P-115-123

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 03 DUTY: SERVICE DIESEL FUEL SYSTEM

TASK NO: 05 TASK: OVERHAUL DIESEL FUEL INJECT

LEVEL: L3 PERFORMANCE STANDARD
OVERHAUL DIESEL FUEL INJECTION PUMP
BENCH AND PARTS SO THAT THE FUEL IN
SPECIFICATION

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Mount fuel injection pump to Knowledge of :
special jigs 1.1 Type and construction of fuel inje

2. Dismantle fuel injection pump Ability to :
component 1.1 Mount fuel injection pump to jig
1.2 Choosing the correct jig and serv

Knowledge of :
2.1 Construction and function of fuel
2.2 Layout of fuel injection pump com

5

TION PUMP

P GIVEN SERVICE MANUAL USING SPECIAL SERVICE TOOLS, TEST
NJECTION PUMP PERFORM ACCORDING TO MANUFACTURER’S

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ection pump 1. Hand tools
2. Diesel test bench
vice special tools (SST) 3. Service special tools
l injection pump 4. Service manual
mponents 5. Spare parts
6. Cleaning kit

3

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill,

Ability to :
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 Knowledge of :

fuel injection pump 3.1 Construction and function of fuel

Ability to :
3.1 Assemble component completely
3.2 Use service special tools

Safety :
3.1 Handle with care

5

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

l injection pump
y and correctly

4

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill,

4. Perform phasing and calibration Knowledge of :
4.1 Phasing and calibrating techniqu
4.2 Test bench function

Ability to :
4.1 Operate test bench
4.2 Carry out phasing and calibratio

Safety/Attitude :
4.1 Handle with care
4.2 Good house keeping

5

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ue

on according to specification

5

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL S

TASK NO: 01 TASK: CHECK CHARGING SYSTEM

LEVEL: L1 PERFORMANCE STANDARD
CHECK CHARGING SYSTEM GIVEN SERVIC
VOLTAGE AND AMPERE MEETS THE MANU

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Check the condition of battery Knowledge of :
1.1 Basic electricity
2. Connect the voltmeter/ampere 1.2 Construction of battery
meter to the identified location 1.3 Specific gravity
1.4 High discharge tester

Ability to :
1.1 Check battery voltage
1.2 Use multi meter
1.3 Use hydrometer

Safety :
1.1 Caution of polarity
1.2 Handle with care
1.3 Task to be performed in a well ve

Knowledge of :
2.1 Charging system wiring layout
2.2 Construction of alternator
2.3 Types of wiring connectors

SYSTEM

CE MANUAL USING MULTI METER SO THAT THE RATE OF CHARGING
UFACTURER’S SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Multi meter
2. Basic electric hand tools
3. Service manual
4. Soldering iron
5. Solder "sucker"
6. Hydrometer
7. High discharge tester

entilated area

56

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A
3. Obtain reading of charging
voltage/ampere Ability to :
2.1 Connect volt/ampere meter at co
2.2 Adjust alternator belt tension
2.3 Remove wire connectors

Knowledge of :
3.1 Correct charging rate
3.2 Current out put

Ability to :
3.1 Obtain charging voltage reading
3.2 Obtain ampere reading

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

orrect location

57

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL S
TASK NO:
LEVEL: 02 TASK: CHECK STARTING SYSTEM

L1 PERFORMANCE STANDARD
CHECK STARTING SYSTEM GIVEN SERVIC
FUNCTIONING PROPERLY.

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Check the battery condition Knowledge of :
1.1 Basic electricity
1.2 Construction of battery
1.3 Specific gravity

Ability to :
1.1 Check battery voltage
1.2 Use volt meter
1.3 Use hydrometer

Safety :
1.1 Caution of polarity

2. Check wiring for starting system Knowledge of :
2.1 Basic starter motor principle
2.2 Construction of starter motor
2.3 Wiring diagram of starter motor

SYSTEM

CE MANUAL USING VOLTMETER ETC, SO THAT THE STARTING SYSTEM IS

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Voltmeter
2. Hand tools
3. Service manual
4. Engine with starter motor
5. Hydrometer

58

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

Ability to :
2.1 Identify location of starter motor
2.2 Use multi meter

3. Check the solenoid switch Knowledge of :
3.1 Function of solenoid switch
3.2 Types of wiring connector's

Ability to :
3.1 Connect and test solenoid switch
3.2 Remove wiring connector

4. Crank engine and check voltage Knowledge of ;
drop 4.1 Ohm’s law
4.2 Fleming’s left hand rule
4.3 Basic electricity and internal resi

Ability to :
4.1 Use multi meter
4.2 Connect multi meter
4.3 Check voltage drop

Safety :
4.1 Caution on polarity

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

h
istance

59

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL S

TASK NO: 03 TASK: CHECK IGNITION SYSTEM

LEVEL: L1 PERFORMANCE STANDARD
CHECK IGNITION SYSTEM GIVEN SERVICE
IGNITION SYSTEM IS FUNCTIONING PROPE

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Identify the ignition system and Knowledge of :
components 1.1 Four stroke cycle engine
1.2 Ignition system and components

Ability to :
1.1 Identify ignition system compone

2. Obtain wiring diagram of ignition Knowledge of :
system 2.1 Layout of wiring diagram of igniti

Ability to :
2.1 Read ignition system wiring diag

3. Check primary circuit by using multi Knowledge of :

meter 3.1 Basic electricity

3.2 Function and operation of primar

SYSTEM

E MANUAL USING MULTI METER AND TIMING LIGHT, SO THAT THE
ERLY.

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

s 1. Hand tools
ents. 2. Multi meter
3. Timing light
4. Service manual

ion system
gram

ry circuit in ignition system
60

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A
4. Check the secondary circuit for
proper output Ability to :
3.1 Use multi meter
5. Check ignition coil
Safety :
6. Check contact breaker 3.1 Handle with care
point/igniter/pick-up coil
Knowledge of :
4.1 Function and operation of the se
4.2 Spark plug function

Ability to :
4.1 Check spark in ignition system

Knowledge of :
5.1 Function, operation and construc

Ability to :
5.1 Check resistance in ignition coil

Knowledge of :
6.1 Function of contact breaker poin

Ability to :
6.1 Check contact breaker point visu
6.2 Use multi meter
6.3 Check igniter/pick-up coil

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

econdary circuit

ction of ignition coil
nt/igniter/pick-up coil
ually

61

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

7. Check ignition timing using timing Knowledge of :
light 7.1 Ignition timing

Ability to :
7.1 Use timing light

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

62

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL S

TASK NO: 04 TASK: CHECK LIGHTING SYSTEM

LEVEL: L1 PERFORMANCE STANDARD
CHECK LIGHTING SYSTEM GIVEN SERVICE
SYSTEM IS FUNCTIONING PROPERLY.

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Identify the lighting system Knowledge of :
component 1.1 Lighting system wiring diagram
1.2 Lighting system components

Ability to :
1.1 Read wiring diagram

2. Determine the location of lighting Knowledge of :
components 2.1 Construction of the lighting syste

Ability to :
2.1 Identify lighting system compone

SYSTEM

E MANUAL USING MULTI METER/TEST LAMP SO THAT THE LIGHTING

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Hand tools
2. Multi meter
3. Test lamp
4. Wiring manual/service manual

em components
ents

63

SUB-TASK / STEP ENABLING RE
3. Test current flow in the system (Knowledge, Skill, A
using multi meter or test lamp
Knowledge of :
4. Replace defective bulb 3.1 Ohm's law

Ability to :
3.1 Use multi meter and test lamp
3.2 Check current and voltage in ligh

Knowledge of :
4.1 Type of the bulbs

Ability to :
4.1 Check continuity of the bulb
4.2 Use multi meter

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

hting system

64

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL S
TASK NO:
LEVEL: 05 TASK: ADJUST ALIGNMENT OF HEAD LA

L1 PERFORMANCE STANDARD
ADJUST ALIGNMENT OF HEAD LAMPS GIVE
TOOLS ETC SO THAT THE HEIGHT OF HEA

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Drive the car to the proper light Knowledge of :
testing area 1.1 Lighting system wiring diagram
1.2 Basic electricity
1.3 Basic requirement of headlight a

Ability to :
1.1 Set up head lamp alignment test

2. Check tyre pressure Knowledge of :
2.1 Proper tyre pressure for head lam

Ability to :
2.1 Use tyre pressure gauge

3. Position light alignment machine or Knowledge of ;

board 3.1 Operation of light alignment mac

SYSTEM
AMPS

VEN SERVICE MANUAL USING HEAD LIGHT ALIGNMENT TESTER, SUITABLE
ADLIGHT BEAM IS ADJUSTED TO MANUFACTURER'S SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

alignment 1. Hand tools
ter 2. Service manual
3. Head lamp alignment tester
4. Tyre pressure gauge

mp alignment

chine
65

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

Ability to :
3.1 Use light alignment board/machi

4. Switch on the dim switch and check knowledge of :

the focusing of the light 4.1 Focusing low beam lighting syste

Ability to :
4.1 Adjust low beam
4.2 Use light alignment board/machi

5. Switch on the high beam Knowledge of :
5.1 Focusing high beam

Ability to :
5.1 Adjust high beam
5.2 Use light alignment board/machi

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS
ine
em
ine

ine

66

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL S
TASK NO:
LEVEL: 06 TASK: CHECK WIPER SYSTEM

L1 PERFORMANCE STANDARD
CHECK WIPER SYSTEM GIVEN SERVICE M
WORKS PROPERLY ACCORDING TO MANU

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Identify location of wiper motor and Knowledge of :

wind screen washer motor 1.1 Basic electricity

1.2 wiring diagrams

Ability to :
1.1 Locate wiper motor and wind scr

Safety :
1.1 Caution of polarity
1.2 Handle with care

2. Check wiper motor at intermittent, Knowledge of :
low and high position 2.1 Ohm’s law
2.2 Wiring diagrams
2.3 Wiper relay’s function

SYSTEM

MANUAL USING HAND TOOLS MULTI METER SO THAT THE SYSTEM
UFACTURERS SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Hand tools
2. Multi meter
3. service manual

reen washer motor

67

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

Ability to :
2.1 Connect test wire at correct posi
2.2 Use multi meter
2.3 Test intermittent relay

3. Check wind screen washer motor Knowledge of :
3.1 Ohm’s law
3.2 Wiring diagram

Ability to :
3.1 Check voltage with multi meter

Safety :
3.1 Caution of polarity
3.2 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ition

68

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL S
TASK NO:
LEVEL: 07 TASK: OVERHAUL STARTER MOTOR

L1 PERFORMANCE STANDARD
OVERHAUL STARTER MOTOR GIVEN SER
GROWLER SO THAT THE STARTER MOTOR

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Disconnect the battery terminal Knowledge of ;
1.1 Basic electricity

Ability to :
1.1 Remove battery terminal accordi

2. Remove starter motor from engine Knowledge of ;
2.1 Starter motor principle
2.2 Ohm’s law

Ability to :
2.1 Identify starter motor location
2.2 Disconnect starter motor connec

SYSTEM

RVICE MANUAL USING HAND TOOLS , MULTI METER, TEST BENCH OR
R FUNCTION PROPERLY ACCORDING TO SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ing to procedure 1. Hand tools
2. Multi meter
3. Electrical test bench
4. Growler tester
5. Service manual

ctor/cable
69

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

Safety :
2.1 Handle with care

3. Dismantle the starter motor Knowledge of :
3.1 Construction of starter motor

Ability to :
3.1 Identify starter motor component

Safety :
3.1 Handle with care
3.2 Caution on polarity

4. Conduct continuity test, short circuit Knowledge of :
and open circuit on coils, armature, 4.1 Basic electric
commutator 4.2 Wiring circuit/diagram
4.3 Starter motor construction

Ability to :
4.1 Use multi meter
4.2 Use growler

Safety :
4.1 Handle with care
4.2 Caution on polarity

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ts

70

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

5. Measure length of the carbon brush Knowledge of :
and replace if necessary 5.1 Function of carbon brush
5.2 Vernier caliper
5.3 Electric soldering iron

Ability to :
5.1 Use vernier caliper
5.2 Use electric soldering iron
5.3 Connect carbon brush wire

Safety :
5.1 Handle with care
5.2 Caution on polarity

6. Check and replace bushing/bearing Knowledge of :
6.1 Type of bearing/bushing use

Ability to :
6.1 Remove and replace bush/bearin
6.2 Determine bush condition
6.3 Check bearing condition

7. Reassemble the starter motor Knowledge of :
7.1 Construction of starter motor

Ability to :
7.1 Assemble starter motor

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

ng
71

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

8. Test the solenoid/starter motor Knowledge of :
- Pull-in test 8.1 Starter motor operation
- Hold-in test 8.2 Solenoid operation
- Free-load test
- Load test Ability to :
8.1 Conduct pull in test and hold in te
8.2 Use test bench

Safety :
8.1 Handle with care
8.2 Caution on polarity

9. Install starter motor to the engine Knowledge of :
9.1 Wiring diagram of starter motor
9.2 Type of connectors

Ability to :
9.1 Fix starter motor in correct positi
9.2 Fix cable and battery terminal in

Safety :
9.1 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

est

ion
correct position

72

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL S
TASK NO:
LEVEL: 08 TASK: OVERHAUL DISTRIBUTOR

L2 PERFORMANCE STANDARD
OVERHAUL DISTRIBUTOR GIVEN SERVICE
FUNCTION ACCORDING TO MANUFACTUR

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Disconnect high tension wire Knowledge of :
1.1 Basic electricity
1.2 Operation in ignition circuit/diagr
1.3 Operation of vacuum advance
1.4 Operation of centrifugal advance
1.5 Component of ignition system
1.6 Firing order

Ability to :
1.1 Identify distributor location
1.2 Identify high tension leads
1.3 Determine correct firing order

Safety :
1.1 Handle with care
1.2 Caution on polarity

SYSTEM

E MANUAL, HAND TOOLS AND MULTI METER SO THAT THE DISTRIBUTOR
RER'S SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Hand tools
2. Service manual
ram 3. Multi meter

e

73

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

2. Remove the distributor from the Knowledge of :
engine 2.1 Function of distributor
2.2 Type of distributor

Ability to :
2.1 Identify type of distributor
2.2 Disconnect wire connector

3. Dismantle the distributor Knowledge of :
3.1 Function of distributor
3.2 Construction of distributor

Ability to :
3.1 Remove distributor cap
3.2 Remove distributor components

Safety :
3.1 Handle with care
3.2 Caution on polarity

4. Check distributor component for Knowledge of :
proper functioning 4.1 Function of component in distribu

Ability to :
4.1 Use multi meter
4.2 Test distributor components

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

utor
74

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

5. Reassemble distributor Knowledge of :
components 5.1 Construction of distributor

Ability to :
5.1 Fix component in correct position

6. Install distributor to the engine Knowledge of :
6.1 Diagram of ignition system
6.2 Ignition timing diagram
6.3 Advance/Retard mechanism

Ability to :
6.1 Set compression stroke for numb
6.2 Fix distributor correctly according
6.3 Install high tension cables/leads

order

7. Start the engine and check ignition Knowledge of :
timing according to specification 7.1 Ignition timing
7.2 Advance and retard mechanism

Ability to :
7.1 Use timing light
7.2 Adjust ignition timing

Safety :
7.1 Handle with care

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

n

ber one cylinder
g to procedure
according to firing

75

OCCUPATION: MOTOR VEHICLE MECHANIC

DUTY NO. 04 DUTY: SERVICE VEHICLE ELECTRICAL S
TASK NO:
LEVEL: 09 TASK: OVERHAUL ALTERNATOR

L2 PERFORMANCE STANDARD
OVERHAUL ALTERNATOR GIVEN SERVICE
CHARGING VOLTAGE AND AMPERE MEETS

SUB-TASK / STEP ENABLING RE
(Knowledge, Skill, A

1. Disconnect battery terminal Knowledge of :
2. Remove alternator from engine 1.1 Basic electricity

Ability to :
1.1 Remove battery terminal

Knowledge of :
2.1 Generator/Alternator principle
2.2 Ohm’s law

Ability to :
2.1 Identify alternator location
2.2 Disconnect alternator connector

Safety :
2.1 Handle with care
2.2 Caution on polarity

SYSTEM

E MANUAL USING MULTI METER/TEST BENCH SO THAT THE RATE OF
S THE MANUFACTURER'S SPECIFICATION

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

1. Hand tools
2. Service manual
3. Multi meter
4. Ampere meter
5. Voltmeter

76

SUB-TASK / STEP ENABLING RE
3. Dismantle the alternator (Knowledge, Skill, A

4. Carry out continuity test Knowledge of :
3.1 Alternator construction
5. Assemble the alternator 3.2 Type of alternator

Ability to :
3.1 Dismantle alternator components

Safety :
3.1 Handle with care
3.2 Caution on polarity

Knowledge of :
4.1 Basic electricity
4.2 Charging system wiring diagram
4.3 Alternator construction

Ability to :
4.1 Use multi meter
4.2 Check alternator components

Safety :
4.1 Handle with care

Knowledge of :
5.1 Alternator construction

EQUIREMENTS TOOLS / EQUIPMENT
Attitude And Safety) / MATERIALS

s

m

77