Lab Specifications

Automotive – 4 Wheeler Repair

An initiative of Ministry of Skill Development & Entrepreneurship, Govt. of India
and National Skill Development Corporation
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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
 If we have to promote the
development of our country
then our mission has to be
‘skill development’ and
‘skilled India’.
Shri Narendra Modi
Honourable Prime Minister

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
 OVERVIEW
The lab standardization guidelines envisions to standardize the lab infrastructure for automotive – 4 wheeler
repair trades across sectors. The document intends to ensure industry linked training with state-of-art
infrastructure.

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
 AUTOMOTIVE –
4 WHEELER
REPAIR
SECTOR
1. Description of Lab
2. List of Tools & Equipment -
Automotive – 4 Wheeler Repair
3. 3D Representation of
Automotive – 4 Wheeler Repair
4. Illustrative Architectural Layout
of Lab
5. Illustrative Pricing of Tools &
Equipment
6. Safety Instructions

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
1 DESCRIPTION OF LAB

1. 4 Wheeler Service Technician – Level 4

2. AC Specialist
3. Brake Specialist
4. Automotive Electrician Level - 4
5. Clutch Specialist
Lab
6. Chauffeur-cum-Taxi Driver
Specifications
for the Listed 7. Automotive Sales Head (Retail)
Sectors / Job 8. Sales Representative
Roles 9. Showroom Hostess
10. Service Office Executive
11. 4 Wheeler Service Technician – Level 3
Some of the above mentioned job roles may
be done with planning and delivery
methodology.

Proposed 25
Batch Size

Machine - Man 1:5

Ratio

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
2 LIST OF TOOLS & EQUIPMENT -
AUTOMOTIVE – 4 WHEELER REPAIR
S. No. Equipment Name Qty Unit Type

1 Service Technician Tool Kit 15 Set

2 Drive Socket Set 2 Set
3 Lever Type Grease Gun 2 Nos
4 Chisel - Drop Forge 16 x 22 x 20 10 Nos
5 Oil Can - Wesco Type 4 Nos
6 Centre Punches 10 Nos
7 Two Leg Puller 1 Nos
8 Hammer Ball Pin 15 Nos
9 Single - Arm Torque Wrench Covering 1 - 7 mkg 1 Nos
10 Single - Arm Torque Wrench Covering 3 - 14 mkg 1 Nos
11 Single - Arm Torque Wrench Covering 5 - 23 mkg 1 Nos
12 Cross Wheel Spanner (17 x 18 - 19 x 21 mm) 5 Nos
13 Bench Vice (100 mm x 4") 2 Nos
14 Working Bench Wooden 2 Nos
15 Vernier Callipers 4 Nos
16 Micrometer (Size: 0 to 25 mm) 4 Nos
17 Digital Multimeter with Various Lead Sets 2 Nos
18 Work Bench Wooden (Two) Size: 4*3*2.5" in Feet 2 Nos
19 Hacksaw (300 mm) with Blade 15 Nos
20 Tyre Pressure Gauge 2 Nos
21 Steel Rule 15 Nos
22 Tape Measure 15 Nos
23 Depth Gauge 2 Nos
24 Hydro Meter 2 Nos

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
2 LIST OF TOOLS & EQUIPMENT -
AUTOMOTIVE – 4 WHEELER REPAIR
S. No. Equipment Name Qty Unit Type

25 Tyre Pressure Gauge 2 Nos

26 Plastic Hammer 5 Nos
27 Filter Adjustable Remover 1 Nos
28 Spark Plug Sockets 67 mm Drive Size 16/21 mm 2 Nos
29 Magnetic Pickup Tool (Bar) 2 Nos
30 Dial Gauge (Mahr 10 mm Range) 5 Nos
31 Wire Brush 5 Nos
32 Hydraulic Jacks 3 Ton 1 Nos
33 Air Compressor and Hoses 1 Nos
34 Tyre Inflator 1 Nos
35 Battery Charger 1 Nos
36 Universal Battery Tester and Probe 2 Nos
37 Creeper 2 Nos
38 Drain Pans / Engine Tray 12" x 18", 18" x 24" 6 Nos
39 Screw Extractor Set 2 Nos
40 Temperature Sensing Device 2 Nos
41 Wheel Chocks 6 Nos
42 Measuring Can 2 Nos
43 Two Post Lift 1 Nos
44 Neon Timing Light 3 Nos
45 Battery & Charging System Tester 1 Nos
46 Injector Tester and Cleaner 1 Nos
47 Air Tester Filter Machine 1 Nos
48 A/C Leakage Tester 1 Nos

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
2 LIST OF TOOLS & EQUIPMENT -
AUTOMOTIVE – 4 WHEELER REPAIR
S. No. Equipment Name Qty Unit Type

49 Diagnostic Tool 1 Nos

50 Brake Bleeder, Pressure or Vacuum 1 Nos
51 Wheel Balancer (Optima D - 6111) 1 Nos
52 Tyre Changer (Trufit) 1 Nos
53 Head Light Focusing 1 Set
54 Pneumatic Tools 1 Set
55 Wheel Aligner 1 Nos
56 Goggles 15 Nos
57 Ear Plugs 15 Nos
58 Gloves 15 Nos
59 First Aid 2 Nos
59 Powder - Based Fire Extinguisher Class ABC, 500 gms 4 Nos
60 Water Stored Pressure Fire - Extinguisher Class A, 9 ltr 2 Nos
61 Safety Sign 1 Nos
62 Complete Car Cut Section 1 Nos
63 Petrol Vehicle - Minimum Maruti Alto 1 Nos
64 Diesel Vehicle - Minimum Indica / Indigo 1 Nos
Aggregate Car Petrol ( Engine, Transmission System, Brake System, Suspension
64 System, Steering System, Electrical System, etc. Mounted on Chassis) - 1 Set
Minimum Maruti Alto
65 Special Maintenance Tool for Maruti Suzuki Alto 1 Set
Diesel Engine Mounted on Stand Four Cylinder Inline Engine 1200 CC
66 1 Nos
Tata Sumo (Preferred)
67 Clutch System Gypsy or Tata Sumo 1 Nos

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
2 LIST OF TOOLS & EQUIPMENT -
AUTOMOTIVE – 4 WHEELER REPAIR
S. No. Equipment Name Qty Unit Type

68 Gear - Box Mounted on Stand Gypsy or Tata Sumo (Synchromesh) 1 Nos

69 Propeller Shaft - Gypsy or Tata Sumo (Preferred) 1 Nos
70 Differential Mounted on Stand - Gypsy or Tata Sumo (Preferred) 1 Nos
71 Starter Motor - Lucas or Equivalent 12 Volt / 1 kW 1 Nos
72 Alternator Lucas or Equivalent 12 Volt / 70 amp 1 Nos
73 Steering System Rack Travel 136 mm Rane Male or Equivalent 1 Nos
74 Air Assisted Brake System 1 Nos
75 Brake System Hydraulic any 4 - Wheeler 1 Nos
76 Fuel Pump (12 V Electrical Fuel Pump) - Maruti or Tata Motor Preferred 3 Nos
77 Water Pump 3 Nos
78 Radiator for 4 - Wheeler 3 Nos
79 Fuel Filter 3 Nos
80 Oil Filter 3 Nos
81 Almirah for Keeping Tools 6'' Height x 3'' Width x 1.75'' Depth and 18 Gauge 2 Nos
82 Tool Board 1 Nos

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
3 3D REPRESENTATION OF
AUTOMOTIVE – 4 WHEELER REPAIR LAB

List of Equipment
Entry Store Room
Engine Cut Section and Aggregates Auto Electrician Cut Section and Work Area
Vertical Hydraulic Hoist Service Area
Work Benches for Observers Classrooms
Diagosnistic Equipment Transmission Cut Section Area
Chassis with Gear Box and Steering Section Air Compressor
Vehicle Service Area

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
4 ILLUSTRATIVE ARCHITECTURAL LAYOUT OF LAB

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
5 ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT

S. No. Equipment Name Qty Unit Unit Price* Amount Brands**

Type (INR) (INR)
1 Service Technician Tool Kit 15 Set 10,000 1,50,000 Multi Branded
2 Drive Socket Set 2 Set 4,000 8,000 Multi Branded
3 Lever Type Grease Gun 2 Nos 340 680 Non Branded
4 Chisel - Drop Forge 16 x 22 x 20 10 Nos 140 1,400 Non Branded
5 Oil Can - Wesco Type 4 Nos 110 440 Non Branded
6 Centre Punches 10 Nos 70 700 Non Branded
7 Two - Leg Puller 1 Nos 1,798 1,798 Non Branded
8 Hammer Ball Pin 15 Nos 171 2,565 Non Branded
9 Single Arm Torque Wrench Covering 1 - 7 mkg 1 Nos 3,700 3,700 Taparia or Equivalent
10 Single Arm Torque Wrench Covering 3 - 14 mkg 1 Nos 4,200 4,200 Taparia or Equivalent
11 Single Arm Torque Wrench Covering 5 - 23 mkg 1 Nos 4,600 4,600 Taparia or Equivalent
12 Cross Wheel Spanner (17 x 18 - 19 x 21 mm) 5 Nos 320 1,600 Taparia or Equivalent
13 Bench Vice (100 mm x 4") 2 Nos 3,000 6,000 Multi Brands
14 Working Bench Wooden 2 Nos 8,000 16,000 Fabricated
15 Vernier Callipers 4 Nos 900 3,600 Mitutoyo or Equivalent
16 Micrometre (Size: 0 to 25 mm) 4 Nos 1,200 4,800 Mitutoyo or Equivalent
17 Digital Multimeter with Various Lead Sets 2 Nos 475 950 Mitutoyo or Equivalent
18 Work Bench Wooden (Two) Size: 4*3*2.5" in Feet 2 Nos 7,500 15,000 Fabricated
19 Hacksaw (300 mm) with Blade 15 Nos 300 4,500 Non Branded
20 Tyre Pressure Gauge 2 Nos 210 420 Multi Branded
21 Steel Rule 15 Nos 75 1,125 Non Branded
22 Tape Measure 15 Nos 75 1,125 Multi Branded
23 Depth Gauge 2 Nos 180 360 Mitutoyo or Equivalent
24 Hydrometer 2 Nos 200 400 Multi Branded

*Price is indicative for the major brands, similar tools/equipment may be used
**Brands are illustrative, other brands with same specifications may be used

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
5 ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT

S. No. Equipment Name Qty Unit Unit Price* Amount Brands**

Type (INR) (INR)
25 Tyre Pressure Gauge 2 Nos 210 420 Multi Branded
26 Plastic Hammer 5 Nos 326 1,630 Non Branded
27 Filter Adjustable Remover 1 Nos 390 390 Non Branded
28 Spark Plug Sockets 67 mm Drive Size 16/21 mm 2 Nos 270 540 Non Branded
29 Magnetic Pickup Tool (Bar) 2 Nos 545 1,090 Non Branded
30 Dial Gauge (Mahr 10 mm Range ) 5 Nos 385 1,925 Mitutoyo or Equivalent
31 Wire Brush 5 Nos 120 600 Non Branded
32 Hydraulic Jacks 3 Ton 1 Nos 1,13,000 1,13,000 Multi Branded
Atlas Capco or
33 Air Compressor and Hoses 1 Nos 1,50,000 1,50,000 Equivalent

34 Tyre Inflator 1 Nos 18,000 18,000 Multi Branded

35 Battery Charger 1 Nos 3,825 3,825 Multi Branded
36 Universal Battery Tester and Probe 2 Nos 899 1,798 Multi Branded
37 Creeper 2 Nos 3,000 6,000 Non Branded
38 Drain Pans / Engine Tray 12" x 18", 18'' x 24" 6 Nos 1,000 6,000 Non Branded
39 Screw Extractor Set 2 Nos 394 788 Non Branded
40 Temperature Sensing Device 2 Nos 150 300 Multi Branded
41 Wheel Chocks 6 Nos 445 2,670 Non Branded
42 Measuring Can 2 Nos 450 900 Non Branded
43 Two Post Lift 1 Nos 1,65,000 1,65,000 Multi Branded
44 Neon Timing Light 3 Nos 4,200 12,600 Multi Branded
45 Battery & Charging System Tester 1 Nos 13,500 13,500 Non Branded
46 Injector Tester and Cleaner 1 Nos 19,500 19,500 Bosch or Equivalent
47 Air Tester Filter Machine 1 Nos 12,490 12,490 Bosch or Equivalent

*Price is indicative for the major brands, similar tools/equipment may be used
**Brands are illustrative, other brands with same specifications may be used

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
5 ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT

S. No. Equipment Name Qty Unit Unit Price* Amount Brands**

Type (INR) (INR)
48 A/c Leakage Tester 1 Nos 4,490 4,490 Bosch or Equivalent
49 Wheel Balancer (Optima D - 6111) 1 Nos 1,14,000 1,14,000 Multi Branded
50 Tyre Changer (Trufit) 1 Nos 1,08,000 1,08,000 Multi Branded
51 Head Light Focusing 1 Set 34,950 34,950 Multi Branded
52 Pneumatic Tools 1 Set 35,320 35,320 Taparia or Equivalent
53 Wheel Aligner 1 Nos 5,61,000 5,61,000 Multi Branded
54 Goggles 15 Nos 119 1,785 3 m or Equivalent
55 Ear Plugs 15 Nos 132 1,980 3 m or Equivalent
56 Gloves 15 Nos 71 1,065 3 m or Equivalent
57 First Aid 2 Nos 2,000 4,000 Non Branded
58 Powder Based Fire Extinguisher Class ABC, 500 gm 4 Nos 2,500 10,000 Cease Fire or
Equivalent
59 Water Stored Pressure Fire Extinguisher Class A, 9 ltr Cease Fire or
2 Nos 2,500 5,000
Equivalent
60 Safety Sign 1 Nos 5,000 5,000 Non Branded
61 Complete Car Cut Section 1 50,000 50,000 Multi Branded
Maruti Alto
62 Petrol Vehicle - Minimum Maruti Alto 1 Nos 1,00,000 1,00,000
or Equivalent
Indica / Indigo
63 Diesel Vehicle - Minimum Indica / Indigo 1 Nos 1,50,000 1,50,000
or Equivalent
Aggregate Car Petrol (Engine, Transmission System,
64 Brake System, Suspension System, Steering System, 1 Set 1,00,000 1,00,000 Non Branded
Electrical System, etc. Mounted on Chassis) - Minimum
Maruti Alto
65 Special Maintenance Tool for Maruti Suzuki Alto 1 Set 15,000 15,000 Taparia or Equivalent
66 Diesel Engine Mounted on Stand Four Cylinder Inline
1 Nos 20,000 20,000 Gypsy or Tata Sumo
Engine 1200 CC Tata Sumo (Preferred)

*Price is indicative for the major brands, similar tools/equipment may be used
**Brands are illustrative, other brands with same specifications may be used

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
5 ILLUSTRATIVE PRICING OF TOOLS & EQUIPMENT

S. No. Equipment Name Qty Unit Unit Price* Amount Brands**

Type (INR) (INR)
67 Clutch System Gypsy or Tata Sumo 1 Nos 4,000 4,000 Gypsy or Tata Sumo
Gear Box Mounted on Stand Gypsy 1 Nos 4,500 4,500 Gypsy or Tata Sumo
68 or Tata Sumo (Synchromesh)
69 Propeller Shaft - Gypsy or Tata Sumo (Preferred) 1 Nos 2,500 2,500 Gypsy or Tata Sumo

70 Differential Mounted on Stand - Gypsy 1 Nos 4,500 4,500 Gypsy or Tata Sumo
or Tata Sumo (Preferred)
71 Starter Motor - Lucas or Equivalent 12 Volt / 1kW 1 Nos 3,000 3,000 Lucas or Equivalent
72 Alternator Lucas or Equivalent 12 Volt / 70 amp 1 Nos 2,500 2,500 Lucas or Equivalent

73 Steering System Rack Travel 136 mm 1 Nos 3,000 3,000 Rane or Equivalent
Rane Male or Equivalent
74 Air Assisted Brake System 1 Nos 2,590 2,590 Bosch or Equivalent
75 Brake System Hydraulic any 4-Wheeler 1 Nos 3,500 3,500 Bosch or Equivalent
Fuel Pump (12 V Electrical Fuel Pump) - 3 Nos 1,800 5,400 Multi Branded
76 Maruti or Tata Motor Preferred
77 Water Pump 3 Nos 1,500 4,500 Multi Branded
78 Radiator for 4-Wheeler 3 Nos 3,000 9,000 Multi Branded
79 Fuel Filter 3 Nos 500 1,500 Bosch or Equivalent
80 Oil Filter 3 Nos 600 1,800 Multi Branded
81 Almirah for Keeping Tools 6' Height x 3' Width x 1.75' 2 Nos 10,000 20,000 Fabricated
Depth and 18 Gauge
82 Tool Board 1 Nos 2,750 2,750 Fabricated

Total 22,92,509

*Price is indicative for the major brands, similar tools/equipment may be used
**Brands are illustrative, other brands with same specifications may be used

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
6 SAFETY INSTRUCTIONS
Given below Safety Instruction posters should be placed at appropriate places in the lab. The posters should
be digitally printed and pasted on sun board.

Power Tools When in Fire Situation,

Precaution
CAUTION Please Remember PASS
PULL... the pin. Some extinguishers may require

SLIPPERY
releasing of a lock latch, pressing a
puncture lever or other motion

AIM... low, pointing the extinguisher nozzle

(or it's horn or hose) towards the base of the fire

SQUEEZE... the handle. This releases the

extinguishing agent

SWEEP... from side to side at the base of the fire

until it appears to be out. Watch the fire area in
case fire breaks out again and repeat use of

FLOOR extinguisher, if necessary

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
6 SAFETY INSTRUCTIONS
Electrical Hazards

• Do not work in wet work areas or cramped up work spaces

• Do not leave naked or loose wires in the lab

Electrical exposure may lead to falls, fractures and other accidents. A small shock
can cause brain damage while death can occur from large shocks. ELECTRICAL HAZARDS

Electrical Safety

• Use dry gloves

• Wear rubber soled shoes
• Protect yourself from surfaces that conduct electricity
• Keep insulation on all equipment
• Components must be dry and in good condition
• Do not do wiring with bare hands, wet gloves or while standing on wet or
ungrounded surfaces

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
 We are a youthful nation.
Our youth is our
strength. The world and
India need a skilled
workforce and we are
committed to achieve this
Shri Rajiv Pratap Rudy
Minister of State (I/C) for
mission.
Skill Development & Entrepreneurship
Govt. of India

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LAB SPECIFICATIONS AUTOMOTIVE – 4 WHEELER REPAIR
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