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AUTO MACHINE (TWO WHEELER /THREE WHEELER)


NAME OF THE TRADE  : AUTO MACHINE (TWO WHEELER /THREE WHEELER)

N.C.O. CODE NO  :843.20, 843.30, 843.50, 843.60,

PERIOD OF BASIC TRAINING :ONE YEAR

TOTAL PERIOD OF APPRENTICE SHIP TRAINING  :TWO YEAR

DURATION OF SHOP FLOOR TRAINING.  :PASSED 8TH CLASS OR ITS EQUIVALENT.

REBATE ALLOWED FOR EX-ITI  :ONE YEAR.TRAINEES TOWARDS APPRENTICESHIP TRAINING PASSED MECHANIC MOTOR VEHICLE UNDER CTS

SYLLBUS FOR THE TRADE OF AUTO MACHINE UNDER APPRENTICESHIP TRAINING SCHEME :-

LIST OF OPERATION – BASIC TRAINING (ONE YEAR)

ACHIEVEMENTS:-

THE TRAINEES SHOULD BE ABLE TO DO:-

  1. Simple fitting operation.
  2. Simple sheet metal joints.
  3. Removing , dismantling the engine of two / three wheelers ( for two stroke and four stroke engine )
  4. Reconditioning the different components and reassembling the engine.
  5. Adjust clutch pedal play.
  6. Repair the defects of clutch, gear, propeller shaft and rear axels.
  7. Check and adjust tooth connect in final drive assembly, adjust backlash.
  8. Dismantling, assembling different components of transmission system, steering and brake system, suspension system, electrical system.
  9. Repair and fitting of tyre.
  10. The tracing and rectifying the trouble shooting complaints.
  11. Servicing of the vehicle.
  12. Body repair and spray painting work.

SYLLABUS FOR PRACTICAL TRAINING (SHOP FLOOR TRAINING):

  1. ENGINE REPAIR WORK.

    1. Removing engine from vehicle, observing all safety precautions.
    2. Dismantling cylinder head and decarbonising.
    3. Reconditioning valves – valve seats ( for four stroke engine)
    4. Removing piston.
    5. Dismantling piston rings, cleaning, checking and refitting.
    6. Checking main bearing and crank shaft connecting rod.
    7. Checking connecting rod bearing and alignment of connecting rod.
    8. Checking and cleaning of oil passage in crank shaft and engine block. (For 4 stroke engine with oil sump.)
    9. Fitting cylinder head and forging to correct specifications.
    10. Assembling overhead valve assembly and adjusting tappers.( 4 stroke engine)
    11. Removing exhaust manifold, silencer pipe, silencer cleaning and refitting.
    12. Cleaning and testing fuel tank for leaks.
    13. Overhauling carburetor.
    14. Checking leakage in fuel line.
    15. Overhauling a fly wheel magneto or a distributor assembly.
    16. Testing induction coil and condenser.
    17. Cleaning and testing spark plug.
    18. Testing engine compression with compression gauge.
    19. Overhauling of oil pump – 4 stroke engine and 2 stroke engine.
    20. Inspection of cam chain, types of cam chain tensioner, valve grinding, inspection of bent valves, valve and valve guide clearance, valve timing, adjustments.
    21. Setting of ignition timing in O.B. point system.
    22. Testing and inspection of various components of electronic ignition system.
    23. Inspection of various intake systems (reed valve, rotary disc. Valve, piston valve etc.)
    24. Inspection of engine foundation bushes and replacement of the same.
    25. Starting engine and adjusting slow speed of engine.
    26. Checking normal speed and high speed of engine.
    27. Trouble shooting in engine.

  2. TRANSMISSION WORK

    1. Overhauling of clutch and gear unit.
    2. Overhauling of the drive assembly and propeller shaft.( for 3 wheeler)
    3. Overhauling of rear axle assembly (for 3 wheeler) and adjusting the tooth contact in final drive assembly.
    4. Identifying noise and rectify in the transmission assembly.
    5. Overhauling of reverse gear mechanism.
    6. Overhauling of gear shifting mechanism.

  3. STEERING, BRAKE, SUSPENSION AND TYRE REPAIRING WORK

    1. Overhauling of the steering system.
    2. Repairing, inflating to correct pressure and fitting of tyre.
    3. Checking the free movement of the steering.
    4. Overhauling of the brake system.
    5. Adjustment of brake and free play of brake pedal.
    6. Checking of brake binding.
    7. Checking / repairing / replacing the suspension system, checking of brake absorber and spring tensioner.
    8. Checking of looseness of spokes and turning the wheel.
    9. Checking of unusual noise from the suspension.

  4. ELECTRICAL WORKS.

    1. Repairing of components in lighting circuits.
    2. Resting bulbs and replacing fuses, maintenance and changing of battery.
    3. Repairing and adjusting electric horn.
    4. Studying the electric circuits and wiring, trouble in electrical circuit using A.V.O. Meter testing voltage regulators, rectifier’s indicator circuits.

  5. SERVICING & SERVICE STATION

    1. 51 Schedule replacement of oil and filter and general servicing work.
    2. Repairing of jacks, grease gun, oil spray guns.
    3. Practice in use of special tools.

  6. TROUBLE SHOOTING

    1. Diagnosis of faults in engine, steering brake, and transmission system and rectify them.
    2. Preventive maintenance.

  7. BODY MAINTANING AND CLEANING.

    1. Practice of time to time complete cleaning of vehicle, Use of buffing compound, polishing, under chassis painting and oil spraying.