national competency standards for earthmoving equipment ...

NATIONAL COMPETENCY STANDARDS

FOR

EARTHMOVING EQUIPMENT MECHANIC

(NC2 & NC3)

Department of Occupational Standards

Ministry of Labour and Human Resources

Thimphu Bhutan

(Developed-2016)

First Publication 2016 © Department of Occupational Standards (DOS), MoLHR

i

FOREWORD

The Department of Occupational Standards of the Ministry of Labour and Human Resources is pleased to present the National Competency Standards (NCSs) for Earthmoving Equipment Mechanic. The standards represent the fruits of hard work and invaluable experiences gained by the department since its establishment in the latter half of 2003. The main aim of developing NCS is to set up a well-defined nationally recognized Vocational Qualifications System that will help set a benchmark for the Technical Vocational Education and Training (TVET) System in our country aligned to international best practices. NCS is one of the base pillars in the Bhutan Vocational Qualifications Framework (BVQF) and is the first step in its implementation. The NCS are developed and revised to ensure that employees or vocational graduates possess and acquire the desired competencies required by industries and employers. In order to ensure this close match in supply and demand of competencies, NCS have been developed and revised in close consultation and partnership with industry experts and validated by the Technical Advisory Committees of the concerned economic sectors. A vocational education and training system based on NCS shall ensure that delivered training is of a high quality and relevant to the needs of the labour market. As a result, future TVET graduates will be better equipped to meet the need and expectations of industries and employers. This positive impact on the employability of TVET graduates will enhance the reputation of vocational education and training and make it attractive to school leavers. I gratefully acknowledge collaboration and the valuable contributions made by experts from industries during the consultation and validation processes of the standards. I look forward for continued engagement and participation of the industry and employers in the development of a quality assured demand driven TVET system and to build competent and productive national workforce that will contribute to the continued socio-economic progress of our country. Director Department of Occupational Standards Ministry of Labour and Human Resource

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INTRODUCTION

A. National Competency Standards (NCS) The National Competency Standards specify the skill, knowledge and attitudes applied to a particular occupation. Standards also specify the standards or criteria of performance of a competent worker and the various contexts in which work may take place. Standards provide explicit advice to assessors regarding the skill and knowledge to be demonstrated by candidates seeking formal recognition either following training or through work experience. Purpose of National Competency Standards National Competency Standards serve a number of purposes including:

Providing advice to curriculum developers about the competencies to be included in curriculum.

Providing specifications to assessment resource developers about the competencies within an occupation to be demonstrated by candidates.

Providing advice to industry/employers about job functions, which in turn can be used for the development of job descriptions, performance appraisal systems and work flow analysis.

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B. Bhutan Vocational Qualifications Framework (BVQF) Bhutan Vocational Qualifications Framework is an agreed system of Assessing, Certifying and Monitoring nationally recognized qualifications for all learning in the TVET sector against national competency standards, in training institutions, in the workplace, in schools or anywhere where learning takes place. Components of the Bhutan Vocational Qualifications Framework (BVQF)

* RPL = Recognition of Prior Learning

*RPL

ASSESSMENT

RESOURCES

ACCREDITED

TRAINING PROGRAMME

COMPETENCY BASED

CURRICULUM

WORKERS FROM WORK PLACE

CERTIFICATION

COMPETENCY BASED ASSESSMENT

INDUSTRY / LABOUR MARKET

CERTIFIED SKILLED WORKER

NATIONAL COMPETENCY

STANDARDS

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BVQF Levels The Bhutan Vocational Qualifications Framework has three levels classified based on the competency of the skilled workers. The three levels are:

National Certificate Level 3 (NC III)

National Certificate Level 2 (NC II)

National Certificate Level 1 (NC I)

BVQF Level Descriptors The qualification levels are decided based on level descriptors. The detail of the qualification level descriptor is as follows: National Certificate Level 1 (Semi Skilled)

Carry out processes that:

Learning demand: Responsibilities which

are applied:

Are narrow in range.

Are established and familiar.

Offer a clear choice of routine responses.

Involve some prioritizing of tasks from known solutions.

Basic operational knowledge and skill.

Utilization of basic available information.

Known solutions to familiar problems.

Little generation of new ideas.

In directed activity.

Under general supervision and quality control.

With some responsibility for quantity and quality.

With no responsibility for guiding others.

v

National Certificate Level 2 (Craftsman)



are applied:

Require a range of well-developed skills.

Offer a significant choice of procedures requiring prioritization.

Are employed within a range of familiar context.

Some relevant theoretical knowledge.

Interpretation of available information.

Discretion and judgments.

A range of known responses to familiar problems

In directed activity with some autonomy.

Under general supervision and quality checking.

With significant responsibility for the quantity and quality of output.

With some possible responsibility for the output of others.

National Certificate Level 3 (Master craftsman)



are applied:

Requires a wide range of technical or scholastic skills.

Offer a considerable choice of procedures requiring prioritization to achieve optimum outcomes.

Are employed in a variety of familiar and unfamiliar contexts.

A broad knowledge base which incorporates some theoretical concepts.

Analytical interpretation of information.

Informed judgment.

A range of sometimes innovative responses to concrete but often unfamiliar problems.

In self–directed activity.

Under broad guidance and evaluation.

With complete responsibility for quantity and quality of output.

With possible responsibility for the output of others.

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PURPOSE

This suite of two qualifications is designed for people interested in a career as Earthmoving Equipment Mechanic at the Certificate level. It comprises of seven units that cover the essential knowledge and skills required for people working as a Earthmoving Equipment Mechanic. The first qualification is the National Certificate level two (L2). It comprises of four units that covers the essential knowledge and skills required to:

Perform servicing of basic electrical system,

Perform servicing of wheel/tyres, undercarriages and attachments,

Perform servicing of lubrication, cooling and fuel system and to

Perform servicing of steering and break system. The first qualification prepares people for entry into National Certificate Level 3. The National Certificate Level 3 comprises of three units that covers the knowledge and skills required to:

Perform servicing of hydraulic and control system

Perform servicing of transmission system

Perform engine overhaul A diagram of the qualification pathway provided by these two qualification certificate follows:

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PACKAGING OF QUALIFICATIONS FOR EARTHMOVING EQUIPMENT

MECHANIC

The National Competency Standards for the Earthmoving Equipment Mechanic comprises of seven units which are clustered into following levels of qualifications.

Perform servicing of transmission system (7233-U6-L3)

Perform engine overhaul (7233-U7-L3)

National Certificate Level 3

ENTRY

National Certificate Level 2

Perform servicing of hydraulic and control system (7233-U5-L3)

Perform servicing of wheel/tyres, undercarriage & attachments (7233-U2-L2)

Perform servicing of lubrication, cooling & fuel system (7233-U3-L2)

Perform servicing of steering and brake system (7233-U4-L2)

Perform servicing of basic electrical system (7233-U1-L2)

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CODING USED FOR NATIONAL COMPETENCY STANDARDS The coding and classification system developed in Bhutan is logical, easy to use, and also aligned with international best practises. The Bhutanese coding and classification system is based on the International Standard Classification of Occupations, 2008 (ISCO-08) developed by the International Labour Organisation (ILO). The coding of the National competency standards forms the basis of the identification code for the Vocational Education and Training Management Information System (VET – MIS) both in terms of economic sector identification and that of the individual standard. Coding the individual national competency standards Coding the individual skills standard has a multiple purpose:

to identify the level,

to identify to which module the standard belongs,

to identify in which order the standard is clustered within that module.

A job can include a number of competencies described in the national competency standards. However, in order to follow a logical order, only national competency standards related to each other and following a logical sequence in terms of training delivery, from the simple to the complex, are clustered into a module. Some standards are so complex that they need to stand alone.

To illustrate with an example, the ILO assigns the code 7233 to the occupation of Earthmoving Equipment Mechanic and related trades. Therefore, in Bhutan’s context, the occupation Earthmoving Equipment Mechanic has been assigned the code 7233 in the National Coding System. The first unit is assigned the code U1. Levels are assigned the code L and follow a logical progression from the National Certificate Level 1 (NC I) to the National Certificate Level 3 (NC III). Therefore the first unit of level two is written as 7233-U1-L2.

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Implementation and operational procedures for National Competency Standards (NCS)

Key: MoLHR – Ministry of Labour and Human Resources DOS – Department of Occupational Standards

Develop National Competency Standards (DOS and industry experts)

Assign National Qualifications (DOS and industry experts)

Design Training Programs (Training Providers)

Course Accreditation (DOS)

Program Implementation (Training Providers)

Conduct National Assessment (DOS)

Award National Certificate (DOS)

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NATIONAL COMPETENCY STANDARDS FOR

EARHMOVING EQUIPMENT MECHANIC Validation date : 29/04/2016 Endorsement date : 04/05/2016 Date of Review : 04/05/2019 (Max. 3 years)

Technical Advisory Committee (TAC) members for the Automobile Service Sector

1. Sangay Wangchuk (Chairperson) Principal Samthang Technicial Training Institute, Wangdue

2. Gyem Dorji, Principal Thimphu Technical Training Institute

3. Karma Lotey, Suptdg. Engineering CDCL. Thimphu.

4. Sonam Tobgay.Sr.Vehicle Inspector RSTA. Thimphu

5. Chimi Dorji, Sales & executives Riwang heavy equipment service. Thimphu

6. Kinley Gyeltshen, Sr.Program Officer DHR, MoLHR

7. Karma Loday, Chief Program Officer/Member Secretary DOS, MoLHR

Subject experts involved during the consultative workshop for the development of NCS for Earthmoving Equipment Mechanic:

1. Sonam, Instructor, Samthang TTI. Wangdue

2. Tandin Wangchuk, Samthang TTI. Wangdue

3. Ngawang Gylentshen. CMU, Bumthang.

4. Dik Bir Ghalley. CMU, Bumthang

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5. Chundu. CMU, Bumthang.

6. Yeshi Wangdi, Lhojong Construction. Wangdue

7. Dal Bahadur Raika. Larsen & Toubro Ltd.

8. Yamanagpo, CDCL. Bumthang

Development Group (Facilitator):

1. Tshewang, Dy. Program Officer. DOS, MoLHR

2. Wangchuk Zangmo, Program Officer. DOS, MoLHR

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TABLE OF CONTENTS

NATIONAL COMPETECNCY STANDARDS FOR EARTHMOVING EQUIPMENT MECHANIC

NATIONAL CERTIFICATE – NC2

UNIT TITLE ELEMENTS OF COMPETENCE PAGE

Perform servicing of basic electrical components

1. Prepare for work

2. Service basic electrical components 1-3

Perform servicing of wheel/tyres, undercarriages & attachments

1. Service wheel/tyre

2. Service undercarriage

3. Service attachments

4-7

Perform servicing of lubrication, cooling and fuel system

1. Service lubrication system

2. Service cooling system

3. Service fuel system

8-12

Perform servicing of steering and brake system

1. Service steering system

2. Service break system 13-16

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NATIONAL COMPETECNCY STANDARDS FOR EARTHMOVING EQUIPMENT MECHANIC

NATIONAL CERTIFICATE – NC3

UNIT TITLE ELEMENTS OF COMPETENCE PAGE

Perform servicing of hydraulic & control system

1. Service hydraulic system

2. Service control system 17-20

Perform servicing of transmission system

1. Service final drive

2. Service clutch system

3. Service gear box

21-24

Perform engine overhauling

1. Overhaul engine

2. Service intake system

3. Service exhaust system

25-29

1

UNIT TITLE : Perform servicing of basic electrical system

DESCRIPTOR: This unit covers the competencies required to prepare for servicing of basic electrical system and to perform the actual servicing of basic electrical system.

CODE: 7233-U1-L2

ELEMENTS OF COMPETENCE

PERFORMANCE CRITERIA

1. Prepare for work

1.1 Select and use PPE as per the job requirement following standard procedure.

1.2 Select tools and materials as per the job requirement following standard procedure.

2. Service basic electrical components

2.1 Diagnose the faults in basic electrical components following standard procedure.

2.2 Remove and replace the electrical components if necessary following standard procedure.

2.3 Service basic electrical components following standard procedure.

2.4 Check the electrical components following standard procedure.

RANGE STATEMENT

PPE may include but not limited to:

Cap

Goggles

Mask

Safety shoes/boots

Gloves

Workshop dress

Tools may include but not limited to:

Heavy duty hand tool set

2

Materials may include but not limited to:

Marking cloth

Insulation tape

Spare parts as required

Faults in basic electrical components may include but not limited to:

Breakage

Blown out fuse

Blown out bulbs

Wear and tear

Loose connection

Basic electrical components may include but not limited to:

Fuse

Bulb

Battery

Horn

ASSESSMENT GUIDE

Form of assessments

Continuous assessment together with collected evidence of performance will be used.

Evidence of the performance shall be based on practical demonstration.

Knowledge can be assessed through diagrams, in writing or orally (viva-voce).

Assessment context

Competency may be assessed in the actual work place or in a simulated workplace setting.

Assessment condition

The candidate shall have access to all required tools, equipments, materials and documents.

Candidate must complete the assessment in industry accepted time frame.

Critical aspect

Demonstrate compliance with safety regulations applicable to work operations at all times.

Diagnose the faults in basic electrical components following

3

standard procedures.

Underpinning Knowledge Underpinning Skills

Occupation Health and safety(OHS) regulations

Basic First aid treatments

Basic electrical circuit

Types of fuse and its function

Types of bulb and its function

Team work

Communication skills

Work planning

Problem solving

Housekeeping(5s)

Interpretation of service manual

Proper handling of tools and equipment

Caring of battery

4

UNIT TITLE: Perform servicing of wheel/tyres, undercarriage and attachments.

DESCRIPTOR: This unit covers the competencies required to service wheel/tyre, undercarriage and attachments.

CODE: 7233-U2-L2



1. Service wheel/tyre


1.2 Select tools, materials and equipment as per the job requirement following standard procedure.

1.3 Diagnose the faults in wheel/tyre following standard procedure.

1.4 Remove and disassemble the wheel/tyre if necessary following the standard procedure.

1.5 Replace the defective wheel/tyre if necessary following standard procedure.

1.6 Repair the defective wheel/tyre as per the job requirement following standard components.

1.7 Assemble the wheel/tyre following the standard procedure.

1.8 Test the wheel/tyre following standard procedure

2. Service undercarriage

2.1 Diagnose the faults in undercarriage components following standard procedure.

2.2 Remove and disassemble the undercarriage components if necessary following standard procedure.

2.3 Replace the defective undercarriage components if necessary following standard

5

procedure.

2.4 Repair the defective undercarriage components if necessary following standard procedure.

2.5 Assemble undercarriage following standard procedure.

2.6 Set/adjust the track chain if necessary following standard procedure.

3. Service attachments

3.1 Diagnose the attachments faults and take necessary action following standard procedure.

3.2 Dismount the attachments if necessary following the standard procedure.

3.3 Replace the defective components of attachments if necessary as per the job requirement following standard procedure.

3.4 Repair the defective components of attachments as per the job requirement following standard procedure.

3.5 Assemble the attachments following standard procedure.

3.6 Test the attachments if necessary following standard procedure.

RANGE STATEMENT


Cap

Goggles

Mask

Safety shoes/boots

Gloves

Workshop dress


Heavy hand tool set

Tire lever

Jack

Inflate nozzle

6

Wheel brace

Grease gun

Valve key

Heavy duty hammer


Marking cloth

Grease


Faults in wheel/tyres & undercarriage may include but not limited to:

Leakage

Breakage

Wear and tear

Misalignment

Equipment may include but not limited to:

Air compressor

Forklift

Track pin remover

Tyre exchanger

Pressure gauge

Track press

Undercarriage may include but not limited to:

Sprocket

Track shoe

Track roller

Travel motor

Carrier roller

Idler roller

Track link

Attachments may include but not limited to:

Rock breaker

Bucket

Blade

Ripper

Stone crusher

Sieve

ASSESSMENT GUIDE

Form of assessments




7

Assessment context





Critical aspect


Diagnose the faults in wheel/tyre, undercarriage and attachments following standard procedure.

UNDERPINNING KNOWLEDGE UNDERPINNING SKILLS



Types of tyres

Definition of tyres

Function of wheel/tyres

Construction of tyres

Dimension of tyres

Components of undercarriage and its functions

Types of tracks

Unit of conversion

Waste management

Functions of attachments

Team work


Work planning

Problem solving

Housekeeping (5s)


Safe and proper use of tools and equipment

8

UNIT TITLE : Perform servicing of lubrication, cooling and fuel system.

DESCRIPTOR : This unit covers the competencies required to service lubrication, cooling and fuel system.

CODE : 7233-U3-L2



1. Service lubrication system


1.2 Select tools, materials and equipment as per the job requirement following standard procedure.

1.3 Diagnose the fault in lubrication system following standard procedure.

1.4 Change the lubricants to required level as per the job requirement following standard procedure.

1.5 Replace the oil filter following standard procedure.

1.6 Replace the defective lubricant pipes as per the job requirement following standard procedure.

1.7 Perform greasing as per the job requirement following standard procedure.

1.8 Test/run the lubrication system and check for leakages following standard procedure.

2. Service cooling systems

2.1 Troubleshoot the cooling system following standard procedure.

2.2 Remove and disassemble the cooling system components if necessary following standard procedure.

2.3 Replace the defective cooling components if

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necessary as per the job requirement following standard procedure.

2.4 Repair the defective cooling components as per the job requirement following standard components.

2.5 Assemble the cooling components following standard procedure.

2.6 Change coolant as per the job requirement following the standards procedures.

2.7 Adjust fan-belt tension if necessary following standard procedure.

3. Service fuel system

3.1 Troubleshoot fuel system following standard procedure.

3.2 Remove and disassemble the components of fuel system if necessary following standard procedure.

3.3 Replace the defective components if necessary as per the job requirement following standard procedure.

3.4 Repair the defective components if required following standard components.

3.5 Assemble the components following standard procedure.

3.6 Set fuel injection timing to required setting following standard procedure.

3.7 Bleed the fuel system following standard procedure.

3.8 Test the fuel system following standard procedure.

10

RANGE STATEMENT


Cap

Goggles

Mask

Safety shoes/boots

Gloves

Workshop dress


Heavy duty hand tool set Filter clamp


Lubricants

Cleaning materials

Rust remover

Distilled water

Marking cloth


coolant

Equipment may include but not limited to:

Grease gun Lubricant dispenser/oil gun

Faults in lubricating system, cooling system and fuel system may include but not limited to:

Leakage

Breakage

Blockage

Wear and tear

Cracks

Lubricants may include but not limited to:

Engine oil

Gear/transmission oil

Grease

Cooling system components may include but not limited to:

Water pump

Hose

Radiator

Pressure cap

Thermostat valve

11

Components of fuel system may include but limited to:

O-ring

Fuel pump

Fuel filter

Injector nozzles

Feed pump

High pressure pipe

ASSESSMENT GUIDE

Form of assessment



Knowledge can be assessed through written form of assessment.

Assessment context



The candidate shall have access to all required tools, equipment, materials and documents.

The candidate must complete the assessment in an accepted time frame.

Critical aspects


Change the lubricants to required level as per the job requirement following standard procedure.

Troubleshoot the cooling system fault following standard procedure.

Troubleshoot fuel system following standard procedure.

12



Basic First Aid treatments

Types of lubricants

Viscosity of lubricants

Types of lubrication system

Working principle of lubrication system

Grade of lubricants

Components of lubrication system

Methods of lubricating

Components of cooling systems and its functions

Working principle of cooling systems

Types of coolant

Types of cooling system

Proprieties of coolant

Ratio of coolant

Components of fuel systems

Working principle of fuel system

Types of fuel

Fuel additives

Function of components

Team work


Work planning

Safe and proper handling of tools and equipment

Problem solving

Housekeeping (5s)

Interpretation of repair manual

Interpretation of parts catalogs

13

UNIT TITLE: Perform servicing of steering and brake system

DESCRIPTOR: This unit covers the competencies required to service steering and brake system.

CODE: 7233-U4-L2



1. Service steering system



1.3 Diagnose the faults in the steering system following standard procedure.

1.4 Remove and disassemble the steering components following the standard procedure.

1.5 Replace the defective components as per the job requirement following standard procedure.

1.6 Repair the defective components as per the job requirement following standard components.

1.7 Lubricate/grease the components as per the job requirement following standard procedure.


1.9 Set wheel alignment if necessary following standard procedure.

1.10 Test/run the steering system following standard procedure

14

2. Service brake system

2.1 Diagnose the fault in brake system following standard procedure.

2.2 Remove and disassemble the brake components following the standard procedure.

2.3 Replace the defective components as per the job requirement following standard procedure.



2.6 Bleed the brake system following standard procedure

2.7 Adjust and test the brake following standard procedure.

RANGE STATEMENT


Cap

Goggles

Mask

Safety shoes/boots

Gloves

Workshop dress




Marking cloth

Fluids


15

Faults in steering components may include but not limited to;

Leakage

Breakage

Wear and tear

Wheel jam

Steering components may include but not limited to:

Steering wheel

Steering column

Steering rack

Tire rid

Steering gear box

Faults in brake system may include but not limited to:

Leakage

Breakage

Wear and tear

Brake failure

Brake components may include but not limited to:

Brake disk

Master cylinder

Brake boaster

Brake pipe

Brake shoe

ASSESSMENT GUIDE

Form of assessments




Assessment context





16

Critical aspect


Diagnose the steering and brake system following standard procedure.

Bleed the brake system following the standard procedure

Adjust and test the brake following standard procedure.



Basic First Aid treatments

Working principle of steering and brake system

Components of steering and brake system

Types of steering and brake systems

Wheel alignment

Types of brake fluids

Environment act

Team work


Work planning

Problem solving

Safe handling of tools and equipment

Interpret service manual

17

UNIT TITLE : Perform servicing of hydraulic and control system

DESCRIPTOR: This unit covers the competencies required to service hydraulic and control system.

CODE: 7233-U5-L3



1. Service hydraulic system



1.3 Troubleshoot/diagnose the faults in hydraulic system following standard procedure.

1.4 Remove and disassemble the hydraulic components if necessary following standard procedure.

1.5 Replace the defective components if necessary as per the job requirement following standard procedure.


1.7 Assemble the components following the standard procedure.

1.8 Change hydraulic fluids as per the job requirement following standards procedures.

1.9 Calibrate the hydraulic pressure as per the manufactures’ specifications.

1.10 Bleed the hydraulic system following standard procedure

1.11 Test the hydraulic system following standard procedure.

18

2. Service control system

2.1 Troubleshoot/diagnose fault in the control system components following standard procedure.

2.2 Remove and replace the defective control components if necessary following standard procedure.

2.3 Repair the defective control components as per the job requirement following standard components.

2.4 Assemble the control components following standard procedure.

2.5 Test the control system components following standard procedure.

RANGE STATEMENT


Cap

Goggles

Mask

Safety shoes/boots

Gloves

Workshop dress




Marking cloth


Hydraulic

Faults in hydraulic and control system may include but not limited to:

Leakage

Breakage

Wear and tear

Blockage

Hydraulic components may include but not limited to:

Hydraulic pump

Pressure pipe

O-ring

Control valve

19

Hydraulic cylinder

Hydraulic tank

Seals

Control system components may include but not limited to:

Joystick

Safety lever

Control valve

ASSESSMENT GUIDE

Form of assessments




Assessment context





Critical aspect


Troubleshoot/diagnose the hydraulic system following standard procedure.

Bleed the hydraulic system following the standard procedure

Troubleshoot/diagnose fault in the control system following standard procedure.

20




Working principle of hydraulic system

Types of hydraulic fluids

Types of O-rings

Components of hydraulic systems

Fluid pressure

Unit conversion

Method of bleeding

Components of control systems and its functions

Working principle of control system

Team work


Work planning

Problem solving

Safe and proper handling of tools and equipment

Housekeeping (5S)


21

UNIT TITLE : Perform servicing of transmission system

DESCRIPTOR: This unit covers the competencies required to service final drive, clutch and gear box.

CODE: 7233-U6-L3



1. Service final drive


1.2 Select tools and materials as per the job requirement following the standard procedure.

1.3 Diagnose the fault in final drive component following standard procedure.

1.4 Remove and disassemble the final drive components if necessary following standard procedure.

1.5 Replace the defective components if necessary following standard procedure.

1.6 Repair the defective components as per the job requirement following standard procedure.


1.8 Set backlash to required setting as per the job requirement following standard procedure.

1.9 Apply hub greasing as per the job requirement following standard procedure.

1.10 Check the lubricant level following standard procedures.

1.11 Test the final drive system following standard procedure.

2. Service clutch 2.1 Troubleshoot the faults in clutch system

22

system following standard procedure.

2.2 Remove and disassemble the clutch components if necessary following standard procedure.

2.3 Replace the defective clutch components if necessary following standard procedure.

2.4 Repair the defective clutch components if necessary following standard procedure.

2.5 Assemble the clutch components following standard procedure.

2.6 Bleed the clutch system as per the job requirement following standard procedure.

2.7 Test the clutch system following standard procedure.

3. Service gear box

3.1 Troubleshoot the faults in gear box following standard procedure.

3.2 Remove and disassemble the gear box if necessary following standard procedure.

3.3 Replace the defective gear box components if necessary as per the job requirement following standard procedure.

3.4 Repair the defective gear box components as per the job requirement following standard components.

3.5 Assemble the gear box components following standard procedure.

3.6 Test the gear box following standard procedure.

RANGE STATEMENT


Cap

Goggles

Safety shoes/boots

Gloves

23

Mask Workshop dress




Marking cloth


Gasket seal

Gear oil

Gasket

Faults may include but not limited to:

Leakages

Breakages

Gear disengagement

Wear and tear

Damages

Gear lock

Final drive may include but not limited to:

Differential gear

Propeller shaft

Cross bearing

Axel

Clutch components may include but not limited to:

Clutch disc Pressure plate

Gear box components may include but not limited to:

Gears Linkages

ASSESSMENT GUIDE

Form of assessments




Assessment context

Competency may be assessed in the actual work place or in a

24

simulated workplace setting.




Critical aspect


Diagnose the fault in transmission system component following standard procedure.

Set backlash to required setting as per the job requirement following standard procedure.

Bleed the clutch system as per the job requirement following standard procedure.




Functions of final drive , clutch system, gear box

Gear ratio

Importance of backlash

Purpose of preload

Types of transmission system

Unit of conversion

Environmental act

Team work


Work planning

Problem solving

Housekeeping (5s)



25

UNIT TITLE : Perform engine overhaul

DESCRIPTOR: This unit covers the competencies required to prepare for engine overhauling and to perform engine overhauling.

CODE: 7233-U7-L3



1. Overhaul engine


1.2 Select tools and materials as per the job requirement following the standard procedure.

1.3 Diagnose the engine faults following standard procedure.

1.4 Dismount the engine as per the job requirement following standard procedure.

1.5 Disassemble the engine components if necessary following the standard procedure.

1.6 Replace the defective engine components if necessary as per the job requirement following standard procedure.

1.7 Assemble the engine components applying specified uniform torque where necessary following standard procedure.

1.8 Set the engine as per manufactures’ specifications following standard procedures.

1.9 Test run the engine following the standard procedure.

1.10 Mount the engine components following standard procedures

2. Service intake system

2.1 Diagnose the intake system faults following standard procedure.

26

2.2 Dismount the intake components as per the job requirement following standard procedure.

2.3 Disassemble the intake components if necessary following the standard procedure.

2.4 Replace the defective intake components if necessary as per the job requirement following standard procedure.

2.5 Assemble the intake components following standard procedure.

3. Service exhaust system

3.1 Diagnose the exhaust system faults following standard procedure.

3.2 Dismount the exhaust components as per the job requirement following standard procedure.

3.3 Disassemble the exhaust components if necessary following the standard procedure.

3.4 Replace the defective exhaust components if necessary as per the job requirement following standard procedure.

3.5 Assemble the exhaust components following standard procedure.

3.6 Test run turbo charger following the standard procedure.

RANGE STATEMENT


Cap

Goggles

Mask

Safety shoes/boots

Gloves

Workshop dress



Engine, intake system, exhaust system faults may include but not

27

limited to:

Leakages

Breakages

Over consumption of fuel/lubrication

Blockage

Over heating

Engine knocking

Low torque

Wear and tear

Engine components may include but not limited to;

Piston

Crank shaft

Connecting rod

Push rod

Valve

Oil pump

Cam shaft

Oil sump

Cylinder head

Cylinder block

Bearing

Set the engine may include but not limited to:

Fuel injection timing

Tappet clearance

Thrust play

Timing chain

Warpage of cylinders

Main journals

Cylinder liner

Engine compression pressure

Torque

Intake components may include but not limited to:

Air filter

Intake manifolds

Filter housing

Exhaust components may include but not limited to:

Exhaust manifold

Turbo charger

Muffler

Catalytic convertor

ASSESSMENT GUIDE

Form of assessments


Evidence of the performance shall be based on practical

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demonstration.


Assessment context





Critical aspect


Diagnose the engine faults following standard procedure.

Assemble the engine components applying specified uniform torque where necessary following standard procedure.

Set the engine as per manufactures’ specifications following standard procedures.

Diagnose the intake system faults following standard procedure

Diagnose the exhaust system faults following standard procedure.




Components of engine

Working principle of engine

Types of engine

Functions of engine

Engine tune up

Team work


Work planning

Problem solving

Housekeeping (5S)


Interpretation of service

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Unit of conversion

Components of intake and exhaust system

Working principle of intake and exhaust system

Functions of intake and exhaust system

Emission level

Environment Act

Basic electrical knowledge

manual

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Department of Occupational Standards Ministry of Labour & Human Resources

Thongsel Lam, Lower Motithang P.O. Box 1036, Thimphu.

Tel: 02-331611, Fax: 02-326873

www.molhr.gov.bt

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