Mechanic Diesel - Directorate General of Employment & Training
Contents
1. 110 Scraper flat 25 cm 2 111 Scraper half round 25 cm 2 112 Scraper Triangular 25 cm 2 113 Scriber 15 cm 2 114 Scriber with scribing black universal 2 115 Set of stock and dies Metric 2 sets 116 Shear Tin Man s 450 mm x 600mm 2 117 Sheet Metal Gauge 2 118 Sher Tinmans 300mm 4 119 Soldering Copper Hatchet type 500gms 2 120 Solid Parallels in pairs Different size in Metric 2 121 Spanner Clyburn 15 cm 1 122 Spanner D E set of 12 pieces 6mm to 32mm 4 123 Spanner T flocks for screwing up and up screwing inaccessible 2 124 Spanner adjustable 15cm 2 125 Spanner ring set of 12 metric sizes 6 to 32 mm 4 126 Spanners socket with speed handle T bar ratchet and universal upto 2 127 Spark lighter 2 128 Spark plug spanner 14mm x 18mm x Size 2 129 Starter motor axial type pre engagement type amp Co axial type leach 130 Steel measuring tape 10 meter in a case 4 131 Steel rule 15 cm inch and metric 4 132 Steel rule 30 cm inch and metric 4 133 Straight edge gauge 2 ft 2 134 Straight edge gauge 4 ft 2 135 Stud extractor set of 3 2 sets 136 Stud remover with socket handle 1 137 Surface gauge with dial test indicator plunger type i e 0 01 mm 4 138 Tachometer Counting type l 139 Tandem master cylinder with booster 4 140 Taps and Dies complete sets 5 types 1 set 141 Taps and w2. Sl No Item with specification Qty Nos 1 Allen Key set of 12 pieces 2mm to 14mm 5 1 2 Caliper inside 15 cm Spring 6 3 Calipers outside 15 cm spring 6 4 Center Punch 10 mm Dia x 100 mm 6 5 Dividers 15 cm Spring 6 6 Electrician Screw Driver 250mm 6 7 Hammer ball peen 0 5 kg with handle 6 8 Hands file 20 cm Second cut flat 6 9 Philips Screw Driver set of 5 pieces 100 mm to 300 mm 6 10 Pliers combination 20 cm 6 11 Screw driver 20cm X 9mm Blade 6 12 Screw driver 30 cm X 9 mm Blade 6 13 Scriber 15 cm 6 14 Spanner D E set of 12 pieces 6mm to 32mm 6 15 Spanner ring set of 12 metric sizes 6 to 32 mm 6 16 Spanners socket with speed handle T bar ratchet and universal upto 32 6 mm set of 28 pieces with box 17 Steel rule 30 cm inch and metric 6 18 Steel tool box with lock and key folding type 400x200x150 mm 6 19 Wire cutter and stripper 6 B Tools Instruments and General Shop outfits Sl No Item with specification Qty Nos 1 Adjustable spanner pipe wrench 350 mm 2 2 Air blow gun with standard accessories 1 3 Air impact wrench with standard accessories 4 4 Air ratchet with standard accessories 4 5 Allen Key set of 12 pieces 2mm to 14mm 4 6 Ammeter 300A 60A DC with external shunt 4 T Angle plate adjustable 250x150x175 1 8 Angle plate size 200x100x200mm 2 9 Anvil 50 Kgs with Stand 1 10 Auto Electrical test bench l 11 Battery
3. charger 2 12 Belt Tensioner gauge 1 13 Blow Lamp 1 litre 2 14 Caliper inside 15 cm Spring 4 15 Calipers outside 15 cm spring 4 16 Car Jet washer with standard accessories 1 17 Chain Pulley Block 3 ton capacity with tripod stand 1 22 18 Chisel 10 cm flat 4 19 Chisels cross cut 200 mm X 6mm 4 20 Circlip pliers Expanding and contracting type 15cm and 20cm each 4 21 Clamps C 100mm 2 22 Clamps C 150mm 2 23 Clamps C 200mm 2 24 Cleaning tray 45x30 cm 4 25 Compression testing gauge suitable for diesel Engine with standard 2 accessories 26 Connecting rod alignment fixture 1 27 Copper bit soldering iron 0 25 Kg 4 28 Cylinder bore gauge capacity 20 to 160 mm 4 29 Cylinder liner Dry amp wet liner press fit amp slidefit liner 1 each 30 DC Ohmmeter 0 to 300 Ohms mid scales at 20 Ohms 2 31 Depth micrometer 0 25mm 4 32 Dial gauge type 1 Gr A complete with clamping devices and with 4 magnetic stand 33 Different type of Engine Bearing model 1 set 34 Different type of piston model leach 35 Dividers 15 cm Spring 4 36 Drift Punch Copper 15 Cm 4 37 Drill point angle gauge 1 38 Drill twist 1 5 mm to 15 mm various sizes by 0 5 mm 4 39 Electric Soldering Iron 230 V 60 watts 230 V 25 watts 2 each 40 Electric testing screw driver 4 Al Engineer s square 15 cm Blade 4
4. Valve stem dia piston diameter and piston pin dia with outside Micrometers Measuring practice on the height of the rotor of an oil pump from the surface of the housing or any other auto component measurement with depth micrometer Measuring practice on valve spring free length Measuring practice on cylinder bore Connecting rod bore inside diameter ID of a camshaft bearing with Telescope gauges Measuring practice on cylinder bore for taper and out of round with Dial bore gauges Measuring practice to measure wear on crankshaft end play crankshaft run out and valve guide with dial indicator Measuring practice to check the flatness of the cylinder head is warped or twisted with straightedge is used with a feeler gauge Measuring practice to check the end gap of a piston ring piston to cylinder wall clearance with feeler gauge Practice to check engine manifold vacuum with vacuum gauge Practice to check the air pressure inside the vehicle tires is maintained at the recommended setting Systems of measurement Description care amp use of Micrometers Outside and depth mirometer Micrometer adjustments Vernier calipers Telescope gauges Dial bore gauges Dial indicators straightedge feeler gauge thread pitch gauge vacuum gauge tire pressure gauge 8 amp 9 Practice on General checking and use of nut studs etc cleaning bolts amp Removal of stud bolt from blind hole Practi
5. amp Equipment for the Trade of Mechanic Diesel Engineering Drawing Note Facilities available in Draughtsman trade can be utilized TRAINEE S TOOLS KIT SI No Name of the items Quantity l Draughtsman drawing instrument box 20 1 set 2 Set square celluloid 45 250 X 1 5 mm 20 1 set 3 Set square celluloid 30 60 250 X 1 5 mm 20 1 set 4 Mini drafter 20 1 set 5 Drawing board 700mm x500 mm IS 1444 20 1 set GENERAL MACHINERY SHOP OUTFIT SI No Name amp Description of Machine Quantity 1 Draughtsman table 20 Nos 2 Draughtsman stool 20Nos 28
6. Drilling machine drill holding devices Work Holding devices Drill bits Taps and Dies Hand Taps and wrenches Calculation of Tap drill sizes for metric and inch taps Different type of Die and Die stock Screw extractors Hand Reamers Different Type of hand reamers Drill size for reaming Lapping Lapping abrasives type of Laps 12 Practice on making Rectangular Tray Pipe bending Fitting nipples unions in pipes Soldering and Brazing of Pipes Sheet metal State the various common metal Sheets used in Sheet Metal shop Sheet metal operations Shearing bending Drawing Squeezing Sheet metal joints Hem amp Seam Joints Fastening Methods Riveting soldering Brazing fluxes used on common joints Sheet and wire gauges The blow lamp its uses and pipe fittings 13 Practice in joining wires using soldering Iron Construction of simple electrical circuits Measuring of current voltage and resistance using digital multimeter practice continuity test for fuses jumper wires fusible links circuit breakers Basic electricity Electricity principles Ground connections Ohm s law Voltage Current Resistance Power Energy Voltmeter ammeter Ohmmeter Mulitmeter Conductors amp insulators Wires Shielding Length vs resistance Resistor ratings 14 Diagnose series parallel series parallel circuits using Ohm s law Check electrical circuit with a test lamp perform voltage drop test i
7. Gn prerie ae sipping OF diese engines Principle amp working of 2 amp 4 stroke diesel engine Compression ignition Engine Observe and report the reading of C D Principle of Spark Ignition Tachometer Odometer temp and Fuel Engine SD differentiate between 2 stroke gauge under ideal and on load condition and 4 stroke C I engine and S I Engine Direct injection and Indirect injection Practice on dismantling Diesel engine of Technical terms used in engine Engine LMV HMV as per procedure specification Study of various gauges instrument on a dash board of a vehicle Speedometer Tachometer Odometer and Fuel gauge and Indicators such as gearshift position Seat belt warning light Parking brake engagement warning light and an Engine malfunction light Different type of starting and stopping method of Diesel Engine Procedure for dismantling of diesel engine from a vehicle 3 amp 4 Overhauling of cylinder head assembly Diesel Engine Components Description Use of service manual for clearance and other parameters Practice on removing rocker arm assembly manifolds Practice on removing the valves and its parts from the cylinder head cleaning Inspection of cylinder head and manifold surfaces for warping cracks and flatness Checking valve seats amp valve guide Replacing the valve if necessary Testing leaks of valve seats for leakage Dismantle rocker shaft assembly clean amp check rocker shaft and levers for
8. Hollow Punch set of seven pieces 6mm to 15mm 2 sets each 73 Injector Multi hole type Pintle type 4 each 74 Injector cleaning unit 1 75 Injector testing set Hand tester l 76 Insulated Screw driver 20 cm x 9mm blade 4 71 Insulated Screw driver 30 cm x 9mm blade 4 78 Left cut snips 250mm 4 79 Lifting jack screw type 3 ton 5ton amp 20 Ton capacity 1 each 80 Magneto spanner set with 8 spanners 1 set 81 Magnifying glass 75mm 2 82 Marking out table 90X60X90 cm 1 83 Multimeter digital 5 84 Oil can 0 5 0 25 liter capacity 4 85 Oil pump for dismantling and assembling 2 86 Oil Stone 15 cm x 5 cm x 2 5 cm 1 87 Oscilloscope 20MHz 2 88 Outside micrometer 0 to 25 mm 4 89 Outside micrometer 25 to 50 mm 4 90 Outside micrometer 50 to 75 mm 1 91 Outside micrometer 75 to 100 mm 1 92 Philips Screw Driver set of 5 pieces 100 mm to 300 mm 2 93 Pipe cutting tool 2 94 Pipe flaring tool 2 95 Piston ring compressor 2 96 Piston Ring expander and remover 2 97 Piston Ring groove cleaner l 98 Pliers combination 20 cm 2 99 Pliers flat nose 15 cm 2 100 Pliers round nose 15 cm 2 101 Pliers side cutting 15 cm 2 102 Portable electric drill Machine l 103 Prick Punch 15 cm 4 104 Punch Letter 4mm Number 2 set 105 Radiator cut section cross flow 1 106 Radiator cut section down flow 1 107 Radiator pressure cap 2 108 Right cut snips 250mm 2 109 Rivet sets snap and Dolly combined 3mm 4mm 6mm 2 24
9. as per workshop manual of the engine assembling Introduction to Gas Turbine Engine component procedures Testing Comparison of single and two stage turbine cylinder compression Checking idle engine Different between gas turbine and speed Removing amp replacing a cam Diesel Engine belt Inspecting amp adjusting an engine drive belt Replacing an engine drive belt 10 12 Practice on Checking amp Top up coolant Need for Cooling systems Heat transfer Draining amp refilling coolant Checking method Boiling point amp pressure replacing a coolant hose Testing Centrifugal force Vehicle coolant cooling system pressure Practice on properties and recommended change of Removing amp replacing radiator interval Different type of cooling systems thermostat Inspect the radiator pressure Basic cooling system components cap Testing of thermostat Cleaning amp Radiator Coolant hoses Water pump reverse flushing Overhauling water Cooling system thermostat Cooling fans pump and refitting Temperature indicators Radiator pressure Practice on Checking engine oil Draining CaP Recovery system Thermo switch engine ail Rep lacing oil filter Refilling Need for lubrication system Functions of engine oil Overhauling of oil pump oil TAS f coolers air cleaners and air filters and ou Y BoOBIY ane K erate 1P hie on oe additives Synthetic oils The lubrication adjust oil pressure relief valves repairs to il flow pipe lin
10. clean oil holes Measure the piston ring close gap in the cylinder clearance between the piston and the liner clearance between crank pin and the connecting rod big end bearing Check connecting rod for bend and twist Assemble the piston and connecting rod assembly Description amp functions of different types of pistons piston rings and piston pins and materials Used recommended clearances for the rings and its necessity precautions while fitting rings common troubles and remedy Compression ratio Description amp function of connecting rod importance of big end split obliquely Materials used for connecting rods big end amp main bearings Shells piston pins and locking methods of piston pins Overhauling of crankshaft Use of service manual for clearance and other parameters Practice on removing damper pulley timing gear timing chain flywheel main bearing caps bearing shells and crankshaft from engine checking oil retainer and thrust surfaces for wear Measure crank shaft journal for wear taper and ovality Checking crankshaft for fillet radii bend amp twist Description and function of Crank shaft camshaft Engine bearings classification and location materials used amp composition of bearing materials Shell bearing and their advantages special bearings material for diesel engine application bearing failure amp its causes care amp maintenance Crank shaft balancing Firing or
11. institute Job opportunities in the automobile sector Machinery used in Trade Types of work done by the students in the shop floor Admission amp introduction to the trade Introduction to the Course duration course content study of the syllabus General rule pertaining to the Institute facilities available Hostel Recreation Medical and Library working hours and time table Practical related Health Importance of maintenance cleanliness of Workshop Interaction with health centre and fire service station to provide demo on First aid and Fire safety Use of fire extinguishers to Safety and and Demonstration on safe handling and Periodic testing of lifting equipment and Safety disposal of Used engine oil Energy saving Tips of ITI electricity Usage Occupational Safety amp Health Importance of Safety and general Precautions to be observed in the shop Basic first aid safety signs for Danger Warning caution amp personal safety message Safe handling of Fuel Spillage Fire extinguishers used for different types of fire Safe disposal of toxic dust safe handling and Periodic testing of lifting equipment Authorization of Moving amp road testing vehicles Energy conservation Definition Energy Conservation Opportunities ECOs Minor ECos and Medium ECOs Major ECOs Safety disposal of Used engine oil Electrical safety tips 3 5 Practice using all marking aids like steel rule wi
12. shown Identify missing lines and missing views 9 12 Free hand sketching of key and screw threads Read and interpret three Types of screw thread representation pictorial schematic and simplified presentation Terms used in describing a threaded Part Designation of Thread Specifications Left Hand Thread Notations read and interpret the different type of Finish Symbols Fillets and Rounds and Machine Slots 13 Drawing of I C engine Diesel and their parts 14 Sketching of otto cycle Diesel cycle valves and valve timing diagram 15 Free hand sketch of piston assembly Free hand sketching of piston gudgeon pins rings and connecting rod 16 Free hand sketching of crank shaft and cam shaft showing all parts 17 Free hand sketching of cylinder block and cylinder head cylinder liners 18 Free hand sketching of different cooling system showing all necessary parts such as water pump thermostatic valve Radiator etc 19 Free hand sketching of lubrication system showing all necessary parts such as filters oil pump pressure release valve etc 20 Freehand sketching of staring system 21 Freehand sketching of charging system and solenoid switch circuit 20 SYLLABUS FOR EMPLOYABILITY SKILLS SEMESTER II Pl ref to www dget nic in 21 A TRAINEES TOOL KIT per 4 Trainees TRADE Mechanic Diesel LIST OF TOOLS amp EQUIPMNT FOR 20 TRAINEES 1 ISTRUCTOR
13. 42 Engineers stethoscope 1 43 Feeler gauge 20 blades metric 4 44 File flat 20 cm bastard 4 45 File half round 20 cm second cut 4 46 File Square 20 cm second cut 4 47 File Square 30 cm round 4 48 File triangular 15 cm second cut 4 49 Files assorted sizes and types including safe edge file 20 Nos 2 set 50 Flat File 25 cm second cut 4 51 Flat File 35 cm bastard 4 52 Fuel feed pump for Diesel 1 53 Fuel injection pump Diesel inline l 54 Fuel injection pump dismantling tool kit Universal Vice 1 55 Fuel injection pump VE pump Distributor fuel rotary pump DPC 1 each pumps along with special tools and accessories 56 Gloves for Welding Leather and Asbestos 5 sets 57 Glow plug tester 2 58 Granite surface plate 1600 x 1000 with stand and cover 1 59 Grease Gun 2 60 Grease Gun heavy duty trolley type 10 kg capciaty l 6l Growler 2 62 Hacksaw frame adjustable 20 30 cm 10 63 Hammer Ball Peen 0 75 Kg 4 23 64 Hammer Chipping 0 25 Kg 5 65 Hammer copper 1 Kg with handle 4 66 Hammer Mallet 4 67 Hammer Plastic 4 68 Hand operated crimping tool i for crimping up to 4mm and ii for 2 crimping up to 10mm 69 Hand reamers adjustable 10 5 to 11 25 mm 11 25 to 12 75 mm 12 75 2sets to 14 25 mm and 14 25 to 15 75 mm 70 Hand Shear Universal 250mm 2 71 Hand vice 37 mm 2 72
14. Engine Fitter repairs services and overhauls diesel or oil engines for efficient performance as prime mover to drive machinery and equipment Examines engine to locate defects using various tools and instruments e Dismantles or partly dismantles it to remove damaged or worn out parts and replaces or repairs them e Replace valve and assembles parts doing supplementary tooling and other functions as necessary to ensure accuracy of fit e Installs assembled or repaired engine in position and connects pulley or wheel to propulsion system Starts engine tunes it up and observes performance noting different meter readings such as temperature fuel level oil pressure etc and sets it to specified standard for optimum performance e Checks adjusts and lubricates engine periodically and performs such other functions to keep engine in good working order e May solder or braze parts and service diesel fuel pumps and injectors e Measures essential parts like cylinder bores piston sizes crank pins etc using gauges micrometer and other precision tools and gets cylinders re bored liners fitted valve seats refaced etc 3 Employment oppurtunities On successful completion of the course the candidates can either get employed or become a self employed Entrepreneur in any one of the following fields a Wage Employment b Self Employment 1 Auto Diesel engine Mechanic 1 Automobile Mechanic 2 Diesel Engine Service Technician 2 Di
15. SYLLABUS OF SEMESTER SYSTEM FOR THE TRADE OF Mechanic Diesel Under Craftsmen Training Scheme CTS One year Two Semesters Redesigned in 2014 By Government of India Ministry of Labour amp Employment DGE amp T Name of the Trade N C O Code No Duration of Craftsmen Training Power Norms Space Norms Entry Qualification Unit strength Instructors Qualification GENERAL INFORMATION Mechanic Diesel 7233 24 1Year Two Semester having duration of six months each 4 8 KW Space Area 210 Sq Mt Including parking area Passed 10 class examination with maths and Science 16 30 super Numeric a Degree in Automobile Mechanical Engg with specialization in Automobile from recognised college University with one year experience in the automobile industry and should possess valid LMV driving license OR Diploma in Automobile Mechanical specialization in automobile from recognized board of technical education with two years experience in the automobile industry and should posses valid LMV driving license OR 10 Passed NTC NAC in the Trade of Mechanic Diesel with 3 years post qualification experience in the relevant field and should possess valid LMV driving license and b With National Crafts Instructor Certificate Note 1 At least one Instructor must have Degree Diploma in Automobile Mechanical Engg with specialization in Automobile when applied for 02 units 2 Inst
16. atings Back pressure Electronic mufflers 14 Practice on removing amp Cleaning fuel Diesel Fuel Systems Description and 16 tanks checking leaks in the fuel lines function of Diesel fuel injection fuel soldering amp repairing pipe lines and characteristics concept of Quiet diesel Unions brazing nipples to high pressure technology amp Clean diesel technology line studying the fuel feed system in Diesel fuel system components diesel engines draining of water Description and function of Diesel tanks amp separators lines Diesel fuel filters water separator Lift pump Plunger pump Priming pump Bleeding of air from the fuel lines inline injection pump Distributor type Servicing primary amp secondary filters injection pump Diesel injectors Glow Removing a fuel injection pump from plugs Cummins amp Detroit Diesel injection an engine refit the pump to the engine Electronic Diesel control Electronic re set timing fill lubricating oil start Diesel control systems Common Rail and adjust slow speed of the engine Diesel f Injection CRDD system Practice on overhauling of injectors and Hydraulically actuated electronically testing of injector controlled unit injector HEUI diesel General maintenance of Fuel Injection CEUCH system Sensors acinators and Pumps FIP ECU Electronic Control Unit used in Diesel Engines 17 Practice on Start engine adjust idling Marine amp Stationary Engine Typ
17. cated power Mean effective pressure Calculation of indicated power Cylinder pressure vs crank angle Mechanical efficiency of an engine Volumetric efficiency Torque vs engine speed Specific fuel consumption vs engine speed Brake power torque and sfc Specific fuel consumption compared Brake mean effective pressure Thermal efficiency Indicated thermal efficiency Brake thermal efficiency petrol vs Diesel 21 Fuels and combustion Calorific value Combustion Products of combustion Relevant combustion equations Air fuel ratio Petrol engine combustion Detonation Pre ignition Octane rating Diesel fuel Flash point Pour point Cloud point Biofuels Liquefied petroleum gas LPG Hydrogen Zero emissions vehicles ZEVs 19 Automobile Group 2 Semester Engineering Drawing Syllabus for the trade of Mechanic Diesel Week Engineering Drawing 3 Hrs week Nos 2 Semester 1 4 Read and interpret drawings Determine information from the title block Read and interpret industrial prints Read and interpret detailed and assembly drawings Identify casting drawings and machining drawings Read and interpret diagrams Distinguish between a monodetail and a multidetail drawing 5 8 Identify different drawing projections Interpret pictorial and multi view drawings Interpret auxiliary and section views Determine views in a drawing and the significance of the view being
18. ce on cutting tools like Hacksaw file chisel Sharpening of Chisels center punch safety precautions while grinding Fasteners Study of different types of screws nuts studs amp bolts locking devices Such as lock nuts cotter split pins keys circlips lock rings lock washers and locating where they are used Washers amp chemical compounds can be used to help secure these fasteners Function of Gaskets Selection of materials for gaskets and packing oil seals Cutting tools Study of different type of cutting tools like Hacksaw File Definition parts of a file specification Grade shape different type of Practice on Hacksawing and filing to given dimensions cut and uses OFF hand grinding with sander bench and pedestal grinders safety precautions while grinding Limits Fits amp Tolerances Definition of limits fits amp tolerances with examples used in auto components 10 amp 11 Practice on Marking and Drilling clear and Blind Holes Sharpening of Twist Drills Safety precautions to be observed while using a drilling machine Practice on Tapping a Clear and Blind Hole Selection of tape drill Size use of Lubrication Use of stud extractor Cutting Threads on a Bolt Stud Adjustment of two piece Die Reaming a hole Bush to suit the given pin shaft scraping a given machined surface Drilling machine Description and study of Bench type Drilling machine Portable electrical
19. der of the engine Checking of flywheel and mounting flanges spigot bearing Check vibration damper for defects Practice on removing cam shaft from engine block Check for bend amp twist of camshaft Inspection of cam lobe camshaft journals and bearings and measure cam lobe lift Fixing bearing inserts in cylinder block amp cap check nip and spread clearance amp oil holes amp locating lugs fix crank shaft on block torque bolts check end play remove shaft check seating repeat similarly for connecting rod and Check seating and refit Description and function of the fly wheel and vibration damper Crank case amp oil pump gears timing mark Chain sprockets chain tensioner etc Function of clutch amp coupling units attached to flywheel Cleaning and Checking of cylinder blocks Surface for any crack flatness Measure cylinder bore for taper amp ovality clean oil gallery passage and oil pipe line Bore descale water passages and examine Removing cylinder liners from scrap cylinder block practice in measuring and Description of Cylinder block Cylinder block construction and Different type of Cylinder sleeves liner 14 refitting new liners as per maker s recommendations precautions while fitting new liners 9 Reassemble all parts of engine in correct Engine assembly procedure with aid of Sequence and torque all bolts and nuts special tools and gauges used for engine
20. e area of solids Rectangular solid Prism cylinder pyramids and cones Frustum of pyramid and cones sphere Hollow sphere segment of sphere circular ring spherical sector Calculation of volume and weight of simple solid bodies such as cubes square and hexagonal prism shop problem 11 13 Statistics Collecting and sorting raw data Definition of Discrete variable continuous Variable with Shop examples Constructing pictographs pie chart Bar chart Frequency and tally Charts Importance of the shape of a frequency distribution histogram frequency polygon Cumulative frequency plot Interpreting statistics sampling arithmetic mean median 14 amp 15 Heat and temperature Temperature Thermodynamic temperature scale Kelvin Cooling system temperature Standard temperature and pressure STP Thermal expansion with calculation Heat Sensible heat Latent heat Specific latent heat Specific heat capacity Quantity of heat with calculation Heat transfer Conduction Convection Radiation 16 amp Heating expansion and compression of gases Absolute pressure Absolute temperature Laws relating to the compression and expansion of gases Heating a gas at constant volume Heating a gas at constant pressure Charles law Expansion or compression at constant temperature isothermal 18 18 20 Internal combustion engines Engine power Brake power Horsepower PS the DIN Indi
21. ergy Energy equation Kinetic energy Energy of a falling body Kinetic energy of rotation 11 Automobile Group 1 year Trade 1 Semester Engineering Drawing Syllabus for the trade of Mechanic Diesel Week Engineering Drawing 3 Hrs week 1 Semester Importance of engineering drawing as a communication medium different types of drawing Machine Drawing Production Drawing Part Drawing Assembly Drawing Drawing instruments equipment and materials and their uses 2 amp 3 Scales Recommended scales reduced amp enlarged Drawing Sheet sizes AO A1 A2 A3 A4 A5 Layout of drawing sheet sizes of title block and its contents Using drawing instruments to draw straight lines rectangles squares circles polygons 4 amp 5 Lettering and Dimensioning Types of Lettering Guide Lines for lettering Recommended sizes of letters and numbers Single stroke letters Dimensioning rules and systems of dimensioning dimensioning a given drawing 6 amp 7 Identify the alphabet of lines Read and Interpret the meaning of various line types with examples Object Lines Hidden Lines Center Lines Phantom Lines Dimension Lines Extension Lines Leaders Break Lines Long break Line Round Solid Hollow Cross Section Section Lines Common Manufacturing Materials Cutting Plane Lines 8 11 Geometric Construction Bisecting a line perpendiculars parallel lines division of a line Angl
22. ering transmission body and load Brief description and uses of Vehicle hoists Two post and four post hoist Engine hoists Jacks Stands 22 23 In plant Training 24 25 Revision and Test 26 NCVT Exam 10 Automobile Group 1 year Trade 1 Semster Workshop Calculation and Science Syllabus for the trade of 1 Mechanic Diesel Week Workshop calculation and No Science 3 Hrs week 1 Units Derived and fundamental types of system FPS CGS MKS and their conversion Metric weights and measurements units conversion factors 2 Fractions Addition and subtraction Fractions and whole numbers Combined addition and subtraction Multiplication and division of fractions Operations in problems involving fractions 3 Order of performing BODMAS Mathematical operators Integers Rules for dealing with integers Addition subtraction Multiplication and division 4 amp 5 Ratio and proportion Percentages Examples of ratios in Automotive technology 6 profit and loss Discount 7 simple interest and compound interest 8 depreciation calculation 9 10 Time and work problem Time and distance clocks and calendar 11 Brief description of manufacturing process of steel and aluminum 12 Meaning of elasticity malleability brittleness hardness compressibility amp ductility and their examples Properties and uses of cast iron ferrous metal gray cast iron white ca
23. es bisection trisection Tangent lines touching circles internally and externally Polygons Regular polygons circumscribed and inscribed in circles Conic sections Definitions of focus directrix eccentricity Construction of Ellipse by Concentric circles method Construction of parabola by rectangular method 12 amp 13 Orthographic Projection Definition Planes of Projection Four quadrants Reference Line First angle projection Third angle projection 14 17 Isometric Projection Definition Isometric axes lines and planes Isometric Scale Isometric view Drawing of isometric views of plane figures Drawing of isometric views of prisms and pyramids Drawing of isometric view of cylinders and cones 18 21 Development of Surfaces Need for preparing development of surface Concept of true length Principal methods of development Development of simple solids like cubes prisms cylinders pyramids cones SYLLABUS FOR EMPLOYABILITY SKILLS SEMESTER I pl ref to www dget nic in 12 Syllabus for the trade of Mechanic Diesel Second Semester Semester code No Duration Six Months Syllabus for Trade practical and Trade Theory Week Trade Practical 27 Hrs week Trade Theory 5 Hrs week No 1 amp 2 Identification of parts in a diesel engine of Introduction to Engine LMV HMV Description of internal amp external combustion engines Classification of IC rest
24. es speed and damping device in pneumatic double acting engines opposed piston governor and venture control unit checking engines starting systems cooling systems Performance of engine with off load lubricating systems supplying fuel oil adjusting timings Start engine adjusting hydraulic coupling reduction gear drive idle speed of the engine fitted with electromagnetic coupling electrical drive mechanical governor checking high generators and motors supercharging speed operation of the engine Checking performance for missing cylinder by isolating defective injectors and test dismantle and replace defective parts and reassemble and refit back to the engine 18 Monitoring emissions procedures by use of Emission Control Vehicle emissions Engine gas analyser or Diesel smoke meter Checking amp cleaning a Positive crank case ventilation PCV valve Obtaining amp interpreting scan tool data Inspection of EVAP canister purge system by use of scan Tool EGR SCR Valve Remove and installation for inspection Standards Euro and Bhart II M IV V Sources of emission Combustion Combustion chamber design Types of emissions Characteristics and Effect of Hydrocarbons Hydrocarbons in exhaust gases Oxides of nitrogen Particulates Carbon monoxide Carbon dioxide Sulfur content in fuels Description of Evaporation emission control Catalytic conversion Closed loop Crankcase emission control Exhaust gas recirc
25. es and unions if necessary Dn Spaeth AAE Sys i Pip y Corrosion noise reduction in the lubrication system Lubrication system components Description and function of Sump Oil collection pan Oil tank Pickup tube different type of Oil pump amp Oil filters Oil pressure relief valve Spurt holes amp galleries Oil indicators Oil cooler 13 Practice on Dismantling air compressor and exhauster and cleaning all parts measuring wear in the cylinder reassembling all parts and fitting them in the engine Dismantling amp assembling of turbocharger check for axial clearance as per service manual Check Exhaust system for rubber mounting for damage deterioration and out of position for leakage loose connection dent and damage Practice on Exhaust manifold removal and installation Practice on Catalytic converter removal and installation 15 Intake amp exhaust systems Description of Diesel induction amp Exhaust systems Description amp function of air compressor exhauster Super charger Intercoolers turbo charger variable turbo charger mechanism Intake system components Description and function of Air cleaners Different type air cleaner Description of Intake manifolds and material Exhaust system components Description and function of Exhaust manifold Exhaust pipe Extractors Mufflers Reactive absorptive Combination Catalytic converters Flexible connections Ceramic co
26. esel Fuel System Service Mechanic 3 Auto Fitter in Manufacturing Concern in 3 Vehicle Operator Assembly Shop or Test Shop 4 Spare Parts Salesman 4 Mechanic in Auto Manufacturing Industry 5 Spare Parts Dealer 5 Dealers service mechanic 6 Driver Vehicle Operator 7 Spare Parts Sales Assistant Manufacturers Representative 8 Laboratory Assistant 4 Further learning pathways gt On successful completion of the course trainee can get themselves enrolled in Apprenticeship training in reputed Industrial organisation gt The qualified candidates have scope for lateral entry into the Diploma courses offered by some of the State Governments gt The qualified candidates can also get themselves upgraded by taking up the Second Semester at his own convenience in the CTS scheme since the first semester is common to the following trades Craftsman Training Scheme 1 Mechanic Motor Vehicle 2 Years 4 Sem 2 Mechanic Diesel 1 Year 2 Sem 3 Mechanic Motor Cycle 1 Year 2 Sem 4 Mechanic Auto Electrical and Electronics 1 Year 2 Sem 5 Mechanic Agricultural Machinery 2 Years 4 Sem 6 Mechanic Tractor Year 2 Sem 7 Pump Operator cum Mechanic 1 Year 2 Sem Syllabus for the trade of Mechanic Diesel First Semester Semester code No Duration Six Months Syllabus for Trade practical and Trade Theory Week No Trade Practical 27 Hrs week Trade Theory 5 Hrs week Familiarisation with
27. n circuits using multimeter measure current flow using multimeter ammeter use of service manual wiring diagram for troubleshooting Fuses amp circuit breakers Ballast resistor Stripping wire insulation cable colour codes and sizes Resistors in Series circuits Parallel circuits and Series parallel circuits Electrostatic effects Capacitors and its applications Capacitors in series and parallel 15 Cleaning and topping up of a lead acid battery Testing battery with Description of Chemical effects Batteries amp cells Lead acid batteries amp Stay Maintenance Free SMF batteries Magnetic effects Heating hydrometer Connecting battery to a charger for battery charging Inspecting amp testing a battery after charging Measure and Diagnose the cause s of excessive Key off battery drain parasitic draw and do corrective action Testing of relay and solenoids and its circuit effects Thermo electric energy Thermisters Thermo couples Electrochemical energy Photo voltaic energy Piezo electric energy Electromagnetic induction Relays Solenoids Primary amp Secondary windings Transformers stator and rotor coils 16 Identify and test power and signal Basic electronics Description of Semi connectors for continuity Identify conductors Solid state devices Diodes and test different type of Diodes ae be eae eee avert NPN PNP Transi for i Metal Oxide Fie ect T
28. ransistors f 7 Panels 1 MOSFETs Logic gates OR AND amp NOT and e _ Logic gates using switches Construct and test simple logic circuits OR AND amp NOT and Logic gates using switches Pe ee mare sma pdas ma Introduction to welding and Heat Treatment 18 Butt Lap amp T joints Manual Metal Arc Welding Welding processes Principles of Arc welding brief Setting of Gas welding flames description Elassineaiy ont applications Manual Metal Arc welding principles power sources practice to make a straight beads and bo electrodes welding parameters edge preparation joints Oxy Acetylene welding f amp fit up and welding techniques Oxy Acetylene Film on Heat treatment process welding principles equipment welding parameters edge preparation amp fit up and welding techniques Heat Treatment Process Introduction Definition of heat treatment Definition of Annealing Normalizing Hardening and tempering Case hardening Nitriding Induction hardening and Flame Hardening process used in auto components with examples 19 amp Practice on Liquid penetrant testing Non destructive Testing Methods Importance 20 method and Magnetic particle testing of Non Destructive Testing In Automotive method Identification of Hydraulic and pneumatic components used in vehicle Tracing of hydraulic circuit on hydraulic jack hydraulic power steering and Brake circuit Identification of componen
29. renches Metric 2 sets 142 Telescope gauge 4 143 Temperature gauge with sensor 0 100 deg c 2 144 Thermostat 2 145 Thread pitch gauge Metric 2 146 Timing lighter 2 147 Torque wrenches 5 35 Nm 12 68 Nm amp 50 225 Nm 1 each 148 Trammel 30 cm 2 149 Turbocharger cut sectional view 1 150 Tyre pressure gauge with holding nipple 2 151 Universal puller for removing pulleys bearings 1 152 V Block 75 x 38 mm pair with Clamps 2 153 Vacuum gauge to read 0 to 760 mm of Hg 2 154 Valve Lifter 1 155 Valve spring compressor universal 1 156 vernier caliper 0 300 mm with least count 0 02mm 4 157 Vice grip pliers 2 158 Water pump for dismantling and assembling 4 25 159 Wire Gauge metric 2 160 Work bench 250 x 120 x 60 cm with 4 vices 12cm Jaw 4 C General Installation Machineries Sl No Item with specification Qty Nos 1 Air conditioned CRDI Vehicle in running condition LMV 1 2 Arbor press hand operated 2 ton capacity 1 3 Automotive exhaust 5 gas analyzer petrol amp Diesel or Diesel Smoke 1 meter 4 Bench lever shears 250mm Blade x 3mm Capacity 1 5 Diesel Engine CRDI 4 stroke for Dismantling and assembling with 1 swivelling stand 6 Diesel engine Running condition Stationary type 1 T7 Discrete Component Trainer Basic Electronics Trainer 1 8 Drilling machine bench to drill up to 12mm dia along
30. required 9 Emery paper 36 60 grit 80 120 As required 10 Engine oil amp Engine coolant As required 11 Gear oils As required 12 Gloves for Welding Leather and Asbestos 5 sets 13 Hacksaw blade consumable As required 14 Hand rubber gloves tested for 5000 V 5 pair 15 Holders lamp teakwood boards plug sockets As required 16 Hydrometer 8 17 Lapping abrasives As required 18 Leather Apron 5 19 Petrol As required 20 Power steering oil As required 21 Radiator Coolants As required 22 Safety glasses As required 23 Steel wire Brush 50mmx 150mm 5 E Workshop Furniture SI Description Quantity No l Book shelf glass panel 6 2 x 3 x 1 2 As required 2 Computer Chair 1 1 3 Computer Table 1 1 4 Desktop computer and related MS office software 1 1 5 Discussion Table 8 x 4 x 2 4 2 6 Fire Extinguishers first aid box As required 7 Instructional Material NIMI Books Ref books As required 8 Internet connection with all accessories As required 9 Laser printer 1 10 LCD projector LED LCD TV 42 1 T As required 12 Online UPS 2KVA 1 13 Stools 21 14 Storage Rack 6 2 x 3 x 1 As required 15 Storage shelf 6 x 3 x 117 As required 16 Suitable class room furniture As required 17 Suitable Work Tables with vices As required 18 Tool Cabinet 6 2 x 3 x 1 2 19 Trainees locker 6 2 x 3 x 1 2 2 Nos to accommodate 20 Lockers 27 List of tools
31. ructor Qualification for WCS amp E D as per the Training Manual 9 For Employability Skills One Contract Part Time Guest Faculty for Generic Module 1 MBA BBA with two years experience OR Graduate in Sociology Social Welfare Economics with Two years experience OR Graduate Diploma with Two years experience and trained in Employability Skills from DGET institutes AND Must have studied English Communication Skills and Basic Computer at 12 Diploma level and above OR Existing Social Study Instructors duly trained in Employability Skills from DGET institutes Distribution of training on Hourly basis Total hours Trade practical Trade Work Engg Employability Extracurricular week theory shop Cal Drawing skills activity amp Sc 42 Hours 27 Hours 5 Hours 3 Hours 3 Hours 2 Hours 2 Hours COURSE INFORMATION MECHANIC DIESEL 1 Introduction gt An intensive industrial survey was made to ascertain the requirements of skill gap in the automobile sector a scientifically designed survey covering labour market survey web survey was conducted Based on the data obtained the skills are identified and accordingly the syllabus has been drafted Subsequently the Trade expert committed reviewed 2 Terminal Competencies Deliverables After successful completion of the above course the trainee shall be able to perform the following skills with proper sequence e Mechanic Diesel Engine Oil
32. st iron wrought iron and plain carbon steel high speed steel and alloy steel 13 Properties and uses in automobile industries copper zinc lead tin aluminum brass bronze solder bearing metals timber and rubber Nylon P V C PP poly prop line polymer 14 15 Materials Stress strain Definition of Stress Types of stress Tensile compressive shear Examples of the three basic stresses in automotive components calculation of stress and strain in automotive application Stress raisers Strain Tensile compressive Shear strain Tensile strength Factor of safety Torsional stress Strain energy 16 Definition of cold working and Hot working and its properties on sheet metal Advantage ofi Deep drawing material Importance of Iron carbon diagram in heat treatment process 17 Different Type of cutting fluids and their properties Calculation of cutting speed feed and drilling time 18 19 Forces Definition of Force Types of force examples Direct forces Attractive forces Explosive forces Describing forces Graphical representation of a force Addition of forces Parallelogram of forces Triangle of forces Resolution of forces Mass Equilibrium Pressure Pressure in hydraulic systems Hooke s law Practical applications 20 21 Work energy power Definition and calculation of Work Power and Work done by a torque Definition and calculation of Energy Potential energy Chemical energy Conservation of en
33. th spring calipers dividers scriber punches Chisel etc Layout a work piece for line circle arcs and circles Practice to measure a wheel base of a vehicle with measuring tape Practice to measure valve spring tension using spring tension tester Practice to remove wheel lug nuts with use of an air impact wrench Practice on General workshop tools amp power tools Hand amp Power Tools Marking scheme Marking material chalk Prussian blue Cleaning tools Scraper wire brush Emery paper Description care and use of Surface plates steel rule measuring tape try square Calipers inside and outside Dividers surface gauges scriber punches prick punch center punch pin punch hollow punch number and letter punch Chisel flat cross cut Hammer ball pein lump mallet Screw drivers blade screwdriver Phillips screw driver Ratchet screwdriver Allen key bench vice amp C clamps Spanners ring spanner open end spanner amp the combination spanner universal adjustable open end spanner Sockets amp accessories Pliers Combination pliers multi grip long nose flat nose Nippers or pincer pliers Side cutters Tin snips Circlip pliers external circlips pliers Air impact wrench air ratchet wrenches Torque wrenches pipe wrenches car jet washers Pipe flaring amp cutting tool pullers Gear and bearing 6 amp 7 Measuring practice on Cam height Camshaft Journal dia crankshaft journal dia
34. trade of 1 Mechanic Diesel Week No Workshop calculation and Science 3 Hrs week 1 amp 2 Factorisation and quadratics multiply expressions in brackets by a number symbol or by another expression in a bracket by extraction of a common factor eg ax ay a x 2 b x 2 by grouping eg ax ay bx by quadratic expressions eg a 2ab b roots of an equation eg quadratic equations with real roots by factorisation and by the use of formula Geometry Use of scientific calculator logarithmic table Angles Angular measurement Angles and rotation Examples of angles in automotive work Adding and subtracting angles Types of angle Adjacent angles Opposite angles Corresponding angles Alternate angle 4 6 Trigonometry Types of triangle Acute angled triangle Obtuse angled triangle Equilateral triangle Isosceles triangle Scalene triangle Right angled triangle Labelling sides and angles of a triangle Sum of the three angles of a triangle Pythagoras theorem Circles Ratio of diameter and circumference Length of arc Timing marks Wheel revolutions and distance travelled Valve opening area Trigonometry Using sines cosines and tangents to solve vehicle problems Formulae for Perimeter and Area of Plane figure Rectangle Square Parallelogram Triangle Hexagon any regular polygon Trapezium Circle sector Fillet Ellipse segment of a circle Formulae for Volume and surfac
35. ts in Air brake systems Industry Definition of NDT Liquid penetrant and Magnetic particle testing method Portable Yoke method Introduction to Hydraulics amp Pneumatics Definition of Pascal law pressure Force viscosity Description symbols and application in automobile of Gear pump Internal amp External single acting double acting amp Double ended cylinder Directional control valves 2 2 3 2 4 2 4 3 way valve Pressure relief valve Non return valve Flow control valve used in automobile Pneumatic Symbols Description and function of air Reciprocating Compressor Function of Air service unit FRL Filter Regulator amp Lubricator 21 Identification of different type of Auto Industry History leading manufacturers Vehicle development in automobile industry trends new Demonstration of vehicle product Brief about Ministry of Road transport amp od Highways specification data The Automotive Research Association of India Identification of vehicle information ARAD National Automotive Testing and R amp D Number VIN Demonstration of Infrastructure Project NATRIP amp Automobile Garage Service station equipments Association Nene liost E we P si and four Definition Classification of vehicles on the post hoist Engine hoists Jacks basis of load as per central motor vehicle rule Stands wheels final drive and fuel used axles position of engine and ste
36. ulation EGR valve Controlling air fuel ratios Charcoal storage devices Diesel particulate filter DPF Selective Catalytic 16 Reduction SCR EGR VS SCR 19 Practice on removing alternator from Description of charging circuit operation vehicle dismantling cleaning checking for of alternators regulator unit ignition defects assembling and testing for warning lamp troubles and remedy in motoring action of alternator amp fitting to charging system vehicles i i Description of starter motor circuit Practice on removing starter motor Vehicle f Constructional details of starter motor and overhauling the starter motor testing of solenoid switches common troubles and starter motor ee remedy in starter circuit 20 amp Practice on troubleshooting in Troubleshooting Causes and remedy for 21 LMV HMV for Engine Not starting Engine Not starting Mechanical amp Mechanical amp Electrical causes High Electrical causes High fuel consumption Engine overheating Low Power fuel consumption Engine overheating f f E f A Generation Excessive oil consumption Low Power ete et EE ie Low High Engine Oil Pressure Engine consumption Low High Engine Oil Noise Pressure Engine Noise 22 23 In plant Training 24 25 Revision and Test 26 NCVT Exam 17 Automobile Group 1 year Trade 2 Semster Workshop Calculation and Science Syllabus for the
37. wear and cracks and reassemble Check valve springs tappets push rods tappet screws and valve stem cap Reassembling valve parts in sequence refit cylinder head and manifold amp rocker arm assembly adjustable valve clearances starting engine after adjustments and Constructional feature of Cylinder head Importance of Cylinder head design Type of Diesel combustion chambers Effect on size of Intake amp exhaust passages Head gaskets Importance of Turbulence Valves amp Valve Trains Description and Function of Engine Valves different types materials Type of valve operating mechanism Importance of Valve seats Valve seats inserts in cylinder heads importance of Valve rotation Valve stem oil seals size of Intake valves Valve trains Valve timing diagram concept of Variable valve timing Description of Camshafts amp drives Description of Overhead camshaft importance of Cam lobes Timing belts amp chains Timing belts amp tensioners 13 Overhauling piston and connecting rod Assembly Use of service manual for clearance and other parameters Practice on removing oil sump and oil pump clean the sump Practice on removing the big end bearing connecting rod with the piston Practice on removing the piston rings Dismantle the piston and connecting rod Check the side clearance of piston rings in the piston groove amp lands for wear Check piston skirt and crown for damage and scuffing
38. with accessories 1 9 Dual Magnetization Yoke AC HWDC 230 VAC 50Hz 1 set 10 Gas Welding Table 1220mm x760mm 2 11 Grinding machine general purpose D E pedestal with 300 mm dia 1 wheels rough and smooth 12 Heavy Commercial vehicle type without body on frame 1 14 Hydraulic jack HI LIFT type 3 ton capacity and 5 Ton capacity 1 each 15 Liquid penetrant Inspection kit 1 set 16 Multi Scan Tool with oscilloscope l 17 Pipe Bending Machine Hydraulic type 12mm to 30mm 1 18 Pneumatic rivet gun with standard accessories 2 19 Spring tension tester 1 20 Tin smiths bench folder 600 x 1 6mm 1 21 Trolley type portable air compressor single cylinder with 45 liters 1 capacity Air tank along with accessories amp with working pressure 6 5 kg sq cm 22 Welding plant Oxy Acetylene complete high pressure 1 23 Welding Transformer 150 300 Amps 1 24 Working Condition of Diesel Engine CRDI 4 stroke Engine Assembly with fault simulation board D List of consumable SL Description Quantity No 1 Battery SMF As required 2 Brake fluids As required 3 Chalk Prussian blue As required 26 4 Chemical compound for fasteners As required 5 Diesel As required 6 Different type gasket material As required 7 Different type of oil seal As required 8 Drill Twist assorted As
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