ENGINEERING PROGRAMMES

ZAMBIA QUALIFICATIONS FRAMEWORK (ZQF) LEVEL 4

SYLLABUS
FOR
CERTIFICATE LEVEL 4
IN
AUTOMOTIVE ENGINEERING
CHART NO. 166
Prepared by:
Curriculum Development Unit,
Technical Education, Vocational and Entrepreneurship Training Authority (TEVETA)
P/Bag RW 16x,
Birdcage Walk,
Lusaka

Phone: +260211253211
E-mail: teveta@teveta.org.zm
Website: http://www.teveta.org.zm

Validated November, 2017

ACRONYMS
ABS Anti-lock Braking System
BJT Bipolar Junction Transistor
ECU Electronic Control Unit
EFI Electronic Fuel Injection
HER Heavy Equipment Repair
IC Intergreted Circuits
ITC Industrial Training Centre
KIT Kabwe Institute of Technology
LMDD Learning Materials Design and Development
LTBC Luanshya Technical and Business College
MILTEZ Military Training Establishment of Zambia
NTC Negative Temperature Coefficient
PTC Positive Temperature Coefficient
RPM Revs Per Minute
TEVETA Technical Education, Vocational and Entrepreneurship Training Authority

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TABLE OF CONTENT
ACRONYMS............................................................................................................ 2
1.0 ABOUT TEVETA.......................................................................................... 4
2.0 ACKNOWLEDGEMENTS.............................................................................4
3.0 RATIONALE................................................................................................. 6
4.0 PROGRAMME PURPOSE............................................................................6
5.0 PROGRAMME OUTCOMES:.......................................................................6
6.0 PROGRAMME DURATION..........................................................................7
7.0 COURSE OUTLINE......................................................................................7
8.0 DELIVERY MODES AND METHODS...........................................................9
9.0 PROGRAMME EVALUATION......................................................................9
11.0 ASSESSMENT............................................................................................10
12.0 ATTENDANCE............................................................................................ 10
13.0 PROGRESSION REQUIREMENTS............................................................10
14.0 STAFF QUALIFICATIONS.........................................................................11
15.0 CERTIFICATION.........................................................................................11
WORKSHOP PRACTICE AND PROCESS...........................................................12
ENGINEERING MATHEMATICS I........................................................................17
COMMUNICATION SKILLS..................................................................................36
INTRODUCTION TO COMPUTERS......................................................................47
AUTOMOTIVE ELECTRICITY I.............................................................................75

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1.0 ABOUT TEVETA
The Technical Education, Vocational and Entrepreneurship Training Authority (TEVETA) is an institution established under TEVET
Act No. 13 of 1998 read together with TEVET (Amendment) Act No. 11 of 2005, to regulate, coordinate and monitor technical
education, vocational and entrepreneurship training in consultation with stakeholders.
TEVETA executes its regulatory function through the provision of services, among others, the development, review and approval of
TEVET Curricula in conjunction with stakeholders.

2.0 ACKNOWLEDGEMENTS
The Technical Education, Vocational and Entrepreneurship Training Authority (TEVETA) wishes to express sincere appreciation to
the following persons who contributed to the review of the Diploma in Automotive Technology at various stages; from development
of the job profile to the approval of the curriculum.

NO NAME POSITION ORGANISATION

1. Buumba C. Sylvester Snr. Lecturer LTBC
2. Chansa Stephen Lecturer - Auto Mech & Electrical TTC MILTEZ
3. Charles Banda Lecturer NORTEC
4. Jairos Phiri Lecturer KIT
5. John Phiri Managing Director Auto Pride
6. Kelvin Sendoi Technical Training Instructor Toyota Zambia
7. Miyoba Hamwaka Lecturer - Auto Mech & Electrical LBTC
8. Mr Elijah K. Mtawali Training Manager CFAO Zambia
9. Mr Kennedy Bowa Manager- Curriculum Development TEVETA
10. Mr Lovemore Wamundila Automotive Electrician Lomuwa Company

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11. Mr Reuben Chirwa Lecturer Northern Technical College
12. Mr. Ackim M. Kalikeka Specialist – LMDD TEVETA
13. Mr. Adam Watama Head- Auto Electrical section MILTEZ
14. Mr. Collins Chota Manager- Automotive Electrical & HER Auto pride
15. Mr. Conrad Mwela Lecturer KIT
16. Mr. Davison Siame Lecturer LTBC
17. Mr. Richard M. Manda Lecturer Industrial Training Centre
18. Ms. Namuchindo Chikoti Curriculum Development Specialist TEVETA
19. Nawa Paul Libuku Coordinator Synchro Auto Mechanics Limited
20. Webster C. Mwaanga Lecturer ITC

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3.0 RATIONALE

Automotive technology is the practical application of knowledge about self-propelled vehicles or machines. Students
studying automotive technology learn about engine construction, fuel and ignition systems, power trains, brakes,
transmissions, electronic and diagnostic equipment, and more.

As technology has evolved, so have the cars we drive. The 21 st century has seen an emergence of technologically advanced
automobiles. This is being experienced in nationally, regionally and also globally. The advancements include motor vehicle
technology, introduction of motor vehicle electronics, the high demand of qualified personnel by industry and the government
policy on encouraging small-scale informal entrepreneurship has necessitated the need for a complete review of the old
programme in order to come up with this new training programme.

The revised curriculum has captured the latest technology in this field and has provided direct entry to the programme for
school leavers, which was not the case before. This new Diploma in Automotive Technology is tailored to meet the increased
demand for competent human resource.

The programme will therefore, provide the nation with qualified Automotive Craftsmen who will apply the skills acquired
through this programme and other related disciplines to meet the highlighted demands in both the formal and informal
sectors of the Zambian economy.

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4.0. 4.0 PROGRAMME LEVEL DESCRIPTOR
A graduate will assume the following competences:
4.1 Foundational Competences
4.1.1 Possession of specialised knowledge and skills in automotive technology
o Ability to correctly identify tools and equipment used in automotive vehicle repairs
o Ability to differentiate automotive body designs
o Ability to correctly label and identify motor vehicle parts
o Ability to correctly describe the operation of the four stroke engine
o
4.2 Practical Competences
o Ability to carry out routine servicing of motor vehicle systems
o Ability to correctly solve engineering mathematics
o Ability to prepare schedule for service
o Ability to repair all types of vehicle faults
o Ability to plan the work schedule for onward transfer to artisans

4.3 Reflexive Competences

o Update clients on the condition and status of the motor vehicle.
o Communicate effectively with clients
o Able to justify repair costs to clients
o Ability to assess and appraise others
o Ability to judge the effectiveness of others with intellect

PROGRAMME PURPOSE
The purpose of the programme is to equip the trainee with knowledge, skills and attitudes in Automotive Engineering to
competently in both the formal and informal sector of the economy. They will be able to diagnose, repair, and maintain motor
vehicles and equipment to acceptable international standards

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5.0 PROGRAMME OUTCOMES:
On completion of the programme the trainee will be able to;
5.1 Diagnose, repair and service motor vehicle engine system
5.2 Diagnose, repair and service motor vehicle steering systems
5.3 Diagnose, repair and service motor vehicle steering systems
5.4 Diagnose, repair and service motor vehicle transmission systems
5.5 Diagnose, repair and maintain vehicle electronic systems

5.6 Diagnose, repair and maintain vehicle electricity systems

5.7 Apply Computer skills
5.8 Interpret Engineering drawing
5.9 Apply engineering science principles
5.10 Apply Engineering mathematics principles
5.11 Apply Entrepreneurial skills

6.0 PROGRAMME DURATION

The programme duration is three (3) years 3 months or 3600 notional learning hours, inclusive of 960 hours (6 months) of
Industrial Attachment.

7.0 PROGRAMME OUTLINE

MODULE TITLE HOURS
FIRST YEAR
166-01-A WORKSHOP PROCESSES 280
166-02-A ENGINEERING MATHEMATICS I 120

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166-03-A ENGINEERING SCIENCE 160
166-04-A ENGINEERING DRAWING I 160
166-05-A COMMUNICATION SKILLS 80
166-06-A INTRODUCTION TO COMPUTERS 80
166-07-A ENGINE AND TRANSMISSION SYSTEMS 240
Sub Total 1200
SECOND YEAR

ATTACHMENT 480
166-08-B STEERING AND SUSPENSION SYSTEM 140
166-09-B AUTOMOTIVE ELECTRICITY 170
166-10-B BRAKING SYSTEMS 100
166-11-B ENTREPRENEURSHIP 80

Sub Total 1200

8.0 DELIVERY MODES AND METHODS

8.1 Delivery Mode
8.1.1 Fulltime or conventional
8.1.2 Blended or flexible
8.1.3 Online

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 8.2 Learning Methods
Learning shall constitute:
8.2.1 Practical training
8.2.2 Group discussions
8.2.3 Demonstration
8.2.4 Individual projects
8.2.5 Audio visual (Simulations, Charts, Video)
8.2.6 Field visits

9.0 PROGRAMME EVALUATION

TEVETA shall evaluate the programme as follows:
9.1 Formative evaluation
9.1.1 Purpose: To determine on an on-going basis whether the programme is being implemented as planned and
to advise on improvements.
9.1.2 Major areas of Evaluation: Programme aims and objectives/ learning outcomes, trainee’s entry
requirements, programme content, teaching / learning activities, learning resources.
9.1.3 Evaluation Instruments: Questionnaires, structured interviews, observations, checklists, examinations/test
records, participation and attendance in class
9.1.4 Sources of Information: Students, trainers, administrative monitors and records.
9.2 Summative Evaluation
9.2.1 Major areas of evaluation – Programme aims and objectives/ learning outcomes, trainees’ entry
requirements, programme content, learning resources, teaching/learning activities, trainers, assessors,
examiners and graduates’ performance in employment.
9.3 Evaluation Instruments: Questionnaires, structured interviews, observations, checklists, records, final integrated
Examinations.

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 9.4 Sources of information: Trainees, trainers, assessors, examiners, administrators, sponsors, student dropouts,
employers, union officials and the general public.
9.0 PROGRAMME ENTRY REQUIREMENTS:
10.1 Direct entry
10.1.1 Grade 12 School Certificate with a minimum of credits in English Language, Mathematics, Science and any
other two (2) subjects.
10.2 Mature entry
10.2.1 A minimum of a Craft Certificate in Automotive Engineering or in a related discipline.
10.2.2 A minimum of Advanced Certificate in Automotive Engineering or in a related discipline
11 ASSESSMENT
Trainees shall be assessed by TEVETA Assessment Guidelines
11.1 Assesment modes
11.1.1 First year: Theory and Practical examinations
11.1.1.1 There shall be a theory paper in each module.
11.1.1.1.1The First Year Practical examination shall cover the following modules:
11.1.1.1.1.1 Workshop Processes,
11.1.1.1.1.2 Engine systems
11.1.1.1.1.3 Transmission systems
11.1.1.1.2Second Year Practical Examination shall cover the following modules:
11.1.1.1.2.1 Braking systems
11.1.1.1.2.2 Steering systems,
11.1.1.1.2.3 Suspension systems
11.1.1.1.2.4 Automotive Electricity

11.2 Continuous assessment 40%

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 11.3 Final Examination 60%
11.4 Pass mark 50%

12.0 ATTENDANCE
The candidate must have an attendance of minimum 85% to be eligible for the final examinations.
13.0 PROGRESSION REQUIREMENTS

13.1 A Trainee failing in a maximum of three (3) Modules for the First Academic Year shall be allowed to proceed to the Second
Academic Year subject to clearing the failed Modules within two (2) consecutive examination sessions.
13.2 A trainee failing in four (4) or more Modules for the First Academic Year shall not be allowed to proceed to the Second
Academic Year. The trainee will have to clear all the failed Modules within two (2) consecutive examination sessions before
being allowed to proceed to the Second Academic Year.

13.3 A trainee failing in a maximum of three (3) Modules for the Second Academic Year shall be allowed to proceed to the
Third Academic Year subject to clearing the failed Modules within two (2) consecutive examination sessions.
.

14.0 STAFF QUALIFICATIONS

13.1 Certificate level 5 In Automotive or any other releted field with three (3) years relevant industrial experience
13.2 Certificate level 4 In Automotive or any other releted field with five (5) years relevant industrial experience
13.3 A Diploma in Teaching Methodology .
13.4 TEVETA accredited trainer

15.0 CERTIFICATION
Certificate Level 4 in Automotive Engineering shall be awarded by the Technical Education, Vocational and
Entrepreneurship Training Authority (TEVETA).

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MODULE: 166-01-A WORKSHOP PROCESSES
MODULE PURPOSE: To equip the trainee with knowledge, skills and MODULE DURATION: 190 CREDITS: 19
appropriate attitudes to carry out workshop processes effectively and HOURS

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efficiently.

MODULE LEARNING OUTCOMES: On completion of this module the trainee will be able to:

1. Organise workspace
2. Demonstrate safe working practices
3. Demonstrate safety practices in the workshop
4. Observe fire safety in the workshop
5. Use workshop tools and equipment
6. Maintain tools and equipment
7. Perform benchwork in the workshop
8. Use fasteners
9. Perform rigging operations
10.Perform welding processes

ASSESSMENT METHODS: The trainee will be assessed through;

o Assignments
o Practical exercises
o Written exercises
o Written and Practical Tests

LEARNING CONDITIONS: Trainee must have access to the following:

 Lecture Notes
 Library
 Internet
 Workshop
 Plant and equipment

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UNIT A1.1: ORGANIZING WORKSPACE UNIT DURATION: 10 HOURS CREDITS: 1

SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ensure ASSESSMENT CRITERIA
OUTCOMES that learning activities for trainee include the
following;

1.1.1 Apply elements of 5S Applying Elements of 5S Elements of 5s applied correctly.

(Kaizen)  Sort – (Seiri)
 Set in order (Seiton)
 Shine (Seiso)
 Standardize (Seiketsu)
 Sustain (Shitsuke)
1.1.2 Carry out Carrying out housekeeping duties. Housekeeping duties correctly carried out.
housekeeping duties  Defining housekeeping
 Performing Housekeeping
o Cleanliness
o Orderly arrangement of tools and
components
o Clearing work area of obstacles
1.1.3 Organise physical Organising physical workspace for functionality and Physical work space organised correctly
workspace for functionality productivity
and productivity  Ventilation
 Temperature
 Room dimension and space
 Lighting
 Proximity of tools and equipment.

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UNIT A1.2: DEMONSTRATING SAFE WORKING PRACTICES UNIT DURATION: 20 HOURS
CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ensure that learning ASSESSMENT CRITERIA
OUTCOMES activities for trainee include the following;

1.2.1 Identify Health and Identifying Health and Safety Hazards Health and safety hazards
Safety Hazards  Defining hazards identified correctly.

 Health Hazards
o Dust
o Radiation
o Fluids
o Noise
o Temperature
 Safety Hazards
o Falling objects
o Rolling objects
o Electricity
o Rotating components
o Heavy equipment
1.2.2 Identify hazardous Identifying hazardous workplace materials Hazardous workplace
workplace materials  Solid Hazardous Materials materials identified
o Cyanide correctly
o Solid workshop waste
o Used filters
o Used batteries.
 Liquid Hazardous Materials
o Oils
o Fuels

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 o Coolant
o Acids
 Gaseous Hazardous Materials
o Carbon monoxide
o Nitrous fumes
o Sulphurous fumes
1.2.3 Use correct Personal Using correct Personal Protective Equipment (PPE) Personal protective
Protective Equipment  Head Protection equipment (PPE) used
(PPE) o Hard hat correctly
 Eye Protection
o Safety goggles
o Welding shield
o Cutting goggles
o Welding goggles
 Ear Protection
o Ear plugs
o Ear muffs
 Body Protection
o Overalls
o Work suit
o Safety belt
o Safety harness
o Apron
 Respiratory Protection
o Dust musk
o Rescue pack
o Gas musk
 Foot Protection

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 o Safety boots
o Safety shoes
o Gum boots
 Hand Protection
o Leather gloves
o PVC gloves

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UNIT A1.3: DEMONSTRATING SAFETY PRACTICES IN THE WORKSHOP UNIT DURATION: 10 HOURS
CREDITS: 1

SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ensure that learning ASSESSMENT CRITERIA
OUTCOMES activities for trainee include the following;

1.3.1 Identify workshop Identifying workshop layout; Workshop layout identified

layout  Work areas correctly
 Walk ways
 Emergency exit and assembly point
 Fire-fighting equipment location
 Location of first aid box/eye wash
 Location of service pit/hoist
 Location of flammable and hazardous substances
 Location of battery charging bay
1.3.2 Apply isolate and Applying isolate and tag out procedure Isolating and tagging out
tag out procedure procedure applied correctly
 Defining isolation and tagging out
 Identifying isolation Points
 Placing notice – work in progress
 Isolating and testing
 Locking and getting the key
 Identifying Hazardous energy sources
o Mechanical
o Electrical
o Gravitational
o Thermal
o Hydraulic
o Pneumatic

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 o Chemical
o Master switch
o Ignition switch
o Control levers
 Identifying Hazard
o Sharp objects
o Rotating devices
o High pressure
o Electrical shocks
o Suspended objects
 Demonstrating correct lock out and tagging procedures
o Park machine on level ground
o Chock wheels
o Secure steering frame
o Isolate source of power
o Lower/support all implements
o Apply park brake
o Put a tag and a lock
1.3.3 Apply safety, health Applying safety, health and environmental regulations safety, health and
and environmental  Explain the importance of safety environmental regulations
regulations  Identify workshop hazards applied correctly
o Mechanical-lifting appliances, running machines
o Noise
o Chemical
o Toxic substances
o Electrical
o Fire
o Oil spillage
o Pressurized systems

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 o Improper ventilation
o Poor lighting
 Personal protective equipment (PPE) -Types and uses
 Adherence to proper disposal of environmentally hazardous
materials.
1.3.4 Apply First Aid Applying First Aid First Aid applied correctly
 Defining First Aid
 Explaining Importance of First Aid
 Identifying First Aid Box and its Contents
 Identifying Different Types of Accidents
 Making Judgments to the Type of Accident
 Defining Shock
 Identifying Signs of Shock
 Applying Shock Treatment
 Applying Methods of Resuscitation
o Mouth to Mouth Method
o Mouth to Nose Method
 Handling Personal Injuries
o Brain Injury
o Broken/Fractured Bones
o Burn/Fire Injuries
o Electrocution
o Spinal Cord/Back Injury

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UNIT A1.4: OBSERVING FIRE SAFETY IN THE WORKSHOP UNIT DURATION: 10 HOURS CREDITS: 1

SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ensure that learning ASSESSMENT CRITERIA
OUTCOMES activities for trainee include the following;

1.4.1 Identify Elements Identifying elements of Fire Elements of Fire identified

of Fire  Define fire correctly
 Elements of a fire
o Fuel/Combustible Substance
o Heat
o Air/Oxygen
1.4.2 Identify Causes of Identifying causes of fire; Causes of Fire identified
Fire  Flammable Liquids correctly
 Flammable Solid Material
 Electricity
 Flammable Gases
1.4.3 Describe Classes Describing classes of fire Classes of Fire described
of Fire  Class A correctly
 Class B
 Class C
 Class D
1.4.4 Use of Fire Using fire extinguishers Fire Extinguishers used
Extinguishers  Types of fire extinguishers correctly
 Demonstrate procedure for operating Fire Extinguishers
1.4.5 Demonstrate Fire Demonstrating fire prevention Fire Prevention
Prevention  Avoid Smoking demonstrated correctly
 Avoid naked flames
 Display ‘No Smoking’ signs in Workshop
 Proper Storage of Flammable Liquids and Materials

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  Avoid Short Circuits
 Carry out house Keeping in the workshop
UNIT A1.5: USING WORKSHOP TOOLS AND EQUIPMENT UNIT DURATION: 20 HOURS CREDITS: 2

SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ensure that learning ASSESSMENT CRITERIA
OUTCOMES activities for trainee include the following;

1.5.1 Identify Identifying workshop tools Workshop tools identified

workshop tools  Precision measuring instruments correctly
 Power tools
 Hand tools
1.5.2 Identify Identifying workshop equipment Workshop equipment
workshop  Drilling machine identified correctly
equipment  Presses
 Lifting equipment
 Pulling equipment
 Grinders
 Lubrication facilities
 Air pressure facilities
 Cleaning facilities
 Surface table
1.5.3 Use workshop Using workshop tools Workshop tools used
tools  Precision measuring instruments correctly
 Power tools
 Hand tools
1.5.4 Use workshop Using workshop equipment Workshop equipment used
equipment  Drilling machine correctly
 Presses
 Lifting equipment

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 Pulling equipment
 Grinders
 Lubrication facilities
 Air pressure facilities
 Clearing facilities
 Surface table

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UNIT A1.6: MAINTAINING TOOLS AND EQUIPMENT UNIT DURATION: 10 HOURS CREDITS: 1

SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ensure that learning ASSESSMENT CRITERIA
OUTCOMES activities for trainee include the following;

1.6.1 Apply tools Applying tools maintenance procedures Tools maintenance

maintenance  Identification of recommended method of reclaiming each tool procedures applied
procedures  Method of restoring tools to usable condition correctly
 Sharpening
 Grinding
1.6.2 Apply equipment Applying equipment maintenance procedure Equipment maintenance
maintenance procedure applied correctly
procedure  Identify recommended methods of maintaining each
equipment
 Method of servicing workshop equipment
o Dressing grinding stone
o Inspecting chain, slings, hook
o Sharpening drill bits
o Servicing
 Air pressure facility
 Lubrication facility
 Hydraulic press
 Cleaning facility
1.6.3 Apply recommended Applying recommended maintenance procedures on tools and Recommended
maintenance equipment maintenance procedures
procedures on tools  Drilling machine on tools and equipment
and equipment.  Hydraulic press applied correctly
 Lifting equipment
 Pulling equipment
 Grinders

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  Surface table
 Air pressure facility
 Lubricating facility
 Cleaning facility
 Precision measuring instruments
 Power tools
 Hand tools
1.6.4 Apply recommended Applying recommended safety procedures Recommended safety
safety procedures  Ear protection procedure applied correctly
 Eye protection
 Body protection
 Foot protection
 Hand protection
 Head protection

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UNIT A1.7: PERFORMING BENCHWORK IN THE WORKSHOP UNIT DURATION: 40 HOURS CREDITS: 4

SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ensure that learning ASSESSMENT CRITERIA
OUTCOMES activities for trainee include the following;

1.7.1 Identify marking out Identifying marking out tools Marking out tools identified
tools  Punches correctly
 Marking Out Table
 Surface Plate
 Combination Set
 Trammels
 Dividers
 Vanier
 Scribing Block
 Surface Gauge
 Scriber
 Square
 Straight Edge
 Odd Leg Caliper
1.7.2 use marking out tools Using marking out tools Marking out tools used
 Punches correctly
 Marking Out Table
 Surface Plate
 Combination Set
 Trammels
 Dividers
 Vanier
 Scribing Block
 Surface Gauge

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  Scriber
 Square
 Straight Edge
 Odd Leg Caliper
1.7.3 Perform Benchwork Performing benchwork Benchwork performed
 Selecting a Project correctly
 Designing the project
 Applying the tools

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UNIT A1.8 USING FASTENERS UNIT DURATION: 10 HOURS CREDITS: 1 ASSESSMENT CRITERIA

SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ensure that learning
OUTCOMES activities for trainee include the following;
1.8.1 Identify types of Identify types of fasteners Types of fasteners
fasteners  Mechanical Fastener identified correctly
o Screw Thread
o Size of Fasteners
o Bolts
o Nuts
o Dowels
 Non-mechanical fasteners
o Glue
o Soldering
o Brazing
1.8.2 Apply torqueing Applying torqueing techniques Torqueing techniques
techniques  Torqueing Tools applied correctly
o Torque wrenches
o Impact wrenches
o Torque multiplier
 Torqueing Sequence
o Diagonal
o Circular
o Criss crossing
o Torqueing Value
1.8.3 Apply fasteners Applying fasteners Fasteners applied correctly
 Separable Joints
 Permanent Joints
 Floating Joints

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UNIT A1.9 PERFORMING RIGGING OPERATIONS UNIT DURATION: 30 HOURS CREDITS: 3

SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ensure that learning ASSESSMENT CRITERIA
OUTCOMES activities for trainee include the following;
1.9.1 Identify different Identifying different types of lifting and support equipment Different types of lifting and
types of lifting and support  Jacks support equipment
equipment  Forklifts identified correctly
 Cranes
 Chain blocks
 Ratchet hoist
1.9.2 Identify different Identifying different lifting accessories Different lifting accessories
lifting accessories  Lifting beams identified correctly
 Spreader bar
 Eye bolt
 Sling hooks
 Link brackets
 Barrel grip
 Shackles
1.9.3 Use lifting Using lifting terminologies Lifting terminologies used
terminologies  WLL – working load limit correctly
 SWL – safety working load
 BL – breaking load
 PL – proof loading
 SF – safety factor
 CG – center of gravity
 SL – shock loading
 Cranes – mobile, overhead

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  Forklift/telescopic handler
 Slings – wire ropes, synthetic ropes, chains
 Chain blocks
 Ratchet hoist
 Lifting accessories
o Lifting beams
o Spreader bar
o Eye bolt
o Sling hooks
o Link brackets
o Barrier grip
o Shackles

1.9.4 Use lifting and Using safety when using lifting and support equipment Lifting and support
support equipment  Hand signals equipment used correctly
 lifting and support points
 lifting technique
 wood/stand blocking
 check for breakages/cracks
 check for loose bolts and knots
1.9.5 Apply safety and Applying safety and certification requirements: Safety and certification
certification requirements o Basic Principles of Rigging requirements applied
o Safe working load correctly
o Sling certification
o Load balancing
o Rigging Certification

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1.9.6 Apply sling work Applying sling work Sling work applied
o Types of sling correctly
o Planning and Preparation
o Hooks
o Shackles
o Sling angles

1.9.7 Use chain blocks Using chain blocks Chain blocks used
o Types of chain blocks correctly
o Chain block
o Tick torque
o Operate chain block

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UNIT A1.10 PERFORMING BASIC WELDING UNIT DURATION: 40 HOURS CREDITS: 4.

SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ensure that learning ASSESSMENT CRITERIA
OUTCOMES activities for trainee include the following;
1.10.1 Describe the Describing Fundamentals of welding Fundamentals of welding
fundamentals of welding o Health and Safety requirements described correctly
o Metals and alloys
o Terminology
o Patterns/shapes
o Storage and handling

1.10.2 Identify different Identifying different types of welding Types of welding identified
types of welding  Arc welding correctly
 Gas welding
1.10.3 Perform Arc welding Performing Arc welding Arc welding performed
 Safety requirements correctly
 AC/DC machines
 Process of welding
1.10.4 Perform Gas Performing Gas welding Gas welding performed
welding  Gases correctly
 Cylinders
 Safety precautions
 Assembly procedures
 Operation procedures

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Bennett, S. (2016). Medium/Heavy Duty Truck Engine Fuel and Computerised Management systems. 5th ed. Delma: Cengage
learning
Bruce, J. (2015). Workshop Processes, Practices and materials, 5th Edition, Burlington
Gus, W., Owen,C., Sean, B. ( 2018). Fundamentals of Mobile Heavy Equipment. Burlington, MA.
Hillier, V. (2014). Fundamentals of Automotive Electronics. Oxford: McMillan publishers.
Huzij, R. (2014). Modern Diesel Technology. 2nd ed. Delmar: Cengage Learning
Joseph, A.B. (2014). Modern Diesel Technology: Electricity & Electronics. 2nd Edition. New York: Clifton Park
Kazeminezhad, M. (2012). Metal forming: Process, Tools, design. Croatia: InTech Publishers
Scott, A.H. (2015). Heavy Duty Equipment Technology: A Systems Approach (Automotive Diesel and Heavy Duty).Pearson
Education.
Sean, B. (2018). Modern Diesel Technology: Heavy Equipment Systems. New York.

xxxiv
MODULE: 166-02-A ENGINEERING MATHEMATICS I
MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate attitudes to use mathematics to solve
problems in heavy equipment Engineering effectively and efficiently.

MODULE DURATION: 100 HOURS CREDITS: 10

MODULE LEARNING OUTCOMES: On completion of this module the trainee will be able to:
1. Computing arithmetic operations
2. Using numerical methods to solve problems
3. Solving problems using mensuration
4. Manipulate Indices and logarithms
5. Plot linear data
6. Solve quadratic relationships
7. Manipulate trigonometric relationships
8. Calculate vectors
9. Calculate sequences and series

Assessment Methods:
o Assignments
o Practical
o Class exercises
o Tests

Learning Conditions: Trainee will have access to the following:

 Books
 Modules
 Library
 Internet
 Handouts

xxxv
  Calculator
UNIT A 2.1 COMPUTING ARITHMETIC OPERATIONS HOURS: 15 CREDITS: 1.5
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
2.1.1 Use scientific Using scientific calculators Scientific calculators used
calculators  Calculator layout correctly
 Accuracy
 Truncation
2.1.2 Compute Computing mathematical problems Mathematical problems
mathematical problems computed correctly
 Arithmetic operations on rational and real numbers
 Formation of equations from an open mathematical
sentence
 Simple algebra
 Single fractions

2.1.3 Interpret Interpreting mathematical tables and charts Mathematical tables and charts
mathematical tables
and charts  Translation of information from tables and charts

2.1.4 Apply significant Applying significant figures and decimal places Significant figures and decimal
figures and decimal  Addition of decimal numbers places applied correctly
places  Subtraction of decimal numbers
 Converting of decimal numbers
 Evaluation of significant figures
2.1.5 Use the standard Using the standard form (scientific notation) The standard form (scientific
form (scientific notation) notation) used correctly
 Converting of fractions to standard form

xxxvi
  Applying of scientific notation by using powers of 10

2.1.6 Apply errors in Applying errors in approximations Errors in used in approximations

approximations  Intermediate values correctly
 Percentage error

xxxvii
UNIT A2.2 USING NUMERICAL METHODS TO SOLVE PROBLEMS HOURS: 8 CREDITS: 0.8

2.2.1 Evaluate Evaluating mathematical problems using ratios Mathematical problems using
mathematical problems  Ratios ratios evaluated correctly
using ratios  Percentages
2.2.2 Apply fractions Applying fractions and proportions Fractions and proportions
and proportions applied correctly
2.2.3 Apply BODMAS Applying BODMAS on algebra BODMAS applied on algebra
on algebra correctly

xxxviii
UNIT A2.3 SOLVING PROBLEMS USING MENSURATION DURATION: 10 HOURS CREDITS:1

2.3.2 Apply properties Applying properties of quadrilaterals Properties of quadrilaterals

of quadrilaterals  Sides applied correctly
 Angles
 Line of symmetry
2.3.3.Calculate areas of Calculating areas of plane figures Areas of plane figures
plane figures calculated correctly
 Rectangle
 Square
 Parallelogram
 Trapezium

2.3.4.Calculate volumes Calculating volumes of regular shapes Volumes of regular shapes

of regular shapes  Squares
 Cones
 Cylinders
 Pyramids

xxxix
UNIT A2.4: MANIPULATING INDICES AND LOGARITHMS DURATION: 18 HOURS CREDITS: 10

SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ensure that ASSESSMENT CRITERIA
OUTCOMES learning activities for trainee include the following;
2.4.1 Calculate indices Calculating indices Indices calculated correctly
 Laws of indices

2.4.2 Calculate Calculating logarithms Indices solved correctly

logarithms  Laws of logarithms
 Natural logarithms
 Indices and logarithms relations

xl
UNIT A2.5: PLOTING LINEAR RELATIONSHIPS DURATION: 18 HOURS CREDITS: 1.8

2.5.1.Plot supplied data Plotting supplied data Supplied data plotted correctly

 coordinates on a pair of labelled Cartesian axes

2.5.2.Solve equations of Solving equations of a straight line Equations of a straight line

a straight line solved correctly.
 Gradient, m, and vertical intercept, c, to find the equation of
a straight line y=mx+c

2.5.3.Interpret Interpreting information from graphs Information from graphs

information from graphs interpreted correctly
 Finding specific values from plotted data

2.5.4.Apply parallel and Applying parallel and perpendicular lines  Parallel and perpendicular
perpendicular lines lines applied correctly
 Gradient of perpendicular and parallel lines

xli
UNIT A2.6: SOLVING QUADRATIC RELATIONSHIPS DURATION: 18 HOURS CREDITS: 1.8
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
2.6.1.Apply the Applying the discriminant The Discriminant Applied
discriminant Correctly
 Role of the discriminant in the nature of roots √ b2−4 ac

2.6.2.Manipulate the x Manipulating the x and y intercepts The x and y intercepts

and y intercepts manipulate correctly
 Roots of quadratic functions

2.6.3.Solve maxima and Solving maxima and minima points Maxima and minima points
minima points solved correctly
 Line of symmetry
 Equation of the vertex

2.6.4.Sketch quadratic Sketching quadratic functions Quadratic functions sketched

functions correctly

xlii
UNIT A2.7: MANIPULATING TRIGONOMETRIC RELATIONSHIPS DURATION: 18 HOURS CREDITS: 1.8
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
2.7.1.Apply the radian Applying the radian measure The radian measure applied
measure correctly
 Converting degrees to radians and vice versa

2.7.2.Sketch graphs of Sketching graphs of trigonometric functions Graphs of trigonometric

trigonometric functions functions sketched correctly
o Sine
o Cosine
o Tangent graphs

2.7.3.Manipulate Manipulate trigonometric identities Trigonometric identities

trigonometric identities manipulated correctly
2.7.4.Apply addition and Applying addition and subtraction formula Addition and subtraction formula
subtraction formula applied correctly
o Expansion of trigonometric formula of the form cos ( A ± B)
sin ¿),
o tan( A ± B) ,
o double angle formulae

2.7.5.Convert  Converting trigonometric functions Trigonometric functions

trigonometric functions converted correctly

xliii
UNIT A2.8: CALCULATING VECTORS DURATION: 12 HOURS CREDITS: 1.2
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
2.8.1.Calculate vectors Calculating vectors in 2 dimensions Vectors in 2 dimensions
in 2 dimensions calculated correctly
 Addition
 Subtraction
 Displacement vectors
 Unit vectors
 Multiplication by a scalar

2.8.2.Calculate vectors Calculating vectors in 3 dimensions Vectors in 3 dimensions

in 3 dimensions calculated correctly
 Addition
 Subtraction
 Direction cosines
 The scalar product

2.8.3.Calculate the work Calculating the work done by force The work done by force
done by force calculated correctly

 The Dot product

 Application of the Dot product
 Calculate angle between two vectors
 Work done by an applied force

xliv
UNIT A2.9: CALCULATING SEQUENCES AND SERIES DURATION: 18 HOURS CREDITS: 1.8
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
2.9.1.Calculate Calculating arithmetic and geometric series Arithmetic and geometric series
arithmetic and calculated correctly
geometric series  The first term and common difference for an arithmetic
progression
 10th term of an AP and Calculate terms
 Parameters of an AP given any two pieces of relevant
information
 Sum of n terms of an AP
 First term and common ratio r of a geometric progression
 nth term of a G.P and calculating terms
 Sum of n terms of a G.P
 Sum to infinity of a G. P

2.9.2.Apply the Applying the Binomial theorem Binomial theorem applied

Binomial theorem correctly
o Pascal triangle
o Convergent series
o Expansion by the binomial theorem
o Binomial theorem for an index

2.9.3.Manipulate Manipulating polynomials by iterative methods Polynomials by iterative

polynomials by iterative methods manipulated correctly
methods  Finding square roots by iterative methods
 Iterative formula
 Using the iterative formula to test for convergence

xlv
REFERENCES
Bird & May, (1991). Technician Mathematics 4 and 5. 2nd ed. Harlow: Pearson Education Limited
Croft, A. et. al, (2015). Engineering Mathematics. 5th ed. United Kingdom: Pearson
Dennis, D. (2016). Advanced Engineering Mathematics. 6th ed. Burlington: Jones & Bennett Learning
Jordan, D. (1997). Mathematical Techniques. 2nd ed. North Carolina: Oxford University Press
Kaufmann, E. (2013). College algebra. 8th ed. California: Brooks Cole Longman Group
Stroud, A.K. (2001). Engineering Mathematics. 5th ed. New York: Industrial Press Inc.
Wood, J.R. ‘et al’, (1991). Essential Pure Mathematics. Books 1 and 2. Essex: Longman Group

xlvi
 MODULE: 166-03-A ENGINEERING SCIENCE
MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate attitudes required to apply principles of engineering
science effectively and efficiently.
MODULE DURATION: 100 Hours CREDITS: 10
MODULE LEARNING OUTCOMES: On completion of this module the trainee will be able to:
1. Apply fundamental quantities
2. Apply Equilibrium under the action of forces
3. Apply moments
4. Calculate linear and angular motion
5. Apply Newton’s laws of motion
6. Calculate friction
7. Calculate work, energy and power
8. Apply principles of simple Machines
9. Apply heat energy principles
10. Apply properties of fluids
11. Apply principles of electricity
12. Applying properties of materials
Assessment Methods:
o Assignments
o Practical
o Class exercises
o Tests

Learning Conditions: Trainee will have access to the following:

 Books
 Modules
 Library
 Internet
 Handouts
 Calculator
 Laboratory

1
UNIT A 3.1: APPLYING FUNDAMENTAL QUANTITIES DURATION:20 HOURS CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
3.1.1 Use SI Units Using SI Units SI Units used correctly
 Measurements and units
 Fundamental units
 Derived units
3.1.2 Identify types of Identifying types of quantities Types of quantities identified correctly
quantities  Length
 Mass
 Time
 Electric current
 Quantity of a substance
 Temperature
 Luminous intensity
 Identifying SI units of measurement
3.1.3 Use conversions Using conversions Conversions used correctly
o Mega gram (Mg) or tonne (I) = 103kg to g to kg
o mg to kg
o mm to m
o cm to m
o dm to m
o km to m
o litres (l) to cubic meters (m3)
 Converting from non-SI to SI units
o feet (ft) to meters (m)
o Horse power (hp) to Watt (W)
o Pound (lb) to kilogram (kg)

2
 o Gallon (gal) to cubic meters (m3)
3.1.4 Analyse Dimensions Analysing dimensions Dimensions correctly analysed
 Identifying dimensions
o Mass
o Length
o Time
 Analysing dimensions of equations and expressions
o Check equations
o Verify dimensional correctness

3
UNIT A 3.2: APPLYING EQUILIBRIUM UNDER THE ACTION OF FORCES DURATION: 30 HOURS CREDITS: 3
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
3.2.1 Apply terminologies Applying terminologies  Terminologies applied correctly
o Scalars
o Vectors
 Carrying out resolution of vectors
o Vertical components
o Horizontal components
 Carrying out addition of vectors
o Triangle of forces
o Polygon of forces
o Parallelogram of forces
 Identifying conditions for equilibrium
o ∑ forces = 0
o ∑ moments = 0
3.2.2 Calculate forces Calculating forces Forces calculated correctly
 Define important terms
o Concurrent forces
o Coplanar forces
o Colinear forces
o Equilibrant
o Resultant
 Calculate;
o Resultant
o Equilibrant
o Force in a Jib and tie
o Forces in a system

4
 Calculate concurrent coplanar forces
o Analytical resolution of forces
o Graphical resolution of forces

5
UNIT A 3.3: APPLYING MOMENTS DURATION: 30 HOURS CREDITS: 3
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
3.3.1 State the Principle of Stating the Principle of Moments Principle of moments stated correctly
Moments  Define
o Moment
o Couple
o Centre of gravity
o Centroid
3.3.2 Calculate moment of Calculating the moments on; Moment of a force calculated correctly
a force
o Beam loading
 Applying moments of a force
o Effects of a force
 Determine
o Torque
o Couple
 Applying principle of moments
o Balance of moments
 Determinining
o Centre of gravity
 Regular plane figures
 Irregular plane figures
o Centroids
 Regular plane figures
 Irregular plane figures

6
UNIT A 3.4: CALCULATING LINEAR AND ANGULAR MOTION DURATION: 30 HOURS CREDITS: 3
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
3.4.1 Calculate linear Calculating linear motion Linear motion calculated correctly
motion  Equations of motion
 Displacement-time graph
 Velocity-time graph
 Free falling bodies
3.4.2 Calculate angular Calculating angular motion Angular motion calculated correctly
motion
 Angular displacement
 Angular velocity
 Angular acceleration
 Linear and angular motion relationship
3.4.3 Calculate projectile Calculating projectile motion Projectile motion calculated correctly
motion o Horizontal component
o Vertical component
o Time of flight
o Greatest height
o Horizontal range

7
UNIT A 3.5: APPLYING NEWTON’S LAWS OF MOTION DURATION: 20 HOURS CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
3.5.1 Apply Newton’s Applying Newton’s laws of motion Newton’s Laws of motion applied
Laws of motion  Newton’s first law correctly
 Newton’s second law
 Newton’s third law
 Inertia
3.5.2 Apply concepts of Applying the concept of mass Concepts of mass applied correctly
mass  Mass and force
 Force of attraction between bodies
 Inertia
o Force
o Weight of a body in a lift
3.5.3.Calculate Impulse Calculating Impulse and momentum Impulse and momentum applied
and momentum o momentum correctly
 Change in momentum
 impulse
 Impulsive force
 Types of collisions

8
UNIT A 3.6 CALCULATING FRICTION DURATION: 20 HOURS: CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ensure that ASSESSMENT CRITERIA
OUTCOMES learning activities for trainee include the following;
3.6.1 State laws of friction Stating laws of friction Laws of friction stated correctly
o Friction
o Coefficient of friction
 Outlining advantages and disadvantages of friction
 Laws of friction between clean dry surfaces
3.6.2 Calculate friction Calculating friction Friction calculated correctly
 Static friction
 Kinetic friction
 Motion up the plane
 Motion down the plane
 Angle of friction
o Total reaction
o Angle of friction

9
UNIT A 3.7 CALCULATING WORK, ENERGY AND POWER DURATIONS: 10 HOURS: CREDITS: 1
3.7.1 Define work, energy Defining work, energy and power
and power  Work
 Energy
 Power
 Kinetic energy
 Potential energy
3.7.2 Calculate work, Calculating work, energy and power
energy and power o Work done by a force (W =F × S )
o Work done by a torque
o Potential energy
o Kinetic energy
o Power generated by a force
Applying conservation of energy principle
Determining the Power generated by a torque

10
UNIT B3.8 APPLYING PRINCIPLES OF SIMPLE MACHINES
HOURS: 20 CREDITS: 2
3.8.1 Explain Principles of Explaining Principles of Simple Machines Principles of simple machines explained
Simple Machines  Simple machine correctly.
 Mechanical advantage
 Velocity ratio
 Efficiency of a simple machine
 Limiting efficiency
 Law of a machine
 Overhauling of simple machine
3.8.2 Apply simple levers Applying simple levers Simple levers applied correctly
 First class
 Second class
 Third class
 Calculate
o Mechanical advantage,
o velocity ratio
o efficiency
3.8.3 Apply screw jack Applying screw jack Screw jack applied correctly
o Mechanical advantage
o Velocity ratio
o Efficiency
3.8.4 Apply pulley Applying pulley systems Pulley systems and gear trains applied
systems and gear  Mechanical advantage, correctly
trains  Velocity ratio
 Efficiency
 Applying gears and gear trains
o Simple gear train
 Velocity ratio

11
  Speed of a gear (rpm)
o Compound gear train
 Velocity ratio
 Speed of a gear (rpm)

12
UNIT 3.9 APPLYING HEAT ENERGY PRINCIPLES HOURS: 20 CREDITS: 2

SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ensure that ASSESSMENT CRITERIA
OUTCOMES learning activities for trainee include the following;
3.9.1 Apply principles of Applying principles of temperature and heat Principles of temperature and heat
temperature and o Temperature scales applied correctly
heat o Heat and (energy)
o Specific heat capacity
o Calorimetry
Explaining heat transfer concepts
o Radiation
o Convection
o Conduction
Applying gas laws
o Charles’ Law
o Pressure law
o Boyle’s Law
o Ideal gas Law

13
UNIT 3.10 APPLYING PROPERTIES OF FLUIDS HOURS: 20 CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
3.10.1 Define fluid Defining fluid properties Properties of fluid defined correctly
properties o Fluid
o Mass density
o Relative density
o Specific volume
o Specific weight
o Specific gravity
o Viscosity
3.10.2 Calculate properties Calculating properties of fluids Properties of fluids calculated correctly
of fluids o Mass density
o Specific weight
o Relative density
F
o Transmission of fluid Pressure ( P= , P = ꞷh)
A

14
UNIT 3.11 APPLYING PRINCIPLES OF ELECTRICITY DURATION: 20HOURS: CREDITS: 2
3.11.1 Apply terminologies Applying terminologies Terminologies applied correctly
o Atomic structure
 Atom
 Electron
 Proton
 Nucleus
 Neutron
o Electrical charge
o Current
o Voltage
o Power

Using conductors and insulators

Constructing series and parallel circuits

o Circuit diagrams
o Symbols
o Electrical symbols
o Electronic symbols
o Electric appliances
3.11.2 Apply Ohm’s law Applying Ohm’s law Ohm’s law applied correctly
State Ohm’s law
Apply Ohm’s law
o Calculate
 Resistance
 Voltage
 Current
 Electric power

15
3.11.3 Apply Kirchhoff’s Applying Kirchhoffs Kirchhoff’s laws applied correctly
laws o Resistance
o Voltage
o Current
o Electric current and its effects

o Resistance

o Semiconductors

o Uses of insulators

Applying Kirchhoff’s Law

o Kirchhoff’s junction theorem
 Current
o Kirchhoff’s loop theorem
 Voltage

16
UNIT 3.12 APPLYING PROPERTIES OF MATERIALS HOURS: 30 CREDITS: 3
3.12.1 Explain properties of Explaining properties of materials; Properties of materials explained
materials o Stress correctly
o Strain
o Young’s modulus
o Tensile strength
Stating Hooke’s law
Explaining properties
o Mechanical
 Tensile strength
 Compressive strength
 Elasticity
 Plasticity
 Ductility
 Malleability
o Electrical
o Chemical
3.12.2 Calculate properties Calculating properties of materials Properties of materials calculated
of materials o Stress correctly
o Strain
o Young’s modulus
o Tensile strength
o Factor of safety
o Yield stress

17
Recommended Textbooks
Bolton, N. (1988). Engineering Science. 6th edn. London: Routledge
Hughes, E. (1994). Engineering Science. 4th ed. London: Pearson Education.
Titcomb, G.R.A. (1988). Fundamentals of Engineering Science.12th ed, London: Stanley Thornes Ltd
Zammit, S.J. (1987). Motor Vehicle Engineering Science for Technicians. England: Pearson Education.

18
MODULE: 166-04-A ENGINEERING DRAWING I
MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate attitudes required to apply principles of
engineering drawing effectively and efficiently.

MODULE DURATION: 100 HOURS CREDITS: 10

MODULE LEARNING OUTCOMES: On completion of this module the trainee will be able to:
1. Use drawing instruments and equipment
2. Produce geometrical figures
3. Produce engineering drawings
4. Produce pneumatic and hydraulic drawings
5. Lay out drawings
ASSESSMENT METHODS
 Drawing tutorial
 Assignments
 Tests
 Examinations
LEARNING CONDITIONS
Trainee will have access to the following:
 Drawing room
 Lecture notes
 Library
 Internet
 Handouts
 Tutorials

19
UNIT A 4.1 USING DRAWING INSTRUMENTS AND EQUIPMENT DURATION: 40 HOURS CREDITS: 4
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
4.1.1 Use various Using various types of instruments Various types of instruments used
types of correctly
instruments  Compasses
 Pencils
 Tee square
 Set squares
 Eraser
 Ruler
4.1.2 Operate types of Operating types of equipment Types of equipment operated correctly
equipment  Radius curve
 French curve
 Drawing board
 Eraser shield
 Same paper block
4.1.3 Use drawing Using drawing standard Drawing standard used correctly
standard  Relevant Zambian Standards
 BS308 Parts 1, 2 and 3
 ISO 1101 o ISO 2595

20
UNIT A 4.2 PRODUCING GEOMETRICAL FIGURES DURATION: 40 HOURS CREDITS: 4
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
4.2.1 Use Conventions Using Conventions Conventions used correctly
 Title block dimensions
 Title block information
 Using conventions
 Manipulating units of measurements
4.2.2 Use Symbols Using Symbols Symbols used correctly
 Spherical diameter
 Pitch circle diameter (PCD)
 Cylindrical
 Undercut
4.2.3 Use Using Abbreviations Abbreviations used correctly
Abbreviations  TOL- Tolerance
 Min- Minimum
 Max- Maximum
 Fig-Figure
 ASSY-Assembly
4.2.4 Use different Using different types of lines Different types of lines used correctly
types of lines  Thickness of lines
 Chain lines
 Dash lines
 Center lines
 Construction lines
 Border lines
 Section lines
 General rules on line work
4.2.5 Scale drawings Scaling drawings Drawings scaled correctly
 Scale multiples of 2,5 and 10

21
  Full size 1:1
 Smaller than full size- 2:2,1:5, 1:10
 Larger than full size- 2:1,5:1, 10:1
4.2.6 Produce types of Producing types of geometrical drawings Types of geometrical drawings applied
geometrical  Basic shapes correctly
drawings  Triangle
 Rectangle
 Polygons
 Circles, arcs
 Inscribing and circumscribing
 Epicycloid
 Oval
4.2.7 Use Using dimensioning Dimensioning used correctly
dimensioning  Function dimensions
 Non- functional dimensions
 Auxiliary dimensions,
 Basic rules of dimensions
 Dimensioning terminology
 Dimension techniques
 ISO conventions for dimensioning

22
UNIT A 4.3 PRODUCING ENGINEERING DRAWINGS DURATION: 40 HOURS CREDITS:

4.3.1 Carry out Free Carrying out Free hand sketching Free hand sketching carried out
hand sketching  Pictorial sketching, correctly
• Sketching in orthographic projection,
• Sketching as an aid to design
4.3.2 Use Projections Using Projections Projections used correctly
 Basic projection principles
• Isometric
Orthographic
First And
Third Angle
•

23
UNIT A 4.4: PRODUCING PNEUMATIC AND HYDRAULIC DRAWINGS DURATION: 50 HOURS CREDITS: 5
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
4.4.1 Produce Producing hydraulic and pneumatic symbols Hydraulic and pneumatic symbols
hydraulic and  Working line produced correctly
pneumatic  Exhaust line
symbols  Temperature gauge
 flexible line
 Check valve
 Pressure gauge
 Spring control
 Safety valve
 Thermometer
 Hydraulic pump
 Single and double acting cylinder
 Non return spring loaded valve
4.4.2 Interpret Interpreting conventions Conventions interpreted correctly
conventions  Interpretation of subject to conventions of pneumatics
and hydraulics presentations
4.4.3 Apply pneumatic Applying pneumatic drawing standards Pneumatic drawing standards applied
drawing  International standard conforming to ISO 1219 correctly
standards
4.4.4 Apply hydraulic Applying hydraulic drawing standards Hydraulic drawing standards applied
drawing  International standard conforming to ISO 1219 correctly
standards

24
UNIT A 4.5: USING DRAWING INSTRUMENTS AND EQUIPMENT DURATION: 50 HOURS CREDITS: 5
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
4.5.1.Prepare title Preparing title blocks Title blocks prepared correctly
blocks  System of labelling
 Cross referencing
4.5.2.reparing drawing Preparing drawing paper Drawing paper prepared correctly
paper  ‘A’ series of drawing sheets
 Paper lay out and positioning
 Air and its properties
 Air hoses
 Valves – types and uses
 Joints
 Pneumatic indicators
 Valves and Actuators
 Circuits
4.5.3.Use precautions Using precautions Precautions used correctly
 Dos and Don’ts
 Storage of drawings

25
Recommended Textbooks
Bland, S. (2009). Graded Exercises in Technical Drawing. 6th edn. England: Longman.
Firth, C.B. (1970). Engineering Drawing Technology, McGraw-Hill
Morling, K. (2006). Geometric & Engineering Drawing. 3rd edn. London: Elsevier.
Ostrowsky, O. (2006). Engineering Drawing with CAD Applications. 5th edn. London: Elsevier.
Yarwood, A. (1994). The Motivate Series : Technical Drawing with Design. 2nd edn. Oxford: Macmillian Education.

26
MODULE: 166-05-A COMMUNICATION SKILLS

MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate MODULE DURATION: CREDITS: 8 Credit
attitudes required to communicate in a workplace effectively and efficiently. 80 Hours Hours

MODULE LEARNING OUTCOMES: On completion of this module the trainee will be able to:
1. Use a library
2. Discuss process of communication
3. Apply study skills
4. Apply correspondence skills
5. Write reports
6. Applying interpersonal skills in an organisation
7. Applying for a Job
8. Using technical English
Assessment Methods:
o Assignments
o Practical
o Class exercises
o Tests

Learning Conditions: Trainee will have access to the following:

 Books
 Modules
 Library
 Internet
 Handouts

27
UNIT A5.1: USING A LIBRARY DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
5.1.1 Illustrate the filing Illustrating the filing system Filing system illustrated correctly
system  Classify books according to class works
 Arrange books alphabetically according to the first three
letters of the author’s name

5.1.2 Identify the Identifying the references and dictionaries References and dictionaries identified
references and  Using material within the library correctly
dictionaries  Selected materials in this section are either in short
supply or are of special nature e.g. dictionaries.
5.1.3 Identify Identifying periodicals in the library Periodicals identified correctly
periodicals in the  Newspapers
library  Magazines
 Current information
5.1.4 Prepare Preparing bibliography in any written work Bibliography prepared correctly
bibliography in  Descriptions of a book
any written work  Location in the library
 Catalogue
5.1.5 Use library Using library facilities Library facilities used correctly
facilities  Information from books
 Book classification and location
 Internet

28
UNIT A5.2: DISCUSSING THE PROCESS OF COMMUNICATION DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
5.2.1 Recognize the Recognizing the nature and purpose of communication Nature and purpose recognised correctly
nature and  Nature and purposes of communication
purpose of  The Use of English
communication  Choices of communication
5.2.2 Identify the Identifying the communication process. Communication process identified correctly
communication  Communication circle
process.  Types of communication channels
o Verbal
 Meetings
 Briefings
o Non-Verbal
 Paralanguage
 Kinesics
 Proximie
 Colour
 Time
o Written
 Journals
 Notices
 Memos
 Reports
5.2.3 Identify barriers to Identifying barriers to effective communication Barriers to effective communication
effective  Non-verbal signs identified correctly
communication o Noise
o Semantic problem

29
  Poor listening skills
o Poor timing
 Prejudgment
o I attitude syndrome
 Emotional response
o Information overload

5.2.4 Apply strategies Applying strategies of effective communication Strategies of effective communication
of effective  Extend language knowledge through reading (Read applied correctly
communication widely)
 Listen attentively
 Be open minded
 Time your communication
 Status
 Maintain High Standards\
 Obtain feedback
5.2.5 Identify the flow of Identifying the flow of communication in organization Flow of communication identified correctly
communication in  Vertical
organization o Upward
o downward
 Horizontal
o Lateral
 Diagnosed communication

30
UNIT A5.3: APPLYING STUDY SKILLS DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
5.3.1 Acquire skills for Acquiring skills for intensive reading Intensive reading skills acquired correctly
intensive reading

5.3.2 Develop writing Developing writing skills Writing skills developed correctly
skills o Main points from a text
o Summarizing paragraphs
o Technical description and definitions
o Systematic approach to business writing
o Five key rules to business writing
 Straight to the point
 KISS principle
 Active and not passive voice
 Use the right tone
 Use modern language
o General guidelines in composing business letters
 Chose simple words
 Use appropriate tone
 Be precise
 Be accurate
 Check consistency
 Use initiative
 Use active and not passive voice
 Write as you speak
5.3.3 Develop listening Developing listening and speaking skills Listening skills developed correctly
and speaking skills  Presenting an argument
 Questioning skills

31
UNIT A5.4: APPLYING CORRESPONDENCE SKILLS DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
5.4.1 Write different Writing different types of letters Different types of letters written correctly
types of letters  Formal
 Informal
5.4.2 Respond to Responding to memorandum Memorandum responded to correctly
memorandum (categorise of formal letters) (Formal letters categorised correctly )
(categorise of formal  Letter of conformation
letters)  Acknowledgement
 Enquiry
 Reply to enquiry
 Complaint
 Adjustment
 Collection letter
 Recommendation
5.4.3 Respond to Responding to circulars(Characteristics of business letters} Circulars responded to correctly
circulars  Definition Structure of a business letter (characteristics if business letters identified
(Characteristics of  Opening paragraphs correctly)
business letters)  Main body
o Closing paragraph
 Qualities of a business letter
o Paper quality
o Envelope
o Type face
o Logo and Corporate Image
o General Impression

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UNIT A5.5: WRITING REPORTS DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
5.5.1 Apply research Applying research techniques Research techniques applied correctly
techniques  Library
 Internet
5.5.2 Write different Writing different types of reports Different types of reports written correctly
types of reports  Routine or regular report
 Financial report
 Equipment maintenance report
 Staff appraisal
 Specialised commissioned reports
 Market research
 Market forecasting
 Investigation report
 Minutes
5.5.3 Use report Using report format Report format used correctly
format  Different report format

5.5.4 Compose Composing different types of report Different types of reports composed
different types of report  Informal correctly
 Formal
5.5.5 Write a proposal Writing a proposal Proposal written correctly
 Components of a proposal

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UNIT A5.6: APPLYING INTERPERSONAL SKILLS IN AN ORGANISATION DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
5.6.1 Make Making consultations Consultations made correctly
consultations  Colleagues
 Supervisors
 Organisations
5.6.2 Carry out joint Carrying out joint considerations of problems Joint consideration carried out correctly
considerations of  Importance of joint consideration
problems  Reaching same conclusion
 Importance of policy or decision
 Favourable attitudes
 Moreland better decisions
 Suggestions available
 More commitment
5.6.3 Receive Receiving of instructions Instructions received correctly
instructions

5.6.4 Participate in Participating in decision making Decision making participated in correctly

decision making  Leadership exercise
 Decisions emerges as the general feeling of the group
 Gives opportunity for all members to have a say
5.6.5 Handle Handling of customers Customers handled correctly
customers

5.6.6 Get permission Getting permission Permission gotten correctly

 Granting permission

34
UNIT A5.7: APPLYING FOR A JOB DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
5.7.1 Write an Writing an application letter Application letter written correctly
application letter  Lay out-blocked/indented
 Standard elements
5.7.2 Write a Writing a Curriculum Vitae Curriculum Vitae written correctly
Curriculum Vitae  Lay out- heading
 Personal details
 Education background
 Referees
5.7.3 Prepare for Preparing for interviews Interviews prepared for correctly
interviews  Interviewee
o Know your self
o Company
o Presentation- (clothes)
o Know the organisation
o Prepare appropriate dress code
o Check your documents by going through
 CV
 Application letter
 Interviewer
 Why
 Who
 Where
 When

35
 What
 How

36
UNIT A5.8: USING TECHNICAL ENGLISH DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
5.8.1 Identify technical Identifying technical tools Technical tools identified correctly
tools  Technical tools
5.8.2 Apply technical Applying technical instructions Technical instructions applied correctly
instructions  Job cards
 Operation of tools
 Grammar used
5.8.3 Use technical Using technical descriptions Technical descriptions used correctly
descriptions  Mechanisms
 Processes of tools

37
REFERENCE MATERIALS
Brieger, N. (1997). Teaching Business English. New York: York Associates Publications.
Dwyer, J., (2003). The business communication handbook. Prentice Hall.
Thill, J.V. (1999). Business communication today. Prentice Hall.

38
MODULE: 166-06-A INTRODUCTION TO COMPUTERS

MODULE PURPOSE: To equip the trainee with knowledge, skills and MODULE DURATION: 80 CREDITS: 8.0 Credit
appropriate attitudes required to carry out basic operations of a computer Hours Hours
effectively and efficiently.

MODULE LEARNING OUTCOMES: On completion of this module the trainee will be able to:
1. Operate a computer
2. Use the operating system
3. Use word processing for technical report
4. Send and receive an e-mail
5. Use spread sheet
6. Use internet
7. Use power point and project presentation
Assessment Methods:
o Assignments
o Practical
o Class exercises
o Tests

Learning Conditions: Trainee will have access to the following:

 Books
 Modules
 Library
 Internet

39
UNIT A6.1: OPERATING A COMPUTER SYSTEM DURATION: 20 HOURS 2 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
6.1.1 Handle computer Handling computer Computer handled correctly
 Switch on and off
 Login
 Logout

6.1.2 Identify basic Identifying basic elements of a personal Basic elements identified correctly
elements of a computer
personal  Elements of a Personal Computer
computer  Input and output devices

6.1.3 Handle removable Handling removable devices Removable devices handled correctly
devices  USB
 CD
 Hard disk
6.1.4 Maintain a Maintaining a Personal Computer Personal computer maintained correctly
Personal  Maintenance procedure
Computer o Servicing
o Cleaning
6.1.5 Identify major Identifying major components of a computer Major components identified correctly
components of a  Software
computer  Hardware
6.1.6 Adhere to health Adhering to health safety Health and safety adhered to correctly
safety  Environment
 Exposure
 Electrical connections

40
UNIT A6.2: USING AN OPERATING SYSTEM DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ASSESSMENT CRITERIA
OUTCOMES ensure that learning activities for trainee include
the following;
6.2.1 Use file system Using file system Filing system used correctly
 Filing system

6.2.2 Handle libraries Handling libraries Libraries handled correctly

 Handling libraries

6.2.3 Install software Installing software programs. Software programmes installed correctly
programs.  Software installation programs

6.2.4 Remove virus on Removing virus on personal Computer system Virus removed correctly
personal Computer  Virus removal procedure
system

41
UNIT A6.3: USING WORD PROCESSING FOR TECHNICAL REPORTS DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ASSESSMENT CRITERIA
OUTCOMES ensure that learning activities for trainee include
the following;
6.3.1 Handle word Handling word documents Word documents handled correctly
documents  Handling procedure
6.3.2 Edit document Editing document Document edited correctly

6.3.3 Use fonts Using fonts Font used correctly

6.3.4 Insert features Inserting features Features inserted correctly

 Picture
 Graphics
 Spreadsheet
6.3.5 Handle tables Handling of tables Tables handled correctly

6.3.6 Carryout Carrying out formatting Formatting carried out correctly

formatting  Footer
 Header
6.3.7 Use grammar Using grammar Grammar used correctly
 Speller
 Grammar
6.3.8 Apply indexing  Indexing Indexing applied correctly

42
UNIT A6.4: SENDING AND RECEIVING E-MAIL DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ASSESSMENT CRITERIA
OUTCOMES ensure that learning activities for trainee include
the following;
6.4.1 Compose e-mail Composing e-mail Email composed correctly
 Internet or Local Area Network (LAN)
 Opening the e-mail server
 Creation of address book
6.4.2 Send e-mail Sending e-mail Email sent correctly
 Compose command
 Use address “To” field
 Copy field
 Edit command
 Document attach command
 Send command
6.4.3 Receive e-mail Receiving e-mail Email received
 Open command
 Saving e-mail in various formats
6.4.4 Reply to e-mail Replying to e-mail Email replied to
 Use reply command

6.4.5 Forward e-mail Forwarding e-mail Email forwarded correctly

 Use forwarding command
6.4.6 Observe etiquette Observing etiquette when using e-mail Etiquette observed
when using e-mail  Email etiquette

43
UNIT A6.5: USING SPREADSHEET DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ASSESSMENT CRITERIA
OUTCOMES ensure that learning activities for trainee include
the following;
6.5.1 Manage Managing Spreadsheet Spreadsheet managed correctly
Spreadsheet

6.5.2 Manage Cells and Managing Cells and contents Cells and contents managed correctly
contents

6.5.3 Handle Rows, Handling of rows, columns and content Rows, columns and content handled correctly
columns and
content

6.5.4. Handle Sheets Handling sheets and content Sheets and content handled correctly
and content
6.5.5 Use arithmetical Using arithmetical Functions Arithmetical functions used correctly
Functions  Use of functions
o Mathematical
o Logical statistical
6.5.6 Create database Creating database Database created correctly

6.5.7 Create Diagrams Creating diagrams and charts Diagrams and charts created correctly
and Charts

44
UNIT A6.6: USING THE INTERNET DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES: The trainer must ASSESSMENT CRITERIA
OUTCOMES ensure that learning activities for trainee include
the following;
6.6.1 Enumerate the Enumerating the benefits of using the Internet Benefits of the internet enumerated correctly
benefits of using
the Internet
6.6.2 Browse the World Browsing the World Wide Web (www) World wide web browsed
Wide Web (www)  Web page addresses
 Search engines
 Links
6.6.3 Save web pages Saving web pages Web pages saved correctly
 Various saving formats (html, text, pdf, word,
other formats)
6.6.4 Download Downloading documents from the Web Documents downloaded correctly
documents from
the Web  Selecting required document or part of it

6.6.5 Observe Rules for Observing Rules for using the Internet Rules observed correctly
using the Internet  Malicious software
 Alteration of third-party web pages

45
UNIT A6.7: USING POWER POINT PRESENTATION DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
6.7.1 Create Creating PowerPoint presentation PowerPoint presentation created correctly
PowerPoint
presentation
6.7.2 Project Projecting presentation Presentation projected correctly
presentation

46
REFERENCE MATERIALS
Simon, H.A. (2007). Computer science as empirical inquiry: Symbols and search. ACM.
Williams, B.K. (2001). Using information technology: A practical introduction to computers and communications. McGraw-Hill Higher
Education.

47
MODULE NO. 166-07-A ENGINE AND TRANSMISSION SYSTEMS

MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate attitudes to MODULE CREDITS:18
effectively and efficiently repair and service motor vehicle engine systems DURATION:
180 Hrs

MODULE LEARNING OUT COMES: On completion of this module the trainee should be able to:
1. Outline the vehicle layout
2. Identify engine components
3. Explain motor vehicle engine operations
4. Carry out repairing and servicing of motor vehicle engine lubrication systems
5. Carry out repairing and servicing of motor vehicle engine ignition System
6. Carry out repairing and servicing of motor Vehicle engine Fuel System
7. Carry out repairing and servicing of motor Vehicle engine cooling System
8. Identify transmission system components
9. Carry out disassembling and Assembling of transmission system components
10. Carry out diagnosis of transmission system faults
11. Rectify transmission faults

ASSESSMENT METHODS
o Exercises
o Class tests
o Assignments
o Practical
o
LEARNING CONDITIONS

48
The trainee must have access to:
 Books
 Library
 Internet
 Lecture notes
 Automotive mechanics workshop
 Running vehicle

49
 UNIT A7.1 OUTLINING THE VEHICLE LAYOUT
DURATION: 20 CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
7.1.1 Identify locations of Identifying locations of vehicle components Locations of vehicle components
vehicle components identified correctly
 Types of vehicle components
o Engine
o gearbox
o Propeller shaft
o Final drive
o Axle/drive shafts
o Road wheels
o Body and chassis
 Location of vehicle components
o Engine
o gearbox
o Propeller shaft
o Final drive
o Axle/drive shafts
o Road wheels
o Suspension
o Steering
7.1.2 Outline functions of Outlining functions of vehicle components functions of vehicle components
vehicle components.  Engine outlined correctly

50
  gearbox
o Propeller shaft
o Final drive
o Axle/drive shafts
o Road wheels
7.1.3 Identify locations of Identifying locations of engines locations of engines identified correctly
engines  Positioning of engines
o Front position
 Advantages of front position
 Disadvantages of front position
o Rear position
 Advantages of rear position
 Disadvantages of rear position
o Engine classification
 In-line engine
 Vee engine
 Horizontally opposed engine
 The Rotary engine

 Types of drive/
o Front engine Rear Wheel Drive (RWD)
 Functions of RWD
 Advantages of RWD
 Disadvantages of RWD
o Front engine Front Wheel Drive (FWD)

51
  Functions of FWD
 Advantages of FWD
 Disadvantages of FWD

o Rear engine Rear Wheel Drive (RRWD)

 Functions of RRWD
 Advantages of RRWD
 Disadvantages of RRWD

o Four Wheel Drive (4x4)

 Functions of 4x4WD
 Advantages of 4x4WD
 Disadvantages of 4x4WD

52
UNIT A7.2 IDENTIFYING ENGINE COMPONENTS
DURATION: 20 CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
7.2.1 Define motor Defining motor vehicle engine terminologies Engine terminologies defined correctly
vehicle engine  Motor vehicle engine terminologies
terminologies o Top Dead Centre (TDC)
o Bottom dead Centre (BDC)
o Compression Ratio
o Stroke
o Crank throw
o Bore
o Engine capacity
o Torque
o Clearance volume
o Total volume
o Swept volume
o ATDC
o BTDC
o ABDC
o BBDC
o SI (Spark Ignition) Engine
o CI (Compression Ignition) Engine
7.2.2 Identify categories of Identifying categories of engine components Categories of engines components
engine components  Categories of engine components identified correctly

53
 o Stationary engine components
o Cylinder head
o Engine block
o Rotary/reciprocating engine components
 Valve train
 Pistons
 Crankshaft
 Flywheel

7.2.3 Outline the Outlining the construction of engine components the construction of engine components
construction of engine  Construction of stationary engine components outlined correctly
components o Cylinder head
 Types of combustion chambers
- Direct combustion chambers
- In-direct combustion chambers
 Starting Aids
- Glow plugs
- Ether
o Cylinder block types
 Monoblock
 Separate
 Construction of reciprocating engine components
o Pistons and rings
o Connecting rods
o Crankshafts

54
 o Camshafts
o Flywheel
o Vibration dumper
o Valve train

7.2.4 Explain functions of Explaining functions of engine components Functions of engine components
engine components  Functions of stationary engine components explained correctly
o Cylinder head
o Cylinder block
 Functions of reciprocating engine components
o Pistons and rings
o Connecting rods
o Crank shafts
o Cam shafts
o Flywheel
o Vibration dumper
o Valve train

7.2.5 Carry out servicing of Carrying out servicing of engine components servicing of engine components
engine components  Stationary engine components outlined correctly
o Cylinder head
o Cylinder block
 Reciprocating engine components
o Pistons and rings
o Connecting rods

55
 o Crank shafts
o Cam shafts
o Flywheel
o Vibration dumper
o Valve train
UNIT 7.3 EXPLAINING MOTOR VEHICLE ENGINE OPERATIONS
DURATION: 10 CREDITS: 1
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
7.3.1 Explain the operation Explaining the operation of a four stroke cycle (Spark ignition operation of a four stroke cycle (spark
of a four stroke cycle (Spark engine) ignition engine) explained correctly
ignition engine)  The operational stages of a four stroke cycle (Spark
Ignition engine)
o Induction stroke
o Compression stroke,
o Power stroke,
o Exhaust stroke,
7.3.2 Explain the operation Explaining the operation of a two stroke cycle ( Spark ignition operation of a two stroke cycle spark
of a two stroke cycle ( Spark engine) ignition engine) explained correctly
ignition engine)  Operational stages of two stroke cycle ( Spark
IgnitionEngine)
o upward stroke.
o downward stroke

7.3.3 Explain the operation Explaining the operation of a four stroke cycle Compression operation of a four stroke cycle
of a four stroke cycle Ignition Engine ( compression ignition engine)
Compression Ignition Engine  The operational stages of a four stroke cycle explained correctly
( compression ignition engine)

56
 o Induction stroke
o Compression stroke,
o Power stroke,
o Exhaust stroke,

7.3.4 Explain the operation Explaining the operation of a two stroke cycle Compression operation of a two stroke cycle
of a two stroke cycle Ignition ( compression ignition engine)
Compression Ignition  The operational stages of a two stroke cycle ( compression explained correctly
ignition engine)
Describe construction of supercharges
o upward stroke
correctly
o downward stroke
 Supercharging Explain operation of superchargers
 Types of superchargers correctly
o Blower
o Turbochager
7.3.5 Explain operation of  Describing construction of rotary engine Construction of rotary engine
rotary engine  Explaining functions of components of rotary engine described correctly
o Rotor Functions of components of rotary
o Accentric shaft engine explained correctly
o Seals
Operation of rotary engine explained
o Apex
correctly
 Explaining operation of roatary engine
7.3.6 outline Valve Timing outlining Valve Timing Diagram (V.T.D), power flow chart and Valve Timing Diagram (V.T.D), power
Diagram (V.T.D), power flow combustion process flow chart and combustion process
chart and combustion  Valve timing diagrams outlined correctly
process o Valve lead
o Valve lag
o Valve overlap
 Power flow chart and combustion process

57
o Induction strokes
o Compression strokes
o Power strokes
o Exhaust strokes

58
UNIT 7.4 REPAIRING AND SERVICING OF MOTOR VEHICLE ENGINE LUBRICATION SYSTEMS
DURATION: 20 CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
7.4.1.Identify motor vehicle Identifying motor vehicle engine lubrication systems Motor vehicle engine lubrication
engine lubrication systems  Motor vehicle engine lubrication systems systems identified correctly.
o Dry sump
o Wet sump
7.4.2.Explain the operation Explaining the operation motor vehicle engine lubrication function of motor vehicle engine
motor vehicle engine system lubrication system explained correctly
lubrication system  Engine lubrication system
 Engine lubrication oil

 Properties of lubricating oil

 Operations of motor vehicle lubrication system
o Wet sump
o Dry sump
 Motor vehicle lubrication system filtration
o Full flow
o By-pass
 Motor vehicle lubrication methods
o Force feed
o Splash feed
o Mist feed
7.4.3.Identify Identifying Components of motor vehicle lubrication system components of motor vehicle
components of motor o Oil pump lubrication systems identified correctly
vehicle lubrication

59
 system o Oil filter
o Oil strainer
o Oil sump
o Oil pressure relief valve
o Oil galleries
o Pressure warning indicators
o By-pass valve

7.4.4.Explain the functions Explaining Function/s of motor vehicle lubrication system functions of motor vehicle lubrication
of motor vehicle lubrication components system components explained
system components o Oil pump correctly
o Oil filter
o Oil strainer
o Oil sump
o Oil pressure relief valve
o Oil galleries
o Pressure warning indicators
o By-pass valve

7.4.5.Carry out motor Carrying out Motor vehicle engine lubrication system servicing
vehicle engine lubrication o Oil pump
system servicing o Oil filter
o Oil strainer
o Oil sump
o Oil pressure relief valve

60
 o Oil galleries
o Pressure warning indicators
o By-pass valve
UNIT A7.5 REPAIRING AND SERVICING OF MOTOR VEHICLE ENGINE IGNITION SYSTEM
DURATION: 20 CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
7.5.1.Identify motor vehicle Identifying Motor vehicle ignition systems Motor vehicle ignition system identified
ignition systems  Conventional ( contact breaker points) correctly
 Electronic
o Hall effect
o Optical pulse
o Magnetic inductance
o Distributor-less

7.5.2.Explain functions of Explaining Function of motor vehicle engine ignition system Explaining functions of motor vehicle
motor vehicle engine ignition  High ignition voltage generation engine ignition system correctly
systems
7.5.3.Identify motor vehicle Identifying Motor vehicle ignition system components motor vehicle ignition system
ignition system components (conventional) components identified correctly
 Battery
 Ignition distributor
 Ignition coil
 Spark plugs
 Condenser (capacitor)
 Ignition key

61
  Contact breaker points
 High tension cables
o Low tension cables
o Rotor
7.5.4.Carry out motor Carrying out Motor vehicle engine ignition system servicing Motor vehicle engine ignition system
vehicle engine ignition o Testing ignition coil resistance servicing outlined correctly
system servicing o Testing spark plugs
o Testing resistance of high tension cables
o Cleaning contact breaker points
 Motor vehicle engine ignition timing
o Static ignition timing
o Dynamic ignition timing

7.5.5.Carry out motor Carrying out Motor vehicle engine fault diagnosis motor vehicle engine ignition fault
vehicle engine ignition fault o No spark generation diagnosis carried out correctly
diagnosis o Weak spark generation
o Intermittent spark generation

62
UNIT A7.6 REPAIRING AND SERVICING OF MOTOR VEHICLE ENGINE FUEL SYSTEM
DURATION: 20 CREDITS:20
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
7.6.1 Identify motor vehicle Identifying Motor vehicle fuel systems Motor vehicle engine fuel system
engine fuel system o Petrol fuel system identified correctly
o Diesel fuel system

7.6.2 Explain the function Explaining the function of the motor vehicle fuel system Function of the motor vehicle fuel
of the motor vehicle  Function of motor vehicle petrol fuel system system explained correctly
fuel system  Function of diesel fuel supply system

7.6.3 Identify motor vehicle Identifying motor vehicle fuel system components Motor vehicle fuel system components
fuel system  Motor vehicle petrol fuel system components identified correctly
components o Fuel tank
o Fuel pump ( mechanical, electrical)
o Fuel filter
 Motor vehicle diesel fuel system components
o Fuel tank
o Low pressure fuel pipes
o Fuel filter
o Fuel pump
o Injector pump

63
 o High pressure pipes

7.6.4Explain the functions of Explaining the functions of the motor vehicle fuel system Functions of the motor vehicle fuel
the motor vehicle fuel  Motor vehicle petrol fuel system components system explained correctly
system o Fuel tank
o Fuel pump ( mechanical, electrical)
o Fuel filter
 Motor vehicle diesel fuel system components
o Fuel tank
o Low pressure fuel pipes
o Fuel filter
o Fuel pump
o Injector pump
o High pressure pipes

7.6.5Carry out motor vehicle Carrying out motor vehicle fuel system servicing Motor vehicle fuel system servicing
fuel system servicing  Motor vehicle engine fuel system servicing outlined correctly
o Fuel tank
o Fuel pump
o Fuel filter
o Fuel lines

7.6.6Outline the construction Outlining the construction of motor vehicle engine fuel system Construction of motor vehicle engine
of motor vehicle engine (diesel) fuel system (diesel) outlined correctly
fuel system (diesel)  Hydro-mechanical

64
 o Injectors
o Injector pumps
o Filters
o Fuel Feed pump

 Electronic Diesel control (EDC)

o Sensors
o Fuel rail
o High pressure pump
o Electronic injection pump
o Electronic unit injectors
o Common Rail
7.6.7 Carry out motor Carrying out motor vehicle engine fuel system servicing motor vehicle engine fuel system
vehicle engine fuel (diesel) servicing outlined correctly
system servicing
(diesel )  Motor vehicle engine fuel system servicing (diesel)
( Calibration and Phasing)
o Injection pumps
o Injectors
o Fuel filters
o Feed pumps
 Carry out injection pump timing
o Spill timing

65
UNIT A7.7 REPAIRING AND SERVICING MOTOR VEHICLE ENGINE COOLING SYSTEM
DURATION: 20 CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
7.7.1 Explain functions of Explaining functions of motor vehicle engine cooling system functions of motor vehicle engine
motor vehicle engine  Identify Motor vehicle engine cooling systems cooling system outlined correctly
cooling system o Air cooled
o Liquid cooled
 Functions of motor vehicle cooling system
7.7.2 Explain motor vehicle Explaining Motor vehicle liquid cooling system basic motor vehicle engine cooling system
engine cooling components components identified correctly
system components o Radiator
o Radiator hoses
o Water jackets
o Radiator fan
 Motor vehicle air cooling system components
 Cowling
 Blower
 Thermostat

 Explaining Motor vehicle liquid cooling system basic

components
o Radiator
o Radiator hoses
o Water jackets
o Radiator fan

66
 o Expansion tank
o Water pump
o Radiator pressure cap
o Thermostat

 Motor vehicle air cooling system components

o Cowling
o Blower
o Thermostat

 Thermosyphon cooling
 Forced Circulating cooling
 Pressurised cooling
 Sealed cooling

7.7.3 Carry out motor Carrying out Motor vehicle engine cooling system fault motor vehicle engine cooling system
vehicle engine diagnosis fault diagnosis and servicing outlined
cooling system fault o Engine overheating correctly
diagnosis and o Engine over cooling
servicing o Frequent loss of coolant

67
UNIT B7.8 IDENTIFYING TRANSMISSION COMPONENTS DURATION: 30 CREDITS: 3
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
7.8.1 Explain Operation of Explaining Operation of clutch assembly Operation of clutch assembly
clutch assembly  Functions of the clutch assembly explained correctly
 Types of clutch units
o Dry
o Fluid
 Components of the dry clutch assembly
o Flywheel
o Clutch plate or friction plate
o Pressure plate
o Bell housing Operation of clutch explained correctly
o Clutch release mechanisms
 Mechanical
 Hydraulic Construction and operation of clutch
 Pneumatic release mechanisms described
 Operational principles of clutch system correctly
7.8.2 Explain the operation Explaining the operation of gearbox Operation of gearbox explained
of gearbox  Functions of gearbox correctly
 Types of gearboxes
o Manual gear boxes
 Sliding mesh gear box
 Constant Mesh
 Synchromesh
o Automatic gear box
o Continuously variable transmission
o Electronically controlled
 Components of manual gear box

68
  Manual gearbox components
 Input shaft
 Lay shaft
 Main shaft
 Set of gears
 Sychromesh
 Interlock mechanism
 Detent mechanism
 Selection mechanism
 Bearings
 Seals
 Housing
 Operational principle of manual gear boxes
 single stage
 Compound stage
 Components of automatic gearbox
 Automatic gearbox components
 Torque convertor
 Epicyclic gear set
 Clutch and band actuators
 Speed and load sensing system
 Hydraulic and electronic control Valve
 Operational principle of torque converters

 Stall phase
 Acceleration phase
 Coupling phase
 Components of the continuously variable transmission
 Clutches

69
  Pulleys
 Shaft
 Chain/belt
 Planetary assembly

7.8.3 Explain the operation Explaining the operation of Transfer case Transfer case operation explained
of Transfer case  Identify types correctly
 Full time
 Part time
 Functions of transfer cases
 Construction and Operation principles

7.8.4Explain functions of Explaing Functions of the propeller shaft Propeller shaft unit identified correctly
propeller shaft and  Types of propeller shafts
universal joints  Hotchkiss propeller shaft
 Torque tube propeller shaft

 Function of universal joints

 Types of universal joints
o Hookes type
o Rubber type
o Constant velocity type

7.8.5Explain Functions of Explaing functions of Components of the propeller shaft and Components of the propeller shaft
components of the universal joint funcitons explained correctly
propeller shaft and o Tube
Universal joint o Yoke
o Sliding Joints
 Functions of propeller shaft components
o Tube

70
 o Yoke
o Sliding Joints
 Operational principle of universal joints
o Hookes universal joint
o Variable universal joint
o Constant velocity joint
7.8.6 Explain the functions Explaining the functions of final drive and differential Types of final drive identified correctly
of final drive and  Functions of the final drive
differential  Locations of the final drive
 Components of the final drive
o Drive pinion,
 Bevel
 Hypoid
 worm
o crown wheel
 Components of the Differential
o sun,
o planet,
o spider
o casing.

7.8.7Apply operational Applying operational principles of a differential Unit Operational principles of a differential
principles of a  Types of differential Units unit applied correctly
differential Unit o Conventional
o limited slip or power lock
 Operational Principle of differential units
o Straight ahead position

71
 o Cornering
 Types differential locks
o Mechanical
o Electrical
o Electronic
 Operational principle of differential locks
o Mechanical
o Electrical
o Electronic
 Types of differential arrangements
o Single differential
o Double differential: full and part-time
o Third differential

7.8.8Identify driving shafts Identifying driving shafts and axle casings Driving shafts identified correctly
and axle casings  Types of driving Shafts
o Fully floating
o Three quarters floating
o Semi floating
Types of axle casings
o Banjo
o Split
o Carrier

72
UNIT B7.9 REPAIRING AND SERVICING TRANSMISSION SYSTEM COMPONENTS
DURATION: 50 CREDITS: 5
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
7.9.1.Apply safety Applying safety procedures Safety procedures applied correctly
procedures  PPE
o Head protection
o Foot wear
o Hand wear
o Eye protection
o Body protection
 Workshop safety
o Workshop safety procedure
o Workshop ventilation and lighting
o Choke road wheels

7.9.2.Use disassembling Using disassembling and assembling tools and equipment for Disassembling and assembling tools
and assembling tools and transmission system and equipment for transmission
equipment for transmission  Tools systems used correctly
o Spanners and sockets
system
o Bearing pullers
o Hammers and mallets
o Special tools
 Equipment
o Transmission jack
o Hydraulic press

7.9.3.Carry out Carrying out disassembling procedures Disassembling procedures for

disassembling procedures transmission system carried out

73
  Disassembling rules correctly
 Disassembling procedure
o Loosen or undo mounting bolts, nuts or fasteners
o Making matching marks
o Separation or detachment of individual units
o Arrangement of units in the order of disassembly

7.9.4.Carry out disassembly Carrying out disassembly and assembling of clutch unit Assembling procedure for clutch unit
and assembling of clutch  Assembly Rules done correctly
unit  Assembling Procedures
o Inspect the clutch plate
o Clean and inspect the pressure plate and flywheel
faces
o Fit the clutch plate on to the alignment tool
o Insert the alignment tool in the pilot bearing/bush in the
crankshaft flange
o Mount the pressure plate and tighten the bolts all round
7.9.5.Carry out Clutch Carrying out clutch bleeding Bleeding of the clutch carried out
bleeding  Students bleed clutch following the right procedure correctly

74
7.9.6.Carry out disassembly Carrying out disassembly and assembly of manual gearbox Disasembling and assemble manual
and assembly of manual  Students disassemble and assemble manual gear box gearbox correctly
gearbox following the right procedure
7.9.7.Disassembly and Disassembling and assembling automatic gear box following Disasemble and assemble automatic
assembly of automatic the right procedure gearbox correctly
gearbox

7.9.8.Disassembly and Disassembling and assembling propeller shaft following the Disasemble and assemble propeller
assembly of propeller shaft right procedure shaft correctly

7.9.9. Disassembly and Disassembling and assembling final drive following the right Disasemble and assemble final drive
assembly of final drive procedure correctly

7.9.10. Disassembly and Disassembling and assembling drive axle following the right Disasemble and assemble drive axle
assembly of drive axle procedure correctly

75
UNIT B7.10 CARRYING OUT DIAGNOSIS OF TRANSMISSION SYSTEM FAULTS
DURATION: 40 CREDITS: 4
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
7.10.1.Apply testing Applying testing procedures Testing procedures applied correctly
procedures  procedure
o equipment arrangement for testing
o Operating of equipment
o Collection of information/results

7.10.2.Carry out recording Carrying out recording procedures Recording procedures carried out
procedures  Record procedures correctly
o Obtain reading of results/information from testing
equipment
o Tabulate information/results
o Compare with manufacturer’s specifications

7.10.3.Apply inspection Applying inspection procedures Inspection procedures applied correctly

procedures  Inspection procedures
o Carry out physical check
 Extent of wear
 Damage or distortion
o Compare results/information with manufacturer’s
specifications
o Interpret the results/information

76
UNIT B7.11 RECTIFYING TRANSMISSION FAULTS
DURATION: 40 CREDITS: 4
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
7.11.1.Carry out Carrying out replacement procedures Replacement procedures carried out
replacement procedures o Removing component correctly
o Cleaning component areas
o Lubricating components
o Fitting components
7.11.2.carry out repairing carrying out repairing and servicing procedures Repairing procedures carried out
and servicing procedures  Repairing procedures correctly
o Detaching/separating the units from component
o Arrange units

7.11.3.Carry out servicing Carrying out servicing procedures Servicing procedures carried out
procedures  Servicing transmission system components correctly
o Visual inspection
o Adjustments
o Oil and lubricating

77
References
Heizler, H. (2006). Vehicle and Engineering Technology. Butterworth-Heinemann
Hillier, V. (2014). Fundamentals of Automotive Electronics. 2nd edn. Oxford
Joseph, A.B. (2014). Modern Diesel Technology: Electricity & Electronics. 2nd edn. Clifton Park, New York.
Liu, l. (2017). Automotive, Mechanical and Electrical Engineeering, UK: London
Manufacturers manuals and bulletins
Scott, A.H. (2015). Heavy Duty Equipment Technology: A Systems Approach (Automotive Diesel and Heavy Duty). Pearson Education.
Sean, B. (2011). Heavy Duty Truck Systems. 5th Ed. Delmar: Cengage Learning
Sean, B. (2013). Medium/Heavy Duty Truck Engines, Fuel & Computerized Management Systems. 4th Ed. Delmar: Cengage Learning

78
MODULE: 166-08-A AUTOMOTIVE ELECTRICITY
MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate MODULE CREDITS: 19 Credit Hours
attitudes required to effectively and efficiently apply fundamental electrical principles in DURATION:
automotive repairs 190 Hours

MODULE LEARNING OUT COMES: On completion of this module the trainee should be able to:
1. Apply electrical fundamentals
2. Use electrical circuits
3. Apply ohm’s law
4. Apply magnetic principles
5. Identify vehicle electrical systems
6. Use electromagnetic equipment
7. Differentiate primary and secondary batteries
8. Wire diagrams of different circuits
9. Construct and Diagnose faults in electrical circuits
10. Repair components in the electrical system
11. Repair electrical Accessories and instruments
12. Repair components in the electrical system
13. Repair air conditioning system
Assessment Methods
o Assignments
o On site practical
o Written class exercises
o Tests
o Workshop projects
o Laboratory exercises

Learning conditions

79
 Books
 Modules
 Library
 Internet
 Workshop
 Laboartory

80
UNIT A8.1: APPLYING ELECTRICAL FUNDAMENTALS
DURATION: 30HOURS CREDITS 3
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
8.1.1 Analyse Analysing composition of atomic matter Composition of matter analysed correctly
composition of  Atomic structure
atomic matter o Neutrons
o Protons
o Free electrons
 Covalent bonding
 Trivalent bonding

8.1.2 Identify types of Identifying types of electricity Types of electricity identified correctly
electricity  Dynamic
 Static
 Characteristics
o Static
o Dynamic
8.1.3 Apply electrical Applying electrical terms Electrical terms applied correctly
terms  Voltage
 Current
 Resistance
 Power
 Energy
 Conductance
 Capacitance
 Charge
 Induction
 Impedance
 Frequency

81
8.1.4 Apply units of Applying units of conversion Units of conversion applied correctly
conversion  Micro
 Mili
 Kilo
 Mega
8.1.5 Use symbols Using symbols Symbols used correctly
 Identify electrical symbols
 Apply electrical symbols


82
UNIT 8.2. ELECRICAL CIRCUITS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
8.2.1. Identify Types Of Identifying Types Of Electrical Circuits Types of electrical circuits identified correctly
Electrical Circuits  Series circuit
 Parallel
 Series-parallel

8.2.2 Apply Circuit Applying Circuit Characteristics Circuit characteristics applied correctly
Characteristics  Kirchhoff’s current law
 Kirchhoff’s Voltage law

8.2.3 Identify Electrical  Short circuit Electrical Circuit Faults identified correctly
Circuit Faults  Open circuit
 Intermittent
 Dead short

83
UNIT 8.3 CURRENT
VOLTAGE AND
RESISTANCE
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
8.3.1 Calculate current Calculating current Current calculated correctly
 Transposing formulae
 Length
 Diameter
 Material
8.3.2 Calculate Voltage Calculating Voltage Voltage calculated correctly
 Transposing formulae
 Length
 Diameter
 Material

8.3.3 Solve resistance Solving resistance Resistance solved correctly

 Transposing formulae
 Length
 Diameter
 Material

84
UNIT 8.4 MAGNETIC
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
8.4.1 Apply magnetic Applying magnetic laws Magnetic laws applied correctly
laws  1st law of magnetism
 2nd law of magnetism
 Domain theory of magnetism
 Demagnetizing

8.4.2 Apply magnetic Applying magnetic rules Magnetic rules applied correctly
rules  Maxwell screw rule
 Magnetic fields
 Characteristics
8.4.3 Apply Direction of Applying Direction of current Direction of current determined correctly
current  Polarity
 Grip rule (Right hand)
 Density of electromagnets
8.4.4 Apply Motor rule Applying Motor rule Motor rule applied correctly
 Fleming’s left-hand
 Field
 Motion
 Current
8.4.5 Apply Dynamo Applying Dynamo rule Dynamo rule applied correctly
rule  Fleming’s right hand
 Induction
 Strength of induced voltage

85
  Faraday’s Law
8.4.6 Apply Lenz’s rule Applying Lenz’s rule Lenz’s rule applied correctly
 Polarity
 Self-induction
 Mutual induction

86
UNIT 8.6 ELECTRICAL
TEST EQUIPMENT
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
8.6.1 Use fundamental Using fundamental electrical test equipment fundamental electrical test equipment used
electrical test  Voltmeter correctly
equipment Testing for voltage
 Ammeter
Testing for current
 Ohmmeter
Testing for resistance

8.6.2 Use specialised Using specialised electrical test equipment Specialised electrical test equipment used
electrical test  Transformer correctly
equipment To step up and step down Voltage
 Tune up tester set
Timing the engine
 Tachometer
For Rev counter
 Oscillator
 For engine tune up
 Multimeter

87
UNIT B 8.7: DIFFERENTIATING PRIMARY AND SECONDARY BATTERIES

DURATION: 10HOURS CREDITS:1

SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
8.7.1 Identify types of Identifying types of batteries Types of batteries identified correctly
batteries
 Primary
 Secondary
 Dry batteries
 Wet batteries
8.7.2. Analyse the Analysing the construction of the battery Construction of batteries analysed
construction of the correctly
 Battery Element
battery
 Container
 Battery Electrolyte
 Terminal posts
8.7.3. Analyse the Analysing the operation of the battery Operation of batteries analsysed
operation of the battery correctly
 Chemical reaction
 Electrolysis

88
  Charging
 Discharge
8.7.4.State methods of Stating methods of charging batteries Types of charging of batteries
charging batteries differentiated correctly
 Fast charge
o Constant voltage charge
 Slow charge
o Constant current charge
 Trickle charge
 Boost charge
8.7.5 Carry out Battery Carrying out Battery Testing Battery Testing carried out correctly
Testing
 Safety precautions
 Battery testing
 Battery tools and equipment
 Battery faults
8.7.6. Apply the ampere Applying the ampere hour rating Ampere hour rating applied correctly
hour rating  Battery capacity
 AH=AxH
 Factors of battery capacitance

89
8.7.7 Apply cold cranking Applying cold cranking rating Cold cranking rating
rating  Temperature applied correctly
 Starting period
 Starting current

8.7..8 Apply reserve Applying reserve capacity rating Reserve capacity rating applied correctly
capacity rating  Discharge period
 Electrical load
 Condition of charging system

90
UNIT B8.8: CONSTRUCT AND DIAGNOSE DIFFERENT ELECTRICAL CIRCUITS

DURATION: 20 HOURS 2 CREDIT HOURS

SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES


8.8.1.Use different types Using different types of symbols Different types of symbols used correctly
of symbols  Pictorial symbols
 Letter code symbols
 Number code symbols
8.8..2 Interpret different Interpreting different types of circuits Different types of circuits interpreted
types of circuits  Pictorial circuits correctly
 Schematic circuits
8.8.3 Use protective Using protective devices Protective devices used correctly
devices  Fuses
 Circuit breaker
 Fusible links
8.8.4.Employ colour Employing colour coding in wiring Colour coding in wiring employed
coding in wiring  Supply line cables correctly
 Earth return cables
 Circuit cables
8.8.5 Construct different Constructing different circuits Different circuit diagrams constructed
circuits  Hazards correctly

91
  Indicator
 Horn
 Head light
 Brake light
 Reverse light
 Dash board
 Fog light
 Parking light
8.8.6. Test hazard circuit Testing hazard circuit Hazard circuit tested correctly
 Battery
 Fuse
 Bulbs
 Flasher unit
 Switch
8.8.7.Test indicator Testing indicator circuit Indicator circuit tested correctly
circuit  Battery
 Fuse
 Bulbs
 Flasher unit
 Ignition switch
 Indicator switch
8.8.8 Test parking light Testing parking light circuit Parking circuit tested correctly
circuit  Battery
 Cables
 Bulbs

92
  Switch
8.8.9.Test reverse light Testing reverse light circuit Reverse circuit tested correctly
circuit  Battery
 Fuse
 Bulbs
 Switch
8.8.10. Test fog light Testing fog light circuit Fog light circuit tested correctly
circuit  Battery
 Fuse
 Bulbs
 Relay
 Switch
8.8.11,Test brake light Testing brake light circuit Brake circuit tested correctly
circuit  Battery
 Fuse
 Bulbs
 Cables
 Switch
8.8.12 Test headlamp Testing headlamp circuit Headlamp circuit tested correctly
circuit  Battery
 Fuse
 Relay
 Switch
 Dimmer switch
 Headlamp

93
UNIT B8.9: DIAGNOSING FAULTS AND REPAIR AUTOMOTIVE ELECTRICAL COMPONENTS

DURATION: 20 HOURS 2 CREDIT HOURS

SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
8.9.1..1 Explain the Explaining the contruction and operation principles of Automotive Starter motor tested correctly
contruction and electrical components
operation principles of  Starter motor
Automotive electrical  Alternator
components  Wiper motor
 Distributor
8.9.2 Test starter motor Testing starter motor Starter motor tested correctly
 Without load test
 Under load test
 Solenoid test
8.9.3 Repair starter Repairing starter motor Starter motor repaired correctly
motor  Components of a starter motor
o Solenoid
o York assembly
o Armature
o Brush gear
o Bendix drive
 Dismantling procedure
 Testing procedures

94
 o Solenoid
o Armature
o York
o Brush gear
o Bendix drive
 Assembling procedure
 Diagnosis of starter motor
o Tear and wear
o Open circuit
o Insulation
o Grounding
 Faulty solenoid
8.9.4.Test alternator Testing alternator Alternator tested correctly
 Full fielding
 Voltage output

8.9.5. Repair Alternator Repairing Alternator Alternator repaired correctly

 Components
o Stator winding
o Rotor winding
o Diode pack
o End Brackets
o Alternator fan

95
 o Pulley
 Dismantling procedure
 Testing procedure
o Stator winding
o Rotor winding
o Diode pack
 Diagnosis of Alternator
o Tear and wear
o Open circuit
o Insulation
o Grounding
o Faulty rectifier park
 Assembling procedure

8.9.6. Repair Voltage Repairing Voltage regulator Regulator repaired correctly

regulator  Components
o Bobbin winding
o Resistor
o Contacts
 Dismantling procedure
 Diagnosis of the regulator
 Assembling

96
8.9.7.Test wiper motor Testing wiper motor Wiper motor tested
 Resistance test correctly
 Continuity test

8.9.8Test distributor Testing distributor Distributor tested correctly

 Resistance test
8.9.9.Repair Distributor Repairing Distributor Distributor repaired correctly
 Components
o Ignition Coil
o Igniter
o Signal generator
o Distributor cap
 Dismantling procedure
 Testing procedure
o Igniter
o Ignition Coil
 Diagnosis of Distributor
o Resistance
o Wear on the rotor
o Assembling procedure

97
UNIT B 8.10: REPAIRING ELECTRICAL ACCESSORIES AND INSTRUMENTS DURATION: 20 HOURS 2
CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
8.10.1 Repair wiper Repairing wiper motor Wipers repaired correctly
motor  Components
o Brush assembly
o Motor
o Gear box peg
o Circuitry
 Testing components
8.10.2. Repair horn Repairing horn Horn repaired correctly
 Components
o Contacts
o Coil
o Core
o Diaphragm
o Armature
o Housing
o Tone disc
 Dismantling
 Testing components
 Assembling

98
8.10..3 Repair flasher Repairing flasher unit Flasher unit repaired correctly
unit  Types
o Electronic
o Thermal
o Vane wire
 Testing
8.10.4. Repair power Repairing power window Power window repaired correctly
window  Components
o Motor
o Switches
o Circuitry
 Dismantling
 Testing
 Assembly
8.10.5.Replace Replacing headlamps Headlamps replaced correctly
headlamps  Types
o Sealed
o Semi sealed
 Installation
 Testing
 Alignment

99
UNIT B 8.11 REPAIRING ELECTRICAL INSTRUMENTS

DURATION: 20 HOURS 2 CREDIT HOURS

SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
8.11.1 Repair car Repairing car heaters Car heaters repaired correctly
heaters  Components
o Heat matrix
o Block resistor
o Blower
o Electrical switch
 Dismantling
 Testing
 Assembly
8.11.2. Repair engine Repairing engine heaters Engine heaters repaired correctly
heaters  Components
o Pre-timer
o Heater plugs
o Relay
 Dismantling
 Testing
 Assembly
8.11.3. Diagnose starting Diagnosing starting system Starting system diagnosed correctly
system  Lay-out
o Battery

100
 o Starter switch
o Cables
o Starter motor
 Testing
 Diagnosis

8.11.4.Diagnose Diagnosing charging system Charging system diagnosed correctly

charging system  Lay-out
o Battery
o Ignition switch
o Cables
o Regulator
o Alternator
 Testing
 Diagnosis
8.11.5. Diagnose lighting Diagnosing lighting system Lighting system diagnosed correctly
system  Lay-out
o Battery
o Combination switch
o Relays
o Dimmer switch
o Headlamps
o Bulbs

101
  Testing
 Diagnosis
8.11.6. Diagnose ignition Diagnosing ignition system Ignition system diagnosed correctly
system  Lay-out
o Battery
o Ignition switch
o Ignition coil
o Signal generator
o Igniter
 Circuit inspection
 Testing
 Diagnosis

102
UNIT B 8.12 REPAIRING AUTOMOTIVE AIR CONDITIONING SYSTEM
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOME
I8.12.1.Identify Identifying components of Air conditioning system Air condition system components
components of Air  Components: correctly identified.
conditioning system o Compressor
o Condenser
o Receiver
o Expansion valve
o Evaporator

8.12.2.Outline the Outlining the function of each of the air conditioning system components
function of each of the Air conditioning components functions
air conditioning system  Compressor correctly outlined.
components  Condenser
 Receiver/Drier
 Expansion valve
 Evaporator

8.12.3. Analyse Analysing construction of air conditioning system.

construction of air  Layout of system components Construction of air conditioning system
conditioning system.  Construction of system components. components correctly analysed.

103
8.12.4.Explain operation Explaining operation of air conditioning system
of air conditioning  Operating principles Operation of air conditioning system
system correctly explained.

8.12.5.Service air Servicing air conditioning system Air conditioning system correctly
conditioning system serviced.
 Servicing the system

8.12.6.Diagnose air Diagnosing air conditioning system faults

conditioning system Air conditioning system faults correctly
faults  Fault finding diagnosed.
 Test procedures
 Symptoms
 Faults

8.12.7.Repair Air Repairing Air conditioning system faults. Air conditioning system faults correctly
conditioning system  Repair system faults repaired.
faults.  Replace unserviceable parts.

104
105
References
Heizler, H. (2006). Vehicle and Engineering Technology. Butterworth-Heinemann
Hillier, V. (2014). Fundamentals of Automotive Electronics. 2nd edn. Oxford
Joseph, A.B. (2014). Modern Diesel Technology: Electricity & Electronics. 2nd edn. Clifton Park, New York.
Liu, l. (2017). Automotive, Mechanical and Electrical Engineeering, UK: London
Manufacturers manuals and bulletins
Scott, A.H. (2015). Heavy Duty Equipment Technology: A Systems Approach (Automotive Diesel and Heavy Duty). Pearson Education.
Sean, B. (2011). Heavy Duty Truck Systems. 5th Ed. Delmar: Cengage Learning
Sean, B. (2013). Medium/Heavy Duty Truck Engines, Fuel & Computerized Management Systems. 4th Ed. Delmar: Cengage Learning

106
 MODULE NO. 166-9-A BRAKING SYSTEMS
MODULE PURPOSE: To equip the trainee with knowledge, skills and MODULE DURATION: 140 CREDITS: 14
appropriate attitudes to effectively and efficiently repair and service Hrs.
motor vehicle brake systems
MODULE LEARNING OUT COMES: On completion of this module the trainee should be able to:
1. Identify brake system
2. Disassemble and assemble brake system components
3. Diagnose brake system faults
4. Rectify brake system faults
Assessment Methods
o Exercises
o Class tests
o Assignments
Practical

Learning condintiions
The trainee must have access to:
 Books
 Library
 Internet
 Lecture notes
 Automotive mechanics workshop
Running vehicle

107
UNIT A 9.1 IDENTIFYING BRAKE SYSTEMS DURATION: 20
CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
9.1.1Describe types of Describing braking principles Types of brakes systems described correctly
braking systems  Purposes of brakes
 Brake system terminologies
 Types of brake systems
o Mechanical breaks
o Hydraulic brakes
o Pneumatic brakes

9.1.2.Identify mechanical Identifying mechanical braking system Components of mechanical braking system identified correctly
braking system  Components of mechanical braking
system
o Foot pedal and hand lever
o Link rods or cables

9.1.3.Identify hydraulic Identifying hydraulic brakes Components of hydraulic brakes identified correctly
brakes  Components of hydraulic brakes
o Brake master cylinder and reservoir
o Hydraulic pipes
o Brake pedal
o Brake boosters
o Brake wheel cylinders/callipers
 Brake fluid

108
 o Properties
o Grades

9.1.4.Identify components Identifying components of pneumatic Components of pneumatic brakes identified correctly
of pneumatic brakes brakes
o Components of Pneumatic brakes
o Pedal control valve
o Reservoir (air tank)
o Regular valve
o Air compressor
o Air service lines
o Unloader valve
o Air filters
o Air gauges
o Brake chambers
o Brake expander cam and lever
o
9.1.5.Explain types of Explaining types of brakes
brakes  Drum brakes
 Disc brakes
9.1.6.Explain the Explaining the operation of Antilock braking operation of Antilock braking system explained correctly
operation of Antilock system (ABS)
braking system (ABS)  ABS components
 Functions of the ABS components
 Operation of ABS

109
  Traction Control
9.1.7.Identify auxiliary Identifying auxiliary brakes Components of auxiliary brakes identified correctly
brakes  Types of auxiliary brakes
o Exhaust retarders
o Engine compression retards
o Electrical retarders
o Hydraulic retarders

110
UNIT A9.2 DISASSEMBLING AND ASSEMBLING BRAKE SYSTEM COMPONENTS
DURATION: 40 CREDITS: 4
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
9.2.1.Use disassembling Using disassembling and assembling tools Assembling and disassembling tools used correctly
and assembling tools  Appropriate tools
o Spanners and screw drivers
o Brake spring pliers
o Hydraulic jack/mechanical jack
o Axle support stands
9.2.2.Apply safety Applying safety procedures Safety procedures applied correctly
procedures  Personal safety -Wear appropriate
o Foot protection
o Hand and Body protection
o Eye protection
 Safe handling of tools and equipment
 Safe handling of machinery
o Supporting on solid ground
o Choking the wheels
 Workplace safety
o Lighting of the work place
o Ventilating of the work place
9.2.3.Carry out Carrying out disassembly procedure Disassembly procedure carried out correctly
disassembly procedure  Loosening and removing mounting bolts
and nuts or devices
 Detaching the units of the component

111
  Arranging the detached units in the
order of disassembly
9.2.4.Carry out assembly Carrying out assembly procedures Assembly procedures carried out correctly
procedures  Clean the units of the disassembled
component
 Lubricate where necessary
 Assemble units of the component
o Mounting components
o Tightening bolts and nuts/fasteners
o Tighten to specified torque rating

112
UNIT9.3 BREAKING SYSTEM
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
9.3.1Apply brake system Applying brake system testing procedures Brake system testing procedures applied correctly
testing procedures  Testing Procedures
o Arrange testing equipment and tools
o Carryout the measurement
o Read the measurement
o Record the reading
9.3.2.Carry out brake Carrying out brake system inspecting Brake system inspecting procedures carried out correctly
system inspecting procedures
procedures  Inspecting procedures
o Visual check for wear/damage or
distortion
o Determine the extent of damage,
wear or distortion
o Add up the figures or information
obtained

113
UNIT 9.4. REPLACING BRAKING SYSTEM
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
9.4.1.Replace braking Replacing braking system components Braking system components replaced correctly
system components  Remove components
o Loosening bolts/nuts of the
components
 Replacing components
o Cleaning area and component to be
fitted
o Fitting components
o hand tighten component
 Tightening to specified torque using the
torque wrench
9.4.2.Repair braking Repairing braking system components Braking system components repaired correctly
system components  Procedure
o Check extent of wear, damage or
distortion using measuring
instruments
o Compare results or information to
specification chart
o Carry out adjustments
o Bleed hydraulic brakes

9.4.3.Carry out Carrying out installation procedure of Carrying out installation procedure of components
installation procedure of components

114
components  Cleaning components to be installed
 Cleaning component’s installation area
 Install the component and mount the
fastening devices

115
Recommended Texts/Books:
References
Heizler, H. (2006). Vehicle and Engineering Technology. Butterworth-Heinemann
Hillier, V. (2014). Fundamentals of Automotive Electronics. 2nd edn. Oxford
Joseph, A.B. (2014). Modern Diesel Technology: Electricity & Electronics. 2nd edn. Clifton Park, New York.
Liu, l. (2017). Automotive, Mechanical and Electrical Engineeering, UK: London
Manufacturers manuals and bulletins
Scott, A.H. (2015). Heavy Duty Equipment Technology: A Systems Approach (Automotive Diesel and Heavy Duty). Pearson Education.
Sean, B. (2011). Heavy Duty Truck Systems. 5th Ed. Delmar: Cengage Learning
Sean, B. (2013). Medium/Heavy Duty Truck Engines, Fuel & Computerized Management Systems. 4th Ed. Delmar: Cengage Learning

116
MODULE NO.166-10-B STEERING AND SUSPENSION SYSTEM
STEERING AND SUSPENSION SYSTEMS
MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate attitudes to effectively and efficiently repair and service
steering system
MODULE LEARNING OUT COMES: On completion of this module the trainee should be able to:
1. Analyse steering systems
2. Maintain steering system
3. Identify suspension systems
4. Inspect suspension systems
5. Carry out Disassembling and assembling suspension system components
6. Rectify suspension system faults
7. Maintain suspension systems
8. Identifying functions of wheels and tyres
9. Disassembling and assembling wheels and tyres
10. Maintaining wheels and tyres
11. Diagnosing wheels and tyre failures
ASSESSMENT METHODS
 Tests
 Examinations
 Assignment
Learning conditions
Trainee will have access to the following:
o Lecture notes
o Library
o Handouts
o Tutorials
o Internet

117
118
UNIT 10.1 ANALYSING STEERING SYSTEM
SPECIFIC LEARNING OUTCOMES LEARNING ACTIVITIES ASSESSMENT CRITERIA
10.1.1.Analyse Functions of steering Explaining functions of the steering systems Functions of steering
system  Analysing characteristics of steering system systems analysed correctly
 Contrasting types of steering systems
o Mechanical
o Power Assisted
o Power
10.1.2.dentify Components of mechanical Identifying components of the mechanical steering system Components of mechanical
steering system steering system identified
o Steering wheel correctly
o Steering column
o Steering box
o Drop arm
o Drag link
o Steering arm Functions of components of
mechanical steering
o Track rod
analysed correctly
o Stub axle
 Stating functions of components of steering system
1O.1.3.Analyse qualities of Steering boxes Analysing qualities of steering box Qualities of steering boxes
analysed correctly
 Identifying types of steering boxes Types of steering boxes
o Worm and wheel identifies correctly
o Worm and sector
o Worm and roller
o Screw and nut Construction and operation of
o Cam and peg steering box described
correctly
o Re-circulating ball

119
 o Rack and pinion
 Describing construction and operation of steering
boxes
10.1.4 Analyse Collapsible steering column Analysing reason for collapsible steering column Reason for designing
collapsible steering column
 Describing construction of collapsible steering column discussed correctly


10.1.5 Analyse Steering joints Analysing functions of steering joints Functions of steering joints
analysed correctly
 Describing construction of steering joints

10.1.6 Analyse Four-wheel steering Analysing types of four- wheel steering Types of four- wheel steering
analysed correctly
o Opposite direction to front wheels Advantages of 4 wheel
o Same direction to front wheels steering discussed correctly
 Discussing advantages of Four-wheel steering
10.1.7 Analyse Twin steering Analysing twin steering Twin steering analysed
correctly
10.1.8 Explain Steering Geometry Explaining steering angles
Defining steering geometry
Explaining steering angles Steering angles explained
correctly
o Camber angle
o Castor angle Centre point steering
o King pin inclination analysed correctly
o Toe-in
o Toe-out
Analysing centre point steering
10.1.9.Analyse Ackerman Layout Analysing Ackerman Layout

120
  Differentiating between beam axle steering and Ackerman layout analysed
Ackerman layout correctly
 Analysing Ackerman layout
o Toe-out –on turns
10.1.10 Analyse Power Assisted Steering  Explaining functions of power assisted steering
 Justifying factors necessitating for power assisted
steering Factors necessitating for
power assisted steering
 Analysing requirements of power assisted steering
justified correctly
 Identifying types of power assisted steering
o Hydraulic Requirements of power
o Electric assisted steering analysed
o Pneumatic correctly

10.1.11 Describe Components of Hydraulic Describing components of hydraulic power assisted steering Operation of components of
power assisted steering hydraulic power assisted
o Pump steering described correctly
o Reservoir
o Control valve
o Ram cylinder and piston
o Pressure relief valve
o Pipes
Describing operation of components of hydraulic power
assisted steering
Analysing merits of using hydraulic
10.1.12 Compare Configurations of Comparing power assisted steering configurations Configurations of hydraulic
hydraulic power assisted steering power assisted steering
o Integral

121
 o Semi integral compared correctly
o linkage

10.1.13 Explain Electric power assisted Explaining types of electric power assisted steering Types of electric power
steering assisted steering explained
o Column drive correctly
o Rack drive
Identifying components of electric power assisted steering
o Electric motor
o Actuators
o Steering input sensor
o Electronic control unit
Explaining functions of components of electric power
assisted steering
Analysing advantages of electric power assisted steering
10.1.14 Analyse Pneumatic Power Assisted Analysing Pneumatic Power Assisted Steering Pneumatic Power Assisted
Steering Steering analysed correctly
o Compressor
o Control valve
o Ram cylinder
o Piston

122
 o pipes

Describing functions of components of pneumatic power

assisted steering

10.1.15 Explain Full Power Steering Explaining Full Power Steering Full power steering explained
Identifying components of full power steering correctly

o Control valve
o Pistons
o Cylinders
o Hydraulic pipes Explaining functions of
components of full power steering

10.1.16 Describe Front Hub Assembly Describing front Hub Assembly Construction of front hub
Identifying types of front hub assemblies assemblies described
corretly
o Non-driving
o Driving
Describing construction of front hub assemblies

10.1.17 Justify Wheel Alignment Justifying the importance of wheel alignment Wheel alignment justified
Identifying Factors affecting true rolling motion correctly

o Toe-out
o Toe-in
o Camber

123
 o Castor

Performing wheel alignment

10.1.18 Justify Steering Box Adjustments  Justifying the importance of wheel steering box Steering box adjustments
adjustments justified correctly
 Identifying factors affecting steering wheel free play
o Worn out gear

10.1.19 Service the Power assisted  Inspecting the electric circuit components Power assisted steering
steering system  Servicing the hydraulic steering system service correctly

124
UNIT B10.2 IDENTIFYING SUSPENSION SYSTEMS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
10.2.1.Explain types of  Explaining purposes and requirements of the suspension system Types of suspension systems
suspension systems  Defining suspension system terminologies identified correctly
 Types of suspension systems
o Independent suspension system
o Dependent suspension system

10.2.2.Identify Identifying components of the suspension system components of the suspension

components of the  Types of springs system identified correctly
suspension system o Steel springs
o Rubber springs
o Air springs
 Shackles
o Fixed shackles
o Swinging shackle
 Oscillation dampers (Shock absorbers)
 Suspension arms
 Ball joints
 Stabilizers
 Wishbone arm upper and lower

125
  Trailing link front and rear
 Stabilizer bars
 Rods
 Axles
o Beam axle
o Split/cross
o Carrier
10.2.3.Identify pneumatic Identifying Pneumatic suspension assembly Pneumatic suspension system
suspension system  Air supply system identified correctly
 Air suspension spring assembly
 Electronically controlled suspension circuit
10.2.4.Identify rubber Identifying rubber suspension assembly Rubber assembly identified
suspension assembly  Rubber load cushion spring correctly
 Rubber shear spring
10.2.5.Identify the Identifying the components of the body and chassis Body and chassis layout
components of the body and assembly correctly identified
chassis layout  Body design
o Integral chassis
o Separate body chasis
 Cab ergonomics
 Frames
 Fifth wheels

10.2.6.dentify forces Identifying forces acting on the frame Forces acting on frames
acting on the frame  Torsional forces correctly identified
 Axial and lateral forces

126
127
UNIT B10.3 CARRYING OUT DISASSEMBLING AND ASSEMBLING SUSPENSION SYSTEM COMPONENTS
DURATION: 20 CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
10.3.1.Use Using disassembling and assembling tools and equipment Assembling and disassembling
disassembling and  Lifting equipment tools and equipment used
assembling tools and o Mechanical jack correctly
equipment o Hydraulic jack
o Solid support stands
o pullers
10.3.2.Carry out Carrying out disassembling and assembling tools and equipment Disassembly and assembling
disassembly procedures  Loosening mounting devices procedures carried out
 Removing individual units of the components correctly
 Arranging the individual component in the order of disassembly
10.3.3Carry out assembly Carry out assembly procedures Assembly procedures carried
procedures  Cleaning components out correctly
 Mounting the disassembled units onto the components
 Tightening units to specified torque rating
10,3.4.Carry out Carrying out Installation procedures Installation procedures carried
Installation procedures  Installing components out correctly
 Cleaning the fitting area
 Mounting the component
 Tightening components to specified torque rating

128
UNIT B10.4 RECTIFYING SUSPENSION SYSTEM FAULTS DURATION: 20 CREDITS: 2
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
10.4.1 Apply safety  Using correct PPE Safety procedures applied
procedures  Using correct lifting equipment correctly
 Using correct choking and supporting appliances
 Identifying welding and drilling warning signs
10.4.2 Diagnose motor Diagnosing motor vehicle suspension system faults Motor vehicle suspensions
vehicle suspension o Removing worn out components system faults diagnosed
system faults o Examining removed components correctly
o Determining extent of tear and amount of distortion and damage
o Comparing components to specification in manuals
Diagnosing Electrical faults
o Examining Actuators
o Examining extent of damage
Diagnosing Electronic faults
o Test Sensors
10.4.3 Repair faults in Repairing faults in suspension system Faults in suspension system
suspension system Repairing mechanical faults repaired correctly
o Servicing mechanical components
o Replacing non-serviceable mechanical components
Repairing Electrical faults
o Servicing actuators
o Replacing non-serviceable actuators
Diagnosing Electronic faults
 Replacing faulty sensors

129
UNIT B10.5 IDENTIFYING FUNCTIONS OF WHEELS AND TYRES
DURATION: 10 CREDITS: 1
SPECIFIC LEARNING OUTCOMES LEARNING ACTIVITIES ASSESSMENT CRITERIA
10.5.1 State functions of wheels and Stating functions of Functions of wheels and tyres
tyres stated correctly
o Wheels
o Tyres

Identifying Types of

o Wheels
o tyres

10.5.2 Explain constructions of Explaining construction of Wheels and tyres correctly

wheels and tyres o Wheels explained
o Tyres
Interpreting tyre markings
o Tyre sizes
o Tyre ratings

130
UNIT B10.6 DISASSEMBLING AND ASSEMBLING WHEELS AND TYRES
DURATION: 40 CREDITS: 4
SPECIFIC LEARNING OUTCOMES LEARNING ACTIVITIES ASSESSMENT CRITERIA
10.6.1 Adhere to safety procedures Adhering to safety procedures pertaining to the task Safety precautions correctly
pertaining to the task Performing dismantling and assembling observed
 Using correct PPE
 Aplying tyre deflating and inflating procedures
 Using correct Tools and equipment
10.6.2 Change wheels Changing wheels Wheel correctly changed
Observing safety
 Jacking and supporting procedure
 Removing procedure
 Installing procedure
 Untightening and torqueing procedure
 Disassembling procedure
 Assembling procedure

131
UNIT B10.7 MAINTAINING WHEELS AND TYRES
DURATION: 40 CREDITS: 4
SPECIFIC LEARNING OUTCOMES LEARNING ACTIVITIES ASSESSMENT CRITERIA
10.7.1 Maintain a wheel assembly Maintaining a wheel assembly Wheel assembly correctly
Observing safety procedures maintained
 Applying inspection procedures
 Applying tyre mending procedures
o Tubed
o tubeless
 Performing wheel balancing
 Performing wheel rotation

132
UNIT B10.8 DIAGNOSING WHEELS AND TYRE FAILURES
DURATION: 40 CREDITS: 4
SPECIFIC LEARNING OUTCOMES LEARNING ACTIVITIES ASSESSMENT CRITERIA
10.8.1 Rectify tyre failures Rectifying tyre failures Tyre failures correctly rectified
Applying trouble shooting techniques
 Analysing tyre inflating pressures and overloading problems
 Analysing tyre wear and failures

133
Recommended Texts/Books:
Heizler, H. (2006). Vehicle and Engineering Technology. Butterworth-Heinemann
Hillier, V. (2014). Fundamentals of Automotive Electronics. 2nd edn. Oxford
Joseph, A.B. (2014). Modern Diesel Technology: Electricity & Electronics. 2nd edn. Clifton Park, New York.
Liu, l. (2017). Automotive, Mechanical and Electrical Engineeering, UK: London
Manufacturers manuals and bulletins
Scott, A.H. (2015). Heavy Duty Equipment Technology: A Systems Approach (Automotive Diesel and Heavy Duty). Pearson
Education.
Sean, B. (2011). Heavy Duty Truck Systems. 5th Ed. Delmar: Cengage Learning
Sean, B. (2013). Medium/Heavy Duty Truck Engines, Fuel & Computerized Management Systems. 4th Ed. Delmar: Cengage
Learning

134
MODULE: 166-11-B ENTREPRENEURSHIP

MODULE PURPOSE: To equip trainees with knowledge, skills and appropriate MODULE DURATION: 110 CREDIT
attitudes to run profitable enterprises efficiently. Hours S: 11

MODULE LEARNING OUTCOMES: On completion of this module the trainee will be able to:
1. Use entrepreneurial concepts
2. Build positive attitude towards entrepreneurship
3. Demonstrate personal entrepreneurial competencies
4. Establish an enterprise
5. Manage business
6. Grow an enterprise
7. Establish business networks
8. Develop a business exit plan
9. Assess business performance
10. Manage profits, excess cash and risk
11. Negotiate agreements and contracts
Assessment Methods:
o Assignments
o Practical
o Class exercises
o Tests

Learning Conditions: Trainee will have access to the following:

 Library
 Internet

135
 Handouts
 Fashion laboratory
 Fashion workrooms

136
UNIT B11.1: USING ENTREPRENEURIAL CONCEPTS DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
11.1.1 Explain Entrepreneurship concepts well
concepts of Explaining concepts of entrepreneurship explained
entrepreneurship
 Generic explanation of the terms
o Enterprise
o Entrepreneurs
o Entrepreneurship
o Enterprise
o Entrepreneurial competences
 Define new enterprise creation
 Differentiate between an Entrepreneur and an
Entrepreneur
11.1.2 Describe Describing different types of entrepreneurs Types of entrepreneurs correctly
different types of  Pushed and pulled entrepreneurs described
entrepreneurs  enterprise, entrepreneurship and the entrepreneur

11.1.3 Discuss the Discussing the background to emergence of Background to emergence of

back ground to entrepreneurship entrepreneurship well discussed
emergence of  Origin of entrepreneurship
entrepreneurship  Motive of entrepreneurship
 Importance of entrepreneurship to national
development
11.1.4 Explain the Explaining the benefits of entrepreneurship Benefits of entrepreneurship correctly
benefits of  Employment and self-employment explained.
entrepreneurship  Benefits of enterprise development

137
UNIT B11.2: BUILD POSITIVE ATTITUDE TOWARDS ENTREPRENEURSHIP DURATION: 10 HOURS 1 CREDIT
HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
11.2.1 Develop Developing positive thinking Positive thinking well developed
positive thinking  The mind-set of a positive entrepreneur
 Positive thinking and goal setting
11.2.2 Develop o The psychological preparedness of an entrepreneur Positive ambition well developed
positive ambition

11.2.3 Discuss positive Developing positive ambition Positive outlook well discussed
outlook  The entrepreneurs psychological preparedness

11.2.4 Develop Developing constructive ambition Constructive ambition appropriately

constructive ambition  Realistic targets developed.
 Setting realistic targets

138
UNIT B11.3: DEMONSTRATING PERSONAL ENTREPRENEURIAL CONCEPTS DURATION: 10 HOURS 1
CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
11.3.1 Identify Identifying competences relating to achievement cluster Personal entrepreneurial competences
competences relating  Practice Opportunity Seeking and Initiative correctly identified
to achievement cluster  Practice Risk Taking
 Practice Demand for Efficiency and Quality
 Practice Persistence
 Practice Commitment to the Work Contract
11.3.2 Assess Assessing competences relating to planning cluster Personal entrepreneurial competences
competences relating  Practice Information Seeking well assessed
to planning cluster  Practice Goal setting
 Practice Systematic Planning and Monitoring and
Evaluation
 Assessing the Personal Entrepreneurial
Competences
o Answer a self-rating questionnaire/peer
assessment
o Apply entrepreneurial competences assessment
tools (Personal Entrepreneurial Competences self-
rating questionnaires)
o Apply peer assessment
o Conduct assessment of entrepreneurial
competences
11.3.3 Apply Applying competences relating to power cluster. Personal entrepreneurial competences
competences relating  Practice Persuasion and Networking appropriately applied
to power cluster.  Practice Independence and self-confidence

139
UNIT B11.4: ESTABLISHING AN ENTERPRISE DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
11.4.1 Generate Generating business ideas Business ideas well generated
business ideas  Identify sources of business ideas
 Discuss techniques of generating business ideas
 Generate a business idea
 Conduct an environmental scanning for the business
idea
 Conduct an feasibility study for the business idea
11.4.2 Select a viable Selecting a viable business idea Viable business idea correctly selected
business idea  Assessing the most viable business idea
 Use a micro screening table
o State solvent demand
o State availability of qualified personnel
o State availability of technology/equipment
o State availability of raw materials
o State competitors
o State critical success factors
1614.3 Identify a Identifying sources of business opportunities Business opportunity correctly identified
business opportunity  Outline steps for business opportunity identification
 Explain considerations in opportunity selection
 Describe opportunity identification dynamics
o Discuss the need of the society
o Discuss capability of the entrepreneur
o Discuss the resource availability in the environment
1614.4 Establish a Establishing a business Enterprise well established
business  Design of the business

140
 o Generate a business idea
o Conduct a market research
o Conduct SWOT analysis
 Develop the business
o Prepare a business plan
o Arrange finance (own capital, family, bank)
o Find location
o Arrange logistics
 Managing the business
o Cost and price
o Market the products
o Establish record keeping systems
o Outline time management schedules
o Apply financial management
o Conduct stock control
o Institute business and private guidelines
 Evaluating the business
o Evaluate financial results
o Evaluate business results
o Adjust plans

141
UNIT B11.5: MANAGING AN ENTERPRISE DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
11.5.1 Apply principles Applying principles of human resource management Human resource management
of human resource  Define human resources terms principles appropriately applied.
management  Discuss how to recruit, interview, and retain employees
more effectively
 Follow up with new employees in a structured manner
 Advocate for your employees’ health and safety
 Provide accurate, actionable feedback to employees
 Act appropriately in situations requiring discipline and
termination

11.5.2 Apply principles Applying principles of financial management Financial management principles
of financial  Use financial terminology appropriately applied.
management  Understand financial statements
 Identify how to analyze financial statements
 Understand budgets
 Outline how to make budgeting easy
 Understand advanced forecasting techniques
 Understand how to manage the budget
 Identify How to make smart purchasing decisions
 Identify the legal aspects of finance
11.5.3 Manage Managing business operations Business operations well executed.
business operations  Operations Strategy and managing change
 Operations Strategy and competitiveness
 Project schedule development
 Product design and process selection

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  Process analysis
 Total Quality Management
 Supply Chain Management
 Capacity Management
 Just-in-Time and Lean Systems
 Resources Planning Systems
 Aggregate Planning
 Forecasting
 Inventory Control
 Material Requirement Planning
 Operations Scheduling
11.5.4 Apply principles Applying principles of marketing management Marketing management principles well
of marketing  Define marketing management applied.
management  Formulate the marketing mix
 Conduct a market research for products and services
 Evaluate results from the market research
 Introduce SWOT analysis framework
11.5.5 Use networking Using networking management information systems Networking management information
management  Define (informal) networking appropriately used.
information systems  Describe Entrepreneur in a SPIDER web environment
 Identify kinds of networks
o Implicit networks (informal)
o Explicit networks (Formal)
 State the three basic principles of networking
o Discuss Trust
o Discuss Maintenance or active participation
o Discuss Reciprocity
 Outline networking Rules
 Set Your PEC Barometer- Networking

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11.5.6 Adhere to Adhering to business ethics and values Business ethics and values well
business ethics and  Define and understand ethics. adhered to.
values  Understand the benefits of ethics.
 Create strategies to implement ethics at work.
 Recognize social and business responsibility.
 Identify ethical and unethical behaviour.
 Learn how to make ethical decisions and lead with
integrity
11.5.7 Fulfil statutory Fulfiling statutory obligations Statutory obligations well complied with.
obligations  Explain the legal framework for small enterprise
 Discuss forms of business
 Outline advantages and disadvantages of different
forms of business
 Discuss registration procedures with PACRA
o Registration of business name
o Incorporation of limited companies
o Registration of co-operatives
 Discuss ZRA procedures
o Discuss types of taxes
o Discuss ZRA returns
o Discuss tax exceptions
11.5.8 Undertake Undertaking strategic planning Strategic planning well undertaken.
strategic planning  Define strategic planning
 Outline the strategic Planning process
 Outline key performance indicators

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UNIT B11.6: GROWING AN ENTERPRISE DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
11.6.1 Identify possible Identifying possible growth avenues Possible growth avenues correctly
growth avenues  Explain the business life cycle identified.
o Explain idea generation
o Explain business launch
o Explain business growth and expansion
o Explain business maturity
o Explain business decline
o Explain business phase out or re-launch
 Explain the business life cycle
11.6.2 Engage Engaging professional staff Professional staff correctly engaged
professional staff  Defining recruitment.
 Understanding the selection process.
 Recognizing the GROW model and how to set goals.
 Preparing for the interview and question process.
 Identifying and avoiding bias when making offers.
 Discovering ways to retain talent and measure growth
11.6.3 Manage Managing business performance Business performance well managed
business performance  Define performance management.
 Understand how performance management works and
the tools to make it work.
 Learn the three phases of project management and how
to assess it.
 Discuss effective goal-setting.
 Learn how to give feedback on performance
management.

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  Identify Kolb’s Learning Cycle.
 Recognize the importance of motivation.
 Develop a performance journal and performance plan.
11.6.4 Mobilise finance Mobilising finance for growth Finance for growth appropriately
for growth Explaining role of finance in an enterprise mobilised
o Discussing sources of finance for an enterprise
o Stating the importance of good financial management

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UNIT B11.7: ESTABLISHING BUSINESS NETWORKS DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
11.7.1 Identify Identifying networking agenda Networking agenda correctly identified
networking agenda  The importance of networking
 An enterprise networking web
11.7.2 Identify Identifying business networks Business networks correctly identified
business  Internal networks
networks  External networks
11.7.3 Join business Joining business networks Business networks joined
networks  Stakeholders and shareholders
 Terms and conditions
 Performance Evaluation
11.7.4 Attend Attending business forums Business forums appropriately attended.
business forums  Business forum
 Types of business forums
 The benefits of business forums
11.7.5 Evaluate and Evaluating and controlling business networks Business networks well evaluated and
control business  Sustaining business networks controlled
networks  Performance of business networks

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UNIT B11.8: DEVELOPING A BUSINESS EXIT PLAN DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
11.8.1 Develop an exit Developing an exit strategy Exit strategy correctly developed
strategy  Mergers
 Acquisitions
 Debentures
 Management buy out
11.8.2 Develop a Developing a succession plan Succession plan correctly developed
succession plan  Business succession planning and its role in your
company.
 Lay the groundwork to develop a succession plan.
 The importance of mentorship.
 SWOT analysis to set goals.
 Plan, assign roles, and execute the plan
 Develop support and manage change.
 Obstacles, and evaluate and adapt goals and plans.
o Success of succession plan.
11.8.3 Explain estate Explaining estate management Estate correctly managed
management  Estate management
 Types estate management
 The enterprise estate management obligations to
government

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UNIT B11.9: ASSESS BUSINESS PERFORMANCE DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
11.9.1.Set targets Setting targets Target well set.
 The target setting process
 Targets
11.9.2 Identify Key Identifying Key Performance Indicators Key Performance indicators correctly
Performance identified.
Indicators
11.9.3 Structure data Structuring data collection tools Data collection tools well structured.
collection tools  Structured interviews
 Questionnaire
 Observations
11.9.4 Outline Outlining measuring criteria Measuring criteria correctly outlined
measuring
criteria

11.9.5 Write a report Writing a report Report well written

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UNIT B11.10: MANAGE PROFITS, EXCESS CASH AND RISK DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
11.10.1Differentiate Differentiating between profit and cash Profit and cash well differentiated
between profit  Profit
and cash
 Nature of profits
 Calculating profit
 Gross profit
 Net profit
 Profitability
 Profitability ratios
 Explaining cash
o Money
o The functions of money
o The abilities of money
o Barter
o The deficiencies of barter, rate of exchange
indivisibility of goods, double coincident of wants
o The early forms of money
o The measurement of money
11.10.2.Select Selecting alternative investments Alternative investments appropriately
alternative  Strategic issues in investment found
investments
 The investment process

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  New technology.
11.10.3.Conduct Conducting investment appraisal Investment appraisal well conducted
investment  Uncertainty and investment decisions
appraisal
 Managers’ risk attitudes
11.10.4.Carryout risk Carrying out risk management Risk management correctly carried out
management  Risk management
 Expected NPV and its variability
 Techniques for assessing project risk
 The risk-return trade off

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UNIT B11.11: NEGOTIATE AGREEMENTS AND CONTRACTS DURATION: 10 HOURS 1 CREDIT HOURS
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA
OUTCOMES
11.11.1.use different Using different approaches of negotiations Approaches of negotiation correctly
approaches of  Basic types of negotiations, the phases of negotiations, used
negotiations and the skills needed for successful negotiating
 Pre-contract negotiations
 Contract negotiations
 Post contract negotiations
 Basic negotiating concepts
 WATNA
 BATNA,
 WAP
 ZOPA
11.11.2.Identify Identifying qualities of good negotiators Qualities of negotiators correctly
qualities of good  Basic negotiation skills identified
negotiators
 Basic bargaining techniques
 Strategies for identifying mutual gain
11.11.3.Prepare for Preparing for negotiations Negotiations well prepared for
negotiations  Groundwork for negotiation
 What information to share and what to keep to yourself

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  Reach consensus and set the terms of agreement
 Deal with personal attacks and other difficult issues
 Negotiating process to solve everyday problems
 Negotiate on behalf of someone else
11.11.4.Manage Managing contracts Contracts correctly managed
contracts  Contracts
 Types of tender
 Open tenders
 Restricted tenders
 Tender procedures
 Bargain for tender

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REFERENCE MATERIALS
David, S. (2006). Small Business Management and Entrepreneurship. 5th edn. London: Thomas learning.
Paul, B. (2001). Entrepreneurship and Small Business. New York: Palgrave Macmillan
Peter, F.D. (1985). Innovation and Entrepreneurship. USA: Harper and Row
Robert, D. ‘et al’, (2005). Entrepreneurship (Sixth Edition). New York: Tata McGraw – Hill Publishing Company Limited,
Robert, G. (2001). Kick-Start Your Business: 100 Days to a Learner, London: Fitter Organization; Virgin Books Limited.
Technical Education Vocational and Entrepreneurship and Training (TEVT) Policy Paper, Government of the Republic of
Zambia, 1996.
Technical Education vocational and Training (TEVET) Statement policy and Intent, GRZ 1999

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