1
COMPETENCY BASED CURRICULUM
FOR THE TRADE OF
MECHANIC MOTOR VEHICLE
UNDER
CRAFTSMAN TRAINING SCHEME (CTS)
IN SEMESTER PATTERN
BY
GOVERNMENT OF INDIA MINISTRY OF SKILL DEVELOPMENT & ENTREPRENUERSHIP
DIRECTORATE GENERAL OF TRAINING
2
CONTENTS
Sl.
No.
Topics Page No.
1. Introduction
2. Job roles: reference NOS & NCO
3. NSQF level compliance
4. Learning outcome
5. General information
6. Course structure
7. General Training Plan, Examination & Pass regulation
8. Assessable Outcome
9. Assessable outcome with assessment criteria
10. Syllabus content with time structure 10.1 Syllabus content for Professional Skill & Knowledge
10.2 Syllabus content of core skills
11. Employability skills 11.1 General information
11.2 Distribution of topics between semesters for employability
skill
11.3 Syllabus content of Employability Skill
12. Infrastructure
13. Assessment standard 13.1Assessment guideline 13.2 Internal assessments (Formative assessment) 13.3 Final assessment- All India Trade Test (Summative assessment)
14. List of trade committee members
15. List of Tools & Equipments-Annexure-I
16. Guidelines for instructors and paper setters- Annexure-II
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1. INTRODUCTION
The Directorate General of Employment & Training (DGE&T) in Ministry of Labour is the apex
organization for development and coordination at National level for the programmes relating to
vocational training including Women's Vocational Training and Employment Services. Employment
service is operated through a countrywide network of Employment Exchanges. Industrial Training
Institutes are under the administrative and financial control of State Governments or Union Territory
Administrations. DGE&T also operates Vocational Training Schemes in some of the specialized areas
through field institutes under its direct control. Development of these programmes at national level,
particularly in the area concerning common policies, common standards and procedures, training of
instructors and trade testing are the responsibility of the DGE&T. But, day-to-day administration of
employment Exchanges and Industrial Training Institutes rests with the State Governments/ Union
Territories Administrations.
CSTARI one of the field institute of DGE&T is mandated to develop curricula for various courses
under different schemes viz., CTS, ATS, MES, CoE& CITS. All the courses are certificate level and run
on pan India basis under the ageis of NCVT. The curricula developed so far by this institute are skill
based which catered the need of the industry manpower there by contributing significantly in the
development of technical manpower. Hence vocational training provides country wide manpower and
these trained manpower actually builds the wealth for the nation.
The broad concept of industry competency concerns the ability to perform particular tasks and
duties to the standard of performance expected in the workplace. Competency requires the application
of specified skills, knowledge and attitudes relevant to effective participation in an industry, industry
sector or enterprise.
Competency covers all aspects of workplace performance and involves performing individual tasks;
managing a range of different tasks; responding to contingencies or breakdowns; and, dealing with the
responsibilities of the workplace, including working with others. Workplace competency requires the
ability to apply relevant skills, knowledge and attitudes consistently over time and in the required
workplace situations and environments.
In line with this concept of competency based curriculum focus on what is expected of a competent
individual in the workplace as an outcome of learning, rather than focusing on the learning process
itself.
“The Competency Based Training” establishes a direct link between the things which trainees must
learn in institutions and knowledge and skills expected from them for employability “The Competency
Based Training” is a means of instruction which :
I) Identifies the competencies required for work performance,
II) Prepares the trainees through precise learning objectives,
III) Is based on the realities of the world of work
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When learning deals with performance type activities, it is necessary to analyse each job performed
under a particular vocation. Skills required for doing a job may be manipulative and may require
sequential and chronological order of performance. Therefore, teaching and learning content shall be
presented in a psychological and methodological manner. Hence, identification of competencies
becomes an essential exercise for planning and design a curriculum for vocational courses.
The elements of competency are the basic building blocks of the unit of competency. They
describe in terms of outcomes the significant functions and tasks that make up the competency.
The performance criteria specify the required performance in relevant tasks, roles, skills and in
the applied knowledge that enables competent performance. They are usually written in passive voice.
Critical terms or phrases may be written in bold italics and then defined in range statement, in the order
of their appearance in the performance criteria.
The essential skills and knowledge are either identified separately or combined. Knowledge
identifies what a person needs to know to perform the work in an informed and effective manner. Skills
describe the application of knowledge to situations where understanding is converted into a workplace
outcome.
The procedure followed for this purpose is as follows:
I) listing of job opportunities,
II) identification of duties for each job,
III) analyzing the elements of competencies and setting Performance criteria against each
elements of competencies,
IV) determining courses objectives,
V) Preparing course content by projecting elements of competencies, Performance
criteria, skills, knowledge and personality traits.
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2. JOB ROLES: Reference NOS & NCO
Brief description of Job roles:
Mechanic Motor Vehicle: Mechanic, Motor vehicle repairs overhauls and
services motor vehicles to keep them in good running condition.
Examines vehicle to ascertain nature and location of defects either by running
engine or driving vehicle on road.
Dismantles partially or completely defective unit or parts of vehicle such as
engine, gear box, rear axle, front axle, steering assembly, radiator, etc. according
to nature of repairs to be done, using hoist, jack, pullers, hand tools and other
devices.
Measures essential parts like cylinder, bores piston, sizes crank pins etc. using
gauges, micrometer and other precision tools and gets cylinders rebored, liners
filled, valve seats refaced, bearings replaced etc. as necessary.
Repairs or overhauls and assembles engine such as replacing defective parts,
scrapping bearings, setting timing, cleaning injectors, tuning carburetor, MPFI and
CRDI Engines etc. according to maker's specification.
Replaces or repairs defective parts of gear box, rear axle, steering mechanism etc.
and sets them right ensuring correct alignment, clearance, meshing of gears,
specified movements and operations.
Relines and builds brakes, sets wheel alignment, adjust, steering, clutch, hand
brakes etc fits new or repaired accessories and body parts, makes electrical
connection, and performs other tasks to effect repairs.
Lubricates, joints, tightens loose parts, tests performance of vehicle by driving on
road and makes necessary adjustments to attain desired standard.
Trouble shooting and rectification of engine, chassis, and auxiliary system.
State the importance of Motor vehicle act and rules
Plan and organize assigned work and detect & resolve issues during execution.
Demonstrate possible solutions and agree tasks within the team.
Communicate with required clarity and understand technical English.
Sensitive to environment, self-learning and productivity.
Reference NCO & NOS:
i) NCO-2004: 7231.10,
ii) ASC/ Q 1401, (Automotive Service Technician L3 )
iii) ASC/ Q 1402 (Automotive Service Technician L4 )
iv) ASC/ Q 1408 (Automotive Electrician Level 4 )
v) ASC/Q3601 (Vehicle Assembly Fitter)
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3. NSQF LEVEL COMPLIANCE
NSQF level for Mechanic Motor Vehicle under CTS: Level 4 As per notification issued by Govt. of India dated- 27.12.2013 on National Skill Qualification Framework total 10 (Ten) Levels are defined.
Each level of the NSQF is associated with a set of descriptors made up of five outcome statements, which describe in general terms, the minimum knowledge, skills and attributes that a learner needs to acquire in order to be certified for that level.
Each level of the NSQF is described by a statement of learning outcomes in five domains, known as level descriptors. These five domains are:
a. Process b. professional knowledge, c. professional skill, d. core skill and e. Responsibility. The Broad Learning outcome of Mechanic Motor Vehicle under ATS mostly matches with the Level descriptor at Level- 4
. The NSQF level-4 descriptor is given below:
LEVEL Process required
Professional knowledge
Professional skill
Core skill Responsibility
Level 4 work in familiar, predictable, routine, situation of clear choice
factual knowledge of field of knowledge or study
recall and demonstrate practical skill, routine and repetitive in narrow range of application, using appropriate rule and tool, using quality concepts
language to communicate written or oral, with required clarity, skill to basic Arithmetic and algebraic principles, basic understanding of social political and natural environment
Responsibility for own work and learning.
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4. Learning outcome
The following are minimum broad learning outcome after completion of the
Mechanic Motor vehicle course of 02 years duration:
A. GENERIC OUTCOME 1. Recognize & comply safe working practices, environment regulation and
housekeeping.
2. Work in a team, understand and practice soft skills, technical English to
communicate with required clarity.
B. SPCIFIC OUTCOME
3. Demonstrate knowledge of concept and principles of basic arithmetic,
algebraic, trigonometric, co-ordinate geometry and statistics and apply
knowledge of specific area of perform practical operations.
4. Understand and explain basic science in the field of study including basic
electrical, electronics and hydraulics & pneumatics.
5. Read and apply engineering drawing for different application in the field
of work.
6. Select appropriate tools, data & information for servicing & overhauling
of vehicle.
7. Understand the knowledge of concept in productivity, quality tools,
labour & welfare legislation and apply such in day to day work.
8. Explain energy conservation, global warming and pollution and
contribute for such in day to day work.
9. Explain personnel finance management, entrepreneurship and manage /
organize related task in day to day work.
10. Ascertain and select measuring instrument and measure dimension of
components and evaluate for accuracy.
11. Identify and use proper fasteners.
12. Perform sheet metal operations and pipe joints.
13. Trace /troubleshoot different wiring circuits in vehicle and prepare
different electrical joints.
14. Service and test battery for proper functioning.
15. Demonstrate practical skill involved in producing different weld joints.
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16. Demonstrate practical skill by using appropriate tools for different metal
cutting operation to produce finished components and check for accuracy
without any assistance.
17. Plan and organize the work in familiar predictable / routine environment
for different maintenance of vehicle parts and accessories.
18. Dismantle and assemble of engine components of MPFI and CRDI
System and check for performance.
19. Overhaul of Light Vehicle /Heavy vehicle chassis system include wheels
and tyres
20. Identify parts of cooling and lubrication system of engine and execute
required servicing.
21. Understand the constructional features and working principles of intake
and exhaust systems of vehicle and related troubleshooting.
22. Apply appropriate rule and tools for starting and charging system and
diagnose & rectify faults.
23. Recognize and apply factual knowledge of emission control system and
Bhart/Euro standards as per norms.
24. State the importance of Motor vehicle act and rules
25. Understand the constructional features and working principles of vehicle
comfort & safety systems and diagnose and rectify related faults.
26. Dismantle repair and re-assemble vehicle transmission includes
automatic transmission & control system and check their functionality.
27. Understand the knowledge of automotive lighting system and their
troubleshooting.
28. Understand the working principle of car network system, Sensors &
actuators, their diagnosis with proper tools and scanners and recognize
scan tool data using manuals.
29. Understand and explain the concept in productivity, quality tools, and
labour welfare legislation and apply such in day to day work to improve
productivity & quality.
30. Explain energy conservation, global warming and pollution and
contribute in day to day work by optimally using available resources.
31. Explain personnel finance, entrepreneurship and manage/organize related
task in day to day work for personal & societal growth.
32. Understand and apply basic computer working, basic operating system
and uses internet services to get accustomed & take benefit of IT
developments in the industry.
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5. GENERAL INFORMATION
GENERAL INFORMATION
1. Name of the Trade : Mechanic Motor Vehicle
2. N.C.O. & NOS Code No. : 7231.10, ASC/ Q 1401, ASC/ Q 1402, ASC/ Q 1408
3. NSQF
4. Duration of Craftsmen
Training
: Level - IV
2 Year (Four Semester having duration of six months each)
5 Entry Qualification : Passed 10
th class examination with maths and Science.
6. Unit strength : 16 + (Max Supernumeraries seats: 5)
7. Distribution of training on Hourly basis:
Total hours
/week
Trade practical Trade
theory
Work
shop Cal.
&Sc.
Engg.
Drawing
Employability
skills
Extracurricular
activity
40 Hours 25 Hours 6 Hours 2 Hours 3 Hours 2 Hours 2 Hours
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6. COURSE STRUCTURE
1. Name of the Qualification :- Mechanic Motor Vehicle
2. Total duration of the course: - 24 Months
3. Training duration details : -
COURSE ELEMENTS HOURLY DISTRIBUTION
A PROFESSIONAL SKILL 2235 HRS
B PROFESSIONAL KNOWLEDGE 510 HRS C WORKSHOP CALCULATION & SCIENCE 170 HRS D ENGINEERING DRAWING 255 HRS E EMPLOYABILITY SKILLS 110 HRS F EXTRA CURRICULAR ACTIVITIES/LIB. 170 HRS G INPLANT TRG./PROJECT WORK 240 HRS H ADMISSION & EXAMINATION 160 HRS
PIE-CHART
Hourly distribution Prof. Skill
Prof. Knowledge
Workshop Calculation& Science
Engineering Drawing
Extra Curr. Activities
Admission &Examination
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7. General Training Plan, Examination & Pass regulation
General Training Plan
The skills stated in assessment outcome are to be imparted in accordance
with the instructions contained within Section 10 in respect of the content and
time structure of the vocational education and training (General Training Plan).
Examination
Each Semester examination is to take place after the end of the six months of
training. The each semester examination encompasses such skills as are listed for
that period of training (Detail in Section -8) and also includes theoretical
knowledge, Core skills & E/S. The E/S will be covered in first two semesters only.
Candidates are to demonstrate that they are able to:
1. read& interpret technical parameters/documentation, plan and organize work
processes, identify necessary materials and tools;
2. perform task with due consideration to safety rules, accident prevention
regulations and environmental protection stipulations;
3. apply professional knowledge, core skills & employability skills while
performing the task.
4. check the job as per drawing/assembly for functioning, identify and rectify
errors in job/assembly.
5. Document the technical parameters related to the task undertaken.
6. Diagnostic the reported problem and rectify the same with due care.
The details of the examination and assessment standard are as per section-11.
Pass regulation
For the purposes of determining the overall result, weighting of 25 percent is
applied to each semester examination. The minimum pass percent for Practical is
60% & minimum pass percent for Theory subjects 40%.
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8. ASSESSABLE OUTCOME
Assessable outcome after completion of two years Mechanic Motor Vehicle course
I. Generic
1. Apply safe working practices.
2. Comply environment regulation and housekeeping
3. Interpret & use Company and technical communication
II. Specific
1. Apply safe working practices in an automotive work shop.
2. Comply environment regulations and housekeeping in the work shop.
3. Perform precision measurements on the components and compare parameters with
specifications used in automotive work shop practices.
4. Make choices to carry out marking out the components for basic fitting operations in
the work shop.
5. Use different types of tools and work shop equipment in the Auto work shop.
6. Use of different type of fastening and locking devices in a vehicle.
7. Perform basic fitting operations used in the work shop practices and inspection of
dimensions.
8. Grinding of cutting tools in the work shop.
9. Perform surface finishing operations in the given job.
10. Produce sheet metal components using various sheet metal operations.
11. Produce components using bending process in the given work piece.
12. Inspect the auto component using Nondestructive testing methods
13. Manufacture components with different types of welding processes in the given job.
14. Identify the hydraulic and pneumatic components in a vehicle.
15. Construct electrical circuits and test its parameters by using electrical measuring
instruments.
16. Perform basic electrical testing in a vehicle.
17. Perform battery testing and charging operations.
18. Construct basic electronic circuits and testing.
19. Identify and check functionality of Dashboard Gauges & engine performance.
20. Overhauling of Diesel Engine.
21. Servicing of Cooling and Lubrication system
22. Service Intake and Exhaust System
23. Service Diesel Fuel System
24. Check and adjust Engine Emissions
25. Overhauling Charging and Starting System
26. Diagnose and Troubleshoot Diesel Engines
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27. Identify and check functionality of major components and assemblies of heavy
vehicle.
28. Interpret & use company technical information of Heavy vehicle Manufactures
29. Carry Out overhauling light vehicle /Heavy vehicle transmission system
30. Record information of overhauling light vehicle /Heavy vehicle transmission
system
31. Trouble shooting of transmission system
32. Identify and check functionality of auto transmission components
33. Carry out automatic transmission adjustments.
34. Carryout overhauling of light vehicle /Heavy vehicle chassis system including
steering, suspension and braking system
35. Record information of overhauling of light vehicle /Heavy vehicle chassis system
including steering, suspension and braking system
36. Carry out steering and Brake adjustments.
37. Trouble shooting of Steering, suspension and braking system
38. Carry out removal and replacement activities of tyres and tubes of light & Heavy
vehicle.
39. Balance wheels and carry out final checks on the vehicle
40. Record information about removal and replacement activities tyres and tubes of
light & Heavy vehicle
41. Trouble shooting of wheel and tyres
42. Trouble shooting of Engine system with Heavy vehicle
43. Identify the components of petrol engine
44. Identify and check functionality of Dashboard Gauges & engine performance on
petrol engine
45. Overhaul the Petrol Engine
46. Carryout repairs in the fuel feed system
47. Perform engine tune up
48. Identify the various components of MPFI petrol engine
49. Check functionality of MPFI Components
50. Identify and check functionality of various sensors installed in engine, Gauges
and instruments on dashboard
51. Find the trouble in electronic circuit and rectify using scan tool
52. Diagnose and Troubleshoot Petrol Engines
53. Troubleshoot the Charging System
54. Troubleshoot the Starting System
55. Troubleshoot the Lighting circuit
56. Identify the components of Air condition system
57. Diagnose and Troubleshoot the AC system
58. Diagnose and troubleshoot the electrical system accessories
59. Safe Driving practice
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9. ASSESSABLE OUTCOME WITH ASSESSMENT CRITERIA
ASSESSABLE OUTCOME ALONGWITH ASSESSMENT CRITERIA TO BE
ACHIEVED AFTER EACH SEMESTER & COMPLETION OF QUALIFICATION
Semester-I
ASSESSABLE
OUTCOME
ASSESSMENT CRITERIA
1. Apply safe working
practices in an
automotive work
shop.
1.1 Follow and maintain procedures to achieve a safe working
environment in line with occupational health and safety
regulations and requirements and according to site policy.
1.2 Recognize and report all unsafe situations according to site
policy.
1.3 Identify and take necessary precautions on fire and safety
hazards and report according to site policy and procedures.
1.4 Identify, handle and store/dispose off dangerous goods and
substances according to site policy and procedures following
safety regulations and requirements.
1.5 Identify and observe site policies and procedures in regard to
illness or accident.
1.6 Identify safety alarms accurately.
1.7 Report supervisor/competent of authority in the event of
accidents or sickness of any staff and record accident details
correctly according to site accident/injury procedures.
1.8 Identify and observe site evacuation procedures according to
site policy.
1.9 Identify personal protective equipment (PPE) and use the
same as per related working environment.
1.10 Identify basic first aid and use them under different
circumstances.
1.11 Identify different fire extinguishers and use the same as per
requirement.
2. Comply
environment
regulations and
housekeeping in the
work shop.
2.1 Identify environmental pollution and contribute to the
avoidance of instances of environmental pollution.
2.2 Carryout maintenance and cleaning of work shop and lifting
equipment.
2.3 Take opportunities to use energy and materials in an
environmentally friendly manner.
2.4 Avoid waste and dispose waste as per procedure.
15
2.5 Recognize different components of 5S and apply the same in
the working environment.
3. Perform precision
measurements on the
components and
compare parameters
with specifications
used in automotive
work shop practices.
3.1 Measure all dimensions in accordance with standard
specifications and tolerances by using precision measuring
instruments.
3.2 Measure the parameters related with the vehicle components
for its effective operation by matching with manufacturer‟s
specification using different gauges
4. Make choices to
carry out marking out
the components for
basic fitting
operations in the
work shop.
4.1 Mark according to drawings by using marking tools on the
work pieces.
4.2 Chip the job in accordance with standard specifications and
tolerances.
4.3 Measure all dimensions in accordance with standard
specifications and tolerances.
5. Use different types
of tools and work
shop equipment in the
work shop.
5.1 Identify the different types of hand and power tools used in
the automotive work shop.
5.2 Operate various tools and work shop equipment.
6. Use of different
type of fastening and
locking devices in a
vehicle
6.1 Identify the different type of fasteners and locking devices
used in the vehicle.
6.2 Use different types of locking devices correctly.
6.3 Specify the bolt and nut threads.
6.4 Practice on removing the damaged studs and bolts
7. Perform basic
fitting operations used
in the work shop
practices and
inspection of
dimensions.
7.1 Mark according to drawing by using marking tools on flat
surfaces.
7.2 Hack saw and file the job using different methods and
perform in accordance with the standard specifications and
tolerances.
7.3 Drilling and reaming on flat surfaces.
7.4 Identify and use hand tools for internal and external threading
with taps and dies.
7.5 Measure all dimensions in accordance with standard
specification and tolerances.
8. Grinding of cutting
tools in the work shop
8.1 Identify cutting tool materials and their application.
8.2 Plan and grind cutting and marking tools.
8.3 Measure the tool angles with gauges.
9.Perform surface
finishing operations
in the given job.
9.1 Do surface finishing of the job to meet specifications by
scraping.
9.2 Sharpen the scraping tool by grinding.
9.3 Check accuracy/correctness of the job using measuring
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instruments.
10. Produce sheet
metal components
using various sheet
metal operations.
10.1 Ascertain and select tools and materials for the job and
make this available for use in a timely manner.
10.2 Plan and organize the work for different types of sheet metal
operations.
10.3 Mark according to drawing by using marking tools on flat
surfaces.
10.4 Produce components as per the drawing.
11.Produce
components using
bending process in
the given work piece.
11.1 Ascertain and select tools, equipment and materials for the
job and make this available for use in a timely manner.
11.2 Plan and organize the work for pipe bending operations.
11.3 Perform bending, soldering and brazing operations in
accordance with standard operating procedure using appropriate
tools.
11.4 Check accuracy/correctness of the job using appropriate
measuring instruments.
12. Inspect the auto
component using
Nondestructive
testing methods
12.1 Classify different vehicle components by its manufacturing
processes.
12.2 Ascertain and select tools and equipment to do NDT test the
given job.
12.3 Plan and organize the work for nondestructive testing.
12.4 Perform different types of nondestructive tests using
appropriate testing equipment.
12.5 Observe safety/precaution during testing the job.
13. Manufacture
components with
different types of
welding processes in
the given job.
13.1 Plan and select appropriate method to produce components
with welding process.
13.2 Comply with safety rules when performing the above
operations.
13.3 Mark according to the drawing using marking tools on the
job.
13.4 Select appropriate tools and equipment to perform the above
operations.
13.5 Set up and produce component as per standard operating
procedure.
14. Identify the
hydraulic and
pneumatic
components in a
vehicle.
14.1 Comply with safety rules when performing the following
operations.
14.2 Locate and identify the hydraulic components in a vehicle.
14.3 Locate and identify the pneumatic components in a vehicle.
15. Construct
electrical circuits and
test its parameters by
15.1 Plan and organize the work for basic electrical operations.
15.2 Select the tools, instruments and materials required to do the
job.
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using electrical
measuring
instruments.
15.3 Comply with safety rules when performing the basic
electrical operations.
15.4 Perform electrical wire joints, form electrical circuits and
test basic electrical parameters as per the circuit drawings and
operating procedures.
16. Perform basic
electrical testing in a
vehicle.
16.1 Plan and organize the work for auto electrical component
testing.
16.2 Tracing the auto electrical components in a vehicle.
16.3 Test continuity and voltage drop in the electrical circuits.
16.4 Operate the electrical components in a vehicle and test
lamps.
17. Perform battery
testing and charging
operations.
17.1 Ascertain and select tools and materials for the job.
17.2 Comply with safety rules when performing the following
operations.
17.3 Plan and select different methods for charging the battery.
17.4 Perform battery testing as per the operating procedure.
18. Construct basic
electronic circuits and
testing.
18.1 Plan and select different types of basic electronic
components and measuring instruments.
18.2 Construct and test the basic electronic gate circuits and its
components as per the standard procedure.
Semester-II
ASSESSABLE
OUTCOME
ASSESSMENT CRITERIA
19.Identify and check
functionality of Dashboard
Guages & engine performance
19.1 Ascertain and select tools and materials for the
job and make this available for use in a timely
manner.
19.2 Identify different gauges fitted on the dashboard
and check for proper functioning.
19.3 Perform daily checks before starting the engine.
19.4 Start the engine and allow it to warm up.
19.5 Identify the problem in functionality of particular
Gauge fitted on dashboard and record the reading and
compare it with standard reading.
19.6 Repair / Replace the defective guages as per
standard operating practice.
19.7 Check for proper functionality
19.8 Stop the engine.
20. Overhauling of Diesel 20.1 Ascertain and select tools and materials for the
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Engine job and make this available for use in a timely
manner.
20.2 Drain coolant and lubricants from the engine and
Remove Accessories of engine
20.3 Service cylinder head assembly.
20.4 Service Oil Sump and Oil Pump
20.5 Service Piston and connecting Rod Assembly
20.6Service Flywheel , Crank shaft, camshaft and its
Bearings and gear
20.7 Service cylinder block.
20.8 Check and adjust valve clearances as per
procedure and recommended specification
20.9 Refit all the accessories.
20.10 Refill all the required coolant and lubricants as
per standard specification.
20.11 Start the engine and observe reading of
dashboard gauges and record Engine Performance
21. Servicing of Cooling and
Lubrication system
21.1 Check Engine Coolant & Reverse flush the
cooling system using flushing solution.
21.2 Service Radiator and radiator cap
21.3 Check Radiator hoses for crack and replace if
necessary.
21.4 Test Thermostat valve for proper functioning and
replace if necessary.
21.5 Check water pump for serviceability and replace
if faulty.
21.6 Check Fan/Alternator Belt for proper tension.
21.7 Check and replace Engine Oil and oil filter
21.8 check and Service Oil Cooler & pressure relief
valve
22. Service Intake and Exhaust
System
22.1 Ascertain and select tools and materials for the
job and make this available for use in a timely
manner.
22.2 Service/Replace Air Cleaner
22.3 Overhaul Air Compressor & Exhauster
Assembly
22.4 Service Turbocharger/Supercharger
22.5 Service Intercooler
22.6 Check Exhaust Leakages and Rubber Mounting
of Exhaust System
22.7 Service Exhaust manifold and catalytic converter
22.8 Check and Replace Resonator/Muffler
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23. Service Diesel Fuel System 23.1 Check leakages in fuel line.
23.2 Service Fuel Tank
23.3 Replace Fuel Filter & Feed pump
23.4 Set Fuel Injection Pump Timing as per
manufacturer specification
23.5 Service Fuel Injectors as per manufacturers
guidelines and Bleed the Fuel System to vent out any
air trapped.
23.6 Start the Engine and check for proper
functioning.
24. Check and adjust Engine
Emissions
24.1 Analyze Engine Emission by using Gas Analyzer
or Smoke meter.
24.2 Service PCV Valve
24.3 Check and Replace EVAP Canister
24.4 Check and Replace EGR/SCR Valve
25. Overhauling Charging and
Starting System
25.1 Check Charging system for proper functioning as
per manufacturer guidelines
25.2 Service alternator for proper functioning
25.3 Check starting system for proper functioning as
per manufacturer guidelines
25.4 Check starter for proper functioning
25.5 Service starter.
26. Diagnose and Troubleshoot
Diesel Engines
Carryout the diagnostic procedure by reviewing
engine technical workshop manual, following the
standard diagnostic procedure for.
a) Engine Not Starting.
b) High Fuel Consumption
c) Engine Overheating
d) Low Power Generation
e) Excessive Oil Consumption
f) Low/High Engine Oil Pressure
g) Abnormal Engine Noise.
20
Semester-III
ASSESSABLE OUTCOME ASSESSMENT CRITERIA
27. Identify and check
functionality of major
components and assemblies of
heavy vehicle.
27.1 support the motor vehicle safely
27.2 Identify and locate the main components of
Heavy vehicle to include:
steering
suspension
gearbox
final drives
brakes
27.3 visually inspect and report on the condition of a
range of chassis components, to include:
brakes
steering
suspension
tyres
exhaust system
28.Interpret & use company
technical information of Heavy
vehicle Manufactures
28.1Obtain sources of information and recognize
information.
28.2 Use documents and technical regulations and
occupationally related provisions.
28.3 Conduct appropriate and target oriented
discussions with higher authority and within the team.
28.4 Present facts and circumstances, possible solutions
& use English special terminology.
28.5 Resolve disputes within the team
28.6 Conduct written communication.
29.Carry Out overhauling light
vehicle /Heavy vehicle
transmission system
29.1 Select and wear suitable personal protective
equipment and use vehicle coverings throughout all
removal and replacement activities.
29.2 Work in compliance with standard safety norms.
29.3 carryout their removal and replacement activities
by reviewing:
• vehicle technical data
21
• removal and replacement procedures
• legal requirements
29.4 Use technical information to support the
overhauling of light vehicle/Heavy Vehicle
transmission units.
29.5 Select tools and materials for the job and make this
available for use in a timely manner.
29.6 Ascertain that equipment has been calibrated to
meet manufacturers‟ and legal requirements
29.7 Use the tools and equipment in the way specified
by manufacturers to overhaul light vehicle/Heavy
vehicle transmission unit.
29.8 perform all overhauling of light vehicle
transmission units, adhering to the specifications and
tolerances for the vehicle and following:
a. the manufacturer‟s approved overhauling methods
b. Standard repair methods
c. health and safety requirements.
d. workplace procedures
Range:
a. Gear box
b. Single plate clutch assembly
c. Diaphragm clutch assembly
d. Constant mesh Gear box
e. synchromesh gear box
f. Gear linkages
g. Propeller shaft
h. Universal Slip Joint
i. Rear axle assembly
j. Differential assembly
29.9 Ascertain the assessment of the dismantled unit
identifies accurately its condition and suitability for
overhaul
29.10 Conduct appropriate and target oriented
discussions with higher authority and within the team,
where an overhaul is uneconomic or unsatisfactory to
perform
29.11 Use testing methods that comply with the
manufacturer‟s requirements.
29.12 Adjust the unit‟s components correctly where
necessary to ensure that they operate to meet the
vehicle operating requirements.
22
29.13 ensure replaced driveline units and assemblies
conform to the vehicle operating specification and any
legal requirements
30. Record information of
overhauling light vehicle
/Heavy vehicle transmission
system
30.1 produce work records that are accurate, complete
and passed to the higher authority relevant promptly in
the format required
30.2 Record and report any additional faults noticed
during the course of their work promptly in the format
required.
31. Trouble shooting of
transmission system
31.1 Perform all system diagnostic activities as per
Workshop manual.
31.2 Rectify the defects following the vehicle
manufacture standard procedure.
32.Identify and check
functionality of auto
transmission components
32.1Safe working practices are observed throughout the
task.
32.2 Carryout test procedures for electronically
controlled transmissions in accordance with the vehicle
manufacturer's specifications.
32.3 Select and use suitable tools & equipment
materials to enable transmission tests and make this
available for use in a timely manner.
32.4 Check the transmission fluid in the manner
prescribed by the manufacturer
32.5 ensure that transmission fluid level is to
specification, and its condition is determined
32.6 Check the transmission filter in the manner
prescribed by the manufacturer
32.7.Perform Fluid pressure tests are conducted in
accordance with the manufacturer's instructions,
32.8 Record the pressures in all ranges at idle and stall
speeds
32.9 An analysis is made of all the in
formation on the test report sheet, and any faults and
their probable causes are identified
33. Carry out automatic
transmission adjustments.
33.1 Safe working practices are observed throughout
the task.
23
33.2 Select and use suitable tools, equipment and
materials to enable adjustments and make this available
for use in a timely manner.
33.3 Carryout adjustments in the prescribed procedure
by the manufacturer, and to the manufacturer's
specifications
Range - Control cable play, shift lever switch, throttle
position sensor, speed sensor and automatic
transmission wiring harness coupler.
34.Carryout overhauling of
light vehicle /Heavy vehicle
chassis system including
steering, suspension and
braking system
34.1Select and wear suitable personal protective
equipment and use vehicle coverings throughout all
removal and replacement activities.
34.2 Work in compliance with standard safety norms.
34.3 carryout their removal and replacement activities
by reviewing:
• vehicle technical data
• removal and replacement procedures
• legal requirements
34.4 Use technical information to support the
overhauling of light vehicle/Heavy Vehicle steering and
suspension system
34.5 Select tools and materials for the job and make this
available for use in a timely manner.
34.6 Ascertain that equipment has been calibrated to
meet manufacturers‟ and legal requirements
34.7 Use the tools and equipment in the way specified
by manufacturers to overhaul steering, suspension and
braking system
34.8 perform all overhauling of light vehicle Chassis
units, adhering to the specifications and tolerances for
the vehicle and following:
a. the manufacturer‟s approved overhauling methods
b. Standard repair methods
c. health and safety requirements.
d. workplace procedures
Range:
a) Shackle
b) Leaf spring
c) Front axle
d) Front and rear suspension
e) Steering Gearbox- worm and roller type
f) Steering Gearbox- Reticulating ball type
24
g) Master cylinder
h) Tandem Master cylinder
i) Front and rear brake
j) Wheel cylinder
k) Vacuum booster
l) Air servo unit
m) Air tank (reservoir)
n) Brake valve
o) Hand/parking brake
p) Single brake chamber
q) Slack adjuster
r) Disc brake
34.9 Ascertain the assessment of the dismantled unit
identifies accurately its condition and suitability for
overhaul
34.10 Conduct appropriate and target oriented
discussions with higher authority and within the team,
where an overhaul is uneconomic or unsatisfactory to
perform
34.11 Use testing methods that comply with the
manufacturer‟s requirements.
34.12 Adjust the unit‟s components correctly where
necessary to ensure that they operate to meet the
vehicle operating requirements.
34.13 ensure replaced driveline units and assemblies
conform to the vehicle operating specification and any
legal requirements
35. Record information of
overhauling of light vehicle
/Heavy vehicle chassis system
including steering, suspension
and braking system
35.14 produce work records that are accurate, complete
and passed to the higher authority relevant promptly in
the format required
35.15 Record and report any additional faults noticed
during the course of their work promptly in the format
required.
36. Carry out steering and
Brake adjustments.
36.1 Safe working practices are observed throughout
the task.
36.2 Select and use suitable tools, equipment and
materials to enable adjustments and make this available
for use in a timely manner.
36.3 Carryout adjustments in the prescribed procedure
by the manufacturer, and to the manufacturer's
specifications
Range - turning angle, drop arm, steering wheel with
25
the front wheel, toe-in, toe-out, camber angle, castor
angle, kingpin inclination and wheel run out..
Brake-Brake pedal, bleeding of brakes, parking brake
cable.
36.4 Check the power steering fluid in the manner
prescribed by the manufacturer
36.5 ensure that power steering fluid level is to
specification, and its condition is determined
36.6 Perform pressure tests of power steering in
accordance with the manufacturer's instructions,
37.Trouble shooting of
Steering, suspension and
braking system
37.1 Carryout the recommended trouble shooting
procedure as per Workshop manual
37.2 Rectify the defects following the vehicle
manufacture standard procedure.
38. carry out removal and
replacement activities of tyres
and tubes of light & Heavy
vehicle
38.1 Use suitable personal protective equipment and
vehicle coverings when working on vehicles
38.2 Carry out inspection of wheels and tyres using
appropriate techniques, suitable tools, equipment and
manufacturers instructions where relevant. To include:
a visual inspection
b measurement of tread depth
c tyre pressures
d balance
38.3 Carry out tyre repair activities within appropriate
timescales, using:
a suitable tools and equipment
b correct repair and replacement techniques
c correct type and size of replacement components
d correct materials
38.4 Carry out tyre replacement activities within
appropriate timescales
39.Balance wheels and carry
out final checks on the vehicle
39.5 Carry out wheel balancing to within acceptable
limits
39.6Carry out final vehicle safety checks in the
workshop,
40. Record information about
removal and replacement
activities tyres and tubes of
light & Heavy vehicle
40.1 Produce work records that are accurate, complete
and passed to the higher authority relevant promptly.
40.2 Record and report any additional faults noticed
during the course of their work.
26
41. Trouble shooting of wheel
and tyres
41.1Carryout the recommended trouble shooting
procedure as per Workshop manual for
a) Abnormal wear
b) Wheel wobbling
c) Poor self centering
d) Hard steering
41.2 Rectify the defects following the vehicle
manufacture standard procedure.
42. Trouble shooting of Engine
system with Heavy vehicle
42.1 Carryout the recommended trouble shooting
procedure as per Workshop manual for
a) Engine Not starting – Mechanical &
b) Electrical causes,
c) High fuel consumption,
d) Engine overheating,
e) Low Power Generation,
f) Excessive oil consumption,
g) Low/High Engine Oil Pressure,
h) Engine Noise.
42.2 Rectify the defects following the vehicle
manufacture standard procedure.
Semester-IV
ASSESSABLE OUTCOME ASSESSMENT CRITERIA
43. Identify the components of
petrol engine
43.1Identify the components of given petrol engine and
its function
44. Identify and check
functionality of Dashboard
Gauges & engine performance
on petrol engine
44.1 Ascertain and select tools and materials for the job
and make this available for use in a timely manner.
44.2 Plan work in compliance with standard safety norms.
44.3 Demonstrate possible solutions and agree tasks
within the team.
44.4 Identify different gauges fitted on the dashboard and
check for proper functioning.
44.5 Perform daily checks before starting the engine.
44.6 Start the engine and allow it to warm up.
44.7 Identify the problem in functionality of particular
Gauge fitted on dashboard and record the reading and
compare it with standard reading.
27
44.8 Repair / Replace the defective gauges as per
standard operating practice.
44.9 Check for proper functionality
44.10 Stop the engine.
45. Overhaul the Petrol Engine 45.1 Ascertain and select tools and materials for the job
and make this available for use in a timely manner.
45.2 Plan work in compliance with standard safety
norms.
45.3 Remove a petrol engine from the vehicle as per
vehicle manufacturer std. Procedure
45.4 Dismantle the petrol engine as per sequence
45.5 Overhaul the cylinder head assembly
45.6 Overhaul the piston and connecting rod assembly
45.7 Check the cylinder bore wear
45.8 Check and compare measurements as per standard
specification.
45.9 Assemble the petrol engine as per sequence
45.10Check and adjust valve clearances as per procedure
and recommended specification of engine manufacturer
46. Carryout repairs in the fuel
feed system
46.1 Ascertain and select tools and materials for the job
and make this available for use in a timely manner.
46.2 Plan work in compliance with standard safety
norms.
46.3 Remove the fuel tank from vehicle
46.4 Servicing the fuel tank & fuel pipe lines
46.5 Servicing of fuel pipes
46.6 Overhaul the different types of fuel pump
46.7 Overhaul the different types of carburettor and make
adjustments
46.8 Replace the air cleaner, fuel filter and charcoal
canister
47. Perform engine tune up 47.1 Ascertain and select tools and materials for the job
and make this available for use in a timely manner.
47.2 Test vacuum and compression of engine
47.3 Make carburetor adjustments
48. Identify the various
components of MPFI petrol
engine
48.1 Identify the MPFI components by its name
48.2 Locate the MPFI Components in the given engine
49. Check functionality of
MPFI Components
49.1 Ascertain and select tools and materials for the job
and make this available for use in a timely manner.
49.2 Plan work in compliance with standard safety
norms.
28
49.3 Test the MPFI fuel pump
49.4 Test the MPFI fuel Injector
49.5 Test the Idle Air control valve
49.6 Test the MPFI fuel pressure regulator
50. Identify and check
functionality of various sensors
installed in engine, Gauges and
instruments on dashboard
50.1 Ascertain and select tools and materials for the job
and make this available for use in a timely manner.
50.2 Plan work in compliance with standard safety
norms.
50.3 Identify and locate the sensors fitted in the given
MPFI engine
50.4 Start the engine and check the function of Mal
Indication Lamp (MIL) ,Oil pressure warning light,
charge indication light, Temperature warning light/gauge,
Seat belt warning light, ABS warning light, Parking light,
fuel level gauge
50.5 Repair / Replace the defective gauges as per
standard operating practice.
50.6 Test the various sensors fitted on the given engine
using multi meter/scan tool
51. Find the trouble in
electronic circuit and rectify
using scan tool
51.1 Connect the scan tool to the Data link connector of
given engine
51.2 Read the Error code
51.3 Test the reference voltage and continuity of the
circuit as per vehicle wiring circuit
51.4 Repair/Replace the defective part or wiring
51.5 Erase the error memory
51.6 Start and check the engine
52. Diagnose and Troubleshoot
Petrol Engines
52.1 Ascertain and select tools and materials for the job
and make this available for use in a timely manner.
52.2 Plan work in compliance with standard safety
norms.
52.3 Carryout the diagnostic procedure by reviewing
engine technical workshop manual, following the
standard diagnostic procedure for.
Engine cranks but Not Starting.
52.4 Engine hard to start
52.5 High Fuel Consumption
52.6 Engine misfiring
53.Troubleshoot the Charging
System
53.1 Check Charging system for proper functioning as
per manufacturer guidelines
53.2 Check alternator for proper functioning
53.3 Remove alternator from the vehicle.
29
53.4 Overhaul and check alternator for proper function.
53.5 Refit Alternator to the vehicle and check for
functioning
54. Troubleshoot the Starting
System
54.1 Check starting system for proper functioning as per
manufacturer guidelines
54.2 Check starter for proper functioning
54.3 Remove starter from the vehicle.
54.4 Overhaul and check starter for proper function.
54.5 Refit starter to the vehicle and check for functioning
55. Troubleshoot the Lighting
circuit
55.1 Read the wiring circuit of lighting of the given
vehicle
55.2 Operate and check the function of combination
switch and other light switches
55.3 Check the lights whether glow or Not
55.4 Replace the defective bulbs/fuse/faulty
wire/electrical or electronic component
55.5 Check the fluid level for oil pressure light, brake
warning light
55.6 Aligning of Head light
55.7 Repair/Rectify any other fault
56. Identify the components of
Air condition system
56.1 Identify the components of Air condition
system in given vehicle, location and its function
57.Diagnose and Troubleshoot
the AC system
57.1 Ascertain and select tools and materials for the job
and make this available for use in a timely manner.
57.2Plan work in compliance with standard safety norms.
57.3 Carryout the diagnostic procedure for the following
troubles
a) No cooling
b) Intermittent cooling
c) Insufficient cooling
d) Abnormal noise from compressor, magnetic clutch,
condenser, evaporator and blower motor
e) High pressure gauge-pressure High and low
f) Low pressure gauge-pressure High and low
58.Diagnose and Troubleshoot
the electrical system accessories
58.1 Ascertain and select tools and materials for the job
and make this available for use in a timely manner.
58.2 Plan work in compliance with standard safety
norms.
58.3 Carryout the diagnostic procedure for the following
troubles in the electrical accessories
a) No horn, poor horn, continuous horn
b) Wiper and washer no operation, continuous
30
operation, Intermittent operation
c) Power window no operation
d) Power Door lock no operation
e) Immobilizer system and keyless entry no operation
f) Trouble(Error indication) in Automatic seat belt
system
g) Trouble(Error indication) in Air bag system
59. Safe Driving practice 59.1 Follow the Road safety measures, Traffic rules and
statutory regulations
59.2 Practice in straight Driving
59.3 Practice in Driving through lanes and curves
59.4 Practice in Reverse Driving
59.5 Practice in Overtaking of another vehicle
59.6 Practice in Driving through sand and wet surface
59.7 Practice in Parking and Diagonal parking
31
10. SYLLABUS CONTENT WITH TIME STRUCTURE
10.1 SYLLABUS CONTENT FOR PROFESSIONAL SKILL & KNOWLEDGE
SYLLABUS FOR THE TRADE OF MECHANIC MOTOR VEHICLE
First Semester
(Semester Code no. - 01)
Duration : Six Month
LEARNING OBJECTIVES OF 1
ST SEMESTER
Week
No.
Professional skills Professional Knowledge
Trade Practical Trade Theory
1
Familiarisation with institute, Job
opportunities in the automobile
sector, Machinery used in Trade.
Types of work done by the students
in the shop floor.
Admission & 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
2
Practical related to Safety and
Health,
Importance of maintenance and
cleanliness of Workshop.
Interaction with health centre and
fire service station to provide demo
on First aid and Fire safety, Use of
fire extinguishers.
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 & Health
Importance of Safety and general
Precautions to be observed in the shop. Basic
first aid, safety signs - for Danger, Warning,
caution & 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 & 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 with 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
Hand & 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 & C-clamps, Spanners- ring spanner, open
32
Practice to remove wheel lug nuts
with use of an air impact wrench
Practice on General workshop tools
& power tools.
end spanner & the combination spanner,
universal adjustable open end spanner. Sockets &
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 & cutting
tool, pullers-Gear and bearing.
6&7
Measuring practice on Cam height,
Camshaft Journal dia, crankshaft
journal dia, 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 &
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 & 9
Practice on General cleaning,
checking and use of nut, bolts, &
Fasteners- Study of different types of screws,
nuts, studs & bolts, locking devices, Such as lock
33
studs etc.,
Removal of stud/bolt from blind
hole.
Practice on cutting tools like
Hacksaw, file, chisel, Sharpening of
Chisels, center punch, safety
precautions while grinding.
Practice on Hacksawing and filing to
given dimensions.
nuts, cotter, split pins, keys, circlips, lock rings,
lock washers and locating where they are used.
Washers & 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
cut and uses., OFF-hand grinding with sander,
bench and pedestal grinders, safety precautions
while grinding.
Limits, Fits & Tolerances:-Definition of limits,
fits & tolerances with examples used in auto
components
10 &
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
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 & 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 & insulators, Wires, Shielding, Length vs.
resistance, Resistor ratings
34
14 Diagnose series, parallel, series-
parallel circuits using Ohm‟s law,
Check electrical circuit with a test
lamp, perform voltage drop test in
circuits using multimeter, measure
current flow using multimeter
/ammeter, use of service manual
wiring diagram for troubleshooting.
Fuses & 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
hydrometer,
Connecting battery to a charger for
battery charging, Inspecting & 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.
Description of Chemical effects, Batteries & cells, Lead
acid batteries & 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 &
Secondary windings, Transformers, stator and
rotor coils.
16 Identify and test power and signal
connectors for continuity, Identify
and test different type of Diodes, NPN &
PNP Transistors for its functionality,
Construct and test simple logic
circuits OR, AND & NOT and Logic
gates using switches.
Basic electronics: Description of Semi conductors,
Solid state devices- Diodes, Transistors, Thyristors,
Uni Junction Transistors ( UJT), Metal Oxide Field
Effect Transistors ( MOSFETs), Logic gates-OR,
AND & NOT and Logic gates using switches.
17&
18
Practice to make straight beads and
Butt, Lap & T joints Manual Metal
Arc Welding.
Setting of Gas welding flames,
practice to make a straight beads and
joints Oxy – Acetylene welding
Film on Heat treatment process
Introduction to welding and Heat Treatment
Welding processes – Principles of Arc welding, brief
description, classification and applications. Manual
Metal Arc welding -principles, power sources,
electrodes, welding parameters, edge preparation
& fit up and welding techniques; Oxy – Acetylene
welding - principles, equipment, welding
parameters, edge preparation & 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 & Practice on Liquid penetrant testing Non-destructive Testing Methods- Importance
35
20
method and Magnetic particle testing
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 components in Air
brake systems.
of Non-Destructive Testing In Automotive
Industry, Definition of NDT, Liquid penetrant
and Magnetic particle testing method – Portable
Yoke method
Introduction to Hydraulics & Pneumatics: -
Definition of Pascal law, pressure, Force,
viscosity. Description, symbols and application in
automobile of Gear pump-Internal & External,
single acting, double acting & 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 & Lubricator).
21 Identification of different type of
Vehicle.
Demonstration of vehicle
specification data;
Identification of vehicle information
Number (VIN). Demonstration of
Garage, Service station equipments.-
Vehicle hoists – Two post and four
post hoist, Engine hoists, Jacks, Stands.
Auto Industry - History, leading manufacturers, development in automobile industry, trends, new product. Brief about Ministry of Road transport & Highways, The Automotive Research Association of India (ARAI), National Automotive Testing and R&D Infrastructure Project (NATRIP), & Automobile Association.
Definition: - Classification of vehicles on the
basis of load as per central motor vehicle rule,
wheels, final drive, and fuel used, axles, position
of engine and steering 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
36
SYLLABUS FOR THE TRADE OF MECHANIC MOTOR VEHICLE Second Semester
(Semester Code no. - 02)
Duration : Six Months
LEARNING OBJECTIVES OF 2ND
SEMESTER
Week
No.
Professional skills Professional Knowledge
Trade Practical (27 Hrs/week) Trade Theory (5 Hrs/week)
1 & 2 Identification of parts in a diesel engine of LMV/ HMV
Practice on starting and stopping of diesel engines.
Observe and report the reading of Tachometer, Odometer, temp and Fuel gauge under ideal and on load condition.
Practice on dismantling Diesel engine of LMV/HMV as per procedure.
Introduction to Engine:
Description of internal & external
combustion engines, Classification of IC
engines, Principle & working of 2&4-stroke diesel
engine (Compression ignition Engine (C.I)), Principle
of Spark Ignition Engine(SI), differentiate
between 2-stroke and 4 stroke, C.I engine
and S.I Engine, Direct injection and Indirect
injection, Technical terms used in engine,
Engine 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 & 4 Overhauling of cylinder head assembly,
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 & valve guide –
Replacing the valve if necessary. Testing
leaks of valve seats for leakage –
Dismantle rocker shaft assembly -clean &
check rocker shaft-and levers, for 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 & rocker arm assembly,
Diesel Engine Components: Description
and Constructional feature of Cylinder
head, Importance of Cylinder head design,
Type of Diesel combustion chambers,
Effect on size of Intake & exhaust
passages, Head gaskets. Importance of
Turbulence
Valves & 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 & drives , Description of
Overhead camshaft, importance of Cam
37
adjustable valve clearances, starting
engine after adjustments. lobes, Timing belts & chains, Timing belts
& tensioners.
5 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 & 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 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 & 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 & function of connecting
rod, importance of big- end split
obliquely, Materials used for connecting
rods big end & main bearings. Shells
piston pins and locking methods of piston
pins.
6 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
& twist.
Description and function of Crank shaft, camshaft, Engine bearings- classification and location – materials used & composition of bearing materials- Shell bearing and their advantages- special bearings material for diesel engine application bearing failure & its causes-care & maintenance. Crank-shaft balancing, Firing order of the engine.
7 Checking of flywheel and mounting
flanges, spigot, bearing. Check vibration
damper for defects, Practice on removing
cam shaft from engine block, Check for
bend & twist of camshaft. Inspection of
cam lobe, camshaft journals and bearings
and measure cam lobe lift. Fixing bearing
inserts in cylinder block & cap check nip
and spread clearance & oil holes & 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 & oil pump, gears timing mark, Chain sprockets, chain tensioner etc. Function of clutch & coupling units attached to flywheel.
8 Cleaning and Checking of cylinder blocks
Surface for any crack, flatness, Measure
cylinder bore for taper & ovality, clean oil
Description of Cylinder block, Cylinder block construction, and Different type of Cylinder sleeves (liner).
38
gallery passage and oil pipe line, Bore -
descale water passages and 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.
9 Reassemble all parts of engine in correct
Sequence and torque all bolts and nuts
as per workshop manual of the engine.
Engine component procedures- Testing
cylinder compression, Checking idle
speed, Removing & replacing a cam
belt, Inspecting & adjusting an engine
drive belt, Replacing an engine drive
belt.
Engine assembly 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.
10-12 Practice on Checking &Top up coolant,
Draining & refilling coolant, Checking /
replacing a coolant hose, Testing
cooling system pressure, Practice on
Removing & replacing radiator/
thermostat. Inspect the radiator pressure
cap, Testing of thermostat. Cleaning &
reverse flushing. Overhauling water
pump and refitting.
Practice on Checking engine oil, Draining engine oil, Replacing oil filter, Refilling engine oil. Overhauling of oil pump, oil coolers, air cleaners and air filters and adjust oil pressure relief valves, repairs to oil flow pipe lines and unions if necessary.
Need for Cooling systems, Heat transfer method, Boiling point & pressure, Centrifugal force, Vehicle coolant properties and recommended change of interval, Different type of cooling systems, Basic cooling system components- Radiator, Coolant hoses, Water pump, Cooling system thermostat, Cooling fans, Temperature indicators, Radiator pressure cap, Recovery system, Thermo-switch.
Need for lubrication system, Functions of 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 & Oil filters Oil pressure relief valve, Spurt holes & 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 & 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
Intake & exhaust systems – Description
of Diesel induction & Exhaust systems.
Description & 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,
39
damage;
Practice on Exhaust manifold removal and
installation.
Practice on Catalytic converter removal and
installation.
Exhaust system components- Description
and function of Exhaust manifold,
Exhaust pipe, Extractors, Mufflers-
Reactive, absorptive, Combination.,
Catalytic converters, Flexible connections,
Ceramic coatings, Back-pressure,
Electronic mufflers.
14 -16
Practice on removing & Cleaning fuel
tanks, checking leaks in the fuel lines,
soldering & 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 & secondary filters.
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.
General maintenance of Fuel Injection
Pumps (FIP).
Diesel Fuel Systems- Description and
function of Diesel fuel injection, fuel
characteristics, concept of Quiet diesel
technology & Clean diesel technology.
Diesel fuel system components – Description and function of Diesel tanks &
lines, Diesel fuel filters, water separator,
Lift pump, Plunger pump, Priming pump,
Inline injection pump, Distributor-type
injection pump, Diesel injectors, Glow
plugs, Cummins & Detroit Diesel injection.
Electronic Diesel control- Electronic
Diesel control systems, Common Rail
Diesel Injection (CRDI) system,
Hydraulically actuated electronically
controlled unit injector (HEUI) diesel
injection system. Sensors, actuators and
ECU (Electronic Control Unit) used in
Diesel Engines.
17 Practice on Start engine adjust idling
speed and damping device in 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 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
Marine & Stationary Engine:- Types,
double acting engines, opposed piston
engines, starting systems, cooling systems,
lubricating systems, supplying fuel oil,
hydraulic coupling, reduction gear drive,
electromagnetic coupling, electrical drive,
generators and motors, supercharging.
18 Monitoring emissions procedures by use of
Engine gas analyser or Diesel smoke meter.
Checking & cleaning a Positive crank case
ventilation (PCV) valve. Obtaining &
interpreting scan tool data. Inspection of
EVAP canister purge system by use of scan
Tool.
EGR /SCR Valve Remove and installation
Emission Control:- Vehicle emissions
Standards- Euro and Bhart II, III, 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
40
for inspection. Description of Evaporation emission
control, Catalytic conversion, Closed loop,
Crankcase emission control, Exhaust gas
recirculation (EGR) valve, Controlling air-
fuel ratios, Charcoal storage devices, Diesel
particulate filter (DPF). Selective Catalytic
Reduction (SCR), EGR VS SCR
19 Practice on removing alternator from vehicle dismantling, cleaning checking for defects, assembling and testing for motoring action of alternator & fitting to vehicles.
Practice on removing starter motor Vehicle and overhauling the starter motor, testing of starter motor
Description .of charging circuit operation
of alternators, regulator unit, ignition
warning lamp- troubles and remedy in
charging system.
Description of starter motor circuit,
Constructional details of starter motor
solenoid switches, common troubles and
remedy in starter circuit.
20 & 21
Practice on troubleshooting in
LMV/HMV for Engine Not starting –
Mechanical & Electrical causes, High
fuel consumption, Engine overheating,
Low Power Generation, Excessive oil
consumption, Low/High Engine Oil
Pressure, Engine Noise.
Troubleshooting : Causes and remedy for
Engine Not starting – Mechanical &
Electrical causes, High fuel consumption,
Engine overheating, Low Power
Generation, Excessive oil consumption,
Low/High Engine Oil Pressure, Engine
Noise.
22-23 In-plant Training
24-25 Revision and Test
26 NCVT Exam
41
SYLLABUS FOR THE TRADE OF MECHANIC MOTOR VEHICLE
Third Semester
(Semester Code no. - 03)
Duration : Six Month
LEARNING OBJECTIVES OF 3
RD SEMESTER
Week
No.
Professional Skills Professional Knowledge
Trade Practical (27 Hrs/week) Trade Theory (5 Hrs/week)
1 Identification of different major components
of Heavy vehicle and their function &
placement study of different make
lorry/bus/tractor in Institute with different
dealers or organizations.
Introduction: Study of different major
components & assemblies of heavy vehicle,
and different make (indigenous). Name
plate-constructional differences and their
merits. leading manufacturers in Heavy
vehicle Industry
2 -4 Practice on adjusting clutch pedal play-
removing gearbox and clutch assembly from
Light & Heavy Vehicle. Dismantling clutch
assembly, cleaning inspecting parts.
Removing & fitting of new pilot bearing,
removing & fitting of ring gear in fly wheel
relining a clutch plate, checking condition of
flywheel and pressure plate surface for
reconditioning.
Assembling of pressure plate adjusting the
fingers checking run out of fly wheel and
aligning clutch assembly 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 & testing for
correct performance identifying noises from
gear boxes and rectifying.
Clutches & Manual Transmissions-Clutch
principles, Single-plate clutches, Multi-plate
clutches, Dual mass flywheels, Operating
mechanisms
Clutch components- Pressure plate, Driven/
center plate, Throw-out bearing.
Manual transmissions- Gear ratios,
Compound gear trains, Gear selection,
Bearings, Oil seals & gaskets, Brief about
Automated Manual Transmission (AMT)
Gearbox layout & operation-
Gearbox layouts, Transaxle designs,
Gearbox operation, Baulk-ring synchromesh
unit, Transaxle synchromesh unit. Gear shift
mechanism.
5-7 Practice on Removing open type propeller
shaft from vehicle, Practice on removing
universal joints, cleaning replacing worn out
parts, re-assembling & refitting to vehicle-
and their alignment special precautions
while removing torque tube drive shaft.
Practice on FWD Driveshaft Removal
and Replacement.
Practice on overhauling & inspection of rear
axle.
Practice on overhauling & inspection of
Final Drive & 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, Type of
Universal joints, Type of Constant velocity
Joints, Rear-wheel final drives, Salisbury
axles, Rear-wheel drive differentials,
42
differential assembly.
Trouble shooting – causes and remedy for
clutch slip, clutch noise, clutch binding, hard
clutch, gearbox noise, gear slip, rear axle
noise, propeller shaft noise, universal joint
noise, differential noise.
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 wheel final drives,
All-wheel drive transfer case, Transfer case
differential action.
8 & 9 Identification of Automatic transmission
components
Checking automatic transmission fluid,
Changing transmission fluid & filter.
Checking automatic transmission fluid,
Changing transmission fluid & filter.
Practice on oil pressure control cable play
adjustments, Inspection of shift lever switch,
throttle position sensor, speed sensor and
automatic transmission wiring harness
coupler.
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 & operation for P,R,N&D (1st & 2
nd)
Selector positions, Planetary gear set, High
range power flow, Low range power flow
Servos & clutches-Rear servo, Front servo,
One way clutch, Multi-plate front clutch,
Clutch pack, Rear clutch.
Hydraulic system & controls-Hydraulic
system components, Spool valves,
Regulating or flow control valves, Control
valves, Orifices
Valve types & functions- Basic valve
action, Regulator & control valves, Shift &
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.
43
10-12 Following practical to be Practiced On Light
& 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 gearbox.
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 & adjusting power
steering fluid, Pressure testing a power
steering system, Flushing a power steering
system, Inspecting & 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 pulling to one side.
Steering Systems:- Description and
function of Steering systems, Principles of
steering, Rack-and-pinion steering system,
Recirculation ball & nut steering system,
Four-wheel steering systems, collapsible
steering system.
Steering boxes & 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 & components- Forward
control vehicle steering, Steering linkages,
Joints, Bushes/bushings
Wheel alignment fundamentals:- Basic principles of wheel alignment,
wheel base, wheel track, king pin
inclination, Caster, Camber, Scrub radius,
Toe-in & toe out, Toe-out on turns,
Turning radius, Thrust angle &
centerlines.
13-15 Following practical to be Practiced On Light
& Heavy Vehicle
Practice on visual Inspection of chassis
frame for crack, bent and twists.
Overhauling and Inspection of shackle,
leaf spring, front & rear suspension.
Practice on removing, inspection and
assembling of shock absorber
Lubricating a suspension system.
Trouble shooting for Suspension system
defects :
wheel hop, ride height (unequal and low),
noises under operation, fluid leakage,
excessive travel, bounce, worn dampers,
worn joints/damaged linkages, vehicle
“crabbing”.
Suspension Systems:-
Principles of suspension, Suspension force,
Unsprung weight, Wheel unit location,
Dampening. Types of suspension-
Suspension systems, Solid axle, Dead axle,
Description, function and advantages of non
independent suspension Independent
suspension, Rear independent suspension,
Rear-wheel drive independent suspension,
electronically controlled air suspension
(ECAS), 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 & components-
Mc person Strut suspension, Short/long arm
suspension, Torsion bar suspension
Rear suspension types & components-Rigid
axle leaf spring suspension, Rigid axle coil
44
spring suspension, Independent type
suspension, Rigid non-drive suspension
16 Practice on removing wheels from light &
Heavy vehicle, dismantling tyres and tubes
checking puncture.
Assembling inflating to correct pressure.
Checking & adjusting tire pressure by use of
air or by Nitorgen
Rotating the wheels in vehicle minor repairs
to wheels and tyres, wheel balancing &
alignment.
Checking for tyre wear patterns.
Caution: vehicle equipped with ABS while
removing the wheel and using on vehicle
balancing never ignition switch on (Follow
the service manual procedure)
Wheels & Tyres-Wheel types & sizes
Wheels, Rim sizes & designations, Types of
wheels
Tyre types & characteristics- Tyres,
Radial ply tyres, Radial ply tyre sidewalls,
Tyre pressure monitoring systems, Run flat
tyres, Space-saver tyres, Tyre distortion,
Center of gravity.
Tyre construction-Tyre construction, Types
of tyre construction, Tyre materials,
Hysteresis, Tyre sizes & designations, Tyre
information, Tyre tread designs, Tyre ratings
for temperature & traction. Descriptions
Tirewear Patterns and causes
Nitrogen vs atmospheric air in tyres
17-19 Practice on Adjusting brake pedal play,
Overhauling and inspection of tandem
master cylinder assembly,
Overhauling and inspection of front and rear
brake assembly, overhauling and inspection
of wheel cylinder assembly.
Bleeding hydraulic brakes & Disk brakes.
Overhauling and inspection of vacuum
assisted brake assembly.
Overhauling and inspection of disc brake.
Adjusting Air brakes- repair to tank unit, air
compressor, wheel brake adjuster- locating
air leaks in the brake lines and rectifying –
general maintenance and care.
Brakes procedures-Checking & adjusting brake
fluid, Replacing brake fluid, Checking brake
pads, Replacing brake pads, Removing &
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.
Braking Systems :- Principles of braking,
Drum & disc brakes, Lever/mechanical
advantage, Hydraulic pressure & force,
Brake pad, Regenerative braking.
Braking systems - Brake type - principles,
Air brakes, Exhaust brakes, Electric brakes,
Parking brakes, Engine brakes, Regenerative
braking
Braking system components-Park brake
system, Brake pedal, Brake lines, Brake
fluid, Bleeding, Master cylinder, 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 & components -Drum brake
system, Drum brake operation, Brake linings
& shoes, Back plate, Wheel cylinders
Disc brakes & components -Disc brake
system, Disc brake operation, Disc brake
rotors, Disc brake pads, Disc brake calipprs,
Proportioning valves, Proportioning valve
operation, Brake friction materials
Antilock braking system & 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.
The construction and operation of heavy
vehicle Anti-Slip Regulation / Traction
Control (ASR) system.
45
20 &
21.
Trouble shooting Practice with Heavy
vehicle for
Engine Not starting – Mechanical &
Electrical causes,
High fuel consumption,
Engine overheating,
Low Power Generation,
Excessive oil consumption,
Low/High Engine Oil Pressure,
Engine Noise.
Study of Motor Vehicle act Rules &
Regulation-Laws governing to use of motor
vehicle & vehicle transport, Licensing of
drivers & conductors, Registration of
vehicle, Traffic rules, Signals & controls,
Accidents, Causes & analysis,
Responsibility of driver, Offences, penalties
& procedures, Different types of forms,
Government administration structure,
Personnel, Authorities & duties, Rules
regarding construction of motor vehicles,
Tax exemption & tax renewal, Insurance
types & significance -Comprehensive
Third party insurance, Duty of driver in case
of accident
22-23 In plant training
24-25 Revision and Test
26 NCVT Exam
46
SYLLABUS FOR THE TRADE OF MECHANIC MOTOR VEHICLE
Fourth Semester
(Semester Code no. - 04)
Duration : Six Month
Week
No.
Professional Skills Professional Knowledge
Trade Practical Trade Theory
1 &
2
Identification of petrol Engine components.
Practice on starting and stopping of petrol engines. Observe and report the reading of Tachometer, Odometer, temp and Fuel gauge under ideal and on load condition.
Removing a petrol engine from a motor
vehicle. Dismantling cylinder head for
Inspection.
Practice on Removing of piston and
connecting rods from engine checking
Cylinder bore wear for ovality and taper.
Piston ring, Piston as per service manual.
Checking valves - replacing worn guides
and weak springs, assembling valves and
cylinder head and adjusting tappet clearance
in engine.
Petrol Engine Basics:
4-stroke spark-ignition engines- Basic 4-stroke
principles.
Spark-ignition engine components- Basic engine
components, Engine cams & camshaft, Engine power
transfer, Scavenging, Counter weights, Piston components.
Intake & exhaust 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.
Gasoline Fuel Systems : Description of Gasoline
fuel, Gasoline fuel characteristics, Controlling fuel burn,
Stoichiometric ratio, Air density, Fuel supply system, Pressure & vacuum.
3 Simple repairs in fuel feed system –
overhauling of fuel pump, carburetors, fuel
Filters and air cleaners. Repair to a car
carburetors – adjusting float level and slow
speed adjustments –studying the fuel flow
circuit in carburetor
Practice in engine tune up in a vehicle –
testing vacuum and compression of engine,
Carburetor operation-Carburation, Carburetor
systems, Metering jets, Accelerating, Carburetor barrels
Carbureted system components
The carburetor, Mechanical fuel pumps, Electric fuel pumps, Tanks & lines, Fuel lines, Charcoal canister, Carburetor filters.
4&5 Practice on Cleaning fuel tank, checking for
leaks 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.
Introduction to Electronic fuel injection
(EFI) fuel supply system , Basic EFI principles, Air
supply, Air volume, Multi-point injection systems
(MPI/MPFI), Simultaneous injection, Efficient
combustion
EFI fuel supply system components - Fuel
pumps, Fuel filters, Tanks & lines, Fuel lines, Fuel rail, Fuel
pressure regulator, Injectors, Tachometric relay, Thermotime
switch, EFI sensors, Potentiometer, Auxiliary air valves, Idle
speed control devices, Inertia sensors.
47
6 & 7 Identification of Electronic control Unit.
Set up for testing, Testing of Electronic
Control Circuit. Fault finding in Electronic
circuit and remedies using scan tool.
Identification of various sensors installed in
engine & it‟s mounting. Checking
instruments & Gauges on dash board.
Rectify replace defective gauges.
Testing of Temperature sensor, Pressure
senor, potentiometer, magnetic induction
sensor, cam shaft sensor, crankshaft position
sensor.
Introduction to EFI Engine Management -
EFI operation Modes of EFI, Electronic fuel injection,
Idle speed control systems, Feedback & looping, Cold start
systems, Air measurement, Air-flow monitoring, Variable
intake manifold system, Electrical functions, EFI wiring
diagram
Electronic control unit (ECU) - EFI system ECU,
Electronic control unit settings, Engine speed limiting, Malfunction indicator lamp. Importance of Diagnostic Trouble Code (DTC) & its general format. Use of scan tool and retrievals of codes.
EFI sensors- Intake Temperature sensor, Mass airflow
sensor, Manifold absolute pressure sensor, Air vortex sensor,
Fuel system sensor, Throttle position sensor, Exhaust gas
oxygen sensor, Crank angle sensor, Hall effect voltage sensor,
8 Diagnosis- Possible causes and remedy for
Engine cranks, but will not or hard to start,
Poor fuel economy or engine performance.
Checking ignition timing, Checking &
changing a spark plug, Identification and
testing of Hall effect sensor, Optical sensor.
Tracing and testing of sensor circuits.
Ignition principles and Faraday‟s laws, Primary
and secondary winding of transformer, Ignition
components, Spark plugs, Spark plug components, Vacuum
& centrifugal units, Plug firing voltage,
Induction, Inductive system operation, Induction wiring, Hall
effect sensors, Hall effect operation, Optical type sensors Distributor less ignition systems, Insulated coils, Distributor
less ignition system timing.
9 & 10
Checking a charging system for the cause
of undercharge, No charge, and over charge
conditions. Removing & replacing an
alternator, Inspection of rotor for ground,
open circuit – field coil resistance, slip ring
surface, Fan, bearing. Inspection of stator
for ground, open circuit, Inspection of Drive
end bearing rotation, Rectifier, brush length
compare with service manual. slip ring
surface. Inspecting & adjusting an engine
drive belt, Replacing an engine drive belt
/ pulleys / Tesnionsers and their alignments.
Trouble shooting, possible causes and
remedy for warning lamp does not glow
when ignition switch is on, Warning lamp
glows dim when ignition switch is on,
warning lamp „on‟ while the alternator is
running, Warning lamp glows „dim‟ while
the alternator is running, warning lamp
flickers considerably.
Charging system- The purpose of Charging system,
charging system components, charging system
circuit, Alternator principles, Alternating current,
Alternator components, Rectification, Phase winding
connections, Rotor circuit, Voltage regulation, System
operating voltage, High voltage charging systems, Rotor,
Stator, Alternator end frames, Slip ring & brush assembly,
Rectifier assembly, Alternator cooling fan.
11 & 12
Removing starter motor from vehicle, and
Performance test for pull-in test, Hold-in
test, pinion (plunger) return test, No-load
performance test.
Solenoid test for Hold in coil open circuit,
Armature test – Ground test, Open circuit
test, pull-in coil open circuit test, field coil
test. Inspections of brush length wear as per
Starting system- purpose of starting system, Staring
system components, Starter motor principles, study
of starter control circuits. Starter motor construction,
Starter magnet types, Starter motor engagement,
Commutation, Switching, solenoid construction.
48
service manual.
Trouble shooting , possible causes and
remedy for starter motor not running,
Starting motor running but too slow (small
torque), staring motor running, but not
cranking engine. Noise, starting motor does
not stop running. Growler testing for rotors.
Checking a starting system, Jump-
starting a vehicle
13 & 14
Trace the light circuit - test bulbs, align head
lamps, Aiming headlights. Changing a
headlight bulb, Checking of a head light
switch and to replace if faulty.
Trouble shooting and remedy for
Headlight - headlight do not light up, only
one headlight does not light up, Only one
beam (“Hi” or “Lo”) does not light..
Trouble shooting and remedy for turn
signal and hazard warning lights -Flash
rate high or one side only flashes, No
Flashing, flash rate low.
Trouble shooting and remedy for
clearance, tail and license plate lights - All
lights do not light up, some lights do not
light up.
Trouble shooting and remedy for Back-
up light - Back-up lights do not light up.
Trouble shooting and remedy for Brake
lights -Brake lights do not light up, Brake
light stay on.
Trouble shooting and remedy for fuel
meter and fuel gauge unit - Fuel meter
shows no operation or incorrect
operation.
Trouble shooting and remedy for Engine
coolant Temp (ECT) meter and ECT
Sensor – Engine coolant temp meter
shows no operation or incorrect
operation.
Trouble shooting and remedy for oil
pressure light – Oil pressure warning
light does not light up when ignition
switch is on at engine off.
Trouble shooting and remedy for brake
and parking brake warning light- Brake
warning light does not light up when fluid
flow level, Brake warning light does not
light up when parking brake pull up,
Brake warning lights stay on.
Lighting system, Lamps/light bulbs, Lamp/light bulb
information, LED lighting, Headlights-description of standard
sealed beam, halogen sealed beam, composite and High intensity discharge (HID) headlights. Headlight & dimmer
circuits, Park & tail light circuits, Brake light circuits, turn
signal circuit, Cornering lights, Fog lights circuit, interior
lights- courtesy, reading and instrument panel lights, Smart lighting , Reverse lights
49
Trouble shooting and remedy for interior
light- Interior light do not light up. Trace the wiring circuit of traffic signal
flashers light circuit-tracing
defects in the flasher circuits, replacing fuse
bulb.
15 & 16
Identification of Air conditioning
components, Performance test on A/c unit,
Checking Charged state of refrigerant,
Inspecting & adjusting an engine drive
belt, Replacing an engine drive belt. Checking a heating system, Compressor
rotation test, air Gap check,
Refrigerant recovery –evacuating –charging
of A/c system. Replenishing compressor oil
level. Troubles diagnose and remedy for No
cooling or warm air, Cool air comes out
only intermittently, Insufficient cooling,
Abnormal noise from compressor, Magnetic
clutch, condenser, evaporator, Blower
motor. Diagnosis test for High pressure
gauge –pressure high and low, Low pressure
gauge for pressure high and low.
Heating Ventilation Air Conditioning (HVAC) legislation,
Vehicle heating, ventilation & cooling systems, Basic air-
conditioning principles, Air-conditioning capacity, Air-
conditioning refrigerant, Humidity Description and
function of Fixed orifice, Control devices, Thermostatic
expansion valve system, Thermal expansion valves, Air-
conditioning compressors, Condensers & evaporators,
Receiver drier, Lines & hoses, TX valve construction,
Temperature monitoring thermostat, Refrigerants, Pressure
switches, Heating elements
Air-conditioning ECU, Ambient air temperature sensor, Servo
motors, Electric servo motors, Automatic climate control
sensors, Evaporator temperature sensor, Blower speed
control, Ventilation systems.
17 & 18
Trouble shooting and remedy for Horn-
No horn operation, poor sound quality,
horn sounds continuously and to replace
the horn if faulty. Remove and install wiper motors and wiper
switches. Checking & replacing wiper
blades.
Trouble shooting and remedy for
windshield wiper and washer - no
operation, intermittent operation, continuous
operation, and wipers will not park.
Diagnose causes for improper operation of
the windshield washer system and to replace
the pump if faulty.
Diagnose the power window system for – all
power window motors do not operate, some
switches do not operate.
Diagnose the power door lock control for –
All power door locks do not operate, only
one power door lock not operate.
Diagnose for remote keyless entry and
immobilizer system.
Familiarization of car radio wiring and speaker circuits Diagnose automatic seat belt systems,
Diagnose air bag system and service
Accessories: Horn circuit, wiper circuit, power
window components and circuit. Power door
lock circuit, automatic door lock circuit, remote
keyless entry system circuit, antitheft system,
immobilizer system. Navigation system, Car
radio and cassette player, car videos.
Description and function of Airbags, Seatbelt, Vehicle safety
systems, Crash sensors, Seat belt pre-tensioners, Tire
pressure monitoring systems
Integrated communications, Proximity sensors, Reflective
displays, Global positioning satellites,
Triangulation/trilateration, Telematics. Networking &
multiplexing .
50
warnings.
19-21 Driving Practice.
Practice in straight driving on wide roads.
Driving through lanes and curves.
Practice in reversing. Practice overtaking
another vehicle. Practice in driving through
sand and wet surfaces. Practice in parking
and Diagonal parking.
Locating vehicle information, Obtaining &
interpreting scan tool data, Using a repair
manual, Using a shop manual, Using an
owner's manual, Using a labor guide, Using a
parts program, Using a service information
program
22-23 Project work
24-25 Revision and Test
26 NCVT Exam
51
10.2 SYLLABUS CONTENT OF CORE SKILLS
First Semester (Semester Code no. - 01)
Duration: Six Month
LEARNING OBJECTIVES OF 1ST
SEMESTER
1. Demonstrate basic arithmatic to derive value of unknown quantity / variable.
2. Understand & apply engineering material, their classification, properties and applications
in the day to day technical application.
3. Explain & apply speed, velocity, work, power & energy for application in field of work.
4. Understand & explain importance of engineering drawing, drawing instruments, their
standard & uses.
5. Draw lines, geometrical figures, free hand sketches.
6. Understand and apply sizes & layout of drawing sheet, method of presentation of
engineering drawing & symbolic representation as per BIS standards
Sl.
No.
Professional Knowledge Professional Knowledge & Skills
Workshop Calculation and Science Engineering
Drawing
1. Unit: Systems of unit- FPS, CGS, MKS/SI
unit, unit of length, Mass and time,
Conversion of units
Engineering Drawing: Introduction and its importance
- Relationship to other technical drawing types
- Conventions
- Viewing of engineering drawing sheets.
- Method of Folding of printed Drawing Sheet as
per BIS SP:46-2003
2. Fractions : Fractions, Decimal fraction,
L.C.M., H.C.F., Multiplication and Division
of Fractions and Decimals, conversion of
Fraction to Decimal and vice versa. Simple
problems using Scientific Calculator.
Drawing Instruments : their Standard and uses
- Drawing board, T-Square, Drafter (Drafting
M/c), Set Squares, Protractor, Drawing
Instrument Box (Compass, Dividers, Scale,
Diagonal Scales etc.), Pencils of different
Grades, Drawing pins / Clips.
3. Square Root : Square and Square Root,
method of finding out square roots, Simple
problem using calculator.
Lines :
- Definition, types and applications in Drawing as
per BIS SP:46-2003
- Classification of lines (Hidden, centre,
construction, Extension, Dimension, Section)
- Drawing lines of given length (Straight, curved)
- Drawing of parallel lines, perpendicular line
- Methods of Division of line segment
4. Ratio & Proportion : Simple calculation on
related problems.
Drawing of Geometrical Figures: Definition,
nomenclature and practice of
- Angle: Measurement and its types, method of
52
bisecting.
- Triangle -different types
- Rectangle, Square, Rhombus, Parallelogram.
- Circle and its elements.
5. Percentage : Introduction, Simple
calculation. Changing percentage to decimal
and fraction and vice-versa.
Lettering and Numbering as per BIS SP46-2003:
- Single Stroke, Double Stroke, inclined, Upper
case and Lower case.
6. Material Science : properties -Physical &
Mechanical, Types –Ferrous & Non-Ferrous,
difference between Ferrous and Non-Ferrous
metals, introduction of Iron, Cast Iron,
Wrought Iron, Steel, difference between Iron
and Steel, Alloy steel, carbon steel, stainless
steel, Non-Ferrous metals, Non-Ferrous
Alloys.
Dimensioning:
- Definition, types and methods of dimensioning
(functional, non-functional and auxiliary)
- Types of arrowhead
- Leader Line with text
7. Mass, Weight and Density : Mass, Unit of
Mass, Weight, difference between mass and
weight, Density, unit of density, specific
gravity of metals.
Free hand drawing of
- Lines, polygons, ellipse, etc.
- geometrical figures and blocks with dimension
- Transferring measurement from the given object to
the free hand sketches.
8. Speed and Velocity: Rest and motion, speed,
velocity, difference between speed and
velocity, acceleration, retardation, equations
of motions, simple related problems.
Sizes and Layout of Drawing Sheets
- Basic principle of Sheet Size
- Designation of sizes
- Selection of sizes
- Title Block, its position and content
- Borders and Frames (Orientation marks and
graduations)
- Grid Reference
- Item Reference on Drawing Sheet (Item List)
9. Work, Power and Energy: work, unit of
work, power, unit of power, Horse power of
engines, mechanical efficiency, energy, use
of energy, potential and kinetic energy,
examples of potential energy and kinetic
energy.
Method of presentation of Engineering Drawing
- Pictorial View
- Orthogonal View
- Isometric view
10.
-----
Symbolic Representation (as per BIS SP:46-2003) of :
- Fastener (Rivets, Bolts and Nuts)
- Bars and profile sections
- Weld, brazed and soldered joints.
- Electrical and electronics element
- Piping joints and fittings
53
Second Semester (Semester Code no. - 02)
Duration: Six Month
LEARNING OBJECTIVES OF 2ND
SEMESTER
1. Demonstrate basic algebraic, mensuration, trigonometric facts and formulas to derive
value of unknown quantity / variable.
2. Apply the factual knowledge of basic heat & temperature, basic electricity for day to day
practical application.
3. Explain & apply principles of simple machine & levers for mechanical advantage, efficiency
for practical application.
4. Draw & practice dimensioning, construction of solid figures and projections as per IS
specifications.
Sl.
No.
Professional Knowledge Professional Knowledge & Skills
Workshop Calculation and Science Engineering
Drawing
1. Algebra : Addition, Subtraction, Multiplication, Division, Algebraic formula, Linear equations (with two variables).
Construction of Scales and diagonal scale
2. Mensuration : Area and perimeter of
square, rectangle, parallelogram, triangle,
circle, semi circle,
Volume of solids – cube, cuboids, cylinder
and Sphere.
Surface area of solids – cube, cuboids,
cylinder and Sphere.
Practice of Lettering and Title Block
3. Trigonometry: Trigonometrical ratios,
measurement of angles.
Trigonometric tables
Dimensioning practice:
- Position of dimensioning (unidirectional, aligned, oblique as per BIS SP:46-2003)
- Symbols preceding the value of dimension and dimensional tolerance.
- Text of dimension of repeated features, equidistance elements, circumferential objects.
4. Heat & Temperature: Heat and
temperature, their units, difference between
heat and temperature, boiling point, melting
point, scale of temperature, relation
between different scale of temperature,
Thermometer, pyrometer, transmission of
heat, conduction, convection, radiation.
Construction of Geometrical Drawing Figures:
- Different Polygons and their values of included angles. Inscribed and Circumscribed polygons.
- Conic Sections (Ellipse& Parabola)
54
5. Basic Electricity: Introduction, use of
electricity, how electricity is produced, Types
of current_ AC, DC, their comparison,
voltage, resistance, their units. Conductor,
insulator, Types of connections – series,
parallel, electric power, Horse power,
energy, unit of electrical energy.
Drawing of Solid figures (Cube, Cuboids, Cone, Prism,
Pyramid, Frustum of Cone and Pyramid.) with
dimensions.
6. Levers and Simple Machines: levers and its
types.
Simple Machines, Effort and Load,
Mechanical Advantage, Velocity Ratio,
Efficiency of machine, Relationship between
Efficiency, velocity ratio and Mechanical
Advantage.
Free Hand sketch of hand tools and measuring tools
used in respective trades.
7. Projections:
- Concept of axes plane and quadrant. - Orthographic projections - Method of first angle and third angle projections
(definition and difference) - Symbol of 1st angle and 3rd angle projection as per
IS specification.
8. Drawing of Orthographic projection from isometric/3D
view of blocks
9. Orthographic Drawing of simple fastener (Rivet, Bolts,
Nuts & Screw)
10. Drawing details of two simple mating blocks and
assembled view.
55
Third Semester (Semester Code no. - 03)
Duration: Six Month
LEARNING OBJECTIVES OF 3RD
SEMESTER
1. Demonstrate & apply calculation of area of cut-out regular & irregular surfaces, Volume of
geometrical shapes and their cut section in related shop floor problems.
2. Calculate value of unknown sides and angles of geometrical shapes by trigonometrical
methods and apply in shop floor problems.
3. Understand & apply concept of forces, stress & strain, factor of safety for practical
application.
4. Factual knowledge of thermal conductivity, temperature measuring instruments, average
velocity and circular motion for day to day application.
5. Understanding drawing of machined components & related symbols for use in
manufacturing purpose.
6. Draw free hand sketches for fasteners, hand tools and components.
7. Prepare simple assembly drawings & their details.
Sl.
No.
Professional Knowledge Professional Knowledge & Skills
Workshop Calculation and Science Engineering
Drawing
1. - Geometrical construction & theorem: division of line segment, parallel lines, similar angles, perpendicular lines, isosceles triangle and right angled triangle.
- Revision of first year topics.
2. - Area of cut-out regular surfaces: circle and segment and sector of circle.
- Machined components; concept of fillet & chamfer; surface finish symbols.
3. - Area of irregular surfaces. - Application related to shop problems.
- Screw thread, their standard forms as per BIS, external and internal thread, conventions on the features for drawing as per BIS.
4. - Volume of cut-out solids: hollow cylinders, frustum of cone, block section. - Volume of simple machine blocks.
- Free hand Sketches for bolts, nuts, screws and other screwed members.
5. - Material weight and cost problems related to trade.
- Free hand Sketching of foundation bolts and types of washers.
6. - Finding the value of unknown sides and angles of a triangle by Trigonometrical method.
- Standard rivet forms as per BIS (Six types).
7. - Finding height and distance by trigonometry.
- Riveted joints-Butt & Lap (Drawing one for each type).
8. - Application of trigonometry in shop problems. (viz. taper angle calculation).
- Orthogonal views of keys of different types
56
9. - Forces definition. - Compressive, tensile, shear forces and simple problems. -Stress, strain, ultimate strength, factor of safety. -Basic study of stress-strain curve for MS.
- Free hand Sketches for simple pipe, unions with simple pipe line drawings.
10. - Temperature measuring instruments. Specific heats of solids & liquids.
- Concept of preparation of assembly drawing and detailing. Preparation of simple assemblies & their details of trade related tools/job/exercises with the dimensions from the given sample or models.
11. - Thermal Conductivity, Heat loss and heat gain.
-Free hand sketch of trade related components /
parts (viz., single tool post for the lathe, etc.)
12. - Average Velocity, Acceleration & Retardation. - Related problems.
- Study of assembled views of Vee-blocks with clamps.
13. - Circular Motion: Relation between circular motion and Linear motion, Centrifugal force, Centripetal force
- Study of assembled views of shaft and pulley.
14. - Study of assembled views of bush bearing.
15. - Study of assembled views of a simple coupling.
16. - Free hand Sketching of different gear wheels and nomenclature.
57
Fourth Semester (Semester Code no. - 04)
Duration: Six Month
LEARNING OBJECTIVES OF 4TH
SEMESTER
1. Read & interpret different types graphs.
2. Solve simple statistical problem and apply sampling method for inspection purpose.
3. Factual knowledge of friction, magnetism and their application and affects.
4. Understand the application of electrical insulating materials & concept of earthing.
5. Understand & apply transmission of power, heat treatment & their advantages.
6. Factual knowledge of pressure, its units and measuring system and understand basic
concept of pneumatics & hydraulic system.
7. Draw free hand sketches of bench vice and bearing.
8. Understand & identify missing lines, symbols & views.
9. Estimate material required as per drawing.
Sl.
No.
Professional Knowledge Professional Knowledge & Skills
Workshop Calculation and Science Engineering
Drawing
1. Graph:
- Read images, graphs, diagrams – bar chart, pie chart. - Graphs: abscissa and ordinates, graphs of straight line, related to two sets of varying quantities.
- Free hand Details and assembly of simple bench vice.
2. Simple problem on Statistics: - Frequency distribution table - Calculation of Mean value. - Examples on mass scale productions. -Cumulative frequency -Arithmetic mean
- Reading of drawing. Simple exercises related to missing lines, dimensions. How to make queries.
3. Acceptance of lot by sampling method (within specified limit size) with simple examples (not more than 20 samples).
- Simple exercises relating missing symbols. - Missing views
4. - Friction- co-efficient of friction, application
and effects of friction in Workshop practice.
Centre of gravity and its practical application.
- Simple exercises related to missing section.
5. - Magnetic substances- natural and artificial magnets.
-Free hand sketching of different types of bearings and its conventional representation.
58
- Method of magnetization. Use of magnets.
6. - Electrical insulating materials. - Basic concept of earthing.
- Free hand sketching of different gear wheels and nomenclature/ Simple duct (for RAC). Free hand sketch of Reciprocating compressor – open type (for RAC)
7. - Transmission of power by belt, pulleys & gear drive. - Calculation of Transmission of power by belt pulley and gear drive.
- Solution of NCVT test. - Simple exercises related to trade related symbols. - Basic electrical and electronic symbols
8. - Heat treatment and advantages. - Study of drawing & Estimation of materials.
9. Concept of pressure – units of pressure, atmospheric pressure, absolute pressure, gauge pressure – gauges used for measuring pressure
- Solution of NCVT test papers.
10. Introduction to pneumatics & hydraulics systems.
59
11. Employability Skills
11.1 GENERAL INFORMATION
1. Name of the subject : EMPLOYABILITY SKILLS
2. Applicability :
CTS- Mandatory for all trades
ATS- Mandatory for fresher only
3. Hours of Instruction : 110 Hrs.
4. Examination : The examination will be held at the end of
semesters.
5. Instructor Qualification :
MBA OR 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 DGT institutes
AND
Must have studied English/ Communication Skills and Basic Computer at 12th
/ Diploma level
and above
OR
Existing Social Studies Instructors duly trained in Employability Skills from DGT institutes
6. Instructor: One full time regular instructor shall be engaged on every 240 number of trainees for
teaching the subject ‘Employability Skills’. One additional full time regular instructor would be required
on increase in every 240 trainees. Wherever the trainees are less than 240 or part thereof, a part-time
instructor may be engaged to teach the subject. This has been illustrated in the table below:
S. No. Number of trainees Instructor (s) required
a) Less than 240 One part-time Instructor
b) 240 One full-time Instructor
c) Between 240 and 480 One full-time Instructor +One part-time Instructor
d) Between 480 and 720 Two full-time Instructors +One part-time Instructor
e) Between 720 and 960 Three full-time Instructors +One part-time Instructor
60
11.2 DISTRIBUTION OF TOPICS BETWEEN SEMESTERS FOR EMPLOYABILITY SKILL
Course
Duration
Semester1 Semester2
Examination Topics Topics
01 Year (Two
semesters)
1. English Literacy
2. I.T. Literacy
3. Communication
Skills
4. Entrepreneurship Skills
5. Productivity
6. Occupational safety , Health
and Environment
Education
7. Labour Welfare
Legislation
8. Quality Tools
Final examination
at the end of second
semester
02 Years (Four
Semesters)
1. English Literacy
2. I.T. Literacy
3. Communication
Skills
4. Entrepreneurship Skills
5. Productivity
6. Occupational safety , Health
and Environment
Education
7. Labour Welfare
Legislation
8. Quality Tools
Final examination
at the end of second
semester
61
11.3 SYLLABUS CONTENT OF EMPLOYABILITY SKILL
SEMESTER-I LEARNING OBJECTIVES OF 1
ST SEMESTER
1. Read, write and communicate in English language for day to day work.
2. Communicate in written and oral and with required clarity ensuring that the information
communicated is clear, concise and accurate.
3. Understand and apply basic computer working, basic operating system and uses internet
services to get accustomed & take benefit of IT developments in the industry.
1. English Literacy
Hours of Instruction: 20 Hrs. Marks Allotted: 09
Pronunciation Accentuation (mode of pronunciation) on simple words, Diction (use of word
and speech)
Functional Grammar Transformation of sentences, Voice change, Change of tense, Spellings.
Reading Reading and understanding simple sentences about self, work and
environment
Writing Construction of simple sentences
Writing simple English
Speaking / Spoken
English
Speaking with preparation on self, on family, on friends/ classmates, on know,
picture reading gain confidence through role-playing and discussions on
current happening job description, asking about someone‟s job habitual
actions. Cardinal (fundamental) numbers ordinal numbers. Taking messages,
passing messages on and filling in message forms Greeting and introductions
office hospitality, Resumes or curriculum vita essential parts, letters of
application reference to previous communication.
2. I.T. Literacy
Hours of Instruction: 20 Hrs. Marks Allotted: 09
Basics of Computer Introduction, Computer and its applications, Hardware and peripherals,
Switching on-Starting and shutting down of computer.
Computer Operating
System
Basics of Operating System, WINDOWS, The user interface of Windows
OS, Create, Copy, Move and delete Files and Folders, Use of External
memory like pen drive, CD, DVD etc, Use of Common applications.
Word processing and
Worksheet
Basic operating of Word Processing, Creating, opening and closing
Documents, use of shortcuts, Creating and Editing of Text, Formatting the
Text, Insertion & creation of Tables. Printing document.
Basics of Excel worksheet, understanding basic commands, creating simple
worksheets, understanding sample worksheets, use of simple formulas and
functions, Printing of simple excel sheets
62
Computer Networking
and INTERNET
Basic of computer Networks (using real life examples), Definitions of Local
Area Network (LAN), Wide Area Network (WAN), Internet, Concept of
Internet (Network of Networks),
Meaning of World Wide Web (WWW), Web Browser, Web Site, Web page
and Search Engines. Accessing the Internet using Web Browser,
Downloading and Printing Web Pages, Opening an email account and use of
email. Social media sites and its implication.
Information Security and antivirus tools, Do‟s and Don‟ts in Information
Security, Awareness of IT – ACT, types of cyber crimes.
3. Communication Skills
Hour of Instruction: 15 Hrs.Marks Allotted: 07
Topic Contents
Introduction to Communication Skills
Communication and its importance
Principles of Effective communication
Types of communication – verbal, nonverbal, written, email,
talking on phone.
Nonverbal communication –characteristics, components-Para-
language
Body – language
Barriers to communication and dealing with barriers.
Handling nervousness/ discomfort.
Listening Skills
Listening-hearing and listening, effective listening, barriers to
effective listening guidelines for effective listening.
Triple- A Listening – Attitude, Attention & Adjustment.
Active Listening Skills.
Motivational Training
Characteristics Essential to Achieving Success
The Power of Positive Attitude
Self-awareness
Importance of Commitment
Ethics and Values
Ways to Motivate Oneself
Personal Goal setting and Employability Planning.
Facing Interviews
Manners, Etiquettes, Dress code for an interview
Do‟s & Don‟ts for an interview
Behavioral Skills
Problem Solving
Confidence Building
Attitude
63
SEMESTER-II LEARNING OBJECTIVES OF 2
ND SEMESTER
1. Knowledge of business activities, ability to interact with consumers for development of
businesses.
2. Understand and apply productivity, its benefits and factors affecting the productivity.
3. Follow and maintain procedures to achieve a safe working environment in line with
occupational health, safety, environment regulations and Labour welfare legislation and
requirements.
4. Understand and apply quality concepts as per ISO and BIS system and its importance.
5. Recognize different components of 5S and apply the same in the working environment.
4. Entrepreneurship skill
Hour of Instruction: 15 Hrs.Marks Allotted: 06
Topic Content
Business & Consumer: Types of business in different trades and the importance of skill, Understanding the consumer, market through consumer behavior, market survey, Methods of Marketing, publicity and advertisement
Self Employment:
Need and scope for self-employment, Qualities of a good Entrepreneur (values attitude, motive, etc.), SWOT and Risk Analysis
Govt Institutions :
Role of various Schemes and Institutes for self-employment i.e. DIC, SIDBI, MSME, NSIC, Financial institutions and banks
Initiation Formalities :
Project Formation, Feasibility, Legal formalities i.e., Shop Act, Estimation & Costing, Investment Procedure - Loan Procurement - Agencies - banking Process
5. Productivity
Hour of Instruction: 10 Hrs.Marks Allotted: 05
Productivity
Definition, Necessity, Meaning of GDP.
64
Benefits
Personal / Workman – Incentive, Production linked Bonus, Improvement in living standard. Industry Nation.
Affecting Factors
Skills, Working Aids, Automation, Environment, Motivation How improves or slows down.
Comparison with developed countries
Comparative productivity in developed countries (viz. Germany, Japan and Australia) in selected industries e.g. Manufacturing, Steel, Mining, Construction etc. Living standards of those countries, wages.
Personal Finance Management
Banking processes, Handling ATM, KYC registration, safe cash handling, Personal risk and Insurance.
6. Occupational Safety, Health & Environment Hour of Instruction: 15 Hrs.Marks Allotted: 06
Safety & Health :
Introduction to Occupational Safety and Health and its importance at workplace
Occupational Hazards :
Occupational health, Occupational hygiene, Occupational Diseases/ Disorders & its prevention
Accident & safety :
Accident prevention techniques- control of accidents and safety measures
First Aid :
Care of injured & Sick at the workplaces, First-aid & Transportation of sick person
Basic Provisions :
Idea of basic provisions of safety, health, welfare under legislation of India
7.Labour Welfare Legislation
Hour of Instruction: 05 Hrs.Marks Allotted: 03 Labour Welfare
Legislation Benefits guaranteed under various acts- Factories Act, Apprenticeship Act, Employees State Insurance Act (ESI), Payment Wages Act, Employees Provident Fund Act, The Workmen‟ s Compensation Act
65
8.Quality Tools Hour of Instruction: 10 Hrs.Marks Allotted: 05
Quality Consciousness :
Meaning of quality, Quality Characteristic
Quality Circles :
Definition, Advantage of small group activity, objectives of Quality Circle, Roles and Functions of Quality Circles in organisation, Operation of Quality Circle, Approaches to Starting Quality Circles, Steps for Continuation Quality Circles
Quality Management System:
Idea of ISO 9000 and BIS systems and its importance in maintaining qualities.
House Keeping :
Purpose of Housekeeping, Practice of good Housekeeping.5S Principles of Housekeeping: SEIRI – Segregation, SEITON – Arrangement, SEISO – Cleaning, SEIKETSU – maintenance of Standards, SHITSUKE - Discipline
66
12. INFRASTRUCTURE
Instructors Qualification
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
10th
Passed + NTC/NAC in the Trade of “Mechanic
Motor Vehicle)” with 3 years post qualification experience in
the relevant field and should possess valid LMV driving license.
and b) With “National Crafts Instructor Certificate”.
2. DESIRABLE QUALIFICATION : Preference will be given to a candidate with CIC
(Craft Instructor Certificate) in MMV trade.
3. SPACE NORMS :Space Area 210 Sq. Mt. (Including parking area)
4. POWER NORMS : 4.8 KW
5.TOOLS, EQUIPMENT& GENERAL
MACHINERY : (AS PER ANNEXURE-II)
Note:
(i) Out of two Instructors required for the unit of 2(1+1), one must have
Degree/Diploma and other must have NTC/NAC qualifications. (ii) Instructor qualification for WCS and E.D, as per the training manual.
(iii) The list of Tools, Equipment& General Machinery listed in Annexure – II are for a
particular trade (Mechanic Motor Vehicle) comprising of four semesters and not for single
semester.
67
13. ASSESSMENT STANDARD
13.1Assessment guideline:
Appropriate arrangements should be made to ensure that there will be no artificial barriers to assessment. The nature of special needs should be taken into account while undertaking assessment. Due consideration to be given while assessing for team work, avoidance/reduction of scrap/wastage and disposal of scarp/wastage as per procedure, behavioral attitude, sensitive to environment and regularity in training. The sensitivity towards OSHE and self-learning attitude to be considered while assessing competency. The following marking pattern to be adopted while assessing: a) Weightage in the range of 60-75% to be allotted during assessment under following performance level: For performance in this grade, the candidate with occasional guidance and showing due regard for safety procedures and practices, has produced work which demonstrates attainment of an acceptable standard of craftsmanship. In this work there is evidence of: demonstration of good skill in the use of hand tools, machine tools and workshop equipment below 70% tolerance dimension achieved while undertaking different work with those
demanded by the component/job. a fairly good level of neatness and consistency in the finish occasional support in completing the project/job. b) Weightage in the range of above75%- 90% to be allotted during assessment under following performance level: For this grade, the candidate, with little guidance and showing due regard for safety procedures and practices, has produced work which demonstrates attainment of a reasonable standard of craftsmanship. In this work there is evidence of: good skill levels in the use of hand tools, machine tools and workshop equipment 70-80% tolerance dimension achieved while undertaking different work with those
demanded by the component/job. a good level of neatness and consistency in the finish little support in completing the project/job c) Weightage in the range of above 90% to be allotted during assessment under following performance level: For performance in this grade, the candidate, with minimal or no support in organization and execution and with due regard for safety procedures and practices, has produced work which demonstrates attainment of a high standard of craftsmanship.
In this work there is evidence of: high skill levels in the use of hand tools, machine tools and workshop equipment above 80% tolerance dimension achieved while undertaking different work with those
demanded by the component/job. a high level of neatness and consistency in the finish. minimal or no support in completing the project
68
13.2. INTERNAL ASSESSMENTS (FORMATIVE ASSESSMENT)
SL COMP.
NO.
ASSESSABLE OUTCOME INTERNAL
ASSESSMEN
T MARKS
1. Apply safe working practices in an automotive work shop
2. Comply environment regulations and housekeeping in the work shop.
3. Perform precision measurements on the components and compare
parameters with specifications used in automotive work shop practices.
4. Make choices to carry out marking out the components for basic fitting
operations in the work shop.
5. Use different types of tools and work shop equipment in the Auto work
shop.
6. Use of different type of fastening and locking devices in a vehicle
7. Perform basic fitting operations used in the work shop practices and
inspection of dimensions.
8. Grinding of cutting tools in the work shop.
9. Perform surface finishing operations in the given job.
10. Produce sheet metal components using various sheet metal operations
11. Produce components using bending process in the given work piece.
12. Inspect the auto component using Nondestructive testing methods
13. Manufacture components with different types of welding processes in the
given job.
14. . Identify the hydraulic and pneumatic components in a vehicle.
15. Construct electrical circuits and test its parameters by using electrical
measuring instruments.
16. Perform basic electrical testing in a vehicle.
17. Perform battery testing and charging operations.
18. Construct basic electronic circuits and testing
Sub-Total of Internal assessment for Semester- I 100
19. Identify and check functionality of Dashboard Gauges & engine
performance.
20. Overhauling of Diesel Engine.
21. Servicing of Cooling and Lubrication system
22. Service Intake and Exhaust System
23. . Service Diesel Fuel System
24. Check and adjust Engine Emissions
25. Overhauling Charging and Starting System
26. Diagnose and Troubleshoot Diesel Engines
Sub-Total of Internal assessment for Semester- II 100
27. Identify and check functionality of major components and assemblies of
heavy vehicle
28. Interpret & use company technical information of Heavy vehicle
Manufactures
69
29. Carry Out overhauling light vehicle /Heavy vehicle transmission system
30. Record information of overhauling light vehicle /Heavy vehicle transmission
system
31. Trouble shooting of transmission system
32. Identify and check functionality of auto transmission components
33. Carry out automatic transmission adjustments.
34. Carryout overhauling of light vehicle /Heavy vehicle chassis system
including steering, suspension and braking system
35. Record information of overhauling of light vehicle /Heavy vehicle chassis
system including steering, suspension and braking system
36. Carry out steering and Brake adjustments
37. Trouble shooting of Steering, suspension and braking system
38. Carry out removal and replacement activities of tyres and tubes of light &
Heavy vehicle.
39. Balance wheels and carry out final checks on the vehicle
40. Record information about removal and replacement activities tyres and
tubes of light & Heavy vehicle
41. Trouble shooting of wheel and tyres
42. Trouble shooting of Engine system with Heavy vehicle
Sub-Total of Internal assessment for Semester- III 100
43. Identify the components of petrol engine
44. Identify and check functionality of Dashboard Gauges & engine
performance on petrol engine
45. Overhaul the Petrol Engine
46. Carryout repairs in the fuel feed system
47. Perform engine tune up
48. Identify the various components of MPFI petrol engine
49. Check functionality of MPFI Components
50. Identify and check functionality of various sensors installed in engine,
Gauges and instruments on dashboard
51. Find the trouble in electronic circuit and rectify using scan tool
52. Diagnose and Troubleshoot Petrol Engines
53. Troubleshoot the Charging System
54. Troubleshoot the Starting System
55. Troubleshoot the Lighting circuit
56. Identify the components of Air condition system
57. Diagnose and Troubleshoot the AC system
58. Diagnose and troubleshoot the electrical system accessories
59. Safe Driving practice
Sub-Total of Internal assessment for Semester- IV 100
Total of Internal assessment 400
70
13.3 FINAL ASSESSMENT- ALL INDIA TRADE TEST (SUMMATIVE ASSESSMENT)
a) There will be a single objective type Examination paper for the subjects Engineering
drawing and Workshop Calculation & Science.
b) There will be a single objective type Examination paper for the subjects Trade Theory
and Employability Skills.
c) The two objective type Examination papers as mentioned above will be conducted by
National Council for Vocational Training (NCVT), whereas examination for the subject
Trade Practical will be conducted by the State Government. NCVT shall supply the
Question Paper for the subject Trade Practical.
Marking Pattern Sl.
No.
Subject for the trade test Maximum marks for the each subject
a) Practical 300
b) Trade Theory 200
Objective type Written test of 200 marks
(Trade Theory 150 marks & Employability Skills
50 marks) c) Employability Skills
d) Work shop Calculation and Science. 100
Objective Type Written test of 100 marks
(Engineering Drawing 50 marks & Work shop
Calculation and Science 50 marks) e) Engineering Drawing
f) Internal assessment 100
TOTAL: 700
71
14. LIST OF TRADE COMMITTEE MEMBERS Sl.
No
.
Name
S/Shri
Designation Organization Mentor
Council
Designation
1. A. Ramesh Professor IIT Chennai Chairman
2. TC Saravanabava DDG(AT) DGE&T, HQ, New Delhi Mentor
3. K Srinivasa Rao JDT CSTARI, Kolkata Team Leader
4. Yuvaraj C DDT ATI, Chennai Member
5 V.Krishna Shankar GM Ashok Leyland Member
6 G.Sathiskumar Senior Mgr Ashok Leyland Member
7 Dr.Abhjit KR Mandal Consultant NATRIP Member
8 M.Sivaraman Consultant Delphi TVS Member
9 Mohan Kumar Manager TAFE, Chennai Member
10 Kanchi Purushotham, Manager Quality Prabha Engineers, Hosur Member
11 Sunil Bagwe, Paint shop Head Prabha Engineers, Hosur Member
12 G.M.Cholanrajan Sr.Manager-
Technical Training
Lanson Toyota, Chennai-107 Member
13 Sunil Kumar S.R, Assistant Manager Toyota Kirloskar Motor Pvt Ltd
Karnataka, 562 109
Member
14 Shri S.Arul Selvan Asst Professor Dept Auto Engg, M.I.T, Anna University,
Chennai.
Member
15 Shri S. Jayaraj, Asst Professor Dept Auto Engg, M.I.T, Anna University,
Chennai.
Member
16 Shri R. Lakshmanan Training Mgr Bosch Ltd, Bangalore Member
17 Shri V.Vadivelan Consultant NATRIP, Global Automotive Research
centre, Chennai
Member
18 Shri B. Gridharan Managing Director Visa Diesel Service, Chennai Member
19 Shri VKR. Vadivelan President Two Wheeler workshop owners
Association, Chennai
Member
20 P. Marveldass, DDT (Electronics) ATI, Chennai Member
21 Swamy S.M ,. Senior Officer,
Training Dept
Toyota Kirloskar Motor Pvt Ltd
Karnataka, 562 109
Member
22 Shri Suresh Babu Service Manager,
Body & Paint shop
ABT Maruti, Chennai-32 Member
23 M. Veerasamy Works Manager Vishnu Cars Pvt Ltd, Chennai-43 Member
24 P.Senthil Kumar, Service Manager DSC Motor Pvt Ltd., Chennai-15 Member
25 Shri T.Selvan, Manager Body
shop
DSC Motor Pvt Ltd., Chennai-15 Member
26 G Venkatesh ADT ATI(V), Hyderabad Member
27 SP Rewaskar ADT ATI(V), Hyderabad Member
28 N Ramesh kumar TO CTI, Chennai Member
29 R Rajeshkanna TO ATI, Chennai Member
30. Akhilesh Pandey TO ATI, Mumbai Member
31 TN Rudra TO ATI, Howrah Member
32 A. Duraichamy Assistant Training Officer (ATO)
Govt ITI Coimbatore Member
33 Gurcharan Singh, ADT ATI, Ludhiana Member
34 O.R. Arjun Mohan, AE Agricultural Engg. Dept, Chennai Member
35 R.Murugesan, AE Agricultural Engg. Dept, Chennai Member
72
36 K.Thaniyarasu ATO Govt ITI Trichy Member
37 W. Nirmal Kumar Israel ATO Govt ITI Trichy Member 38. N. Duraimurugan ATO Govt ITI Guindy Member 39. K. Ravindranath ATO Govt. ITI, Ambattur Member 40. K. Veerappan ATO Govt. ITI, Nagapattinam Member 41 V.Palanikumar ATO Govt ITI, Pudukottai. Member 42 H.S.Kalra Principal Govt ITI Chandigarh Member
43 B Ramarao ATO Govt ITI, Vizag , AP Member
44 Suresh Naik ATO Govt ITI, Mangalore , Karnataka Member
45 ND Zaware Principal ITI, Pimpri-Chinchwad Member
46 RM Gotmare TO ITI, Gowandi, Maharastra Member
47 Pranjit Das, DDT Govt ITI Assam Member
48 M. Madaswamy Principal Ramco, ITC, Rajapalayam, TN Member
49 Damachadramouli Agricultural Er SFMT & TI Hyderabd Member
50 V. Gopalakrishnan Training Officer, Co-ordinator, NIMI, Chennai.
73
Annexure - I
TRADE: Mechanic Motor Vehicle
LIST OF TOOLS & EQUIPMNT
A. TRAINEES TOOL KIT per 4 Trainees FOR 20 TRAINEES +1 ISTRUCTOR
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
mm set of 28 pieces with box
6
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. AC alternator slip ring puller 1
2. Adjustable spanner (pipe wrench 350 mm) 2
3. Air blow gun with standard accessories 1
4. Air Brake Assembly 1.
5. Air impact wrench with standard accessories 4
6. Air ratchet with standard accessories 4
7. Allen Key set of 12 pieces (2mm to 14mm) 4
8. Alternator assembly used for LMV 2
9. Ammeter 300A/ 60A DC with external shunt 4
10. Angle plate adjustable 250x150x175 1
11. Angle plate size 200x100x200mm 2
12. Anti theft device 1
13. Anvil 50 Kgs with Stand 1
14. Auto Electrical test bench 1
15. Battery –charger 2
16. Belt Tensioner gauge 1
17. Blow Lamp 1 litre 2
18. Caliper inside 15 cm Spring 4
74
19. Calipers outside 15 cm spring 4
20. Car Jet washer with standard accessories 1
21. Carburetor – Solex, Mikuny for dismantling and assembling 1 each
22. Carburetor repair tool kit 1
23. Chain Pulley Block-3 ton capacity with tripod stand 1
24. Chisel 10 cm flat 4
25. Chisels cross cut 200 mm X 6mm 4
26. Circlip pliers Expanding and contracting type 15cm and 20cm each 4
27. Clamps C 100mm 2
28. Clamps C 150mm 2
29. Clamps C 200mm 2
30. Cleaning tray 45x30 cm. 4
31. Coil spring compressor for suspension spring 1
32. Compression testing gauge suitable for diesel Engine with standard
accessories
2
33. Connecting rod alignment fixture 1
34. Constant Mesh Gear box with stand for Dismantling and assembly. 1
35. Copper bit soldering iron 0.25 Kg 4
36. Cut section Model of Mock layout of a motor car –electrical system
working model
1 set
37. Cut section models of shock absorbers 1
38. Cut section of cross ply and radial tyres 1
39. Cut section working model of automatic transmission Gear box 1
40. Cut section working model of centrifugal clutch assembly. 1
41. Cut section working model of Diaphragm clutch assembly. 1 42. Cut section working model of Single plate clutch assembly. 1
43. Cylinder bore gauge capacity 20 to 160 mm 4
44. Cylinder liner- Dry & wet liner, press fit & slidefit liner 1 each
45. DC Ohmmeter 0 to 300 Ohms, mid scales at 20 Ohms 2
46. Demonstration board of 2W Ignition system, ignition coil 1
47. Demonstration board of electronic Ignition system, ignition coil 1
48. Demonstration board of MPFI system 1
49. Depth micrometer 0-25mm 4
50. Dial gauge type 1 Gr. A (complete with clamping devices and with
magnetic stand)
4
51. Different type of Engine Bearing model 1 set
52. Different type of piston model 1each
53. Disk brake with caliper assembly 2
54. Distributor –Duel advance type, reluctance type 1 each
55. Dividers 15 cm Spring 4
56. Drift Punch Copper 15 Cm 4
57. Drill point angle gauge 1
58. Drill twist 1.5 mm to 15 mm (various sizes) by 0.5 mm 4
59. Drum brake assembly 1
60. Electric Soldering Iron 230 V 60 watts 230 V 25 watts 2 each
61. Electric testing screw driver 4
62. Engineer‟s square 15 cm. Blade 4
63. Engineers stethoscope 1
75
64. Executive Auto Electrical tool kit 1
65. Feeler gauge 20 blades (metric) 4
66. File flat 20 cm bastard 4
67. File, half round 20 cm second cut 4
68. File, Square 20 cm second cut 4
69. File, Square 30 cm round 4
70. File, triangular 15 cm second cut 4
71. Files assorted sizes and types including safe edge file (20 Nos) 2 set
72. Flat File 25 cm second cut 4
73. Flat File 35 cm bastard 4
74. Front axle ( Rzeeppa Joint) with stand for Dismantling and assembly 1
75. Fuel feed pump for diesel 1
76. Fuel injection pump (Diesel) inline 1
77. Fuel injection pump dismantling tool kit /Universal Vice 1
78. Fuel injection pump, VE pump / Distributor fuel rotary pump (DPC)
pumps / along with special tools and accessories.
1 each
79. Full floating axle and semi-floating axle assembly 1
80. Functional/experiment model of different type of sensors. 1 set
81. Garage stand 4
82. Gloves for Welding (Leather and Asbestos) 5 sets
83. Glow plug tester 2
84. Granite surface plate 1600 x 1000 with stand and cover 1
85. Grease Gun 2
86. Grease Gun heavy duty trolley type 10 kg capciaty 1
87. Growler 2
88. Hacksaw frame adjustable 20-30 cm 10
89. Hammer Ball Peen 0.75 Kg 4
90. Hammer Chipping 0.25 Kg 5
91. Hammer copper 1 Kg with handle 4
92. Hammer Mallet 4
93. Hammer Plastic 4
94. Hand operated crimping tool (i) for crimping up to 4mm and (ii) for crimping up to 10mm
2
95. Hand reamers adjustable 10.5 to 11.25 mm, 11.25 to 12.75 mm, 12.75 to 14.25 mm and 14.25 to 15.75 mm
1 sets
96. Hand Shear Universal 250mm 2
97. Hand vice – 37 mm 2
98. Hollow Punch set of seven pieces 6mm to 15mm 2 sets each
99. Horn and Horn relay 2
100. Impact screw driver 2
101. Injector – Multi hole type, Pintle type 4 each
102. Injector cleaning unit 1
103. Injector testing set (Hand tester) 1
104. Insulated Screw driver 20 cm x 9mm blade 4
105. Insulated Screw driver 30 cm x 9mm blade 4
106. Left cut snips 250mm 4
107. Lifting jack screw type 3 ton, 5ton & 20 Ton capacity 1 each
76
108. Magneto spanner set with 8 spanners 1 set
109. Magnifying glass 75mm 2
110. Marking out table 90X60X90 cm. 1
111. Multimeter digital 5
112. Multi-point fuel injection pump 2
113. Oil can 0.5/0.25 liter capacity 4
114. Oil pump for dismantling and assembling. 2
115. Oil Stone 15 cm x 5 cm x 2.5 cm 1
116. Oscilloscope 20MHz 1
117. Outside micrometer 0 to 25 mm 4
118. Outside micrometer 25 to 50 mm 4
119. Outside micrometer 50 to 75 mm 1
120. Outside micrometer 75 to 100 mm 1
121. Petrol nozzle 2
122. Philips Screw Driver set of 5 pieces (100 mm to 300 mm) 2
123. Pipe cutting tool 2
124. Pipe flaring tool 2
125. Piston ring compressor 2
126. Piston Ring expander and remover. 2
127. Piston Ring groove cleaner. 2
128. Pliers combination 20 cm. 2
129. Pliers flat nose 15 cm 2
130. Pliers round nose 15 cm 2
131. Pliers side cutting 15 cm 2
132. Portable electric drill Machine 1
133. Prick Punch 15 cm 4
134. Punch Letter 4mm (Number) 2 set
135. Radiator cut section-cross flow 1
136. Radiator cut section-down flow 1
137. Radiator pressure cap 2
138. Rear axle full floating type with stand for Dismantling and assembly 1
139. Right cut snips 250mm 2
140. Rivet sets snap and Dolly combined 3mm, 4mm, 6mm 2
141. Scraper flat 25 cm 2
142. Scraper half round 25 cm 2
143. Scraper Triangular 25 cm 2
144. Scriber 15 cm 2
145. Scriber with scribing black universal 2
146. Set of stock and dies – Metric 2 sets
147. Shear Tin Man‟s 450 mm x 600mm 2
148. Sheet Metal Gauge 2
149 Sher Tinmans 300mm 4
150 Soldering Copper Hatchet type 500gms 2
151 Solid Parallels in pairs (Different size) in Metric 2
152 Spanner Clyburn 15 cm 1
153 Spanner D.E. set of 12 pieces (6mm to 32mm) 4
154 Spanner T. flocks for screwing up and up-screwing inaccessible positions
2
155 Spanner, adjustable 15cm. 2
77
156 Spanner, ring set of 12 metric sizes 6 to 32 mm. 4
157 Spanners socket with speed handle, T-bar, ratchet and universal upto
32 mm set of 28 pieces with box
2
158 Spark lighter 2
159 Spark plug spanner 14mm x 18mm x Size 2
160 Starter motor axial type, pre-engagement type & Co-axial type 1each
161 Steel measuring tape 10 meter in a case 4
162 Steel rule 15 cm inch and metric 4
163 Steel rule 30 cm inch and metric 4
164 Steering assembly - 1.Rack & pinion, 2.Worm & roller 3. Recirculating
ball, 4.Power steering
1 each
165 Straight edge gauge 2 ft. 2 166 Straight edge gauge 4 ft. 2
167 Stud extractor set of 3 2 sets
168 Stud remover with socket handle 1
169 Surface gauge with dial test indicator plunger type i.e. 0.01 mm 4
170 Synchronous Gear box with stand for Dismantling and assembly. 1
171 Tachometer (Counting type) 1
172 Tandem master cylinder with booster 4
173 Taps and Dies complete sets BSF 1 set
174 Taps and wrenches - metric 2 sets
175 Telescope gauge 4
176 Temperature gauge with sensor 0-100 deg c 2
177 Tester sparking plug „NEON‟ Type 1
178 Thermostat 2
179 Thread pitch gauge metric, BSW 2
180 Timing lighter 2
181 Toe-in, toe-out gauge 1set
182 Torque wrenches 5-35 Nm, 12-68 Nm & 50-225 Nm 1 each
183 Trammel 30 cm 2
184 Tread wear indicator 1
185 Tubed tyre of car, trucks & motorcycle 1
186 Tubeless tyre of cars & trucks 1
187 Tubeless tyre repair kit
188 Turbocharger cut sectional view 1
189 Tyre & split rim wheel assembly 1
190 Tyre pressure gauge with holding nipple 2
191 Universal puller for removing pulleys, bearings 1
192 V‟ Block 75 x 38 mm pair with Clamps 2
193 Vacuum assisted hydraulics brake assembly with vacuum booster 1
194 Vacuum gauge to read 0 to 760 mm of Hg. 2
195 Valve Lifter 1
196 Valve spring compressor universal. 1
197 vernier caliper 0-300 mm with least count 0.02mm 4
198 Vice grip pliers 2
199 Water pump for dismantling and assembling 4
200 Wheel cylinder 4
201 Wiper motor assembly 2
78
202 Wire Gauge (metric) 2
203 Work bench 250 x 120 x 60 cm with 4 vices 12cm Jaw 4
204 Working Model of power windows 1
205 Working model of torque converter 1
206 4 Point relays 2
207 5 Point relays 2
C. General Installation/ Machineries
Sl.No. Item with specification Qty (Nos.)
1. Air bag simulator 1
2. Air conditioned CRDI Vehicle in running condition -LMV 1
3. Air conditioning service Unit (Car) 1
4. Air conditioning trainer kit 1
5. Arbor press hand operated 2 ton capacity 1
6. Automotive exhaust 5 gas analyzer (petrol & Diesel) or Diesel Smoke
Meter
1
7. Bench lever shears 250mm Blade x 3mm Capacity 1
8. Diesel Engine – CRDI - 4 stroke for Dismantling and assembling with
swivelling stand
9. Diesel engine ( Running condition ) Stationary type 1
10. Discrete Component Trainer / Basic Electronics Trainer 1
11. Drilling machine bench to drill up to 12mm dia along with accessories 1
12. Dual Magnetization Yoke : AC / HWDC, 230 VAC, 50Hz 1 set
13. Four stroke petrol engine with CNG setup-working condition 1
14. Gas Welding Table 1220mm x760mm 2
15. Grinding machine (general purpose) D.E. pedestal with 300 mm dia
wheels rough and smooth
1
16. Hand operated Hydraulic press 1
17. Heavy Commercial vehicle type (without body on frame) 1
18. Hydraulic jack HI-LIFT type -3 ton capacity, and 5 Ton capacity 1 each
19. Liquid penetrant Inspection kit 1 set
20. MPFI petrol engine with swiveling stand along with special tools for
dismantling and assembling
1
21. Multi Scan Tool with oscilloscope 1
22. Petrol Engine(2-stroke) Motor Cycle/Scooter along with special tools
and accessories
1
23. Pipe Bending Machine (Hydraulic type) 12mm to 30mm 1
24. Pneumatic rivet gun with standard accessories 2
25. Spring tension tester 1
26. Tin smiths bench folder 600 x 1.6mm 1
27. Transfer case with stand for Dismantling and assembly. 1
79
28. Trolley type portable air compressor single cylinder with 45 liters
capacity Air tank, along with accessories & with working pressure 6.5
kg/sq cm
1
29. Tube/ tyre vulcanizing machine 1
30. Two post car lift – capacity 4000 kg 1
31. Tyer Changer Machine 1
32. Ultrasonic Injection cleaning equipment 1
33. Welding plant Oxy-Acetylene complete ( high pressure) 1
34. Welding Transformer ( 150-300 Amps) 1
35. Wheel alignment Machine –computerised 3D 1
36. Wheel balancing machine 1
37. Working Condition of Diesel Engine – CRDI - 4 stroke Engine
Assembly with fault simulation board
1
38. Working Condition of Petrol MPFI Engine Assembly with fault
simulation board
1
D. List of consumable:
Sl.
No.
Description Quantity
1. Automatic Transmission oils As required
2. Battery- SMF As required 3. Brake fluids As required
4. Chalk, Prussian blue. As required
5. Chemical compound for fasteners As required
6. Diesel As required
7. Different type gasket material As required
8. Different type of oil seal As required
9. Drill Twist (assorted) As required
10. Emery paper - 36–60 grit , 80–120 As required 11. Engine coolant As required
12. Engine oil As required 13. Gear oils As required
14. Gloves for Welding (Leather and Asbestos) 5 sets 15. Hacksaw blade (consumable) As required 16. Hand rubber gloves tested for 5000 V 5 pair 17. Holders, lamp teakwood boards, plug sockets,
solders, flux wires and cables batteries round
consumable blocks and other consumables as required
As required
18. Hydrometer 4 19. Lapping abrasives As required
20. Leather Apron 5 21. Petrol As required
22. Power steering oil As required
23. Radiator Coolants As required
24. Safety goggles As required 25. Steel wire Brush 50mmx150mm 5
80
E. Workshop Furniture
Sl.
No.
Description Quantity
1. Book shelf (glass panel) 6½ „ x 3‟ x 1½‟ 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 2½ „ 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
11. Multimedia DVD for Automotive application/subjects
As required
12. Online UPS 2KVA 1
13. Stools 21
14. Storage Rack 6½ „ x 3‟ x 1½‟ As required
15. Storage shelf 6½ „ x 3‟ x 1½‟ As required.
16. Suitable class room furniture As required
17. Suitable Work Tables with vices As required
18. Tool Cabinet - 6½ „ x 3‟ x 1½‟ 2
19. Trainees locker 6½ „ x 3‟ x 1½‟ 2 Nos. to accommodate 20 Lockers
81
ANNEXURE-II
GUIDELINES FOR INSTRUCTORS AND PAPER SETTERS
1. Allthequestionsoftheorypaperforthetradewillbeinobjectivetypeformat.
2.Due care to be taken for proper & inclusive delivery among the batch. Some of the
following method of delivery may be adopted:
A) LECTURE
B) LESSON
C) DEMONSTRATION
D) PRACTICE
E) GROUP DISCUSSION
F) DISCUSSION WITH PEER GROUP
G) PROJECT WORK
H) INDUSTRIAL VISIT
3. Maximum utilization of latest form of training viz., audio visual aids, integration
of IT, etc. May be adopted.
4. The total hours to be devoted against each topic may be decided with due
diligence to safety & with prioritizing transfer of required skills.
5. Questions may be set based on following instructions:-
Sl.
No.
Question on different
aspect
Weightage in %age Key Words may be like
1 Information received 25 What, Who, When
2 Knowledge 50 Define, Identify, Recall, State, Write, List & Name
3 Understanding 15 Describe, Distinguish, Explain, Interpret & Summarize
4 Application 10 Apply, Compare, Demonstrate, Examine, Solve & Use
6. Due weightage to be given to all the topics under the syllabus while setting
the question paper.