STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN (NATIONAL OCCUPATIONAL SKILL STANDARD)

Transcription

1 STANDARD KEMAHIRAN PEKERJAAN KEBANGSAAN (NATIONAL OCCUPATIONAL SKILL STANDARD) P MEKANIK KENDERAAN MOTOR (MOTOR VEHICLE MECHANIC) P MEKANIK KENDERAAN MOTOR (MOTOR VEHICLE MECHANIC) P JURUTEKNIK KENDERAAN MOTOR (MOTOR VEHICLE TECHNICIAN) Kementerian Sumber Manusia, Malaysia

2 5. JAWATANKUASA PROFIL TUGASAN 6. PROFIL TUGASAN

3 PENDAHULUAN 1. Pembentukan Standard Kemahiran Kebangsaan (SKK) 1.1 Standard Kemahiran Pekerjaan Kebangsaan (SKPK) [National Occupational Skill Standard (NOSS) adalah satu dokumen yang menggariskan perkaraperkara yang perlu diperolehi oleh seseorang pekerja di dalam sesuatu bidang kemahiran. Semua perkara yang terkandung di dalam SKPK akan dinilai berasaskan ketrampilan untuk memastikan setiap pekerja berkebolehan melakukan perkara-perkara berkenaan pada tahap yang boleh diterima. 1.2 Pembentukan Standard Kemahiran Pekerjaan Kebangsaan dilakukan dengan melibatkan pakar-pakar dari industri (awam dan swasta) dan personel dari agensi/institusi latihan, mengikut bidang masing-masing. Pembentukannya dilakukan dalam dua peringkat: Peringkat pertama dinamakan Job Analysis melibatkan antara lapan hingga sepuluh orang personel industri yang dijemput mengambil bahagian dalam pembentukan standard berkenaan. Mereka bersidang antara dua hingga tiga hari untuk menghasilkan rangka standard, yang disusun dalam bentuk carta. Carta ini mengandungi dua komponen penting iaitu Duti (Duty) dan Tugasan (Task) yang dinamakan carta profil pekerjaan. Carta ini kemudiannya diedarkan kepada industri yang terlibat untuk mendapatkan komen. Peringkat kedua dinamakan Task Analysis dilakukan dengan melibatkan ahli-ahli jawatankuasa peringkat pertama tadi dan ditambah dengan beberapa orang personel dari agensi/institusi latihan. Mereka bersidang empat hingga lima hari. Pada peringkat ini, carta profil pekerjaan yang mengandungi duti dan tugasan itu dikupas secara terperinci. Sesuatu tugasan itu disediakan dengan Performance Standard (PS), langkah-langkah kerja, keperluan memboleh (Enabling Requirement) dan peralatan dan perkakas. Produk Task Analysis ini dinamakan Task Profile. 2. Format Standard Kemahiran Pekerjaan Kebangsaan 2.1 Dokumen standard adalah mengandungi perkara-perkara berikut: Tajuk Takrif Pekerjaan Task Profile yang merupakan jadual-jadual yang mengandungi Performance Standard, langkah-langkah kerja, keperluan memboleh Enabling Requirement dan peralatan dan perkakas.

4 2.2 Tiap-tiap dokumen standard yang dibentuk, disediakan dengan Takrif Pekerjaan (Occupational Defination) mengikut tajuk standard berkenaan. Seboleh mungkin, takrif pekerjaan ini akan berlandaskan kepada Dictionary of Classification (DOC) yang dikeluarkan oleh Jabatan Tenaga Manusia Kementerian Sumber Manusia. Terdapat dua kategori takrif pekerjaan iaitu: Takrif pekerjaan tahap 1 dan 2 merangkumi kemahiran pengetahuan di peringkat operasi/pengeluaran. Takrif pekerjaan 3 merangkumi kemahiran dan pengetahuan diperingkat penyelia / juruteknik. 2.3 Sesuatu standard mengandungi sekumpulan duti yang merupakan unit-unit kemahiran dalam standard berkenaan, dan duti-duti tersebut adalah tidak bergantungan di antara satu sama lain. Tiap-tiap duti mengandungi sekumpulan tugasan. Pengrekodan tugasan-tugasan adalah mengikut ciri berikut: Ia mengandungi kata perbuatan (action verb) dan objek yang menerima perbuatan tersebut. Ia mestilah jelas dan tepat. Ia boleh mengandungi satu atau lebih qualifier 3. Tahap-tahap dalam Standard Kemahiran Pekerjaan Kebangsaan 3.1 Dokumen standard ini mengandungi tiga tahap iaitu 1.2 dan 3. Tahap-tahap tersebut adalah berkait rapat dengan sistem Persijilan Kemahiran Kebangsaan. Dalam erti kata lain, seseorang individu yang telah mencapai kemahiran dalam tahap 1akan diberi Sijil Kemahiran Malaysia Tahap 1 dan seterusnya. 3.2 Penjelasan bagi ketiga-tiga tahap adalah seperti berikut: Tahap 1 Trampil dalam melakukan sekumpulan duti pada tahap ini bagi bidang pekerjaan berkaitan. Ketrampilan yang terkandung dalam tajap ini kebanyakannya adalah routine dan predictable. Tahap 2 Trampil dalam melakukan sekumpulan duti pada tahap ini. Ketrampilan yang terkandung dalam tahap ini sesetengahnya adalah bukan routine dan dilakukan dalam pelbagai konteks yang memerlukan tanggungjawab persendirian dan autonomi. Tahap 3

5 Trampil dalam melakukan sekumpulan duti pada tahap ini. Ketrampilan yang terkandung dalam tahap ini merangkumi sekumpulan duti yang luas dalam pelbagai konteks dan bukan routine dan autonomi serta perlu memberi kawalan dan panduan kepada yang lain. 3.3 Khusus bagi Tahap 3, kandungan kemahiran yang terdapat dalam dokumen ini adalah meliputi kemahiran teknikal sahaja dan tidak meliputi kemahiran penyeliaan. Untuk kemahiran penyeliaan perlu menggunakan dokumen tambahan bidang penyeliaan tahap Kelulusan Jawatan Standard dan Persijilan (JSP) 4.1 Dokumen ini telah diluluskan oleh Jawatankuasa Standard dan Persijilan (JSP) Majlis Latihan Vokasional Kebangsaan pada 16 Julai NOSS asal yang bertajuk Mekanik Kenderaan Motor telah diwujudkan pada 7 Julai Ketua Pengarah Majlis Latihan Vokasional Kebangsaan Kementerian Sumber Manusia Malaysia KUALA LUMPUR

6 TAKRIF PEKERJAAN (OCCUPATIONAL DEFINITION) LEVEL 1 Occupational Definition of A Motor Vehicle Mechanic A Motor Vehicle Mechanic is designated to perform activities such as servicing, overhauling and replacing of defective components including recommending to customer the life span of parts and their durability. In particulars he/she: 1. Performs vehicle maintenance. 2. Services carburetion system, diesel fuel system, and vehicle electrical system. 3. Performs engine repair by service cooling and lubricating system and carry out top overhaul. 4. Repairs manual drive train by checking transaxle, transmission and rear axle. 5. Repairs brake system by bleeding brake system. 6. Repairs steering and suspension system.

7 TAKRIF LEVEL 2 OCCUPATIONAL Definition of A Motor Vehicle Mechanic A Motor Vehicle Mechanic is designated to perform activities such as servicing, overhauling and replacing of defective components including recommending to customer the life span of part and their durability. In particular he/she: 1. Services carburetion system 2. Services diesel system 3. Services vehicle electrical system 4. Performs engine repair by carrying out engine overhaul 5. Services electronic fuel injection system 6. Repairs clutch system 7. Repairs manual drive train 8. Repairs brake system 9. Repairs steering system 10. Services turbocharger

8 LEVEL 3 OCCUPATIONAL Definition of A Motor Vehicle Technician A Motor Vehicle Technician is designated to perform activities that involves analysis, synopsis and performs diagnostics testing for the whole motor vehicle system. He also determines the serviceability and the life spans of component including recommending suitable components for charges. He also responsible for supervising, training and guiding mechanics under his supervision in arranging out normal duties. In particular he/she: 1. Performs road test and analyze test results. 2. Services diesel duel system by overhaul fuel injection pump. 3. Repairs manual drive train by overhaul transfer box. 4. Repairs automatic transmission by conducting pressure and stall test, test drive, gear shift pattern and overhaul automatic transmission. 5. Overhaul turbocharger. 6. Performs supervisory function.

9 AHLI JAWATANKUASA ANALISIS PERKERJAAN BAGI BIDANG MEKANIK KENDERAAN BERMOTOR EN. LEONG CHOK FONG Tractor s Malaysia Sdn. Bhd. EN. CHEAH WING YEW Cycle & Carriage Bintang Bhd. EN. VINCENT CHONG Perunding Kemahiran Penyeliaan & Pengurusan Sdn. Bhd. EN. MOHD YUNUS BIN AHMAD IKM- Lumut EN. MOHD NOR BIN BORHAN IKM- Lumut EN. MOHD EFFENDI OOI ABDULLAH MPT-Cheras EN. MOHD AINI BIN MAHNI PPKK, Jab. Kebajikan Masyarakat, Malaysia. EN. WANG ANUAR FOOT HIANG Tractor s Malaysia Sdn. Bhd. EN. ANUAR BIN OTHMAN Tan Chong Motor & Sons EN. AHMAD ZAMRI BIN SAID IJED, Port Dickson EN. ISMAIL BIN IBRAHIM IJED, Port Dickson

10 EN. P. PERIASAMY Sek. Men. Teknik, Port Dickson URUSETIA EN ZAHARUDIN BIN ABDUL LATIF MLVK

11 JOB PROFILE FOR A 1) MOTOR VEHICLE MECHANIC - LEVEL 1 2) MOTOR VEHICLE MECHANIC - LEVEL 2 3) MOTOR VEHICLE TECHNICIAN - LEVEL 3 DUTY TASK PERFORM VEHICLE MAINTENANCE AND ROAD TEST Carry out service on vehicle Carry out check according to vehicle maintenance charts Carry out corrective measures Carry out road test Analyse road test result L L L L L3 SERVICE CARBURETOR SYSTEM Check fuel system for proper function Check air and fuel filters Replace fuel pump Tune up carburetor Replace fuel tank Overhaul carburetor L L L L L L2 SERVICE DIESEL FUEL SYSTEM Check diesel fuel system for proper functioning Change diesel fuel filter Test diesel fuel injectors Time diesel fuel injection pump to engine Overhaul diesel fuel injection pump L L L L L3 SERVICE VEHICLE ELECTRICAL SYSTEM Check charging system Check starting system Check ignition system Check lighting system Adjust alignment of head lamp Check wiper system Overhaul starter motor Overhaul distributor Overhaul alternator L L L L L L L L L2 Check dashboard instruments Check power windows L L3 PERFORM ENGINE REPAIR Service cooling system Service lubricating system Determine engine condition Carry out top overhaul Carry out engine overhaul L L L L L2 P-010-1/2/3 (JSP 2/98)16 Julai 98

12 DUTY Task SERVICE ELECTRONIC FUEL INJECTION SYSTEM Check electronic fuel injection electronic fuel injection (EFI) system pressure Replace electrical fuel pump Replace fuel injectors Replace air flow meter Replace electronic fuel injection (EFI) sensors Replace electronic fuel injection (EFI) relay Check electronic fuel injection (EFI) wiring system Replace electronic control unit (ECU) Check function of emission control devices L L L L L L L L L3 REPAIR CLUTCH SYSTEM Check condition of clutch system Replace clutch cable Bleed clutch hydraulic system Overhaul clutch master pump/slave cylinder Replace clutch pressure plate, disc and bearing L L L L L2 REPAIR MANUAL DRIVE TRAIN Check transaxle Check transmission Check rear axle Overhaul transmission Overhaul rear axle Overhaul transaxle Overhaul transfer box L L L L L L L3 REPAIR AUTOMATIC TRANSMISSION Service automatic transmission Replace torque converter Conduct pressure and stall test Test drive gear shift pattern Check electronic transmission sensors Overhaul automatic transmission L L L L L L3 REPAIR BRAKING SYSTEM Replace brake pad and lining Replace brake disc and drums Replace brake booster Bleed brake system Overhaul master pump Overhaul brake calipers and wheel cyclinders Test brake system performance on the road Test anti-lock brake system L L L L L L L L3 REPAIR STEERING SYSTEM Service manual steering system Replace manual steering system component Carry out wheel alignment Overhaul manual steering box Service power steering system Overhaul power steering system L L L L L L2 REPAIR SUSPENSION SYSTEM Replace ball joints Replace suspension bushes Replace shock absorbers/bump stoppers Remove tyres from rims Remove coil springs/leaf springs Service suspension components L L L L L L2

13 SERVICE AIR CONDITIONING SYSTEM Check airconditioning belt and tension Check air conditioning system cooling capacity Check air conditioning system for gas leak Service air conditioning gas system Install air conditioning hoses, receiver drier, compressor and condenser Install evaporator coil and blower L L L L L L2 SERVICE TURBO CHARGER Carry out check on turbocharger Test turbocharger boost pressure Check turbocharger lubrication pressure Replace turbocharger Overhaul turbocharger L L L L L3

14 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 01 DUTY: PERFORM VEHICLE MAINTENANCE AND ROAD TEST TASK NO: 01 TASK: CARRY OUT SERVICE ON VEHICLE LEVEL: L1 PERFORMANCE STANDARD : CARRY OUT SERVICE ON VEHICLE GIVEN SERVICE MANUALS USING HAND TOOLS ETC. SO THAT THE VEHICLE CAN OPERATE AT OPTIMUM CONDITION. SUB-TASK / STEP 1. Change lubrication oil and oil filter 1.1 Function of lubrication system 1.2 Types of oil filter 1.3 Grade of lubrication oil 1.4 Service intervals chart 1.1 Interpret service chart 1.2 Drain out lubrication oil 1.3 Remove oil filter 1.4 Install new oil filter 1.5 Fill in lubrication oil 1. Service manual 2. Maintenance chart 3. Hand tolls 4. Lubrication oil 5. Grease 6. Vacuum cleaner 7. High water pressure pump 8. Air filter 9. Oil filter 11

15 2. Replace air filter 3. Wash vehicle Attitude : 1.1 No spilling on the floor 1.2 Good house keeping 1.3 Fender cover 1.4 Handle lubrication and oil filter with care 1.5 Use funnel 1.1 Remove battery terminals 1.2 Use parking brake 1.3 Use wheel stopper 1.4 Ensure no leakage at drain plug and oil filter 2.1 Purpose of air filter 2.2 Types of air filter 2.1 Remove air filter 2.2 Identify correct air filter 2.3 Install new air filter and tighten according to specification Attitude/safety : 2.1 Ensure air filter properly installed 2.2 Handle air filter with care 3.1 Area prohibited to spray with high water pressure 3.2 Types of cleaning detergent 3.3 Types of degreaser 12

16 4. Vacuum interior of vehicle 5. Lubricate door hinges and cable 3.1 Use suitable cloth for washing and drying 3.1 Ensure the water hose do not scratch paint work 3.2 Use suitable cleaning detergent 4.1 Operation of vacuum machine 4.1 Vacuum the interior compartment Attitude : 4.1 Cleanliness 5.1 Types of lubrication 5.2 Types of grease 5.1 Lubricate the cable 5.2 Grease the door hinges Attitude : 5.1 Good house keeping 5.2 Do not slam the door 5.1 Do not spill oil on the floor 13

17 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 01 DUTY: PERFORM VEHICLE MAINTENANCE AND ROAD TEST TASK NO: 02 TASK: CARRY OUT CHECK ACCORDING TO VEHICLE MAINTENANCE CHARTS LEVEL: L1 PERFORMANCE STANDARD CARRY OUT CHECK ACCORDING TO VEHICLE MAINTENANCE CHARTS GIVEN SERVICE MANUAL USING HAND TOOLS ETC. SO THAT VEHICLE CAN FUNCTION ACCORDING TO MANUFACTURER'S SPECIFICATION. SUB-TASK / STEP 1. Determine the maintenance schedule of vehicle 2. Carry out vehicle maintenance 1.1 Maintenance chart list 1.1 Select correct maintenance charts 2.1 Read maintenance chart 2.1 Interpret maintenance chart 1. Maintenance chart 2. Hand tools 3. Floor jack 4. Special tools 5. Hoist 6. Sand paper 7. Service manual 8. Replacement part 14

18 Attitude 2.1 Good working habit 2.2 Cleanliness 2.3 Good house keeping 2.4 Use fender/seat/steering wheel cover 2.1 Remove battery terminal 15

19 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 01 DUTY: PERFORM VEHICLE MAINTENANCE AND ROAD TEST TASK NO: 03 TASK: CARRY OUT CORRECTIVE MEASURES LEVEL: L2 PERFORMANCE STANDARD : CARRY OUT CORRECTIVE MEASURES GIVEN SERVICE MANUAL AND USING MAINTENANCE CHECK LIST SO THAT VEHICLE CAN OPERATE WITH OPTIMUM PERFORMANCE ACCORDING TO MANUFACTURER S SPECIFICATION. SUB-TASK / STEP 1. Follow vehicle maintenance check list, diagnose all faults 1.1 Basic principle of automobile 1.1 Diagnose the faults 1.2 Interprete the service manual Attitude : 1.1 Use fender cover 1.2 Good house keeping 1.1 Remove battery terminal 1. Service manual 2. Fender cover 3. Hand tools 4. Special tools 5. Replacement part 16

20 2. Removal of faulty parts 2.1 Serviceable parts 2.1 Remove faulty parts 2.2 Interprete workshop manual Attitude : 2.1 Handle the parts with care 2.2 Good house keeping 2.3 Use fender cover 2.1 Remove battery terminal 3. Inspect faulty parts 3.1 Condition of serviceable faulty parts 3.1 Differentiate serviceable faulty parts Attitude : 3.1 Handle parts with care 3.2 Good house keeping 17

21 4. Install new parts 4.1 Serviceable parts condition 4.1 Select the serviceable parts 4.2 Install the parts in systematic procedure 4.3 Carry out adjustment (if necessary) according to specification Attitude/safety : 4.1 Use fender cover 4.2 Good house keeping 4.3 Handle the parts with care 18

22 OCCUPATION : MOTOR VEHICLE MECHANIC DUTY NO. 01 DUTY: PERFORM VEHICLE MAINTENANCE AND ROAD TEST TASK NO: 04 TASK: CARRY OUT ROAD TEST LEVEL: L3 PERFORMANCE STANDARD CARRY OUT ROAD TEST GIVEN SERVICE MANUAL USING VEHICLE STETHOSCOPE ETC. SO THAT ANY DEFECT OR MALFUNCTION OF VEHICLE SYSTEM CAN BE DETECTED SUB-TASK / STEP 1. Check vehicle before road test 1.1 Basic principle of automobile 1.1 Check the vehicle condition 1. Service manual 2. Job card 3. Vehicle 4. Stethoscope 2. Drive vehicle for road test 2.1 Basic principle of automobile 2.2 Road safety sign 2.1 Select all gears during driving 2.2 Handle vehicle on various road condition 19

23 Attitude : 2.1 Road courtesy 2.2 Safe driving 2.1 Use seat belt 2.2 Possess a valid driving license 2.3 Obey road signs 3. Identify and locate noise source/ defects 3.1 Various types of noise 3.1 Differentiate the types of noise ; a) rattle b) humming c) vibration d) engine sound 3.2 Locate abnormal noise of vehicle Attitude : 3.1 Road courtesy 3.2 Safe driving 3.1 Use seat belt 3.2 Possess a valid driving license 20

24 4. Record test result 4.1 Test report job card 4.1 Write the job card 21

25 OCCUPATION: MOTOR VEHICLE TECHNICIAN DUTY NO. 01 DUTY: PERFORM VEHICLE MAINTENANCE AND ROAD TEST TASK NO: 05 TASK: ANALYZE ROAD TEST RESULT LEVEL: L3 PERFORMANCE STANDARD ANALYZE ROAD TEST RESULT GIVEN SERVICE MANUAL USING TECHNICAL REPORT, EVALUATION FORM ETC. SO THAT THE VEHICLE PERFORMANCE MEET THE MANUFACTURER S SPECIFICATION. SUB-TASK / STEP 1. Analyze the road test result report 1.1 Various types of noise 1.1 Differentiate the types of noise ; a) rattle b) humming c) vibration d) engine sound 1. Service manual 2. Vehicle 3. Road test report form 22

26 2.Report job that not meet the specification 2.1 Basic principle of automobile 2.2 Test report 2.1 Locate abnormal noise from vehicle 3. Send the vehicle to workshop for rework 3.1 Basic principle of automobile 3.1 Rectify the defect 3.2 Follow service manual Attitude : 3.1 Use fender cover 3.2 Good house keeping 3.1 Disconnect battery terminals 4. Retest the vehicle 4.1 Basic principle of automobile 4.2 Road safety sign 23

27 4.1 Select all gears during driving 4.2 Handle vehicle on various road condition Attitude : 4.1 Road courtesy 4.2 Safe driving 4.1 Use seat belt 4.2 Possess a valid driving license 24

28 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 02 DUTY: SERVICE CARBURATION SYSTEM TASK NO: 01 TASK: CHECK FUEL SYSTEM FOR PROPER FUNCTION LEVEL: L1 PERFORMANCE STANDARD CHECK FUEL SYSTEM FOR PROPER FUNCTION GIVEN WORKSHOP SERVICE MANUAL USING HAND TOOLS AND EQUIPMENT SO THAT THE FUEL SYSTEM FUNCTION ACCORDING TO MANUFACTURER S STANDARD SUB-TASK / STEP 1. Inspect fuel system components for damage and fuel leaks 1.1 Fuel system layout 1.2 Fuel system component 1.1 Visual check for damaged components 1.2 Visual check fuel leaks 1.3 Check and tighten connecting clips on fuel hoses 1.1 No smoking 1.2 Keep away from spark or fire 1.3 Perform task in well ventilated area 1. Service manual 2. Hand tools 3. Fuel pressure gauge 25

29 2. Install fuel pressure gauge to the fuel system 2.1 Basic operation of fuel system 2.2 Follow service manual 2.1 Connect fuel pressure gauge 2.1 No smoking 2.2 Keep away from spark or fire 3. Start engine and observe fuel pressure when engine running 3.1 Basic operation of fuel system 3.2 Pressure gauge 3.1 Read fuel pressure gauge 3.2 Read service manual 3.1 Handle with care 4. Remove fuel pressure gauge from fuel system 4.1 Fuel system layout 26

30 4.1 Disconnect fuel pressure gauge 4.2 Install fuel system pipe line 4.3 Check fuel system in proper fixing 4.1 Take care for fuel leakage 27

31 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 02 DUTY: SERVICE CARBURATION SYSTEM TASK NO: TASK: CHECK AIR AND FUEL FILTERS LEVEL: L1 PERFORMANCE STANDARD CHECK AIR AND FUEL FILTERS GIVEN SERVICE MANUAL USING HAND TOOLS SO THAT THE ENGINE PERFORMANCE MEETS MANUFACTURER S STANDARD SUB-TASK / STEP 1. Determine the condition of air filter. (Replace if necessary) 1.1 Design and function of air filter 1.1 Remove air filter 1.2 Check air filter 1.3 Clean air filter 1.4 Install air filter 1. Service manual 2. Hand tools 3. Air filter 4. Fuel filter 2. Determine the condition of fuel filter. (Replace if necessary) 2.1 Design and function of fuel filter 28

32 2.1 Remove fuel filter 2.2 Check fuel filter 2.3 Install fuel filter 2.1 Keep away from spark or fire 3. Check engine performance 3.1 Engine performance criteria 3.1 Check engine performance 3.2 Visual check for fuel leak at fuel filter joint 3.1 Handle with care 29

33 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 02 DUTY: SERVICE CARBURATION SYSTEM TASK NO: TASK: REPLACE FUEL PUMP LEVEL: L1 PERFORMANCE STANDARD REPLACE FUEL PUMP GIVEN SERVICE MANUAL USING HAND TOOLS, FUEL PUMP SO THAT THE FUEL SYSTEM WILL FUNCTION ACCORDING TO MANUFACTURER S STANDARD SUB-TASK / STEP 1. Remove fuel hoses connected to the fuel pump 1.1 Fuel system layout or diagram 1.2 Type of fuel hose 1.1 Disconnect fuel hose from fuel pump 1. Service manual 2. Hand tools 3. Fuel pump 1.1 Keep away from spark or fire 1.2 Remove negative battery terminal 2. Remove fuel pump from the engine 2.1 Types and construction of fuel pump 30

34 2.2 Operation of fuel pump 2.1 Remove fuel pump 2.2 Check function of fuel pump 2.1 Keep away from spark or fire 3. Install new fuel pump to the engine and connect the hoses 3.1 Operation of fuel pump 3.1 Test fuel pump 3.2 Fix fuel pump correctly to the engine 4. Start engine and check engine performance 4.1 Engine performance criteria 31

35 4.1 Check engine performance 4.2 Visual inspection of fuel leak at fuel pump 4.3 Connect battery terminal 4.1 Handle with care 32

36 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 02 DUTY: SERVICE CARBURATION SYSTEM TASK NO: TASK: TUNE UP CARBURETOR LEVEL: L1 PERFORMANCE STANDARD TUNE UP CARBURETOR GIVEN SERVICE MANUAL USING HAND TOOLS SO THAT AIR FUEL MIXTURE IS TUNE TO MEET THE MANUFACTURER S STANDARD SUB-TASK / STEP 1. Calibrate exhaust gas analyzer 1.1 Exhaust gas analyzer 1.1 Handle exhaust gas analyzer 1.2 Connect gas analyzer probe to the exhaust pipe and other connection 1. Service manual 2. Hand tools 3. Exhaust gas analyzer (4-gas) 4. Tachometer 1.1 Ensure the exhaust gas analyzer is connected properly 33

37 2. Adjust air fuel mixture 2.1 Basic carburetor tune up 2.2 Exhaust gas analyser 2.1 Adjust idling speed 2.2 Read gas value for carbon monoxide (CO) and hydrocarbon (HC) at exhaust gas analyzer 2.3 Adjust air/fuel mixture 2.4 Use tachometer 3. Disconnect probe and exhaust gas analyzer 3.1 Exhaust gas analyzer 3.2 Engine performance criteria 3.1 Remove exhaust gas analyzer from engine 3.2 Check engine performance Attitude : 3.1 Maintain good house keeping 34

38 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 02 DUTY: SERVICE CARBURATION SYSTEM TASK NO: TASK: REPLACE FUEL TANK LEVEL: L2 PERFORMANCE STANDARD REPLACE FUEL TANK GIVEN SERVICE MANUAL USING HAND TOOLS SO THAT THE FUEL TANK CAN BE INSTALLED ACCORDING TO MANUFACTURER'S STANDARD SUB-TASK / STEP 1. Disconnect fuel pipe/line 2. Remove fuel tank 1.1 Fuel system layout 1.2 Fuel tank construction and function 1.1 Identify component of fuel system 1.2 Drain fuel from fuel tank 1.3 Use hand tools/container/funnel 1.1 Keep away from fire or spark 2.1 Fuel system layout 1. Service manual 2. Hand tools 3. Petrol 4. Container 5. Funnel 6. Vehicle 35

39 2.1 Remove fuel tank securing bolts 2.1 Handle with care 3. Install new fuel tank 3.1 Fuel system layout 3.1 Connect fuel lines/pipe to the tank 3.2 Tighten securing bolts for fuel tank 3.3 Tighten fuel lines/pipe clips 3.1 Handle with care 4. Check engine performance 4.1 Fuel system layout 36

40 4.1 Tighten fuel tank drain plug 4.2 Refill fuel into the tank 4.3 Check fuel leakage Attitude : 4.1 Maintain good house keeping 37

41 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 02 DUTY: SERVICE CARBURATION SYSTEM TASK NO: TASK: OVERHAUL CARBURETOR LEVEL: L2 PERFORMANCE STANDARD OVERHAUL CARBURETOR GIVEN SERVICE MANUAL USING HAND TOOLS SO THAT THE CARBURETOR FUNCTION ACCORDING TO THE MANUFACTURER S STANDARD SUB-TASK / STEP 1. Remove carburetor from intake manifold 1.1 Layout of fuel system 1.2 Function of carburetor 1.1 Identify location of carburetor 1.2 Remove air cleaner and housing from carburetor 1.3 Remove fuel line/wire connector/cable from carburetor 1.1 Remove battery terminal 1. Service manual 2. Hand tools 3. Petrol 4. Tray 5. Carburetor repair kit 6. Exhaust gas analyzer 7. Tachometer 8. Carburetor Services special tool 9. Straight edge 38

42 2. Dismantle and clean carburetor 2.1 Construction and operation of carburetor 2.2 Function of carburetor circuit 2.1 Remove mounting bolts 2.2 Clean carburetor components and kits 2.1 Keep away from fire or spark 3. Assemble carburetor components and kits 3.1 Construction and operation of the carburetor 3.1 Replace parts according to condition 3.2 Measure and adjust float level 3.3 Fix carburetor components 4. Check intake manifold surface 4.1 Straight edge 39

43 5. Install carburetor to intake manifold 4.1 Clean surface of intake manifold 4.2 Measure surface of intake manifold for carburetor position 5.1 Fuel system layout 6. Check engine performance 5.1 Fix carburetor insulator and gasket 5.2 Tighten carburetor mounting bolts 5.3 Fix fuel hose/cable/wire connector 5.1 Handle with care 6.1 Engine performance criteria 6.2 Exhaust gas analyzer 6.3 Exhaust gas and air/fuel mixture 6.1 Check fuel leakage 6.2 Tune up carburetor to specification 6.3 Use exhaust gas analyzer Attitude : 6.1 Use fender cover 6.2 Good housekeeping 40

44 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 03 DUTY: SERVICE DIESEL FUEL SYSTEM TASK NO: 01 TASK: CHECK DIESEL FUEL SYSTEM FOR PROPER FUNCTIONING LEVEL: L1 PERFORMANCE STANDARD CHECK THE DIESEL FUEL SYSTEM FOR PROPER FUNCTIONING GIVEN SERVICE MANUAL USING HAND TOOLS, FILTER WRENCH ETC, SO THAT THE SYSTEM FUNCTION ACCORDING TO THE MANUFACTURER S SPECIFICATIONS SUB-TASK / STEP 1. Determine fuel system layout 2. Check fuel feed (lift) pump 1.1 Fuel system layout 1.2 Basic diesel engine operation 1.1 Locate diesel fuel system component 1.1 Perform task in a well ventilated area 2.1 Operation of lift pump 2.2 Location of lift pump Ability to 2.1 Operation fuel feed pump 1. Hand tools 2. Service manual 3. Filter wrench 4. Diesel tray 5. Service special tools (SST) 41

45 3. Check hoses and pipes for leaks 3.1 Function of hoses and pipes 3.1 Distinguish low pressure and high pressure pipes 3.2 Check and rectify leaks 4. Check fuel injection pipe (FIP) linkages or proper connections 5. Check fuel filter for clog 4.1 Function and operation of fuel injection pipe (FIP) 4.2 Type of fuel injection pipe (FIP) 4.1 Check loose linkages 4.2 Use correct hand tools 4.1 Use only flaring tools service special tools (SST) 5.1 Design and function of fuel filter 42

46 5.1 Check fuel filter 5.2 Remove fuel filter 5.3 Install fuel filter 5.4 Bleed diesel fuel system 5.1 Keep away from spark or fire 43

47 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 03 DUTY: SERVICE DIESEL FUEL SYSTEM TASK NO: 02 TASK: CHANGE DIESEL FUEL FILTER LEVEL: L1 PERFORMANCE STANDARD CHANGE DIESEL FUEL FILTER GIVEN NEW FILTER USING HAND TOOLS AND FILTER WRENCH, SO THAT THE FILTER ARE SECURELY INSTALLED ACCORDING TO SPECIFICATION SUB-TASK / STEP 1.Locate the primary and secondary fuel filter 1.1 Filter construction and function 1.1 Identify the primary and secondary filter 1. Filter wrench 2. Hand tools 3. Diesel tray 4. Diesel fuel filter 2. Remove the fuel filter 2.1 Type of filter 2.1 Remove fuel filter mounting bolts 44

48 Safety / attitude : 2.1 Good housekeeping 3. Check the new filter 3.1 Part number of the diesel fuel filter 3.1 Identify the correct fuel filter 4. Install the new filter and tighten to proper torque 4.1 Diesel fuel system 4.1 Use torque wrench 4.1 Do not over tighten 5. Bleed the fuel system 5.1 Bleeding procedure of the diesel fuel system 5.2 Purpose of bleeding diesel fuel system 5.1 Prime fuel feed pump 5.2 Identify bleeding screws 5.3 Carry out bleeding according to procedure 45

49 Safety / attitude : 5.1 Proper house keeping 5.2 Handle with care 46

50 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 03 DUTY: SERVICE DIESEL FUEL SYSTEM TASK NO: 03 TASK: TEST DIESEL FUEL INJECTORS LEVEL: L1 PERFORMANCE STANDARD TEST DIESEL FUEL INJECTORS GIVEN SERVICE MANUAL USING THE HAND TOOLS, NOZZLE TESTING EQUIPMENT AND NOZZLE CLEANING KIT ETC, SO THAT THE INJECTORS ARE FUNCTIONING ACCORDING TO MANUFACTURER S SPECIFICATIONS. SUB-TASK / STEP 1. Remove the fuel injectors from the engine 2. Mount the fuel injector to the diesel injector tester 1.1 Type and construction of injectors 1.2 Function of injector 1.1 Unscrew the injectors from engine 2.1 The functions of injector tester 2.1 Install the injector to injector tester 2.2 Operate the injector tester 1. Hand tools 2. Nozzle testing equipment 3. Test oil/filtered diesel 4. Nozzle cleaning kit 5. Diagram of correct spray pattern 6 Diesel tachometer 7 Service manual 47

51 3. Determine the spray pattern and pressure 2.1 Handle with care 3.1 Type of spray pattern 3.2 Specification of injector pressure 3.1 Operate injector tester 3.2 Read fuel gauge 3.1 Keep hand away from nozzle while testing 4. Service fuel injector 4.1 Construction of injector 4.1 Dismantle injectors 4.2 Clean injector 4.3 Adjust injector 4.1 Handle with care 5. Install the injectors to the engine 5.1 Layout of diesel fuel system 5.2 Function of injector 48

52 Ability to 5.1 Install the fuel injector 5.2 Connect high pressure line 5.3 bleed fuel system 6. Start engine and adjust idling speed 6.1 Air intake system 6.2 Principle of diesel engine 6.1 Adjust idling speed 6.2 Use diesel tachometer 49

53 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 03 DUTY: SERVICE DIESEL FUEL SYSTEM TASK NO: 04 TASK: TIME DIESEL FUEL INJECTION PUMP TO ENGINE LEVEL: L2 PERFORMANCE STANDARD TIME DIESEL FUEL INJECTION PUMP TO ENGINE GIVEN THE SERVICE MANUAL USING HAND TOOLS, SPECIAL TIMING TOOLS, SWAN NECK ETC, SO THAT THE FUEL INJECTION PUMP IS CORRECTLY TIMED TO THE ENGINE ACCORDING TO MANUFACTURER S SPECIFICATION SUB-TASK / STEP 1. Select special timing tools 1.1 Type of fuel injection pump (FIP) 1.2 Special timing tools 1.1 Use special timing tools 1. Special timing tools 2. Swan neck 3. hand tools 4. Service manual 2. Set injection timing 2.1 Type and construction of engine 2.2 Basic diesel engine operation 50

54 2.1 Mount service special tools (SST) 2.2 Set timing alignment 3. Install fuel injection pump (FIP) to engine 3.1 Injection timing 3.2 Timing of engine and fuel injection pump (FIP) 3.1 Locate install and time fuel injection pump (FIP) to the engine Attitude : 3.1 Tighten mounting bolt 4. Perform spill port timing 4.1 Injection pump timing 4.2 Spill port timing procedures 4.1 Perform spill port timing 4.2 Use swan neck 4.1 Adhere to all safety and proper working procedure 4.2 Maintain good house keeping 51

55 5. Start engine and adjust timing 5.1 Bleeding technique 5.2 Injection pump timing 5.1 Bleed fuel system and start engine 5.2 Check timing by using tachometer 5.3 Adjust idling speed 5.1 Maintain good house keeping 5.2 Observe safety while adjusting injection pump timing 52

56 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 03 DUTY: SERVICE DIESEL FUEL SYSTEM TASK NO: 05 TASK: OVERHAUL DIESEL FUEL INJECTION PUMP LEVEL: L3 PERFORMANCE STANDARD OVERHAUL DIESEL FUEL INJECTION PUMP GIVEN SERVICE MANUAL USING SPECIAL SERVICE TOOLS, TEST BENCH AND PARTS SO THAT THE FUEL INJECTION PUMP PERFORM ACCORDING TO MANUFACTURER S SPECIFICATION SUB-TASK / STEP 1. Mount fuel injection pump to special jigs 2. Dismantle fuel injection pump component 1.1 Type and construction of fuel injection pump 1.1 Mount fuel injection pump to jig 1.2 Choosing the correct jig and service special tools (SST) 2.1 Construction and function of fuel injection pump 2.2 Layout of fuel injection pump components 1. Hand tools 2. Diesel test bench 3. Service special tools 4. Service manual 5. Spare parts 6. Cleaning kit 53

57 2.1 Overhaul fuel injection pump 2.2 Use special service tools Safety/Attitude : 2.1 Handle with care 2.2 Arrange part in orderly manner 3. Assemble the parts/components to fuel injection pump 3.1 Construction and function of fuel injection pump 3.1 Assemble component completely and correctly 3.2 Use service special tools 3.1 Handle with care 54

58 4. Perform phasing and calibration 4.1 Phasing and calibrating technique 4.2 Test bench function 4.1 Operate test bench 4.2 Carry out phasing and calibration according to specification Safety/Attitude : 4.1 Handle with care 4.2 Good house keeping 55

59 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL SYSTEM TASK NO: 01 TASK: CHECK CHARGING SYSTEM LEVEL: L1 PERFORMANCE STANDARD CHECK CHARGING SYSTEM GIVEN SERVICE MANUAL USING MULTI METER SO THAT THE RATE OF CHARGING VOLTAGE AND AMPERE MEETS THE MANUFACTURER S SPECIFICATION SUB-TASK / STEP 1. Check the condition of battery 2. Connect the voltmeter/ampere meter to the identified location 1.1 Basic electricity 1.2 Construction of battery 1.3 Specific gravity 1.4 High discharge tester 1.1 Check battery voltage 1.2 Use multi meter 1.3 Use hydrometer 1.1 Caution of polarity 1.2 Handle with care 1.3 Task to be performed in a well ventilated area 2.1 Charging system wiring layout 2.2 Construction of alternator 2.3 Types of wiring connectors 1. Multi meter 2. Basic electric hand tools 3. Service manual 4. Soldering iron 5. Solder "sucker" 6. Hydrometer 7. High discharge tester 56

60 2.1 Connect volt/ampere meter at correct location 2.2 Adjust alternator belt tension 2.3 Remove wire connectors 3. Obtain reading of charging voltage/ampere 3.1 Correct charging rate 3.2 Current out put 3.1 Obtain charging voltage reading 3.2 Obtain ampere reading 57

61 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL SYSTEM TASK NO: 02 TASK: CHECK STARTING SYSTEM LEVEL: L1 PERFORMANCE STANDARD CHECK STARTING SYSTEM GIVEN SERVICE MANUAL USING VOLTMETER ETC, SO THAT THE STARTING SYSTEM IS FUNCTIONING PROPERLY. SUB-TASK / STEP 1. Check the battery condition 1.1 Basic electricity 1.2 Construction of battery 1.3 Specific gravity 1.1 Check battery voltage 1.2 Use volt meter 1.3 Use hydrometer 1.1 Caution of polarity 1. Voltmeter 2. Hand tools 3. Service manual 4. Engine with starter motor 5. Hydrometer 2. Check wiring for starting system 2.1 Basic starter motor principle 2.2 Construction of starter motor 2.3 Wiring diagram of starter motor 58

62 2.1 Identify location of starter motor 2.2 Use multi meter 3. Check the solenoid switch 3.1 Function of solenoid switch 3.2 Types of wiring connector's 3.1 Connect and test solenoid switch 3.2 Remove wiring connector 4. Crank engine and check voltage drop Knowledge of ; 4.1 Ohm s law 4.2 Fleming s left hand rule 4.3 Basic electricity and internal resistance 4.1 Use multi meter 4.2 Connect multi meter 4.3 Check voltage drop 4.1 Caution on polarity 59

63 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL SYSTEM TASK NO: 03 TASK: CHECK IGNITION SYSTEM LEVEL: L1 PERFORMANCE STANDARD CHECK IGNITION SYSTEM GIVEN SERVICE MANUAL USING MULTI METER AND TIMING LIGHT, SO THAT THE IGNITION SYSTEM IS FUNCTIONING PROPERLY. SUB-TASK / STEP 1. Identify the ignition system and components 1.1 Four stroke cycle engine 1.2 Ignition system and components 1.1 Identify ignition system components. 1. Hand tools 2. Multi meter 3. Timing light 4. Service manual 2. Obtain wiring diagram of ignition system 2.1 Layout of wiring diagram of ignition system 2.1 Read ignition system wiring diagram 3. Check primary circuit by using multi meter 3.1 Basic electricity 3.2 Function and operation of primary circuit in ignition system 60

64 4. Check the secondary circuit for proper output 3.1 Use multi meter 3.1 Handle with care 4.1 Function and operation of the secondary circuit 4.2 Spark plug function 4.1 Check spark in ignition system 5. Check ignition coil 5.1 Function, operation and construction of ignition coil 5.1 Check resistance in ignition coil 6. Check contact breaker point/igniter/pick-up coil 6.1 Function of contact breaker point/igniter/pick-up coil 6.1 Check contact breaker point visually 6.2 Use multi meter 6.3 Check igniter/pick-up coil 61

65 7. Check ignition timing using timing light 7.1 Ignition timing 7.1 Use timing light 62

66 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL SYSTEM TASK NO: 04 TASK: CHECK LIGHTING SYSTEM LEVEL: L1 PERFORMANCE STANDARD CHECK LIGHTING SYSTEM GIVEN SERVICE MANUAL USING MULTI METER/TEST LAMP SO THAT THE LIGHTING SYSTEM IS FUNCTIONING PROPERLY. SUB-TASK / STEP 1. Identify the lighting system component 1.1 Lighting system wiring diagram 1.2 Lighting system components 1.1 Read wiring diagram 1. Hand tools 2. Multi meter 3. Test lamp 4. Wiring manual/service manual 2. Determine the location of lighting components 2.1 Construction of the lighting system components 2.1 Identify lighting system components 63

67 3. Test current flow in the system using multi meter or test lamp 3.1 Ohm's law 3.1 Use multi meter and test lamp 3.2 Check current and voltage in lighting system 4. Replace defective bulb 4.1 Type of the bulbs 4.1 Check continuity of the bulb 4.2 Use multi meter 64

68 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL SYSTEM TASK NO: 05 TASK: ADJUST ALIGNMENT OF HEAD LAMPS LEVEL: L1 PERFORMANCE STANDARD ADJUST ALIGNMENT OF HEAD LAMPS GIVEN SERVICE MANUAL USING HEAD LIGHT ALIGNMENT TESTER, SUITABLE TOOLS ETC SO THAT THE HEIGHT OF HEADLIGHT BEAM IS ADJUSTED TO MANUFACTURER'S SPECIFICATION SUB-TASK / STEP 1. Drive the car to the proper light testing area 1.1 Lighting system wiring diagram 1.2 Basic electricity 1.3 Basic requirement of headlight alignment 1.1 Set up head lamp alignment tester 1. Hand tools 2. Service manual 3. Head lamp alignment tester 4. Tyre pressure gauge 2. Check tyre pressure 2.1 Proper tyre pressure for head lamp alignment 2.1 Use tyre pressure gauge 3. Position light alignment machine or board Knowledge of ; 3.1 Operation of light alignment machine 65

69 3.1 Use light alignment board/machine 4. Switch on the dim switch and check the focusing of the light knowledge of : 4.1 Focusing low beam lighting system 4.1 Adjust low beam 4.2 Use light alignment board/machine 5. Switch on the high beam 5.1 Focusing high beam 5.1 Adjust high beam 5.2 Use light alignment board/machine 66

70 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL SYSTEM TASK NO: 06 TASK: CHECK WIPER SYSTEM LEVEL: L1 PERFORMANCE STANDARD CHECK WIPER SYSTEM GIVEN SERVICE MANUAL USING HAND TOOLS MULTI METER SO THAT THE SYSTEM WORKS PROPERLY ACCORDING TO MANUFACTURERS SPECIFICATION SUB-TASK / STEP 1. Identify location of wiper motor and wind screen washer motor 2. Check wiper motor at intermittent, low and high position 1.1 Basic electricity 1.2 wiring diagrams 1.1 Locate wiper motor and wind screen washer motor 1.1 Caution of polarity 1.2 Handle with care 2.1 Ohm s law 2.2 Wiring diagrams 2.3 Wiper relay s function 1. Hand tools 2. Multi meter 3. service manual 67

71 2.1 Connect test wire at correct position 2.2 Use multi meter 2.3 Test intermittent relay 3. Check wind screen washer motor 3.1 Ohm s law 3.2 Wiring diagram 3.1 Check voltage with multi meter 3.1 Caution of polarity 3.2 Handle with care 68

72 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL SYSTEM TASK NO: 07 TASK: OVERHAUL STARTER MOTOR LEVEL: L1 PERFORMANCE STANDARD OVERHAUL STARTER MOTOR GIVEN SERVICE MANUAL USING HAND TOOLS, MULTI METER, TEST BENCH OR GROWLER SO THAT THE STARTER MOTOR FUNCTION PROPERLY ACCORDING TO SPECIFICATION SUB-TASK / STEP 1. Disconnect the battery terminal Knowledge of ; 1.1 Basic electricity 1.1 Remove battery terminal according to procedure 1. Hand tools 2. Multi meter 3. Electrical test bench 4. Growler tester 5. Service manual 2. Remove starter motor from engine Knowledge of ; 2.1 Starter motor principle 2.2 Ohm s law 2.1 Identify starter motor location 2.2 Disconnect starter motor connector/cable 69

73 2.1 Handle with care 3. Dismantle the starter motor 3.1 Construction of starter motor 3.1 Identify starter motor components 3.1 Handle with care 3.2 Caution on polarity 4. Conduct continuity test, short circuit and open circuit on coils, armature, commutator 4.1 Basic electric 4.2 Wiring circuit/diagram 4.3 Starter motor construction 4.1 Use multi meter 4.2 Use growler 4.1 Handle with care 4.2 Caution on polarity 70

74 5. Measure length of the carbon brush and replace if necessary 5.1 Function of carbon brush 5.2 Vernier caliper 5.3 Electric soldering iron 5.1 Use vernier caliper 5.2 Use electric soldering iron 5.3 Connect carbon brush wire 5.1 Handle with care 5.2 Caution on polarity 6. Check and replace bushing/bearing 6.1 Type of bearing/bushing use 6.1 Remove and replace bush/bearing 6.2 Determine bush condition 6.3 Check bearing condition 7. Reassemble the starter motor 7.1 Construction of starter motor 7.1 Assemble starter motor 71

75 8. Test the solenoid/starter motor - Pull-in test - Hold-in test - Free-load test - Load test 8.1 Starter motor operation 8.2 Solenoid operation 8.1 Conduct pull in test and hold in test 8.2 Use test bench 8.1 Handle with care 8.2 Caution on polarity 9. Install starter motor to the engine 9.1 Wiring diagram of starter motor 9.2 Type of connectors 9.1 Fix starter motor in correct position 9.2 Fix cable and battery terminal in correct position 9.1 Handle with care 72

76 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL SYSTEM TASK NO: 08 TASK: OVERHAUL DISTRIBUTOR LEVEL: L2 PERFORMANCE STANDARD OVERHAUL DISTRIBUTOR GIVEN SERVICE MANUAL, HAND TOOLS AND MULTI METER SO THAT THE DISTRIBUTOR FUNCTION ACCORDING TO MANUFACTURER'S SPECIFICATION SUB-TASK / STEP 1. Disconnect high tension wire 1.1 Basic electricity 1.2 Operation in ignition circuit/diagram 1.3 Operation of vacuum advance 1.4 Operation of centrifugal advance 1.5 Component of ignition system 1.6 Firing order 1. Hand tools 2. Service manual 3. Multi meter 1.1 Identify distributor location 1.2 Identify high tension leads 1.3 Determine correct firing order 1.1 Handle with care 1.2 Caution on polarity 73

77 2. Remove the distributor from the engine 2.1 Function of distributor 2.2 Type of distributor 2.1 Identify type of distributor 2.2 Disconnect wire connector 3. Dismantle the distributor 3.1 Function of distributor 3.2 Construction of distributor 3.1 Remove distributor cap 3.2 Remove distributor components 3.1 Handle with care 3.2 Caution on polarity 4. Check distributor component for proper functioning 4.1 Function of component in distributor 4.1 Use multi meter 4.2 Test distributor components 74

78 5. Reassemble distributor components 5.1 Construction of distributor 5.1 Fix component in correct position 6. Install distributor to the engine 6.1 Diagram of ignition system 6.2 Ignition timing diagram 6.3 Advance/Retard mechanism 6.1 Set compression stroke for number one cylinder 6.2 Fix distributor correctly according to procedure 6.3 Install high tension cables/leads according to firing order 7. Start the engine and check ignition timing according to specification 7.1 Ignition timing 7.2 Advance and retard mechanism 7.1 Use timing light 7.2 Adjust ignition timing 7.1 Handle with care 75

79 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL SYSTEM TASK NO: 09 TASK: OVERHAUL ALTERNATOR LEVEL: L2 PERFORMANCE STANDARD OVERHAUL ALTERNATOR GIVEN SERVICE MANUAL USING MULTI METER/TEST BENCH SO THAT THE RATE OF CHARGING VOLTAGE AND AMPERE MEETS THE MANUFACTURER'S SPECIFICATION SUB-TASK / STEP 1. Disconnect battery terminal 1.1 Basic electricity 1.1 Remove battery terminal 1. Hand tools 2. Service manual 3. Multi meter 4. Ampere meter 5. Voltmeter 2. Remove alternator from engine 2.1 Generator/Alternator principle 2.2 Ohm s law 2.1 Identify alternator location 2.2 Disconnect alternator connector 2.1 Handle with care 2.2 Caution on polarity 76

80 3. Dismantle the alternator 3.1 Alternator construction 3.2 Type of alternator 3.1 Dismantle alternator components 3.1 Handle with care 3.2 Caution on polarity 4. Carry out continuity test 4.1 Basic electricity 4.2 Charging system wiring diagram 4.3 Alternator construction 4.1 Use multi meter 4.2 Check alternator components 4.1 Handle with care 5. Assemble the alternator 5.1 Alternator construction 77

81 5.1 Fix the components at the correct position 5.2 Assemble alternator 6. Install alternator to the engine 6.1 Location of alternator in the engine 6.2 Type of belt 6.1 Fix alternator at correct position 6.2 Adjust alternator belt tension 7. Test voltage and current output 7.1 Ohm s law 7.2 Alternator operation 7.1 Perform alternator output test 7.1 Caution on polarity 7.2 Handle with care 78

82 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL SYSTEM TASK NO: 10 TASK: CHECK DASH BOARD INSTRUMENTS LEVEL: L2 PERFORMANCE STANDARD CHECK DASH BOARD INSTRUMENT GIVEN WIRING BLUE PRINT OF VEHICLE USING A MULTI METER, ETC SO THAT THE GAUGES AND INDICATOR LAMPS FUNCTION CORRECTLY SUB-TASK / STEP 1. Obtain wiring circuit diagram of vehicle 1.1 Wiring diagram system 1.1 Read wiring diagram 1. Multi meter 2. Wiring blue print of vehicle 3. Hand tools 4. Service manual 2. Identify wiring sockets and connectors 2.1 Type of socket connector 2.2 Wire colour coding and sizes 2.1 Disconnect connector 2.2 Read wiring diagram 79

83 3. Remove meter panel from dash board 3.1 Layout of meter panel/instrument cluster 3.2 Symbol of meter panel/instrument cluster 3.1 Disconnect the connector from meter panel 3.2 Disassemble meter panel from dash board 3.1 Handle with care 4. Check gauges and indicators for proper functioning (replace if necessary) 4.1 Layout of meter panel/instrument cluster 4.1 Use multi meter 4.2 Identify connection and continuity at meter panel 4.3 Test gauges at meter panel 5. Install meter panel to dash board 5.1 Layout of meter panel/instrument cluster 5.1 Fix meter panel at correct position to dash board 5.2 Connect connector to panel meter/instrument cluster 5.1 Handle with care 80

84 OCCUPATION: MOTOR VEHICLE TECHNICIAN DUTY NO. 04 DUTY: SERVICE ELECTRICAL SYSTEM TASK NO: 11 TASK: CHECK POWER WINDOWS LEVEL: L3 PERFORMANCE STANDARD CHECK POWER WINDOWS GIVEN SERVICE MANUAL USING MULTI METER, HAND TOOLS ETC SO THAT POWER WINDOWS FUNCTION PROPERLY ACCORDING MANUFACTURER S SPECIFICATION SUB-TASK / STEP 1. Check wiring circuit for : - Solenoid motor - Switches - Relays - Linkage 2. Check continuity of each components 1.1 Basic electricity/ Electromagnetic Force 1.2 Function of solenoid motor and relays 1.3 Layout of power windows wiring diagram 1.1 Use multi meter 1.2 Read wiring diagram 1.3 Identify and locate of power window parts 1.4 Test voltage in wiring circuit Safety / attitude : 1.1 Handle with care 2.1 Ohm s law 2.2 Multi switch function 2.3 Fuse type and function 1. Hand tools 2. Service manual 3. Multi meter 81

85 2.1 Use multi meter 2.2 Test multi switch/switches/fuse 2.3 Remove multi switch/switches Safety / attitude : 2.1 Handle with care 82

86 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 05 DUTY: PERFORM ENGINE REPAIR TASK NO: 01 TASK: SERVICE COOLING SYSTEM LEVEL: L1 PERFORMANCE STANDARD SERVICE COOLING SYSTEM GIVEN SERVICE MANUAL USING RADIATOR PRESSURE TESTER, HAND TOOLS ETC SO THAT THE OPERATION MEET THE REQUIREMENT OF MANUFACTURER S SPECIFICATION SUB-TASK / STEP 1. Identify the component location 1.1 Cooling system layout 1.1 Locate each individual component 1.1 Handle with care 1. Hand tools 2. Service manual 3. Radiator pressure tester 4. Radiator hoses 2. Check leakage of the system with radiator pressure tester 2.1 The function of radiator pressure tester 2.2 Cooling system 2.1 Use radiator pressure tester 2.2 Interpret test result 83

87 2.1 Follow manufacturer s specification when pressurizing the cooling system Attitude : 2.1 Good house keeping 2.2 Use fender cover 3. Conduct visual inspection on hoses ( replace if necessary) 4. Check thermostat for proper functioning 3.1 Cooling system layout 3.1 Identify faulty hoses 3.2 Replace new hoses 3.1 Beware of hot hoses Attitude : 3.1 Good house keeping 3.2 Use fender cover 4.1 Function of thermostat 4.2 Engine working temperature Ability to: 4.1 Carry out testing on thermostat 4.2 Read thermometer 4.1 Handle with care 84

88 Attitude : 4.1 Good house keeping 5. Check water pump (replace if necessary) 5.1 Function of water pump 5.1 Identify faulty water pump 5.2 Replace water pump 5.3 Check and adjust fan belt 5.1 Handle with care Attitude : 5.1 Use fender cover 5.2 Good house keeping 6. Flush radiator 6.1 Function of radiator 6.1 Remove radiator from vehicle 6.1 Do not open the cap of hot radiator 6.2 Release system pressure before removing radiator cap Attitude : 6.1 Use fender cover 6.2 Good house keeping 85

89 OCCUPATION: MOTOR VEHICLE MECHANIC DUTY NO. 05 DUTY: PERFORM ENGINE REPAIR TASK NO: 02 TASK: SERVICE LUBRICATING SYSTEM LEVEL: L1 PERFORMANCE STANDARD SERVICE LUBRICATING SYSTEM GIVEN SERVICE MANUAL USING HAND TOOLS PRESSURE GAUGE, AND MULTI METER SO THAT THE ENGINE LUBRICATING SYSTEM OPERATE ACCORDING TO THE MANUFACTURER S SPECIFICATION SUB-TASK / STEP 1. Determine the layout of lubricating system components 1.1 Function of lubricating system and components 1.1 Identify system and components layout Attitude : 1.1 Use fender cover 1. Hand tools 2. Oil pressure gauge 3. Service manual 4. Multi meter 5. Fender cover 86

90 2. Check lubricating oil for leakage while engine running 2.1 Function of lubricating system 2.1 Identify oil leakage Safety / attitude : 2.1 Good house keeping 2.2 Use fender cover 3. Check the pressure of lubricating system 3.1 Function of lubricating system 3.1 Read oil pressure gauge/oil warning light Safety / attitude : 3.1 Good house keeping 3.2 Use fender cover 4. Replace oil pressure switch 4.1 Procedure of testing oil pressure switch 4.1 Use and read multi meter 87