wet or ungrounded surfaces 18

of India We are a youthful nation. Our youth is our strength.

19 Shri Rajiv Pratap Rudy Minister of State (I/C) for Skill Development & Entrepreneurship Govt. of India We are a youthful nation. Our youth is our strength. The world and India need a skilled workforce and we are committed to achieve this mission. 19

Lab Specifications. Automotive 2 Wheeler Repair

Lab Specifications. Automotive 2 Wheeler Repair Lab Specifications Automotive 2 Wheeler Repair An initiative of Ministry of Skill Development & Entrepreneurship, Govt. of India and National Skill Development Corporation 02 If we have to promote the