mechanic motor vehicle -...

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

3

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

4

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.

5

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)

6

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.

7

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.

8

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.

9

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

10

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

11

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%.

12

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

13

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

14

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.


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.


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

16

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.

17

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

18

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

19

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


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


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


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


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


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


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


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


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



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.


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



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.



Semester-IV

ASSESSABLE OUTCOME ASSESSMENT CRITERIA

43. Identify the components of

petrol engine

43.1Identify the components of given petrol engine and

its function


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


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


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




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


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




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


functionality of various sensors

installed in engine, Gauges and

instruments on dashboard




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


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




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


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



57.2Plan 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




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

http://www.cdxetextbook.com/electrical/princ/fund/basicelectricity.html

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

http://www.cdxetextbook.com/electrical/princ/effects/heateffect.html

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

http://www.cdxetextbook.com/toolsEquip/workshop/lifting/jacks.html

http://www.cdxetextbook.com/toolsEquip/workshop/lifting/jacks.html

36

SYLLABUS FOR THE TRADE OF MECHANIC MOTOR VEHICLE Second Semester


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

http://www.cdxetextbook.com/engines/comp/vlves/oilseals.html

http://www.cdxetextbook.com/engines/comp/vlves/oilseals.html

http://www.cdxetextbook.com/engines/comp/vlves/intakevalves.html

http://www.cdxetextbook.com/engines/comp/vlves/variablevalvetiming.html

http://www.cdxetextbook.com/engines/comp/vlves/variablevalvetiming.html

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,

http://www.cdxetextbook.com/engines/lube/oil/viscosity.html

http://www.cdxetextbook.com/engines/lube/oil/oiladditives.html

http://www.cdxetextbook.com/engines/lube/oil/oiladditives.html

http://www.cdxetextbook.com/engines/lube/systems/lubesystem.html



http://www.cdxetextbook.com/engines/lube/systems/pressuresystem.html

http://www.cdxetextbook.com/engines/lube/systems/corrosion.html

http://www.cdxetextbook.com/engines/lube/sysComp/sump.html

http://www.cdxetextbook.com/engines/lube/sysComp/oiltank.html

http://www.cdxetextbook.com/engines/lube/sysComp/oiltank.html

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

http://www.cdxetextbook.com/fuelSys/intakeExhaust/exComp/catalyticconverters.html

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


26 NCVT Exam

41


Third Semester



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,

http://www.cdxetextbook.com/trans/clutchMan/manual/gearratios.html

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

http://www.cdxetextbook.com/steersusp/steer/boxesColumns/helix.html

http://www.cdxetextbook.com/steersusp/steer/boxesColumns/powersteer.html

http://www.cdxetextbook.com/steersusp/steer/boxesColumns/powersteer.html

http://www.cdxetextbook.com/steersusp/steer/boxesColumns/steeringprocess.html

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.

http://www.cdxetextbook.com/brakes/brake/brakes/replacerotor.html

http://www.cdxetextbook.com/brakes/brake/brakes/replacerotor.html

http://www.cdxetextbook.com/brakes/brake/brakes/repbrakelinings.html

http://www.cdxetextbook.com/brakes/brake/comp/brakeforce.html

http://www.cdxetextbook.com/brakes/brake/disc/title.html

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


26 NCVT Exam

46


Fourth Semester



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.

http://www.cdxetextbook.com/electrical/chargStartLight/altCons/rotor.html

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.


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.


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 .

http://www.cdxetextbook.com/hvac/heatAir/princ/humidity.html

http://www.cdxetextbook.com/hvac/heatAir/fixedOrifice/fixedorifice.html

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


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.



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.



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.



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


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


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



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




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.