REPUBLIC OF KENYA

COMPETENCY BASED MODULAR CURRICULUM

FOR

CONSTRUCTION PLANT TECHNOLOGY

KNQF LEVEL 5

ISCED PROGRAMME CODE: 0716 454A

©QAI 2025 ii
©2025

All rights reserved. No part of this Curriculum may be reproduced, distributed, or transmitted
in any form or by any means, including photocopying, recording, or other electronic or
mechanical methods without the prior written permission of …….., except in the case of brief
quotations embodied in critical reviews and certain other non-commercial uses permitted by
copyright law. For permission requests, write to the Council Secretary/CEO/Chief Principal
at the address below:

©QAI 2025 iii

 FOREWORD
The provision of quality education and training is fundamental to the Government’s overall
strategy for social and economic development. Quality education and training contribute to
the achievement of Kenya’s development blueprint and sustainable development goals.

Reforms in the education sector are necessary to achieve Kenya Vision 2030 and meet the
provisions of the Constitution of Kenya 2010. The education sector had to be aligned to the
Constitution, and this resulted in the formulation of the Policy Framework for Reforming
Education and Training in Kenya (Sessional Paper No. 14 of 2012). A key feature of this
policy is the radical change in the design and delivery of TVET training. This policy
document requires that training in TVET be competency-based, curriculum development be
industry-led, certification be based on demonstration of competence, and the mode of
delivery allow for multiple entry and exit in TVET programmes.

These reforms demand that Industry takes a leading role in curriculum development to ensure
the curriculum addresses its competence needs. It is against this background that this
curriculum has been developed. For trainees to build their skills on foundational hands-on
activities of the occupation, units of learning are grouped in modules. This has eliminated
duplication of content and streamlined exemptions based on skills acquired as a trainee
progresses in the up-skilling process, while at the same time allowing trainees to be
employable in the shortest time possible through the acquisition of part qualifications.

It is my conviction that this curriculum will play a great role in developing competent human
resources for the Mechanical Engineering Sector’s growth and development.

PRINCIPAL SECRETARY

STATE DEPARTMENT FOR TVET

MINISTRY OF EDUCATION

©QAI 2025 iv
 PREFACE
Kenya Vision 2030 aims to transform Kenya into a newly industrializing middle-income
country, providing high-quality life to all its citizens by the year 2030. Kenya intends to
create globally competitive and adaptive human resource base to meet the requirements of a
rapidly industrializing economy through lifelong education and training. TVET has a
responsibility to facilitate the process of inculcating knowledge, skills, and worker behaviour
necessary for catapulting the nation to a globally competitive country, hence the paradigm
shift to embrace Competency-Based Education and Training (CBET).

TVET Act, CAP 210A and Sessional Paper No. 1 of 2019 on Reforming Education and
Training in Kenya for Sustainable Development emphasized the need to reform curriculum
development, assessment, and certification. This called for a shift to CBET to address the
mismatch between skills acquired through training and skills needed by industry, as well as
increase the global competitiveness of the Kenyan labour force.

This curriculum has been developed in adherence to the Kenya National Qualifications
Framework and CBETA standards and guidelines. The curriculum is designed and organized
into Units of Learning with Learning Outcomes, suggested delivery methods, learning
resources, and methods of assessing the trainee’s achievement. In addition, the units of
learning have been grouped in modules to concretize the skills acquisition process and
streamline upskilling.

I am grateful to all expert trainers and everyone who played a role in translating the
Occupational Standards into this competency-based modular curriculum.

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 ACKNOWLEDGMENT

This curriculum has been designed for competency-based training and has independent units
of learning that allow the trainee flexibility in entry and exit. In developing the curriculum,
significant involvement and support were received from expert trainers, institutions and
organizations.

I recognize with appreciation the role of the Engineering and Manufacturing National Sector
Skills Committee (NSSC) in ensuring that competencies required by the industry are
addressed in the curriculum. I also thank all stakeholders in the Construction Plant
Engineering sector for their valuable input and everyone who participated in developing this
curriculum.

I am convinced that this curriculum will go a long way in ensuring that individuals aspiring to
work in the Construction Plant Engineering Sector acquire competencies to perform their
work more efficiently and effectively.

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 TABLE OF CONTENTS
FOREWORD............................................................................................................................iv
PREFACE..................................................................................................................................v
ACKNOWLEDGMENT...........................................................................................................vi
ABBREVIATIONS AND ACRONYMS...............................................................................viii
KEY TO ISCED UNIT CODE.................................................................................................ix
COURSE OVERVIEW..............................................................................................................x
MODULE I...............................................................................................................................1
DIGITAL LITERACY...............................................................................................................2
TECHNICAL DRAWING.......................................................................................................28
CONSTRUCTION PLANT ENGINES MAINTENANCE.....................................................34
MODULE II............................................................................................................................48
COMMUNICATION SKILLS................................................................................................49
APPLIED MATHEMATICS...................................................................................................53
ELECTRICAL AND ELECTRONICS PRINCIPLES............................................................59
CONSTRUCTION PLANT HYDRAULIC SYSTEM MAINTENANCE.............................81
MODULE III..........................................................................................................................95
ENTREPRENEURIAL SKILLS.............................................................................................96
CONSTRUCTION PLANT TRANSMISSION SYSTEM MAINTENANCE.....................101
CONSTRUCTION PLANT BRAKE SYSTEM MAINTENANCE.....................................117
MODULE IV........................................................................................................................128
WORK ETHICS AND PRACTICES....................................................................................129
MECHANICAL SCIENCE...................................................................................................135
CONSTRUCTION PLANT STEERING AND SUSPENSION SYSTEMS MAINTENANCE
................................................................................................................................................141

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 ABBREVIATIONS AND ACRONYMS
TVET Technical and Vocational Education and Training
RAM Random Access Memory
DVD Digital Versatile Disk
HDMI High-Definition Multimedia Interface
DVI Digital Visual Interface
VGA Video Graphics Array
USB Universal Serial Bus
ISCED International Standard Classification of Education
IEEE Institute of Electrical and Electronics Engineers
PPE Personal Protective Equipment
PLC Programmable Logic Controller
PCB Printed Circuit Board
LCD Liquid Crystal Display
LED Light Emitting Diode
ADC Analog-to-Digital Converter
DAC Digital-to-Analog Converter
IC Integrated Circuit
TRIAC Triode for Alternating Current
MOSFET Metal-Oxide-Semiconductor Field-Effect Transistor
BJT Bipolar Junction Transistor
RC Resistor Capacitor
RL Resistor Inductor
DC Direct Current
EMF Electromotive Force
MMF Magnetomotive Force
EV Electric Vehicle
SOC State of Charge
DOD Depth of Discharge
AC Alternating Current
KVL Kirchhoff's Voltage Law
KCL Kirchoff's Current Law
CV Curriculum Vitae

©QAI 2025 viii

 KEY TO ISCED UNIT CODE

©QAI 2025 ix
 COURSE OVERVIEW
The Construction Plant Technician Level 5 curriculum consists of competencies that a person
must achieve to enable him/her to service, maintain the construction plant in industry. It
includes applying digital literacy, applying communication skills, applying work ethics and
practices, applying entrepreneurial skills, applying workshop technology, applying technical
drawings, applying electrical and electronics principles, applying mathematics, and applying
mechanical science. It also includes; maintaining construction plant hydraulic system,
maintaining construction plant engine, maintaining construction plant brake system,
maintaining construction plant transmission system and maintaining construction plant
steering and suspension systems,

The units of competency comprising Construction Plant Technician Certificate Level 5

qualifications include the following competencies:

UNIT CODE UNIT NAME DURATION(Hours)

MODULE I

0611451 01A Digital Literacy 80

0715 451 02A Apply Workshop Technology 80

0732 441 03A Apply Technical Drawing 80

0716451 04A Maintain Construction Plant Engines 160

TOTAL 400 HRS

MODULE II
0031441 05A Communication Skills 40

0541 441 06A Apply Mathematics 80

0713441 07A Electrical and Electronics Principles 80

0716451 08A Maintain Construction Plant Hydraulic 160
System

TOTAL 360 HRS

MODULE III
0413441 09A Entrepreneurial Skills 40
0716 451 10A Maintain Construction Plant 160
Transmission System

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 0716 451 11A Maintain Construction Plant Brake 150
System
TOTAL 350 HRS
MODULE IV
0417441 12A Work Ethics and Practices 40
0715 441 13A Mechanical science 80
0716 451 14A Maintain Construction Plant Steering 150
and Suspension Systems
TOTAL 340HRS
INDUSTRIAL ATTATCHMENT 480 HRS
GRAND TOTAL 1930 HRS

Entry Requirements
An individual entering this course should have any of the following minimum requirements:
a) Kenya Certificate of Secondary Education (KCSE) mean grade D (Plain) or KCE
Division III
Or
b) Completion of KNQF level 4 certificate in construction plant
c) Equivalent qualification as determined by TVETA.

Trainer Qualification
A trainer for any of the units of competency in this course must:

a) Possession of at least level 6 qualification in Construction Plant Engineering or its

equivalent in Construction Plant Engineering.
b) Licensed by TVETA.
c) Registered by Engineer Board of Kenya (E.B.K) or Kenya Engineering Technology
Registration Board (KETRB).

Industry Training
An individual enrolled in this course will be required to undergo Industry training for a
minimum period of 480 hours in Construction Plant Engineering sector. The industrial
training may be taken after completion of all units for those pursuing the full qualification or
be distributed equally in each unit for that pursuing part qualification. In the case of dual
training model, industrial training shall be as guided by the dual training policy.

Assessment
The course shall be assessed formatively and summatively:

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 a) During formative assessment all performance criteria shall be assessed based on
performance criteria weighting.
b) Number of formative assessments shall minimally be equal to the number of
elements in a unit of competency.
c) During summative assessment basic and common units may be integrated in the
core units or assessed as discrete units.
d) Theoretical and practical weight shall be as follows:
i. 10:90 for unit in module 1 and module 2 for each unit of learning.
ii. 30:70 for units in module 3 and module 4 for each unit of learning.
e) Formative and summative assessments shall be weighted at 60% and 40%
respectively in the overall unit of learning score
f) For a candidate to be declared competent in a unit of competency, the candidate
must meet the following conditions:
i) Obtained at least 40% in theory assessment in formative and summative
assessments.
ii) Obtained at least 60% in practical assessment in formative and summative
assessment where applicable.
iii) Obtained at least 50% in the weighted results between formative assessment
and summative assessment where the former constitutes 60% and the latter
40% of the overall score.
g) Assessment performance rating for each unit of competency shall be as follows:
MARKS COMPETENCE RATING

80 -100 Attained Mastery

65 - 79 Proficient

50 - 64 Competent

49 and below Not Yet Competent

Y Assessment Malpractice/irregularities

h) Assessment for Recognition of Prior Learning (RPL) may lead to award of part
and/or full qualification.
Certification

©QAI 2025 xii

A candidate will be issued with a Certificate of Competency upon demonstration of
competence in a core Unit of Competency. To be issued with Kenya National TVET
Certificate in Construction Plant KNQF Level 5, the candidate must demonstrate competence
in all the Units of Competency as given in the qualification pack. A Statement of Attainment
certificate may be issued upon demonstration of competence in a certifiable element within a
unit.

The certificates will be issued by the Qualification Awarding Institution

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 MODULE I

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 DIGITAL LITERACY
ISCED UNIT CODE: 0611 451 01A
Relationship with Occupational Standards
This unit addresses the Unit of Competency: Apply Digital Literacy
Duration of Unit: 40 Hours
Unit Description
This unit covers the learning outcomes to demonstrate digital literacy. It involves operating
computer devices, solving tasks using the office suite, managing data and information,
performing online communication and collaboration, applying cybersecurity skills and job
entry techniques, and performing jobs online.
Summary of Learning Outcomes
By the end of this unit of learning, the trainee will be able to:
S/No. Learning Outcome Duration (Hours)
1. Solve tasks using office suite 5
2. Manage data and information 10
3. Perform online communication and collaborations 5
4. Apply cybersecurity skills 5
5. Perform online jobs 10
6. Apply job entry techniques. 5
Total 40

Learning Outcomes, Content, and Suggested Assessment Methods

Learning Outcome Content Suggested
Assessment
Methods
1. Solve tasks using Office 2.1 Meaning and Importance of ● Observation
suite Word Processing ● Written

2.2 Examples of Word Processors ● Practical

2.3 Working with word documents assessment

● Portfolio of
2.3.1 Open and close word
Evidence
processor
● Project
2.3.2 Create a new
● assessment
document

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Learning Outcome Content Suggested
Assessment
Methods
2.3.3 Save a document
2.3.4 Switch between open
documents
2.4 Enhancing productivity
2.4.1 Set basic
options/preferences
2.4.2 Help resources
2.4.3 Use magnification/zoom
tools
2.4.4 Display, hide built-in tool
bar
2.4.5 Using navigation tools
2.5 Typing Text
2.6 Document editing (copy, cut,
paste commands, spelling and
Grammar check)
2.7 Document formatting
2.7.1 Formatting text
2.7.2 Formatting paragraph
2.7.3 Formatting styles
2.7.4 Alignment
2.7.5 Creating tables
2.7.6 Formatting tables
2.8 Graphical objects
2.8.1 Insert object (picture,
drawn object)
2.8.2 Select an object
2.8.3 Edit an object

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Learning Outcome Content Suggested
Assessment
Methods
2.8.4 Format an object
2.9 Document Print setup
2.9.1 Page layout,
2.9.2 Margins set up
2.9.3 Orientation.
2.10 Word Document Printing
2.11 Meaning & Importance of
electronic spreadsheets
2.12 Components of Spreadsheets
2.13 Application areas of
spreadsheets.
2.14 Using spreadsheet application
2.14.1 Parts of Excel screen:
ribbon, formula bar,
active cell, name box,
column letter, row
number, Quick Access
Toolbar.
2.14.2 Cell Data Types
2.14.3 Block operations
2.14.4 Arithmetic operators
(formula bar (-, +,
*, /).
2.14.5 Cell Referencing
2.15 Data Manipulation
2.15.1 Using Functions (Sum,
Average, SumIF,
Count, Max, Max, IF,
Rank, Product, mode

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Learning Outcome Content Suggested
Assessment
Methods
etc)
2.15.2 Using Formulae
2.15.3 Sorting data
2.15.4 Filtering data
2.15.5 Visual representation
using charts
2.16 Worksheet printing
2.17 Electronic Presentations
2.18 Meaning and Importance of
electronic presentations
2.19 Examples of Presentation
Software
2.20 Using the electronic
presentation application
2.20.1 Parts of the
PowerPoint screen
(slide navigation pane,
slide pane, notes, the
ribbon, quick access
toolbar, and scroll
bars).
2.20.2 Open and close
presentations
2.20.3 Creating Slides (Insert
new slides, duplicate,
or reuse slides.)
2.20.4 Text Management
(insert, delete, copy,
cut and paste, drag and

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Learning Outcome Content Suggested
Assessment
Methods
drop, format, and use
spell check).
2.20.5 Use
magnification/zoom
tools
2.20.6 Apply or change a
theme.
2.20.7 Save a presentations
2.20.8 Switch between open
presentations
2.21 Developing a presentation
2.21.1 Presentation views
2.21.2 Slides
2.21.3 Master slide
2.22 Text
2.22.1 Editing text
2.22.2 Formatting
2.22.3 Tables
2.23 Charts
2.23.1 Using charts
2.23.2 Organization charts
2.24 Graphical objects
2.24.1 Insert, manipulate
2.24.2 Drawings
2.25 Prepare outputs
2.25.1 Applying slide effects
and transitions
2.25.2 Check and deliver

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Learning Outcome Content Suggested
Assessment
Methods
2.25.2.1 Spell check a
presentation
2.25.2.2 Slide
orientation
2.25.2.3 Slide shows,
navigation
2.26 Print presentations (slides and
handouts)
2. Manage Data and 3.1 Meaning of Data and information  Observation
Information 3.2 Importance and Uses of data and  Portfolio of

information Evidence
 Project
3.3 Types of internet services
 Written
3.3.1 Communication
assessment
Services
 Practical
3.3.2 Information Retrieval
assessment
Services
3.3.3 File Transfer
3.3.4 World Wide Web
Services
3.3.5 Web Services
3.3.6 Automatic Network
Address Configuration
3.3.7 News Group
3.3.8 Ecommerce
3.4 Types of Internet Access
Applications
3.5 Web browsing concepts
3.5.1 Key concepts

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Learning Outcome Content Suggested
Assessment
Methods
3.5.2 Security and safety
3.6 Web browsing
3.6.1 Using the web browser
3.6.2 Tools and settings
3.6.3 Clearing Cache and
cookies
3.6.4 URIs
3.6.5 Bookmarks
3.6.6 Web outputs
3.7 Web based information
3.7.1 Search
3.7.2 Critical evaluation of
information
3.7.3 Copyright, data
protection
3.8 Downloads Management
3.9 Performing Digital Data Backup
(Online and Offline)
3.10 Emerging issues in internet
3. Perform online 4.1 Netiquette principles  Observation
communication and 4.2 Communication concepts  Written
collaboration  Practical
4.2.1 Online communities
assessment
4.2.2 Communication tools
 Portfolio of
4.2.3 Email concepts
Evidence
4.3 Using email
 Project
4.3.1 Sending email
 assessment
4.3.2 Receiving email
4.3.3 Tools and settings

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Learning Outcome Content Suggested
Assessment
Methods
4.3.4 Organizing email
4.4 Digital content copyright and
licenses
4.5 Online collaboration tools
4.5.1 Online Storage (Google
Drive)
4.5.2 Online productivity
applications (Google Docs
& Forms)
4.5.3 Online meetings (Google
Meet/Zoom)
4.5.4 Online learning
environments
4.5.5 Online calendars (Google
Calendars)
4.5.6 Social networks
(Facebook/Twitter -
Settings & Privacy)
4.6 Preparation for online
collaboration
4.6.1 Common setup features
4.6.2 Setup
4.7 Mobile collaboration
4.7.1 Key concepts
4.7.2 Using mobile devices
4.7.3 Applications
4.7.4 Synchronization
4. Apply cybersecurity skills 5.1 Data protection and privacy  Observation

5.1.1 Confidentiality of  Written

©QAI 2025 9
Learning Outcome Content Suggested
Assessment
Methods
data/information  Practical

5.1.2 Integrity of assessment

data/information  Portfolio of
Evidence
5.1.3 Availability of
 Project
data/information
 assessment
5.2 Internet security threats
5.2.1 Malware attacks
5.2.2 Social engineering
attacks
5.2.3 Distributed denial of
service (DDoS)
5.2.4 Man-in-the-middle
attack (MitM)
5.2.5 Password attacks
5.2.6 IoT Attacks
5.2.7 Phishing Attacks
5.2.8 Ransomware
5.3 Computer threats and crimes
5.4 Cybersecurity control measures
5.4.1 Physical Controls
5.4.2 Technical/Logical
Controls (Passwords,
PINs, Biometrics)
5.4.3 Operational Controls
5.5 Laws governing protection of
ICT in Kenya
5.5.1 The Computer Misuse
and Cybercrimes Act

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Learning Outcome Content Suggested
Assessment
Methods
No. 5 of 2018
5.5.2 The Data Protection
Act No. 24 Of 2019
5. Perform Online Jobs 6.1 Introduction to online working  Observation

6.2 Types of online Jobs  Written

 Practical
6.3 Online job platforms
assessment
6.3.1 Remotask
 Portfolio of
6.3.2 Data annotation tech
Evidence
6.3.3 Cloud worker
 Project
6.3.4 Upwork
 assessment
6.3.5 Oneforma
6.3.6 Appen
6.4 Online account and profile
management
6.5 Identifying online jobs/job
bidding
6.6 Online digital identity
6.7 Executing online tasks
6.8 Management of online payment
accounts.
6. Apply job entry 7.1 Types of job opportunities  Observation
techniques 7.1.1 Self-employment  Written
 Practical
7.1.2 Service provision
assessment
7.1.3 product development
 Portfolio of
7.1.4 salaried employment
Evidence
7.1.4.1 Sources of job
 Project
opportunities
 assessment
7.2 Resume/ curriculum vitae

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Learning Outcome Content Suggested
Assessment
Methods
7.2.1 What is a CV
7.2.2 How long should a CV
be
7.2.3 What to include in a
CV
7.2.4 Format of CV
7.2.5 How to write a good
CV
7.2.6 Don’ts of writing a CV
7.3 Job application letter
7.3.1 What to include
7.3.2 Addressing a cover
letter
7.3.3 Signing off a cover
letter
7.4 Portfolio of Evidence
7.4.1 Academic credentials
7.4.2 Letters of
commendations
7.4.3 Certification of
participations
7.4.4 Awards and
decorations
7.5 Interview skills
7.5.1 Listening skills
7.5.2 Grooming
7.5.3 Language command
7.5.4 Articulation of issues

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Learning Outcome Content Suggested
Assessment
Methods
7.5.5 Body language
7.5.6 Time management
7.5.7 Honesty
7.6 Generally knowledgeable in
current affairs and technical area

Suggested Methods Instruction

● Instructor-led facilitation using active learning strategies
● Demonstration
● Practical
● Viewing of related videos
● Group discussions
● Project
● Role play
● Case study
Recommended Resources for 30 Trainees
S/ Category/Item Description/Specifications Quantit Recommended
No. y Ratio (Item:
Trainee)
A Learning Materials
1. Textbooks Comprehensive texts books 30 pcs 1:1
on Digital Literacy
2. Installation Manuals Detailed guides for 5 pcs 1:6
equipment and software
installation and
troubleshooting
3. PowerPoint For trainer’s use, covering
Presentations course content and practical
applications
4. Projector Functional projector for 1 1:30

©QAI 2025 13
 displaying content during
presentations
5. White board Quality whiteboard of 1 1:30
approximately 6 ft by 3 ft for
writing during theory
instruction
6. Printer An ink-jet, laser-jet or toner- 1 1:30
cartridge printer for printing
notes, instructions and
working drawings
7. Templates Templates for creating 30 1:1
various documents e.g. CV,
Cover Letter, etc.
B Learning Facilities &
Infrastructure
1. Lecture/Theory Room Spacious, equipped with 1 1:30
/Learning Resource projectors and Seats for 30
Area* trainees, approximately 45
sqm (5 m x 9 m)
2. Computer Laboratory Equipped with at least 30 30 1:1
functional computers with
internet connectivity and the
following software:
• Windows/ Linux/
Macintosh Operating
System
• Microsoft Office
Software
• Google Workspace
Account
• Antivirus Software
C Consumable
Materials

©QAI 2025 14
1. Printing Papers A4 and A3 Printing papers Enough
suitable for the task
2. Whiteboard Marker Dry-erase markers for Enough
Pens trainers use. Assorted colors
3. Storage devices Any of the following storage Enough
devices:
 USB Flash Drive
 USB Hard Drive
 Compact Disks
(CDs)
 Digital Versatile
Disks (DVDs)

©QAI 2025 15
 WORKSHOP TECHNOLOGY
UNIT CODE: 0715 441 05A

Relationship with Occupational Standards:

This unit addresses the unit of competency: Apply workshop technology

Duration of Unit: 80 Hours

Unit description

This unit describes the competencies required by a technician in order to apply workshop
practice in their work. It includes applying workshop safety, material science principles and
workshop tools and equipment, carryout metal joining processes. It also includes performing
material preservation and Applying workshop organisation techniques house keeping
Summary of Learning Outcomes

By the end of this unit of learning, the trainee will be able to:
S/No. Learning Outcome Duration (Hours)
1. Apply workshop safety 5
2. Apply material science principles 10
3. Apply workshop tools and equipment 10
4. Carry out metal joining processes 20
5. Perform material preservation 20
6. Apply workshop organization techniques 15
Total 80

Learning Outcomes, Content and suggested assessment methods

Suggested Assessment
Learning Outcome Content
Methods
1. Apply workshop 1.1 Workshop safety  Written tests.
safety 1.1.1 Workshop safety definition  Practical
1.1.2 Types and uses of PPE’s
 Project
1.2 Emergency responses steps
 Portfolio of
1.2.1 Common emergencies
evidence
1.2.1.1 Fire
1.2.1.2 Chemical spills  Third party report

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 Suggested Assessment
Learning Outcome Content
Methods
1.2.1.3 Injuries
1.3 Fire safety
1.3.1 Fire extinguishers types
and uses
1.3.2 Flammable materials
identification
1.3.3 Fire prevention
1.4 Safe handling and disposal of
chemicals and materials
1.4.1 Chemical hazard
identification
1.4.2 Safe handling procedure
1.4.3 Storage and labelling of
chemicals
1.4.4 Chemical disposal
procedures
1.4.5 Emergency response for
chemical exposure
1.5 Identifying and marking
hazardous zones
1.5.1 Common hazardous zones
1.5.1.1 Flammable zones
1.5.1.2 High traffic zones
1.5.1.3 Electrical hazard
zones
1.5.1.4 Chemical storage
areas
1.6 Work area organization and
maintenance
1.6.1 Setting up
1.6.2 Proper storage and
labelling of tools and
equipment
1.7 Workplace hazards
1.7.1 Physical hazards
1.7.1.1 Noises
1.7.1.2 Vibration
1.7.1.3 Heat
1.7.1.4 Sharp object
1.7.2 Chemical hazards
1.7.2.1 Fuels
1.7.2.2 Oils

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 Suggested Assessment
Learning Outcome Content
Methods
1.7.2.3 Cleaning agents
1.7.3 Electric hazards
1.7.3.1 Live wires
1.7.3.2 Batteries
1.7.3.3 Electrical systems
1.8 Workshop accidents, causes and
prevention
1.8.1 Near Accident
1.8.2 Trivial Accident
1.8.3 Minor Accident
1.8.4 Serious Accident
1.8.5 Fatal Accident:
2. Apply material 2.1 Material science principles  Practical
science principles 2.1.1 Definition  Project
2.1.2 Importance of material
 Portfolio of
science in engineering
evidence
2.2 Engineering materials
 Third party report
Classification and characteristics
2.2.1 Metals  Written tests.
2.2.2 Polymers
2.2.3 Ceramics
2.3 Properties of engineering materials
2.3.1 Mechanical properties
2.3.1.1 Strength
2.3.1.2 Hardness
2.3.1.3 Toughness
2.3.1.4 Malleability
2.3.1.5 Ductility
2.3.1.6 Rigidity
2.3.2 Thermal properties
2.3.2.1 Specific heat
2.3.2.2 Thermal
expansion
2.3.3 Chemical properties
2.3.3.1 Corrosion
resistance
2.3.4 Electrical properties
2.3.4.1 Electrical
conductivity
2.3.4.2 Insulation
properties
2.4 Material selection for engineering

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 Suggested Assessment
Learning Outcome Content
Methods
materials
2.4.1 Factors to consider
2.5 Material handling safety
2.5.1 Handling metals and
alloys
2.5.2 Chemical and fuels
2.5.3 Safety measures for
plastics and composites
2.5.4 Electrical safety and
conductive materials
3. Apply Workshop 3.1 Tools and equipment safety and  Written tests
tools and equipment maintenance practices  Practical
3.1.1 Inspection
 Project
3.1.2 Safe handling
 Portfolio of
techniques
evidence
3.2 Technical drawing interpretation
3.2.1 Purpose of assembly  Third party report
drawing
3.2.2 Bill of quantity
3.2.3 Assembly instructions
3.3 Workshop tools and equipment
uses and maintenance
3.3.1 Measuring tools
3.3.1.1 Tape measure
3.3.1.2 Steel rule
3.3.1.3 Callipers
3.3.1.4 Micrometer gauge
3.3.1.5 Protractor
3.3.1.6 Spirit level
3.3.1.7 Dial indicator
3.3.1.8 Torque wrench
3.3.2 Marking out tools
3.3.2.1 Scriber
3.3.2.2 Marking gauge
3.3.2.3 Combination square
3.3.3 Cutting tools
3.3.3.1 Hacksaw
3.3.3.2 Chisel
3.3.3.3 Files
3.3.3.4 Scissors
3.3.4 Fitting tools
3.3.4.1 Wrenches

©QAI 2025 19
 Suggested Assessment
Learning Outcome Content
Methods
3.3.4.2 Sockets
3.3.4.3 Pliers
3.3.4.4 Hammers
3.3.4.5 Punch
3.3.4.6 Tap and die
3.3.5 Forging tools
3.3.5.1 Anvil
3.3.5.2 Hammers
3.3.5.3 Tongs
3.3.5.4 Swage block
3.3.6 Sheet metal tools
3.3.6.1 Shears
3.3.6.2 Tin snips
3.3.6.3 Rivet gun
3.3.6.4 Vise
3.3.7 Workshop machine
3.3.7.1 Grinding machine
3.3.7.2 Arc welding
machine
3.3.7.3 Gas welding
machine
3.3.7.4 Drilling machine
4. Carry out metal 4.1 Observation of safety  Practical
joining processes 4.1.1 Safety gears  Project
4.1.2 Machine operation
 Portfolio of
manuals
evidence
4.2 Metal joining methods
 Third party report
4.2.1 Welding
 Written tests.
4.2.1.1 Arc welding
4.2.1.2 Gas welding
4.2.2 Riveting
4.2.3 Fastening
4.3 Material preparation
4.3.1 Measuring
4.3.2 Marking out
4.4 Process of metal finishing
4.4.1 Grinding
4.4.2 Filing
4.4.3 Polishing
5. Perform engineering 5.1 Material preservation  Practical

©QAI 2025 20
 Suggested Assessment
Learning Outcome Content
Methods
material preservation 5.1.1 Definition of material  Project
preservation  Portfolio of
5.1.2 Importance of material evidence
preservation  Third party report
5.1.3 Storage techniques  Written tests.
5.1.4 Material preservation
safety measures
5.2 Common preservation methods
5.2.1 Protective coatings
5.2.2 Chemical treatments
5.2.3 Controlled storage
conditions
5.2.4 Proper handling
techniques
5.2.5 Cleaning and
maintenance
5.3 Material preservation procedure
5.3.1 Work requirements
assessment
5.3.2 Selection of
appropriate
preservation method
6. Apply workshop  Practical
organisation 1.1 Workshop layout  Project
techniques 1.1.1 Types of workshop
 Portfolio of
layout
evidence
1.1.1.1 Fixed layout
 Third party report
1.1.1.2 Process layout
1.1.1.3 Line layout  Written tests.
1.1.1.4 Operation
layout
1.1.1.5 Combination/
group layout
1.1.2 Safety signs
1.1.3 Emergency exits
1.2 Management inventory
1.2.1 Types of inventories
1.2.2 Record keeping
1.2.3 Job card preparation
1.3 Maintenance schedules
1.3.1 Goals of maintenance

©QAI 2025 21
 Suggested Assessment
Learning Outcome Content
Methods
schedule
1.3.1.1 Reactive
1.3.1.2 Equipment
failure
1.3.1.3 Maintenance
backlog
1.3.2 Types of maintenance
1.3.2.1 Preventive
maintenance
1.3.2.2 Corrective
maintenance
1.3.2.3 Condition based
maintenance
1.3.2.4 Predictive
maintenance
1.3.2.5 Break down
maintenance
1.4 Housekeeping
1.4.1 Definition
1.4.2 Importance of
housekeeping
1.5 Housekeeping activities and their
Importance
1.5.1 Tool and equipment
organization
1.5.2 Work area cleanliness
1.5.3 Safe handling and
disposal of hazardous
materials
1.5.4 Inspection and
maintenance of
equipment
1.5.5 Personal protective
equipment
management
1.5.6 Air and ventilation
maintenance
1.5.7 Incident prevention
and reporting
1.6 Housekeeping tools and
equipment
1.6.1 Uses and maintenance

©QAI 2025 22
 Suggested Assessment
Learning Outcome Content
Methods
1.6.1.1 Brooms and
brushes
1.6.1.2 Dustpans and
squeegees
1.6.1.3 Vacuum
cleaners
1.6.1.4 Mops and mop
buckets
1.6.1.5 Waste bins and
recycling
containers
1.7 Housekeeping materials
1.7.1 Cleaning cloths and
rags
1.7.2 Cleaning agents and
solvents
1.7.3 Lubricants
1.7.4 Gloves and PPE’s
1.7.5 Disposable bags and
liners
1.8 Workshop waste sorting and
disposal
1.8.1 Types of waste
1.8.1.1 General waste
1.8.1.2 Hazardous
waste
1.8.1.3 Recyclable
waste
1.8.1.4 Organic waste
1.8.1.5 e-waste
1.8.2 Waste sorting
procedure
1.8.2.1 Designated bins
for different
types of waste
1.8.2.2 Sorting by
material
1.8.2.3 Pre-sorting
hazardous waste
1.8.3 Hazardous waste
disposal
1.8.3.1 Chemical waste

©QAI 2025 23
 Suggested Assessment
Learning Outcome Content
Methods
1.8.3.2 Used oil and
solvents
1.8.3.3 Paints and
finishes
Suggested Delivery Methods
 Demonstration
 Discussions
 Practical
 Exercises
 Industrials visits
 Simulation
List of Recommended Resources for 25 trainees

S/ Category/Item Description/Specifications Quantity Recommended

No. Ratio (Item:
Trainee)
A Learning Materials
1. Textbooks Comprehensive textbooks on 25 1:1
Manual Metal Arc Welding
(MMAW)
2. Projector Functional projector for 1 1:25
displaying content during
presentations
3. Computer Functional desktop computer 1 1:25
with online instructional content
4. White board Quality whiteboard of 1 1:25
approximately 6 ft by 3 ft for
writing during theory instruction
5. Printer An ink-jet, laser-jet or toner- 1 1:25
cartridge printer for printing
notes, instructions and working
drawings
B Learning Facilities
& Infrastructure
1. Lecture/Theory Spacious room with seats for 25 1 1:25
Room trainees, approximately 60 sqm
2. Workshop Standard workshop with 1 1:25
bench/fitting area and welding
booths approximately 80 sqm
C Materials and
Supplies

©QAI 2025 24
 1. Dust coat/ overall Shields skin and regular clothes 25 1:
from sparks

2. Gloves Shields hands from sharp edges, 25 1:1

heat, and chemical exposure

3. Safety boots Protects feet from heavy objects, 25 1:1

sharp materials, and impact.

4. Welding helmets Protecting the eyes while 25 1:1

providing a clear view of the
weld.
5. Ear muffs/ ear plugs Shields against prolonged 25 1:1
exposure to high noise levels
from machinery

6. Safety goggles Protects eyes from flying metal 25 1:1

particles, sparks, and dust

7. Raw materials Steel and aluminum

Plates
 4mm thickness.
 6 mm thickness.
Pipes
 4 mm thickness
 6 mm thickness

8. Arc welding Electrodes used in Arc welding 20

electrodes packets
9. First Aid kit Fully equipped First Aid kit for 1 1:25
use in case of accidents
10. Brooms and cleaning Hand brooms and mops for 10 2:5
stuff cleaning
11. Cotton waste Absorbent cotton waste for Enough
cleaning of oils and other dirt on
machines, tools and equipment
12. Cleaning detergents General degreasers 10 litres
Floor detergents 10 litres
Hand detergents 10 litres
D Tools and
Equipment
Measuring tools
1. Steel rules Calibrated steel rules for linear 20 4:5
measurements
2. Vernier calipers Calibrated Vernier calipers for 20 4:5
linear measurements
3. Tri squares Properly aligned steel Tri-square 5 1:5
for checking perpendicular edges
4. Vernier height gauge Calibrated Vernier height gauges 5 1:5

©QAI 2025 25
 and surface plates and surface plates for
measurement of heights
5. Measuring tapes Calibrated measuring tapes for 20 4:5
linear measurements
6. Angle gauges Calibrated steel rules for linear 5 1:5
measurements
Marking out tools

1. Scribers steel pencil scribers for marking 20 4:5

out lines on metal surfaces
2. Dot punches steel dot punches for marking out 20 4:5
centres
3. Callipers Quality steel callipers for 5 1:5
marking out arcs on metal
surfaces
Cutting Tools
1. Assorted hand files Flat and round hand files for 20 4:5
material preparation and
finishing
2. Hacksaws Hack saws with functional 20 4:5
frames and blades for cutting
metal plates and pipes
3. Tinsnips 10 2:5
4. Angle grinders Portable angle grinders with 5 1:5
cutting and grinding disks for
cutting and grinding metal plates
and pipes
Work holding tools
5. Work benches Stable work benches for carrying 5 1:5
out bench work
6. Collet Hold the tungsten electrode in 5 1:5
place
7. Bench vices Functional bench vices/clamps 20 4:5
for holding work pieces during
bench work
8. Tongs Functional pairs of tongs for 10 2:5
holding hot pieces of metal
during welding
Finishing tools
1. Wire brushes To clean metal surfaces 20 4:5
2. File cards Cleaning tool used to maintain 5 1:5
files
Machines and
Equipment
1. Arc welding machine 5 1:5

2. Gas welding machine 5 1:5

©QAI 2025 26
 3. Firefighting for ensuring safety in workshops 3
equipment where fire hazards are present,
such as sparks

4. Welding gun Feeds the filler wire into the 5 1:5

weld pool

5. Drilling machine
Reference Materials
1 Working drawings
2 Operation sheets/
templates
3 Welding Procedure 25 pcs 1:1
Specifications (WPS)
4 Training Digital format for shared access 1 1:25
Presentations/Slides among trainees
6 Practical Assessment Worksheets for practical 25 pcs 1:1
Guides assessments

©QAI 2025 27
 TECHNICAL DRAWING

UNIT CODE: 0732451/07A

Relationship to Occupational Standards
This unit addresses the unit of competency: Apply technical drawing
Duration of Unit: 80
Unit Description
This unit covers the competences required to apply technical drawings. It involves using
technical drawing tools, equipment and materials, producing plane geometry drawings,
orthographic drawings of components, solid geometry drawings, isometric drawings and
assembly drawings.
Summary of Learning Outcomes
By the end of this unit of learning, the trainee will be able to:
S/No. Learning Outcome Duration (Hours)
1. Use technical drawing tools, equipment and 10
materials
2. Produce plane geometry drawings 10
3. Produce orthographic drawings of components 20
4. Produce solid geometry drawings 10
5. Produce Isometric drawings 20
6. Produce assembly drawings 10
Total 80

Learning Outcomes, Content and Suggested Assessment Methods:

Learning Outcome Content Suggested Assessment
Methods
1. Use and maintain 1.1. Drawing equipment
drawing equipment 1.1.1. T square  Practical Tests
and materials 1.1.2. Set square  Written tests
1.1.3. Protractor  Portfolio of
1.1.4. Engineering drawing set evidence
1.2. Drawing materials
1.2.1. Drawing papers
1.2.2. Maskin tape

©QAI 2025 28
Learning Outcome Content Suggested Assessment
Methods
1.2.3. Clips
1.2.4. Drawing board
1.2.5. Clutch pencils
1.3. Use and maintenance of
drawing equipment
2. Produce plane 2.1 Types of lines in drawings
geometry drawings 2.1.1 Boarder lines  Practical Tests
2.1.2 Faint continuous lines  Written tests
2.1.3 Broken lines  Portfolio of
2.1.4 Chain lines evidence
2.1.5 Centre lines
2.1.6 Cutting lines
2.2 Construction of angles
2.2.1 Acute angles
2.2.2 Right angles
2.2.3 Reflex angles
2.2.4 Obtuse angles
2.2.5 Straight angles
2.3 Bisection of angles
2.3.1 Acute angles
2.3.2 Right angles
2.3.3 Reflex angles
2.3.4 Obtuse angles
2.4 Measurement of angles
2.4.1 Acute angles
2.4.2 Right angles
2.4.3 Reflex angles
2.4.4 Obtuse angles
2.4.5 Straight angles
2.5 Construction of plane geometric
forms

©QAI 2025 29
Learning Outcome Content Suggested Assessment
Methods
2.5.1 Triangles
2.5.2 Quadrilaterals
2.5.3 Polygons
2.5.4 Circles and tangents
2.6 Construction of scales
2.6.1 Plane scales
2.6.2 Diagonal scale
2.6.3 Reducing and
enlargement scales

3. Produce orthographic 3.1 Orthographic drawings

 Practical Tests
drawings of 3.1.1 First angle projection
 Written tests
components 3.1.2 Third angle projection
 Portfolio of
3.2 Dimensioning
evidence
3.3 Sectional views
3.4 Free hand sketches
3.4.1 Geometric forms
3.4.2 Tools
3.4.3 Equipment
3.4.4 Mechanical components

4. Produce solid 4.1 Sketches and drawings of

patterns  Practical Tests
geometry drawings
4.1.1 Cylinders  Written tests
4.1.2 Prisms  Portfolio of
4.1.3 pyramids evidence
4.2 solids drawings
4.2.1 Prisms
4.2.2 Cones
4.2.3 Cylinders
4.3 Development and
interpenetrations of solids
4.3.1 cylinder to cylinder

©QAI 2025 30
 Learning Outcome Content Suggested Assessment
Methods
4.3.2 cylinder to prisms
4.3.3 prism to prism
4.4 Different symbols and
abbreviations
4.5 Auxiliary views and true shapes
of truncated solids
4.5.1 Truncated cylinder
4.5.2 Truncated prism
4.5.3 Truncated pyramid

5.1 Isometric sketches and drawings  Practical Tests

5. Produce isometric
of components  Written tests
drawings
5.2 Isometric curves and circles  Portfolio of
5.3 Oblique sketches of components evidence
6. Produce assembly 6.1 Orthographic views of assembly  Practical Tests
drawings drawings  Written tests
6.1.1 First angle projection  Portfolio of
6.1.2 Third angle projection evidence
6.2 Sectional views
6.3 Parts list

Suggested Methods of Delivery

 Projects
 Demonstration
 Practice
 Discussions
Recommended Resources for 30 trainees
S/ Category/Item Description/Specifications Quantity Recommended
No. Ratio (Item:
Trainee)

©QAI 2025 31
A Learning Materials
1. Textbooks Comprehensive texts books 30 pcs 1:1
on Technical Drawing
2. PowerPoint For trainer’s use, covering 1 1:30
Presentations course content and practical
applications
3. Working drawings Working drawings giving a
detailed overview of the task
at hand
4. Projector Functional projector for 1 1:30
displaying content during
presentations
5. White board Quality whiteboard of 1 1:30
approximately 6 ft by 3 ft for
writing during theory
instruction
B Learning Facilities &
Infrastructure
6. Drawing Room Spacious, equipped with a 1 1:30
/Learning Resource projector and drawing tables
Area* for 25 trainees,
approximately 45 sqm (5 m x
9 m)
C Consumable
Materials
7. Drawing papers A4, A3 and A2 size drawing 1 ream 1:30
papers for drafting of
sketches and working
drawings
8. Drawing Pencils For drawing Enough
 HB
 2H/3H
 2B

©QAI 2025 32
9. Eraser Dustless eraser for pencil 30
stains
10. Masking Tape For attaching the drawing Enough
paper to the drawing board
D Tools and Equipment
11. Drawing Instruments The include: 30 sets 1:1
 T-squares
 30-60 degree set
squares
 45 degree set square
 Protractor
 Compass set
12. Pencil Sharpener For creating sharp pencil tips 30 pcs 1:1
13. Drawing Tables For drawing 30 pcs 1:1
E Reference Materials
14. Welding /blueprint Reference on industry 5 pcs 1:6
/drawing Standards standards (e.g., BS, ANSI,
AWS etc.)
15. Multimedia Learning Videos and tutorials 30 pcs 1:1
Modules

©QAI 2025 33
©QAI 2025 34
 CONSTRUCTION PLANT ENGINES MAINTENANCE
UNIT CODE: 0716 451 11A
UNIT DURATION: 160 Hours

Relationship to Occupational Standards

This unit addresses the Unit of Competency: Maintain Construction Plant Engines

Unit Description

This unit describes the competencies required to perform construction plant engine overhaul,
service construction plant engine cooling system, service construction plant engine
lubrication system, Service construction plant exhaust system and Service construction plant
fuel system.

Summary of Learning Outcomes

By the end of this unit of learning, the trainee will be able to:
S/No. Learning Outcome Duration (Hours)
1. Perform construction plant engine overhaul 80
2. Service construction plant engine cooling system 30
3. Service construction plant engine lubrication system 20
4. Service construction plant exhaust system 10
5. Service construction plant fuel system. 20
Total 160

Learning Outcomes, Content and Suggested Assessment Methods

Learning Outcome Content Suggested

Assessment Methods
1. Perform  Practical
1.1 Personal protective equipment (PPE)
construction assessment
1.1.1 Apron
plant engine  Project
1.1.2 Safety boots
overhaul  Third party report
1.1.3 Gloves
 Written test
1.1.4 Goggles
 Portfolio of
1.1.5 Cartridges/nose mask
evidence

©QAI 2025 35
 1.1.6 Helmet
1.1.7 Ear muffs
1.2 Safety precautions
1.2.1 Training
1.2.2 Ventilation
1.2.3 Machine isolation
1.2.4 Hazard identification
1.2.5 Tool safety
1.2.6 Chemical handling
1.2.7 Communication
1.2.8 Securing the earth moving
machine
1.3 Preparation of the work area
1.4 Identify tools and equipment
1.4.1 Fully equipped toolbox
with assorted spanners
1.4.2 Engine lifting equipment
1.4.2.1 Engine hoist
1.4.3 Measuring and inspection
tools
1.4.3.1 Vernier callipers
1.4.3.2 Optical gauge
1.4.3.3 Dial gauge
1.4.3.4 Micrometre screw gauge
1.4.3.5 Straight edge
1.4.3.6 Feeler gauge
1.4.3.7 Valve spring compressor
1.4.3.8 Spring tension gauge
1.4.3.9 Vernier height gauge
1.4.3.10 Try square
1.4.3.11 Engine
compression test
kit

©QAI 2025 36
 1.4.4 Vee block
1.4.5 Lapping stick
1.4.6 Lapping paste
1.5 Engine removal
1.5.1 Draining engine oil
1.5.2 Draining the engine coolant
1.5.3 Removing of the engine
peripherals
1.5.3.1 Intake manifolds
1.5.3.2 Exhaust manifold
1.5.3.3 Wire harness
1.5.3.4 Coolant piping
1.5.4 Setting up the engine
lifting equipment
1.5.5 Removing engine
mountings
1.5.6 Disconnecting engine from
the gear box
1.5.6.1 Removing the engine
1.6 Engine dismantling
1.7 Cleaning engine major components
1.7.1 Cylinder head
1.7.2 Engine block
1.7.3 Pistons
1.7.4 Crankshafts
1.7.5 Camshafts
1.7.6 Valves
1.7.7 Connecting rods
1.8 Inspection of engine components
1.8.1 Cylinder head
1.8.2 Engine block
1.8.3 Pistons
1.8.4 Crankshafts
1.8.5 Camshafts

©QAI 2025 37
 1.8.6 Valves
1.8.7 Connecting rods
1.8.8 Valve springs
1.9 Engine component measurements and
tests
1.9.1 Crankshaft
1.9.1.1 Main journal bearing area
ovality measurement
1.9.1.2 Con bearing area ovality
measurement
1.9.2 Engine block
1.9.2.1 Warpage test
1.9.2.2 Cylinders ovality test
1.9.2.3 Cylinder taper test
1.9.3 Piston

1.9.3.1 Taper test

1.9.3.2 Ovality
1.9.4 Valves
1.9.4.1 Straightness
1.9.4.2 Sealing ability
1.9.5 Valve spring
1.9.5.1 Length
1.9.5.2 Squareness
1.9.5.3 Tension
1.9.6 Cylinder head
1.9.6.1 Warpage test
1.10 Cylinder head servicing
1.10.1 Valve lapping
1.10.2 Cylinder refacing
1.10.3 Leakage test

©QAI 2025 38
 1.11 Replacement of worn-out engine
components
1.11.1 Piston rings
1.11.2 Cylinder head gasket
1.11.3 Valves
1.11.4 Valve springs
1.11.5 Bearings
1.11.6 Valve guide bearing
1.11.7 Engine oil seals
1.11.7.1 Crankshaft main
seal
1.11.7.2 Valve seals
1.11.7.3 Top cover oil seal
1.12 Assembly of engine components
1.13 Engine timing
1.14 Tappet adjustment
1.15 Engine compression test
1.16 Fitting engine back to the
earthmoving machine.
1.17 Fitting back engine peripherals
1.17.1 Exhaust manifold
1.17.2 Intake manifold
1.17.3 Piping
1.17.4 Wire harness
1.18 Topping up engine oil
1.19 Topping up engine coolant
1.20 Fitting back the battery
1.21 Running the engine
1.21.1 Engine performance test
1.21.2 Engine tune up
1.21.3 Dynamometer test
2. Service 2.1 Gathering of tools and equipment  Practical
construction 2.1.1 Cooling system service kit assessment
plant engine

©QAI 2025 39
 cooling system 2.1.1.1 Radiator cap pressure  Project
testing kit  Third party report
2.1.1.2 thermometer  Written test
2.1.2 Fully equipped tool box  Portfolio of
with assorted spanners evidence
2.2 Introduction to cooling system
2.2.1 Identification of cooling
systems
2.2.1.1 Water cooling system
2.3 Inspection and servicing of the
cooling system
2.3.1 Inspection of cooling fans
2.3.2 Inspection of fan belts
2.3.3 Inspection of the radiator
2.3.3.1 Radiator pressure test
2.3.3.2 Radiator cap pressure
testing
2.3.3.3 Radiator leakage test
2.3.3.4 Radiator fins and tubing
checks
2.4 Thermostat test
2.5 Water pump inspection
2.5.1 Visual inspection
2.5.1.1 Leakage checks
2.5.1.2 Corrosion checks
2.5.1.3 Coolant stains checks
2.5.2 Pulley and belt
2.5.2.1 Belt condition
2.5.2.2 Pulley movement
2.5.3 Unusual noises listening
2.5.3.1 Grinding or whining
sounds
2.5.4 Coolant flow checking
2.6 Inspection of the coolant horses

©QAI 2025 40
 2.7 Replacement of worn-out cooling
system parts
2.8 Refilling of the coolant
2.9 Documentation of the service
2.9.1 Job cards
2.9.2 Checklists
2.9.3 Files
2.9.4 Logbooks
2.10 House keeping
2.10.1 Tool and equipment
organization
2.10.2 Work area cleanliness
2.10.3 Safe handling and disposal
of hazardous materials
2.10.4 Inspection and maintenance
of equipment
2.10.5 Personal protective
equipment management
2.10.6 Air and ventilation
maintenance
2.10.7 Incident prevention and
reporting
3. Service  Practical
1.1 Preparing work area
construction assessment
1.2 Tools selection
plant engine  Project
1.2.1 Grease guns
lubrication  Third party report
1.2.2 Oil can
system  Written test
1.2.3 Assorted spanners
 Portfolio of
1.2.4 Oil filter wrench
evidence
1.2.5 Oil filter cap wrench
1.2.6 Oil filter pliers
1.2.7 Oil drain pan
1.2.8 Funnel
1.2.9 Oil extractor pump

©QAI 2025 41
 1.2.10 Oil filter cutter
1.2.11 Lubricating flushing kit
1.2.12 Oil analysis kit
1.2.13 Torque wrench
1.3 Selecting of Service kits
1.3.1 Seal kits
1.3.2 Filter kits
1.3.3 Hose repair kits
1.3.4 Lubricants kits
1.3.5 Pump repair kits
1.3.6 Pressure gauge kits
1.4 Draining engine oil
1.5 Identifying engine lubrication
components
1.5.1 Oil sump
1.5.2 Oil pump
1.5.3 Oil filters
1.5.4 Lubrication ducts
1.6 Identifying engine lubrication faults
1.6.1 Oil leaks
1.6.2 Clogged oil filters
1.6.3 Low oil level
1.6.4 Malfunctioning oil pumps
1.7 Rectifying engine lubrication faults
1.8 Flushing engine lubrication system
1.9 Replenishing the engine oil
1.10 Testing the engine lubrication
system
1.11 Documenting the lubrication
system service.
1.12 Performing house keeping

4.0 Service  Practical

4.1 Work area preparation
construction assessment

©QAI 2025 42
 plant exhaust  Project
4.2 Selecting of tools and equipment
system  Third party report
4.2.1 Exhaust gas analyser kit
 Written test
4.2.2 Exhaust back pressure gauge
 Portfolio of
4.2.3 Catalytic converter test kit
evidence
4.2.4 Exhaust pipe cutters
4.2.5 Tool box with assorted
spanners
4.2.6 multimeter
4.2.7 Exhaust system service kit
4.2.7.1 Exhaust hoses
4.2.7.2 Mufflers
4.2.7.3 Heat shield
4.2.7.4 Insulation materials
4.2.7.5 Gasket and seals
4.3 Checking for the exhaust system
faults
4.3.1 Exhaust leaks
4.3.2 Faulty catalytic converter
4.3.3 Damaged muffler
4.3.4 Faulty oxygen sensor
4.3.5 Exhaust system vibration
4.4 Testing catalytic converter/
particulate filter
4.4.1 Emission test
4.4.2 Exhaust gas analysis
4.4.3 Visual inspection of the
particulate filter
4.5 Dismantling exhaust system
4.6 Repairing exhaust system faults
4.6.1 Exhaust leaks
4.6.2 Faulty catalytic converter
4.6.3 Damaged muffler
4.6.4 Faulty oxygen sensor

©QAI 2025 43
 4.6.5 Exhaust system vibration
4.7 Reassembling exhaust system
4.8 Testing and checking oxygen sensors
4.9 Testing exhaust system
4.10 Documenting exhaust system
service
4.11 House keeping

4. Service  Practical
4.1 Safety observation
construction assessment
4.2 Work area preparation
plant fuel system  Project
4.3 Selection of tools and equipment
 Third party report
4.3.1 Assorted spanners
 Written test
4.3.2 Injector nozzles tester
 Portfolio of
4.4 Service kit selection
evidence
4.4.1 Fuel filters
4.4.2 Fuel hoses
4.4.3 Fuel pumps
4.4.4 Seal and gaskets
4.4.5 Fuel additives
4.4.6 Cleaning tools
4.4.7 Diagnostic tools
4.4.8 Service manual
4.5 Fuel induction components
identification
4.5.1 Fuel tank
4.5.2 Fuel pump
4.5.3 Priming pump (lift pump)
4.5.4 Fuel filter
4.5.5 Injector nozzles
4.6 Fuel system induction system
induction system components testing
and service
4.6.1 Fuel tank

©QAI 2025 44
 4.6.1.1 Leakage tests
4.6.1.2 Cleaning
4.6.2 Injectors pump
4.6.2.1 Phasing
4.6.2.2 Pressure test
4.6.2.3 Calibration
4.6.3 Injector nozzle
4.6.3.1 Spray pattern test
4.7 Fuel system component’s fault
inspection
4.7.1 Fuel tank
4.7.2 Fuel pump
4.7.3 Priming pump (lift pump)
4.7.4 Fuel filter
4.7.5 Injector nozzles
4.7.6
4.8 Repairing fuel components faults
4.9 Documenting fuel system service
4.10 Performing house keeping

Suggested Methods of delivery

 Practicals
 Projects
 Demonstration
 Group discussion
 Direct instruction
 Industrial Visits

Recommended Resources for 25 Trainees

©QAI 2025 45
S/No. Category/Item Description/ Quantity Recommende
Specifications d Ratio
(Item:
Trainee)
A Learning Materials
1. Textbooks 5 pcs 1:5
2. Projector For trainer’s use 1 1:25
3. Installation manuals
4. Charts
5. PowerPoint presentations For trainer’s use 1
6. learning models For trainer’s use 1 1:25
7. Earth moving machine 5 1:5
engines
B Learning Facilities &
Infrastructure
1. Lecture/theory room 1 1:25
2. Workshop 1 1:25
3. Workbenches 5 1:5
C Consumable materials
1. Assorted sealant silicone 400grams 16:1
2. Assorted gaskets
3. Assorted oil seals
4. Engine oil 20 litres 4:5
5. First aid kit 1 1:25
6. Cleaning detergents Enough 1 litre 1: 25
7. Cotton wool waste Enough 2 kilograms 2:25
8. Kerosene 20 litres 4:5
9. Assorted Emery papers 1 roll 1:25
D Tools and Equipment
1. Assorted spanners 2 2:25
2. Filter wrench 4 4:25
3. Torque wrench 4 4:25
4. jaw puller 2 2:25

©QAI 2025 46
 5. Seal installer 4 4:25
6. Injector nozzle pressure 5 1:5
tester
7. Micro meter screw gauge 10 2:5
8. Vernier callipers 10 2:5
9. Try Square 10 2:5
10. Vernier height gauge 10 2:5
11. Vee block 10 2:5
12. Dial gauge 10 2:5
13. Optical gauge 10 2:5
14. Straight edge 10 2:5
15. Lapping stick 10 2:5
16. Oil cans 5 1:5
17. Multimeter 5 1:5
18. Torque wrench 5 1:5
19. Feeler gauge 5 1:5
20. Hammer 5 1:5
21. Valve spring compressor 3 3:25
22. Spring tension gauge 3 3:25
23. Radiator pressure testing kit 2 2:25
24. Engine dynamometer tester 1 1:25
25. Thermometer 5 1:5
26. Exhaust gas analyzer kit 2 2:25
27. Exhaust back pressure 2 2:25
gauge
28. Catalytic converter test kit 1 1:25
29. Exhaust pipe cutters 2 2:25
E. Earth Moving machines
1. Bulldozer 1 1:25
2. Excavators 1 1:25
3. Backhoe loader 1 1:25
4. Grader 1 1:25

©QAI 2025 47
©QAI 2025 48
 MODULE II
Unit Code Unit Title Unit Duration (Hours) Credit

003144104A Communication Skills 40 4

0541 441 06A Apply Mathematics 80 15

071344109A Electrical and Electronics Principles 80 13

0716451 11 A Maintain Construction Plant Hydraulic 160 16

System

©QAI 2025 49
 COMMUNICATION SKILLS
ISCED UNIT CODE: 0031 441 02A
Relationship with Occupational Standards
This unit addresses the Unit of Competency: Apply Communication Skills
Duration of Unit: 40 Hours

Unit Description
This unit covers the competencies required to apply communication skills. It involves
applying communication channels, written, non-verbal, oral, and group communication skills.
Summary of Learning Outcomes

By the end of this unit of learning, the trainee will be able to:
S/No. Learning Outcome Duration (Hours)
1. Apply communication channels. 8
2. Apply written communication skills. 8
3. Apply non-verbal communication skills. 8
4. Apply oral communication skills. 8
5. Apply group communication skills. 8
Total 40

Learning Outcomes, Content, and Suggested Assessment Methods

Learning Outcome Content Suggested Assessment
Methods
1. Apply 1.1 Communication process  Oral questions
communication 1.2 Principles of effective  Written assessment
channels communication  Observation
 Portfolio of Evidence
1.3 Channels/medium/modes of
 Practical assessment
communication
 Third party report
1.4 Factors to consider when
selecting a channel of
communication
1.5 Barriers to effective
communication
1.6 Flow/patterns of
communication

©QAI 2025 50
Learning Outcome Content Suggested Assessment
Methods
1.7 Sources of information
1.8 Organizational policies
2. Apply written 2.1 Types of written  Oral assessment
communication communication  Written assessment
skills 2.2 Elements of communication  Observation
 Portfolio of Evidence
2.3 Organization requirements for
 Practical assessment
written communication
 Third party report
3. Apply non- 3.1 Utilize body language and  Oral assessment
verbal gestures  Written assessment
communication 3.2 Apply body posture  Observation
skills  Portfolio of Evidence
3.3 Apply workplace dressing code
 Practical assessment
 Third party report
4. Apply oral 4.1 Types of oral communication  Oral assessment
communication pathways  Written assessment
skills 4.2 Effective Questioning  Observation

Techniques  Portfolio of Evidence

 Practical assessment
4.3 Workplace etiquette
 Third party report
4.4 Active listening
5. Apply group 5.1 Establishing rapport  Oral assessment
discussion skills 5.1.1 Facilitating resolution  Written assessment
of issues  Observation
 Portfolio of Evidence
5.1.2 Developing action
 Practical assessment
plans
5.1.3 Group organization
techniques
5.1.4 Turn-taking
techniques
5.1.5 Conflict resolution
techniques
5.1.6 Team-work

©QAI 2025 51
Suggested Methods of Instruction
 Discussion
 Roleplaying
 Simulation
 Direct instruction
 Demonstration
 Field trips
Recommended Resources for 30 trainees
S/ Category/Item Description/Specifications Quantit Recommended
No. y Ratio (Item:
Trainee)
A Learning Materials
1. Textbooks Comprehensive texts books 30 pcs 1:1
on Communication Skills
2. Mobile Phones Smartphone for use by 30 pcs 1:1
trainees
3. Internet connection Internet connection to aid
communication between
trainees
4. PowerPoint For trainer’s use, covering 1 1:30
Presentations course content and practical
applications
5. Projector Functional projector for 1 1:30
displaying content during
presentations
6. White board Quality whiteboard of 1 1:30
approximately 6 ft by 3 ft for
writing during theory
instruction
7. Printer An ink-jet, laser-jet or toner- 1 1:30
cartridge printer for printing
notes, instructions and
working drawings
8. Templates Templates for creating 30 1:1
various documents e.g. CV,
Cover Letter, minutes,
reports etc.
B Learning Facilities &
Infrastructure
1. Lecture/Theory Room Spacious, equipped with 1 1:30
/Learning Resource projectors and Seats for 30
Area* trainees, approximately 45
sqm (5 m x 9 m)
2. Computer Laboratory Equipped with at least 30 30 1:1
functional computers with
internet connectivity and the
following software:
• Windows/ Linux/

©QAI 2025 52
 Macintosh Operating
System
• Microsoft Office
Software
• Google Workspace
Account
• Antivirus Software
C Consumable
Materials
1. Printing Papers A4 and A3 Printing papers Enough
suitable for the task
2. Flashcards For carrying out various Enough
activities by trainees
3. Flipcharts Sufficient for group work Enough
activities and displaying
4. Whiteboard Marker Dry-erase markers for Enough
Pens trainers use. Assorted colors

©QAI 2025 53
 APPLIED MATHEMATICS
Unit Code: 0541 441 07A

Relationship with Occupational Standards

This unit addresses the Unit of Competency: Apply Mathematics

Unit Duration: 80 Hours

Unit Description

This unit describes the competences required in order to Apply trigonometric functions,
carrying out mensuration, Apply statistics and probability
Summary of Learning Outcomes
S/No. Learning Outcomes Duration (Hours)
1. Apply algebra 20
2. Apply trigonometric functions 20
3. Carry out mensuration 20
4. Apply statistics and probability 20
5. TOTAL 80

Learning Outcomes, Content and Suggested Assessment Methods

Learning Content Suggested Assessment
Outcome Methods
1. Apply 1.1 Indices  Written tests
algebra 1.1.1 Power zero
1.1.2 Negative powers
1.1.3 Fractional powers
1.1.4 Laws of indices
1.1.4.1 Addition
1.1.4.2 Subtraction
1.1.4.3 Division
1.1.4.4 Multiplication
1.2 BODMAS
1.3 Roots

©QAI 2025 54
 1.3.1 Square roots
1.3.2 Cube roots
1.3.3 nth roots
1.4 Logarithms
1.4.1 Laws of Logarithms
1.4.1.1 Product Law
1.4.1.2 Quotient Law
1.4.1.3 Power Law
1.5 Use of scientific calculator
1.5.1 Power ON/OFF
1.5.2 Mode
1.5.2.1 Degree
1.5.2.2 Radian
1.5.2.3 Gradient
1.5.2.4 SD
1.5.3 Clear
1.5.4 Save
1.5.5 Shift
1.6 Simultaneous equations
(up to 3 equations)
1.6.1 Elimination
1.6.2 Substitution
1.6.3 Reduction
1.6.4 Graphical
1.7 Quadratic equations
1.7.1 Factorization
1.7.2 Quadratic formula
1.7.3 Completing the square
1.7.4 Graphical
2. Apply 2.1 Angles  Written tests
trigonome 2.1.1 Acute
tric 2.1.2 Obtuse
functions 2.1.3 Reflex

©QAI 2025 55
 2.1.4 Right angle
2.2 Triangles
2.2.1 Isosceles
2.2.2 Equilateral
2.2.3 Right angled
2.2.4 Scalene
2.3 Trigonometric Ratios
2.3.1 Sine
2.3.2 Cosine
2.3.3 Tangent
2.3.4 Cosecant
2.3.5 Secant
2.3.6 Cotangent
2.4 Trigonometric Identities
2.4.1 Proof of identities
2.4.2 Pythagorean identities
2.5 Solve trigonometric equations
2.6 Hyperbolic functions
2.6.1 Sinh x
2.6.2 Cosh x
2.6.3 Cosech x
2.6.4 Tanh x
2.6.5 Sech x
2. Carry 4.1 Units and symbols of measurement  Written tests
out 4.1.1 Mass
mensura 4.1.2 Distance
tion 4.1.3 Speed
4.1.4 Temperature
4.1.5 Time
4.2 Imperial and metric units
4.2.1 Conversions
4.3 Perimeter
4.3.1 Regular shapes

©QAI 2025 56
 4.4 Area
4.4.1 Regular shapes
4.5 Volume
4.5.1 Regular shapes
3. Apply 5.1 Data presentation  Written tests
statistics 5.1.1 Continuous variables
and 5.1.1.1 Histogram
probabil 5.1.1.2 Line
ity 5.1.2 Discrete variable
5.1.2.1 Bar graph
5.1.2.2 Pie graph
5.1.3 Grouped data
5.1.3.1 Histogram
5.1.3.2 Bar
5.1.3.3 Cumulative
frequency
5.1.3.4 ogive
5.1.4 Ungrouped data
5.1.4.1 Line
5.1.4.2 Cumulative
frequency
5.2 Measures of central tendency
5.2.1 Mean
5.2.1.1 Grouped data
5.2.1.2 Ungrouped data
5.2.2 Mode
5.2.2.1 Grouped data
5.2.2.2 Ungrouped data
5.2.3 Medium
5.2.3.1 Grouped data
5.2.3.2 Ungrouped data
5.3 Measures of dispersion
5.3.1 Standard deviation

©QAI 2025 57
 5.3.1.1 Grouped data
5.3.1.2 Ungrouped data
5.3.2 Variance
5.3.2.1 Grouped data
5.3.2.2 Ungrouped data
5.4 Probability
5.4.1 With replacement
5.4.2 Without replacement
5.5 Probability distribution functions
5.5.1 Binomial distribution
5.5.2 Poisson distribution
5.6 Normal distribution

Suggested Delivery Methods

 Demonstration
 Group discussions
 Exercises
 Online materials
 Direct instructions
 Simulation
Recommended Resources for 30 trainees
S/ Category/Item Description/Specifications Quantity Recommended
No. Ratio (Item:
Trainee)
A Learning Materials
1. Textbooks Comprehensive textbooks on 30 1:1
Engineering Mathematics
2. Graph books For graphical representation of 30 1:1
solutions
3. Projector Functional projector for 1 1:30
displaying content during
presentations
4. Computer Functional desktop computer 1 1:30
with online instructional

©QAI 2025 58
 content
5. White board Quality whiteboard of 1 1:30
approximately 6 ft by 3 ft for
writing during theory
instruction
6. Printer An ink-jet, laser-jet or toner- 1 1:30
cartridge printer for printing
notes, instructions and working
drawings
B Learning Facilities & Infrastructure
Lecture/Theory Spacious room with seats for 1 1:30
Room 25 trainees, approximately 60
sqm
C Materials and Supplies
First Aid kit Fully equipped First Aid kit for 1 1:30
use in case of accidents
D Tools and Equipment
Set of Mathematical For constructions and 30 1:1
instruments measurements

Scientific Calculator For Calculations 30 1:1

Firefighting Water, carbon dioxide and 1 1:30
extinguishers chemical powder fire
extinguishers for fire fighting
E Reference Materials
Training Digital format for shared 1 1:30
Presentations/Slides access among trainees
Standard For reference on formulae, 30 1:1
Mathematical identities, laws and principles
Tables

©QAI 2025 59
 ELECTRICAL AND ELECTRONICS PRINCIPLES
UNIT CODE: 0713 441 09A
Relationship with Occupational Standards
This unit addresses the unit of competency: Apply Electrical and electronics principles.
Unit Duration: 80 Hours
Unit Description
This unit describes the competences required in order to apply electrical and electronics
principles. It involves applying basic concepts of electrical quantities, cells and batteries,
magnetism and electromagnetism, basic electrical machines and electronics principles.
Summary of Learning Outcomes
By the end of this unit of learning, the trainee will be able to:
S/No. Learning Outcome Duration (Hours)
1. Apply basic concepts of electrical quantities 10
2. Apply DC and AC circuits 10
3. Apply the concept of cells and batteries 10
4. Apply magnetism and electromagnetism 10
5. Apply basic electrical machines 20
6. Apply electronics components 20
Total 80

Learning Outcomes, Content and Suggested Assessment Methods

Suggested Assessment
Learning Outcome Content
Methods
1. Use the concept of basic 1.1 Basic SI Units
Electrical quantities 1.1.1 Overview of SI Units  Portfolio of
1.1.1.1 Power (Watts, evidence
W)  Practical test
1.1.1.2 Current  Third party report
(Amperes, A)  Written tests
1.1.1.3 Resistance  Project work
(Ohms, Ω)
1.1.1.4 Voltage (Volts,

©QAI 2025 60
 V)
1.2 Conductors and Insulators
1.2.1 Identification and
Characteristics
1.2.1.1 Metals vs. non-
metals
1.2.1.2 Applications in
electrical
circuits
1.3 Electrical Quantities
1.3.1 Charge, Force,
Work, and Power
1.3.2 Definitions and
units
1.3.3 Calculations
involving
Electrical
quantities
1.4 Ohm’s Law
1.4.1 Understanding
Ohm's Law
1.4.2 Practical
applications and
calculations
1.5 Basic Electrical and
Electronic Measurements
1.5.1 Measurement
Techniques
1.5.2 Use of
Multimeters,
oscilloscopes, and
ammeters
1.5.3 Measurement
accuracy and

©QAI 2025 61
 calibration
2. Apply DC and AC 2.1 Introduction to Electrical  Portfolio of
circuits Circuits evidence
2.1.1 Introduction to  Practical test
electricity:  Third party report
2.1.2 Voltage, current,  Written tests
and power.  Project work
2.1.3 Overview of DC
and AC circuits.
2.1.4 Basic circuit
elements:
Resistors,
capacitors, and
inductors.
2.2 DC Circuit Analysis
2.2.1 Series and parallel
circuits.
2.2.2 Voltage and
current division
principles.
2.2.3 Kirchhoff's
Voltage Law
(KVL) and
Kirchhoff's
Current Law
(KCL).
2.2.4 Analysis of
complex circuits
using KVL and
KCL.
2.2.5 Hands-on lab:
Building and
testing DC

©QAI 2025 62
 circuits.
2.3 AC circuits analysis
2.3.1 Introduction to
AC: Sinusoidal
waveforms,
frequency, and
period.
2.3.2 RMS values, peak
values, and
average values.
2.3.3 AC voltage and
current sources.
2.3.4 Phasor
representation of
AC quantities.
2.3.5 Impedance and
admittance.
2.3.6 Series and parallel
AC circuits.
2.3.7 Resonance in RLC
circuits.
2.3.8 Practical analysis
of AC circuits
using phasors.
2.3.9 Power in AC
Circuits
2.3.9.1 Power factor
and power
factor
correction.
2.3.9.2 Real, reactive,
and apparent
power.
2.3.9.3 AC power

©QAI 2025 63
 calculations for
single-phase
and three-
phase circuits.
2.3.9.4 Energy
consumption
and efficiency.
2.3.9.5 Applications of
AC power in
household and
industrial
settings.
2.4 Practical Activity:
2.4.1 Connection in
series and Parallel
Simulation
3. Apply the concept of 3.1 Introduction to Cells and  Portfolio of
cells and batteries Batteries evidence
3.2 Overview of energy storage  Practical test
and electrochemical cells.  Third party report
3.3 Basic concepts: Voltage,  Written tests
current, capacity, and energy  Project work
density.
3.4 e.m.f and internal resistance
of cells
3.5 Electrochemical principles:
Redox reactions and electrode
potentials.
3.6 Components of a cell: Anode,
cathode, electrolyte, and
separator.
3.7 Types of cells: Primary vs.
secondary cells (non-
rechargeable vs.

©QAI 2025 64
 rechargeable).
3.8 Primary Cells (Non-
Rechargeable)
3.8.1 Zinc-Carbon Cells:
Construction,
chemistry, and
applications.
3.8.2 Alkaline Cells:
Advantages over
zinc-carbon, usage,
and performance
characteristics.
3.8.3 Comparison of
common primary
cells (e.g., lithium
primary cells).
3.8.4 Performance
limitations and
efficiency of
primary cells.
3.8.5 Environmental
impact and
disposal
considerations for
non-rechargeable
batteries.
3.8.6 Hands-on lab:
Testing the
performance of
different primary
cells.
3.9 Secondary Cells
(Rechargeable)
3.9.1 Lead-Acid

©QAI 2025 65
 Batteries:
Chemistry,
construction, and
applications (e.g.,
automotive).
3.9.2 Nickel-Cadmium
(NiCd) and
Nickel-Metal
Hydride (NiMH):
Differences, pros,
and cons.
3.9.3 Charging and
discharging cycles
of rechargeable
cells.
3.9.4 Lithium-Ion
Batteries: Working
principles,
construction, and
applications.
3.9.5 Advantages of
lithium-ion
technology over
older battery types.
3.9.6 Safety
considerations:
Overcharging,
thermal runaway,
and battery
management
systems.
3.9.7 Emerging
Technologies:
Solid-state

©QAI 2025 66
 batteries, lithium-
sulphur, and other
advancements.
3.9.8 Energy density and
power density
considerations in
modern
applications.
3.9.9 Batteries
maintenance
3.9.10 Hands-on lab:
Disassembling and
examining a
rechargeable
battery.
3.10 Battery Performance and
Characteristics
3.10.1 Battery capacity:
Ampere-hour (Ah)
ratings and energy
content.
3.10.2 Factors affecting
battery life:
Temperature,
charge/discharge
rates, and cycling.
3.10.3 Internal resistance
and its effect on
performance.
3.10.4 Battery efficiency
and energy losses.
3.10.5 State of charge
(SOC) and depth
of discharge

©QAI 2025 67
 (DOD).
3.10.6 Battery
degradation and
aging mechanisms.
3.10.7 Measuring battery
parameters
(voltage, current,
capacity).
3.10.8 Testing techniques
for battery health
and performance.
3.10.9 Hands-on lab:
Performance
testing of different
battery types.
3.11 Applications of Batteries
3.11.1 Batteries in
consumer
electronics (e.g.,
smartphones,
laptops).
3.11.2 Automotive
applications:
Starting, lighting,
and ignition (SLI)
batteries.
3.11.3 Electric vehicles
(EVs) and hybrid
electric vehicles
(HEVs): Battery
requirements and
challenges.
3.11.4 Industrial and grid
storage

©QAI 2025 68
 applications.
3.11.5 Renewable energy
integration: Solar
and wind energy
storage solutions.
3.11.6 Specialized
applications:
Medical devices,
aerospace, and
military.
3.11.7 Case studies on
battery failure and
safety incidents.
3.11.8 Discussion on
regulations and
standards for
battery use.
3.12 Environmental Impact
and Recycling
3.12.1 Environmental
impact of battery
production and
disposal.
3.12.2 Strategies for
reducing the
ecological
footprint of battery
technologies.
3.12.3 Recycling
processes for
different types of
batteries.
3.12.4 Government
policies and

©QAI 2025 69
 regulations
regarding battery
disposal.
3.12.5 Advances in
battery recycling
technologies.
3.13 Hands-on lab: Exploring
the recycling process and
evaluating eco-friendly
battery alternatives.
4. Apply magnetism and 4.1 Magnetic Circuits and  Portfolio of
electromagnetism Devices evidence
4.1.1 Introduction to  Practical test
magnetic circuits.  Third party report
4.1.2 Magnetic flux,  Written tests
magnetic field  Project work
density, magnetic
field strength,
Reluctance,
magnetomotive
force (MMF), and
magnetic flux.
4.1.3 Calculations
involving magnetic
circuits
4.1.4 Analogies between
electric and
magnetic circuits.
4.1.5 Magnetic materials
in electrical devices
(soft and hard
magnetic materials).
4.2 Electromagnetic Induction
4.2.1 Faraday’s Law of

©QAI 2025 70
 electromagnetic
induction.
4.2.2 Lenz's Law:
Direction of induced
EMF.
4.2.3 Practical
applications: Electric
generators and
transformers.
4.2.4 Induced EMF in
different
configurations
(moving conductors,
changing magnetic
fields).
4.2.5 Self-induction and
mutual induction.
4.2.6 Transformers:
Working principles,
construction, and
applications.
4.2.7 Step up and step-
down transformers
4.2.8 Power losses in
transformers.
4.2.9 Calculations
involving
transformers
4.2.10 Energy stored in
magnetic fields.
5. Apply basic electrical 5.1 DC Machines
machines 5.1.1 DC machine  Portfolio of
construction and evidence
types (motors and

©QAI 2025 71
 generators).  Practical test
5.1.2 Working principle  Third party report
of DC generators  Written tests
and back EMF.  Project work
5.1.3 Types of DC
generators: Series,
shunt, and
compound.
5.1.4 Working principle
of DC motors.
5.1.5 Types of DC
motors: Series,
shunt, and
compound.
5.1.6 Speed-torque
characteristics of
DC motors.
5.1.7 Performance
analysis and
efficiency of DC
machines.
5.1.8 Starting methods
for DC motors.
5.1.9 Hands-on lab:
Testing and
operating a DC
motor/generator.
5.2 Induction Motors (AC
Machines)
5.2.1 Introduction to
induction motors:
Construction and
working
principles.

©QAI 2025 72
 5.2.2 Types of induction
motors: Squirrel
cage and wound
rotor.
5.2.3 Rotating magnetic
fields and slip in
induction motors.
5.2.4 Equivalent circuit
model of an
induction motor.
5.2.5 Torque-speed
characteristics.
5.2.6 Methods of
starting and speed
control.
5.2.7 Performance
analysis of
induction motors.
5.2.8 Losses and
efficiency
considerations.
5.3 Hands-on lab: Testing and
operating an induction
motor.

6. Apply electronics 1.1 Introduction to Electronic  Portfolio of

components Components evidence
1.1.1 Overview of  Practical test
electronics: What  Third party report
are electronic  Written tests
components?  Project work
1.1.2 Classification of
components:

©QAI 2025 73
 Passive, active, and
electromechanical.
1.1.3 Introduction to
circuit symbols and
schematic
diagrams.
1.1.4 Basic electrical
quantities and units
(voltage, current,
resistance).
1.1.5 Understanding
datasheets and
component
specifications.
1.1.6 Overview of testing
and measurement
tools (multimeters,
oscilloscopes).
1.2 Passive Components
1.2.1 Resistors: Types,
color codes, power
ratings, and
applications.
1.2.2 Capacitors: Types
(ceramic,
electrolytic, film),
capacitance value,
and working
voltage.
1.2.3 Charging and
discharging of
capacitors in DC
circuits.
1.2.4 Applications of

©QAI 2025 74
 capacitors in
filtering, timing,
and energy storage.
1.2.5 Inductors: Types,
inductance value,
and applications.
1.2.6 Inductor behavior
in DC and AC
circuits.
1.2.7 Introduction to
filters: RC, RL, and
RLC circuits.
1.3 Semiconductor Devices
1.3.1 Diodes:
Introduction to PN
junctions,
characteristics, and
types (LEDs, Zener
diodes, Schottky
diodes).
1.3.2 Applications of
diodes in
rectification,
voltage regulation,
and signal clipping.
1.3.3 Transistors: Types
(BJT and
MOSFET),
characteristics, and
configurations.
1.3.4 Basic transistor
circuits: Switches
and amplifiers.
1.3.5 Hands-on lab:

©QAI 2025 75
 Building and testing
simple diode and
transistor circuits.
1.3.6 Special
semiconductor
devices: Thyristors,
TRIACs, and
optoelectronic
devices.
1.3.7 Characteristics and
applications in
switching and
control.
1.4 Integrated Circuits (ICs)
1.4.1 Overview of
integrated circuits:
Analog vs. digital
ICs.
1.4.2 Operational
amplifiers (Op-
Amps):
Characteristics and
basic
configurations.
1.4.3 Applications of Op-
Amps in signal
processing.
1.4.4 Timers and
oscillators: 555
timer IC and its
applications.
1.4.5 Voltage regulators:
Linear and
switching

©QAI 2025 76
 regulators.
1.4.6 Introduction to data
converters (ADC
and DAC).
1.4.7 Digital ICs: Logic
gates and flip-flops.
1.4.8 Applications of
digital ICs in basic
logic circuits.
1.4.9 Hands-on lab:
Building circuits
using Op-Amps,
timers, and logic
gates.
1.5 Electromechanical and
Specialized Components
1.5.1 Relays: Types,
operation, and
applications in
switching.
1.5.2 Switches and
connectors: Types
and usage in
electronic circuits.
1.5.3 Transformers:
Basic operation,
step-up/step-down
functions, and
isolation.
1.5.4 Displays: LED,
LCD, and seven-
segment displays.
1.5.5 Circuit Design and
Practical

©QAI 2025 77
 Applications
1.5.6 Basic circuit design
principles: Bread
boarding, PCB
layout, and
soldering.
1.5.7 Introduction to
circuit simulation
tools (e.g.,
Multisim,
LTSpice).
1.5.8 Testing and
troubleshooting
techniques.
1.5.9 Real-world
applications of
electronic
components.
1.5.10 Building practical
projects: Power
supplies, audio
amplifiers, and
sensor-based
circuits.
1.5.11 Hands-on lab: Final
project assembly
and testing.

Suggested Methods of Instruction

 Demonstration
 Practice
 Field trips
 Discussions
Recommended Resources for 30 trainees

©QAI 2025 78
S/ Category/Item Description/Specifications Quantity Recommended
No. Ratio (Item:
Trainee)
A Learning Materials
1 Textbooks Comprehensive texts on 5 pcs 1:6
electrical and control
principle.
2 Charts Visual aids covering electrical 10 pcs 1:3
theories and safety protocols
3 PowerPoint For trainer’s use, covering 1 1:30
Presentations course content and practical
applications
B Learning Facilities
& Infrastructure
1 Lecture/Theory Equipped with projectors and 1 1:30
Room seating for 25 trainees, ~60
sqm
2 Workshop Hands-on training area with 1 1:30
workbenches, tools, and safety
equipment, ~80 sqm
3 Computer Equipped with testing setups 30 1:1
Laboratory for electrical experiments, ~50
sqm.
Equipped with computers
installed with Circuit
simulation software.
C Consumable
Materials
1 Electrical Wires Assorted sizes and color- 6 rolls 1:5
coded (e.g., 1.5mm², 2.5mm²,
4mm²)
2 Insulation Tapes For securing connections and 30 pcs 1:1
insulation, assorted colors
3 Breadboard For prototyping and testing 6 pcs 1:5

©QAI 2025 79
 circuits
4 Sensors Assorted types (temperature, 10 pcs 1:3
pressure, proximity)
5 Signal generators For generating AC signals 6pcs 1:5
6 Transducers Assorted 10 pcs 1:3
7 Electronic Resistors, transistors, 100pcs 4:3
components capacitors, relays,
transformers. Integrated IC,
OPAM.
D Tools and
Equipment
1 Screwdrivers Assorted sets for various 2 sets 1:15
applications
2 Side Cutters For cutting wires and cables 4 pcs 1:7.5
3 Pliers For gripping and bending 3 pcs 1:10
wires
4 Stripping Knives For stripping insulation from 4 pcs 1:7.5
wires
5 Computers Equipped with electrical and 6 pcs 1:5
electronics simulation
software
6 Multimeters For measuring voltage, 6 pcs 1:5
current, and resistance
7 Clamp Meters For measuring current flow in 6 pcs 1:5
circuits
8 Oscilloscope For observing waveforms and 1 1:30
signals
9 Voltmeter For measuring voltage 1 1:30
10 Ammeter For measuring current 1 1:30
11 Signal Generator For generating electrical 1 1:30
signals for testing
12 Soldering gun For soldering 10 1:3
13 Soldering wire For making joints in electrical 10 1:3

©QAI 2025 80
 circuits
14 PLC For program practice 6 1:5
15 Cells and batteries For learning 6 1:5
E PPE (Personal
Protective
Equipment)
1 PPE Sets Includes helmets, gloves, 30 sets 1:1
safety goggles, shoes, and
harnesses
2 Safety Signs and For simulating safety zones 10 sets 1:3
Barriers and hazards
3 Earthing Test Kits For ground testing and 6 pcs 1:5
demonstrating earthing
procedures
4 Electrical Test For hands-on testing of 6 pcs 1:5
Benches functionality and circuit
design
F Reference
Materials
1 Industrial Covering principles and 30 pcs 1:1
Automation Manuals practices in automation
2 Electrical Standards Reference on industry 6 pcs 1:5
standards (e.g., IEEE
Guidelines)
3 Technical On motors, drives, and wiring 30 pcs 1:1
Handbooks systems
4 Training Digital format for shared 1 1:30
Presentations/Slides access among trainees
5 Multimedia Learning Digital licenses for videos and 30 pcs 1:1
Modules tutorials
6 Practical Assessment Worksheets for practical 30 pcs 1:1
Guides assessments

©QAI 2025 81
 CONSTRUCTION PLANT HYDRAULIC SYSTEM MAINTENANCE
UNIT CODE: 0716 451 10A

UNIT DURATION: 160 Hours

Relationship to Occupational Standards

This unit addresses the unit of competency: Maintain construction plant hydraulic system

UNIT DESCRIPTION

This unit describes the competencies required to service construction plant hydraulic valves,
replace construction plant hydraulic filter, service construction plant fuel tank, service
construction plant pump, service construction plant hydraulic cylinder.

Summary of Learning Outcomes

By the end of this unit of learning, the trainee will be able to:
S/No. Learning Outcome Duration (Hours)
1. Service construction plant hydraulic valves 45
2. Replace construction plant hydraulic filter 15
3. Service construction plant fuel tank 15
4. Service construction plant hydraulic pump 55
5. Service construction plant hydraulic cylinder. 30
Total 160

Learning Outcomes, Content and Suggested Assessment Methods

Learning Outcome Content Suggested

Assessment Methods
1. Service 1.1 Safety observation
construction  Practical
1.1.1 Personal protective
plant hydraulic  Written test
equipment (PPE)
valves  Project
1.1.2 Apron
1.1.3 Safety boots  Third party

1.1.4 Gloves report

©QAI 2025 82
  Portfolio of
1.1.5 Goggles
evidence
1.1.6 Cartridges/ nose mask
1.1.7 Helmet
1.1.8 Ear muffs
1.2 Safety precautions
1.2.1 Training
1.2.2 Ventilation
1.2.3 Machine isolation
1.2.4 Machine stabilization
1.2.5 Hazard identification
1.2.6 Tool safety
1.2.7 Chemical handling
1.2.8 Communication
1.3 Identification of hydraulic valves
components
1.3.1 valve body
1.3.2 Spool
1.3.3 Solenoid
1.3.4 Springs
1.3.5 Seals
1.3.6 Ports
1.3.7 Actuators
1.3.8 Mounting brackets
1.4 Selection of tools
1.4.1 Hydraulic valves faults
diagnosis
1.4.2 Application of
Diagnostic kits
1.4.3 Hydraulic diagnostic
kits
1.4.4 Electrical diagnostics
kits
1.4.5 Engine diagnostics kits

©QAI 2025 83
 1.5 Hydraulic valves service kit
selection
1.5.1 Seal kits
1.5.2 Filter kits
1.5.3 Hose repair kits
1.5.4 Valve repair kits
1.5.5 Pump repair kits
1.5.6 Cylinder repair kits
1.5.7 Pressure gauge kits
1.5.8 Hydraulic fluid kits
1.5.9 Hydraulic tool kits
1.6 Hydraulic system dismantling
1.7 Cleaning and inspection of
hydraulic system components
1.7.1 valve body
1.7.2 Spool
1.7.3 Solenoid
1.7.4 Springs
1.7.5 Seals
1.7.6 Ports
1.7.7 Actuators
1.7.8 Mounting brackets
1.8 Replacement of Damaged
hydraulic valve components
1.8.1 Worn out parts
1.8.2 Broken parts
1.8.3 Rusted parts
1.8.4 Weak springs
1.9 Testing hydraulic valves
1.9.1 Leakage test
1.9.2 Pressure drop test
1.9.3 Operation or functional
test

©QAI 2025 84
 1.9.4 Crack pressure test
1.9.5 Response time test
1.9.6 Contamination test
1.9.7 Temperature test
1.10 Service documentation
1.10.1 Job cards
1.10.2 Checklists
1.10.3 Files
1.10.4 Logbooks
1.11 Housekeeping
1.11.1 Tool and equipment
organization
1.11.2 Work area cleanliness
1.11.3 Safe handling and
disposal of hazardous
materials
1.11.4 Inspection and
maintenance of
equipment
1.11.5 Personal protective
equipment management
1.11.6 Air and ventilation
maintenance
1.11.7 Incident prevention and
reporting

2. Replace  Practical
2.1 Identification of hydraulic filters
construction assessment
2.1.1 Suction filter
plant hydraulic  Project
2.1.2 Pressure filter
filter  Third party
2.1.3 Return filter
report
2.1.4 Inline filter
 Written test
2.1.5 Duplex filter
 Portfolio of

©QAI 2025 85
 evidence
2.1.6 Magnetic filter
2.1.7 Hydraulic oil filter
2.1.8 Spin-on filter
2.1.9 Cartridge filter
2.2 Selection of hydraulic filters
Service kits
2.2.1 O-rings
2.2.2 Seals
2.2.3 Fuel
2.2.4 Compressed air
2.3 Removal of the hydraulic filters
2.3.1 Suction filter
2.3.2 Pressure filter
2.3.3 Return filter
2.3.4 Inline filter
2.3.5 Duplex filter
2.3.6 Magnetic filter
2.3.7 Hydraulic oil filter
2.3.8 Spin-on filter
2.3.9 Cartridge filter
2.4 Cleaning and inspection of the
hydraulic filters
2.5 Replacement of faulty hydraulic
filters components
2.5.1 Clogged hydraulic filters
2.5.2 Worn out seals and O-
rings
2.6 Installation of hydraulic filters
2.7 Service documentation
2.7.1 Job cards
2.7.2 Checklists
2.7.3 Files
2.7.4 Logbooks

©QAI 2025 86
 2.8 Housekeeping
2.8.1 Tool and equipment
organization
2.8.2 Work area cleanliness
2.8.3 Safe handling and
disposal of hazardous
materials
2.8.4 Inspection and
maintenance of
equipment
2.8.5 Personal protective
equipment management
2.8.6 Air and ventilation
maintenance
2.8.7 Incident prevention and
reporting
3. Service  Practical
3.1 Work area preparation
construction assessment
3.2 Locating fuel tank
plant fuel tank.  Project
3.3 Types of hydraulic fuel tank
 Third party
3.3.1 Steel tanks
report
3.3.2 Aluminum tanks
 Written test
3.3.3 Polyethylene tanks
 Portfolio of
3.3.4 Integrated fuel tanks
evidence
3.3.5 Customized
3.3.6 Pressurized hydraulic
tanks
3.3.7 Auxiliary or external
fuel tanks
3.4 Functions of hydraulic fuel tanks
3.4.1 Fuel storage
3.4.2 Fuel supply to engine
3.4.3 Ventilation and pressure
management

©QAI 2025 87
 3.4.4 Contaminant separation
3.4.5 Heat dissipation
3.4.6 Support for fuel gauging
3.4.7 Safety and spill and
prevention
3.4.8 Fuel sedimentation
collection
3.5 Tools selection
3.5.1 Fuel transfer pump
3.5.2 Fuel transfer hoses
3.5.3 Drip trays
3.5.4 Fuel storage container
3.5.5 Degreasers and cleaning
solvents
3.5.6 Scrub brushes or wire
brushes
3.5.7 Fuel quality tester
3.5.8 Borescope flashing or
inspection light
3.6 Selecting service kits
3.6.1 Tank filter
3.6.2 Seals
3.6.3 Gaskets
3.7 Inspecting fuel tank
3.7.1 Leakages test
3.7.2 Cracks identification
3.7.3 Sediments check
3.8 Performing housekeeping
3.8.1 Tool and equipment
organization
3.8.2 Work area cleanliness
3.8.3 Safe handling and
disposal of hazardous

©QAI 2025 88
 materials
3.8.4 Inspection and
maintenance of
equipment
3.8.5 Personal protective
equipment management
3.8.6 Air and ventilation
maintenance
3.8.7 Incident prevention and
reporting
4. Service  Practical
4.1 Preparing work area
construction assessment
4.2 Selecting service kits
plant hydraulic  Project
4.2.1 Seals
pump  Third party
4.2.2 O-ring
report
4.2.3 Bearings
 Written test
4.2.4 Bushings
 Portfolio of
4.2.5 Valves
evidence
4.2.6 Springs
4.2.7 Hydraulic shafts and
couplings
4.2.8 Hydraulic pump piston
4.2.9 Hydraulic pump rotors
and vanes
4.2.10 Gaskets
4.2.11 Seal carrier
4.2.12 Adjustment kit.
4.3 Detaching of Hydraulic pump drive
belt
4.4 Inspecting hydraulic pump drive
belt
4.5 Identification of hydraulic fuel
pumps.
4.5.1 Gear pump

©QAI 2025 89
 4.5.2 Vane pump
4.5.3 Piston pump
4.5.4 Screw pump
4.5.5 Axial piston pump
4.5.6 Radial piston pump
4.5.7 Hand pump
4.5.8 Electric hydraulic pump
4.5.9 Hydraulic gear motor
4.5.10 Pressure compensator
Gear pump
4.5.11 Vane pump
4.5.12 Piston pump
4.5.13 Screw pump
4.5.14 Axial piston pump
4.5.15 Radial piston pump
4.5.16 Hand pump
4.5.17 Electric hydraulic pump
4.6 Dismantling of hydraulic pump
components.
4.7 Inspecting hydraulic pump
components.
4.7.1 Pump housing
4.7.2 Pump drive shaft
4.7.3 Rotor and vanes
4.7.4 Pistons
4.7.5 Swash plate
4.7.6 Gears
4.7.7 Valves
4.7.8 Seals and gaskets
4.7.9 Inlet and outlet ports
4.7.10 Bearings
4.7.11 Wear plates
4.7.12 Coupling

©QAI 2025 90
 4.7.13 Hydraulic gear motor
4.7.14 Pressure compensator
4.8 Replacing of Hydraulic pump
components
4.9 Testing of Hydraulic pump
components
4.10 Replacing of hydraulic pump
drive belt
4.11 Service documentation
4.11.1 Job cards
4.11.2 Checklists
4.11.3 Files
4.11.4 Logbooks
4.12 Performing housekeeping
4.12.1 Tool and equipment
organization
4.12.2 Work area cleanliness
4.12.3 Safe handling and
disposal of hazardous
materials
4.12.4 Inspection and
maintenance of
equipment
4.12.5 Personal protective
equipment management
4.12.6 Air and ventilation
maintenance
4.12.7 Incident prevention and
reporting

5. Service  Practical
1.1 Preparing work area
construction assessment
1.2 Selecting service kits
plant hydraulic  Project
1.2.1 Hydraulic diagnostic

©QAI 2025 91
 cylinder.  Third party
1.2.2 Seal
report
1.2.3 Wear ring
 Written test
1.2.4 Rod end
 Portfolio of
1.2.5 Piston
evidence
1.2.6 Glad
1.2.7 Backup ring
1.2.8 O-ring
1.2.9 Rod wiper
1.2.10 Fastener
1.2.11 Lubrication and anti-
corrosion
1.2.12 Bleed valve
1.3 Tools identification
1.3.1 Cylinder disassembly
and assembly tools
1.3.2 Seal installation and
removal
1.3.3 Hydraulic pressure
gauge
1.3.4 Torque wrench
1.3.5 Cleaning and inspection
tools
1.3.6 Bench vice
1.3.7 Cylinder hone
1.4 Draining of hydraulic oil
1.5 Disassembling of hydraulic
cylinder components
1.5.1 Double-acting cylinder
1.5.2 Single-acting cylinder
1.5.3 Telescopic cylinder
1.5.4 Rodless cylinder
1.5.5 Pneumatic cylinder
1.5.6 Miniature cylinder

©QAI 2025 92
 1.5.7 High-pressure cylinder
1.5.8 Hydraulic lift cylinder
1.5.9 Welded cylinder
1.5.10 Tie-rod cylinder
1.6 Inspecting of hydraulic cylinder
1.7 Disassembling of hydraulic
cylinder
1.8 Reassembling of hydraulic cylinder
1.9 Testing of the hydraulic cylinder
1.9.1 Leak test
1.9.2 Pressure test
1.9.3 Drift test
1.9.4 Rod straightness test
1.9.5 Speed test
1.9.6 Load test
1.9.7 Endurance test

Suggested Methods of Delivery

 Practical
 Project
 Demonstration
 Group discussion
 Direct instruction
The delivery may also be supplimented and enhanced by the following , if the opportunity
allows;
- Costruction plant industrial visits
Recommended Resources for 25 Trainees

S/No. Category/Item Description/ Quantity Recommended

Specifications Ratio
(Item: Trainee)
A Learning Materials
1. Textbooks 5 pcs 1:5

©QAI 2025 93
 2. Projector For trainer’s use 1 1:25

3. Installation manuals

4. Charts

5. PowerPoint presentations For trainer’s use 1

6. Learning models For trainer’s use 1 1:25

B Learning Facilities &

infrastructure
2. Lecture/theory room 1 1:25

3. Workshop 1 1:25

4. Work benches 5 1:5

C Consumable materials
1. Assorted Sealants 5 rolls 1:5

2. Assorted gaskets Enough

Enough
3. Assorted oil seals

4. hydraulic oil 20 litres 4:5

5. First aid kit 1 1:25

6. Cleaning detergents 1 litre 1: 25

7. Cotton wool waste 2 2:25

kilograms
8. Kerosene 20 litres 4:5

9. Grease 5 5:25
kilograms
10. Lubricating oil 20 litres 4:5

11. Assorted Emery papers 1 roll 1:25

D Tools and Equipment

1. Assorted fully equipped tool 2 2:25
box

©QAI 2025 94
 2. Filter wrench 5 1:5

3. Hydraulic pressure gauge 1 1:25

4. Oil analysis kit 2 2:25

5. Torque wrench 5 1:5

6. Hydraulic puller 2 2:25

7. Fluid transfer pump 1 1:25

8. Hydraulic cylinder repair kit 4 4:25

9. Seal installer 4 4:25

E. Earth Moving machines

1. Bulldozer 1 1:25

2. Excavators 1 1:25

3. Backhoe loader 1 1:25

4. Cranes 1 1:25

5. Loader 1 1:25

6. Grader 1 1:25

7. Concrete mixer 1 1:25

8. Trencher 1 1:25

9. Paver 1 1:25

10. Hydraulic breaker 1 1:25

11. Backhoe loader 1 1:25

©QAI 2025 95
©QAI 2025 96
 MODULE III

©QAI 2025 97
 ENTREPRENEURIAL SKILLS
ISCED UNIT CODE: 0413 441 04A
Relationship with occupational standards
This unit addresses the unit of competency: Apply Entrepreneurial skills.
Duration of unit: 40 Hours
Unit Description:
This unit covers the competencies required to demonstrate an understanding of
entrepreneurship. It involves demonstrating an understanding of financial literacy, applying
entrepreneurial concepts identifying entrepreneurship opportunities, applying business legal
aspects, and developing business innovative strategies and business plans.
Summary of Learning Outcomes
By the end of this unit of learning, the trainee will be able to:
S/No. Learning Outcome Duration (Hours)
1. Apply financial literacy 5
2. Apply the entrepreneurial concept 5
3. Identify entrepreneurship opportunities 5
4. Apply business legal aspects 5
5. Innovate Business Strategies 10
6. Develop business plan 10
Total 40

Learning Outcomes, Content and Suggested Assessment Methods

Suggested Assessment
Learning Outcome Content Methods
1. Apply financial literacy 1.1 Personal finance management  Observation

1.2 Balancing between needs and  Project

wants  Written assessment

 Third party report
1.3 Budget Preparation
 Interviews
1.4 Saving management
1.5 Factors to consider when
deciding where to save
1.6 Debt management
1.7 Factors to consider before

©QAI 2025 98
 Suggested Assessment
Learning Outcome Content Methods
taking a loan
1.8 Investment decisions
1.9 Types of investments
1.10 Factors to consider when
investing money
1.11 Insurance services
1.12 insurance products
available in the market
1.13 Insurable risks
2. Apply entrepreneurial 2.1 Difference between  Observation
concept Entrepreneurs and Business  Project
persons  Written assessment

2.2 Types of entrepreneurs  Third party report

2.3 Ways of becoming an

entrepreneur
2.4 Characteristics of
Entrepreneurs
2.5 salaried employment and self-
employment
2.6 Requirements for entry into
self-employment
2.7 Roles of an Entrepreneur in
an enterprise
2.8 Contributions of
Entrepreneurship
3. Identify 3.1 Sources of business ideas  Observation
entrepreneurship 3.2 Factors to consider when  Project
opportunities evaluating business  Written assessment

opportunity  Third party report

©QAI 2025 99
 Suggested Assessment
Learning Outcome Content Methods
3.3 Business life cycle
4. Apply business legal 4.1 Forms of business ownership  Observation
aspects 4.2 Business registration and  Project

licensing processing  Written assessment

 Third party report
4.3 Types of contracts and
agreements
4.4 Employment laws
4.5 Taxation laws
5. Innovate business 5.1 Creativity in business  Observation
Strategies 5.2 Innovative business strategies  Project
 Written assessment
5.3 Entrepreneurial Linkages
 Third party report
5.4 ICT in business growth and
development
6. Develop Business Plan 6.1 Business description  Observation

6.2 Marketing plan  Written assessment

 Project
6.3 Organizational/Management
 Third party report
6.4 plan
6.5 Production/operation plan
6.6 Financial plan
6.7 Executive summary
6.8 Business plan presentation
6.9 Business idea incubation

Suggested Methods of Instruction

 Direct instruction with active learning strategies
 Project (Business plan)
 Case studies
 Field trips
 Group Discussions
 Demonstration

©QAI 2025 100

  Question and answer
 Problem solving
 Experiential
 Team training
 Guest speakers

Recommended Resources for 30 Trainees

S/ Category/Item Description/Specifications Quantit Recommended
No. y Ratio (Item:
Trainee)
A Learning Materials
1. Textbooks Comprehensive texts books 30 pcs 1:1
on Entrepreneurial Skills
2. PowerPoint For trainer’s use, covering
Presentations course content and practical
applications
3. Projector Functional projector for 1 1:30
displaying content during
presentations
4. Media Resources These include but are not
limited to:
 Video Clips
 Audio Clips
 TV Sets
 Radio Sets
 Newspapers
 Business Journals
 Case studies
5. Templates Templates for creating 30 1:1
various documents e.g.
business plan, invoices etc.
6. White board Quality whiteboard of 1 1:30
approximately 6 ft by 3 ft for
writing during theory

©QAI 2025 101

 instruction
B Learning Facilities &
Infrastructure
1. Lecture/Theory Room Spacious, equipped with 1 1:30
/Learning Resource projectors and Seats for 30
Area* trainees, approximately 45
sqm (5 m x 9 m)
2. Computer Laboratory Equipped with at least 15 1 1:1
functional computers with
internet connectivity and the
following software:
• Windows/ Linux/
Macintosh Operating
System
• Microsoft Office
Software
• Google Workspace
Account
• Antivirus Software
C Consumable
Materials
1. Writing Materials Writing materials for note Enough
taking
2. Flashcards For carrying out various Enough
activities by trainees
3. Charts Sufficient for group work Enough
activities and displaying
4. Whiteboard Marker Dry-erase markers for Enough
Pens trainers use. Assorted
colours
CONSTRUCTION PLANT TRANSMISSION SYSTEM MAINTENANCE
UNIT CODE: 0716 451 13 A
UNIT DURATION: 160 Hours
Relationship to Occupational Standards

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This unit addresses the Unit of Competency: Maintain construction plant transmission
system

Unit Description

This unit describes the competencies required to troubleshoot construction plant transmission
system, sservice construction plant clutch assembly, and service construction plant
hydrostatic transmission system, construct on plant hydrokinetic transmission system, Service
construction plant final drive and service construction plant hydraulic motor

Summary of Learning Outcomes

By the end of this unit of learning, the trainee will be able to:
S/No. Learning Outcome Duration (Hours)
1. Troubleshoot construction plant transmission 50
systems
2. Service construction plant clutch assembly 20
3. Service construction plant hydrostatic transmission 30
system
4. Service construction plant final drive 30
5. Service construction plant hydraulic motor 30
Total 160

Learning Outcomes, Content and Suggested Assessment Methods

Learning Outcome Content Suggested

Assessment
Methods
1. Troubleshoot 1.1 Personal protective equipment (PPE)
construction plant 1.1.1 Apron  Practical
transmission 1.1.2 Safety boots assessmen
system 1.1.3 Gloves t
1.1.4 Goggles  Project
1.1.5 Cartridges/ nose mask  Third
1.1.6 Helmet party
1.1.7 Ear muffs report
1.2 Safety precautions  Written

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 1.2.1 Training test
1.2.2 Ventilation Portfolio of
1.2.3 Machine isolation evidence
1.2.4 Machine stabilization
1.2.5 Hazard identification
1.2.6 Tool safety
1.2.7 Chemical handling
1.2.8 Communication
1.3 Selecting Service Kits
1.3.1 Hydraulic Filters
1.3.2 Seals and O-Rings
1.3.3 Gaskets:
1.3.4 Hydraulic Fluid
1.3.5 Check and Relief Valves
1.3.6 Pump Rebuild Kits
1.4 Selecting tools and equipment
1.4.1 Pressure Gauges
1.4.2 Flow Meters
1.4.3 Leak Detection Tools
1.4.4 Torque Wrenches
1.4.5 Cleaning Kits
1.4.6 Dial Indicators
1.4.7 Service Laptop with
Diagnostic Software
1.4.8 Cleaning Kits
1.5 Dismasting transmission components
1.5.1 Gearbox
1.5.2 Clutch assembly
1.5.3 Drive shafts
1.5.4 Torque converter
1.5.5 Differential
1.5.6 Transmission fluid
1.5.7 Synchronizers
1.5.8 Shift linkage

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 1.5.9 Transmission housing
1.5.10 Bearings
1.6 Inspecting transmission system
components
1.6.1 Check for Leaks
1.6.2 Inspect Hoses and
Fittings
1.6.3 Examine Seals and O-
Rings
1.6.4 Reservoir Inspection
1.7 Diagnosing transmission system faults
1.7.1 Leakages
1.7.2 Cracks
1.7.3 Worn parts
1.7.4 Hard shifting
1.8 Testing hydraulic transmission system
1.8.1 Pressure test
1.8.2 Flow testing
1.8.3 Temperature testing
1.8.4 Leak detection
1.8.5 Component testing
1.8.6 Hydraulic and control
system testing
1.8.7 System run down test
1.9 Service documentation
1.9.1 Job cards
1.9.2 Checklists
1.9.3 Files
1.9.4 Logbooks
1.10 Housekeeping
1.10.1 Tool and equipment
organization
1.10.2 Work area cleanliness
1.10.3 Safe handling and

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 disposal of hazardous
materials
1.10.4 Inspection and
maintenance of
equipment
1.10.5 Personal protective
equipment management
1.10.6 Air and ventilation
maintenance
1.10.7 Incident prevention and
reporting
2. Service 2.1 Preparing work area  Practical
construction plant 2.1.1 Safety Precautions assessmen
clutch assembly 2.1.2 Organize Tools and t
Equipment  Project
2.1.3 Prepare for Cleanliness  Third
2.1.4 Organize Parts and party
Components report
2.1.5 Prepare the Vehicle  Written
2.1.6 Review Service Manual and test
Instructions  Portfolio
2.1.7 Lighting and Visibility of
2.2 Identify clutch assembly components evidence
2.2.1 Clutch disc
2.2.2 Pressure plate
2.2.3 Flywheel
2.2.4 Clutch release bearing
2.2.5 Clutch fork
2.2.6 Clutch master cylinder
2.2.7 Clutch slave cylinder
2.2.8 Clutch cable
2.2.9 Diaphragm spring
2.2.10 Pilot bearing

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 2.3 Selecting tools and equipment
2.3.1 Bleeder Kit
2.3.2 Brake and Clutch Fluid
2.3.3 Fluid Catch Bottle
2.3.4 Socket and Wrench Set
2.3.5 Brake Cleaner
2.3.6 Clutch Pedal Depressor Tool
2.3.7 Pliers and Screwdrivers
2.3.8 Hydraulic Jack and Jack
Stands
2.3.9 Replacement Seals and
Gaskets
2.4 Disassembling of construction plant
clutch assembly
2.5 Inspecting of clutch components
2.5.1 Friction Material
2.5.2 Disc Thickness
2.5.3 Hub Splines
2.5.4 Surface Condition
2.5.5 Excessive Play
2.5.6 Alignment and Fit
2.5.7 Cracks or Bends
2.5.8 Hydraulic Lines
2.5.9 Fluid Quality:
2.6 Service clutch components assembly
2.6.1 Fluid Inspection and
Replacement
2.6.2 Clutch Master Cylinder
Service
2.6.3 Slave Cylinder Service
2.6.4 Clutch Line Inspection and
Replacement
2.6.5 Adjustment of Clutch Pedal
2.6.6 Release (Throw-Out)

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 Bearing Service
2.6.7 Pilot Bearing or Bushing
Replacement
2.6.8 Bleeding the Clutch
Hydraulic System
2.6.9 Flywheel Inspection and
Resurfacing
2.7 Testing of the clutch components
2.7.1 Checks for leaks
2.7.2 Inspect clutch pedal
2.7.3 Master cylinder pressure test
2.7.4 Slave cylinder pressure test
2.7.5 Clutch pedal force test
2.7.6 Cutch pedal travel test
2.7.7 Engagement test
2.7.8 Disengagement test
2.7.9 Flow meter testing
2.8 Service documentation
2.8.1 Job cards
2.8.2 Checklists
2.8.3 Files
2.8.4 Logbooks
2.9 Housekeeping
2.9.1 Tool and equipment
organization
2.9.2 Work area cleanliness
2.9.3 Safe handling and disposal
of hazardous materials
2.9.4 Inspection and maintenance
of equipment
2.9.5 Personal protective
equipment management
2.9.6 Air and ventilation
maintenance

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 2.9.7 Incident prevention and
reporting
3. Service 3.1 Preparing work area  Practical
construction plant 3.1.1 Safety Precautions assessmen
hydrostatic 3.1.2 Organize Tools and t
transmission Equipment  Project
system 3.1.3 Prepare for Cleanliness  Third
3.1.4 Organize Parts and party
Components report
3.1.5 Prepare the Vehicle  Written
3.1.6 Review Service Manual test
and Instructions  Portfolio
3.1.7 Lighting and Visibility of
3.2 Identify hydrostatic transmission evidence
components
3.2.1 Hydraulic Pump
3.2.2 Hydraulic Motor
3.2.3 Reservoir
3.2.4 Control Valve
3.2.5 Charge Pump
3.2.6 Relief Valve
3.2.7 Filter
3.2.8 Heat Exchanger
3.2.9 Hoses and Tubing
3.3 Selecting of tools and equipment
3.3.1 Pressure Gauge Kit
3.3.2 Flow Meter
3.3.3 Hydraulic Test Ports and
Fittings
3.3.4 Dial Indicator
3.3.5 Torque Wrench
3.3.6 Hydraulic Fluid Filter
Wrench

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 3.3.7 Oil Sample Kit
3.4 Dismantling hydrostatic transmission
system
3.5 Inspecting of hydrostatic transmission
fittings
3.5.1 Checking the hydraulic
pressure system
3.5.2 Inspecting of hydraulic
drive motors
3.5.3 Replacing of hydraulic
fluid
3.5.4 Performing adjustment and
calibrations of hydrostatic
clutch system to
specifications
3.6 Testing of hydrostatic transmission
system
3.7 Inspecting of clutch components
3.7.1 Friction Material
3.7.2 Disc Thickness
3.7.3 Hub Splines
3.7.4 Surface Condition
3.7.5 Excessive Play
3.7.6 Alignment and Fit
3.7.7 Cracks or Bends
3.7.8 Hydraulic Lines
3.7.9 Fluid Quality:
3.8 Service clutch components assembly
3.8.1 Fluid Inspection and
Replacement
3.8.2 Clutch Master Cylinder
Service
3.8.3 Slave Cylinder Service
3.8.4 Clutch Line Inspection and

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 Replacement
3.8.5 Adjustment of Clutch Pedal
3.8.6 Release (Throw-Out)
Bearing Service
3.8.7 Pilot Bearing or Bushing
Replacement
3.8.8 Bleeding the Clutch
Hydraulic System
3.8.9 Flywheel Inspection and
Resurfacing
3.9 Service documentation
3.9.1 Job cards
3.9.2 Checklists
3.9.3 Files
3.9.4 Logbooks
3.10 Housekeeping
3.10.1 Tool and equipment
organization
3.10.2 Work area cleanliness
3.10.3 Safe handling and disposal
of hazardous materials
3.10.4 Inspection and maintenance
of equipment
3.10.5 Personal protective
equipment management
3.10.6 Air and ventilation
maintenance
3.10.7 Incident prevention and
reporting
4. Service 4.1 Preparing work area  Practical
construction plant 4.1.1 Safety Precautions assessmen
final drive 4.1.2 Organize Tools and t
Equipment  Project
 Third

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 4.1.3 Prepare for Cleanliness party
4.1.4 Organize Parts and report
Components  Written
4.1.5 Prepare the Vehicle test
4.1.6 Review Service Manual  Portfolio
and Instructions of
4.1.7 Lighting and Visibility evidence
4.1. Identify construction plant final
drive components
4.1.1 Hydraulic Motor
4.1.2 Planetary Gearbox (or Gear
Reduction Assembly)
4.1.3 Brake Assembly
4.1.4 Final Drive Housing (or Casing)
4.1.5 Output Shaft
4.2. Selection of tools and equipment
4.1. Hydraulic jack lifts
4.2. Torque wrenches
4.3. Cranes
4.4. Sealant and gasket removal
tools
4.5. Pressure testing equipment
4.6. Bearing pullers
4.7. Alignment tools
4.8. Diagnostic tools
4.3. Dismantling of hydrostatic final
drive
4.4. Identifying drive configuration of
transmission
 Input stage
 Planetary gears
 Output stage
4.5. Inspecting final drive for faults
4.4.1 Excessive vibration or noise

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 4.4.2 Leaks of hydraulic fluids
4.4.3 Loos of power or reduced
speed
4.4.4 Overheating of the final
drive
4.4.5 Final drive lockup
4.6. Servicing/repairing of damage final
drive components
4.7. Inspecting of clutch components
4.6.1 Friction Material
4.6.2 Disc Thickness
4.6.3 Hub Splines
4.6.4 Surface Condition
4.6.5 Excessive Play
4.6.6 Alignment and Fit
4.6.7 Cracks or Bends
4.6.8 Hydraulic Lines
4.6.9 Fluid Quality:
4.8. Service clutch components assembly
4.7.1 Fluid Inspection and
Replacement
4.7.2 Clutch Master Cylinder
Service
4.7.3 Slave Cylinder Service
4.7.4 Clutch Line Inspection and
Replacement
4.7.5 Adjustment of Clutch Pedal
4.7.6 Release (Throw-Out)
Bearing Service
4.7.7 Pilot Bearing or Bushing
Replacement
4.7.8 Bleeding the Clutch
Hydraulic System
4.7.9 Flywheel Inspection and

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 Resurfacing
4.2 Service documentation
4.2.1 Job cards
4.2.2 Checklists
4.2.3 Files
4.2.4 Logbooks
4.3 Housekeeping
4.3.1 Tool and equipment
organization
4.3.2 Work area cleanliness
4.3.3 Safe handling and disposal
of hazardous materials
4.3.4 Inspection and
maintenance of equipment
4.3.5 Personal protective
equipment management
4.3.6 Air and ventilation
maintenance
4.3.7 Incident prevention and
reporting
5. Service 5.1 Preparing work area  Practical
construction plant 5.1.1 Safety Precautions assessmen
hydraulic motor 5.1.2 Organize Tools and t
Equipment  Project
5.1.3 Prepare for Cleanliness  Third
5.1.4 Organize Parts and party
Components report
5.1.5 Prepare the Vehicle  Written
5.1.6 Review Service Manual test
and Instructions  Portfolio
5.1.7 Lighting and Visibility of
5.2 Identification of hydraulic motor evidence
components

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 5.2.1 Rotor
5.2.2 Stator
5.2.3 Drive shaft
5.2.4 Valve plate
5.2.5 Bearings
5.2.6 Housing
5.2.7 Pistons
5.2.8 Swashplate
5.2.9 Port plate
5.2.10 Seals
5.3 Selecting tools and equipment
5.3.1 Hydraulic pressure gauge
5.3.2 Torque range
5.3.3 Hydraulic oil filtration
equipment
5.3.4 Seal puller/seal installation
tool
5.3.5 Micrometres and callipers
5.3.6 Hydraulic motor pulley
puller
5.3.7 Bearing puller
5.3.8 Vibration analysis
equipment
5.4 Dismantling of hydraulic motor
5.5 Cleaning of hydraulic motor components
5.6 Inspecting of hydraulic motor
components for faults
5.6.1 Visual inspection
5.6.2 Operational checks
5.6.3 Pressure and flow testing
5.6.4 Hydraulic fluid inspection
5.6.5 Seal and gasket inspection
5.6.6 Shaft and bearing
inspection

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 5.6.7 Alignment check
5.6.8 Torque testing
5.7 Servicing/Replacing faulty hydraulic
motor components
5.8 Seal and bearing replacement
5.9 Cleaning and filtration
5.10 Reconditioning and rebuilding
5.11 Performance calibrations
5.12 Testing of hydraulic motor
components
5.12.1 Test for run out
5.12.2 Test for shaft wear
5.12.3 Check for end play in
bearing
5.12.4 Pressure testing on seals
and gaskets
5.12.5 Hydraulic test
5.12.6 Pressure relief valve test
5.12.7 Fluid quality test
5.13 Service documentation
5.13.1 Job cards
5.13.2 Checklists
5.13.3 Files
5.13.4 Logbooks
5.14 Housekeeping
5.14.1 Tool and equipment
organization
5.14.2 Work area cleanliness
5.14.3 Safe handling and disposal
of hazardous materials
5.14.4 Inspection and maintenance
of equipment
5.14.5 Personal protective
equipment management

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 5.14.6 Air and ventilation
maintenance
5.14.7 Incident prevention and
reporting

Suggested Methods of Instruction

 Practical
 Projects
 Demonstration
 Group discussion
 Direct instruction
 Industrial Visits

S/No. Category/Item Description/ Quantity Recommended

Specifications Ratio
(Item: Trainee)
A Learning Materials
1. Textbooks 5 pcs 1:5
2. Installation manuals
3. Projectors For trainer’s use 1 1:25
4. Laptops For trainer’s use 1 1:25
5. Charts
6. PowerPoint presentations For trainer’s use
B Learning Facilities &
infrastructure
1. Lecture/theory room 1 1:25
2. Workshop 1 1:25
3. Work benches 5 1:5
4. Transmission Models For trainer’s use 1 1:25
C Consumable materials
1. Transmission fluids/oil 20 litters 4:5
2. Transmission filters 1 5 1:5

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 3. Gaskets and seals 5 pieces 5 1:5
4. Grease 2kilograms 5 2:5
5. Transmission belts 5 pieces 5 1:5
6. Clutches and friction 1 piece 5 1:5
materials
7. Transmission Coolant 5 litters 5 1:5
D Tools and Equipment
1. Earth moving machines 1 1:25
2. Transmission fluid pumps 5 1:5
3. Fluid exchange machine 5 1:5
4. Fluid extractor 5 1:5
5. Scan tools/diagnostic 5 1:5
computers
6. Pressure testers 5 pcs 1:5
7. Torque wrenches 5 pcs 1:5
8. Pneumatic tools 5 pcs 1:5
9. Hydraulic jacks For machines 5pcs 1:5
10. Transmission jacks 2 2:25
11. Cleaning equipment
12. Specialized repair tools 5 1:5
13. Assorted Measuring and 5 1:5
calibration tools
14. Transmission flush and 1 1:25
cooling system equipment
15. Safety equipment 25 1:1

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 CONSTRUCTION PLANT BRAKE SYSTEM MAINTENANCE

UNIT CODE: 0716 451 12A

UNIT DURATION: 150 Hours
Relationship to Occupational Standards
This unit addresses the Unit of Competency: Maintain Construction Plant Brake System

Unit Description
This unit describes the competencies required to inspect construction plant braking system,
service construction plant band brakes, service construction plant disk and drum brake
system, service construction plant anchor type brake system and service construction plant
toggle brakes.
Summary of Learning Outcomes
By the end of this unit of learning, the trainee will be able to:
S/No. Learning Outcome Duration (Hours)
1. Inspect construction plant braking system 30
2. Service construction plant band brakes 30
3. Service construction plant disk and drum brake 30
system
4. service construction plant anchor type brake system 30
5. Service construction plant toggle brakes. 30
Total 150

Learning Outcomes, Content and Suggested Assessment Methods

Learning Content Suggested

Outcome Assessment
Methods
1. Inspect 1.1 Personal protective equipment (PPE)  Practical
constructi 1.1.1 Apron assessment
on plant 1.1.2 Safety boots  Project
braking 1.1.3 Gloves  Third party
system 1.1.4 Goggles report
1.1.5 Cartridges/ nose mask  Written test
1.1.6 Helmet  Portfolio of

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 1.1.7 Ear muffs evidence
1.2 Observing safety precautions
1.2.1 Training
1.2.2 Ventilation
1.2.3 Personal protective gear
1.2.4 Machine isolation
1.2.5 Machine stabilization
1.2.6 Hazard identification
1.2.7 Tool safety
1.2.8 Chemical handling
1.3 Introduction to construction plant braking system
1.3.1 Types of construction plant
brakes
1.3.1.1 Hydraulic Wet Disc
Brakes
1.3.1.2 Drum Brakes
1.3.1.3 Hydraulic Dry Disc
Brakes
1.3.1.4 Air Brakes
1.3.1.5 Parking Brakes
1.3.1.6 Anti-Lock Braking
Systems (ABS)
1.4 Checking construction plant brake components
1.4.1 Brake Pads and Shoes
1.4.2 Brake Discs and Drums
1.4.3 Master Cylinder
1.4.4 Brake Calipers
1.4.5 Brake Lines and Hoses
1.4.6 Parking Brake Mechanism
1.4.7 Brake Actuators
1.4.8 Brake Booster (Power Brake
Unit)
1.4.9 ABS (Anti-Lock Braking
System) Sensors

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 1.4.10 Brake Fluids and Lubricants
2. Service 2.1 Identify construction plant band brakes  Practical
constructi 2.1.1 Winch Brakes on Cranes assessment
on plant 2.1.2 Drum Winches on Excavators  Project
band 2.1.3 Crawler Dozers  Third party
brakes 2.1.4 Mining and Quarry Equipment report
2.2 Preparing work area  Written test
2.2.1 Safety Precautions  Portfolio of
2.2.2 Organize Tools and Equipment evidence
2.2.3 Prepare for Cleanliness
2.2.4 Organize Parts and
Components
2.2.5 Prepare the Vehicle
2.2.6 Review Service Manual and
Instructions
2.2.7 Lighting and Visibility
2.3 Selecting correct tools and materials
2.3.1 Basic Hand Tools
2.3.2 Brake Band Lining Tools
2.3.3 Calipers and Measuring Tools
2.3.4 Brake Band Adjustment Tools
2.3.5 Lifting and Support Equipment
2.3.6 Cleaning and Lubrication
Supplies
2.3.7 Inspection and Testing
Equipment
2.4 Dismantling construction brake band
component
2.5 Cleaning internal components for brake bands
2.6 Inspecting brake band component for faults
2.6.1 Check for Cracks or
Fractures
2.6.2 Examine for Deformation

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 2.6.3 Inspect for Corrosion
2.6.4 Inspect Brake Lining
2.6.5 Look for Signs of Glazing
2.6.6 Examine Rivets or Adhesive
Bonding
2.6.7 Evaluate Drum Condition
2.6.8 Inspect Adjustment
Mechanisms
2.7 Servicing and repair of damages in brake bands
2.7.1 Install New Lining
2.7.2 Remove Rust and Corrosion
2.7.3 Reshape or Adjust the Band if
Needed
2.7.4 Replace Worn Springs and
Tensioners
2.7.5 Lubricate Moving Part
2.7.6 Smooth Drum Surface
2.7.7 Reinstall the Brake Band
2.7.8 Reconnect Tensioners and
Adjusters
2.7.9 Adjust Band Tension
2.7.10 Check Band Alignment
2.8 Testing of construction plant brake band
2.8.1 Functional Test
2.8.2 Load Test
2.8.3 Check for Uneven Contact
2.9 Service documentation
2.9.1 Job cards
2.9.2 Checklists
2.9.3 Files
2.9.4 Logbooks
2.10 Housekeeping
2.10.1 Tool and equipment
organization

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 2.10.2 Work area cleanliness
2.10.3 Safe handling and disposal of
hazardous materials
2.10.4 Inspection and maintenance of
equipment
2.10.5 Personal protective equipment
management
2.10.6 Air and ventilation
maintenance
2.10.7 Incident prevention and
reporting

3.1 Identify construction drum brake and disk brake  Practical

3. Service system assessment
constructi 3.1.1 Drum Brake Components  Project
on plant 3.1.1.1 Brake Drum  Third party
drum and 3.1.1.2 Brake Shoes report
disk brake 3.1.1.3 Brake Lining  Written test
system 3.1.1.4 Wheel Cylinder  Portfolio of
3.1.1.5 Return Springs evidence
3.1.1.6 Adjuster Mechanism
3.1.1.7 Backing Plate
3.1.2 Disc Brake Components
3.1.2.1 Brake Rotor (Disc
3.1.2.2 Brake Caliper
3.1.2.3 Brake Pads
3.1.2.4 Brake Piston (s
3.1.2.5 Caliper Bracket
3.1.2.6 Brake Fluid Lines
3.1.2.7 Anti-Rattle Clips
3.1.2.8 ABS Sensor (if
equipped)
3.1.2.9 Dust Boots and Seals
3.2 Dismantling of brake drum and disk brake

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 system
3.3 Clean the drum and disk brake components
3.4 Inspecting of brake drum and disk for faults
3.4.1 Check for Grooves, Scoring, or
Cracks
3.4.2 Measure Drum Diameter
3.4.3 Check Lining Thickness
3.4.4 Look for Glazing or
Contamination
3.4.5 Check for Weak or Damaged
Springs
3.4.6 Inspect Mounting Hardware
3.4.7 Check for Leaks
3.4.8 Check Piston Operation
3.4.9 Look for Wear Marks or
Grooves
3.4.10 Check for Rust or Corrosion
3.4.11 Check for Free Movement
3.5 Serving/Replacing faulty disk and drum
components
3.5.1 Remove Worn Brake Shoes
3.5.2 Install New Brake Shoes
3.5.3 Replace Brake Lining if Needed
3.5.4 Rebuild the Cylinder
3.5.5 Replace Return Spring
3.5.6 Resurface the Drum
3.5.7 Replace Seals and Dust Boots
3.5.8 Resurface the Rotor
3.6 Reassemble drum and disk components
3.7 Carry out brake bleeding
3.8 Testing disk and drum brake components
3.9 Service documentation
3.9.1 Job cards
3.9.2 Checklists

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 3.9.3 Files
3.9.4 Logbooks
3.10 Housekeeping
3.10.1 Tool and equipment organization
3.10.2 Work area cleanliness
3.10.3 Safe handling and disposal of
hazardous materials
3.10.4 Inspection and maintenance of
equipment
3.10.5 Personal protective equipment
management
3.10.6 Air and ventilation maintenance
3.10.7 Incident prevention and
reporting

4. Service 1.1 Identify construction plant anchor brake system  Practical

constructi components assessment
on plant 1.1.1 Anchor plate  Project
anchor 1.1.2 Brake shoe  Third party
type brake 1.1.3 Brake drum report
system 1.1.4 Actuating lever  Written test
1.1.5 Springs  Portfolio of
1.1.6 Pivot pin evidence
1.1.7 Adjustment screw
1.1.8 Brake lining
1.1.9 Mounting bracket
1.2 Dismantle construction plant anchor brake
system
1.3 Clean the internal anchor brake system
components
1.4 Inspecting anchor type brakes components for
faults
1.4.1 Check for Damage or Excessive

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 Wear
1.4.2 Inspect for Cracks
1.4.3 Examine Brake Shoe Lining
Thickness
1.4.4 Check for Uneven Wear
1.4.5 Check for Secure Mounting
1.4.6 Inspect Pin and Bushing Wear
1.4.7 Corrosion
1.4.8 Check for Wear and Surface
Condition
1.5 Servicing anchor type brake components
1.5.1 Replace or Rebuild Brake Shoes
1.5.2 Adjust Shoe Position
1.5.3 Install New Anchor Pin and
Bushing
1.5.4 Align and Secure the Anchor Pin
1.5.5 Install New Springs
1.5.6 Lubricate and Reinstall
1.5.7 Flush and Replace Brake Fluid
1.5.8 Adjust Brake Shoe Clearance
1.6 Reassemble anchor brake system components
1.7 Testing anchor type brake components
1.8 Service documentation
1.8.1 Job cards
1.8.2 Checklists
1.8.3 Files
1.8.4 Logbooks
1.9 Housekeeping
1.9.1 Tool and equipment organization
1.9.2 Work area cleanliness
1.9.3 Safe handling and disposal of
hazardous materials
1.9.4 Inspection and maintenance of
equipment

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 1.9.5 Personal protective equipment
management
1.9.6 Air and ventilation maintenance
1.9.7 Incident prevention and reporting

5. Service 1.1 Identify construction plant toggle brakes  Practical

constructi 1.1.1 Brake lever assessment
on plant 1.1.2 Toggle mechanism  Project
toggle 1.1.3 Brake shoes  Third party
brakes 1.1.4 Brake drum report
1.1.5 Spring  Written test
1.1.6 Actuating rod  Portfolio of
1.1.7 Pivot pin evidence
1.1.8 Mounting bracket
1.1.9 Adjustment nut
1.1.10 Cable assembly
1.2 Select the require tools
1.2.1 Wrenches and Socket Sets
1.2.2 Brake Spring Pliers
1.2.3 Brake Shoe Adjustment Tools
1.2.4 Hydraulic Jack
1.2.5 Hydraulic Fluid Dispenser
1.2.6 Brake Pressure Tester
1.2.7 Torque Wrench
1.3 Dismantle construction plant toggle brake
1.4 Inspect the toggle brakes for faulty
1.4.1 Toggle Link Wear
1.4.2 Brake Pads and Shoes
1.4.3 Drums and Rotors
1.4.4 Springs and Retainers
1.4.5 Check Fluid Levels
1.4.6 Inspect Brake Lines and Hoses
1.4.7 Inspect Brake Lines and Hoses

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 1.5 Servicing faulty toggle brake components
1.6 Testing toggle brake component
1.6.1 Brake Pedal Feel
1.6.2 Brake Engagement
1.6.3 Parking Brake Check
1.7 Service documentation
1.7.1 Job cards
1.7.2 Checklists
1.7.3 Files
1.7.4 Logbooks
1.8 Housekeeping
1.8.1 Tool and equipment
organization
1.8.2 Work area cleanliness
1.8.3 Safe handling and disposal of
hazardous materials
1.8.4 Inspection and maintenance of
equipment
1.8.5 Personal protective equipment
management
1.8.6 Air and ventilation maintenance
1.8.7 Incident prevention and
reporting

Suggested Methods of Delivery

 Practical
 Projects
 Demonstration
 Group discussion
 Direct instructions
Recommended Resources for 25 Trainees
S/No. Category/Item Description/ Quantity Recommended
Specifications Ratio

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 (Item: Trainee)
A Learning Materials
1. Textbooks 5 pcs 1:5

2. Installation manuals

3. Projectors For trainer’s use 1 1:25

4. Laptops For trainer’s use 1 1:25

5. Charts

4. PowerPoint presentations For trainer’s use

B Learning Facilities &

infrastructure

1. Lecture/theory room 1 1:25

2. Workshop 1 1:25

3. Work benches 5 1:5

4. Undercarriage model For trainer’s use 1 1:25

C Consumable materials
1. Brake Pads and Linings For machine use 1 1:25

2. Brake Fluid For machine use 2 2:25

3. Lubricants and Grease For machine use 1 1:25

4. Brake Cleaner For machine use 1 1:25

5. Brake Hardware Kits For machine use 1 1:25

6. Brake Dust Shields and Boots For machine use 1 1:25

7. Sealing Washers and Gaskets For machine use 1 1:25

8. Rotors and Brake Drums For machine use 1 1:25

D Tools and Equipment

1. Earth Moving machines 1 1:25

2. Assorted/Specialized tools 5 1:5

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 3. Welding equipment 2 2:25

4. Measuring tools 5 1:5

5. Lifting chains equipment 2 2:25

6. Service manual 2 2:25

7. Track press cylinder seal kits 5 1:5

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 MODULE IV

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 WORK ETHICS AND PRACTICES
ISCED UNIT CODE: 0417 441 03A
Relationship with Occupational Standards
This unit addresses the Unit of Competency: Apply work ethics and practices.
Duration of Unit: 40 Hours
Unit Description
This unit covers competencies required to demonstrate employability skills. It involves the
ability to: conduct self-management, promote ethical work practices and values, promote
teamwork, manage workplace conflicts, maintain professional and personal development,
apply problem-solving, and promote customer care.
Summary of Learning Outcomes
By the end of this unit of learning, the trainee will be able to:
S/No. Learning Outcome Duration (Hours)
1. Apply self-management skills 5
2. Promote ethical practices and values 5
3. Promote Teamwork 10
4. Maintain professional and personal development 10
5. Apply Problem-solving skills 5
6. Promote Customer care. 5
Total 40

Learning Outcomes, Content, and Suggested Assessment Methods

Learning Outcome Content Suggested Assessment
Methods
1. Apply self- 1.1 Self-awareness ● Observation
management skills 1.2 Formulating personal vision, ● Written assessment

mission, and goals ● Third party reports

1.3 Healthy lifestyle practices ● Portfolio of evidence

● Project
1.4 Strategies for overcoming work
● Practical
challenges
1.5 Emotional intelligence
1.6 Coping with Work Stress.
1.7 Assertiveness versus

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Learning Outcome Content Suggested Assessment
Methods
aggressiveness and passiveness
1.7.1 Developing and
maintaining high self-
esteem
1.7.2 Developing and
maintaining positive
self-image
1.7.3 Time management
1.7.4 Setting performance
targets
1.7.5 Monitoring and
evaluating
performance targets
2. Promote ethical work 2.1 Integrity ● Observation
practices and values 2.2 Core Values, ethics and beliefs ● Written assessment

2.3 Patriotism ● Third party reports

● Portfolio of evidence
2.4 Professionalism
● Project
2.5 Organizational codes of
● Practical
conduct
2.6 Industry policies and
procedures

3. Promote Teamwork 3.1 Types of teams ● Observation

3.2 Team building ● Written assessment

3.2.1 Individual ● Third party reports

responsibilities in a ● Portfolio of evidence

team ● Project
● Practical
3.2.2 Determination of
team roles and
objectives

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Learning Outcome Content Suggested Assessment
Methods
3.2.3 Team parameters and
relationships
3.2.4 Benefits of
teamwork
3.2.5 Qualities of a team
player
3.2.6 Leading a team
3.2.7 Team performance
and evaluation
3.3 Conflicts and conflict resolution
3.4 Gender and diversity
mainstreaming
3.5 Developing Healthy workplace
relationships
3.6 Adaptability and flexibility
3.7 Coaching and mentoring skills
4. Maintain professional 4.1 Personal vs professional ● Observation
and personal development and growth ● Written assessment
development 4.2 Avenues for professional ● Third party reports

growth ● Portfolio of evidence

4.3 Recognizing career ● Project

advancement ● Practical

4.4 Training and career

opportunities
4.4.1 Assessing training
needs
4.4.2 Mobilizing training
resources
4.5 Licenses and certifications for
professional growth and

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Learning Outcome Content Suggested Assessment
Methods
development
4.6 Pursuing personal and
organizational goals
4.7 Managing work priorities and
commitments
4.8 Dynamism and on-the-job
learning
5. Apply Problem- 5.1 Causes of problems ● Observation
solving skills 5.2 Methods of solving problems ● Written assessment

5.3 Problem-solving process ● Third party reports

● Portfolio of evidence
5.4 Decision making
● Project
5.5 Creative thinking and critical
● Practical
thinking process in development
of innovative and practical
solutions
6. Promote Customer 6.1 Identifying customer needs ● Observation
Care 6.2 Qualities of good customer ● Written assessment

service ● Third party reports

6.3 Customer feedback methods ● Portfolio of evidence

● Project
6.4 Resolving customer concerns
● Practical
6.5 Customer outreach programs
6.6 Customer retention

Suggested Methods of Instruction

● Instructor lead facilitation of theory using active learning strategies.
● Demonstrations
● Simulation/Role play
● Group Discussion
● Presentations

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 ● Projects
● Case studies
● Assignments
Recommended Resources for 30 Trainees
S/ Category/Item Description/Specifications Quantit Recommended
No. y Ratio (Item:
Trainee)
A Learning Materials
1. Textbooks Comprehensive texts books 30 pcs 1:1
on Work Ethics and Practices
2. PowerPoint For trainer’s use, covering
Presentations course content and practical
applications
3. Projector Functional projector for 1 1:30
displaying content during
presentations
4. Media Resources This include but are not
limited to:
 Video Clips
 Audio Clips
 TV Sets
 Radio Sets
5. White board Quality whiteboard of 1 1:30
approximately 6 ft by 3 ft for
writing during theory
instruction
B Learning Facilities &
Infrastructure
1. Lecture/Theory Room Spacious, equipped with 1 1:30
/Learning Resource projectors and Seats for 30
Area* trainees, approximately 45
sqm (5 m x 9 m)
2. Computer Laboratory Equipped with at least 30 30 1:1
functional computers with

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 internet connectivity and the
following software:
• Windows/ Linux/
Macintosh Operating
System
• Microsoft Office
Software
• Google Workspace
Account
• Antivirus Software
C Consumable
Materials
1. Printing Papers A4 and A3 Printing papers Enough
suitable for the task
2. Flashcards For carrying out various Enough
activities by trainees
3. Charts Sufficient for group work Enough
activities and displaying
4. Whiteboard Marker Dry-erase markers for Enough
Pens trainers use. Assorted colors

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 MECHANICAL SCIENCE
UNIT CODE: 0715 441 08A
Relationship with Occupational Standards: Apply Mechanical Science
Duration of Unit: 80 Hours
Unit Description
This unit describes the competences required in order to apply mechanical science. It includes
resolving forces, determining effects of loads in mechanical systems, analysing properties of
materials, determining the nature of friction in mechanical systems and solving problems
related to motion.
Summary of Learning Outcomes
By the end of this unit of learning, the trainee will be able to:
S/No. Learning Outcome Duration (Hours)
1. Resolve forces 10
2. Determine effects of loads in mechanical systems. 20
3. Analyze properties of materials. 10
4. Determine the nature of friction in mechanical 20
systems
5. Solve problems related to motion. 20
Total 80

Learning Outcomes, Content and Suggested Assessment Methods

Learning Outcome Content Suggested Assessment
Methods
1. Resolve forces 1.1 Definition of force  Written Tests
1.2 Types of force systems  Portfolio of
1.2.1 Colinear Evidence
1.2.2 Coplanar
1.2.3 Concurrent
1.3 Theorems of forces
1.3.1 Triangle

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 1.3.2 Parallelogram
1.3.3 Polygon
1.4 Resolution of forces
1.4.1 Analysis
1.4.2 Graphical Method
2. Determine 2.1 Types of Forces  Written Tests
effects of loads 2.1.1 Friction  Portfolio of
in mechanical 2.1.2 Centrifugal Evidence
systems. 2.1.3 Centripetal
2.1.4 Gravitational
2.1.5 Inertia
2.2 Moments
2.2.1 Definition
2.2.2 Calculations of moment of
force about an axis
2.3 Principles of Moments
2.3.1 Clockwise and anticlockwise
moments
2.4 Application of Moments of Forces
in Engineering
2.4.1 Simply supported beams
having point loads
2.5 Determination of moment couples
2.5.1 Simply supported beams with
couples
3 Analyze 3.1 Mechanical Properties of Materials:  Written Tests
properties of 3.1.2 Strength (Compressive, Shear.  Portfolio of
materials And Tensile) Evidence
3.1.3 Brittleness
3.1.4 Hardness
3.1.5 Malleability
3.1.6 Plasticity
3.1.7 Elasticity

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 3.1.8 Toughness
3.2 Mechanical Materials Properties
Tests
3.2.1 Tensile Test
3.2.2 Hardness Test
3.3 Direct Stresses
3.3.1 Define Stress
3.3.2 Types of Stress:
3.3.2.1 Tensile stress
3.3.2.2 Compressive stress
3.3.3 Calculate Stress
3.4 Selection of Materials
3.4.1 Factors to Consider in
Materials Selection
4 Determine the 4.1 Friction  Written Tests
nature of 4.1.2 Definition  Portfolio of
friction in 4.1.3 Advantages and disadvantages Evidence
mechanical of friction
systems 4.2 Laws of Friction:
4.2.2 Laws of static friction
4.2.3 Laws of dynamic friction
4.3 Effects of Friction
4.4 Applications of Friction
4.4.2 Lubrication
4.4.3 Tyre Traction
4.4.4 Braking Systems
4.4.5 Bearing and Bushings
4.4.6 Grinding of Tools
4.4.7 Transmission Systems
5 Solve problems 5.1 Definition of terms  Written Tests
related to 5.1.2 Distance  Portfolio of
motion. 5.1.3 Displacement Evidence
5.1.4 Time

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 5.1.5 Speed
5.1.6 Velocity
5.1.7 Acceleration
5.2 Laws of Motion
5.2.2 Newton’s First Law of Motion
5.2.3 Newton’s Second Law of
Motion
5.2.4 Newton’s Third Law of
Motion
5.3 Calculating Parameters of Motion
5.3.2 Equations of linear and angular
motion
5.3.3 Calculations
5.3.3.1 Displacement
5.3.3.2 Speed
5.3.3.3 Velocity
5.3.3.4 Acceleration
5.4 Linear and Angular Motion
5.4.2 Converting
5.4.2.1 Angular to Linear
Motion
5.4.2.2 Linear to angular
motion
5.5 Motion Graphs
5.5.2 Displacement/Time Graphs
5.5.3 Velocity/Time Graphs
Suggested Delivery Methods
 Group discussions
 Demonstration by the trainer
 Online video clips
 Power point presentation
Recommended Resources for 30 Trainees
S/ Category/Item Description/Specifications Quantit Recommended

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No. y Ratio (Item:
Trainee)
A Learning Materials
1. Textbooks Comprehensive textbooks on 30 1:1
Engineering Mathematics
2. Graph books For graphical representation of 30 1:1
solutions
3. Projector Functional projector for 1 1:30
displaying content during
presentations
4. Computer Functional desktop computer 1 1:30
with online instructional
content
5. White board Quality whiteboard of 1 1:30
approximately 6 ft by 3 ft for
writing during theory
instruction
6. Printer An ink-jet, laser-jet or toner- 1 1:30
cartridge printer for printing
notes, instructions and working
drawings
B Learning Facilities & Infrastructure
1. Lecture/Theory Spacious room with seats for 1 1:30
Room 25 trainees, approximately 60
sqm
C Materials and Supplies
1. First Aid kit Fully equipped First Aid kit for 1 1:30
use in case of accidents
D Tools and Equipment
Scientific Calculator For Calculations 30 1:1
E Reference Materials
1. Training Digital format for shared 1 1:30
Presentations/Slides access among trainees

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2. Standard For reference on formulae, 30 1:1
Mathematical identities, laws and principles
Tables

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 CONSTRUCTION PLANT STEERING AND SUSPENSION SYSTEMS
MAINTENANCE
UNIT CODE: 0716 451 14A
UNIT DURATION: 150 Hours
Relationship to Occupational Standards
This unit addresses the Unit of Competency: Maintain construction plant steering and
suspension systems.

Unit Description

This unit describes the competencies required to service construction plant hydraulic valves,
replace construction plant hydraulic filter, service construction plant fuel tank, service
construction plant pump, service construction plant hydraulic cylinder.

Summary of Learning Outcomes

By the end of this unit of learning, the trainee will be able to:
S/No. Learning Outcome Duration (Hours)
1. Inspect construction plant steering and suspension 50
systems.
2. Service construction plant steering system 50
3. Service construction plant suspension system 50
Total 150

Learning Outcomes, Content and Suggested Assessment Methods

Learning Content Suggested

Outcome Assessment
Methods
1. Inspect  Project
1.1 Personal protective equipment (PPE)
construction  Third party
1.1.1 Apron
plant report
1.1.2 Safety boots
steering and  Written test
1.1.3 Gloves
suspension  Portfolio of
1.1.4 Goggles
systems. evidence
1.1.5 Cartridges/ nose mask
Practical
1.1.6 Helmet

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 assessment
1.1.7 Ear muffs
1.2 Safety precautions
1.2.1 Training
1.2.2 Ventilation
1.2.3 Machine isolation
1.2.4 Machine stabilization
1.2.5 Hazard identification
1.2.6 Tool safety
1.2.7 Chemical handling
1.2.8 Communication
1.3 Selecting tools and equipment
1.3.1 Wrenches and ratchet
1.3.2 Impact wrench
1.3.3 Hammers
1.3.4 Pin punch sets
1.3.5 Bearing press
1.3.6 Service manual
1.3.7 Grease gun
1.3.8 Screw drivers
1.3.9 Pliers
1.3.10 Torque wrenches
1.3.11 Hydraulic pullers
1.3.12 Spring compressors
1.4 Inspecting steering system
1.4.1 Steering wheels
1.4.2 Steering column
1.4.3 Steering gearboxes
1.4.4 Tie rods
1.4.5 Pitman arm
1.4.6 Centre link/drag link
1.4.7 Steering pump
1.4.8 Steering fluid reservoirs
1.4.9 Steering shaft

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 1.4.10 Steeling coupler
1.5 Activity documenting
1.5.1 Job cards
1.5.2 Checklists
1.5.3 Files
1.5.4 Logbooks
1.6 Performing housekeeping
1.6.1 Waste disposal method
1.6.2 Recycling methods
1.6.3 Resource management
1.6.4 Pollution control
1.6.5 Cleaning
2.  Project
2.1 Selecting tools and equipment
Service  Third party
2.1.1 Wrenches and ratchet
construction report
2.1.2 Impact wrench
plant steering  Written test
2.1.3 Hammers
system  Portfolio of
2.1.4 Pin punch sets
evidence
2.1.5 Bearing press
Practical
2.1.6 Service manual
assessment
2.1.7 Grease gun
2.1.8 Screw drivers
2.1.9 Pliers
2.1.10 Torque wrenches
2.1.11 Hydraulic pullers
2.1.12 Spring compressors
2.2 Draining lubricant
2.2.1 Hydraulic fluid
2.2.2 Grease
2.2.3 Power steering fluid
2.2.4 Penetrating oil
2.2.5 Silicone based lubricant
2.3 Disassembling Steering components
2.3.1 Steering wheels

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 2.3.2 Steering column
2.3.3 Steering gearboxes
2.3.4 Tie rods
2.3.5 Pitman arm
2.3.6 Centre link/drag link
2.3.7 Steering pump
2.3.8 Steering fluid reservoirs
2.3.9 Steering shaft
2.3.10 Steering coupler
2.4 Inspecting Steering components
2.4.1 leaks
2.4.2 Breakages
2.4.3 Cracks
2.4.4 Rust
2.4.5 Play or looseness
2.4.6 Bends
2.4.7 dents
2.5 Testing steering components
2.5.1 Straightness
2.5.2 Wheel play
2.5.3 Hydraulic pressure
2.5.4 Steering gear and linkage
2.5.5 Tie rod ends
2.5.6 Steering assists
2.5.7 Powe steering test
2.5.8 Alignment test
2.5.9 Load test
2.5.10 Steering stop function
2.6 Servicing Steering components
2.6.1 Steering wheels
2.6.2 Steering column
2.6.3 Steering gearboxes
2.6.4 Tie rods

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 2.6.5 Pitman arm
2.6.6 Centre link/drag link
2.6.7 Steering pump
2.6.8 Steering fluid reservoirs
2.6.9 Steering shaft
2.6.10 Steeling coupler
2.7 Applying technical information
2.7.1 Service manual reference
2.8 Assembling steering system
2.8.1 Assembly of steering component
2.9 Application lubricant
2.9.1 Steering linkage joints
2.9.2 Steering box and gears
2.9.3 Kingpin and bushing
2.9.4 Swivel joint and pivot joints
2.9.5 Hydraulic connections
2.9.6 Steering system testing
2.10 Road test
3. Service 3.1 Selection tools and equipment  Practical
construction 3.1.1 Spring compressor assessment
plant 3.1.2 Hydraulic jack and lift  Project
suspension 3.1.3 Torque wrenches  Third party
system 3.1.4 Suspension alignment tools report
3.1.5 Component puller  Written test
3.1.6 Shock absorber tester  Portfolio of
3.1.7 Grease gun evidence
3.1.8 Measuring tools
3.1.8.1 Micrometre
3.1.8.2 Callipers screw gauge
3.1.9 Bushing removal tool
3.1.10 Hydraulic press equipment
3.1.11 Assorted spanners
3.2 Inspection of suspension system

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 3.2.1 Steering linkages
3.2.1.1 Checking for any damage
3.2.1.2 Wear, cracks and ben ding
3.2.1.3 Misalignment
3.2.2 Steering cylinder
3.2.2.1 Leakage inspection
3.2.2.2 Damage inspection
3.2.3 Steering pump and fluid
3.2.3.1 Leakage checks
3.2.4 Steering wheel or control
mechanism
3.2.4.1 Test for smooth operation
3.2.5 Tie rods and ball joints
3.2.5.1 Wear and damage checks
3.2.6 Operation test
3.2.6.1 Turning steering checks
3.3 Steering suspension system dismantling
3.3.1 Disconnect the Power Sources
3.3.1.1 Hydraulic Systems
3.3.1.1.1 Depressurizing the system
3.3.1.1.2 Disconnection of hydraulic
hoses
3.3.1.1.3 Capping off any open
hydraulic lines to prevent
contamination.
3.3.1.2 Pneumatic Systems
3.3.1.2.1 Releasing air pressure from
the system.
3.3.1.2.2 Disconnecting air lines
3.3.1.3 Electrical Systems
3.3.1.3.1 Disconnection of any electrical
connections
3.3.2 Removal of Suspension Components
3.3.2.1 Removal of external attachments

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 3.3.2.2 Loosening and removal of fasteners
3.3.2.3 Disconnection of the Suspension
Arms and Linkages
3.3.2.4 Removal of springs, shock
absorbers, or dampers
3.4 suspension system components cleaning
3.5 Inspection of suspension system components
3.5.1 Visual inspection
3.5.1.1 Coil springs
3.5.1.1.1 Checking for deformation
3.5.1.1.2 Inspect for Surface damage
3.5.1.1.2.1 Spring Tension
3.5.1.2 Shock absorbers/dampers:
3.5.1.2.1 Looking for leaks
3.5.1.2.2 Checking for damage
3.5.1.2.3 Compression test
3.5.1.3 Suspension Arms
3.5.1.3.1 Inspection for cracks and
deformation
3.5.1.3.2 Checking of for rust or
corrosion
3.5.1.4 Linkages and mounting points
3.5.1.4.1 Checking of bolts and
fasteners
3.5.1.4.2 Inspection of bearings and
bushings
3.6 Replacement of faulty suspension system
components
3.7 Assembling suspension system
3.7.1 Installation of suspension frame
3.7.2 Installation of suspension springs:
3.7.3 installation of shock absorbers
3.7.4 Installation of suspension arms and
linkages

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 3.7.5 Installation of hydraulic/pneumatic
components:
3.7.6 Installation of cables/chains/rods
3.7.7 Reconnection of systems
3.7.8 Alignment and clearance
3.7.9 Testing
3.7.10 Final inspection
3.8 Adjustment of steering system
3.8.1 Adjusting steering linkages
3.8.2 Aligning and tightening linkages.
3.8.3 Checking steering play
3.8.4 Adjusting steering gear for play
3.8.5 Hydraulic steering adjustment
3.8.6 Adjusting steering stops
3.8.7 Testing steering system
3.9 Performing road-tests
3.9.1 Initial visual inspection
3.9.2 Checking for fluid levels
3.9.3 Testing steering operation
3.9.4 Checking suspension functionality
3.9.5 low-speed test
3.9.6 High-speed test
3.9.7 Check for unusual noises
3.9.8 Testing turning and maneuvering
3.9.9 Load test (if applicable)
3.9.10 Final checks

Suggested Methods of Instruction

 Practicals
 Projects
 Demonstration
 Group discussion
 Direct instruction

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  Industrial Visits

Recommended Resources for 25 Trainees

S/No. Category/Item Description/ Quantity Recommende
Specifications d Ratio
(Item:
Trainee)
A Learning Materials
1. Textbooks 5 pcs 1:5
2. Projector For trainer’s use 1 1:25
3. Installation manuals 5 copies 1:5
4. Charts For trainer’s use 10 2:5
5. PowerPoint presentations For trainer’s use 1
6. learning models For trainer’s use 1 1:25
7. Earth moving steering and For trainer’s use 2 2:25
suspension system
B Learning Facilities &
infrastructure
1. Lecture/theory room 1 1:25
2. Workshop 1 1:25
3. Work benches 5 1:5
C Consumable materials
1. Assorted sealant silicone 400 grams 16:1
2. Assorted gaskets 5 1:5
3. Assorted oil seals 5 1:5
4. First aid kit 1 1:25
5. Kerosene 20 litres 4:5
6. Assorted Emery papers 1 roll 1:25
7. Hydraulic fluid 30 litres 6:5
8. Power steering fluid 20 litres 4:5
9. Grease 10 2:5
kilograms
10. Assorted steering fluid 5 litres 1:5

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 filters
11. Assorted belt 5 1:5
12. Brake fluid 10 litres 2:5
13. Assorted dust cover boots 5 1:5
14. Assorted bushings and 5 1:5
bearings
15. Assorted replacement bolts 5 1:5
and nuts
16. Shock absorber fluid 20 litres 4:5
17. Suspension fluid 20 litres 4:5
18. Assorted suspension 5 1:5
bushings
19. Assorted O-rings 5 1:5
20. Assorted air suspension 5 1:5
filters
21. Assorted Suspension fluid 5 1:5
filters
D Tools and Equipment
1. Hydraulic Pump Tester 2 2:25
2. Torque Wrench 4 4:25
3. Steering Alignment Tools 4 4:25
4. Power Steering Pump Puller 2 2:25
5. Electronic Diagnostic Scan 3 3:25
Tool
6. Wheel Alignment Machine 1 1:25
7. Steering and Suspension 3 3:25
Tester
8. Hydraulic Pressure Tester 3 3:25
9. Suspension Load Tester 3 3:25
10. Ball Joint Press 1 1:25
11. Tie Rod End Puller 5 1:5
12. Pitman Arm Puller 3 3:25
13. Steering Box Puller 3 3:25

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 14. Steering Gearbox Tester 2 2:25
15. Tie Rod Remover Tool 3 3:25
16. Suspension Spring 5 1:5
Compressor
17. Shock Absorber Testing 1 1:25
Equipment
18. Strut Spring Compressor 3 3:25
19. Ball Joint Separator 3 3:25
20. Suspension Bushings Tool 2 2:25
21. Suspension Alignment Tool 1 1:25
22. Hydraulic Jack 5 5:25
23. Hydraulic Press 1 1:25
24. Hydraulic Lifting 1 1:25
Equipment
25. Impact Wrench 1 1:25
26. Torque Wrench 2 2:25
27. Pry Bars 2 2:25
28. Screwdrivers and Pliers 2 sets 2:25
29. Suspension Vibration 1 1:25
Analyzer
30. Suspension Bushings 5 1:5
31. Workbenches with Vices 5 5:25
32. Wheel and Tire Balancer 2 2:25
E. Earth Moving machines
1. Bulldozer 1 1:25
2. Excavators 1 1:25
3. Backhoe loader 1 1:25
4. Grader 1 1:25

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