Syllabus - ITI Rohtak
Contents
1. Ball press No 4 single body Ino 60 Pipe Bending Machine Hydraulic type 12mm to 30mm Ino 61 Spring tension tester Ino 62 Bench lever shears 250mm Blade x 3mm Capacity Ino 63 Gas Welding Table 1220mm x760mm Ino 64 Hydraulic Trainer Kit Basic along with accessories Ino 65 Pneumatic Trainer Kit Basic along with accessories Ino 66 Electronic component trainer kit Ino 67 Cylinder Block CI Engine Overhead camshaft amp camshaft in leach block air cooled 68 Carburetor Solex Mikuny for dismantling and assembling 1 each 69 Carburetor repair tool kit Ino 70 Demonstration board of 2W Ignition system ignition coil Ino 71 Demonstration board of electronic Ignition system ignition coil Ino 72 Spark Plug cleaning and testing eguipment Ino 73 Starter motor axial type pre engagement type amp Co leach axial type 74 Distributor Duel advance type reluctance type 1 each 75 Tester sparking plug NEON Type Ino 76 Alternator assembly used for LMV 2 nos 77 Starter motor assembly used for LMV 2 nos 78 Electronic engine control module Ino 79 Working Condition of Petrol MPFI Engine Assembly with fault Ino simulation board 80 MPFI petrol engine with swiveling stand along with special tools Ino for dismantling and assembling 81 Demonstration board of MPFI system Ino 82 Ultrasonic Injection cleaning equipment Ino 83 Fuel feed pump Ino 84 Multi point fuel injection pump Ino 85 Petrol nozzle 4 nos2. amp 2 Selector positions Planetary gear set High range power flow Low range power flow Servos amp clutches Rear servo Front servo One way clutch Multi plate front clutch Clutch pack Rear clutch Hydraulic system amp controls Hydraulic system components Spool valves Regulating or flow control valves Control valves Orifices Valve types amp functions Basic valve action Free hand sketch of Torque converter Lay out for gearbox Selector positions Planetary gear set High range power flow Low range power flow Properties of transmission fluid Gear ratio calculation for Automatic transmission 28 Page Regulator amp control valves Shift amp governor valves Pressure regulation The primary regulating valve Line pressure variation Modulator valve pressure The governor Governor pressure Kickdown pressure Flow control Gear position 1 1 2 shift valve 2 3 shift valve assembly The servo orifice control valve 3 2 kick down Continuously variable transmission C V T Continuously variable transmission Drive or reverse The steel belt Secondary pulley shaft 12 14 Following practical to be Practiced On Light amp Heavy Vehicle Practice on removing the drop arm Check and adjust the turning angle align the drop arm and steering wheel with the front wheel Check and correct toe in Practice on removing steering wheel steering gear
3. metal Sheets used in Sheet Metal shop 15 Practice in joining wires Basic electricity Free hand Electricity and its using soldering Iron Electricity sketching of effects static and Construction of simple principles Ground Millimeter dynamic electrical circuits connections ammeter electricity Measuring of current Ohm s law voltmeter and AC and DC voltage and resistance Voltage Current their parts differences using digital multimeter Resistance Power practice continuity test for Energy fuses jumper wires fusible Voltmeter links circuit breakers ammeter Ohmmeter Mulitmeter Conductors amp 11 Page insulators Wires Shielding Length VS resistance Resistor ratings l6 Diagnose series parallel Fuses amp circuit Free hand Calculations series parallel circuits breakers Ballast sketching of relating to electric using Ohm s law Check resistor electrical symbols Circuits electrical circuit with a test Stripping wire and drawing of Measurement of lamp perform voltage drop insulation cable simple electrical test in circuits using colour codes and Electrical circuits power watt and multimeter measure sizes Resistors in kilowatt current flow using Series circuits relationship with multimeter ammeter use Parallel circuits Horse of service manual wiring and Series parallel Power diagram for circuits troubleshooting Electrostatic effects Capacit
4. 13 Electrician Screw Driver 250mm 17 nos 14 Centre punch 10 cm 17 nos 15 Chisel cold flat 20 mm x 150 mm 17 nos 16 Hammer ball peen 0 5 kg with handle 17 nos 17 Screw driver 20cm X 9mm Blade 17 nos 18 Screw driver 30 cm X 9 mm Blade 17 nos 19 Spanner D E set of 12 pieces 6mm to 32mm 17 nos 20 Pliers combination 20 cm 17 nos 21 Pliers side cutting 15 cm 17 nos 22 Pliers round nose 15 cm 17 nos 23 Pliers flat nose 15 cm 17 nos 24 Hands file 20 cm Second cut flat 17 nos 25 Hand file 20 cm Second cut half round 17 nos 26 Hand file 20 cm smooth triangular 17 nos 2f Hand file 30 cm bastard 17 nos 28 Hand file 30 cm round bastard 17 nos 29 File card or cleaner 17 nos 30 Wire cutter and stripper 17 nos 31 Steel tool box with lock and key folding type 400x200x150 mm 17 nos 41 Page B Tools Instruments and General Shop outfits SI No Item with specification Oty l Outside micrometer 0 to 25 mm Ino 2 Outside micrometer 25 to 50 mm Ino 3 Outside micrometer 50 to 75 mm Ino 4 Outside micrometer 75 to 100 mm Ino oe Internal micrometer 5 to 30 mm Ino 6 Depth micrometer 0 25mm Ino 7 Thread Micrometer 0 25mm Ino 8 Drift Punch Copper 15 Cm 4 nos 9 Prick Punch 15 cm 4 nos 10 Adjustable micrometer sprit level to measure flatness indication In
5. MPI MPFD Simultaneous injection Efficient combustion EFI fuel supply system components Fuel pumps Fuel filters Tanks amp lines Fuel lines Fuel rail Fuel pressure regulator Injectors Tachometric relay Thermotime switch EFI sensors Potentiometer Auxiliary air valves Idle speed control devices International standard and norms for testing of MPFI Free hand sketching of wiring diagram of MPFI system Free hand sketching of symbols used in vehicle electrical systems subtracting angle Examples of angles in automotive work Type of triangle Pythagoras s theorem Trignometery Using scientific calculator to find the value of sin cos tangent with examples in automotive application 34 Page Inertia sensors 8 amp 9 Identification of Introduction to EFI Sketching of various Binary system Electronic control Engine Management EFI Electronic devices Most significant Unit operation used in motor Bit MSB Least Set up for testing Modes of EFI Electronic vehicle significant Bit Testing of fuel injection Idle speed LSB Electronic control systems Feedback Free hand sketching hexadecimal Control Circuit amp looping Cold start of wiring diagram of converting base Fault finding in systems Air EFI system 10 numbers to Electronic circuit measurement Air flow binary uses of and remedies monitoring Variable binary numbers intake manifold system
6. the brake lines and rectifying general maintenance and care Brakes procedures Checking amp adjusting brake fluid Replacing brake fluid Checking brake pads Replacing brake pads Removing amp replacing a rotor Replacing brake linings Adjusting a parking brake cable Trouble tracing in braking system of a heavy vehicle adjusting brakes and balancing all four wheel brakes precautions to be observed while testing brakes points to be remember while preparing the vehicle for brake certificate Practice of maintaining of ABS system Divided systems Tandem master cylinder Power booster or brake unit Hydraulic brake booster Electro hydraulic braking EHB Applying brakes Brake force Brake light switch Drum brakes amp components Drum brake system Drum brake operation Brake linings amp shoes Backing plate Wheel cylinders Disc brakes amp components Disc brake system Disc brake operation Disc brake rotors Disc brake pads Disc brake calipers Proportioning valves Proportioning valve operation Brake friction materials Antilock braking system amp components ABS brake system Antilock braking system operation Principles of ABS braking ABS master cylinder Hydraulic control unit Wheel speed sensors ABS with EBD electronic control unit layout of vacuum assisted Hydraulic brake system Freehand sketching of the lay out of Air brake system and sketching of slacken adj
7. Officer ATI Kolkata Member 23 R N Manna Training Officer CSTARI Kolkata 91 Member 24 Mrs S Das Training Officer CSTARI Kolkata 91 Member 25 Jyoti Balwani Training Officer RVTI Kolkata 91 Member 26 Pragna H Ravat Training Officer RVTI Kolkata 91 Member 27 Sarbojit Neogi Vocational Instructor RVTI Kolkata 91 Member 28 Nilotpal Saha Vocational Instructor 1 T I Berhampore Murshidabad Member W B 29 Vijay Kumar Data Entry Operator RVTI Kolkata 91 Member 4 Page GENERAL INFORMATION Name of the Trade Mechanic Motor Vehicle N C O Code No Duration of Craftsmen 2 Year Four Semester Training Power Norms 48 KW Space Norms 84Sq mtr amp Parking room 125 Sq mt Entry Qualification Passed in 10 Class Examination Unit strength 16 Instructors a Degree in Automobile Mechanical Engineering from Qualification recognized engg college university with one year experience in the relevant field OR Diploma in Automobile Mechanical Engg From recognized board of technical education with two years experience in the relevant field OR 10 Passed NTC NAC in the Trade of Mechanic Motor Vehicle with 3 years post qualification experience in the relevant field b Preference will be given to a candidate with Crafts Instructor Certificate CIC Note At least one Instructor must have Degree Diploma in Automobile Mechanical Engg when applied for 02 units 5 Page TRA
8. Plunger pump Priming pump Inline injection pump Mechanical or pneumatic governors Distributor type injection pump Diesel injectors Glow plugs Cummins amp Detroit Diesel injection Electronic Diesel control Electronic Diesel control systems Common Rail Diesel Injection CRDI system Hydraulically actuated electronically controlled unit injector HEUT diesel injection system Sensors actuators and ECU Electronic Control Unit used in Diesel Engines Free hand sketching of fuel feed system in diesel engines and fuel filters Free hand sketching of different types of injectors Free hand sketching of single element plunger of fuel injection pump Freehand sketching of water separators and fuel tanks with dimension from sample Freehand sketching of Distributor fuel injection pump with dimension from samples Freehand sketching of a pneumatic governor with dimensions from samples Freehand sketching of mechanical governor with dimensions from sample Alternate Fuel Systems Bio diesel fuel Importance of Alternative fuels Ethanol Methanol Liquefied Petroleum Gas Compressed Natural Gas Liquefied Natural Gas Fuel cells solar Hybrid system 19 amp 20 Practice on Start engine adjust idling speed and damping Marine amp Stationary Engine Types double acting do Problems on Equations of motion 23 Page device in
9. an regulation System it alternator operating voltage High Inspecting amp voltage charging systems adjusting an engine Rotor Stator Alternator drive belt end frames Slip ring amp Replacing an engine brush assembly drive belt pulleys Rectifier assembly Tesnionsers and Alternator cooling fan their alignments 15 Perform starter Starting system Starter Sketching of Permanent motor current draw motor principles Starter Exploded view of magnet test Perform starter voltage drop test test starter motor relay solenoid switch connectors and wires Removing starter motor from vehicle overhauling and testing Of starter motor Differentiate motor construction Starter magnet types Starter motor engagement Commutation Switching solenoid construction Checking a starting system Jump starting a vehicle starter motor Sketching of starter motor circuit along with symbols in it The magnetic effect of an electric current Direction of the magnetic field due to an electric current in a straight conductor Magnetic field caused by a coil of wire 36 Page between electrical and mechanical problems that cause slow crank and no crank Growler testing for rotors 16 amp 17 Trace the light circuit test bulbs align head lamps replacing fuses testing the tail and brake lights in vehicle Checking amp changing an exterior light
10. and cycle Three phases of combustion Compression ignition engine components Basic diesel engine components Diesel engine passages Diesel fuel delivery Direct injection Indirect injection Diesel valves amp components scavenging Crankshaft rotation crankshaft Diesel engine pistons Lettering number amp alphabet Free hand sketching of 4 stroke cycles amp 2 stroke cycles of engine Calculation of Horse Power IHP FHP and applied shop problem Simple problems straight and ball cranked levers 16 Page Practice on Diesel Principle of Spark Explanation of Calculation engine cleaning Ignition engine simple Orthographic of volume dismantling as per Differentiate projection 1 angle and weight of procedure between C I engine simple solid and S I Engine Views of simple bodies such 4 stroke and 2 hollow and solid as cubes strokes bodies with square and Otto cycle and dimensions hexagonal Diesel cycle prism shop Different type of problem starting and stopping method of Diesel Engine Engine output Power range Overhauling of Engine Components Explanation of Heat and cylinder head assembly Description and simple orthographic temperature with use of service Constructional projection 3 angle thermometric manual for clearance feature of Cylinder Simple isometric scale and other parameters head Importance of drawings isometric Fahrenheit Practic
11. fuel angle Spark timing unknown economy or engine quantity performance 35 Page 12 Checking ignition timing Checking amp changing a spark plug Removing amp replacing contact points Battery power source Description and function of Capacitor condenser Distributors Distributor types High tension leads Advance amp retard mechanisms Sketching of battery and assorted capacitor condenser Calculation of time constant for capacitance circuit Calculation relating to capacitor in series and parallel 13 Identification and Induction Inductive Sketching of sensors Calculation of testing of Hall effect system operation symbols sketching of time constant for sensor Optical Induction wiring Hall Hall effect sensor inductive circuit sensor Tracing and effect sensors Hall effect Optical sensor testing of sensor operation Optical type circuits sensors Distributor less ignition systems Insulated coils Distributor less ignition system timing 14 Checking a Charging system Sketching of Lenz s law charging system for Alternator principles Exploded view of simple the cause of Alternating current alternator calculation of undercharge No Alternator components back emf charge and over Rectification Phase Sketching of charge conditions winding connections Charging circuit Removing amp Rotor circuit Voltage along with symbols in replacing
12. respect to pack unit equation temperature Mechanical 13 Page Advantage with Hydraulics Description and use of Gear pump Internal amp External Vane pump Hydraulic motor Hydraulic symbols Description use and application of single acting double acting amp Double ended cylinder Directional control valves 3 2 4 2 4 3 way valve Pressure control valve Non return valve Flow control valve in automobile Introduction to Pneumatics Boyle s law Pneumatic Symbols Description and function of air Reciprocating Compressor function of Air service unit FRL Filter Regulator amp Lubricator 21 Practice on 5S Maintenance Drawing of Preparation of Preventive quality of Maintenance Periodical amp break awareness sign schedule chart down board week month year maintenance ly Definition amp importance of Quality control Quality assurance quality circle Basic Concept of TPM TQM amp ISO 9000 14 Page 22 23 Introduction to computer basics Basic of computer Ms Word Ms Power Point MS Excel Familiarization amp Identification of computer parts Practice on computer for MS word MS power point Ms Excel 24 Identification of different Introduction to Drawing of I C Vacuum and air type of engine components Engine engine and their pressure Description of parts principles internal amp ex
13. seating and refit 10 Cleaning and Checking Description of Free hand sketching Definition of of cylinder blocks Cylinder block of cylinder block stress strain surface for any crack Cylinder block and cylinder head and modulus flatness construction Free hand sketching of elasticity Measure cylinder bore Different type of of cylinder liners ultimate for taper amp ovality Cylinder sleeves with dimensions strength types clean oil gallery liner form sample of stresses passage and oil pipe factor of line Bore descale safety water passages and examples examine Removing cylinder liners from scrap cylinder block practice in measuring and refitting new liners as per maker s recommendations precautions while fitting new liners 11 Reassemble all parts of Engine assembly Free hand sketching Simple engine in correct sequence and torque all bolts and nuts as workshop manual of the engine Engine component procedures Testing cylinder compression Checking idle speed Removing amp replacing a cam belt Inspecting amp adjusting an engine drive belt Replacing an engine drive belt procedure with aid of special tools and gauges used for engine assembling Introduction to Gas Turbine Comparison of single and two stage turbine engine Different between gas turbine and Diesel Engine of plain and elevation of simple objects like hexagonal bar square bar circular bar taper
14. 0 Synchronous Gear box with stand for Dismantling and assembly Ino 11 Transfer case with stand for Dismantling and assembly Ino 12 Cut section model of synchronous gear box working Ino 13 Cut section model of sliding mesh gearbox working Ino 14 Cut section model of constant mesh gearbox working Ino 15 Full floating axle and semi floating axle assembly Ino 16 Cut section working model of automatic transmission Gear box Ino 17 Working model of fluid fly wheel Ino 18 Working model of torgue converter Ino 19 Steering assembly 1 each 1 Rack amp pinion 45 Page 2 Worm amp roller 3 Recirculating ball 4 Power steering 20 Suspension and steering system trainer Ino 2N Cut section models of shock absorbers Ino 22 Stock absorber testing bench Ino 23 Spring Tension scale 0 4 5 kg Ino 24 Coil spring compressor for suspension spring Ino 25 Turbo charger variable Turbo charger 1 each 26 Wheel alignment gauge magnetic type with turn tables Ino 2T Wheel alignment setup instrument Ino 28 Tyre changer Ino 29 Nitrogen Tyre Inflation system Ino 30 Tube vulcanizing machine Ino 31 Tyre vulcanizing machine Ino 32 Camber angle gauge lset 33 Toe in toe out gauge Iset 34 Wheel balancing machine with accessory Ino 35 Tubed tyre of cars 2 each 36 Tread wear indi
15. 00x100x200mm 2 nos 70 Angle plate adjustable 250x 150x175 Ino 71 Solid Parallels in pairs Different size in Metric 2 nos 72 Pliers combination 20 cm 2 nos 73 Pliers side cutting 15 cm 2 nos 74 Pliers round nose 15 cm 2 nos 75 Pliers flat nose 15 cm 2 nos 76 Vice grip pliers 2 nos 77 Circlip pliers Ezpanding and contracting type 15cm and 20cm 2 nos each 78 Grip Wrench 200mm 2 nos 79 Torque wrenches 5 35 Nm 12 68 Nm amp 50 225 Nm 1 each 80 Workshop plain goggles 17 nos 81 Air impact wrench Ino 82 Air ratchet Ino 83 Air chisel Ino 84 Air blow gun Ino 85 Car Jet washer Ino 86 Pipe flaring tool Ino 43 Page 87 Pipe cutting tool Ino 88 Universal puller for removing pulleys bearings Ino 89 Cleaning tray 45x30 cm 4 nos 90 Cleaning tray Aluminum 45 x 30 cm 4 nos 91 Stud extractor set of 3 2 sets 92 Stud remover with socket handle Ino 93 Rivets sets snap and dolly combined 3mm 4mm 6mm 2 each 94 Chemical compound for fasteners Consumable As required 95 Paraffin pressure Gun 2 nos 96 Grease Gun 2 nos 97 Hacksaw frame adjustable 20 30 cm 2 nos 98 Hacksaw blade consumable As reguired 99 Flat File 35 cm bastard 4 nos 100 Flat File 25 cm second cut 4 nos 101 File flat 20 cm bastard 4 nos 102 Files assorted sizes and types including
16. 86 Air conditioning trainer kit Ino 87 Air conditioning service Unit Car Ino 88 Working Model of power windows Ino 89 Petrol Engine 2 stroke Motor Cycle Scooter along with special Ino tools and accessories 90 Cut model of 4 stroke Petrol engine on stand Ino 91 Cut model of 2 stroke Petrol engine on stand Ino 92 Mechanical Hoist Plate Form Type Ino 93 Multi scan tool ECU diagnostics kit Ino 94 Four stroke petrol engine with CNG setup working condition Ino 95 AC alternator slip ring puller Ino 96 Functional experiment model of different type of sensors 1 set 97 Ezecutive Auto Electrical tool kit Ino 98 Auto Electrical test bench Ino 99 Cut section Model of Mock layout of a motor car electrical 1 set 47 Page system working model 100 Car stereo Ino 101 Battery 12V Lead acid amp Alkaline 2 nos 102 Battery charger 6V 24 V Ino 103 Electrical horn different types 2 nos 104 Wiper motor assembly 2 nos 105 Anti theft device 2 nos 106 Horn and Horn relay 2 nos 107 Air conditioned MPFI vehicle with accessories Ino 108 5 Point relays 2 nos 109 4 Point relays 2 nos 110 Air bag simulator Ino 111 Driving Simulator Ino 112 Trolley type portable air compressor single cylinder with 45 Ino liters capacity Air tank along with accessories amp with working pre
17. DE MECHANIC MOTOR VEHICLE FIRST SEMESTER Semester Code MMV SEM I Week Trade Practical Trade Theory Engineering Workshop No Drawing calculation and Science 1 amp 2 Admission amp Introduction to the Units Derived introduction to the trade course duration and fundamental Familiarization with course contain types of system institute Job opportunities study of the FPS CGS MKS in the automobile sector syllabus General and their Machinery used in Trade rule pertaining to conversion Types of work done by the the Institute Metric weights students in the shop floor facilities available and Hostel measurements Recreation units conversion Medical and factors Library working hours and time table 3 amp 4 Practical related to Safety Occupational Introduction to Common and Health Safety amp Health Engineering Fractions Demonstration on PPE Basic safety drawing and Blue addition Personal Protection introduction Print Reading subtraction Equipments Personal Free hand Multiplication and protection sketching of Division of Interaction with health Basic injury straight lines Common center and fire service prevention Basic rectangles Fractions Simple station to provide demo on first aid Hazard squares circles Shop problems First aid and Fire safety identification and polygons etc Involving Use of fire extinguishers avoidance safety Fractions signs for Danger Warning ca
18. High fuel consumption Engine overheating Low Power Generation Excessive oil consumption Low High Engine Oil Pressure Engine Noise 3 5 Practice on adjusting Clutches amp Manual Isometric drawing Study of Gear clutch pedal play Transmissions Clutches of simple objects nomenclature removing gearbox and Clutch principles Single such as squire and clutch assembly from plate clutches Multi plate rectangular Light amp Heavy clutches Dual mass blocks with Applied Vehicle Dismantling flywheels Operating grooves problems in clutch assembly mechanisms keyways force work cleaning inspecting Clutch components done energy amp parts Pressure plate Isometric view of power Removing amp fitting of Driven center plate clutch pedal new pilot bearing Throw out bearing clutch release Applied removing amp fitting of Manual transmissions Gear bearing fork and problems in ring gear in fly wheel ratios Compound gear clutch plate free horsepower relining a clutch plate trains Gear selection hand sketching of calculation of checking condition of Bearings Oil seals amp clutch assembly speed ratios in flywheel and pressure gaskets Free hand 4 speed gearbox plate surface for Gearbox layout amp sketching of amp 5 speed reconditioning operation shifter gearbox 26 Page Assembling of pressure plate adjusting the fingers checking run out of fly wheel and aligning clutch asse
19. STARL Kolkata 91 Chairman Zi K L Kuli Joint Director of Training CSTARI Kolkata 91 Member 3 K Srinivasa Rao CSTARI Kolkata 91 Member Joint Director of Training 4 L K Muhkerjee CSTARI Kolkata 91 Member Deputy Director of Training 5 Ashoke Rarhi ATI EPI Dehradun Member Deputy Director of Training 6 N Nath CSTARI Kolkata 91 Member Assistant Director of Training 7 S Srinivasu ATI EPI Hyderabad 13 Member Assistant Director of Training 8 Sharanappa ATI EPI Hyderabad 13 Member Assistant Director of Training 9 Ramakrishne Gowda FTI Bangalore Member Assistant Director of Training 10 Goutam Das Modak RVTI Kolkata 91 Member Assistant Director of Trg Principal 11 Venketesh Ch Principal Govt ITI Dollygunj Andaman amp Member Nicobar Island 12 A K Ghate Training Officer ATI Mumbai Member 13 V B Zumbre Training Officer ATI Mumbai Member 14 P M Radhakrishna pillai CTI Chennai 32 Member Training Officer 15 A Jayaraman Training officer CTI Chennai 32 Member 3 Page 16 S Bandyopadhyay Training Officer ATI Kanpur Member 17 Suriya Kumari K Training Officer RVTI Kolkata 91 Member 18 R K Bhattacharyya Training Officer RVTI Trivandrum Member 19 Vijay Kumar Training Officer ATI Ludhiana Member 20 Anil Kumar Training Officer ATI Ludhiana Member 21 Sunil M K Training Officer ATI Kolkata Member 22 Devender Training
20. SYLLABUS FOR THE TRADE OF MECHANIC MOTOR VEHICLE Semester Pattern UNDER CRAFTSMAN TRAINING SCHEME CTS Designed in 2013 By Government of India CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE Directorate General of Employment amp Training Ministry of Labour amp Employment EN 81 Sector V Salt Lake City Kolkata 700 091 List of trade committee members approved the syllabus of semester system for the trade of Mechanic Motor Vehicle held at ATI Chennai SA Name amp Designation Representing Organisation Remarks 1 Shri R Senthil Kumar Director ATI Chennai Chairman 2 Shri S Harinath Babu Joint Director of ATI Chennai Member Training 3 Shri E Balakrishna Ex_Joint Director of NIMI Chennai Member Training 4 Shri A Suganthan Assistant Training officer Govt ITI Arakkonam Member 5 Shri N Ramesh Kumar Training Officer CTI Chennai Member 6 Shri T Nandagopal Anna University Chennai Member 7 Shri K Thaniyarasau Assistant Training Govt ITI Trichy Member officer 8 Shri P K Ramakrishnan Nair Ram international Industrial Member Academy p Ltd Chennai 9 Shri S Arul Selvan Assistant professor Dept Auto Engg M LT Member Anna University Chennai 10 Shri S Jayaraj Associate Professor Dept Auto Engg M LT Member Anna University Chennai 11 Shri R Lakshmanan Bosch Ltd Bangalore Member 12 Shri V ChandraMo
21. and material Exhaust system components Description and function of Exhaust manifold Exhaust pipe Extractors Mufflers Catalytic converters Flexible connections Ceramic coatings Back pressure Electronic mufflers Free hand sketching of air cleaner amp Turbocharger system Machines basic principles determination of velocity ratio mechanical advantage and efficiency 22 Page 17 amp 18 Practice on removing amp Cleaning fuel tanks checking leaks in the fuel lines soldering amp repairing pipe lines and Unions brazing nipples to high pressure line studying the fuel feed system in diesel engines draining of water separators Bleeding of air from the fuel lines Servicing primary amp secondary filters Dismantling fuel injection pump feed pump governor studying the parts and reassemble general maintenance of Fuel Injection Pumps FIP Removing a fuel injection pump from an engine refit the pump to the engine re set timing fill lubricating oil start and adjust slow speed of the engine Practice on overhauling of injectors and testing of injector Diesel Fuel Systems Description and function of Diesel fuel injection fuel characteristics concept of Quiet diesel technology amp Clean diesel technology Diesel fuel system components Description and function of Diesel tanks amp lines Diesel fuel filters water separator Lift pump
22. and remedy blue print Engine Engine Not starting for specification Mechanical amp Engine Not starting Electrical causes Mechanical amp High fuel Electrical causes consumption High fuel Engine overheating consumption Low Power Engine overheating Generation Low Power Excessive oil Generation consumption Excessive oil Low High Engine Oil consumption Pressure Low High Engine Engine Noise Oil Pressure Engine Noise 25 i Project Work ii Industrial Visit Optional 26 Examination 25 Page TRADE MECHANIC MOTOR VEHICLE THIRD SEMESTER Semester Code MMV SEM III Week Trade Practical Trade Theory Engineering Workshop No Drawing calculation and science 1 Identification of Study of different major different major components amp assemblies components of Heavy of heavy vehicle and vehicle and their different make function amp placement indigenous Name plate study of different constructional differences make lorry bus tractor and their merits in Institute with leading manufacturers in different dealers or Heavy vehicle Industry organizations 2 Trouble shooting Review of Trouble Simple Blue Print Materials used Practice with Heavy shooting Reading and I S I in the vehicle Causes and remedy for symbols of construction of Engine Not starting different different parts of Mechanical amp materials Heavy vehicle Electrical causes
23. box Inspect and overhaul steering boxes adjusting steering gear backlash pre load and adjust toe in toe out camber angle castor angle kingpin inclination and wheel run out Checking amp adjusting power steering fluid Pressure testing a power Steering Systems Description and function of Steering systems Principles of steering Rack and pinion steering system Recirculation ball amp nut steering system Four wheel steering systems collapsible steering system Steering boxes amp columns Description and function of Steering columns Rack and pinion gearbox Helix Variable ratio steering Worm gearbox Power Assisted steering Steering process Flow control valve Electric power assisted steering Basic electric power steering operation Steering arms amp components Forward control vehicle steering Steering linkages Joints Bushes bushings Wheel alignment Free hand sketching of different types of steering boxes Free hand sketching of caster camber king pin angle Ackerman s angle toe in amp toe out Problems in steering geometry calculation of caster camber 29 Page steering system Flushing a power steering system Inspecting amp adjusting an engine drive belt Servicing a steering system Servicing wheel bearings Troubleshooting Causes and remedy for abnormal wear of tyre wheel wobbling poor self centering hard steering and vehicle pullin
24. bulb Checking incorrect turn signal or hazard light operation Checking amp changing a headlight bulb Aiming headlights Identify system voltage and safety precaution associated with high intensity discharge light Removing an electrical horn from vehicle assembling the horn and adjusting the horn for correct sound tuning double horn repairing of horn relay and horn switches Removing a wiper motor dismantling cleaning inspecting and repairing Lighting system Lamps light bulbs Lamp light bulb information LED lighting Stop lights Reverse lights Indicators Headlights High intensity discharge HID lights Driving lights Fog lights Cornering lights Smart lighting Park amp tail light circuits Headlight amp dip circuits Circuit diagrams Networking amp multiplexing Sketching of 1 Head lamp amp Tail light circuit 2 Interior lighting circuit 3 Hazard light and turn light 4 Horn amp Wiper circuit Park Graph scales variables coordinates straight line graphs Geometry and trigonometry Angles angular measurements the radian 37 Page electrical wiper motors assembling and fitting Diagnose wiper speed control and park problem setting blades for correct functioning Trace the wiring circuit of traffic signal flashers light circuit tracing defects in the flasher circuits replacing fuse bulb Removing d
25. cator Ino 37 Tyre amp split rim wheel assembly Ino 38 Solid tyre Ino 39 Tubed tyre of car trucks amp motorcycle Ino 40 Tubeless tyre of cars amp trucks Ino 41 Cut section of cross ply and radial tyres Ino 42 Disk brake with caliper assembly 2 nos 43 Drum brake assembly Ino 44 Tandem master cylinder with booster 4 nos 45 Wheel cylinder 4 nos 46 Vacuum assisted hydraulics brake assembly with vacuum booster Ino 47 Air Brake Assembly Ino 48 Brake Lining riveting machine foot operated Ino 49 Brake testing eguipment to test efficiency of vehicle where Ino motion after braking is plotted 50 Motor vehicle in running condition Diesel heavy Ino 51 Light Motor Vehicle Ino 52 Mechanical Hoist Plate Form Type Ino 53 Trolley type portable air compressor single cylinder with 45 Ino liters capacity Air tank along with accessories amp with working pressure 6 5 kg sq cm 54 Grinding machine general purpose D E pedestal with 300 mm Ino dia wheels rough and smooth 55 A C welding transformer 300 Amps with complete accessories 2 set 56 Oxy acetylene welding equipment with complete accessories 2 nos Low amp high pressure 57 Spot welding machine with complete accessories Ino 58 Guillotine shearing Machine foot operation Ino 46 Page 1mt x 18G Capacity 59 Fly press
26. ces 6mm to 15mm 2 sets each 42 Ball Peen Hammer 0 75 Kg 2 nos 42 Page 43 Hammer copper 1 Kg with handle 2 nos 44 Hammer Mallet 2 nos 45 Hammer Plastic 2 nos 46 Hammer ball peen 0 25 kg with handle 2 nos 47 Philips Screw Driver set of 5 pieces 100 mm to 300 mm 2 sets 48 Insulated Screw driver 30 cm x 9mm blade 2 nos 49 Insulated Screw driver 20 cm x 9mm blade 2 nos 50 Electric testing screw driver 2 nos 51 Allen Key set of 12 pieces 2mm to 14mm 2 nos 52 Hand vice 37 mm 2 nos 53 Work bench 250 x 120 x 60 cm with 4 vices 12cm Jaw Ino 54 Magnifying glass 75mm 2 nos 55 V Block 75 x 38 mm pair with Clamps 2 nos 56 Clamps C 100mm 2 nos 57 Clamps C 150mm 2 nos 58 Clamps C 200mm 2 nos 59 Spanner D E set of 12 pieces 6mm to 32mm 4 nos 60 Spanner adjustable 15cm 2 nos 61 Spark plug spanner 14mm x 18mm x Size 2 nos 62 Spanners socket with speed handle T bar ratchet and universal 2 nos upto 32 mm set of 28 pieces with box 63 Adjustable spanner pipe wrench 350 mm 2 nos 64 Spanner ring set of 12 metric sizes 6 to 32 mm 2 nos 65 Spanner T flocks for screwing up and up screwing inaccessible 2 nos positions 66 Spanner Clyburn 15 cm Ino 67 Magneto spanner set with 8 spanners 1 set 68 Spirit level 2V 250 05 metre 2 nos 69 Angle plate size 2
27. e on removing Cylinder head views of simple and rocker arm assembly design Type of objects such as centigrade manifolds cylinder Diesel combustion square rectangles les amp their head from the engine chambers Effect on cubes rectangular Powe size of Intake amp blocks etc ee exhaust passages Name enue Head gaskets of Importance of temperature Turbulence measuring instruments normally used in Workshop Practice on removing Valves amp Valve Sketching valve Calculation the valves and its parts Trains timing diagram of Engine from the cylinder head Description and displacement cleaning amp Function of Engine Free hand sketch of Calculation decarbonising Valves different Different types of of spring Inspection of cylinder types materials cams and followers stiffness head and manifold Type of valve surfaces for warping operating Free hand sketching Shop cracks and flatness mechanism of crank shaft problems on checking valve seats amp Importance of Valve showing all parts determination valve guide seats Valve seats of volume amp reconditioning valve inserts in cylinder weight of seats and re facing heads importance simple valves lapping valves of Valve rotation bodies on its seat testing Valve stem oil seals leaks of valve seats for size of Intake valves 17 Page leakage Dismantle rocker shaft assembly clean amp check rocker shaft and levers f
28. ed bar hollow bar etc calculation of stress compressive Strain compressive stress E Shear stress G Tensile strength Factor of safety and The allowable working stress 20 Page 12 amp 13 Practice on Checking Need for Cooling Free hand sketching Calculation amp adjusting coolant systems Heat of different cooling of Volumetric Draining amp refilling transfer method system showing all efficiency coolant Boiling point amp necessary parts Torque Vs Checking amp replacing pressure Centrifugal Engine speed a coolant hose force Vehicle Freehand sketching Specific fuel Testing cooling system coolant properties of water pump consumption pressure and recommended thermostatic valve amp vs engine Practice on Removing change of interval water jackets inthe speed amp replacing a radiator Different type of cylinder block thermostat cooling systems Inspect the radiator Basic cooling pressure cap Testing system components of thermostat Radiator Coolant Cleaning amp reverse hoses Water pump flushing Cooling system Overhauling water thermostat Cooling pump and refitting fans Temperature indicators Radiator pressure cap Recovery system Thermo switch 14 amp 15 Practice on Checking Need for lubrication Free hand sketching Properties of engine oil Draining system Functions of of lubrication Diesel engine engine oil Replacing oil filter R
29. efilling engine oil Overhauling of oil pump oil filters oil coolers air cleaners and air filters and adjust oil pressure relief valves repairs to oil flow pipe lines and unions if necessary oil Viscosity and its grade as per SAE Oil additives Synthetic oils The lubrication system Splash system Pressure system 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 system filters and different types of oil pump pressure release valve cylinder lubricating oil Definition of emulsion viscosity index 21 Page 16 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 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
30. el tank guides and weak components 4 amp 2 stroke springs assembling engine differences valves and cylinder Engine cams amp camshaft head and adjusting Engine power transfer tappet clearance in Scavenging Counter engine weights Piston components 3 Practice on Intake amp exhaust A free hand sketching Circle length of Removing assembling of piston and connecting rods from engine checking cylinder bore wear for ovality and taper and finding next oversize Piston ring Piston as per service manual Checking amp changing an air filter systems Carbureted systems Electronic fuel injection systems Exhaust systems Intake system components Air cleaners Carburetor air cleaners EFI air cleaners Intake manifolds Intake air heating of 2 stroke and 4 stroke engines Free hand sketching of Intake system and exhaust system Air cleaners arc Timing marks wheel revolutions and distance travelled calculation of valve opening area 33 Page 4 amp 5 Simple repairs in Gasoline Fuel Systems Free hand sketching Calculation of fuel Description of Gasoline of valve Operating piston Engine feed system fuel Gasoline fuel mechanisms displacement overhauling of fuel characteristics Free hand sketching Swept volume pump carburetors Controlling fuel burn of clearance volume fuel Stoichiometric ratio Air Carburetor total volume Fi
31. enance Crank shaft balancing Firing order of the engine Free hand sketching of crankshaft and flywheels with dimensions from samples Drafting of Bush bearing Split bearing Thrust bearing Ball bearing Roller bearing straight and needle calculation of effective power on crank shaft by using mechanical efficiency Centre of gravity of bodies stable amp unstable Neutrals amp equilibrium Examples amp Problems on Centre of gravity 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 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 Free hand sketching of gears timing mark Simple levers with examples i e bell crank lever amp other used in engine Advantage in using them Problems on lever 19 Page fix crank shaft on block torque bolts check end play remove shaft check seating repeat similarly for connecting rod and Check
32. formation Tyre tread designs Tyre ratings for temperature amp traction 20 22 Practice on Adjusting Braking Systems Free hand Square root of brake pedal play Principles of braking sketching of perfect square Overhauling and Drum amp disc brakes brake linings square root of inspection of tandem Lever mechanical wheel brake whole numbers master cylinder advantage Hydraulic assembly and decimals assembly pressure amp force Brake sectioned views relating to Overhauling and fade Regenerative braking of master braking distance inspection of front and Braking systems Brake cylinder rear brake assembly type principles Air Simple levers overhauling and brakes Exhaust brakes Free hand problems related inspection of wheel Electric brakes Parking sketching of to as applied to cylinder assembly brakes Engine brakes brake wheel motor vehicles Bleeding hydraulic Regenerative braking cylinders cam brakes amp Disk brakes Braking system adjuster brake Meaning of Overhauling and components Park brake shoe assembly friction inspection of vacuum system Brake pedal Brake and anchor pins examples of assisted brake lines Brake fluid Freehand useful and assembly Bleeding Master cylinder sketching the wasteful friction 31 Page Overhauling and inspection of disc brake Adjusting Air brake s repair to tank unit air compressor wheel brake adjuster locating air leaks in
33. g to one side fundamentals Basic principles of wheel alignment wheel base wheel track king pin inclination Caster Camber Scrub radius Toe in amp toe out Toe out on turns Turning radius Thrust angle amp centerlines 15 17 Following practical to be Practiced On Light amp Heavy Vehicle Practice on visual Inspection of chassis frame for crack bent and twists Overhauling and Inspection of shackle leaf spring front amp rear suspension Practice on removing inspection and assembling of shock absorber Lubricating a suspension system Suspension Systems Principles of suspension Suspension force Unsprung weight Wheel unit location Dampening Types of suspension Suspension systems Solid axle Dead axle Independent suspension Rear independent suspension Rear wheel drive independent suspension Adaptive air suspension operation Types of springs Description and function of Coil springs Leaf springs Torsion bars Rubber springs Shock absorber types Description and function of Hydraulic shock absorbers Gas pressurized shock absorbers Load adjustable shock absorbers Manual adjustable rate shock absorbers Electronic adjustable rate shock absorbers Automatic load adjustable shock absorbers Front suspension types amp components Mc person Strut suspension Free hand sketching of Suspension system layouts Driven rear suspension layouts Non drive
34. g vehicle Free hand Applied Practice in straight information Obtaining amp sketching of workshop driving on wide interpreting scan tool different traffic Problems roads data Using a repair Signals calculation Driving through manual Using a shop Fuel average lanes manual Using an owner s gear ratios and curves manual Using a labor Practice in guide Using a parts 39 Page reversing Practice overtaking another vehicle Practice in driving through sand and wet surfaces Practice in parking and Diagonal parking program Using a service information program 25 Revision 26 Examination 40 Page A TRAINEES TOOL KIT FOR 16 TRAINEES 1 INSTRUCTOR Trade Mechanic Motor Vehicle LIST OF TOOLS amp EQUIPMNT SI No Item with specification Oty l Steel rule 15 cm inch and metric 17 nos 2 Steel rule 30 cm inch and metric 17 nos 3 Steel measuring tape 10 meter in a case 17 nos 4 Try Sguare 10 cm Blade 17 nos 5 Calipers outside 15 cm spring 17 nos 6 Caliper inside 15 cm Spring 17 nos 7 Dividers 15 cm Spring 17 nos 8 Safety glasses 17 nos 9 Scriber 15 cm 17 nos 10 Knife double Blade Electrician 17 nos 11 Wire insulation Stripper for shinning conductors from 0 4mm to 17 nos 4mm 12 Electrician testing Pencil Line Neon tester 17 nos
35. han NATRIP Global Automotive Member Research centre Chennai 13 Shri V Vadivelan NATRIP Global Automotive Member Research centre Chennai 14 Shri A D Shewale Training Officer CTI chennai Member 15 Shri B Gridharan Visa Diesel Service Chennai Member 16 Shri K k Valasarajan Vice president Two Wheeler workshop Member owners Association Chennai 17 Shri Jayapal Two Wheeler workshop Member owners Association Chennai 18 Shri V Vadivelan Two Wheeler workshop Member owners Association Chennai 19 Shri Syedshwath Two Wheeler workshop Member owners Association Chennai 20 P Marveldass Assistant Director of Training ATI Chennai Member Electronics 21 K ArulSelvi Training Officer Electronics ATI Chennai Member 22 Shri Gurcharan Singh Assistant Director of ATI Ludhiana Member Training 23 Shri O R Arjun Mohan Assistant Executive Agricultural Engg Dept Member Engineer Chennai 24 Shri R Murugesan Assistant Executive Agricultural Engg Dept Member Engineer Chennai 25 Shri Ramakrishne Gowda Assistant Director FTI Bangalore Member of Training 26 C Yuvaraj Assistant Director of Training ATI Chennai Member 2 Page List of members attended the Workshop to finalize the syllabi of existing CTS into Semester Pattern held from 6 to 10 May 2013 at CSTARI Kolkata SI No Name amp Designation Organisation Remarks 1 R N Bandyopadhyaya Director C
36. ic 5 nos 131 Hand operated crimping tool 1 for crimping up to 4mm and ii 2 nos for crimping up to 10mm 132 Hand rubber gloves tested for 5000 V 5 pair 133 Holders lamp teakwood boards plug sockets solders flux wires As required and cables batteries round consumable blocks and other consumables as required 134 Multimeter digital 5 nos 135 Growler Ino 136 Scientific Calculator Ino 137 Hydrometer 2 nos 138 High rate discharge tester cell tester Ino 139 Spray Gun Painting 500ml Ino 140 Techometer Ino 141 Valve Timing Diagram Ino 142 Belt Tensioner Gauge Ino 143 Portable electric drill Machine Ino 144 Spring tension tester Ino 145 Carburetor repair kit Ino 146 Hot patch clamp Ino C General Installation Machineries 1 Lathe general purpose all geared height of center 150 mm to Ino below Gap bed between centers 1000mm with all accessories with all attachment 2 Drilling machine bench to drill up to 12mm dia along with Ino accessories 3 Cut section working model of Single plate clutch assembly Ino 4 Cut section working model of Diaphragm clutch assembly Ino 5 Cut section working model of centrifugal clutch assembly Ino 6 Front axle Rzeeppa Joint with stand for Dismantling and Ino assembly 7 Rear axle with stand for Dismantling and assembly Ino 8 Constant Mesh Gear box with stand for Dismantling and Ino assembly 9 Sliding mesh Gear box with stand for Dismantling and assembly Ino 1
37. in vehicle Electrical functions EFI systems wiring diagram Binary codes Electronic control unit ASCII ECU EFI system ECU Electronic control unit settings Engine speed limiting Malfunction indicator lamp 10 Identification of EFI sensors Intake Free hand sketching Directed various sensors Temperature sensor of sensors numbers installed in engine Mass airflow sensor Free hand cut Addition amp its mounting Manifold absolute sectional view of subtraction Checking pressure sensor Air petrol nozzle multiplication instruments amp vortex sensor Fuel and Division Gauges on dash system sensor Throttle Active sensors board position sensor Exhaust Passive sensors Rectify replace gas oxygen sensor Crank defective angle sensor Hall effect gauges voltage sensor 11 Check and Ignition principles and Free hand sketching Algebra replace ignition Faraday s laws Primary of Multiplying two coil and secondary winding of Transformer binomial overhauling transformer Ignition windings Ignition expressions Distributor components Spark plugs circuit of a in brackets Assembly Spark plug components vehicle Algebraic Diagnosis Possible Vacuum amp centrifugal Sketching various expressions and causes and remedy units Plug firing voltage type of spark plugs simplification for Engine cranks Contact breaker system finding the but will not or hard ballast resistor coil Dwell value of the to start Poor
38. ismantling magnetos adjusting BD oud in points testing magnetos 18 Identification of Heating Ventilation Air Sketching of Air Definition Air conditioning Conditioning HVAC conditioning system Absolute components legislation Vehicle using an expansion humidity Boiling Performance test on heating ventilation amp valve and orifice tube point Heat A c unit cooling systems Basic transfer Checking Charged air conditioning convection state of refrigerant principles Air conduction Inspecting amp conditioning capacity radiation Latent adjusting anengine Air conditioning heat of drive belt refrigerant Humidity vaporization Replacing an engine super heat the drive belt effect of pressure on boiling or condensation 19 amp Checking a heating Description and function Drawing of A c Properties of 20 system of Fixed orifice Control wiring circuit motor refrigerants Compressor rotation devices Thermostatic vehicle refrigerant oil test air Gap check expansion valve system Fluorinated Refrigerant Thermal expansion Sketching of TX refrigerants recovery valves Air conditioning valve construction Refrigeration evacuating compressors Condensers process charging of A c amp evaporators Receiver Sketching of block pressure enthalpy system drier Lines amp hoses TX diagram of AC diagram 38 Page Replenishing valve construction compre
39. its OR AND amp Junction Simple set theory NOT and Logic gates using Transistors UJT problems like switches Metal Oxide Field Union Effect Transistors Intersection and MOSFETs Null sets Logic gates OR AND amp NOT and Logic gates using switches 19 Introduction to centre lathe Lathe Free hand Definition of setting up work between Introduction types Sketching of Cutting speeds centers Use of side cutting of lathes different type of feed and depth of tools Parallel turning and specifications cutting tools cut and their stepped turning description and Block diagram of calculation Taper functions of lathe lathe and its parts and thread parts calculation feed mechanism drives and transmission work holding devices turning tools Lathe operations plain turning facing centering parting off undercutting taper turning eccentric turning drilling reaming thread cutting and knurling speeds and feeds of cut 20 Identification of Hydraulic Introduction to Drawing of Simple problems and pneumatic Hydraulics hydraulic and on work energy components Definition of pneumatic and power Tracing of hydraulic circuit Pascal law symbol Simple piston on hydraulic power pressure Force Black Diagram of Force velocity steering viscosity effect Hydraulic and calculation hydraulic Pneumatic press of viscosity with pneumatic power General gas and Brake circuit
40. lters and air density Fuel supply Block diagram of Compression cleaners system Pressure amp Petrol fuel feed ratio Check your Repair to a car vacuum system results carburetors Carburetor operation by looking in the adjusting Carburation manufacturers float level and slow Carburetor system manual speed adjustments components Carburetor studying the fuel systems Metering jets Units of Heat flow Accelerating Carburetor Temp Pressure circuit in carburetor barrels and its Carbureted system conversion Practice in engine components Basic of calorific tune The carburetor value calculation up in a vehicle Mechanical fuel pumps Comparison of testing Electric fuel pumps various fuel vacuum and Tanks amp lines Fuel lines w r to calorific compression of Charcoal canister values Relevant engine Carburetor filters combustion adjusting tappets equation setting Detonation ignition timing and adjusting carburetor For slow speeds 6 amp 7 Practice on Introduction to Electronic Block diagram of Angels amp rotation Cleaning fuel tank fuel injection EFT fuel MPFI system Type of angels checking for leaks supply system Basic EFI adding and in Fuel tank Identification of various components of MPFI system Testing of MPFI components and replacement if necessary Check delivery from fuel Pump Replacing a fuel filter principles Air supply Air volume Multi point injection systems
41. mbly with flywheel Dismantling cleaning and assembling of gearshift mechanism changing oil in gear box Dismantling a synchromesh gear box cleaning inspecting parts replacing worn out defective parts assembling amp testing for correct performance identifying noises from gear boxes and rectifying Gearbox layouts Transaxle designs Gearbox operation Baulk ring synchromesh unit Transaxle synchromesh unit mechanism and hear shift lever Free hand sketching of the arrangement of gears inside the sliding mesh gear box in different gear positions 6 8 Practice on Removing open type propeller shaft from vehicle Practice on removing universal joints cleaning replacing worn out parts re assembling amp refitting to vehicle special precautions while removing torque tube drive shaft Practice on Removing and refitting rear axle assembly Practice on overhauling amp inspection of rear axle Practice on overhauling amp inspection of differential assembly Trouble shooting causes and remedy for clutch slip clutch Final Drive amp Drive Shafts Basic layouts Front wheel drive layout Rear wheel drive layout Four wheel drive layout All wheel drive layout 4WD v s AWD Front wheel drive Front wheel drive shafts Front wheel final drives Front wheel differentials Rear wheel drive Propeller shaft Universal joints Rear wheel final drives Salisbury axles Rear wheel dri
42. n rear suspension layouts Independent rear suspension layouts Front suspension layouts Bushes bushings Arms amp linkages Definition of longitudinal vibration Transverse vibration and torsional vibrations Simple problem on frequency of Transverse vibration and torsional vibrations 30 Page Short long arm suspension Torsion bar suspension Rear suspension types amp components Rigid axle leaf spring suspension Rigid axle coil spring suspension Independent type suspension Rigid non drive suspension 18 19 Practice on removing Wheels amp Tyres Wheel Free hand Rounding of wheels from light amp types amp sizes Wheels Rim sketching of Numbers Power Heavy vehicle sizes amp designations different type of amp roots dismantling tyres and Types of wheels tyre thread General rule for tubes checking Tyre types amp design indices puncture Assembling characteristics Tyres Multiplying and inflating to correct Radial ply tyres Radial ply dividing pressure tyre sidewalls Tyre numbers in Rotating the wheels in pressure monitoring standard form vehicle minor repairs systems Run flat tyres to wheels and tyres Space saver tyres Tyre wheel balancing amp distortion Center of alignment gravity Checking for tyre Tyre construction Tyre wear patterns construction Types of tyre construction Tyre materials Hysteresis Tyre sizes amp designations Tyre in
43. nce of big end split obliquely Materials used for connecting rods big end amp main bearings Shells piston pins and locking methods of piston pins Free hand sketch of piston assembly valve assembly Free hand isometric sketching of simple objects with dimensions Free hand sketching of piston gudgeon pins rings and connecting rod with dimensions from samples Calculation of volume compression ratio force on the piston due to combustion pressure average piston velocity internal power of engine respecting two or four stroke 18 Page between crank pin and the connecting rod big end bearing Check connecting rod for bend and twist Assemble the piston and connecting rod assembly Overhauling of crankshaft with 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 t 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 maint
44. ngular blocks cylinders etc 8 Page 8 Practice on cutting tools Cutting tools Sketching of Different Type of like Hacksaw file chisel Study of different views of simple cutting fluids and OFF hand grinding with type of cutting solid bodies as their properties sander bench and pedestal tools like cubes rectangular grinders safety precautions Hacksaw File blocks cylinders while grinding Definition parts when viewed of a file perpendicular to specification their surfaces and Grade shape axis different type of cut and uses chisel OFF hand grinding with sander bench and pedestal grinders safety precautions while grinding 9 Practice on Filing filing to Limits Fits amp do Properties and line marking off use of Tolerances uses of copper centre punch dividers Definition of zinc lead tin calipers steel rule etc limits fits amp aluminum brass Filing true and square tolerances with bronze solder examples used in bearing metals auto components timber and rubber Nylon P V C PP poly prop line polymer 10 Practice on Marking and Drilling machine Sketching of Calculation of Drilling clear and Blind Description and Files drill bit cutting speed Holes Sharpening of Twist study of Bench feed and drilling Drills Safety precautions to type Drilling time be observed while usinga machine Portable drilling machine electrical Drilling Use of ta
45. o and taper with prismatic measuring base 11 Vernier caliper A 200 with inside and depth measurement Ino 12 Direct reading vernier caliper B 300 direct reading with dial Ino 13 Vernier depth Gauge 0 150 mm Ino 14 Vernier height gauge 500 mm Ino 15 Telescope gauge Ino 16 Dial gauge type 1 Gr A complete with clamping devices and 4 nos stand 17 Surface gauge with dial test indicator plunger type i e 0 01 mm 2 nos 18 Cylinder bore gauge capacity 20 to 160 mm 2 nos 19 Compression testing gauge suitable for petrol engine 2 nos 20 Vacuum gauge to read 0 to 760 mm of Hg 2 nos 21 Tyre pressure gauge with holding nipple 2 nos 22 Marking Material Consumable As required 23 Marking out table 90X60X90 cm Ino 24 CI surface plate 400 x 400 mm with stand and cover Ino 25 Granite surface plate 1600 x 1000 with stand and cover Ino 26 Steel rule 15 cm inch and metric 2 nos 2T Steel rule 30 cm inch and metric 2 nos 28 Steel measuring tape 10 meter in a case 2 nos 29 Try Square 10 cm Blade 2 nos 30 Engineer s square 15 cm Blade 2 nos 31 Calipers outside 15 cm spring 2 nos 32 Caliper inside 15 cm Spring 2 nos 33 Calipers 15 cm Hermaphrodite 2 nos 34 Dividers 15 cm Spring 2 nos 35 Scriber 15 cm 2 nos 36 Scriber with scribing black universal 2 nos 37 Punch Letter 4mm 2 set 38 Chisels cross cut 200 mm X 6mm 2 nos 39 Chisel 10 cm flat 2 nos 40 Safety Goggles 2 nos 41 Hollow Punch set of seven pie
46. on hardening and Flame Hardening process used in auto components with examples Introduction to Metallic and Non metallic Coatings Necessity of metallic and non metallic coatings principles and processes of electroplating galvanizing vacuumizing metal spraying painting and their applications Sketching of Iron carbon diagram Free hand sketch of weld symbols Importance Iron carbon diagram Meaning of tenacity elasticity malleability brittleness hardness compressibility amp ductility and their examples 10 Page preparation of base materials Uses of primers paints and finish coatings powder coating and its advantages with examples used in auto components Introduction to Welding Processes Arc welding Gas welding GTAW TIG GMAW MIG amp Resistance welding 14 Joining of metal parts by Sheet metal Drawing of Definition of cold Soft Soldering worker s common riveted joints lap rolling and Hot Simple marking out on hand tools their and Butt joints rolling and its sheet metal and cutting names and properties on Bending and folding description of sheet metal Practice in silver soldering simple soldering Advantage of pipe bending Nipples and brazing fluxes Deep drawing Unions soldering and used on common material Brazing of pipes joints Sheet and wire gauges The blow lamp its uses and pipe fittings Explanation of various common
47. or 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 decarbonising 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 6 amp 7 Overhauling piston and connecting rod assembly with 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 clean oil holes Measure the piston ring close gap in the cylinder clearance between the piston and the liner clearance 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 importa
48. ors and its applications Capacitors in series and parallel 17 Cleaning and Description of DO Explanation of topping up of a lead acid battery Testing battery with 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 Chemical effects Batteries amp cells Lead acid batteries amp Stay Maintenance Free SMF batteries Magnetic effects Heating 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 open and short circuits locating short circuits with the help of meters 12 Page 18 Identify and test power and Basic electronics Free hand Problems on signal connectors for Description of sketching of Charging continuity Identify and test Semi conductors Electronic current ampere different type of Diodes Solid state symbols and hours NPN amp PNP Transistors devices Diodes drawing of simple Decimal Binary for its functionality Transistors Electronic number Construct and test simple Thyristors Uni circuits conversions logic circu
49. p extractor machine drill holding devices Drill bits Hand Taps and wrenches Calculation of Tap drill sizes for metric and inch taps Different type of Die and Die stock 11 Practice on Tapping a Hand Reamers Views of simple Brief description Clear and Blind Hole Different Type of hollow and solid of manufacturing Selection of tape drill Size use of Lubrication Cutting Threads on a Bolt Stud hand reamers Lapping Lapping abrasives type of bodies with dimensions use of different types of process of steel copper aluminum and P V C 9 Page Adjustment of two piece Die Reaming a hole Bush to suit the given pin shaft scraping a given machined surface Laps Function of Gaskets oil seals lines and symbols for drawing 12 Visit to industries for observation of material testing casting and forging process Mechanical properties of materials Tensile Compressive amp Temperature stress Forging process amp Casting Processes used in auto components with examples Classification of steel the effect of alloying element on steel Free hand sketching of rivets and washers with dimensions from samples Ratios and proportions 13 Practice on Arc welding Gas welding Resistance welding Introduction to Heat treatment Definition of Annealing Normalizing Hardening and tempering Case hardening Nitriding Inducti
50. pneumatic governor and venture control unit checking performance of engine with off load adjusting timings Start engine adjusting idle speed of the engine fitted with mechanical governor checking high speed engines opposed piston engines starting systems cooling systems lubricating systems supplying fuel oil hydraulic coupling reduction gear drive electromagnetic coupling electrical drive generators and v u at s u y t 2 v u 2as s ut at 2 u initial velocity in m s v final velocity in m s operation of the motors a engine supercharging acceleration Checking performance in m s for missing cylinder by t time in isolating defective seconds injectors and test s distance dismantle and replace and their defective parts and application to reassemble and refit vehicle back to the engine technology Visit to marine engine service station 21 On board diagnostics Emission Control Views of simple Determinatio OBD systems Vehicle emissions solid and hollow n of Diagnostic trouble standards bodies cut by section efficiency of codes Monitoring Sources of emission plane simple emissions Combustion machines like Emissions procedures Combustion winch pulley Checking amp cleaning a chamber design locks wheel Positive crank case Types of emissions and ventilation PCV Characteristics and compound valve Obtaining amp Effect of axles inte
51. rpreting scan tool data 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 24 Page recirculation EGR valve Controlling air fuel ratios Charcoal storage devices Diesel particulate filter DPF 22 Practice on removing Description of Freehand sketching Magnets alternator from vehicle charging circuit of charging system natural and dismantling cleaning operation of artificial checking for defects alternators regulator types poles of assembling and testing unit ignition magnets for motoring action of warning lamp magnetic alternator amp fitting to troubles and remedy fields vehicles in charging system 23 Practice on removing Description of Sketching starter Principle of starter motor vehicle starter motor circuit motor circuit and Solenoid and and overhauling the comparison of wire solenoid switch relay starter motor testing thickness in starter circuit Electromagne of starter motor motor circuit tic induction constructional Fleming s details of starter rule motor solenoid switches common troubles and remedy in starter circuit 24 Practice on Troubleshooting Reading of simple Study of troubleshooting for Causes
52. safe edge file 20 Nos 2 set 103 Drill Twist assorted Consumables 10 Nos 104 Drill twist 1 5 mm to 15 mm various sizes by 0 5 mm 4 nos 105 Drill point angle gauge Ino 106 Set of stock and dies UNC UNF and metric 2 sets 107 Taps and wrenches UNC UNF and metric 2 sets 108 Taps and Dies complete sets 5 types 1 set 109 Hand reamers adjustable 10 5 to 11 25 mm 11 25 to 12 75 mm 2sets 12 75 to 14 25 mm and 14 25 to 15 75 mm 110 Lapping abrasives consumable As required 111 Oil can 0 5 0 25 liter capacity 2 nos 112 Oil Stone 15 cm x 5 cm x 2 5 cm Ino 113 Different type gasket material consumable As required 114 Different type of oil seal consumable As required 115 Sheet Metal Gauge 2 nos 116 Feeler gauge 20 blades metric 2 nos 117 Straight edge gauge 2 ft Ino 118 Straight edge gauge 4 ft Ino 119 Thread pitch gauge metric BSX BSF MC MF amp SAE Ino 120 Valve Lifter Ino 121 Ladle 150mm Dia Ino 122 Blow Lamp 1 litre 2 nos 123 Crow bar 910 x25mm 2 nos 124 Voltmeter 50V DC 5 nos 125 Ammeter 300A 60A DC with external shunt Snos 126 DC Ohmmeter 0 to 300 Ohms mid scales at 20 Ohms lno 127 Electric Soldering Iron 230 V 60 watts 230 V 25 watts 2 each 128 Copper bit soldering iron 0 25 Kg 5 nos 44 Page 129 Thimbles of different sizes 2 nos 130 Wire Gauge metr
53. ssor compressor oil level Temperature monitoring Trouble diagnose thermostat Refrigerants and remedy for Pressure switches No cooling or warm Heating elements air Cool air comes out Air conditioning ECU only intermittently Ambient air temperature Insufficient cooling sensor Servo motors Abnormal noise Electric servo motors from compressor Automatic climate control Magnetic clutch sensors Evaporator condenser temperature sensor evaporator Blower Blower speed control motor Ventilation systems 21 Carrying out a Description and function Drawing of visual inspection of Airbags Seatbelt Automatic door lock Inspecting under Vehicle safety systems system circuit body components Crash sensors Seat belt Measuring a pre tensioners Tire Drawing of power wheelbase pressure monitoring window system Checking systems circuit windshield washer liquid Checking amp Air bag safety and service replacing wiper warnings blades Checking a__ Security systems Remote security system control keys Theft Checking door deterrent systems hinges Integrated Diagnose automatic communications Body seat belt systems controlled lighting Checking interior systems Proximity trim Checking sensors Reflective driver s seat fabric displays Vehicle valet service Routine Global positioning vehicle checks satellites Triangulation trilateration Satellite navigation Telematics 22 24 Driving Practice Locatin
54. ssure 6 5 kg sq cm 113 Grinding machine general purpose D E pedestal with 300 mm Ino dia wheels rough and smooth 114 Tyer Changer Machine Ino C Workshop Furniture SI Description Ouantity No l Suitable class room furniture As required Za Suitable Work Tables with vices As reguired 3 Stools 17 nos 4 Discussion Table 1 no 5 Tool Cabinet 2 nos 6 Trainees locker 2 Nos to accommodate 16 lockers 7 Fire Extinguishers first aid box As required 8 Book shelf glass panel 1 no 9 Storage Rack As reguired 10 Storage shelf As reguired 11 LCD projector LED LCD TV big size 1 no 12 Multimedia CD for Automotive application As reguired 13 Desktop computer and related MS office software 5 1 no 14 Online UPS 2KVA 1 no 15 Laser printer 1 no 16 Computer Table 1 no 17 Computer Chair 2 no 48 Page
55. ternal Layout of an Pressure amp combustion automobile temperature engines different chassis Pressure amp types of LC volume Engines Temperature amp Definition energy Classification of Understanding vehicles on the power and torque basis of load wheels final drive and fuel used axles position of engine and steering transmission body and load 25 i Project Work ii Industrial Visit Optional 26 Ezamination 15 Page TRADE MECHANIC MOTOR VEHICLE SECOND SEMESTER Semester Code MMV SEM II Week No Trade Practical Trade Theory Engineering Workshop Drawing calculation and science 1 Identification of Auto Industry in Use of drawing Mensuration different types of India History instruments T area of Vehicles leading square and drawing rectangles manufacturers board squares tri development in Use of different angles automobile industry types of scales in circles trends new product inches and regular Basic millimeters polygons etc thermodynamics calculation of areas Identification of parts in a diesel engine Practice on starting and stopping of diesel engines Use of speed counter in determining the engine speed running of engine on load checking temperature fuel and oil Diesel Engine Basics Introduction Compression ignition engines Description of Basic 4 stroke diesel principles and cycle Basic 2 stroke diesel principles
56. tion care and use of Surface plates steel rule measuring tape try square Free hand sketching of key and screw threads with dimensions from samples Properties and uses of cast iron ferrous metal gray cast iron white cast iron wrought iron and plain carbon steel high speed steel and alloy steel 7 Page Practice on General workshop tools amp power tools and equipments Practice on visual Identification of materials used in workshop Calipers dividers surface gauges scriber punches Chisel Hammer Screw drivers Allen key Vices amp clamps Spanners Sockets amp accessories Pliers Wrenches air impact wrench air ratchet air chisel air blowgun Torque wrenches jet washers and cleaners Pipe flaring amp cutting tool pullers Cleaning tools amp equipment Practice on General Fasteners Study Free hand Use of scientific cleaning checking and use of different types sketching with calculator of nut bolts amp studs etc of screws nuts dimension of studs amp bolts simple solid such Removal of stud bolt from blind hole locking devices Such as lock nuts cotter split pins keys Circlip lock rings lock washers and locating where they are used Washers amp chemical compounds can be used to help secure these fasteners Selection of materials for gaskets and packing Description of Riveting tools as cubes recta
57. uster in vehicles co efficient of friction simple problems on frication Definition of mass unit of force weight of a body energy and power Applied problems in force work done energy and power 23 24 Study of Motor Vehicle act Exercise in Rules amp Regulation driving a Lorry Bus with different implements 25 i Project Word ii Industrial Visit Optional 26 Examination 32 Page FOURTH SEMESTER Semester Code MMV SEM IV TRADE MECHANIC MOTOR VEHICLE Week Practical Trade Theory Engineering Workshop No Drawing Calculation and Science 1 Identification of Auto Industry in India Statistics petrol Engine History leading definition components manufacturers collecting and development in sorting raw data automobile industry tally chart trends new product 2 Removing a petrol Petrol Engine Basics Make a simple sketch Constructing engine from a motor 4 stroke spark ignition in plan view of a front pictograph pie vehicle engines Basic 4 stroke engine FWD vehicle chart bar chart dismantling principles 4 stroke engine Label the main arithmetic mean cylinder head cycle components the median and decorbonising 2 stroke principles 2 engine clutch the mode checking valves stroke engine cycle gearbox drive shafts cutting valves seats Spark ignition engine driving wheels replacing worn components Basic engine radiator fu
58. ution amp personal safety message emergency evacuation procedure Safe handling of Fuel Spillage Use of Fire extinguishers safe disposal of toxic dust safe handling and Periodic testing of lifting equipment 6 Page Authorization of Moving amp road testing vehicles Environment control of Running indoors engines Safety disposal of Used engine oil Electrical safety practices House Keeping 5S Concept Measuring practice on engine components with aid of instrument studied Systems of measurement conversion of English into metric Systems of measurement amp vice versa Description care amp use of Micrometers Inside Outside and depth measurements Thread Micrometer Micrometer adjustments Vernier calipers vernier depth gauge vernier height gauge Telescope gages Dial bore gauges Dial indicators vacuum gauge tire pressure gauge Free hand sketching of Vernier caliper and Micrometer Dial gauge Reduction of common fractions to decimal fractions shop problems Definition of least count Accuracy Calibration Derive the least count for Vernier caliper and Micrometer Practice using all marking aids like steel rule with spring calipers dividers surface gauges scriber punches Chisel etc Layout a work piece for line circle arcs and circles Hand amp Power Tools Marking scheme Marking material Descrip
59. ve differentials Limited slip differentials Four wheel drive Four wheel drive shafts Four wheel final drive Four wheel drive transfer case Freewheeling hubs Four wheel drive differentials All wheel drive four Free hand sketching of Front wheel drive layout Rear wheel drive layout Four wheel drive layout All wheel drive layout joints amp Universal Joint Study of Gear terminology Belt drives Problems on gear and belt drives Gear ratio calculation 27 Page noise clutch binding hard clutch gearbox noise gear slip rear axle noise propeller shaft noise universal joint noise differential noise wheel final drives All wheel drive transfer case Transfer case differential action 9 11 Identification of Automatic transmission components Checking automatic transmission fluid Changing transmission fluid amp filter Automatic Transmissions Torque converters Torque converter principles drive plate Converter operation Torque multiplication Fluid flow Heat exchanger Lock up converters clutches Planetary gearing Planetary gears Simple planetary gear sets Compound planetary gear sets Automatic transmission brake bands Multi disc clutches Electronic control transmission Electronic control Unit Fully hydraulically controlled transmission Electronic shift programs Manual selection Layout amp operation for P R N amp D 1
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