lab specifications 4 wheeler · pdf filemachine - man ratio 1. 4 ... 65 special maintenance...

Lab Specifications

An initiative of Ministry of Skill Development & Entrepreneurship, Govt. of India

and National Skill Development Corporation

Automotive – 4 Wheeler Repair

02LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR

03

Shri Narendra ModiHonourable Prime Minister

If we have to promote the

development of our country

then our mission has to be

‘skill development’ and

‘skilled India’.

LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR

04

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.


05

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

SECTOR

AUTOMOTIVE – 4 WHEELER REPAIR


06

DESCRIPTION OF LAB

Lab Specifications for the Listed Sectors / Job Roles

1

Proposed Batch Size


Machine - ManRatio

1. 4 Wheeler Service Technician – Level 4

2. AC Specialist

3. Brake Specialist

4. Automotive Electrician Level - 4

5. Clutch Specialist

6. Chauffeur-cum-Taxi Driver

7. Automotive Sales Head (Retail)

8. Sales Representative

9. Showroom Hostess

10. Service Office Executive

11. 4 Wheeler Service Technician – Level 3

Some of the above mentioned job roles may be done with planning and delivery methodology.

25

1:5

LIST OF TOOLS & EQUIPMENT - AUTOMOTIVE – 4 WHEELER REPAIR

2

07

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 20 10 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



12 Cross Wheel Spanner (17 x 18 - 19 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


2

08

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




2

09

49 Diagnostic Tool 1 Nos

50 Brake Bleeder, Pressure or Vacuum 1 Nos

51 Wheel Balancer (Optima D - 6111) 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

Aggregate Car Petrol ( Engine, Transmission System, Brake System, Suspension 64 1 Set System, Steering System, Electrical System, etc. Mounted on Chassis) - 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




2

10


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



3D REPRESENTATION OF AUTOMOTIVE – 4 WHEELER REPAIR LAB

3

11

List of Equipment

Entry Store Room

Engine Cut Section and Aggregates Auto Electrician Cut Section and Work Area

Vertical Hydraulic Hoist Service Area

Work Benches for Observers Classrooms

Diagosnistic Equipment Transmission Cut Section Area

Chassis with Gear Box and Steering Section Air Compressor

Vehicle Service Area


12

ILLUSTRATIVE ARCHITECTURAL LAYOUT OF LAB4


ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT5

13

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 340 680 Non Branded

4 Chisel - Drop Forge 16 x 22 x 20 10 Nos 140 1,400 Non Branded

5 Oil Can - Wesco Type 4 Nos 110 440 Non Branded

6 Centre Punches 10 Nos 70 700 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



12 Cross Wheel Spanner (17 x 18 - 19 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 475 950 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 210 420 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 180 360 Mitutoyo or Equivalent

24 Hydrometer 2 Nos 200 400 Multi Branded

S. No. Equipment Name Qty Unit Unit Price* Amount Brands**(INR) (INR)Type

*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

25 Tyre Pressure Gauge 2 Nos 210 420 Multi Branded

26 Plastic Hammer 5 Nos 326 1,630 Non Branded

27 Filter Adjustable Remover 1 Nos 390 390 Non Branded

28 Spark Plug Sockets 67 mm Drive Size 16/21 mm 2 Nos 270 540 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 120 600 Non Branded

32 Hydraulic Jacks 3 Ton 1 Nos 1,13,000 1,13,000 Multi Branded

Atlas Capco or 1 Nos 1,50,000 1,50,000 33 Air Compressor and Hoses 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 394 788 Non Branded

40 Temperature Sensing Device 2 Nos 150 300 Multi Branded

41 Wheel Chocks 6 Nos 445 2,670 Non Branded

42 Measuring Can 2 Nos 450 900 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

S. No. Equipment Name Qty Unit Unit Price* Amount Brands**(INR) (INR)Type





15

S. No. Equipment Name Qty Unit Unit Price* Amount Brands**(INR) (INR)

48 A/c Leakage Tester 1 Nos 4,490 4,490 Bosch or Equivalent

49 Wheel Balancer (Optima D - 6111) 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

Cease Fire or 58 Powder Based Fire Extinguisher Class ABC, 500 gm 4 Nos 2,500 10,000 Equivalent

Cease Fire or 59 Water Stored Pressure Fire Extinguisher Class A, 9 ltr 2 Nos 2,500 5,000 Equivalent

60 Safety Sign 1 Nos 5,000 5,000 Non Branded

61 Complete Car Cut Section 1 50,000 50,000 Multi Branded

Maruti Alto 62 Petrol Vehicle - Minimum Maruti Alto 1 Nos 1,00,000 1,00,000

or Equivalent

Indica / Indigo 63 Diesel Vehicle - Minimum Indica / Indigo 1 Nos 1,50,000 1,50,000

or Equivalent

Aggregate Car Petrol (Engine, Transmission System,

1 Set 1,00,000 1,00,000 Non Branded 64 Brake System, Suspension System, Steering System,Electrical System, etc. Mounted on Chassis) - MinimumMaruti Alto

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 1 Nos 20,000 20,000 Gypsy or Tata Sumo

Engine 1200 CC Tata Sumo (Preferred)

Type





16

S. No. Equipment Name Qty Unit Unit Price* Amount Brands**(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 Sumo68 or Tata Sumo (Synchromesh)

69 Propeller Shaft - Gypsy or Tata Sumo (Preferred) 1 Nos 2,500 2,500 Gypsy or Tata Sumo

Differential Mounted on Stand - Gypsy 1 Nos 4,500 4,500 Gypsy or Tata Sumo70 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

Steering System Rack Travel 136 mm 1 Nos 3,000 3,000 Rane or Equivalent73 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 Branded76 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

Type




SAFETY INSTRUCTIONS6

17

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

FLOOR

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

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


18

SAFETY INSTRUCTIONS6

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 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

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

19

Shri Rajiv Pratap RudyMinister 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.


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