Approved Syllabus - Diploma in Automotive Engineering 18-01-2021

ENGINEERING PROGRAMMES
ZAMBIA QUALIFICATIONS FRAMEWORK (ZQF) LEVEL 6

SYLLABUS FOR
DIPLOMA
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
Approved November, 2020

Approved syllabus - Diploma in Automotive Engineering
ACRONYMS
ABS Anti-lock Braking System

BJT Bipolar Junction Transistor
ECU Electronic Control Unit
EFI Electronic Fuel Injection
HER Heavy Equipment Repair
IC Integrated 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........................................................................................................................................................ 5
2.0. ACKNOWLEDGEMENTS .......................................................................................................................................... 5
3.0. RATIONALE............................................................................................................................................................... 6
4.0. PROGRAMME PURPOSE ......................................................................................................................................... 7
5.0. PROGRAMME LEVEL DESCRIPTOR ...................................................................................................................... 7
6.0. PROGRAMME OUTCOMES:..................................................................................................................................... 8
7.0. PROGRAMME DURATION........................................................................................................................................ 8
8.0. PROGRAMME OUTLINE ........................................................................................................................................... 9
9.0. DELIVERY MODES AND METHODS ...................................................................................................................... 10
10.0. PROGRAMME EVALUATION ................................................................................................................................. 10
11.0. PROGRAMME ENTRY REQUIREMENTS: ............................................................................................................. 11
12.0. TRAINEE ASSESSMENT ........................................................................................................................................ 12
13.0. ATTENDANCE ......................................................................................................................................................... 12
14.0. PROGRESSION REQUIREMENTS ......................................................................................................................... 12
15.0. STAFF QUALIFICATIONS....................................................................................................................................... 12
15.0 CERTIFICATION ...................................................................................................................................................... 13
MODULE 166-01-A WORKSHOP PROCESSES .......................................................................................................... 14
MODULE 166-02-A ENGINEERING MATHEMATICS I ................................................................................................. 32
MODULE 166-03-A ENGINEERING SCIENCE ................................................................................................................ 0
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MODULE 166-04-A ENGINEERING DRAWING I .............................................................................................................. 12

MODULE: 166-05-A COMMUNICATION SKILLS .............................................................................................................. 18
MODULE 166-06-A INTRODUCTION TO COMPUTERS................................................................................................... 28
MODULE 166-07-A ENGINE AND TRANSMISSION SYSTEMS ....................................................................................... 35
MODULE 166-8-A AUTOMOTIVE ELECTRICITY............................................................................................................ 62
MODULE 166-9-A BRAKING SYSTEMS ......................................................................................................................... 82
MODULE 166-10-B APPLIED MECHANICS ...................................................................................................................... 89
MODULE 166-11- B ENGINEERING MATHEMATICS II ................................................................................................... 96
MODULE 166-12-B STEERING AND SUSPENSION SYSTEM ....................................................................................... 103
MODULE 166-13-B AUTOMOTIVE ELECTRONICS ....................................................................................................... 116
MODULE 166-14-B ENGINEERING DRAWING II ........................................................................................................ 131
MODULE: 166-15-B ENTREPRENEURSHIP ................................................................................................................... 138
MODULE 166-16-B ENGINEERING MATERIALS ........................................................................................................... 154
MODULE 166-17-B MANAGEMENT AND ORGANISATION ........................................................................................ 163
MODULE 166-18-B APPLIED THERMODYNAMICS ...................................................................................................... 170
MODULE 166-19-C FLUID MECHANICS ..................................................................................................................... 177
MODULE 166-20-C MACHINE DESIGN ......................................................................................................................... 182
MODULE 166-21-C STRENGTH OF MATERIALS .......................................................................................................... 194
MODULE 166-22- C MOTOR INDUSTRY MANAGEMENT ............................................................................................. 203
MODULE 166-23-C ADVANCED MOTOR VEHICLE TECHNOLOGY............................................................................. 217
MODULE 166-24-C DESIGN PROJECT ......................................................................................................................... 225
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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 Engineering 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
11. Mr Reuben Chirwa Lecturer Northern Technical College
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12. Mr. Ackim M. Kalikeka Specialist – LMDD TEVETA

13. Mr. Adam Watama Head- Auto Electrical section Military Training Establishment of
Zambia (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
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 21st 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.
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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 Engineering is tailored to meet the
increased demand for competent human resource.
The programme will therefore, provide the nation with qualified Automotive Technologists 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.
4.0. PROGRAMME PURPOSE

The purpose of the programme is to equip the trainee with knowledge, skills and appropriate 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
5.0. PROGRAMME LEVEL DESCRIPTOR

A graduate will assume the following competences:
5.1. Foundational Competences
5.1.1. Possession of specialised knowledge and skills in automotive technology
5.1.2. Knowledge of principles of moments
5.1.3. Knowledge of different automotive body designs
5.1.4. Knowledge of motor vehicle systems components.
5.1.5. Knowledge of transfer technical information
5.2. Practical Competences
5.2.1. Ability to carry out routine servicing of motor vehicle systems
5.2.2. Ability to diagnose faults and create appropriate solutions to resolve faults
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5.2.3. Ability to operate high tech machinery in the automotive industry

5.2.4. Ability to interpret data and transfer such information and skills to others
5.2.5. Ability to prepare budget for repairs and estimate hours for repairing a particular fault.
5.3. Reflexive Competences

5.3.1. Apply management skills in automotive technology
5.3.2. Ability to exercise personal responsibility and decision-making.
5.3.3. Update clients on the condition and status of the motor vehicle.
5.3.4. Communicate effectively with clients
5.3.5. Able to justify repair costs to clients
5.3.6. Ability to assess and appraise others
5.3.7. Ability to judge the effectiveness of others based on job performance
6.0. PROGRAMME OUTCOMES:

On completion of the programme the trainee will be able to;
6.1. Diagnose, repair and service motor vehicle engine system
6.2. Diagnose, repair and service motor vehicle steering systems
6.3. Diagnose, repair and service motor vehicle steering systems
6.4. Diagnose, repair and service motor vehicle transmission systems
6.5. Diagnose, repair and maintain vehicle electronic systems
6.6. Diagnose, repair and maintain vehicle electricity systems
6.7. Apply Computer skills
6.8. Interpret Engineering drawing
6.9. Apply engineering science principles
6.10. Apply Engineering mathematics principles
6.11. Apply Entrepreneurial skills
7.0. PROGRAMME DURATION

The programme duration is three (3) years 3 months or 3600 notional learning hours, inclusive of 480 hours (3 months) of
Industrial Attachment.
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8.0. PROGRAMME OUTLINE
MODULE TITLE HOURS
FIRST YEAR
166-01-A WORKSHOP PROCESSES 100
166-02-A ENGINEERING MATHEMATICS I 120
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 200
166-08-A AUTOMOTIVE ELECTRICITY 140
166-09-A BRAKING SYSTEMS 160
Sub Total 1200
SECOND YEAR
INDUSTRIAL ATTACHMENT 480

166-10-B APPLIED MECHANICS 80
166-11-B ENGINEERING MATHEMATICS II 90
166-12-B STEERING AND SUSPENSION SYSTEM 90
166-13-B AUTOMOTIVE ELECTRONICS 120
166-14-B ENGINEERING DRAWING II 60
166-15-B ENTREPRENEURSHIP 90
166-16-B ENGINEERING MATERIALS 100
166-17-B MANAGEMENT AND ORGANISATION 80
Sub Total 1200
THIRD YEAR
166-18-C APPLIED THERMODYNAMICS 150
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166-19-C FLUID MECHANICS 160

166-20-C MACHINE DESIGN 130
166-21-C STRENGTH OF MATERIALS 180
166-22-C MOTOR INDUSTRY MANAGEMENT 150
166-23-C ADVANCED MOTOR VEHICLE TECHNOLOGY 200
166-24-C DESIGN PROJECT 230
Sub Total 1368
TOTAL 3600
9.0. DELIVERY MODES AND METHODS

9.1. Delivery Mode
9.1.1. Fulltime or conventional
9.1.2. Blended or flexible
9.1.3. Online
9.2. Learning Methods
Learning shall constitute:
9.2.1. Practical training
9.2.2. Group discussions
9.2.3. Demonstration
9.2.4. Individual projects
9.2.5. Audio visual (Simulations, Charts, Video)
9.2.6. Field visits
10.0. PROGRAMME EVALUATION

TEVETA shall evaluate the programme as follows:
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10.1. Formative evaluation
10.1.1. Purpose: To determine on an on-going basis whether the programme is being implemented as planned
and to advise on improvements.
10.1.2. Major areas of Evaluation: Programme aims and objectives/ learning outcomes, trainee’s entry
requirements, programme content, teaching / learning activities, learning resources.
10.1.3. Evaluation Instruments: Questionnaires, structured interviews, observations, checklists,
examinations/test records, participation and attendance in class
10.1.4. Sources of Information: Students, trainers, administrative monitors and records.
10.2. Summative Evaluation
10.2.1. 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.
10.3. Evaluation Instruments: Questionnaires, structured interviews, observations, checklists, records, final integrated
Examinations.
10.4. Sources of information: Trainees, trainers, assessors, examiners, administrators, sponsors, student dropouts,
employers, union officials and the general public.
11.0. PROGRAMME ENTRY REQUIREMENTS:

11.1. Direct entry
11.1.1. Grade 12 School Certificate with a minimum of credits in English Language, Mathematics, Science and any
other two (2) subjects.
11.2. Mature entry
11.2.1. A minimum of a Craft Certificate in Automotive Engineering or in a related discipline.
11.2.2. A minimum of Advanced Certificate in Automotive Engineering or in a related discipline
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12.0. TRAINEE ASSESSMENT

Trainees will be subjected to:
12.1. Assessment modes
12.1.1. Assignment
12.1.2. Practicals
12.1.3. Class exercises
12.1.4. Tests
12.2. Assessment Composition
12.2.1. Continuous Assessment
12.2.2. Final examination
12.2.3. Pass mark
13.0. ATTENDANCE
The candidate must have an attendance of minimum 85% to be eligible for the final examinations.
14.0. PROGRESSION REQUIREMENTS
14.1. Failures
Trainees failing in four (4) or more modules shall be considered as outright failures and shall be removed from the
programme. Trainees failing in less than four modules shall only be given a chance to resit the failed subjects before
proceeding to the next level.
14.2. Referrals
Trainees failing in three (3) modules or less shall be allowed to continue with the programme.
15.0. STAFF QUALIFICATIONS

15.1. Qualification of Trainers
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15.1.1. Minimum of Degree in Automotive Engineering or any other related programme with two years relevant
Industrial experience.
15.1.2. Minimum of Diploma in Automotive Engineering or any other related programme, with five years relevant
industrial experience
15.1.3. A Diploma in Teaching Methodology from a recognized examining board
15.1.4. TEVETA accredited trainer
15.2. Qualifications for Examiners and Assessors
Assessors should possess a qualification that is higher than the qualification of the learners as follows:
15.2.1. Diploma - Degree
15.0 CERTIFICATION
Successful candidates will be awarded a Diploma in Automotive Engineering by the Technical Education, Vocational and
Entrepreneurship Training Authority (TEVETA).
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MODULE 166-01-A WORKSHOP PROCESSES MODULE DURATION: 100 HOURS CREDITS: 10
Module Purpose: To equip the trainee with knowledge, skills and appropriate attitudes to carry out workshop processes
effectively and 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
Learning Conditions: Trainee must Values and Attitudes Assessment Methods: The trainee will
have access to the following: be assessed through;
 Lecture Notes  Honest  Assignments
 Library  Hard working  Practical exercises
 Internet  Integrity  Written exercises
 Workshop  Written and Practical Tests
 Plant and equipment
UNIT A1.1: ORGANIZING WORKSPACE UNIT DURATION: 10 HOURS CREDITS: 1
SPECIFIC LEARNING LEARNING ACTIVITIES: ASSESSMENT CRITERIA
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OUTCOMES
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 housekeeping Carrying out housekeeping duties. Housekeeping duties correctly carried out.
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 Physical work space organised correctly
workspace for functionality and productivity
and productivity  Ventilation
 Temperature
 Room dimension and space
 Lighting
 Proximity of tools and equipment.
UNIT A1.2: DEMONSTRATING SAFE WORKING PRACTICES UNIT DURATION: 10 HOURS CREDITS: 1

OUTCOMES
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
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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
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 (PPE)  Head Protection equipment (PPE) used
o Hard hat correctly
 Eye Protection
o Safety goggles
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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
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

OUTCOMES
1.3.1 Identify workshop layout Identifying workshop layout; Workshop layout identified
 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 Applying isolate and tag out procedure Isolating and tagging out
isolate and tag out procedure applied correctly
procedure  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
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o Pneumatic
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 and Applying safety, health and environmental regulations safety, health 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
o Improper ventilation
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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 Judgements 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

OUTCOMES
1.4.1 Identify Elements of Identifying elements of Fire Elements of Fire identified
Fire  Define fire correctly
 Elements of a fire
o Fuel/Combustible Substance
o Heat
o Air/Oxygen
1.4.2 Identify causes of Fire Identifying causes of fire Causes of Fire identified
 Flammable Liquids correctly
 Flammable Solid Material
 Electricity
 Flammable Gases
1.4.3 Describe Classes of Describing classes of fire Classes of Fire described
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
 Avoid Short Circuits
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 Carry out house Keeping in the workshop

UNIT A1.5: USING WORKSHOP TOOLS AND EQUIPMENT UNIT DURATION: 10 HOURS CREDITS: 1

OUTCOMES
1.5.1 Identify workshop Identifying workshop tools Workshop tools identified
tools  Precision measuring instruments correctly
 Power tools
 Hand tools
1.5.2 Identify workshop Identifying workshop equipment Workshop equipment
equipment  Drilling machine identified correctly
 Presses
 Lifting equipment
 Pulling equipment
 Grinders
 Lubrication facilities
 Air pressure facilities
 Cleaning facilities
 Surface table
1.5.3 Use workshop tools Using workshop tools Workshop tools used
 Precision measuring instruments correctly
 Power tools
 Hand tools
1.5.4 Use workshop Using workshop equipment Workshop equipment used
equipment  Drilling machine correctly
 Presses
 Grinders
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 Lubrication facilities
 Air pressure facilities
 Clearing facilities
 Surface table
UNIT A1.6: MAINTAINING TOOLS AND EQUIPMENT UNIT DURATION: 10 HOURS CREDITS: 1
OUTCOMES
1.6.1 Apply tools Applying tools maintenance procedures Tools maintenance
maintenance  Identification of recommended method of reclaiming each procedures applied
procedures tool correctly
 Method of restoring tools to usable condition
 Sharpening
 Grinding
1.6.2 Apply equipment Applying equipment maintenance procedure Equipment maintenance
maintenance procedure  Identify recommended methods of maintaining each procedure applied correctly
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
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 Grinders
 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
UNIT A1.7: PERFORMING BENCHWORK IN THE WORKSHOP UNIT DURATION: 10 HOURS CREDITS: 1
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA

OUTCOMES
1.7.1 Identify marking out tools Identifying marking out tools Marking out tools identified
 Punches correctly
 Marking Out Table
 Surface Plate
 Combination Set
 Trammels
 Dividers
 Vanier
 Scribing Block
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 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
 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
UNIT A1.8 USING FASTENERS UNIT DURATION: 10 HOURS CREDITS: 1

OUTCOMES
1.8.1 Identify types of fasteners Identifying types of fasteners Types of fasteners
 Mechanical Fastener identified correctly
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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 techniques Applying torqueing techniques Torqueing 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: 10 HOURS CREDITS: 1

OUTCOMES
1.9.1 Identify different types ofIdentifying different types of lifting and support equipment Different types of lifting and
lifting and support equipment  Jacks support equipment
 Forklifts identified correctly
 Cranes
 Chain blocks
 Ratchet hoist
1.9.2 Identify different lifting Identifying different lifting accessories Different lifting accessories
accessories  Lifting beams identified correctly
 Spreader bar
 Eye bolt
 Sling hooks
 Link brackets
 Barrel grip
 Shackles
1.9.3 Use lifting terminologies Using lifting terminologies Lifting terminologies used
 WLL – working load limit correctly
 SWL – safety working load
 BL – breaking load
 PL – proof loading
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 SF – safety factor
 CG – center of gravity
 SL – shock loading
 Cranes – mobile, overhead
 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 support Using lifting and support equipment Lifting and support
equipment  Hand signals equipment used correctly
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 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  Basic Principles of Rigging requirements applied
o Safe working load correctly
o Sling certification
o Load balancing
o Rigging Certification
1.9.6 Apply sling work Applying sling work Sling work applied
 Types of sling correctly
 Planning and Preparation
 Hooks
 Shackles
 Sling angles
1.9.7 Use chain blocks Using chain blocks Chain blocks used
 Types of chain blocks correctly
o Chain block
o Tick torque
o Operate chain block
29
UNIT A1.10 PERFORMING BASIC WELDING UNIT DURATION: 10 HOURS CREDITS: 1

OUTCOMES
1.10.1 Describe the Describing Fundamentals of welding Fundamentals of welding
fundamentals of welding  Health and Safety requirements described correctly
 Metals and alloys
 Terminology
 Patterns/shapes
 Storage and handling
1.10.2 Identify different types Identifying different types of welding Types of welding identified
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 welding Performing Gas welding Gas welding performed
 Gases correctly
 Cylinders
 Safety precautions
 Assembly procedures
 Operation procedures
30
REFERENCES
Bennett, S. (2015). Heavy Duty Truck Systems. 6th ed. Boston: Cengage learning
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.
31
MODULE DURATION: 120 CREDITS: 20

MODULE 166-02-A ENGINEERING MATHEMATICS I HOURS
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 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
Learning Conditions Values and attitudes Assessment Methods:

Trainee will have access to the  Assignments
following:  Honest  Practical
 Books  Integrity  Class exercises
 Modules  Hard work  Tests
 Library
 Internet
 Handouts
 Calculator
32
UNIT A 2.1 COMPUTING ARITHMETIC OPERATIONS UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
2.1.1 Use scientific calculators Using scientific calculators Scientific calculators used
 Calculator layout correctly
 Accuracy
 Truncation
2.1.2 Compute mathematical Computing mathematical problems Mathematical problems
problems  Arithmetic operations on rational and real computed correctly
numbers
 Formation of equations from an open
mathematical sentence
 Simple algebra
 Single fractions
2.1.3 Interpret mathematical Interpreting mathematical tables and charts Mathematical tables and charts
tables and charts
 Translation of information from tables and charts
2.1.4 Apply significant figures Applying significant figures and decimal places Significant figures and decimal
and decimal places  Addition of decimal numbers places applied correctly
 Subtraction of decimal numbers
 Converting of decimal numbers
 Evaluation of significant figures
33
2.1.5 Use the standard form Using the standard form (scientific notation) The standard form (scientific
(scientific notation) notation) used correctly
 Converting of fractions to standard form
 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
UNIT A2.2 USING NUMERICAL METHODS TO SOLVE PROBLEMS UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
2.2.1 Evaluate mathematical Evaluating mathematical problems using ratios Mathematical problems using
problems using ratios  Ratios ratios evaluated correctly
 Percentages
2.2.2 Apply fractions and Applying fractions and proportions Fractions and proportions
proportions applied correctly
2.2.3 Apply BODMAS on Applying BODMAS on algebra BODMAS applied on algebra
algebra correctly
UNIT A2.3 SOLVING PROBLEMS USING MENSURATION DURATION: 10 HOURS CREDITS:1

OUTCOMES
2.3.1 Apply properties of Applying properties of quadrilaterals Properties of quadrilaterals
quadrilaterals  Sides applied correctly
 Angles
34
 Line of symmetry
2.3.2 Calculate areas of plane Calculating areas of plane figures Areas of plane figures
figures calculated correctly
 Rectangle
 Square
 Parallelogram
 Trapezium
2.3.3.Calculate volumes of Calculating volumes of regular shapes Volumes of regular shapes

regular shapes  Squares
 Cones
 Cylinders
 Pyramids
UNIT A2.4: MANIPULATING INDICES AND LOGARITHMS UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
2.4.1 Calculate indices Calculating indices Indices calculated correctly
 Laws of indices
2.4.2 Calculate logarithms Calculating logarithms Indices solved correctly

 Laws of logarithms
 Natural logarithms
 Indices and logarithms relations
35
UNIT A2.5: PLOTTING LINEAR RELATIONSHIPS UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
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 a Solving equations of a straight line Equations of a straight line

straight line solved correctly.
 Gradient, m, and vertical intercept, c, to find the
equation of a straight line
2.5.3.Interpret information Interpreting information from graphs Information from graphs

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
36
UNIT A2.6: SOLVING QUADRATIC RELATIONSHIPS UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
2.6.1.Apply the discriminant Applying the discriminant The Discriminant Applied
Correctly
 Role of the discriminant in the nature of roots
2.6.2.Manipulate the x and y Manipulating the x and y intercepts The x and y intercepts
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
37
UNIT A2.7: MANIPULATING TRIGONOMETRIC RELATIONSHIPS UNIT DURATION 13 HOURS CREDITS: 1.3

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
 Sine
 Cosine
 Tangent graphs
2.7.3.Manipulate trigonometric Manipulate trigonometric identities Trigonometric identities

identities manipulated correctly
2.7.4.Apply addition and Applying addition and subtraction formula Addition and subtraction formula
subtraction formula  Expansion of trigonometric formula of the form applied correctly
),
 double angle formulae

2.7.5.Convert trigonometric Converting trigonometric functions Trigonometric functions
functions converted correctly
38
UNIT A2.8: CALCULATING VECTORS UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
2.8.1.Calculate vectors in 2 Calculating vectors in 2 dimensions Vectors in 2 dimensions
dimensions calculated correctly
 Addition
 Subtraction
 Displacement vectors
 Unit vectors
 Multiplication by a scalar
2.8.2.Calculate vectors in 3 Calculating vectors in 3 dimensions Vectors in 3 dimensions

dimensions calculated correctly
 Addition
 Subtraction
 Direction cosines
 The scalar product
2.8.3.Calculate the work done Calculating the work done by force The work done by force
by force calculated correctly
 The Dot product
 Application of the Dot product
 Calculate angle between two vectors
 Work done by an applied force
UNIT A2.9: CALCULATING SEQUENCES AND SERIES UNIT DURATION 13 HOURS CREDITS: 1.3
39
OUTCOMES
2.9.1.Calculate arithmetic and Calculating arithmetic and geometric series Arithmetic and geometric series
geometric series calculated correctly
 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 Binomial Applying the Binomial theorem Binomial theorem applied
theorem correctly
 Pascal triangle
 Convergent series
 Expansion by the binomial theorem
 Binomial theorem for an index
2.9.3.Manipulate polynomials Manipulating polynomials by iterative methods Polynomials by iterative

by iterative methods methods manipulated correctly
 Finding square roots by iterative methods
 Iterative formula
 Using the iterative formula to test for convergence
REFERENCES
40
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
41
MODULE DURATION: 160 CREDITS: 16
MODULE 166-03-A ENGINEERING SCIENCE HOURS
MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate attitudes required to apply principles of engineering
science effectively and efficiently.
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. Apply properties of materials
Assessment Methods:
 Assignments
 Practical
 Class exercises
 Tests
Learning Conditions: Trainee will have access to the following:

 Books
 Modules
 Library
 Internet
 Handouts
 Calculator
 Laboratory
UNIT A 3.1: APPLYING FUNDAMENTAL QUANTITIES UNIT DURATION 13 HOURS CREDITS: 1.3

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
3.1.3 Use conversions Using conversions Conversions used correctly

and convert from o Mega gram (Mg) or tonne (I) = 103kg to g to kg
non SI to SI units 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)
1
o Pound (lb) to kilogram (kg)

o Gallon (gal) to cubic meters (m3)
3.1.4 Analyse DimensionsAnalysing dimensions Dimensions correctly analysed
o Mass
o Length
o Time
 Analysing dimensions of equations and expressions
o Check equations
o Verify dimensional correctness
UNIT A 3.2: APPLYING EQUILIBRIUM UNDER THE ACTION OF FORCES UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
3.2.1 Apply terminologies Applying terminologies  Terminologies applied correctly
and carry out o Scalars
resolution of vectors 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 =0
o =0
3.2.2 Calculate forces Calculating forces Forces calculated correctly
o Concurrent forces
2
o Coplanar forces
o Colinear forces
o Equilibrant
o Resultant
 Calculating
o Force in a Jib and tie
o Forces in a system
 Calculating concurrent coplanar forces
o Analytical resolution of forces
o Graphical resolution of forces
UNIT A 3.3: APPLYING MOMENTS UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
3.3.1 State the Principle of Stating the Principle of Moments Principle of moments stated correctly
Moments o Moment
o Couple
o Centre of gravity
o Centroid
3.3.2 Calculate, apply and  Calculating the moments on; Moment of a force calculated correctly
determine moment
of a force o Beam loading
 Apply moments of a force
o Effects of a force
 Determine
o Torque
o Couple
 Apply principle of moments
3
o Balance of moments
 Determine
o Centre of gravity
 Regular plane figures
 Irregular plane figures
o Centroids
 Regular plane figures
 Irregular plane figures
UNIT A 3.4: CALCULATING LINEAR AND ANGULAR MOTION UNIT DURATION 13 HOURS CREDITS: 1.3

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
4
UNIT A 3.5: APPLYING NEWTON’S LAWS OF MOTION UNIT DURATION 13 HOURS CREDITS: 1.3

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
 Force
 Weight of a body in a lift
3.5.3 Calculate Calculating Impulse and momentum Impulse and momentum applied
Impulse and o momentum correctly
momentum  Change in momentum
 impulse
 Impulsive force
 Types of collisions
UNIT A 3.6 CALCULATING FRICTION UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
3.6.1 State laws of friction Stating laws of friction Laws of friction stated correctly
and outline advantages o Friction
and disadvantages of o Coefficient of friction
friction Outlining advantages and disadvantages of friction
5
o 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
Calculating Angle of friction
o Total reaction
o Angle of friction
UNIT A 3.7 CALCULATING WORK, ENERGY AND POWER UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
3.7.1 Define work, energy
Defining; work, energy and power defined
and power  Work correctly
 Energy
 Power
 Kinetic energy
Potential energy
3.7.2 Calculate work, Calculating work, energy and power work, energy and powerand apply
energy and o Work done by a force ( ) conservation of energy principle
powerand apply o Work done by a torque calculated correctly
conservation of o Potential energy
energy principle o Kinetic energy
o Power generated by a force
Applying conservation of energy principle
Determining the Power generated by a torque
UNIT B3.8 APPLYING PRINCIPLES OF SIMPLE MACHINES UNIT DURATION 13 HOURS CREDITS: 1.3
6

OUTCOMES
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
7
 Speed of a gear (rpm)

o Compound gear train
 Velocity ratio
 Speed of a gear (rpm)
UNIT 3.9 APPLYING HEAT ENERGY PRINCIPLES UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
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
UNIT 3.10 APPLYING PROPERTIES OF FLUIDS UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
3.10.1 Define fluid Defining fluid properties Properties of fluid defined correctly
properties o Fluid
o Mass density
o Relative density
8
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
o Transmission of fluid Pressure ( , P = ꞷh)
UNIT 3.11 APPLYING PRINCIPLES OF ELECTRICITY UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
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
9
o Symbols
o Electrical symbols
o Electronic symbols
Electric appliances
3.11.2 Apply Ohm’s law Applying Ohm’s law Ohm’s law applied correctly
Stating Ohm’s law
Calculating;
 Resistance
 Voltage
 Current
 Electric power
3.11.3 Define Kirchhoff’s Defining Kirchhoff,s laws of; 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
3.12 APPLYING PROPERTIES OF MATERIALS UNIT DURATION 13 HOURS CREDITS: 1.3

OUTCOMES
10
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
Explaining Hooke’s law
Explaining the following mechanical properties;
 Tensile strength
 Compressive strength
 Elasticity
 Plasticity
 Ductility
 Malleability
o Electrical
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
REFERENCES
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.
11
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: 160 HOURS CREDITS: 16

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
UNIT A 4.1 USING DRAWING INSTRUMENTS AND EQUIPMENT UNIT DURATION 32 HOURS CREDITS: 3.2
12

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
UNIT A 4.2 PRODUCING GEOMETRICAL FIGURES UNIT DURATION 32 HOURS CREDITS: 3.2

OUTCOMES
4.2.1 Use Conventions Using Conventions Conventions used correctly
 Title block dimensions
 Title block information
 Units of measurements
13
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
 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
14
 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
UNIT A 4.3 PRODUCING ENGINEERING DRAWINGS UNIT DURATION 32 HOURS CREDITS: 3.2

OUTCOMES
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
•
UNIT A 4.4: PRODUCING PNEUMATIC AND HYDRAULIC DRAWINGS UNIT DURATION 32 HOURS CREDITS:
15
3.2
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
UNIT A 4.5: USING DRAWING INSTRUMENTS AND EQUIPMENT UNIT DURATION 3.2 HOURS CREDITS: 3.2

OUTCOMES
16
4.5.1.Prepare title Preparing title blocks Title blocks prepared correctly

blocks  System of labelling
 Cross referencing
4.5.2.preparing 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
4.5.3Use precautions Using precautions Precautions used correctly
 Dos and Don’ts
 Storage of drawings
References
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.
17
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
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:
18
 Assignments
 Practical
 Class exercises
 Tests

 Books
 Modules
 Library
 Internet
 Handouts
UNIT A5.1: USING A LIBRARY DURATION: 10 HOURS 1 CREDIT HOURS

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
19
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
UNIT A5.2: DISCUSSING THE PROCESS OF COMMUNICATION DURATION: 10 HOURS 1 CREDIT HOURS

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
20
 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
 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
21
o Lateral
 Diagnosed communication
UNIT A5.3: APPLYING STUDY SKILLS DURATION: 10 HOURS 1 CREDIT HOURS

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  Main points from a text
 Summarizing paragraphs
 Technical description and definitions
 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
22
5.3.3 Develop listening

Developing listening and speaking skills Listening skills developed correctly
and speaking skills  Presenting an argument
 Questioning skills
UNIT A5.4: APPLYING CORRESPONDENCE SKILLS DURATION: 10 HOURS 1 CREDIT HOURS

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 of business letter Circulars responded to correctly
circulars o Opening paragraphs (characteristics if business letters identified
(Characteristics of o Main body correctly)
business letters) o Closing paragraph
 Qualities of a business letter
o Paper quality
o Envelope
o Type face
o Logo and Corporate Image
o General Impression
23
UNIT A5.5: WRITING REPORTS DURATION: 10 HOURS 1 CREDIT HOURS

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
UNIT A5.6: APPLYING INTERPERSONAL SKILLS IN AN ORGANISATION DURATION: 10 HOURS 1 CREDIT HOURS
24
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
5.5.3 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
UNIT A5.7: APPLYING FOR A JOB DURATION: 10 HOURS 1 CREDIT HOURS

OUTCOMES
25
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
26
 When
 What
 How
UNIT A5.8: USING TECHNICAL ENGLISH DURATION: 10 HOURS 1 CREDIT HOURS

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
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.
27
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
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:
 Assignments
 Practical
 Class exercises
 Tests

 Books
 Modules
 Library
 Internet
28
UNIT A6.1: OPERATING A COMPUTER SYSTEM DURATION: 20 HOURS 2 CREDIT HOURS

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
29
 Electrical connections
UNIT A6.2: USING AN OPERATING SYSTEM DURATION: 10 HOURS 1 CREDIT HOURS

OUTCOMES
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
UNIT A6.3: USING WORD PROCESSING FOR TECHNICAL REPORTS DURATION: 10 HOURS 1 CREDIT HOURS

OUTCOMES
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
30
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
UNIT A6.4: SENDING AND RECEIVING E-MAIL DURATION: 10 HOURS 1 CREDIT HOURS

OUTCOMES
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
31
 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
UNIT A6.5: USING SPREADSHEET DURATION: 10 HOURS 1 CREDIT HOURS

OUTCOMES
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
32
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
UNIT A6.6: USING THE INTERNET DURATION: 10 HOURS 1 CREDIT HOURS

OUTCOMES
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)
33
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
UNIT A6.7: USING POWER POINT PRESENTATION DURATION: 10 HOURS 1 CREDIT HOURS

OUTCOMES
6.7.1 Create Creating PowerPoint presentation PowerPoint presentation created correctly
PowerPoint
presentation
6.7.2 Project Projecting presentation Presentation projected correctly
presentation
REFERENCE
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.
34
MODULE 166-07-A ENGINE AND TRANSMISSION SYSTEMS

MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate attitudes to
MODULE CREDITS:20
effectively and efficiently repair and service motor vehicle engine systems DURATION:
200 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
 Exercises
 Class tests
 Assignments
 Practical
LEARNING CONDITIONS
The trainee must have access to:
 Books
 Library
35
 Internet
 Lecture notes
 Automotive mechanics workshop
 Running vehicle
UNIT A7.1 OUTLINING THE VEHICLE LAYOUT UNIT DURATION 18 HOURS CREDITS: 1.8

OUTCOMES
7.1.1. Identify locations Identifying locations of vehicle components Locations of vehicle components
of vehicle identified correctly
components  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
36
7.1.2. Outline functions Outlining functions of vehicle components functions of vehicle components
of vehicle Engine outlined correctly
components. o 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)
37
 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
UNIT A7.2 IDENTIFYING ENGINE COMPONENTS UNIT DURATION 18 HOURS CREDITS: 1.8

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
38
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
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
39
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
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
40
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
o Crank shafts
o Cam shafts
o Flywheel
o Vibration dumper
o Valve train
UNIT 7.3 EXPLAINING MOTOR VEHICLE ENGINE OPERATIONS UNIT DURATION 18 HOURS CREDITS: 1.8

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)
41
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) explained
Compression Ignition Engine  The operational stages of a four stroke cycle ( correctly
compression ignition engine)
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) explained
Compression Ignition  The operational stages of a two stroke cycle ( compression correctly
ignition engine)
Describe construction of supercharges
o upward stroke
o downward stroke correctly
 Supercharging Explain operation of superchargers
 Types of superchargers correctly
o Blower
o Turbochager
7.3.6 Explain operation of Explaining operation of rotary engine Construction of rotary engine
rotary engine  Explaining functions of components of rotary engine described correctly
o Rotary Functions of components of rotary
o Accentric shaft
engine explained correctly
o Seals
o Apex Operation of rotary engine explained
 Explaining operation of roatary engine correctly
7.3.5 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
42
chart and combustion 

Valve timing diagrams outlined correctly
process o Valve lead
o Valve lag
o Valve overlap
 Power flow chart and combustion process
o Induction strokes
o Compression strokes
o Power strokes
o Exhaust strokes
UNIT 7.4 REPAIRING AND SERVICING OF MOTOR VEHICLE ENGINE LUBRICATION SYSTEMS UNIT DURATION 18 HOURS
CREDITS: 1.8
OUTCOMES
7.4.1 Identify motor Identifying motor vehicle engine lubrication systems Motor vehicle engine lubrication
vehicle engine  Motor vehicle engine lubrication systems systems identified correctly.
lubrication o Dry sump
systems 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
43
 Motor vehicle lubrication methods

o Force feed
o Splash feed
o Mist feed
7.4.3 Identify components Identifying Components of motor vehicle lubrication system components of motor vehicle
of motor vehicle o Oil pump lubrication systems identified correctly
lubrication 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
7.4.4Explain the functions of Explaining Function/s of motor vehicle lubrication system functions of motor vehicle lubrication
motor vehicle components system components explained
lubrication system o Oil pump correctly
components 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
7.4.5Carry out motor vehicle Carrying out Motor vehicle engine lubrication system servicing
engine lubrication  Oil pump
44
system servicing  Oil filter

 Oil strainer
 Oil sump
 Oil pressure relief valve
 Oil galleries
 Pressure warning indicators
 By-pass valve
UNIT A7.5 REPAIRING AND SERVICING OF MOTOR VEHICLE ENGINE IGNITION SYSTEM
UNIT DURATION 18 HOURS CREDITS: 1.8
OUTCOMES
7.5.1 Identify motor Identifying Motor vehicle ignition systems Motor vehicle ignition system identified
vehicle ignition correctly
systems o Conventional ( contact breaker points)
o Electronic
 Hall effect
 Optical pulse
 Magnetic inductance
 Distributor-less
7.5.2 Explain functions Explaining Function of motor vehicle engine ignition system Explaining functions of motor vehicle
of motor vehicle o High ignition voltage generation engine ignition system correctly
engine ignition
systems
45
7.5.3Identify motor vehicle Identifiying Motor vehicle ignition system components motor vehicle ignition system
ignition system (conventional) components identified correctly
components o Battery
o Ignition distributor
o Ignition coil
o Spark plugs
o Condenser (capacitor)
o Ignition key
o Contact breaker points
o High tension cables
o Low tension cables
o Rotor
7.5.4Carry out motor vehicle Carrying out Motor vehicle engine ignition system servicing Motor vehicle engine ignition system
engine ignition system servicing outlined correctly
servicing o Testing ignition coil resistance
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
7.5.5Carry out motor vehicle Carrying out Motor vehicle engine fault diagnosis motor vehicle engine ignition fault
engine ignition fault o No spark generation diagnosis carried out correctly
o Weak spark generation
46
diagnosis o Intermittent spark generation
UNIT A7.6 REPAIRING AND SERVICING OF MOTOR VEHICLE ENGINE FUEL SYSTEM UNIT DURATION 18 HOURS
CREDITS: 1.8

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
47
o Fuel pump
o Injector pump
o High pressure pipes
7.6.4 Explain 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

7.6.5 Carry 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
o
7.6.6 Outline 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
48
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 Carry out motor vehicle engine fuel system servicing (diesel) motor vehicle engine fuel system
vehicle engine fuel servicing outlined correctly
system servicing 
Motor vehicle engine fuel system servicing (diesel) (
(diesel ) Calibration and Phasing)
o Injection pumps
o Injectors
o Fuel filters
o Feed pumps
 Carry out injection pump timing
o Spill timing
UNIT A7.7 REPAIRING AND SERVICING MOTOR VEHICLE ENGINE COOLING SYSTEM UNIT DURATION 18 HOURS
CREDITS: 1.8
OUTCOMES
7.7.1 Explain functions of Explaining functions of motor vehicle engine cooling system functions of motor vehicle engine
49
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  Identifying 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
o Expansion tank
o Water pump
o Radiator pressure cap
o Thermostat
 Motor vehicle air cooling system components
50
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
UNIT B7.8 IDENTIFYING TRANSMISSION COMPONENTS UNIT DURATION 18 HOURS CREDITS: 1.8

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
51
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
 Manual gearbox components
 Input shaft
 Lay shaft
 Main shaft
 Set of gears
 Sychromesh
 Interlock mechanism
 Detent mechanism
 Selection mechanism
 Bearings
 Seals
 Housing
52
 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
 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 Explaining functions of the propeller shaft Propeller shaft unit identified correctly
53
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 Explaining functions Components of the propeller shaft Components of the propeller shaft
components of the o Tube funcitons explained correctly
propeller shaft and o Yoke
o Sliding Joints
Universal joint
 Functions of propeller shaft components
o Tube
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
differential  Functions of the final drive
 Locations of the final drive
 Components of the final drive
54
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
o Cornering
 Types differential locks
o Mechanical
55
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
UNIT B7.9 REPAIRING AND SERVICING TRANSMISSION SYSTEM COMPONENTS UNIT DURATION 18 HOURS
CREDITS: 1.8
56

OUTCOMES
7.9.1Apply 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
7.9.2Use disassembling Using disassembling and assembling tools and equipment for Disassembling and assembling tools
and assembling tools transmission system and equipment for transmission
and equipment for  Tools systems used correctly
o Spanners and sockets
transmission system
o Bearing pullers
o Hammers and mallets
o Special tools
 Equipment
o Transmission jack
o Hydraulic press
7.9.3Carry out Carrying out disassembling procedures Disassembling procedures for

disassembling  Disassembling rules transmission system carried out
procedures  Disassembling procedure . correctly
o Loosen or undo mounting bolts, nuts or fasteners
57
o Making matching marks

o Separation or detachment of individual units
o Arrangement of units in the order of disassembly
7.9.4Carry out Carrying out disassembly and assembling of clutch unit Assembling procedure for clutch unit
disassembly and  Assembly Rules done correctly
assembling of clutch 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
7.9.6.Carry out disassembly Carrying out disassembly and assembly of manual gearbox Disasemble and assemble manual
and assembly of manual  Students disassemble and assemble manual gear box gearbox correctly
gearbox following the right procedure
 Students disassemble and assemble automatic gear box Disasemble and assemble automatic
7.9.7.Disassembly and following the right procedure gearbox correctly
assembly of automatic
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
58
7.9.9.Diassembly and Disassembling and assembleling final drive following the right Disasemble and assemble final drive
assembly of final drive procedur 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
UNIT B7.10 CARRYING OUT DIAGNOSIS OF TRANSMISSION SYSTEM FAULTS UNIT DURATION 18 HOURS
CREDITS: 1.8

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 Carrying out recording procedures Recording procedures carried out
recording 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
59
 Extent of wear
 Damage or distortion
o Compare results/information with manufacturer’s
specifications
o Interpret the results/information
UNIT B7.11 RECTIFYING TRANSMISSION FAULTS UNIT DURATION 18 HOURS CREDITS: 1.8

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 Carrying out servicing procedures Servicing procedures carried out
servicing procedures  Servicing transmission system components correctly
o Visual inspection
o Adjustments
o Oil and lubricating
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.
60
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
61
MODULE 166-8-A AUTOMOTIVE ELECTRICITY
MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate MODULE CREDITS: 14 Credit
attitudes required to effectively and efficiently apply fundamental electrical principles in DURATION: 140 Hours
automotive repairs. Hours
1. Apply electrical fundamentals
2. Use electrical circuits
3. Apply ohm’s law
4. Apply magnetic principles
5. Identify vehicle electrical systems
6. Differentiate primary and secondary batteries
7. Diagnosing different electrical circuits
8. Repair faults in electrical components
9. Repair electrical Accessories and instruments
10. Repair electrical instruments
11. Repair automotive air conditioning system
Assessment Methods
 Assignments
 On site practical
 Written class exercises
 Tests
 Workshop projects
 Laboratory exercises
62
Learning conditions
 Books
 Modules
 Library
 Internet
 Workshop
 Laboratory
UNIT A8.1: APPLYING ELECTRICAL FUNDAMENTALS UNIT DURATION 12 HOURS CREDITS: 1.2

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
63
 Power
 Energy
 Conductance
 Capacitance
 Charge
 Induction
 Impedance
 Frequency
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
UNIT A8.2: USING ELECTRICAL CIRCUITS UNIT DURATION 12 HOURS CREDITS: 1.2

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
64
 Kirchhoff’s Voltage law
8.2.3 Identify Electrical Identifying Electrical circuit faults Electrical Circuit Faults identified correctly
Circuit Faults  Short circuit
 Open circuit
 Intermittent
 Dead short
UNIT A8.3: APPLY OHM’S LAW UNIT DURATION 12 HOURS CREDITS: 1.2

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
 Length
 Diameter
 Material
8.3.3 Solve resistance Solving resistance Resistance solved correctly
 Length
 Diameter
 Material
65
UNIT A8.4: APPLYING MAGNETIC PRINCIPLES UNIT DURATION 12 HOURS CREDITS: 1.2

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
 Faraday’s Law
66
8.4.6 Apply Lenz’s rule Applying Lenz’s rule Lenz’s rule applied correctly
 Polarity
 Self-induction
 Mutual induction
UNIT A8.5: IDENTIFYING VEHICLE ELECTRICAL SYSTEMS UNIT DURATION 12 HOURS CREDITS: 1.2

OUTCOMES
8.5.1 Use fundamental Using fundamental electrical test equipment fundamental electrical test equipment used
electrical test  Voltmeter correctly
equipment o Testing for voltage
 Ammeter
o Testing for current
 Ohmmeter
o Testing for resistance
8.5.2 Use specialised Using specialised electrical test equipment Specialised electrical test equipment used
electrical test  Transformer correctly
equipment o To step up and step down Voltage
 Tune up tester set
o Timing the engine
 Tachometer
o For Rev counter
 Oscillator
 For engine tune up
 Multimeter
UNIT B8.6: DIFFERENTIATING PRIMARY AND SECONDARY BATTERIES UNIT DURATION 12 HOURS CREDITS: 1.2
67
OUTCOMES
8.6.1 Identify types of Identifying types of batteries Types of batteries identified correctly
batteries  Primary
 Secondary
 Dry batteries
 Wet batteries
8.6.2 Analyse the Analysing the construction of the battery Construction of batteries analysed
construction of  Battery Element correctly
the battery  Container
 Battery Electrolyte
 Terminal posts
8.6.3 Analyse the Analysing the operation of the battery Operation of batteries analysed
operation of the  Chemical reaction correctly
battery  Electrolysis
 Charging
 Discharge
8.6.4 State methods of Stating methods of charging batteries Types of charging of batteries
charging batteries  Fast charge differentiated correctly
o Constant voltage charge
 Slow charge
o Constant current charge
 Trickle charge
 Boost charge
8.6.5 Carry out Battery Carrying out Battery Testing Battery Testing carried out correctly
Testing  Safety precautions
 Battery testing
 Battery tools and equipment
 Battery faults
68
8.6.6. Apply the ampere Applying the ampere hour rating Ampere hour rating applied correctly
hour rating  Battery capacity
 AH=AxH
 Factors of battery capacitance
8.6.7 Apply cold Applying cold cranking rating Cold cranking rating
cranking rating  Temperature applied correctly
 Starting period
 Starting current
8.6.8 Apply reserve Applying reserve capacity rating Reserve capacity rating applied
capacity rating  Discharge period correctly
 Electrical load
 Condition of charging system
UNIT B8.7. DIAGNOSING DIFFERENT ELECTRICAL CIRCUITS UNIT DURATION 12 HOURS CREDITS: 1.2

OUTCOMES
8.7.1. Use different Using different types of symbols Different types of symbols used
types of symbols  Pictorial symbols correctly
 Letter code symbols
 Number code symbols
8.7.2 Interpret different Interpreting different types of circuits Different types of circuits interpreted
types of circuits  Pictorial circuits correctly
 Schematic circuits
8.7.3 Use protective Using protective devices Protective devices used correctly
devices  Fuses
 Circuit breaker
69
 Fusible links
8.7.4 Employ colour Employing colour coding in wiring Colour coding in wiring employed
coding in wiring  Supply line cables correctly
 Earth return cables
 Circuit cables
8.7.5 Construct different Constructing different circuits Different circuit diagrams constructed
circuits  Hazards correctly
 Indicator
 Horn
 Head light
 Brake light
 Reverse light
 Dash board
 Fog light
 Parking light
8.7.6 Test hazard circuit Testing hazard circuit Hazard circuit tested correctly
 Battery
 Fuse
 Bulbs
 Flasher unit
 Switch
8.7.7 Test indicator Testing indicator circuit Indicator circuit tested correctly
circuit  Battery
 Fuse
 Bulbs
 Flasher unit
 Ignition switch
 Indicator switch
70
8.7.8 Test parking light Testing parking light circuit Parking circuit tested correctly
circuit  Battery
 Cables
 Bulbs
 Switch
8.7.9 Test reverse light Testing reverse light circuit Reverse circuit tested correctly
circuit  Battery
 Fuse
 Bulbs
 Switch
8.7.10 Test fog light Testing fog light circuit Fog light circuit tested correctly
circuit  Battery
 Fuse
 Bulbs
 Relay
 Switch
8.7.11 Test brake light Testing brake light circuit Brake circuit tested correctly
circuit  Battery
 Fuse
 Bulbs
 Cables
 Switch
8.7.12. Test headlamp Testing headlamp circuit Headlamp circuit tested correctly
circuit  Battery
 Fuse
 Relay
 Switch
 Dimmer switch
71
 Headlamp
UNIT B8.8: REPAIRING FAULTS AUTOMOTIVE ELECTRICAL COMPONENTS UNIT DURATION 12 HOURS CREDITS: 1.2

OUTCOMES
8.8.1 Explain the Explaining the construction and operation principles of Automotive Starter motor tested correctly
construction and electrical components
operation principles of  Starter motor
Automotive electrical  Alternator
components  Wiper motor
 Distributor
8.8.2 Test starter motor Testing starter motor Starter motor tested correctly
 Without load test
 Under load test
 Solenoid test
8.8.3 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
Repairing procedure
Testing procedures;
o Solenoid
o Armature
o York
72
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
8.8.3 Test alternator Testing alternator Alternator tested correctly
 Full fielding
 Voltage output
8.8.4 Repair Alternator Repairing Alternator Alternator repaired correctly

 Components
o Stator winding
o Rotor winding
o Diode pack
o End Brackets
o Alternator fan
o Pulley
 Dismantling procedure
 Testing procedure
o Stator winding
o Rotor winding
o Diode pack
73
 Diagnosis of Alternator
o Tear and wear
o Open circuit
o Insulation
o Grounding
o Faulty rectifier park
8.8.5 Repair Voltage Repairing Voltage regulator Regulator repaired correctly
regulator  Components
o Bobbin winding
o Resistor
o Contacts
 Diagnosis of the regulator
 Assembling
8.8.6. Test wiper motor Testing wiper motor Wiper motor tested
 Resistance test correctly
 Continuity test
8.8.7 Test distributor Testing distributor Distributor tested correctly

 Resistance test
74
8.8.8 Repair Distributor

Repairing Distributor Distributor repaired correctly
 Components
o Ignition Coil
o Igniter
o Signal generator
o Distributor cap
o Igniter
o Ignition Coil
 Diagnosis of Distributor
o Resistance
o Wear on the rotor
o Assembling procedure
UNIT B8.9 REPAIRING ELECTRICAL ACCESSORIES AND INSTRUMENTS UNIT DURATION 12 HOURS CREDITS: 1.2

OUTCOMES
8.9.1 Repair wiper Repairing wiper motor Wipers repaired correctly
motor  Components
o Brush assembly
o Motor
o Gear box peg
o Circuitry
 Testing components
8.9.2 Repair horn Repairing horn Horn repaired correctly
 Components
75
o Contacts
o Coil
o Core
o Diaphragm
o Armature
o Housing
o Tone disc
 Dismantling
 Testing components
 Assembling
8.9.3 Repair flasher Repairing flasher unit Flasher unit repaired correctly
unit  Types
o Electronic
o Thermal
o Vane wire
 Testing
8.9.4.Repair power Repairing power window Power window repaired correctly
window  Components
o Motor
o Switches
o Circuitry
 Dismantling
 Testing
 Assembly
8.9.5. Replace Replacing headlamps Headlamps replaced correctly
headlamps  Types
o Sealed
o Semi sealed
76
 Installation
 Testing
 Alignment
UNIT B 8:10 REPAIRING ELECTRICAL INSTRUMENTS UNIT DURATION 12 HOURS CREDITS: 1.2

OUTCOMES
8.10.1 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
8.10.2 Repair engine Repairing engine heaters Engine heaters repaired correctly
heaters  Components
o Pre-timer
o Heater plugs
o Relay
 Dismantling
 Testing
 Assembly
8.10.3 Diagnose Diagnosing starting system Starting system diagnosed correctly
starting system  Lay-out
o Battery
o Starter switch
77
o Cables
o Starter motor
 Testing
 Diagnosis
8.10.4. 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
8.10.5 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
 Testing
 Diagnosis
78
8.10.6 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
UNIT: 8.11 REPAIRING AUTOMOTIVE AIR CONDITIONING SYSTEM UNIT DURATION 12 HOURS CREDITS: 1.2

OUTCOMES
8.11.1.Identify Identifying components of Air conditioning system Air condition system components
components of Air  Components: correctly 8identified.
conditioning system o Compressor
o Condenser
o Receiver
o Expansion valve
o Evaporator
8.11.2.Outline the Outlining the function of each of the air conditioning system
function of each of the components Air conditioning components functions
air conditioning system  Compressor correctly outlined.
components  Condenser
 Receiver/Drier
79
 Expansion valve
 Evaporator
8.11.3. 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.
8.11.3.Explain Explaining operation of air conditioning system

operation of air  Operating principles Operation of air conditioning system
conditioning system correctly explained.
8.11.4.Service air Servicing air conditioning system Air conditioning system correctly
conditioning system  Servicing the system serviced.
8.11.5.Diagnose air Diagnosing air conditioning system faults Air conditioning system faults correctly
conditioning system  Fault finding diagnosed.
faults  Test procedures
 Symptoms
 Faults
8.11.6. Repair Air Repairing Air conditioning system faults. Air conditioning system faults correctly
conditioning system  Repair system faults repaired.
faults.  Replace unserviceable parts.
REFERENCES

80

81
MODULE 166-9-A BRAKING SYSTEMS
MODULE PURPOSE: To equip the trainee with knowledge, skills and MODULE DURATION: 160 CREDITS: 16
appropriate attitudes to effectively and efficiently repair and service Hrs.
motor vehicle brake systems
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
o Practical
Learning conditions
The trainee must have access to:
 Books
 Library
 Internet
 Lecture notes
 Automotive mechanics workshop
 Running vehicle
UNIT A9.1 IDENTIFYING BRAKE SYSTEMS UNIT DURATION 40 HOURS CREDITS: 4
82

OUTCOMES
9.1.1.Describe 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
9.1.2Identify 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
9.1.3Identify 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
o Properties
o Grades
9.1.4Identify components Identifying components of pneumatic Components of pneumatic brakes identified correctly
of pneumatic brakes brakes
83
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
9.1.5. Explain types of Explaining types of brakes Types of brakes explained correctly
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
 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
UNIT A9.2 DISASSEMBLING AND ASSEMBLING BRAKE SYSTEM COMPONENTS UNIT DURATION 40 HOURS
84
CREDITS: 4

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
 Arranging the detached units in the
85
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
UNIT A9.3. DIAGNOSING BRAKE SYSTEM FAULTS UNIT DURATION 40 HOURS CREDITS: 4

OUTCOMES
9.3.1.Apply 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
86
obtained
UNIT A9.3. RECTIFYING BRAKE SYSTEM FAULTS UNIT DURATION 40 HOURS CREDITS: 4

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
87
installation procedure of components

components  Cleaning components to be installed
 Cleaning component’s installation area
 Install the component and mount the
fastening devices
REFERENCES
88
MODULE 166-10-B APPLIED MECHANICS
MODULE DURATION HOURS: 80 CREDITS 8

MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate attitudes to apply principles of mechanics of
machines effectively and efficiently.
1. Analyse kinetics of machine elements
2. Analyse types of friction and lubrication
3. Analyse balancing of machines
4. Analyse simple harmonic motion
5. Analyse vibrations on rotating machines
Assessment Methods:
 Assignments
 Practical
 Class exercises
 Tests
 Books
 Modules
 Library
 Internet
 Handouts
 Workshop
 Laboratory
UNIT B10.1 ANALYSING KINETICS OF MACHINE ELEMENTS UNIT DURATION 16 HOURS CREDITS: 1.6
89
SPECIFIC LEARNING ACTIVITIES ASSESSMENT CRITERIA

LEARNING
OUTCOMES
10.1.1.Compute Computing inertia forces Inertia forces computed correctly
inertia forces  Newton’s Laws of motion
 Forces opposing vehicle motion
o Rolling resistance
o Air resistance
o Gradient resistance
10.1.2.Analyse Analysing work, energy and power Work, energy and power analysed correctly
work, energy and  Work
power  Energy
o Potential
o Kinetic
o Strain
 Principle of conservation of energy
 Power
o Calculate efficiency
10.1.3.Analyse Analysing engine fluctuation energy and speed engine fluctuation energy and speed determined
engine fluctuation o Fluctuation of energy correctly
energy and speed o Fluctuation of speed
 Draw turning moment diagrams
10.1.4.Solve Solving problems related to crank and Problems related to crank and connecting rod
problems related to connecting rod mechanism mechanism solved correctly
crank and  Relative velocity
connecting rod  Absolute velocity
mechanism  Rotation of link
 Angular velocity of link
 Draw Velocity diagrams
90
o Velocity of point on a link

10.1.5.Compute Computing piston loads and speeds piston loads and speeds computed correctly
piston loads and  Piston loading
speeds  Speed of the piston
10.1.6.Illustrate Illustrating functions of the governor and fly functions of the governor and fly wheel illustrated
functions of the wheel correctly
governor and fly  Functions of the flywheel
wheel  Functions of the governor
Calculate flywheel
o Coefficient of fluctuation of speed
o Energy stored
o Angular acceleration
o Turning moment diagrams
Analyse governor
UNIT B10.2 ANALYSING TYPES OF FRICTION AND LUBRICATION UNIT DURATION 16 HOURS CREDITS: 1.6

LEARNING
OUTCOMES
10.2.1.Analyse Analyzing friction friction analysed correctly
friction  Explain causes of friction
 Calculate friction on an inclined plane
o Wedges
 Analyse square screw threads
o Raising the load
91
o Lowering the load

o Overhauling of the screw
10.2.2.Analyse Analysing lubricants lubricants analysed correctly
lubricants  Calculate friction torque in journal
bearings
o Friction in journal bearing
o Power lost through friction
 Need for lubricants
Solid lubricants
o Graphite
Liquid lubricants
o Oils
o Grease
UNIT B10.3 ANALYSING BALANCING OF MACHINES UNIT DURATION 16 HOURS CREDITS: 1.6

LEARNING
OUTCOMES
10.3.1Compute out  Computing out balance of forces; out of balance forces computed correctly
of balance forces o Dynamic
o Static
 Identifying Rotating masses
 Calculating centrifugal force
10.3.2.Analyse  Analysing static balancing types of balancing analysed correctly

types of balancing o Two masses in one plane
o Several masses in one plane
 Analysing dynamic balancing
92
o Two masses in a plane

o Several masses in one plane
10.3.3.Analyse Analysing vehicle balancing vehicle balancing analysed correctly

vehicle balancing  Stability of vehicle on circular path
o Tendency to skid
o Tendency to overturn
o Banking of roads and racing tracks
UNIT B10.4 ANALYSING SIMPLE HARMONIC MOTION UNIT DURATION 16 HOURS CREDITS: 1.6

LEARNING
OUTCOMES
10.4.1.Analyze Analysing simple harmonic motion simple harmonic motion analysed correctly
simple harmonic o simple harmonic motion
motion o Periodic time
o Amplitude
o Frequency
 Derive equations of simple harmonic

motion
 Analyse s.h.m for maximum velocity and
acceleration:
o Crank piston mechanism
o Mass-spring
o Pendulum
 Simple
 Conical
93
 Explain resonance
UNIT B10.5 ANALYSING VIBRATIONS ON ROTATING MACHINES UNIT DURATION 16 HOURS CREDITS: 1.6

LEARNING
OUTCOMES
10.5.1.Analyze free Analysing free and forced vibrations free and forced vibrations analysed correctly
and forced  Define
vibrations o Free vibrations
o Forced vibrations
 Types of vibrations
o Free or natural
 Longitudinal
 Transverse
 Torsional
o Forced
o Damped
 Analyse Free vibrations
o Equilibrium method
o Energy method
o Raleigh’s method
10.5.2.Analyze Analysing damping vibrations damping of vibrations analysed correctly
damping of  Using oil
vibrations  Using springs
 Analyse frequency of free damped
vibrations
o Overdamping
o Underdamping
o Critical damping
 Calculate damping factor
94
10.5.3.Explain Explaining effects of vibrations on machines Effects of vibrations on machines explained correctly
effects of vibrations  Wear and tear of machines
on machines  Mechanical looseness
REFERENCES
Bolton, W. (1990). Engineering Science. 6th ed. London: Routledge
Edward, H. (1994). Engineering Science. 4th ed. London: Pearson Education.
Hannah, J.H. (1995). Applied Mechanics. 3rd ed. England: Addison Wesley Longman, 1995.
Titcomb, G.R.A. (1988). Fundamentals of Engineering Science. 12th ed. London: Stanley Thornes Ltd.
Walker, J.D. (1979). Applied Mechanics. 11th ed. London: Hodder & Stoughton.
Zammit, S.J. (1987). Motor Vehicle Engineering Science for Technicians. England: Pearson Education.
95
MODULE 166-11- B ENGINEERING MATHEMATICS II

MODULE PURPOSE: To equip the trainee with knowledge, skills, and appropriate attitudes to apply engineering
mathematics in heavy equipment engineering effectively and efficiently.
NOMINAL DURATION: 80 HOURS CREDITS: 8

LEARNING OUTCOMES:
On completion of this module, the trainee will be able to:
1. Carry out differentiation
2. Carry out integration
3. Apply Boolean algebra
4. Manipulate complex numbers
5. Calculate properties of a circle
6. Solve statistics and probability
Assessment Methods:
 Assignments
 Practical
 Class exercises
 Tests

 Library
 Internet
 Handouts
96
UNIT B11.1: CARRYING OUT DIFFERENTIATION UNIT DURATION: 15 HRS CREDITS: 1.5

OUTCOME
11.1.1 Differentiate from Differentiating from first principles First principles differentiated correctly
first principles
11.1.2.Differentiate linear Differentiating linear functions Linear functions differentiated correctly

functions  Differentiating polynomials
11,1,3. Differentiate Differentiating trigonometric functions Trigonometric functions differentiated
trigonometric functions  Sine function correctly
 Cosine function
 Exponential functions
 Logarithmic functions
 Composite function
 Product rule
 Chain rule
 Quotient rule
11.1.4.Apply Applying differentiation Differentiation applied correctly
differentiation  Partial differentiation
 Small changes
 Rates of change
97
UNIT B11.2: CARRYING OUT INTEGRATION UNIT DURATION: 14 HRS CREDITS: 1.4

OUTCOME
11.2.1.Reverse Reversing differentiation Differentiation reversed correctly
differentiation  Integrating by rule and apply the constant of
integration
11.2.2.Integrate Integrating functions Functions integrated correctly
functions  Trigonometric functions
 Exponential functions
 Definite integrals
 Integrating Composite functions
 Integrating by parts
11.2.3.Apply integration Applying integration Integration applied correctly
 Velocity
 Acceleration
 Area under curve
 Area between two curves
UNIT B11.3: APPLYING BOOLEAN ALGEBRA UNIT DURATION: 16 HRS CREDITS: 1.6

OUTCOME
11.3.1.Manipulate Manipulating convention and Boolean algebra Convention and Boolean algebra
convention and Boolean  Truth or false of a given preposition or manipulated
variable
98
algebra
11.3.2.Use defined Using defined symbols Defined symbols used correctly

symbols  OR gates
 AND gates
 NOR gates
 NOT gates
11.3.3.Apply laws of Applying laws of Boolean algebra Laws of Boolean algebra applied
Boolean algebra  23 laws of Boolean correctly
 De-Morgan’s theorem
11.3.4.Use Venn Using Venn diagrams Venn Diagrams used correctly
Diagrams  Using Venn diagrams to simplify Boolean
expressions and statements
11.3.5.Simplify Boolean Simplifying Boolean expressions and statements Boolean expressions and statements
expressions and  Karnaugh maps simplified correctly
statements  Truth tables
UNIT B11.4: MANIPULATING COMPLEX NUMBERS UNIT DURATION: 15 HRS CREDITS: 1.5

OUTCOME
11.4.1Apply the J Applying the J operator The J operator applied correctly
operator  Definition of complex numbers as of the form
 Add complex numbers
99
 Subtract complex numbers

 Find conjugate of complex numbers in
Cartesian form
 Representation of complex numbers on an
Argand diagram
11.4.2.Calculate Calculating modulus and argument Modulus and argument calculated
modulus and argument  Convert from rectangular to polar form correctly
 Des theorem
11.4.3.Use remainder Using remainder and factor theorem Remainder and factor theorem used
and factor theorem  Applying the remainder and factor theorem to correctly
solve problems
 Roots of polynomial experience
UNIT B11.5: CALCULATING PROPERTIES OF A CIRCLE UNIT DURATION: 10 HRS CREDITS: 1

OUTCOME
11.5.1.Obtain equation Obtaining equation of a circle Equation of a circle obtained correctly
of a circle  Obtain general equation of a circle
11.5.2.Show points of Showing points of intersection Points of intersection shown correctly
intersection  Points of intersection of a line and a circle
11.5.3.Derive the centre Deriving the centre and radius of a circle The centre and radius of a circle
and radius of a circle derived correctly
 General application of the centre of the circle
and radius.
100
UNIT B11.6: SOLVE STATISTICS AND PROBABILITY UNIT DURATION: 10 HRS CREDITS: 1

OUTCOME
11.6.1.Calculate Calculating measures of central tendency for Measures of central tendency for
measures of central grouped data grouped data calculated correctly
tendency for grouped  Mean
data  Median
 Mode
 Binomial theory
 Poisson’s theory
11.6.2.Calculate Calculating measure of dispersion from grouped Measure of dispersion from grouped
measure of dispersion data data calculated correctly
from grouped data  Standard deviation
11.6.3.Apply simple Applying simple probability Simple probability applied correctly
probability  Laws of probability
11.6.4.Apply sampling Applying sampling theory Sampling theory applied correctly
theory  Combination distribution
 Normal distribution
REFERENCES
Dass, H.K. (2006). Advanced Engineering Mathematics. 2nd ed. New Delhi: S. Chand & Company Ltd, 2006.
Dass, H.K. (2006). Engineering Mathematics. 2nd ed. New Delhi: S. Chand & Company Ltd.
John, B. (2014). Engineering Mathematics. 8th ed. London: Routledge.
John, B. (2014). Higher Engineering Mathematics. 8th ed. London: Routledge.
101
Stroud, K.A. (2001). Engineering Mathematics. 6th ed New York: Palgrave.

Stroud, K.A. (2003). Advanced Engineering Mathematics. 4th ed. London: Palgrave/McMillan publishers.
Talbert, J. (2016). Addition Mathematics: Pure & Applied. 24th ed. London: Pearson Education.
102
MODULE 166-12-B STEERING AND SUSPENSION SYSTEM
MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate MODULE CREDITS 9.0
attitudes to effectively and efficiently repair and service steering system DURATION 90
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
 Lecture notes
 Library
 Handouts
 Tutorials
 Internet
103
UNIT 12.1 ANALYSING STEERING SYSTEM UNIT DURATION 8 HOURS CREDITS 0.8
SPECIFIC LEARNING OUTCOMES LEARNING ACTIVITIES ASSESSMENT CRITERIA
12.1.1Analyse Functions of steering  Analysing 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
12.1.2.Identify Components of mechanical  Identifying components of the mechanical steering Components of mechanical
steering system system steering system identified
correctly
o Steering wheel
o Steering column
o Steering box
o Drop arm
o Drag link Functions of components of
o Steering arm mechanical steering
o Track rod analysed correctly
o Stub axle
 Stating functions of components of steering system
12.1.3.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
identifies correctly
o Worm and wheel
o Worm and sector
o Worm and roller
Construction and operation of
o Screw and nut
steering box described
104
o Cam and peg correctly

o Recirculating ball
o Rack and pinion
 Describing construction and operation of steering
boxes
12.1.4 Analyse Collapsible steering  Describing construction of collapsible steering Reason for designing
column column collapsible steering column
discussed correctly
 Analysing reason for collapsible steering column
12.1.5 Analyse Steering joints  Analysing functions of steering joints Functions of steering joints
analysed correctly
 Describing construction of steering joints
12.1.6 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
 Analysing advantages of Four-wheel steering
12.1.7 Analyse Twin steering  Analysing twin steering Twin steering analysed
correctly
12.1.8 Explain Steering Geometry  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
105
12.1.9 Analyse Ackerman Layout  Analysing beam axle steering and Ackerman layout
Ackerman layout analysed
 Analysing Ackerman layout correctly
o Toe-out –on turns
12.1.10 Analyse Power Assisted Steering Analysing Power Assisted Steering;
 functions of power assisted steering Factors necessitating for
power assisted steering
 Justifying factors necessitating for power assisted
justified correctly
steering
 Analysing requirements of power assisted steering Requirements of power
assisted steering analysed
 Identifying types of power assisted steering correctly
o Hydraulic
o Electric
o Pneumatic
12.1.11 Describe Components of Describing components of hydraulic power assisted steering Operation of components of
Hydraulic 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
 Analysing merits of using hydraulic
106
12.1.12 Compare Configurations of Comparing Configurations of hydraulic power assisted Configurations of hydraulic
hydraulic power assisted steering steering; power assisted steering
compared correctly
o Integral
o Semi integral
o linkage
12.1.13 Explain Electric power assisted  Comparing 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
12.1.14 Analyse Pneumatic Power  Identifying Component of system Pneumatic Power Assisted
Assisted Steering Steering analysed correctly
o Compressor
o Control valve
o Ram cylinder
o Piston
o pipes
 Describing functions of components of pneumatic
107
12.1.15 Explain Full Power Steering  Explaining components of full power steering Full power steering explained
correctly
o Control valve
o Pistons
o Cylinders
o Hydraulic pipes
 Explaining functions of components of full power
steering
13.1.16 Describe Front Hub Assembly Describing front hub Assembly Construction of front hub
assemblies described
 Describing types of front hub assemblies correctly
o Non-driving
o Driving
 Describing construction of front hub assemblies
12.1.17 Justify Wheel Alignment  Justifying the importance of wheel alignment Wheel alignment justified
correctly
 Identifying Factors affecting true rolling motion
o Toe-out
o Toe-in
o Camber
o Castor
108
 Performing wheel alignment
13.1.18 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
12.1.19 Service the Power assisted Servicing the power assisted steering system Power assisted steering
steering system service correctly
 electric circuit components
 Servicing the hydraulic steering system
UNIT B12.2 IDENTIFYING SUSPENSION SYSTEMS UNIT DURATION 8 HOURS CREDITS 0.8
12.2.1.Explain types of suspension  Explaining purposes and requirements of the suspension Types of suspension
systems system systems identified correctly
 Defining suspension system terminologies
 Types of suspension systems
o Independent suspension system
o Dependent suspension system
12.2.2.Identify components of the Identifying Types of springs components of the
suspension system o Steel springs suspension system identified
o Rubber springs correctly
o Air springs
 Shackles
o Fixed shackles
109
o Swinging shackle
 Oscillation dampers (Shock absorbers)
 Suspension arms
 Ball joints
 Stabilizers
 Wishbone arm upper and lower
 Trailing link front and rear
 Stabilizer bars
 Rods
 Axles
o Beam axle
o Split/cross
o Carrier
12.2.3.Identify pneumatic suspension Identifying pneumatic suspension system ; Pneumatic suspension
system  Air supply system system identified correctly
 Air suspension spring assembly
 Electronically controlled suspension circuit
12.2.4.Identify rubber suspension Identifying ; Rubber assembly identified
assembly  Rubber load cushion spring correctly
 Rubber shear spring
12.2.5.Identify the components of the body Identifying the components of the body and chassis layout Body and chassis layout
and chassis layout design correctly identified
o Integral chassis
o Separate body chassis
 Cab ergonomics
 Frames
 Fifth wheels
110
12.2.6.Identify forces acting on the frame Identifying forces acting on the frame; Forces acting on frames
 Torsional forces correctly identified
 Axial and lateral forces
UNIT B12.3 CARRYING OUT DISASSEMBLING AND ASSEMBLING SUSPENSION SYSTEM COMPONENTS
UNIT DURATION 8 HOURS CREDITS 0.8
12.3.1.Use disassembling and assembling  Using Tools Assembling and

tools and equipment  Using equipment disassembling tools and
o Lifting equipment equipment used correctly
 Mechanical jack
 Hydraulic jack
o Solid support stands
o Pullers
12.3.2.Carry out disassembly procedures Carrying out disassembling procedures of; Disassembly procedures
 loosening mounting devices carried out correctly
 Removing individual units of the components
 Arranging the individual component in the order of
disassembly
12.3.3.Carry out assembly procedures Carry out assembly procedures; Assembly procedures carried
 Cleaning components out correctly
 Mounting the disassembled units onto the components
 Tightening units to specified torque rating
12.3.4.Carry out Installation procedures Carrying ou Installation procedures of components Installation procedures
o Cleaning the fitting area carried out correctly
111
o Mounting the component

o Tightening components to specified torque rating
UNIT B12.4 RECTIFYING SUSPENSION SYSTEM FAULTS UNIT DURATION 8 HOURS CREDITS 0.8
12.4.1 Apply safety procedures Applying correct PPE Safety procedures applied
 Using correct lifting equipment correctly
 Using correct choking and supporting appliances
 Identifying welding and drilling warning signs
12.4.2 Diagnose motor vehicle suspension  Diagnosing mechanical faults Motor vehicle suspensions
system faults o Removing worn out components system faults diagnosed
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
12.4.3 Repair faults in suspension system Repairing mechanical faults Faults in suspension system
o Servicing mechanical components repaired correctly
o Replacing non-serviceable mechanical
components
 Repairing Electrical faults
o Servicing actuators
112
o Replacing non-serviceable actuators

 Diagnosing Electronic faults
 Replacing faulty sensors
UNIT B12.5 IDENTIFYING FUNCTIONS OF WHEELS AND TYRES UNIT DURATION 8 HOURS CREDITS 0.8
12.5.1 State functions of wheels and tyres 

Stating functions: Functions of wheels and
o Wheels tyres stated correctly
o Tyres
 Identifying Types:
o Wheels
o tyres
12.5.2 Explain constructions of wheels and  Explaining construction Wheels and tyres correctly
tyres o Wheels identified
o Tyres
 Interpreting tyre markings
o Tyre sizes
o Tyre ratings
UNIT B12.6 DISASSEMBLING AND ASSEMBLING WHEELS AND TYRES UNIT DURATION 8 HOURS CREDITS
0.8
12.6.1 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
 Applying tyre deflating and inflating procedures
113
 Using correct Tools and equipment

12.6.2 Change wheels Changing wheels; Wheel correctly changed
 Observing safety
 Jacking and supporting procedure
 Removing procedure
 Installing procedure
 Untightening and torqueing procedure
 Disassembling procedure
UNIT B12.7 MAINTAINING WHEELS AND TYRES UNIT DURATION 8 HOURS CREDITS 0.8
12.7.1 Maintain a wheel assembly Maintaining a wheel assembly; Wheel correctly maintained
 Observing safety procedures
 Applying inspection procedures
 Applying tyre mending procedures
o Tubed
o tubeless
 Performing wheel balancing
 Perfoming wheel rotation
UNIT B12.8 DIAGNOSING WHEELS AND TYRE FAILURES
UNIT DURATION 8 HOURS CREDITS 0.8
12.8.1 Rectify tyre failures Rectifying tyre failures ; Tyre failures correctly
 Applying trouble shooting techniques diagnosed
114
 Analysing tyre inflating pressures and overloading

problems
 Analysing tyre wear and failures
REFERENCES

115
MODULE 166-13-B AUTOMOTIVE ELECTRONICS
MODULE PURPOSE: To equip the trainee with knowledge, skills MODULE DURATION: CREDITS: 12 Credit Hours
and appropriate attitudes required to effectively and efficiently 120 Hours
diagnose, repair and maintain vehicle electronic systems
1. Differentiate conductors
2. Identify electronic circuits
3. Identify semiconductors
4. Test semiconductors components
5. Construct semiconductor circuits
6. Use different types of switches
7. Describe electronic fuel control system
8. Repair electronic systems
9. Diagnose fault in electronic system
UNIT B13.1: DIFFERENTIATING CONDUCTORS UNIT DURATION: 13 HOURS CREDITS: 1.3

OUTCOMES
13.1.1 Identify types of Identifying types of conductors Types of conductor identified correctly
conductors o Characteristics
 Free electron flow
o Examples
 Copper
 Silver
 Aluminium
 Semiconductors
o Characteristics
116
 Electrical resistance than a conductor

 Electrical current production
 Bonding of electrons to atomic ‘home’
o Examples
 Silicon
 Germanium
 Non- conductors
o Characteristics
 Electron flow
 Electrons bound
o Example
 Plastic
 Rubber
 Wood
13.1.2 Identify types of Identifying types of materials Material types identified correctly
materials  P-type materials
o Boron or indium to be doped to either pure silicon
or Germanium to produce p- type
 N-type materials
o Arsenic to be doped to either Silicon or Germanium
to produce N- type semiconductor
13.1.3 Identify atomic Identifying atomic structure of different Atomic structure of different identified
structure of  Conductors correctly
different o Type of Electron bonds
conductors o Number of electrons
 Semi-Conductors
o Type of Electron bonds
o Number of electrons
 Non-Conductors
117
o Trunk Atom
UNIT B13.2: USING ELECTRONIC SYMBOLS UNIT DURATION: 13 HOURS CREDITS: 1.3

OUTCOMES
13.2.1 Identify Identifying electronic symbols Basic circuits constructed correctly
electronic  Diodes
symbols  Transistors
 Resistor
 Thermistors
 Capacitors
 Thyristors
13.2.2 Apply electronic Applying electronic symbols Electronic symbols applied correctly
symbols  Creating circuit diagrams
 Series circuit
 Parallel
 Series-parallel
UNIT B13.2: IDENTIFYING ELECTRONIC CIRCUITS UNIT DURATION: 13 HOURS CREDITS: 1.3

OUTCOMES
13.2.1 Identify types of Identifying types of circuits Basic circuits constructed correctly
circuits  Analog
 Digital
118
13.2.2 Construct logic Constructing logic circuits Logic circuits constructed correctly
circuits  AND gates
 OR gates
 NAND gates
 NOT gates
 NOR gate
UNIT B13.3: IDENTIFYING SEMICONDUCTORS UNIT DURATION: 13 HOURS CREDITS: 1.3

OUTCOMES
13.1 Identify diodes Identifying diodes Diodes identified correctly
 Diodes
o Colour code
o Characteristics
 Zener diode
o Colour code
o Characteristics
 Photo diode
o Construction
o Characteristics
 Light emitting diode
o Construction
o Characteristics
13.3.2 Identify Identifying transistors Transistors identified correctly
transistors  Bipolar
o Classification
119
 NPN
 PNP
 Photo
o Construction
o Characteristics
 Unipolar
o Field effect transistor
o Construction
o Characteristics
13.3.3 Identify Identifying Capacitors Capacitors identified correctly
Capacitors  Construction
o Cylindrical type
o Flat type
 Characteristics
o Chargeable
o Dischargeable
13.3.4 Identify Identifying thermistors Thermistor identified correctly
thermistors  Construction
 Characteristics
o Negative temperature coefficient
o Positive temperature coefficient
 Piezo element
o Characteristics
13.3.5 Identify resistors Identifying resistors Resistors identified correctly
 Color code
 Characteristics
 Variable resistor
o Characteristics
13.3.6 Identify photo Identifying photo conducting cell Photo conducting cell identified correctly
conducting cell  Characteristics
120
UNIT B13.4: TESTING SEMICONDUCTOR COMPONENTS UNIT DURATION: 13 HOURS CREDITS: 1.3

OUTCOMES
13.4.1 Carry out tests Carrying out tests on Diodes Tests on diode carried out correctly
on Diodes o Using of analogue meter
o Forward bias test
o Reverse bias test
 Connections
13.4.2 Carry out test Carrying out test on Bipolar Junction Transistors (BJT) Tests on transistor carried out correctly
on Bipolar  Test NPN transistor
Junction o Using Ohmmeter
Transistors (BJT) o Types of connections
o Interpreting level resistance
 Low
 High
 Test PNP transistor
o Using Ohmmeter
o Types of connections
 Low
 High
13.4.3 Carry out tests Carrying out tests on Capacitors Tests on capacitors carried out correctly
on Capacitors  Test procedure
o Using ohmmeter
o Connection types
o Meter reading
o Charging of capacitor
121
o Discharging of capacitor
13.4.4 Carry out tests Carrying out tests on Resistors Tests on resistor carried out correctly
on Resistors  Follow procedure
o Using ohmmeter
o Connection types
o Specifications or colour band value
13.4.5 Carry out tests Carrying out tests on Thermisters Tests on thermistors carried out correctly
on Thermisters  Positive Temperature coefficient ( PTC)
o Using Ohmmeter
 Low
 High
 Negative Temperature Co-efficient ( NTC)
o Using Ohmmeter
 Low
 High
13.4.6 Carry out tests Carrying out tests on Thyristors Tests on thyristors carried out correctly
on Thyristors  Use ohmmeter
 Connections
o Anode
o Cathode
 Supply of current
 Interpreting meter reading
13.4.7 Carry out tests Carrying out tests on Sensors Tests on sensors carried out correctly
on Sensors  Using ohmmeter
 Connections
122
 Interpreting value
13.4.8 Carry out tests Carrying out tests on Integrated circuit Tests on Integrated circuit carried out
on Integrated  Integrated Circuits (ICs) correctly
circuit o Specification
UNIT B13.5: CONSTRUCTING SEMICONDUCTOR CIRCUITS ON BOARDS UNIT DURATION: 13 HOURS CREDITS: 1.3

OUTCOMES
13.5.1 Construct Constructing circuits using diodes Circuit board using diodes constructed
circuits using  Procedure correctly
diodes o Identify the polarity of the diode
o Connect the diode according to its Characteristics
o Forward bias
o Reverse bias
o Connecting from the source in put terminal
o Connecting to the appliance output
13.5.2 Construct circuits Constructing circuits using transistors Circuit board using transistors constructed
using transistors  Identify symbols correctly
 C -collector
 B- Base
 E –emitter
o Connections
13.5.3 Construct circuits Constructing circuits using capacitors Circuit board using capacitors constructed
using capacitors  Identify types of capacitors correctly
o Value specification
o Connections
 Input
 Output
123
13.5.4 Construct Constructing circuits using resistors Circuit board using resistors constructed
circuits using  Identify types of resistors correctly
resistors o Fixed
o Variable
o Values
o Colour codes
o Connections
 Input
 Output
13.5.5 Construct Constructing circuits using thermistor Circuit board using thermistors constructed
circuits using  Identify types of thermistors correctly
thermistor  PTC
 NTC
 Connections
 Input
 Output
13.5.6 Construct circuits Constructing circuits using thyristors Circuit board using thyristors constructed
using thyristors  Identify terminals correctly
o Connections
o Supply line
o Gate line
o Cathode line
o Grounding of appliance
13.5.7 Construct Constructing circuits using sensors Circuit board using sensors constructed
circuits using  Identify types of sensors correctly
sensors o Connections
 Positive
 Negative
13.5.8 Construct circuits Constructing circuits using transistors Circuit board using transistors Constructed
using transistors  Connecting circuits correctly
o Voltage
124
o Battery ground
o Outputs
o Inputs
UNIT B13.6: USING DIFFERENT TYPES OF SWITCHES UNIT DURATION: 13 HOURS CREDITS: 1.3

OUTCOMES
13.6.1 Use Integrated Using Integrated switches Integrated switches used correctly
switches  Electronic Fuel Control Unit ( ECU
 Integrated Circuits ( IC)
o 14 pin
o 21 pin
o 7 pin
 Observing polarity
13.6.2 Use Transistorised Using Transistorised switches Transistorised switches used
switches  Using transistors correctly
 Using thyristors
 Using diodes
 Observing polarity
UNIT B13.7: DESCRIBING ELECTRONIC FUEL CONTROL UNIT DURATION: 13 HOURS CREDITS: 1.3

OUTCOMES
13.7.1 Describe process of Describing process of Electronic Fuel Injection(EFI) in petrol Process of EFI in petrol engines
Electronic Fuel engines described correctly
Injection(EFI) in petrol  Petrol
engines  Combustion
o Spark ignition engine
 Factors affecting combustion
125
o Design of combustion chamber
13.7.2 Describe process of Describing process of Electronic Fuel Injection(EFI) in diesel Process of EFI in diesel engines
Electronic Fuel engines described correctly
Injection(EFI) in diesel  Common rail
engines o Design
 Components
o Common pressure accumulator (the ‘Rail’).
o High pressure regulator.
o High pressure supply pump.
o Injectors.
o Electronic solenoids.
o Electronic Control Unit.
o Filter unit.
13.7.3 Identify components Identifying components of EFI Components of EFI identified
of EFI  Fuel injectors correctly
 Injector resistor
 Fuel pump
 Fuel pressure regulator
 Cold start injector and thermo time switch
 Combination relay
 Electronic control unit
 Lambda sensor
 Actuator
13.7.4 Identify differences Identifying differences between carburettor and EFI Differences between carburetor and
between carburettor  Carburetor EFI identified correctly
and EFI  Electronic control of carburetor
 Advantages of EFI
126
UNIT B13.8: REPAIRING ELECTRONIC SYSTEMS UNIT DURATION: 13 HOURS CREDITS: 1.3

OUTCOMES
13.8.1 Repair Ant-Locking Repairing Anti-Locking Braking System (ABS) Ant-Locking Braking System system
Braking System (ABS)  Components repaired correctly
o Wheel speed sensor
 Resistance test
 Replacement
o Electronic controller
 Output voltage
 Specification
 Replacement
o Hydraulic modulation
o Voltage input
o Voltage output
o Specification
o Replacement
13.8.2. Repair Repairing Electronic fuel system Electronic fuel system repaired
Electronic fuel system  Components correctly
 Sensor
o Resistance test
o Continuity test
 Electronic Computer Unit
o Visual inspection
o Input voltage
o output voltage
o Replacement
 Actuators
o Resistance test
127
o Continuity test
o Replacement
13.8.3 Repair cruise control
Repairing cruise control system Cruise control system repaired
system  Components correctly
o Driver command switch
o Continuity test
o Replacement
 Brake switch
o Continuity test
o Replacement
 Clutch switch
o Continuity test
o Replacement
 Control unit
o terminal input voltage
o terminal output voltage
o Replacement
 Speed sensor
o Resistance test
o Replacement
 Actuator
o Resistance test
o Replacement
UNIT B13.9: DIAGNOSING FAULT IN ELECTRONIC SYSTEM UNIT DURATION: 13 HOURS CREDITS: 1.3

OUTCOMES
13.9.1 Apply testing Applying testing procedures Testing procedure adhered to
procedures  Anti- Lock Braking Electronic computer unit correctly
128
o Visual inspection
o Continuity
o Resistance
 Electronic sensors
o Continuity
o Resistance
 Actuators
o Continuity
o Resistance
 Electronic Fuel system
o Visual inspection
o Continuity
o Resistance
 Cruise control system
o Components
o Micro processor
 Sensors
o Actuators
o Switches
o Visual inspection
o Continuity
o Resistance
13.9.2 Use multimeters and Using multimeters and scanners Multimeters and scanners used
scanners  Measuring resistance correctly
 Measuring voltage
 Measuring signal frequency
 Measuring temperature measurement
 Measuring current
 Measuring revs per minute (RPM)
129
13.9.3 Record fault codes in Recording fault codes in the electronic system Faults in electronic system recorded
the electronic system  Using specifications on systems correctly
13.9.4 Rectify faults in the Rectifying faults in the electronic system Faults in electronic system rectified
electronic system  Replacing procedures correctly
REFERENCE
Scott, A.H. (2015). Heavy Duty Equipment Technology: A Systems Approach (Automotive Diesel and Heavy Duty). Pearson
Education.
Sean, B. (2013). Medium/Heavy Duty Truck Engines, Fuel & Computerized Management Systems. 4th Ed. Delmar: Cengage
Learning
130
MODULE 166-14-B ENGINEERING DRAWING II
MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate attitudes required to produce drawings

1. Produce assembly drawings
2. Produce bearing drawings
3. Produce coupling drawings
4. Produce drawings of machine drives
5. Produce drawings of design mechanisms
6. Use 2d and 3d solid cad systems to generate drawings
ASSESSMENT METHODS
 Drawing tutorial
 Assignments
 Tests
 Examinations
LEARNING CONDITIONS
 Drawing room
 Lecture notes
 Library
 Internet
 Handouts
 Tutorials
UNIT B 14.1: PRODUCING ASSEMBLY DRAWINGS UNIT DURATION: 10 HOURS CREDITS: 1.0
131

LEARNING
OUTCOMES
14.1.1 Construct  Constructing individual parts Conventions used correctly
individual o Title block dimensions
parts o Title block information
o Using conventions
o Manipulating units of measurements
14.1.2 Apply  Applying dimensions Dimensions applied correctly
dimensions o Size dimensions
o Location dimensions
o Auxiliary dimensions
14.1.3 Apply cutting Applying cutting planes Cutting planes applied correctly
planes o Illustrate internal features clearly
o Show the shape of internal features
14.1.4 Draw Drawing sectional views; Sectional views drawn correctly
sectional o Show clearly the relative positions of parts forming
views an assembly
14.1.5 Insert parts Inserting parts list Parts list inserted correctly
list o Magnify the required component in an assembly
drawing
14.1.6 Assemble Assembling individual parts Individual parts assembled correctly
individual o Form of component
parts o Full dimensions and tolerances
o Material to be used and its specifications
o Manufacturing process and machining instructions
14.1.7 Prepare parts Preparing parts list Parts list prepared correctly
list o Part number
o Name of description of the material
o The material from which the part is to be made
132
o The quantity required
UNIT B14.2 PRODUCING BEARING DRAWING UNIT DURATION: 10 HOURS CREDITS: 1.0

LEARNING
OUTCOMES
14.2.1 Produce Producing bearing drawings of different types Bearing drawings of different types
bearing  Sections produced correctly
drawings of  Dimensions
different  Conventions
types  Limits
 Fits
14.2.2 Construct Constructing bearing mounting arrangements Bearing mounting arrangements
bearing  Detailed bearing mounting arrangements for constructed correctly
mounting tapered roller and ball bearings
arrangement
s
14.2.3 Apply skills Applying skills on bearings Skills on bearings applied correctly
on bearings  Conventional representation
 Journal bearing
 Thrust bearings
UNIT B14.3: PRODUCING COUPLING DRAWINGS UNIT DURATION: 10 HOURS CREDITS: 1.0

LEARNING
133
OUTCOMES
14.3.1 Analyse Analysing types of coupling Types of couplings analysed correctly

types of  Rigid couplings
couplings  Flexible couplings
14.3.2 Produce Producing coupling drawings Coupling drawings produced correctly

coupling
drawings
14.3.3 Applying Outlining types of couplings Types of couplings applied correctly
pneumatic o Gear couplings
drawing o Chain couplings
standards o Pin couplings
o Tyre coupling
UNIT B 14.4: PRODUCING DRAWINGS OF MACHINE DRIVES UNIT DURATION: 10 HOURS CREDITS: 1.0

LEARNING
OUTCOMES
14.4.1 Outline types Outlining types of machine drives Types of machine drives outlined correctly
of machine  Chain drives
drives o Simplex
o Duplex
o Triplex (sprockets)
 Belt drives
o Flat V-belt
o Toothed (pulleys)
134
14.4.2 Construct Constructing gear Machine drive nomenclature used

gear  Gears correctly
nomenclature o Pitch circle diameter
o Addendum
o Dedendum
o Root
o Diametric pitch
o Crest
14.4.3 Construct Constructing bearing assemblies Machine bearing assembly drawings

bearing  Design procedures constructed correctly
assemblies  Drive assembly
 Bearing arrangement
 Limits
 Fits
UNIT B14.5 PRODUCING DRAWINGS OF DESIGN MECHANISMS UNIT DURATION: 10 HOURS CREDITS:
1.0
LEARNING
OUTCOMES
14.5.1 Construct loci Constructing Loci of mechanisms Loci of mechanisms constructed correctly
of  Reciprocating mechanisms
mechanisms  Ratchet
14.5.2 Sketch Sketching motion of mechanisms Motion of mechanisms sketched correctly
motion of  Rotary cams
mechanisms  Linkages
 Levers
 Clamps
 Geneva mechanism
135
14.5.3 Apply motion Applying motion of mechanisms to actual machine design Motion of mechanisms applied on actual
of  Switches machine design correctly
mechanisms  Toggles
on actual
machine
design
UNIT B14.6 USING 2D SOLID CAD SYSTEMS TO GENERATE A DRAWINGS UNIT DURATION: 10 HOURS
CREDITS: 1.0
LEARNING
OUTCOMES
14.6.1 Use Using Computer Aided Draughting (CAD) Computer Aided Draughting (CAD) used
Computer Aided correctly
Draughting (CAD)
14.6.2 Make Line Making Line drawings Line drawings made correctly
drawings
14.6.3 Carry out 3D Carrying out 3D sketching 3D sketching carried out correctly
sketching
14.6.4 Carry out 3D Carrying out 3D modelling 3D modelling carried out correctly
modeling
14.6.5 Use Using configuration of parts Configuration of parts used correctly
configuration
of parts
14.6.6 Use feature Using feature tree Feature tree used correctly
tree
REFERENCES
Bland, S. (2009). Graded Exercises in Technical Drawing. 6th edn. England: Longman.
136
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.
137
MODULE: 166-15-B ENTREPRENEURSHIP
MODULE PURPOSE: To equip trainees with knowledge, skills and appropriate MODULE DURATION: CREDITS: 11
attitudes to run profitable enterprises efficiently. 100 Hours
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:
 Assignments
 Practical
 Class exercises
 Tests

 Library
 Internet
 Handouts
 Fashion laboratory
138
 Fashion workrooms
UNIT B15.1: USING ENTREPRENEURIAL CONCEPTS DURATION: 10 HOURS 1 CREDIT HOURS

OUTCOMES
15.1.1 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

Intrapreneur
15.1.2 Describe Describing different types of entrepreneurs Types of entrepreneurs correctly
different types of  Pushed and pulled entrepreneurs described
entrepreneurs  enterprise, entrepreneurship and the entrepreneur
15.1.3 Discuss the Discussing the background to emergence of Background to emergence of

back ground to entrepreneurship entrepreneurship well discussed
emergence of  Origin of entrepreneurship
139
entrepreneurship  Motive of entrepreneurship

 Importance of entrepreneurship to national
development
15.1.4 Explain the Explaining the benefits of entrepreneurship Benefits of entrepreneurship correctly
benefits of  Employment and self-employment explained.
entrepreneurship  Benefits of enterprise development
UNIT B15.2: BUILD POSITIVE ATTITUDE TOWARDS ENTREPRENEURSHIP DURATION: 10 HOURS 1 CREDIT
HOURS
OUTCOMES
15.2.1 Develop Developing positive thinking Positive thinking well developed
positive thinking  The mind-set of a positive entrepreneur
 Positive thinking and goal setting
15.2.2 Develop  The psychological preparedness of an entrepreneur Positive ambition well developed
positive ambition
15.2.3 Discuss positive Developing positive ambition Positive outlook well discussed
outlook  The entrepreneurs psychological preparedness
15.2.4 Develop Developing constructive ambition Constructive ambition appropriately

constructive ambition  Realistic targets developed.
 Setting realistic targets
UNIT B15.3: DEMONSTRATING PERSONAL ENTREPRENEURIAL CONCEPTS DURATION: 10 HOURS 1
CREDIT HOURS
OUTCOMES
15.3.1 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
140
 Practice Demand for Efficiency and Quality

 Practice Persistence
 Practice Commitment to the Work Contract
15.3.2 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
15.3.3 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
UNIT B15.4: ESTABLISHING AN ENTERPRISE DURATION: 10 HOURS 1 CREDIT HOURS
OUTCOMES
15.4.1 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
141
 Conduct an feasibility study for the business idea

15.4.2 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
15.4.3 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
15.4.4 Establish a Establishing a business Enterprise well established
business  Design of the business
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
142
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
UNIT B15.5: MANAGING AN ENTERPRISE DURATION: 10 HOURS 1 CREDIT HOURS
OUTCOMES
15.5.1 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
5.5.2 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
143
 Understand how to manage the budget

 Identify How to make smart purchasing decisions
 Identify the legal aspects of finance
15.5.3 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
 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
15.5.4 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
15.5.5 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
144
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
15.5.6 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
15.5.7 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
16.5.8 Undertake Undertaking strategic planning Strategic planning well undertaken.
145
strategic planning  Define strategic planning

 Outline the strategic Planning process
 Outline key performance indicators
UNIT B15.6: GROWING AN ENTERPRISE DURATION: 10 HOURS 1 CREDIT HOURS
OUTCOMES
15.6.1 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
15.6.2 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
15.6.3 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.
146

Learn how to give feedback on performance
management.
 Identify Kolb’s Learning Cycle.
 Recognize the importance of motivation.
 Developing a performance journal and performance
plan.
15.6.4 Mobilise finance Mobilising finance for growth Finance for growth appropriately
for growth o ;Explain role of finance in an enterprise mobilised expanded
o Discuss sources of finance for an enterprise
o State the importance of good financial management
UNIT B15.7: ESTABLISHING BUSINESS NETWORKS DURATION: 10 HOURS 1 CREDIT HOURS
OUTCOMES
15.7.1 Identify Identifying networking agenda Networking agenda correctly identified
networking agenda  The importance of networking
 An enterprise networking web
15.7.2 Identify Identifying business networks Business networks correctly identified
business  Internal networks
networks  External networks
15.7.3 Join business Joining business networks Business networks joined
networks  Stakeholders and shareholders
 Terms and conditions
 Performance Evaluation
15.7.4 Attend Attending business forums Business forums appropriately attended.
business forums  Business forum
 Types of business forums
 The benefits of business forums
147
15.7.5 Evaluate and Evaluating and controlling business networks Business networks well evaluated and
control business  Sustaining business networks controlled
networks  Performance of business networks
UNIT B15.8: DEVELOPING A BUSINESS EXIT PLAN DURATION: 10 HOURS 1 CREDIT HOURS
OUTCOMES
15.8.1 Develop an exit Developing an exit strategy Exit strategy correctly developed
strategy  Mergers
 Acquisitions
 Debentures
 Management buy out
15.8.2 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.
15.8.3 Explain estate Explaining estate management Estate correctly managed
management  Estate management
 Types estate management
 The enterprise estate management obligations to
148
government
UNIT B15.9: ASSESS BUSINESS PERFORMANCE DURATION: 10 HOURS 1 CREDIT HOURS

OUTCOMES
15.9.1.Set targets Setting targets Target well set.
 The target setting process
 Targets
15..9.2 Identify Key Identifying Key Performance Indicators Key Performance indicators correctly
Performance identified.
Indicators
15.9.3 Structure data Structuring data collection tools Data collection tools well structured.
collection tools  Structured interviews
 Questionnaire
 Observations
15.9.4 Outline Outlining measuring criteria Measuring criteria correctly outlined
measuring
criteria
15.9.5 Write a report Writing a report Report well written
UNIT B15.10: MANAGE PROFITS, EXCESS CASH AND RISK DURATION: 10 HOURS 1 CREDIT HOURS
OUTCOMES
149
15.10.1. Differentiating between profit and cash Profit and cash well differentiated
Differentiate  Profit
between profit
and cash  Nature of profits
 Calculating profit
 Gross profit
 Net profit
 Profitability
 Profitability ratios
 Explaining cash
oMoney
oThe functions of money
oThe abilities of money
oBarter
oThe deficiencies of barter, rate of exchange
indivisibility of goods, double coincident of wants
o The early forms of money
o The measurement of money
10.10.2 Select Selecting alternative investments Alternative investments appropriately
alternative  Strategic issues in investment found
investments
 The investment process
 New technology.
15.10.3 Conduct Conducting investment appraisal Investment appraisal well conducted
investment  Uncertainty and investment decisions
appraisal
150
 Managers’ risk attitudes
15.10.4 Carryout Carrying out risk management Risk management correctly carried out
risk  Risk management
management
 Expected NPV and its variability
 Techniques for assessing project risk
 The risk-return trade off
UNIT B15.11: NEGOTIATE AGREEMENTS AND CONTRACTS DURATION: 10 HOURS 1 CREDIT HOURS
OUTCOMES
15.11.1 Use Using different approaches of negotiations Approaches of negotiation correctly
different  Basic types of negotiations, the phases of negotiations, used
approaches of and the skills needed for successful negotiating
negotiations
 Pre-contract negotiations
 Contract negotiations
 Post contract negotiations
 Basic negotiating concepts
 WATNA
 BATNA,
 WAP
 ZOPA
151
15.11.2 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
15.11.3 Prepare Preparing for negotiations Negotiations well prepared for
for negotiations  Groundwork for negotiation
 What information to share and what to keep to yourself
 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
15.11.4 Manage Managing contracts Contracts correctly managed
contracts  Contracts
 Types of tender
 Open tenders
 Restricted tenders
 Tender procedures
 Bargain for tender
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
152
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
153
MODULE 166-16-B ENGINEERING MATERIALS

MODULE PURPOSE: To equip trainees with knowledge, skills and appropriate attitudes to select engineering materials for different
purposes effectively and efficiently.
MODULE LEARNING OUTCOMES: On completion of this module the trainee should be able to:
1. Describing materials and their properties
2. Analysing the basic science of materials
3. Analysing alloying of metals
4. Analysing heat treatment of plain carbon steels
5. Analysing steels, alloys and non-metals
6. Analyse corrosion
7. Conduct material inspection
ASSESSMENT METHODS:
 Exercises
 Class Test
 Assignments
LEARNING CONDITIONS: The trainee must have access to:

 Calculator
 Library
 Handouts
 Tutorials
 Manuals
 Laboratory
UNIT B16.1: DESCRIBING MATERIALS AND THEIR PROPERTIES
154

OUTCOMES
16.1.1 select materials Selecting materials Materials selected correctly
 Commercial factors
 Engineering factors
16.1.2 Explain properties of Engineering materials selected
materials Explaining properties of materials correctly
 Mechanical properties
 Physical properties
16.1.3 Classify Engineering
Classifying engineering materials physical and mechanical properties of
materials  Metals ferrous and non-ferrous metals
o Ferrous discussed correctly.
o Non-ferrous
 Non-metals
o Synthetic
o Natural
 Composite materials (composites)
UNIT B16.2 ANALYSING THE BASIC SCIENCE OF MATERIALS UNIT DURAITON: 10 HOURS CREDITS:1

OUTCOMES
16.2.1 Discuss basic atomic Discussing basic atomic structure Basic atomic structure discussed
structure  Atom correctly
 Ions
 Isotopes
155
16.2.2 Describe Molecules and Describing Molecules and lattices Molecules and lattices described
lattices  Covalent bond correctly
 Ionic bond
 Metallic bond
 Van der Waal’s forces
16.2.3 Discuss elements, Discussing elements, compounds and mixtures Elements, compounds and mixtures
compounds and mixtures discussed correctly
16.2.4 Analyse crystals Analysing crystals Crystals analysed correctly
 Cubic
 Face centered cubic
 Body centered cubic
 Hexagonal close packed
UNIT.B16.3 ANALYSING ALLOYING OF METALS UNIT DURATION: 15 HOURS CREDITS:1.5

OUTCOMES
16.3.1 Describe alloying Describing alloying elements Alloying elements described correctly
elements  Alloys
 Alloying elements
16.3.2 Analyse solubility and Analysing solubility and solid solutions Solubility and solid solutions analysed
solid solutions  Solid solutions correctly
 Intermetallic compounds
 Cooling curves
16.3.3 Discuss Phase Discussing Phase equilibrium diagrams (Eutectic type) Phase equilibrium diagrams (Eutectic
equilibrium diagrams (Eutectic  Phase type) discussed correctly
type)  Alloy types
 Eutectic type
 Solid solution type
156
 Combination type
16.3.5 Analyse plain carbon

Analysing plain carbon steels Iron-carbon phase equilibrium
steels  Ferrous metals diagram analysed correctly
 The iron-carbon system (phase equilibrium diagram)
UNIT B16.4: ANALYSING HEAT TREATMENT OF FERROUS METALS UNIT DURATION: 15 HOURS CREDITS: 1.5

OUTCOMES
16.4.1 Analyse Analysing hardening Hardening analysed correctly
hardening  Definition of hardening
 Types of hardening
o Case hardening
o Normal hardening
o Hardening temperature
o Quenching media
o Carburising
o Flame hardening
o Induction hardening
o Nitriding
16.4.2 Analyse Analysing annealing Annealing analysed correctly
annealing
 Definition of annealing
 Types of annealing
o Stress relief annealing
o Spheroidising annealing
o Full annealing
16.4.3 Analyse Analysing Normalising process; Normalizing process analysed
Normalising  Definition of normalising correctly
process  Normalizing temperature
157
 Normalising process
16.4.4 Analyse Analysing tempering process; Tempering process analysed

tempering  Definition of tempering correctly
process  Temperature tempering
 Temperature process
UNIT B16.5: ANALYSING STEELS, ALLOYS AND NON-METALS UNIT DURATION: 15 HOURS CREDIT: 1.5

OUTCOMES
16.5.1 Analyse types of Analysing types of steel and alloys Types of steel and alloys analysed
steel and alloys  Plain carbon steels correctly
 High carbon steels
 Mild steel
 Cast steel
 Stainless steel
 High speed steel
16.5.2 Examine Examining properties of steels and alloys Properties of steels and alloys
properties of  Physical and mechanical properties examined correctly
steels and alloys o Density
o Melting temperature
o Electrical conductivity
o Thermal conductivity
o Fusibility
o Magnetic properties
 Types of alloys
o Aluminium
o Chromium
o Cobalt
o Copper
158
o Lead
o Manganese
o Molybdenum
o Nickel
o Vanadium
o Phosphorus
o Silicon
o Sulphur
o Tungsten
o Solubility in liquid and solid states
o Solid solution
o Substitution
o Interstitial
16.5.3 Explain uses of Explaining uses of steels and alloys Uses of steels and alloys explained
steels and alloys o Application of alloys steels correctly
o In construction
o Machine parts
o Tools
 Application of alloys alloys
o In construction
o Machine parts
o Tools
16.5.4 Explaining uses of Explaining uses non-metals Uses of non-metals explained
non-metals  Wood correctly
 Rubber
 Asbestos
 Plastic
 Wood
o Construction
o Furniture
 Asbestos
159
o Construction
o Insulation
 Rubber
o Insulation
o Wheel construction
 Plastics
o Insulation
o Wheel construction
UNIT B16.6: ANALYSING CORROSION NOMINAL DURATION: 10 HOURS OR; 1.0 CREDIT HOURS

OUTCOMES
16..6.1 Explain causes Explaining causes of corrosion Causes of corrosion explained
of corrosion  Analyse causes of corrosion correctly
o Types of metal
o Protective surface on metal
o The environment
 Factors affecting corrosion
o Structural design
o Environmental
o Applied or internal stresses
o Composition
o Structure
o Temperature
16.6.2 Describe types of Describing types of corrosion Types of corrosion described

corrosion  Dry corrosion correctly
 Wet corrosion
 Galvanic corrosion
 Atmosphere corrosion
160
16.6.3 Analyse Analysing prevention of corrosion Prevention of corrosion analysed

prevention of  Prevention of corrosion correctly
corrosion o Chemical inhibition
o Cathodic protection
o Protective coatings
 Electroplate
 Hot dipping
 Cladding
 Chromating
 Plastic coating
 Spraying
 Cementation
 Anodising
 Painting
UNIT B16.7: CONDUCTING MATERIAL INSPECTION AND TESTING UNIT DURATION: 20 HOURS CREDITS: 2

OUTCOMES
16.7.1 Inspect materials Inspecting materials Materials inspected correctly
 By use of sound (ultrasonic)
 By use of light
 Visual inspection
 Radiograph
16.7.2 Perform tensile Performing tensile and compression test Tensile and compression test
And compression  Tensile test specimen and tests performed correctly
test  Test results of a tensile test
 Interpretation of tensile results
 The compression test procedure
 Specimen for compressive test
 Interpretation
161
16.7.3 Perform impact Performing impact tests Impact test performed correctly
tests  Types of impact tests
o The Izod test
o The charpy test
 Interpretation of results
16.7.4 Perform Performing hardness test Hardness test performed correctly
hardness test  Review of hardness property
 Types of hardness test
o The Brinell hardness test
o The Vickes hardness test
o The Rockwell hardness test
o Hardness testing machines
o Preparation of specimen
o Interpretation of results
REFERENCE
Calister, W. (2014). Materials science and Engineering. 9th Ed. USA: John Wiley and Sons Inc.
Donald, R.A. (2015). The Science and Engineering of Materials. 7th Edition, Boston, MA 02210, USA.
Hibbeler, R.C. (2016). Mechanics of Materials. 10th edn. Ohio: Pearson publishing
Martins, J. (2006). Materials for Engineering. Cambridge: Woodhead publishing
Timings, R.L. (1989). Engineering Materials. 2nd ed. San Francisco: Pearson Education
162
MODULE 166-17-B MANAGEMENT AND ORGANISATION

MODULE PURPOSE:
To equip the trainee with knowledge, skills and appropriate attitudes to apply principles of management and organisation

LEARNING OUTCOMES: On completion of this module, trainees will be able to:
1. Apply management concepts
2. Identify scientific management elements and principles of economics
3. Employ various types of management
4. Apply management techniques
5. Apply law of contract
 Library
 Internet
 Hand-outs
 Lecture Notes
ASSESSMENT METHODS: To achieve the assessment the trainee will be given:

 Assignments
 Class exercises
 Practicals
 Test
 Final examinations
UNIT B17.1 APPLYING MANAGEMENT CONCEPTS
163
UNIT DURATION: 18 HOURS CREDITS: 1.8

OUTCOME
17.1.1Describe the nature of Describing the nature of management Nature of management
management  Working with and through others described correctly
 Achieving organizational objectives;
 Balancing effectiveness and Efficiency;
 Making the most of limited resources; and
 Coping with a changing environment.
17.1.2.Explain organizations in Explaining organizations in Management Organizations in Management
Management  Management objectives explained correctly
 Management functions
 What managers do
17.1.3Explain purpose and  Explaining responsibility of management Purpose and types of controls
types of controls explained correctly
UNIT B17.2 IDENTIFYING SCIENTIFIC MANAGEMENT ELEMENTS AND PRINCIPLES OF ECONOMICS
OUTCOME
17.2.1.Describe the concept Describing the concept scientific management The concept scientific
scientific management  Definition of scientific management management described
 Operational approach correctly.
17.2.2.Explain the evolution of Explaining the evolution of management thought The evolution of management
management thought  Henri fayol and administrative management thought explained correctly.
 Fredrick W. Taylor and scientific management
 Elton mayo and the human relations school
 The hawthorne studies
 Chester Bernard and the systems approach
164
 Contemporary management thought

17.2.3.Describe elements of Describing elements of scientific management Elements of scientific
scientific management  standardization management described
 Time and task study correctly.
 Systematic selection and training
 Pay incentives
17.2.4.Describe the concept of Describing the concept of production The concept of production
production  Definition of production described correctly.
 Production function
o Inputs
 Transformation process
o Outputs
o Continuous feedback
UNIT B17.3 EMPLOYING VARIOUS TYPES OF MANAGEMENT
OUTCOME
17.3.1.Describe financial Describing financial management Financial management described
management correctly.
 Definition of financial management
 Brief overview of Financial management
techniques;
o Capital investment
o Working capital management
o Long-term finance
o Short-term finance
o cost of capital
165
17.3.2.Describe time Describing time management Time management described

management correctly.
 Definition of time management
 Time as a limited resource
 Time management tips
 Time allocation
17.3.3.Describe risk Describing risk management Risk management described

management correctly
 Define sensitivity analysis
 Risk management process
 Importance of risk and sensitivity analysis
17.3.4.Describe industrial relation Describing industrial relation Industrial relation described

correctly.
 Defining of industrial relations
 Industrial obligations
o Duties of an employee
o Duties of the employer
 Industrial conflict and trade unions
 The nature of industrialisation
 Bargaining processes and procedures
 Legal requirements
 Disciplining and grievance Procedures
 Disciplinary procedures Grievance
procedure Disciplinary penalties Appeals
processes
 Redundancy
166
17.3.5.Describe banking Describing banking Banking described correctly
 Definition of banking
 Importance of banking
UNIT B17.4 APPLYING MANAGEMENT TECHNIQUES

OUTCOME
17.4.1.Describe motivation Describing motivation Motivation described correctly
 The nature of motivation
 Factors affecting motivation
 Motivation theories
o Content theories
o Process theories
o Re-enforcement theories
o Contemporary issue in motivation
17.4.2.Describe training Definition of training Training described correctly
 Training and development
 Benefits of training
 Learning principles
17.4.3.Describe conflict Describing conflict management conflict management
management  Define conflict management described correctly
 Why are there conflicts at places of work
 Functions of conflict
17.4.4.Provide leadership Providing leadership Leadership provided
 The nature of leadership appropriately
 Distinguish between a manager and a leader
 Components of emotional intelligence
 Approaches to leadership
167
o Trait theory
o Styles of leadership
o The managerial grid
o Path goal theory
o Situational leadership theory
UNIT B17.5 APPLYING LAW OF CONTRACT UNIT DURATION: 18 HOURS CREDITS: 1.8

OUTCOME
17.5.1.Apply the terms and  Applying the terms and Learning Conditions of The terms and Learning
conditions of a valued contract a valued contract Conditions of a valued
o Full definition of a contract: Contract applied correctly
 Offer and offeree’
 Counter offer
 Acceptance
17.5.2.Apply principles of  Applying principles of agreement Apply principles of agreement
agreement o Full definition of Learning Conditions of a applied correctly
valid
 Contract
 Agreement
 Consideration
o Full description of violation factors
o Misrepresentation
o Mistake
o Undue influence
17.5.3.Apply vitiating factors Applying vitiating factors Apply vitiating factors applied
correctly
17.5.4.Identify the factors for Identifying the factors for breach of documents Identify the factors for breach
breach of documents of documents identified
correctly
168
REFERENCES
Buchanan, D. (1997). Organisation Behaviour: Introductory tests. 3rd ed. London: Practice Hall International
Lucey, T. Costing
Morgan, G. (1996) Images and Organisations
Turnner, P.H. (1994). Business Management Studies
169
MODULE 166-18-B APPLIED THERMODYNAMICS
MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate MODULE CREDITS: 15 Credit
attitudes to apply thermodynamics effectively and efficiently. DURATION: 150 Hours
Hours
1. Apply the laws of thermodynamics

2. Analyse reversible process
3. Apply heat engine cycles
4. Calculate Air fuel Ratio
5. Compute heat flow in different media
6. Analyse Engine performance
Assessment Methods
 Assignments
 On site practical
 Written class exercises
 Tests
 Workshop projects
Learning conditions
 Books
 Modules
 Library
 Internet
 Workshop
170
 Laboratory
UNIT C18.1 APPLYING THE LAWS OF THERMODYNAMICS UNIT DURATION: 25 CREDITS: 2.5

OUTCOMES
18.1.1 Apply the laws of Applying the laws of thermodynamics: Laws of thermodynamics analysed correctly
thermodynamics  Zeroth law of thermodynamics
 The first law of thermodynamics
o Non-flow energy equation
 The second law of thermodynamics
o Steady flow energy equation
o Entropy.
18.1.2 Illustrate open Illustrating open and closed systems: Open and closed systems illustrated correctly
and closed systems  The non-flow systems
 The steady flow systems
18.1.3 Analyse heat Analysing heat engine: Heat engine analysed correctly
engine  Forward and reversed heat engines
 Coefficient Of Performance (COP)
 Cycle efficiency
UNIT A18.2: ANALYSING REVERSIBLE PROCESS UNIT DURATION: 25 CREDITS: 2.5

OUTCOMES
18.2.1.Analyse Analysing reversible non-flow: Reversible non-flow processes analysed
reversible non-flow correctly
processes  Constant volume processes
 Constant pressure processes
171
 Constant temperature or isothermal processes
18.2.2.Analyse Analysing adiabatic non-flow processes: Adiabatic non-flow processes analysed correctly
adiabatic non-flow  Definition of adiabatic process
processes  Calculation of the work done
 Adiabatic process for a perfect gas
18.2.3.Analyse Analysing polytropic processes: Polytropic processes analysed correctly
polytropic  Definition of polytrophic process
processes  The work done in the polytropic process
 The heat transfer during the polytropic process
18.2.4. Analyse Analysing reversible flow processes:
reversible flow  Definition of reversible flow process
processes  The non-flow energy equation
 The work done
UNIT A18.3: APPLYING HEAT ENGINE CYCLES UNIT DURATION: 25 CREDITS: 2.5

OUTCOMES
18.3.1 Applied the Applying the Carnot cycle: The Carnot cycle applied correctly
Carnot cycle  Efficiency
 T-S Diagram
18.3.2Analyse the Otto Analysing the Otto cycle: The Otto cycle analysed correctly
cycle  P.V. Diagram
 Thermal efficiency
 Application
18.3.3 Analyse Diesel Analysing Diesel cycle Diesel cycle analysed correctly
cycle  P.V. Diagram
 Thermal efficiency
172
 Application
18.3.4. Calculate Mean

Calculating Mean Effective Pressure Diesel cycle analysed correctly
Effective Pressure  P.V. Diagram
 Define mean effective pressure
 Calculate mean effective pressure
 Compare similar engines using mean effective
pressure (Pm)
UNIT A18.4: CALCULATING AIR FUEL RATIO UNIT DURATION: 25 CREDITS: 2.5

OUTCOMES
18.4.1.Analyse types of Analysing types of fuel
fuel  Solid fuels Types of fuel analysed correctly
 Liquid fuels
 Gaseous fuels
18.4.2.Analyse Analysing chemical equation of combustion: Chemical equation combination of combustion
constituents of fuel  The combustion process constructed correctly
 Chemical equations
 Balancing of equation
 Combustion analysis by mass
 Combustion analysis by volume
18.4.3.Analyse Analysing chemical equation of combustion: Chemical equation combination of combustion
chemical equation of  The combustion process constructed correctly
combustion  Chemical equations
 Balancing of equation
 Combustion analysis by mass
173
 Combustion analysis by volume
18.4.4.Calculate air fuel

Calculating air fuel ratio Air fuel ratio calculated correctly
ratio  Definition of stoichiometric air fuel ratio
 Percentage of excess air
 Mixture strength
 Exhaust gas analysis
UNIT B18.5. COMPUTING HEAT FLOW IN DIFFERENT MEDIA UNIT DURATION: 25 CREDITS: 2.5

OUTCOMES
18.5.1.Analyse heat Analysing heat transfer mechanism: Heat transfer mechanism analysed correctly
transfer mechanism  Conduction
 Convection
 Radiation
18.5.2.Apply Fourier’s Applying Newton’s law of cooling Stefan –Boltzman law applied correctly
law of conduction  Heat transfer from one surface to another through a
dividing wall
 Over heat transfer coefficient
18.5.3.Apply Newton’s Applying Stefan Boltzmam Statement of the law Stefan –Boltzman law applied correctly
law of cooling  Emissivity and absorptivity
 Grey and black bodies
 Calculation of heat radiated and absorbed
18.5.5.Apply the Applying principles of heat exchangers: Principles of heat exchangers applied correctly
principles of heat  The recuperator
exchangers  Parallel flow and counter flow recuperators
174
UNIT B18.6: ANALYSING ENGINE PERFORMANCE UNIT DURATION: 25 CREDITS: 2.5

OUTCOMES
18.6.1.Compute Computing indicated power Indicated power computed correctly
indicated power  Definition
 Calculate Mean effective pressure
 Analyse Indicated power
18.6.2.Analysed brake Analysing brake power: Brake power Analysed correctly
power  Definition of brake power
 The dynamometer
18.6.3.Compute friction Computing friction power and mechanical efficiency: Friction power and mechanical
power and  Definition of friction power efficiency computed correctly
mechanical  Definition of mechanical efficiency
efficiency  Friction power and mechanical efficiency
18.6.4.Compute brake Computing brake mean effective pressure (B.M.E.P) Brake mean effective pressure
mean effective  Definition of B.M.E.P computed correctly
pressure  Calculation of brake mean effective pressure
(B.M.E.P)
18.6.5.Compute Computing thermal efficiency and fuel consumption : Thermal efficiency and fuel
thermal  Definition of thermal efficiency consumption computed correctly
efficiency and  Definition of fuel consumption
fuel  Calculation of thermal efficiency and fuel consumption
consumption
18.6.6.Analyse engine Analysing engine output and efficiency Engine output and efficiency analysed
output and  Vehicle performance curves correctly
efficiency  Vehicle performance tables
REFERENCES
175
Eastop, T.D. (1993), Applied thermodynamics for engineering technologist. 5th ed. England: Pearson/ Prentice Hall,
Michael, A.B. (2018). Thermodynamics: An engineering approach. 9th edn. McGraw-Hill Education.
Rayner, J. (1987). Basic engineering thermodynamics. 4th ed. England: Longman Scientific & Technical
176
MODULE 166-19-C FLUID MECHANICS

MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate attitudes apply principles of fluid mechanics
1. Analyse pressure and its measurements
2. Analyse fluid pressure measuring devices
3. Compute head losses in pipe flow system
4. Analyse fluid machines
5. Computing hydrostatic forces on immersed plates
ASSESSMENT METHODS:
 Exercises
 Class Test
 Assignments
LEARNING CONDITIONS: The trainer must have access to:

 Calculator
 Library
 Handouts
 Tutorials
 Manuals
 Laboratory
177
UNIT C19.1 ANALYSE PRESSURE AND ITS MEASUREMENT UNIT DURATION:32 HOURS CREDITS: 3.2

OUTCOMES
19.1.1 Calculate pressure at a Calculating pressure at a point Pressure at a point calculated
point  correctly
19.1.2 Apply Pascal’s law Applying Pascal’s law Pascal’s law applied correctly
19.1.3 Analyse pressure variation Analysing pressure variation in a fluid at rest Pressure variation in a fluid at rest
in a fluid at rest analysed correctly
UNIT C19.2 ANALYSE PRESSURE MEASURING DEVICES UNIT DURATION: 20 HOURS CREDITS:2

OUTCOMES
Explaining types of pressure
19.2.1.Explain types of pressure Types of pressure explained correctly
 Gauge pressure
 Absolute pressure
 Atmospheric pressure
 Vacuum pressure
19.2.2Analyse mechanical Analysing pressure measuring devices: Mechanical pressure measuring
pressure measuring devices  Bourdon tube devices analysed correctly
 Diaphragm pressure gauge
19.2.3.Analyse manometers Analysing manometers: Manometers analysed correctly
 Piezometer
 U tube manometer
 Computing pressure from manometers
UNIT C19.3 COMPUTING HEAD LOSSES IN PIPE FLOW SYSTEM UNIT DURATION:32 HOURS CREDITS: 3.2
178

OUTCOMES
19.3.1 Analyse Bernoulli’s Analysing Bernoulli’s theorem Bernoulli’s theorem analysed
theorem  Derive Bernoulli’s equation correctly
Discharge (volumetric flow rate)
19.3.2 Analyse types of head Analysing types of head losses components: Types of head losses components
losses components  Major or head loss due to friction analysed
 Minor head losses due to
o Contraction
o Enlargement
o Obstruction
o Bend
o Pipe fittings
o Entrance to pipes
19.3.3 Compute head losses Computing head losses: Head losses computed correctly
 Darcy – Weisbach formula
 Loss of head due to
o Contraction
o Enlargement
o Obstruction
o Bend
o Pipe fittings
o Entrance to pipes
19.3.4.Analyse types of flow Analysing types of flow Types of flow analysed correctly
 Lamination flow
 Turbulent flow
 Criterial for classifying flow
19.3.5 Compute Reynolds number Computing Reynolds number: Reynolds number computed correctly
 Formula for calculating Reynold’s number
179
UNIT C19.4 ANALYSING FLUID MACHINES UNIT DURATION:32 HOURS CREDITS: 3.2

OUTCOMES
Analysing centrifugal pumps:
19.4.1 Analyse centrifugal pumps Centrifugal pumps analysed correctly
 Parts
 Working
 Functions
 Calculations of
o Head
o Discharge
o Specific speed
o Efficiency
 Selection of pumps
19.4.2.Analyse turbines Analysing turbines : Turbines analysed correctly
 The hydraulic turbines
o Impulse turbine
o Reaction turbine
o Operation of the Pelton wheel
o Operation of the Francis turbine
19.4.3.Analyse pneumatic Analysing compressors and control systems: Pneumatic machines and control
machines and control systems  Definition systems analysed correctly
o
 Examples of pneumatic control
 Mechanisms and machines
UNIT C19.5 COMPUTING HYDROSTATIC FORCES ON IMMERSED PLATES UNIT DURATION:32 HOURS
CREDITS: 3.2

OUTCOMES
19.5.1.Compute total pressure on Computing total pressure on an immersed plate: Total pressure on an immersed plate
180
an immersed plate  Horizontal plate computed correctly

 Vertical plates
 Inclined plates
19.5.2.Locate the centre of Locating the center of pressure on a plate: Centre of pressure on a plate located
pressure on a plate  The centre of pressure correctly
o Definition
o Calculating position of centre of pressure
19.5.3.Compute hydrostatic thrust Computing hydrostatic thrust on a sluice gate: Hydrostatic thrust on a sluice gate
on a sluice gate  Moments on a fluid system computed correctly
REFERENCES
Bansal, R.K. (2018).Fluid Mechanics and Hydraulic Machines. Mumbai: Repro Ltd,
Chand, S. (2016). A Textbook of Fluid Mechanics & Hydraulic Machines in SI Units. 6th ed. New Delhi: S.Chand & Company PVT. Ltd
Douglas, J.F. (1996). Solving Problems in Fluid Mechanics Volume 1 & 2. 3rd ed. England: Pearson Education.
181
MODULE 166-20-C MACHINE DESIGN
MODULE DURATION: 130 HOURS CREDITS:13
MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate attitudes to apply principles of machine design on
heavy equipment effectively and efficiently.
1. Design screws and fasteners
2. Design Axle and Shafts
3. Select Bearings
4. Analyse Gears
5. Analyse Clutches
6. Analyse brakes
7. Apply belt and chain drive mechanism
8. Analyse springs
9. Analyse internal combustion engine parts design features
ASSESSMENT METHODS:
 Exercises
 Class Tests
 Assignments

 Calculator
182
 Library
 Handouts
 Tutorials
 Manuals
 Laboratory
UNIT C20.1 DESIGNING SCREWS AND FASTENERS UNIT DURATION:14 HOURS CREDITS: 1.4

LEARNING
OUTCOMES
20.1.1 Select Selecting screws and fasteners: Screws and fasteners selected
screws correctly
and  Nomenclature of screw thread
 Forms of screw threads
fasteners
 Types of screw fastenings
 Location of screwed joints
20.1.2 Apply Applying locking devices: Locking devices applied correctly

locking
devices  Types of locking devices
 Application of locking devices
20.1.3 Use standard Using dimensions of screws and fasteners: Standard dimension of screws and
dimension of fasteners used correctly
screws and  Designation of screw threads
 ISO and British standards
fasteners
20.1.4 Calculate Calculating stress in screwed fastening: Stress in screwed fastening calculated
stress in
 Static loading
183
screwed  Screwing up forces

fastening  Extended forces
 Combined forces
20.1.5 Use thread Using thread inserts: Thread used inserts

inserts
 Types of threads
 Application of threads
20.1.6 Apply Applying connections using bolt and Nuts Connections applied correctly
connections
UNIT C20.2 DESIGNING AXLES AND SHAFTS UNIT DURATION:14 HOURS CREDITS: 1.4

LEARNING
OUTCOMES
20.2.1 Identify axles Identifying Axles and Shafts Axles and Shafts identified correctly
and shafts
20.2.2 Identify Identifying materials used for making shafts: Materials used for making shafts
Materials identified correctly
used  Machine properties of steel used for shaft
for making  Manufacturing process used
shafts
20.2.3 classify Classifying shafts Shaft classified correctly
shafts
 Transmission
 Machine shaft
184
20.2.4 Select Selecting Standard sizes of transmission shafts Standard sizes of transmission shafts
standard Selected correctly
sizes of
transmission
shafts
20.2.5 Calculate Calculating stresses in shafts Stresses in shafts calculated correctly
stresses in
shafts  Twisting moments
 Bending moments
 Axial loads
 Combined torsional bending loads
20.2.6 Discussing Discussing shaft couplings: Shaft couplings discussed correctly

shaft
couplings  Rigid coupling
 Flexible coupling
UNIT C20.3 SELECTING BEARINGS UNIT DURATION:14 HOURS CREDITS: 1.4

LEARNING
OUTCOMES
20.3.1 Classify Classifying bearings Bearings classified correctly
bearings
 Sliding contact bearing
 Rolling contact bearing
20.3.2 Select Selecting contact bearings: Contact bearings selected correctly

contact
185
bearings  Hydrodynamic lubricated bearings
 Journal bearings
 Bearing characteristic number and bearing modulus for
journal bearings
 Co-efficient of friction for journal bearings
 Critical pressure of the journal bearing
 Somerfield number
 Heat generated in a journal bearing

 Designing procedure from Journal bearing
 Thrust bearings
 Collar bearings
 Types of rolling contact bearings
 Static load of rolling contact bearing
 Static equivalent load for rolling contact bearing
 Life of a bearing dynamic load rating of rolling contact bearings
 Dynamic load rating of rolling contact bearing under variable
loads
 Selection of radial ball bearings
20.3.3 Schedule Scheduling maintenance of bearings: Maintenance of bearings scheduled

maintenance correctly
of bearings  Lubrication
 bearing life
UNIT C20.4 ANALYSING GEARS UNIT DURATION:14 HOURS CREDITS: 1.4
186

LEARNING
OUTCOMES
20.4.1 Identify Identifying types of gears: Types of gears identified correctly
types
of gears  Spur
 Helical
 Bevel
 Worm
 Gear terminology
20.4.2 Classify Classifying gears by: Gears classified correctly

gears
 Position of axis of the shaft
 Peripheral velocity of the gears
 Type of gearing
 Position of teeth on the gear surface
20.4.3 Illustrate Illustrating gears: Gear Geometry illustrated correctly

Gear
Geometry  Cycloid teeth
 Involute teeth
20.4.4 Apply the law Applying law of gears: Law of gears applied correctly
of gears
 Spur
 Helical
 Bevel
187
 Worm
UNIT C20.5 ANALYSING CLUTCHES UNIT DURATION:14 HOURS CREDITS: 1.4

LEARNING
OUTCOMES
20.5.1 Classify Classifying clutches: Clutches classified correctly
clutches
 Types of clutches
 Design of a friction clutch
 Function of clutches
 Material for friction surfaces
20.5.2 Analyse Analysing single friction discs: Single friction disc analysed correctly
friction single  Design of a disc
disc o Uniform pressure
o Uniform axial wear
20.5.3 Analyse Analysing multiple disc clutch : Multiple disc clutch analysed correctly
multiple disc
clutch  Design of a multiple disc clutch
20.5.4 Analyse Analysing centrifugal clutch: Centrifugal clutch analysed correctly

centrifugal
clutch Design a centrifugal clutch
UNIT C20.6 ANALYSING BRAKES UNIT DURATION:14 HOURS CREDITS: 1.4

LEARNING
188
OUTCOMES
20.6.1 Calculate Calculating energy absorbed by brakes: Energy absorbed by brakes calculated
energy correctly
absorbed by  When motion of body is pure translation
 When motion of body is under rotation
a brake
 When motion is a combination of translation and rotation
20.6.2 Calculate Calculating heat dissipated by a brake Heat dissipated by a brake calculated
Heat correctly
dissipated  When motion of body is pure translation
 When motion of body is under rotation
by a brake
 When motion is a combination of translation and rotation
20.6.3 Examine Examining materials for brake lining : Materials for brake lining examined
materials for correctly
brake lining  Co-efficient of friction
 Wear out
 Heat resistance
 Co-efficient of thermal expansion
 Mechanical strength
 Moisture and oil
20.6.4 Classify Classifying brakes: Brakes classified correctly

brakes
 Hydraulic
 Electric
 Mechanical
20.6.5 Analyse Analysing single block brake: Single block brake analysed correctly
single
189
block brake  Pivoted block brake
20.6.6 Analyse Analysing double block brake Double block brake analysed correctly
double block
brake  Spring force
 Width of brake shoes
20.6.7 Analyse Analysing internal expanding brake: Internal expanding brake analysed
internal correctly
expanding  Forces acting on the brake
 Braking torque generated
brake
UNIT C20.7 DESIGNING BELTS AND CHAIN DRIVES UNIT DURATION:14 HOURS CREDITS: 1.4

LEARNING
OUTCOMES
20.7.1 Identify types Identifying types of machine drives Types of machine drives identified
of machine drives correctly
chain drives  Belt
 chain
 Pulley and sprockets
20.7.2 Classify belt Classifying belt drives: Belt drives classified correctly
drives
 Flat belts
 V-belts
 Timing belts
190
20.7.3 Classify Classifying chain drives: Chain drives classified correctly

chain
drives  Hoisting chains
 Conveyor chains
 Power transmitting chains
20.7.4 Calculate Calculating power transmitted by the drive: Power transmitted by the drive
power calculated correctly
transmitted  Flat belt
 V-belt
by
 Round belt
the belt drive
20.7.5 Use pulleys Using pulleys and sprockets: Pulleys and sprockets used correctly
and
sprockets  Types of pulleys
 Types of sprockets
 Application
UNIT C20.8 ANALYSE SPRINGS UNIT DURATION:14 HOURS CREDITS: 1.4

LEARNING
OUTCOMES
20.8.1 Identify Identifying types of springs: Springs identified correctly
springs
 Functions of springs
 Materials for springs
 Classification of springs
o Helical
o Leaf
191
20.8.2 Calculate Calculating load deflection relationship Load deflection relationships

load calculated correctly
deflection  Tension
 Compression
relationships
 Springs in series
 Spring in parallel
 Leaf springs
20.8.3 Analyse Analysing suspension springs; Suspension springs analysed correctly

suspension
springs  Stand sizes of automobile suspension springs
20.8.4 Maintain  Maintaining types of failure Springs maintained correctly

springs
UNIT C20.9 ANALYSING INTERNAL COMBUSTION ENGINE PARTS DESIGN FEATURES UNIT DURATION:14 HOURS
CREDITS: 1.4

LEARNING
OUTCOMES
20.9.1 Analyse Analysing piston and piston ring design Piston and piston ring design analysed
piston and piston correctly
ring design  Piston features
 Material
 Design consideration
 Auxiliary parts
20.9.2 Analyse Analysing connecting rods design Connecting rods design analysed
connecting correctly
rods design  Forces acting on the connecting rod
192
 Design considerations
20.9.3 Analyse Analysing Crankshafts and camshaft design Crankshafts and camshaft design
crankshafts analysed correctly
and  Types of crankshafts
camshaft  Material used
 Design considerations
design
20.9.4 Analyse Analysing valve mechanism Valve mechanism analysed correctly
valve
mechanism  Valves
 Rocker Arm
20.9.5 Analyse Analysing engine blocks construction features Engine blocks construction features
engine analysed correctly
blocks  Cylinder block
construction  Crankcase
 Camshaft location and support
features
 Cylinder head
20.9.6 Apply gasket Applying gasket and seals Gasket and seals applied correctly
and seals
REFERENCES
Khurmi, (2016). Machine Design, New Delhi: S. Chand & Company LTD
Khurmi, R.S. (2013). Machine Design. New Delhi: S. Chand & Company LTD,
Khurmi, R.S. (2003). Strength of Materials. New Delhi: S. Chand & Company LTD
Shigley, J.E. ‘et al’ (2000). Mechanical Engineering, Mc Graw-Hill
193
MODULE 166-21-C STRENGTH OF MATERIALS
MODULE PURPOSE: To equip trainees with knowledge, skills and attitudes to apply principles of strength of materials to enable
them carry out repairs and maintenance.
1. Calculate stress and strain

2. Analyse torsion in circular shafts
3. Determine shear force and bending moment
4. Analyse bending of beams
5. Design riveted and welded joints
6. Analyse strain energy
7. Apply theories of failure
ASSESSMENT METHODS: The trainee will be assessed through;

 Assignments
 Practical exercises
 Written exercises
 Written and Practical Tests
 Laboratory tests
LEARNING CONDITIONS: Trainee must have access to the following:

 Lecture Notes
 Library
 Internet
 Workshop
194
 Laboratory
UNIT C21.1: CALCULATING STRESS AND STRAIN UNIT DURATION: 25 HOURS CREDITS: 2.5.

OUTCOMES
21.1.1 Classify loads Classifying loads Loads classified correctly
 Point load
 Distributed load
21.1.2 Calculate stress Calculating stress Stress calculated correctly

 Direct stress
 Shear stress
21.1.3 Calculate strain Calculating strain Strain calculated correctly

Tensile strain
Compressive strain
Shear strain
21.1.4 Relate stress and Relating stress and strain Stress and strain related correctly
strain  Hooke’s Law
 Young’ modulus
 Modulus of rigidity
 Graphical analysis
 Factor of safety
21.1.5 Apply Poisson’s Applying Poisson’s ratio Poisson’s ratio applied correctly
ratio  Lateral strain
 Volumetric strain
195
 Common materials Poisson’s ratio
21.1.6 Apply strain energy Applying strain energy Strain energy applied correctly
 Impact loads
 Suddenly applied loads
21.1.7 Calculate thermal Calculating thermal stress and strain Thermal stress and strain calculated
stress and strain  Single materials correctly
 Bimetallic materials
UNIT C21.2 ANALYSING TORSION IN CIRCULAR SHAFTS UNIT DURATION: 25 HOURS CREDITS: 2.5.

OUTCOMES
21.2.1 Determine shaft Determining shaft loads Shaft loads determined correctly
loads  Torsion load
 Bending load
 Axial load
21.2.2 Apply torsion Applying torsion equation Torsion equation applied correctly
equation
21.2.3 Relate shear stress Relating shear stress and shear strain Shear stress and strain related
and shear strain  Modulus of rigidity correctly
21.2.4 Calculate twisting of Calculating twisting of solid and hollow shafts Twisting of solid and hollow shafts
solid and hollow shafts Angle of twist calculated correctly
 Stresses in shafts 999
 shear stress
 Maximum longitudinal shear stress
196
 Maximum tensile stress

21.2.5 Calculate power and Calculating power and torque transmitted by shaft Power and torque transmitted by
torque transmitted by shaft  Solid shafts shaft calculated accurately
 Hollow shafts
21.2.6 Calculate torsion Calculating torsion resilience (strain energy) Torsion resilience calculated
resilience (strain energy)  Solid shafts correctly
 Hollow shafts
21.2.7 Analyse shaft Analysing shaft couplings Shaft couplings analysed correctly
couplings  Bolted
 Keyed
21.2.8 Analyse combined Analysing combined bending and torsion Combined bending and torsion
bending and torsion  Bolted analysed correctly
 Keyed
UIT C21.3: DETERMINING SHEAR FORCE AND BENDING MOMENT UNIT DURATION: 25 HOURS
CREDITS: 2.5.

OUTCOMES
21.3.1 Calculate shear Calculating shear force and bending moment Shear force and bending moment
force and bending moment  Classification by beams calculate
 Sign conventions
 Cantilever
 Simply supported beam
21.3.2 Draw shear force Drawing shear force and bending moment diagrams Shear force and bending moment
and bending moment  Sketching diagrams drawn correctly
diagrams  Drawing to scale
21.3.3 Determine shear Determining shear forces and bending moments Shear forces and bending
197
forces and bending  Uniformly distributed loads moments determined correctly

moments  Combined loading
 Varying distributed loads
21.3.4 Determine points of Determining points of maximum bending value of maximum Points of maximum bending value
maximum bending value of bending moment of maximum bending moment
maximum bending moment  Points at which it occurs determined correctly
21.3.5 Determine points of Determining points of contra flexure Point of contraflexure determined
contra flexure correctly
UNIT C21.4: ANALYSING BENDING OF BEAMS UNIT DURATION: 25 HOURS CREDITS: 2.5.

OUTCOMES
21.4.1 Apply theory of Applying theory of simple bending Theory of simple bending applied
simple bending  Bending equations correctly
 Assumptions
21.4.2 Determine the Determining the position of neutral axis Position of neutral axis determined
position of neutral axis  Centre of mass correctly
21.4.3 Determine the Determining the modulus of section Modulus of section determined
modulus of section  Rectangular section correctly
 Hollow rectangular section
 Circular section
 Hollow circular section
21.4.4 Derive the moment Deriving the moment of inertia of rectangular and circular Moment of inertia of rectangular
198
of inertia of rectangular and section and circular section derived

circular section  Solid section correctly
 Hollow section
21.4.5 Determine the Determining the strength of a beam in bending Strength of a beam in bending
strength of a beam in  Radius of curvature determined correctly
bending  Bending stress
UNIT C21.5: DESIGNING RIVETED AND WELDED JOINTS UNIT DURATION: 25 HOURS CREDITS: 2.5.

OUTCOMES
21.5.1 Classify riveted Classifying riveted joints Riveted joints classified correctly
joints  Lap joints
 Butt joints
21.5.2 Analyse failure of Analysing failure of riveted joints Failure of riveted joints analysed
riveted joints  Tearing correctly
 Shearing
 Bearing
21.5.3 Calculate efficiency Calculating efficiency of riveted joint Efficiency of riveted joint calculated
of riveted joint correctly
21.5.4 Classify welded Classifying welded joints Welded joints classified correctly
joints  Butt welds
 Lap welds
21.5.5 Analyse strength of Analysing strength of butt welds Strength of butt welds analysed
butt welds  Working stress correctly
199
 Twisting moment
 Size of weld
21.5.6 Use riveting Using terminology used in riveting Riveting terminology
terminology  Pitch used correctly
 Gauge line
 Gauge distance
 Back pitch
 Nominal diameter
 Gross diameter
 Edge distance
 Repeating section
UNIT C21.6: ANALYSING STRAIN ENERGY UNIT DURATION: 25 HOURS CREDITS: 2.5.

OUTCOMES
21.6.1 Analyse strain Analysing strain energy in torsion Strain energy in torsion analysed
energy in torsion  Solid shaft correctly
 Hollow shaft
21.6.2 Analyse strain Analysing strain energy in simple torsion and compression Strain energy in simple torsion and
energy in simple torsion  Stress due to compression analysed correctly
and compression o Gradually applied loads
o Suddenly applied loads
o Falling or impact load
21.6.3 Determine strain Analysing Determining strain energy in pure shearing Strain energy in pure shearing
energy in pure shearing o Solid shaft analysed correctly
21.6.4 Determine strain Determining strain energy due to bending Strain energy due to bending
energy due to bending analysed correctly
200
UNIT C21.7: APPLYING THEORIES OF FAILURE UNIT DURATION: 25 HOURS

CREDITS: 2.5.
OUTCOMES
21.7.1 Apply maximum Applying maximum principal stress theory Maximum principle stress theory
principal stress theory o Maximum tensile stress applied accordingly
o Working stress for materials
21.7.2 Apply maximum Applying maximum shear stress theory Maximum shear stress theory
shear stress theory  Maximum shear stress applied correctly
 Safe stress
21.7.3 Apply strain energy Applying strain energy theory Strain energy theory applied
theory o Elastic limit stress (tension) correctly
o Elastic limit stress (compression)
21.7.4 Apply shear strain Applying shear strain energy theory Shear strain energy theory applied
energy theory o Principal stresses per unit volume correctly
21.7.5 Apply maximum Applying maximum principal strain theory Poisson’s ratio applied correctly
principal strain theory  Poison’s Ratio
21.7.6 Represent Representing graphically theories for two-dimensional stress Theories for two dimensional
graphically theories for two system stress system graphically
dimensional stress system  Maximum principal stress theory presented correctly
 Maximum shear stress theory
 Maximum principal strain theory
 Maximum strain energy theory
201
 Maximum shear strain energy theory

 Motor circle
REFERENCES
Bansal, R.K. (2018). Strength of Materials (Mechanics of Solids). Mumbai: Repro India Ltd
Khurmi, R.S (2016). Machine Design, New Delhi: S. Chand & Company LTD
Khurmi, R.S. (2013). Machine Design. New Delhi: S. Chand & Company LTD,
Khurmi, R.S. (2003). Strength of Materials. New Delhi: S. Chand & Company LTD
Ryder, G.H. (1989). Strength of Materials. 3rd ed., England: Macmillian EducationLtd,.
Shigley, J.E. ‘et al’ (2000). Mechanical Engineering, Mc Graw-Hill
202
MODULE 166-22- C MOTOR INDUSTRY MANAGEMENT
MODULE PURPOSE: To equip trainees with knowledge, skills and attitudes required to enable them manage the motor vehicle
industry effectively and efficiently.
1. Interpret the Zambia legal system
2. Use engineering factors
3. Analyse operational requirements
4. Apply preventive maintenance measures
5. Use service equipment
6. Establish accident repair work
7. Produce invoice and costs
8. Identify appropriate department organization
9. Calculate transport operational costs
10. Apply transport management techniques
11. Interpret major transport Acts
ASSESSMENT METHODS: The trainee will be assessed through;

 Assignments
 Written exercises
 Tutorials
 Class tests
 Assignments
LEARNING CONDITIONS: Trainee must have access to the following:
203
 Lecture Notes
 Library
 Internet
UNIT C22.1 INTERPRETING THE ZAMBIAN LEGAL SYSTEM UNIT DURATION: 9 HOURS 0.9 CREDIT HOURS

LEARNING
OUTCOMES
22.1.1 Explain  Explaining the Zambian legal system Zambian legal system explained
Zambian legal system  Define correctly
o Law
o Legal action
o Customary law
o English common law
o Civil law
o Criminal law
22.1.2 Identify  Identifying sources of law Sources of law identified correctly
Sources of law o African customary law
o Judicial precedents
o Judicial precedents and the court system
o English law
o The common law
o Legislation and international agreements
22.1.3 Identify Court Identifying the court systems Court systems identified correctly
systems  Local courts
 Subordinate courts
 The High courts
o Industrial relations court
o Lands tribunal
204
 Supreme court
o Constitutional court
22.1.4 Describe Describing Arbitration Arbitration described correctly
Arbitration  Definition
 Arbitrator
 Process
 Arbitrability
22.1.5 Describe Describing mediation Mediation described correctly
Mediation  Definition
 Mediator
 Process
 Benefits
o Uses
22.1.6 Explain the Explaining the Law of sale of goods and services Law of sale of goods and services
Law of sale of goods  Sale of Goods Act explained correctly
and services o Terms of the contract
o Acceptance
o Passing of Property
o Specific and unascertained goods
o Rules on presuming intention
o Duties of seller & buyer
UNIT C22.2 APPLYING MOTOR TRANSPORT FACTORS UNIT DURATION: 6 HOURS
0.6 CREDIT HOURS
LEARNING
OUTCOMES
205
22.2.1 Identify Types

Identifying Types of freight and passenger vehicles Freight and passenger vehicles
of freight and  Freight vehicles identified correctly
passenger vehicles o Heavy Equipment
o Locomotive
o Light trucks and vans
o Medium trucks
o Heavy haulage trucks
 Passenger vehicles
o Cars
o Light buses
o Medium passenger buses
o Heavy passenger buses
22.2.2 Explain Role Explaining Role stability Role stability explained correctly
stability o Description
o Load capacity
o Axle rating
o Load distribution
22.2.3 Discuss Discussing Vehicle replacement Vehicle replacement discussed
Vehicle replacement o Description correctly
o Determinants
o Usability
o Service life
o Cost implications
22.2.4 Discuss Load  Discussing Load security system Load securing system discussed
security system o Description correctly
o Securing basics
o Responsibility for load securing
o Types of vehicles
o Load securing solutions
UNIT C22.3 APPLYING PREVENTIVE MAINTENANCE MEASURES UNIT DURATION: 8 HOURS 0.8 CREDIT
HOURS
206

LEARNING
OUTCOMES
22.3.1 Apply Applying Lubrication chart Lubrication chart applied correctly
lubrication chart o Description
o Charts
22.3.2 Discuss Flow- Discussing Flow-line service
line service  Definition
 Process
o Assembly line
o Continuous assembly line
22.3.3 Discuss Discussing Service records Service records discussed correctly
Service records o Description
o Vehicle service history
o Digital service record
o Job card
22.3.4 Discuss  Discussing Vehicle valeting process Vehicle valeting process discussed
Vehicle valeting o Description correctly
process o Vehicle preparation
o Process
UNIT C22.4 ANALYSING OPERATIONAL REQUIREMENTS UNIT DURATION: 8 HOURS
CREDITS: 0.8

LEARNING
OUTCOMES
22.4.1 Discuss Discussing operational Requirements Operational Requirements
operational  Code of practice discussed correctly
Requirements  Projecting loads
 Special type of vehicles
207
22.4.2 Apply MaterialApplying Material handling Material handling applied correctly

handling  Types of equipment for material handling:
 Manual Vs Automated systems
 Packaging design and types
 Marking and labelling
 Storage equipment
22.4.3 Apply Applying Maintenance records and standards Maintenance records and standards
Maintenance records  Need for Quality Maintenance Process applied correctly
and standards  Quality Control Charts for use in Maintenance
 Post-Maintenance Tests records
 Safety and Maintenance records
22.4.4 Apply Applying Maintenance schemes Maintenance schemes applied
Maintenance schemes  Description correctly
 Cost per page of maintenance scheme
 Labour maintenance scheme
 Leasing and maintenance scheme
22.4.5 Apply Applying Tachographs Tachographs applied correctly
Tachographs  Definition
o Data stored by the tachograph
o Types
o Entries
UNIT C22. 5 USING SERVICE EQUIPMENT UNIT DURATION: 6 HOURS 0.6 CREDIT HOURS

LEARNING
OUTCOMES
22.5.1 Apply Applying Equipment Purchase procedures Equipment purchase procedures
Equipment Purchase  Description applied correctly
procedures o Purpose
o Cost
208
o National regulations
22.5.2 Apply Applying Equipment Hiring Procedures Equipment Hiring procedures
Equipment Hiring  Description applied correctly
procedures o Agreements and contracts
o Merits and demerits
o Insurance waivers
22.5.3 Apply Applying equipment maintenance management Maintenance of equipment correctly

equipment  Plant Records System applied
maintenance  Scheduling of Maintenance Jobs
management  Specification of Maintenance Jobs
 Use of the Checklist
 Maintainability Assurance
 Feedbacks and Improvements
 Structure of the Maintenance Department
22.5.4 Commission Commissioning and decommissioning of equipment Commissioning and
and decommission of  Definitions decommissioning of equipment
equipment o Safety and legal compliance correctly applied
o Reliability
o Process and system operation
UNIT C22.6 MANAGING INSURANCE CLAIMS UNIT DURATION: 5 HOURS CREDIT HOURS0.5
LEARNING
OUTCOMES
22.6.1 Interpret Interpreting Insurance policy Insurance policy interpreted
Insurance policy  Define Insurance correctly
 Describe types of motor covers
 Outline procedure of making a claim
 Insurance assessor
209
22.6.2 Discuss Discussing Production of insurance quotations Production of insurance quotations

Production of  Description discussed correctly
insurance quotations  Assessment
 Types of quotations
 Process
22.6.3 Discuss Discussing Insurance invoices and completion notes Insurance invoices and completion
Insurance invoices  Description note discussed correctly
and completion notes  Pricing
 Invoices
 Completion notes
UNIT C22.7 PRODUCING INVOICE AND COSTS DURATION: 8 HOURS 0.8 CREDIT HOURS
LEARNING
OUTCOMES
22.7.1 APPLY Applying Principles of costing Principles of costing applied
Principles of costing  Definitions correctly
 Direct and indirect costs
 Elements of cost
o Fixed and Variable cost
 Functional costs
o Product cost
o Period cost
 Other cost classification
o Discretionary,
o Avoidable vs unavoidable
22.7.2 Discuss Discussing Manufacturer operational times Manufacturer operational times
Manufacturer  Explaining operational times discussed correctly
operational times  Defining operating cycle
o Lead/lag times
210
o Seasonal productional loads

o Plant location
22.7.3 Assess Vehicle Assessing Vehicle repair costs Vehicle repair costs assessed
repair costs  Reasons for Maintenance Costing. correctly
 Types of Maintenance Costs.
 Maintenance Labor Cost Estimations.
 Maintenance Material Cost Estimations.
 Maintenance Cost Estimation Models.
22.7.4 Apply Labour Applying Labour charge-out rate Labour charge-out rate applied
charge-out rate  Description correctly
Determinants of charge-out rate
o Chargeable hour rate
o Material cost for specific job
o Overhead cost for specific job
22.7.5 Discuss Site Discussing Site breakdowns Site breakdowns discussed correctly
breakdowns  Breakdown report
 Service request
 Service history
 Inspection chart and cost
UNIT C22.8 MANAGING PARTS DEPARTMENT IN AN ORGANISATION UNIT DURATION: 8 HOURS CREDIT :0.8
LEARNING
OUTCOMES
22.8.1 Analyse Need Analysing Need for parts department Need for parts department correctly
for parts department  Purpose analysed
 Cost factors
 Size of freight
 Material delivery time
211
22.8.2 Explain Explaining Warrant procedure Warrant procedure explained

Warrant procedure  Definition correctly
o Exemption clauses
o Signing of written documents
o Notice
22.8.3 Analyse Stock Analysing Stock control system Stock control system analysed
control system  Use documentation correctly
 Apply stock checking procedure e.g. 4-month stock
 Use stock control system
o Control of tools
o Control of equipment
o Control of material
22.8.4 Analyse Analysing Stock/turnover ratios Stock/turnover ratios analysed
Stock/turnover ratios  Definitions correctly
o Stock or inventory
o Goods sold
o Turnover
 Turnover ratio:
 Limitations
22.8.5 Apply Stock Applying Stock checking procedure Stock taking procedure applied
checking procedure  Reason for stock check correctly
o Periodical stocktaking
o Continuous stocktaking
o Planning and preparation
o Methods of stock check
o Spot check
o Valuing stock items
o Stock counting sheets
212
o Stock takers
UNIT C22.9 APPLYING TRANSPORT MANAGEMENT TECHNIQUES DURATION: 8 HOURS CREDITS: 0.8
LEARNING
OUTCOMES
22.9.1.Use data Using data Data used correctly
 Description
o Key objectives
o Charts and graphs
o Data, visual and text
22.9.2 Analyse Analysing Probability of vehicle breakdown Probabilities of vehicle breakdown
Probabilities of vehicle  Reasons why equipment fail analysed correctly
breakdown  Factors that cause equipment to fail
 Reliability
 Availability and Maintainability
 Maintenance Aids
22.9.3 Discuss Unit Discussing Unit and vehicle replacement Unit and Vehicle replacement
and vehicle  Life correctly discussed
replacement  Usage
 Factors
22.9.4 Apply Route Applying Route plans Route plans applied correctly
plans  Definition
o Factors affecting route planning
o Route planning
o Lost time
o Driver aids
o Determinants of optimal route
213
22.9.5 Design Vehicle

Designing Vehicle schedules Vehicle schedules designed
schedules  Description correctly
o Depot location
o Transport requisition
o Schedule
UNIT C22.10 CALCULATING TRANSPORT OPERATIONAL COSTS DURATION: 9HOURS 0.9 CREDIT HOURS
LEARNING
OUTCOMES
22.10.1 Analyse Cost Analysing Cost centres Cost centres analysed correctly
centres  Basis for apportionment
 Types of costs
 Cost distribution
 Overheads cost proportioning
 Recovery of overheads costs
 Overheads charges to customers
22.10.2 Analyse Costs Analysing Costs Costs analysed correctly
 Types of cost and their behaviour
o Direct and indirect
o Fixed and variable
 Treatment of assets and capital depreciation
o Infrastructure vehicle/carrying unit and others
 Transport costs
o Infrastructure
o Terminal
o Track access and facility charges
o Operating costs
 An approach to transport costing for single and multi‐modal
operations
214
22.10.3 Analyse Analysing Depreciation Depreciation analysed correctly

Depreciation
 Purpose
 Causes
 Appreciation
 Validity of appreciation
 Factors on which method of depreciation depends
22.10.4 Apply Break Applying breakeven charts Break even charts applied correctly
even charts  Uses
 Break even analysis
 Charts
22.10.5 Apply Applying Elasticity of demand Elasticity of demand applied
Elasticity of demand  Price correctly
 Income and cross
 Determinants
 Arc or point elasticity
22.10.6 Determine Determining Fare levels Fare levels determined correctly
Fare levels  Pricing principles
o The marginal cost pricing rule
 Efficient pricing
o Cost complexities and cost recovery
o Peak-load pricing
o Second-best pricing
o Transport subsidies
 Price discrimination.
 Pricing and market conditions – monopoly v competition
UNIT C22.11 INTERPRETING MAJOR TRANSPORT ACTS UNIT DURATION: 5 HOURS CREDIT: 0.5

LEARNING
215
OUTCOMES
22.11.1 Apply Applying Zambia Road Traffic Act Zambian Road Traffic Act applied
Zambian the Road  Register motor vehicle correctly
Traffic Act  Change of ownership
 Operators and drivers Licenses
 Goods and PSV regulations
22.11.2 Apply the Applying the Petroleum Act The Petroleum Act applied correctly
Petroleum Act o Handling of petroleum products
o Licences
 Forecourts
o Role
o Layout and management
o Operating procedure
22.11.3 Apply Applying the Factories Act The Factories Act applied correctly
Factories Act  Construction and Use (C&U) Regulation
 Workshop and warehouse setting and lay out
 Workshop equipment/machinery requirements
REFERENCE
Chandler, B. (1986). Motor Vehicle Workshop, Organisation and Administration. 4th ed. London: Oxford University Press
Cole, G.A. (2003). Management Theory and Practice
Edward, H. (2002). World-Class Warehousing and Materials Handling, McGraw Hill
Kelly, D. (2006). Business Law. Routledge Cavendish: UKC B March
Laws of Zambia
Mobley, et al, (2008). Maintenance Engineering Handbook. McGraw-Hill Professional.
Robert, G. (2001). Kick-Start Your Business: 100 Days to a Learner. London: Fitter Organization
White, P.R. (2002). Public Transport: its Planning, Management and Operation. 4th ed. London: Spon Press.
216
MODULE 166-23-C ADVANCED MOTOR VEHICLE TECHNOLOGY
MODULE PURPOSE: To equip the trainee with knowledge, skills and MODULE CREDIT HOURS: 20
appropriate attitudes to effectively and efficiently apply principles of DURATION: 200
advanced motor vehicle systems. HOURS
1. Analyse alternative energy motor vehicles
2. Analyse Environmental pollution control
3. Analyse Automated gearbox
4. Analyse Networking and communication in motor vehicles
5. Analyse multiplexing
6. Design vehicle safety systems
7. Design vehicle security systems
Assessment Criteria
 Exercises
 Class tests
 Assignments
 Practical projects
Learning conditions
 Lecture notes
 Library
 Handouts
 Tutorials
 Internet
 OEM manuals
UNIT 23.1 ANALYSING ALTERNATIVE ENERGY MOTOR VEHICLES UNIT DURATION CREDIT
217

OUTCOMES
Unit 23.1.1 Identify Identifying alternative energy motor vehicles Alternative energy motor
Alternative Energy o Electric Vehicles vehicles identified
Vehicles correctly
o Fuel Cell vehicles
o Hybrid vehicles
o Solar powered vehicle
Unit C23.1.2 Analyse Analysing Electric traction vehicle Types of electric vehicles
electric vehicles o Electric Vehicle batteries analysed correctly
o Drive motors
o AC Motors
o DC Motors – Series wound
o DC motors – separately excited shunt wound
 Fuel-cell Vehicles
o Fuel Cell Technology
o Power generation
o Transmission system
 Hybrid vehicle
o Prime mover
o DC/DC converter
o DC/AC inverter
o Controller
o Energy storage System
218
o Transmission system
Unit C23.1.3 Describe Describing layout of electric vehicles Layout of electric vehicles
layout of electric vehicles  Location of electric traction vehicle components described correctly
o Traction motor
o Power electronics controller
o DC/DC Converter
o Traction Battery Pack
 Location of hybrid vehicle components
o Engine
o Generator
o Batteries
o Traction motor
o Transmission
Unit C23.1.4 Explain Explaining operation of electric vehicles Operation of electric
operation of electric  Operations of electric traction vehicle vehicles explained
vehicles  Operations of hybrid vehicle correctly
Unit C23.1.5 Diagnose Diagnosing faults in electric vehicles Faults of electric vehicles
faults in electric vehicles  Electric traction vehicle components diagnosed correctly
o Traction motor
o Power electronics controller
o DC/DC Converter
o Traction Battery Pack
 Hybrid vehicle components
o Engine
o Generator
219
o Batteries
o Traction motor
o Transmission
UNIT C23.2 ANALYSING ENVIRONMENTAL POLUTION CONTROL

OUTCOMES
C23.2.1 Analyse Analysing Environmental pollution control Analysing, identifying and describing
Environmental pollution of components carried out correctly
control  Analyse various emission levels
 Environmental pollution control systems
 Exhaust Gas Recirculation (EGR)
 Selective Catalytic Reduction (SCR)
 Crankcase ventilation (CCV)
 Variable geometry turbocharger (VGT)
Particulate Diesel filter (PDF)
Unit C23.2.2 Diagnose and Diagnosing and Servicing Environmental pollution control Diagnosing, Disassembling and
Service components assembling of components carried
Environmental pollution out correctly
control components
 Disassemble and assemble of Exhaust Gas Recirculation
(EGR) components
 Replace Selective Catalytic Reduction (SCR) components
 Disassemble and assemble of crankcase ventilation (CCV)
220
components
 Disassemble and assemble of Variable geometry
turbocharger (VGT)
 Disassemble and assemble of Particulate Diesel filter (PDF)
C23.2.3 Describe the Describing the Operation of an Automated gearbox Operation of automated gearbox
Operation of an Automated  Components explained correctly
gearbox
 Construction
 Operation
Unit C23.2.4 Diagnose and Diagnosing and Servicing automated Gearbox; Diagnosing, Disassembling and
Service assembling of components carried
Automated Gearbox  Disassembling and assembling of Automated gearbox out correctly
components
 Replacing of Pneumatic cylinders
 Replacing of actuator pistons
 Replacing sensors
UNIT C23.3 ANALYSING NETWORKING AND COMMUNICATION IN MOTOR VEHICLES

OUTCOMES
221
Unit C23.3.1 Explain Explaining Networking and communication in motor vehicles ; Networking and communication in motor
Networking and  Defining terms ‘Networking and communication’ vehicles correctly explained
communication in motor  Explaining LANS and intranet system
vehicles  Identifying The telecommunications system
o Transmission media
o Security issues
o Satellite communications technology
o Vehicle navigation
o Vehicle control center
o Infrared information system [IRIS]
 Maintaining vehicle networking and communication system
Diagnosing vehicle networking and communication system
UNIT C23.4 ANALYSING MULTIPLEXING

OUTCOMES
Unit C23.4.1 Analyse Analysing Multiplexing; multiplexing analysed correctly
Multiplexing  Explaining Multiplexing
 Analysing Multiplexing Principles
o Powerline carrier
o Types of logic
o Serial data transmission
o ISO 9141
o The 1939 Backbone
o Diamond Logic
o Virtual fusing
 Stating benefits of networking
o Accessing the Data Bus
o J1587/1708 Connector
o J1939 Connector
222
o Connect to chassis Data Bus

 Maintaining multiplex system
Diagnosing multiplex system faults
UNIT C23.5 DESIGNING VEHICLE SAFETY SYSTEMS

OUTCOMES
Unit C23.5.1 Identify the 
Identifying the vehicle safety Security system Vehicle security system Identified
Vehicle Security system o Supplemental Restraint system (SRS) correctly
o Collision warning
o Alcohol detection system
 Turning Headlamps
Unit C23.5.1 Analyse the  Identifying the vehicle safety system Vehicle security system analysed
Vehicle Security system o Supplemental Restraint system (SRS) correctly
o Collision warning
o Alcohol detection system
o Turning Headlamps
UNIT C23.6 DESIGNING VEHICLE SECURITY SYSTEMS

OUTCOMES
23.6.1 Vehicle security  Identifying Central looking system Vehicle security system explained
system o Overview and maintained correctly
o Variants
o Wireless remote control
 Identifying Immobilizer circuit and operation
o Location
o Functional behaviour
 Identifying Electronic window system
o Function
223
o Component location
 Explaining Supplementary restraint system [SRS]
o Function
o Component location
 Alarm system
o Function
o Types
o Arming
o Disarming
 Maintaining vehicle security system
 Diagnosing vehicle security system faults
REFERENCE
224
MODULE 166-24-C DESIGN PROJECT

MODULE PURPOSE: To equip the trainee with knowledge, skills and appropriate attitudes to design and execute a project
1. Explain the requirements of a viable project

2. Analyze sources of viable project ideas
3. Select an appropriate project
4. Review literature appropriate to the project
5. Plan a realistic budget and timeline for the project
6. Design the project prototype
7. Evaluate the performance of the prototype
8. Present a project report
LEARNING CONDITIONS: Values and attitudes ASSESSMENT METHODS: The trainee will be
Trainee must have access to assessed through;
the following: Hardwork  Written project proposal
 Lecture Notes  Project proposal presentation
 Library Integrity  Written project report
 Internet  Laboratory exercises
Orderliness
 Workshop  Prototype evaluation
 Laboratory
UNIT C24.1: EXPLAINING THE REQUIREMENTS OF A VIABLE PROJECT UNIT DURATION: 10 HOURS
CREDITS: 1
225
SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT

OUTCOMES CRITERIA
24.1.1 Identify project Identifying project design challenges Project design challenges
design challenges identified correctly
24.1.2 Explain the Explaining the requirements of a viable project: Requirements of a viable
requirements of a viable  well organised project report project explained
project  working prototype correctly
 cost effective
 An innovative, adaptive or new
 Positive impact on the environment
 Solution to an existing problem in industry
UNIT C24.2: ANALYSING SOURCES OF VIABLE PROJECT IDEAS
UNIT DURATION: 10 HOURS CREDITS: 1
OUTCOMES CRITERIA
24.2.1 Identify potential Identifying potential project idea sources Potential project idea
project idea sources sources identified
correctly
24.2.2 Analyse sources of Analysing sources of viable project ideas; Sources of viable project
viable project ideas  Industry ideas analysed correctly
 Internet
 Lecturers
 Experts in the field
 Experience
24.2.3 Compare the Comparing sources of project ideas; Sources of project ideas
sources of project ideas  Industry compared correctly
 Internet
 Lecturers
226
 Experts in the field

 Experience
UNIT C24.3 SELECTING AN APPROPRIATE PROJECT UNIT DURATION: 20 HOURS CREDITS: 2

OUTCOMES CRITERIA
24.3.1 Identify workable Identifying workable project ideas; Workable project ideas
project ideas  possible projects identified correctly
 manageable projects
 Non-workable ideas
24.3.2 Select an Selecting an appropriate project: An appropriate project
appropriate project  Relevant to the field selected correctly
 Within the scope and discipline of the student
 Provoking creativity and innovation
 Cost effective and environmentally friendly
UNIT C24.4: REVIEWING LITERATURE APPROPRIATE TO THE PROJECT
UNIT DURATION: 10 HOURS CREDITS: 1
OUTCOMES CRITERIA
24.4.1 Identify relevant Identifying relevant literature; Relevant literature
literature  Student papers on the internet identified correctly
 YouTube
 Journals
 Books/Machine Manufactures’ manuals
 Research papers published by experts and institutions
 Questionnaires and interviews
227
24.4.2 Review literature Reviewing literature relevant to the project: literature relevant to the
relevant to the project  Student papers on the internet project reviewed correctly
 YouTube
 Journals
 Books/Machine Manufacturers’ manual
 Research papers published by experts and institutions
 Questionnaires and interviews
UNIT C24.5: PLANNING A REALISTIC BUDGET AND TIMELINE FOR THE PROJECT
OUTCOMES CRITERIA
24.5.1 Identify project costs Identifying project costs Project costs identified
 Direct costs correctly
 Indirect costs
 Contingency costs
 Unforeseen costs
24.5.2 Plan a realistic Planning a realistic project budget A realistic project budget
project budget  Direct costs planned correctly
 Indirect costs
 Contingency costs
 Unforeseen costs
24.5.3 Plan a realistic Planning a realistic timeline for the project: A realistic timeline for the
timeline for the project  Prepare Gantt chart project planned correctly
 Stick to milestones
 Each activity with well-defined time frame
228
UNIT C24.6: DESIGNING THE PROJECT PROTOTYPE UNIT DURATION: 60 HOURS CREDITS: 6
OUTCOMES CRITERIA
24.6.1 Outline project Outlining project layout Project layout outlined
layout  Block diagrams correctly
 Schematic diagrams
 Draft project proposal
 Present project proposal
 Well acknowledged project research report
24.6.2 Identify the Identifying the prototype materials in line with the layout The prototype materials
prototype materials in line  Locally procured in line with layout
with layout  Overseas identified correctly
 Within institution
24.6.3 Designthe Designing the prototype Prototype designed

prototype  Organising tools correctly
 Assembling materials/components
 Testing and modification
UNIT C24.7: EVALUATING THE PERFORMANCE OF THE PROTOTYPE
UNIT DURATION: 30 HOURS
CREDITS: 3
OUTCOMES CRITERIA
24.7.1 Apply safety Applying safety procedures Safety procedures
procedures  Verification of compliance to safety applied correctly
229
24.7.2 Evaluate the Evaluating the performance of the prototype Prototype performance
prototype performance  Setting up evaluated correctly
 Running
 Documenting observed phenomena or any other areas
worth reporting
 Make conclusions and recommendations
UNIT C24.8: PRESENTING A PROJECT REPORT
OUTCOMES CRITERIA
24.8.1 Identify conditions Identifying conditions for effective project presentation Tools for effective project
for effective project  Appropriate attire presentation
presentation  Well organised and bound report
 Well timed rehearsals way in advance
 Neat, well presented and labelled prototype
24.8.2 Present a Project Presenting a project report: Project Reported
Report  Appropriate attire presented correctly
 Well organised and bound report
 Well timed rehearsals way in advance
Neat, well presented and labelled prototype
REFERENCES
Mobley, et al (2008). Maintenance Engineering Handbook, McGraw-Hill Professional, Seventh Edition.
Robert, G. (2001). Kick-Start Your Business: 100 Days to a Learner, Fitter Organization; Virgin Books Limited. London
White, P.R. (2002). Public Transport: its Planning, Management and Operation. (4th ed.), London: Spon Press
230

Approved Syllabus - Diploma in Automotive Engineering 18-01-2021

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ENGINEERING PROGRAMMES

ZAMBIA QUALIFICATIONS FRAMEWORK (ZQF) LEVEL 6

Approved November, 2020

ABS Anti-lock Braking System

MODULE 166-04-A ENGINEERING DRAWING I .............................................................................................................. 12

1.0. ABOUT TEVETA

NO NAME POSITION ORGANISATION

12. Mr. Ackim M. Kalikeka Specialist – LMDD TEVETA

4.0. PROGRAMME PURPOSE

5.0. PROGRAMME LEVEL DESCRIPTOR

5.2.3. Ability to operate high tech machinery in the automotive industry

5.3. Reflexive Competences

6.0. PROGRAMME OUTCOMES:

7.0. PROGRAMME DURATION

8.0. PROGRAMME OUTLINE

MODULE TITLE HOURS

INDUSTRIAL ATTACHMENT 480

166-19-C FLUID MECHANICS 160

9.0. DELIVERY MODES AND METHODS

10.0. PROGRAMME EVALUATION

10.1. Formative evaluation

11.0. PROGRAMME ENTRY REQUIREMENTS:

12.0. TRAINEE ASSESSMENT

15.0. STAFF QUALIFICATIONS

MODULE 166-01-A WORKSHOP PROCESSES MODULE DURATION: 100 HOURS CREDITS: 10

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

SPECIFIC LEARNING LEARNING ACTIVITIES: ASSESSMENT CRITERIA

SPECIFIC LEARNING LEARNING ACTIVITIES: ASSESSMENT CRITERIA

SPECIFIC LEARNING LEARNING ACTIVITIES: ASSESSMENT CRITERIA

 Identifying isolation Points

 Placing notice – work in progress

 Isolating and testing

 Locking and getting the key

 Identifying Hazardous energy sources

SPECIFIC LEARNING LEARNING ACTIVITIES: ASSESSMENT CRITERIA

 Carry out house Keeping in the workshop

SPECIFIC LEARNING LEARNING ACTIVITIES: ASSESSMENT CRITERIA

SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA

SPECIFIC LEARNING LEARNING ACTIVITIES: ASSESSMENT CRITERIA

UNIT A1.9 PERFORMING RIGGING OPERATIONS UNIT DURATION: 10 HOURS CREDITS: 1

SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA

 lifting and support points

UNIT A1.10 PERFORMING BASIC WELDING UNIT DURATION: 10 HOURS CREDITS: 1

SPECIFIC LEARNING LEARNING ACTIVITIES: ASSESSMENT CRITERIA

MODULE DURATION: 120 CREDITS: 20

Learning Conditions Values and attitudes Assessment Methods:

SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA

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

SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA

SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA

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

SPECIFIC LEARNING LEARNING ACTIVITIES: ASSESSMENT CRITERIA

2.4.2 Calculate logarithms Calculating logarithms Indices solved correctly

SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA

 coordinates on a pair of labelled Cartesian axes

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

2.5.3.Interpret information Interpreting information from graphs Information from graphs

SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA

2.6.4.Sketch quadratic Sketching quadratic functions Quadratic functions sketched

SPECIFIC LEARNING LEARNING ACTIVITIES ASSESSMENT CRITERIA

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

2.7.3.Manipulate trigonometric Manipulate trigonometric identities Trigonometric identities

 double angle formulae

UNIT A2.8: CALCULATING VECTORS UNIT DURATION 13 HOURS CREDITS: 1.3