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SYLLABUS FOR THE TRADE

OF

MECH NIC MOTOR VEHICLE[Semester Pattern]

UNDERCRAFTSMAN TRAINING SCHEME (CTS)

Designed in– 2013

ByGovernment of India

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTEDirectorate General of Employment & Training

Ministry of Labour & EmploymentEN-81, Sector-V, Salt Lake City

Kolkata-700 091



2

List of trade committee members approved the syllabus of semester system for the tradeof “ Mechanic Motor Vehicle ” held at ATI, Chennai

Sl.No.

Name & Designation Representing Organisation Remarks

1 Shri R. Senthil Kumar, Director ATI, Chennai Chairman2 Shri S.Harinath Babu, Joint Director of Training ATI, Chennai Member

3 Shri E.Balakrishna, Ex_Joint Director of Training NIMI, Chennai Member4 Shri A.Suganthan, Assistant Training officer Govt, ITI, Arakkonam Member5 Shri N. Ramesh Kumar, Training Officer CTI, Chennai Member6 Shri T Nandagopal, Anna University, Chennai Member7 Shri K. Thaniyarasau, Assistant Training officer Govt . ITI, Trichy Member8 Shri P.K. Ramakrishnan Nair Ram international Industrial

Academy (p) Ltd, ChennaiMember

9 Shri S.Arul Selvan , Assistant professor Dept Auto Engg, M.I.T, AnnaUniversity, Chennai.

Member

10 Shri S. Jayaraj, Associate Professor Dept Auto Engg, M.I.T, AnnaUniversity, Chennai.

Member

11 Shri R. Lakshmanan Bosch Ltd, Bangalore Member12 Shri V.ChandraMohan NATRIP, Global Automotive

Research centre, ChennaiMember

13 Shri V.Vadivelan NATRIP, Global AutomotiveResearch centre, Chennai

Member

14 Shri A.D.Shewale Training Officer CTI, chennai Member15 Shri B. Gridharan Visa Diesel Service, Chennai Member16 Shri K.k.Valasarajan , Vice president Two Wheeler workshop owners

Association, ChennaiMember

17 Shri Jayapal, Two Wheeler workshopowners Association, Chennai

Member

18 Shri V. Vadivelan Two Wheeler workshop owners

Association, Chennai

Member

19 Shri Syedshwath Two Wheeler workshop ownersAssociation, Chennai

Member

20 P. Marveldass, Assistant Director of Training(Electronics)

ATI, Chennai Member

21 K. ArulSelvi, Training Officer (Electronics) ATI, Chennai Member22 Shri Gurcharan Singh, Assistant Director of

TrainingATI, Ludhiana Member

23 Shri O.R. Arjun Mohan, Assistant ExecutiveEngineer

Agricultural Engg. Dept,Chennai

Member

24 Shri R.Murugesan, Assistant Executive Engineer Agricultural Engg. Dept,Chennai

Member

25 Shri Ramakrishne Gowda, Assistant Director ofTraining

FTI, Bangalore Member

26 C.Yuvaraj, Assistant Director of Training ATI, Chennai Member



3

List of members attended the Workshop to finalize the syllabi of existing CTS into Semester Pattern held from 6 th to 10 th May’2013 at CSTARI, Kolkata.

Sl. No. Name & Designation Organisation Remarks1. R.N. Bandyopadhyaya, Director CSTARI, Kolkata-91 Chairman2. K. L. Kuli, Joint Director of Training CSTARI, Kolkata-91 Member3. K. Srinivasa Rao,

Joint Director of TrainingCSTARI, Kolkata-91 Member

4. L.K. Muhkerjee,Deputy Director of Training

CSTARI, Kolkata-91 Member

5. Ashoke Rarhi,Deputy Director of Training

ATI-EPI, Dehradun Member

6. N. Nath,Assistant Director of Training

CSTARI, Kolkata-91 Member

7. S. Srinivasu,

Assistant Director of Training

ATI-EPI, Hyderabad-13 Member

8. Sharanappa,Assistant Director of Training

ATI-EPI, Hyderabad-13 Member

9. Ramakrishne Gowda,Assistant Director of Training

FTI, Bangalore Member

10. Goutam Das Modak,Assistant Director of Trg./Principal

RVTI, Kolkata-91 Member

11. Venketesh. Ch. , Principal Govt. ITI, Dollygunj, Andaman & Nicobar Island

Member

12. A.K. Ghate, Training Officer ATI, Mumbai Member

13. V.B. Zumbre, Training Officer ATI, Mumbai Member14. P.M. Radhakrishna pillai,

Training OfficerCTI, Chennai-32 Member

15. A.Jayaraman, Training officer CTI Chennai-32, Member16. S. Bandyopadhyay, Training Officer ATI, Kanpur Member17. Suriya Kumari .K , Training Officer RVTI, Kolkata-91 Member18. R.K. Bhattacharyya, Training Officer RVTI, Trivandrum Member19. Vijay Kumar, Training Officer ATI, Ludhiana Member20. Anil Kumar, Training Officer ATI, Ludhiana Member21. Sunil M.K. Training Officer ATI, Kolkata Member22. Devender, Training Officer ATI, Kolkata Member23. R. N. Manna, Training Officer CSTARI, Kolkata-91 Member24. Mrs. S. Das, Training Officer CSTARI, Kolkata-91 Member25. Jyoti Balwani, Training Officer RVTI, Kolkata-91 Member26. Pragna H. Ravat, Training Officer RVTI, Kolkata-91 Member27. Sarbojit Neogi, Vocational Instructor RVTI, Kolkata-91 Member28. Nilotpal Saha, Vocational Instructor I.T.I., Berhampore, Murshidabad,

(W.B.)Member

29. Vijay Kumar, Data Entry Operator RVTI, Kolkata-91 Member



4

GENERAL INFORMATION

1. Name of the Trade : Mechanic Motor Vehicle

2.

N.C.O. Code No. :3. Duration of Craftsmen

Training: 2 Year (Four Semester)

4. Power Norms : 4.8 KW

5. Space Norms : 84 Sq. mtr. & Parking room 125 Sq. mt

6. Entry Qualification : Passed 10th class examination under 10+2 system ofeducation with Science and Mathematics or its equivalent.

7. Unit strength : 16

8. InstructorsQualification

: a) Degree in Automobile/Mechanical Engineering fromrecognized engg. college/university with one yearexperience in the relevant field

ORDiploma in Automobile/Mechanical Engg Fromrecognized board of technical education with two yearsexperience in the relevant field

OR10 th Passed + NTC/NAC in the Trade of “ MechanicMotor Vehicle) ” with 3 years post qualification

experience in the relevant field

b) Preference will be given to a candidate with CraftsInstructor Certificate (CIC)

* Note : At least one Instructor must have Degree/Diploma in Automobile/ Mechanical Engg.when applied for 02 units.



5

TRADE: “MECHANIC MOTOR VEHICLE ”FIRST SEMESTERSemester Code: MMV;SEM-I

WeekNo.

Trade Practical Trade Theory EngineeringDrawing

Workshopcalculation and

Science1 & 2 Admission &

introduction to the trade:Familiarization withinstitute, Job opportunitiesin the automobile sector,Machinery used in Trade.Types of work done by thestudents in the shop floor.

Introduction to thecourse duration,course contain,study of thesyllabus. Generalrule pertaining tothe Institute,facilities available

– Hostel,Recreation,Medical andLibrary workinghours and timetable

Units, Derivedand fundamental,types of systemFPS, CGS, MKSand theirconversion.Metric weightsandmeasurements,units conversionfactors

3 & 4 Practical related to Safetyand Health ,Demonstration on PPE(Personal ProtectionEquipments)

Interaction with healthcenter and fire servicestation to provide demo onFirst aid and Fire safety,Use of fire extinguishers.

OccupationalSafety & HealthBasic safetyintroduction,Personal

protection:-Basic injury

prevention, Basicfirst aid, Hazardidentification andavoidance, safetysigns for Danger,Warning, caution& personal safetymessage.emergencyevacuation

procedure, Safehandling of FuelSpillage, Use ofFire extinguishers,safe disposal oftoxic dust, safehandling andPeriodic testing oflifting equipment,Authorization ofMoving & road

testing vehicles,

Introduction toEngineeringdrawing and BluePrint Reading,Free handsketching ofstraight lines,rectangles,squares, circles,

polygons etc

CommonFractionsaddition,subtractionMultiplication andDivision ofCommonFractions SimpleShop problemsInvolvingFractions.



6

Environmentcontrol ofRunning indoorsengines, Safetydisposal of Usedengine oil,

Electrical safety practices.House Keeping –5S Concept.

5 Measuring practice onengine components withaid of instrument studied.

Systems ofmeasurement,conversion ofEnglish intometric Systems ofmeasurement &vice- versa. Description, care& use of :-Micrometers-Inside, Outsideand depthmeasurements,ThreadMicrometer,Micrometeradjustments,Vernier calipers,vernier depthgauge, vernierheight gaugeTelescope gages,Dial bore gauges,Dial indicators,vacuum gauge,tire pressuregauge.

Free handsketching ofVernier caliperand Micrometer,Dial gauge

Reduction ofcommon fractionsto decimalfractions-shop

problems.

Definition ofleast count,Accuracy,Calibration,

Derive the leastcount for Verniercaliper andMicrometer.

6 Practice using all marking

aids, like steel rule withspring calipers, dividers,surface gauges, scriber,

punches, Chisel etc.,Layout a work piece- forline, circle, arcs andcircles.

Practice on Generalworkshop tools & powertools and equipments.

Hand & Power

Tools:-Marking scheme,Marking material,Description, careand use of Surface

plates, steel rule,measuring tape,try square.Calipers, dividers,surface gauges,scriber, punches,

Chisel, Hammer,

Free hand

sketching of keyand screw threadswith dimensionsfrom samples.

Properties and

uses of cast iron,ferrous metal,gray cast iron,white cast iron,wrought iron, and

plain carbon steel,high speed steeland alloy steel.



7

Practice on visualIdentification of materialsused in workshop.

Screw-drivers,Allen key, Vices& clamps,Spanners, Sockets& accessories,Pliers, Wrenches,

air impact wrench,air ratchet, airchisel, air

blowgun, Torquewrenches, jetwashers andcleaners, Pipeflaring & cuttingtool, pullers,Cleaning tools &equipment.

7 Practice on Generalcleaning, checking and useof nut , bolts, & studs etc.,

Removal of stud/bolt from blind hole.

Fasteners- Studyof different typesof screws, nuts,studs & bolts,locking devices,Such as lock nuts,cotter, split pins,keys, Circlip, lockrings, lockwashers andlocating wherethey are used.Washers &chemicalcompounds can beused to helpsecure thesefasteners.Selection ofmaterials forgaskets and

packing,Description ofRiveting tools

Free handsketching withdimension ofsimple solid suchas cubes,rectangular

blocks, cylindersetc.

Use of scientificcalculator

8 Practice on cutting toolslike Hacksaw, file, chisel,OFF-hand grinding withsander, bench and pedestalgrinders, safety precautionswhile grinding.

Cutting tools :-Study of differenttype of cuttingtools likeHacksaw, File- Definition, partsof a file,specification,

Grade, shape,

Sketching ofviews of simplesolid bodies ascubes, rectangular

blocks, cylinderswhen viewed

perpendicular totheir surfaces and

axis.

Different Type ofcutting fluids andtheir properties.



8

different type ofcut and uses.,chisel, OFF-handgrinding withsander, bench and

pedestal grinders,

safety precautionswhile grinding.

9 Practice on Filing-filing toline-marking off-use ofcentre punch, dividers,calipers, steel rule etc.Filing true and square.

Limits, Fits &Tolerances :-Definition oflimits, fits &tolerances withexamples used inauto components.

-do- Properties anduses of copper,zinc, lead, tin,aluminum, brass,

bronze, solder bearing metals,timber and rubber.

Nylon, P.V.C., PP(poly prop line,

polymer)10 Practice on Marking and

Drilling clear and BlindHoles, Sharpening of TwistDrills Safety precautions to

be observed while using adrilling machine.Use of tap extractor

Drilling machine -Description andstudy of Benchtype Drillingmachine, Portableelectrical Drillingmachine, drillholding devices,Drill bits. HandTaps andwrenches,Calculation of Tapdrill sizes formetric and inchtaps. Differenttype of Die andDie stock.

Sketching ofFiles, drill bit.

Calculation ofcutting speed,feed and drillingtime.

11 Practice on Tapping aClear and Blind Hole,Selection of tape drill Size,

use of Lubrication, CuttingThreads on a Bolt/ Stud.Adjustment of two pieceDie, Reaming a hole/ Bushto suit the given pin/ shaft,scraping a given machinedsurface.

Hand Reamers –Different Type ofhand reamers,

Lapping, Lappingabrasives, type ofLaps. Function ofGaskets, oil seals,

Views of simplehollow and solid

bodies with

dimensions, use ofdifferent types oflines and symbolsfor drawing.

Brief descriptionof manufacturing

process of steel

copper, aluminumand P.V.C.



9

12 Visit to industries forobservation of materialtesting, casting and forging

process.

Mechanical properties ofmaterials, Tensile,Compressive &Temperaturestress,

Forging process &Casting Processes used in autocomponents withexamples . Classification of

steel, the effect ofalloying elementon steel

Free handsketching of rivetsand washers withdimensions fromsamples.

Ratios and proportions.

13 Practice on Arc welding,Gas welding, Resistancewelding.

Introduction toHeat treatment –Definition ofAnnealing,

Normalizing,Hardening andtempering. Casehardening,

Nitriding,Inductionhardening andFlame Hardening,

process used inauto componentswith examples.Introduction toMetallic and Non-metallic Coatings

Necessity ofmetallic and non-metallic coatings,

principles and processes of

electroplating,galvanizing,vacuumizing,metal spraying,

painting and theirapplications,

preparation of base materials.Uses of primers,

paints and finishcoatings, powder

coating and its

Sketching of Ironcarbon diagramFree hand sketchof weld symbols.

Importance Iron-carbon diagramMeaning oftenacity elasticity,malleability,

brittleness,hardness,compressibility &ductility and theirexamples.



10

advantages, withexamples used inauto components. Introduction toWeldingProcesses- Arc

welding, Gaswelding, GTAW(TIG), GMAW(MIG) &Resistancewelding.

14 Joining of metal parts bySoft Soldering ,Simple marking out on

sheet metal and cutting,Bending and folding.Practice in silver soldering,

pipe bending, NipplesUnions soldering andBrazing of pipes.

Sheet metalworker’s commonhand tools- theirnames anddescription ofsimple solderingand brazing fluxesused on common

joints. Sheet andwire-gauges. The

blow lamp- itsuses and pipefittings.Explanation of various commonmetal Sheets usedin Sheet Metalshop.

Drawing ofriveted joints, lapand Butt joints.

Definition of coldrolling and Hotrolling and its

properties onsheet metal.Advantage ofDeep drawingmaterial.

15 Practice in joining wiresusing soldering Iron,Construction of simpleelectrical circuits,Measuring of current,voltage and resistanceusing digital multimeter,

practice continuity test for

fuses, jumper wires, fusiblelinks, circuit breakers.

Basic electricity, Electricity

principles, Groundconnections,Ohm's law,Voltage, Current,Resistance, Power,Energy.

Voltmeter,ammeter,OhmmeterMulitmeter,Conductors &insulators, Wires,Shielding, Lengthvs. resistance,Resistor ratings

Free handsketching ofMillimeter,ammeter,voltmeter andtheir parts

Electricity and itseffects static anddynamicelectricity,AC and DCdifferences

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

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



12

for its functionality , Construct and test simplelogic circuits OR, AND &

NOT and Logic gates usingswitches.

Transistors,Thyristors, UniJunctionTransistors ( UJT),Metal Oxide FieldEffect Transistors

( MOSFETs),Logic gates-OR,AND & NOT andLogic gates usingswitches.

Electroniccircuits.

numberconversions,Simple set theory

problems likeUnion,Intersection and

Null sets

19 Introduction to centre lathesetting up work betweencenters. Use of side cuttingtools. Parallel turning andstepped turning.

Lathe :Introduction, typesof lathes,specifications,description andfunctions of lathe

parts,feed mechanism,drives andtransmission,work holdingdevices, turningtools, Latheoperations – plainturning, facing,centering, partingoff, undercutting,taper turning,eccentric turning,drilling, reaming,thread cutting andknurling, speedsand feeds of cut.

Free handSketching ofdifferent type ofcutting toolsBlock diagram oflathe and its parts.

Definition ofCutting speeds,feed and depth ofcut and theircalculation. Taperand threadcalculation.

20 Identification of Hydraulicand pneumaticcomponents.Tracing of hydraulic circuit

on hydraulic powersteering,hydraulic/Pneumatic pressand Brake circuit.

Introduction toHydraulics :-Definition of Pascal law,

pressure, Force,viscosity, effectof viscosity withrespect totemperature,MechanicalAdvantage withHydraulics,Description anduse of Gear pump-Internal &

External, Vane

Drawing ofhydraulic and

pneumaticsymbol.

Black Diagram ofHydraulic and pneumatic power pack unit.

Simple problemson work, energyand power.Simple piston

Force , velocitycalculation,General gasequation.



13

pump, Hydraulicmotor. Hydraulicsymbols.Description, useand application ofsingle acting,

double acting &Double endedcylinder;Directional controlvalves-3/2, 4/2,4/3 way valve,Pressure controlvalve, Non returnvalve, Flowcontrol valve inautomobile.Introduction toPneumatics: -Boyle’s law ,PneumaticSymbols,Description andfunction of airReciprocatingCompressor,function of Airservice unit (FRL-Filter, Regulator& Lubricator).

21 Practice on 5S Maintenance:Preventive,Periodical & breakdownmaintenance.Definition &importance ofQuality control,

Quality assurance,quality circle.Basic Concept ofTPM, TQM,& ISO 9000.

Drawing ofquality ofawareness sign

board.

Preparation ofMaintenanceschedule chart/week/month/year ly

22-23 Introduction to computerbasics :Basic of computer, MsWord, Ms Power Point,MS Excel

Familiarization & Identification of computer parts.Practice on computer for MS word, MS power point, MsExcel.



14

24 Identification of differenttype of engine components.

Introduction toEngine:Description ofinternal & externalcombustionengines different

types of I.C.Engines.Definition: -Classification ofvehicles on the

basis of load,wheels, finaldrive, and fuelused, axles,

position of engineand steeringtransmission, bodyand load.

Drawing of I .Cengine and their

parts.Layout of anautomobilechassis,

Vacuum and air pressure principles ,Pressure &temperature,Pressure &

volume,Temperature &energy,Understanding

power and torque.

25 Project Work / Industrial Visit (Optional)26 Examination



15

TRADE: “MECHANIC MOTOR VEHICLE ”SECOND SEMESTERSemester Code: MMV;SEM-II

Week No. Trade Practical Trade Theory EngineeringDrawing

Workshopcalculation

and science1 Identification of

different types ofVehicles

Auto Industry inIndia -History,leadingmanufacturers,development inautomobile industry,trends, new product.Basicthermodynamics

Use of drawinginstruments, T-square and drawing

board.Use of differenttypes of scales ininches andmillimeters

Mensuration -area ofrectangles,squares, tri-angles,circles,regular

polygons etc.calculation ofareas.

2 Identification of partsin a diesel engine.Practice on startingand stopping of dieselengines.Use of speed counterin determining theengine speed – runningof engine on load,checking temperaturefuel and oil.

Diesel EngineBasics: Introduction,Compression-ignition engines-Description ofBasic 4-stroke diesel

principles and cycle,Basic 2-stroke diesel

principles and cycle,Three phases ofcombustionCompression-ignition enginecomponents –Basic diesel enginecomponents, Dieselengine passages,Diesel fuel delivery,Direct injection,

Indirect injection,Diesel valves &components,scavenging,

Crankshaft rotation,crankshaft, Dieselengine pistons

Lettering number &alphabet

Free hand sketchingof 4 stroke cycles &2 stroke cycles ofengine

Calculationof HorsePower- IHP,FHP andapplied shop

problem.

Simple problemsstraight and

ball-crankedlevers.

3 Practice on Dieselengine cleaning,dismantling as per

procedure.

Principle of SparkIgnition engine,Differentiate

between C.I engine

and S.I Engine,

Explanation ofsimple Orthographic

projection- 1 st angle

Views of simple

Calculationof volumeand weight ofsimple solid

bodies such



16

4-stroke and 2strokes,Otto cycle andDiesel cycle.Different type ofstarting and stopping

method of DieselEngine.Engine output ,Power range.

hollow and solid bodies withdimensions.

as cubes,square andhexagonal

prism-shop problem.

4 Overhauling ofcylinder head assemblywith use of servicemanual for clearanceand other parameters:-Practice on removingrocker arm assemblymanifolds, cylinderhead from the engine.

Engine Components Description andConstructionalfeature of Cylinderhead, Importance ofCylinder headdesign, Type ofDiesel combustionchambers, Effect onsize of Intake &exhaust passages,Head gaskets.Importance ofTurbulence.

Explanation ofsimple orthographic

projection 3 rd angle.Simple isometricdrawings, isometricviews of simpleobjects, such assquare, rectangles,cubes , rectangular

blocks etc

Heat andtemperaturethermometricscaleFahrenheitandcentigradescales & theirconversion.Name & useoftemperaturemeasuringinstrumentsnormallyused inWorkshop.

5 Practice on removingthe valves and its partsfrom the cylinder head,cleaning &decarbonising.Inspection of cylinderhead and manifoldsurfaces for warping,cracks and flatness.checking valve seats &

valve guide –reconditioning valveseats and re-facingvalves- lapping valveson its seat- testingleaks of valve seats forleakage –Dismantle rocker shaftassembly -clean &check rocker shaft-andlevers, for wear and

cracks and reassemble.

Valves & ValveTrainsDescription andFunction of EngineValves, differenttypes, materials, Type of valveoperatingmechanism,Importance of Valve

seats , Valve seatsinserts in cylinderheads , importanceof Valve rotation ,Valve stem oil seals , size of Intake valves , Valve trains , Valve-timing diagram ,concept of Variablevalve timing . Description of

Camshafts & drives ,

Sketching valvetiming diagram.

Free hand sketch ofDifferent types ofcams and followers

Free hand sketchingof crank shaftshowing all parts.

Calculationof Enginedisplacement.Calculationof springstiffness

Shop problems ondetermination

of volume &weight ofsimple

bodies.

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









17

Check valve springs,tappets, push rods,tappet screws andvalve stem cap.Reassembling valve

parts in sequence, refit

cylinder head andmanifold & rocker armassembly, adjustablevalve clearances,starting engine afterdecarbonising.

Description of Overhead camshaft ,importance of Camlobes , Timing belts& chains , Timing

belts & tensioners .

6 & 7 Overhauling piston andconnecting rodassembly with use ofservice manual forclearance and other

parameters:-Practice on removingoil sump and oil pump

– clean the sumpPractice on removingthe big end bearing,connecting rod withthe piston.Practice on removingthe piston rings;Dismantle the pistonand connecting rod.Check the sideclearance of pistonrings in the pistongroove & lands forwear.Check piston skirt andcrown for damage andscuffing, clean oilholes.

Measure -the pistonring close gap in thecylinder, clearance

between the piston andthe liner, clearance

between crank pin andthe connecting rod bigend bearing.Check connecting rodfor bend and twist.Assemble the piston

and connecting rod

Description &functions ofdifferent types of

pistons, piston ringsand piston pins andmaterials. Usedrecommendedclearances for therings and itsnecessity

precautions whilefitting rings,common troublesand remedy.Compression ratio.

Description &function ofconnecting rod,importance of big-end split obliquely,Materials used forconnecting rods bigend & main

bearings. Shells piston pins and

locking methods of piston pins.

Free hand sketch of piston assembly,valve assembly.

Free hand isometricsketching of simpleobjects withdimensions.

Free hand sketchingof piston gudgeon

pins rings andconnecting rod withdimensions fromsamples

Calculationof volume,compressionratio, forceon the pistondue tocombustion

pressure,average

pistonvelocity,internal

power ofenginerespectingtwo or fourstroke,



18

assembly.

8 Overhauling ofcrankshaft with use ofservice manual forclearance and other

parameters:-Practice on removingdamper pulley, timinggear/timing chain,flywheel, main bearing

caps, bearing shellsand crankshaft t fromenginechecking oil retainerand thrust surfaces forwear, Measure crankshaft journal for wear,taper and ovality,Checking crankshaftfor fillet radii, bend &twist.

Description andfunction of Crankshaft, camshaft,Engine bearings-classification andlocation – materialsused & compositionof bearing materials-Shell bearing and

their advantages-special bearingsmaterial for dieselengine application

bearing failure & itscauses-care &maintenance.Crank-shaft

balancing, Firingorder of the engine.

Free hand sketchingof crankshaft andflywheels withdimensions fromsamples

Drafting of- Bush bearing- Split bearing

- Thrust bearing,- Ball bearing- Roller bearing –straight and needle.

calculation ofeffective

power oncrank shaft byusingmechanicalefficiency

Centre ofgravity ofbodies-stable& unstable,Neutrals &equilibrium-Examples &Problems onCentre of

gravity.9 Checking of flywheeland mounting flanges,spigot, bearing.Check vibrationdamper for defects,Practice on removingcam shaft from engine

block,Check for bend & twistof camshaft.

Inspection of camlobe, camshaft journalsand bearings andmeasure cam lobe lift.

Fixing bearing insertsin cylinder block &cap check nip andspread clearance & oilholes & locating lugsfix crank shaft on

block-torque bolts -

Description andfunction of the flywheel and vibrationdamper. Crank case& oil pump, gearstiming mark, Chainsprockets, chaintensioner etc.Function of clutch &coupling units

attached to flywheel.

Free hand sketchingof gears timingmark.

Simple leverswithexamples i. e.bell - cranklever & otherused inengine –Advantage inusing them.Problems on

lever.



19

check end play removeshaft - check seating,repeat similarly forconnecting rod andCheck seating andrefit.

10 Cleaning and Checkingof cylinder blockssurface for any crack,flatness,Measure cylinder borefor taper & ovality,clean oil gallery

passage and oil pipeline, Bore - descalewater passages andexamineRemoving cylinderliners from scrapcylinder block,

practice in measuringand refitting new linersas per maker’srecommendations

precautions whilefitting new liners.

Description ofCylinder block,Cylinder blockconstruction,Different type ofCylinder sleeves(liner).

Free hand sketchingof cylinder blockand cylinder headFree hand sketchingof cylinder linerswith dimensionsform sample

Definition ofstress, strainand modulusof elasticityultimatestrength typesof stresses-factor ofsafetyexamples.

11 Reassemble all parts ofengine in correctsequence and torqueall bolts and nuts asworkshop manual ofthe engine.Engine component

procedures -Testing cylindercompression , Checkingidle speed , Removing& replacing a cam belt ,

Inspecting & adjustingan engine drive belt ,Replacing an enginedrive belt.

Engine assembly procedure with aidof special tools andgauges used forengine assembling.Introduction to GasTurbine,Comparison ofsingle and two stageturbine engine,Different betweengas turbine and

Diesel Engine.

Free hand sketchingof plain andelevation of simpleobjects likehexagonal bar,square bar, circular

bar, tapered bar,hollow bar etc.

Simplecalculation ofstress,compressiveStrain,compressivestress (E),Shear stress(G), Tensilestrength,Factor ofsafety, and

Theallowableworkingstress.



20

12&13 Practice on Checking& adjusting coolant,Draining & refillingcoolant,Checking & replacinga coolant hose,

Testing cooling system pressure,Practice on Removing& replacing a radiator,thermostat.Inspect the radiator

pressure cap, Testingof thermostat.Cleaning & reverseflushing.Overhauling water

pump and refitting.

Need for Coolingsystems , Heattransfer method,Boiling point &

pressure, Centrifugalforce, Vehicle

coolant propertiesand recommendedchange of interval,Different type ofcooling systems,Basic coolingsystem components - Radiator, Coolanthoses, Water pump,Cooling systemthermostat, Coolingfans, Temperatureindicators, Radiator

pressure cap,Recovery system,Thermo-switch.

Free hand sketchingof different coolingsystem showing allnecessary parts.

Freehand sketching

of water pumpthermostatic valve &water jackets in thecylinder block.

Calculationof Volumetricefficiency,Torque VsEngine speed,Specific fuel

consumptionvs. enginespeed.

14 & 15 Practice on Checkingengine oil , Drainingengine oil , Replacingoil filter , Refillingengine oil .Overhauling of oil

pump, oil filters, oilcoolers, air cleanersand air filters andadjust oil pressurerelief valves, repairs tooil flow pipe lines andunions if necessary.

Need for lubricationsystem, Functions ofoil, Viscosity and itsgrade as per SAE ,Oil additives ,Synthetic oils, Thelubrication system ,Splash system ,Pressure system ,Corrosion/noisereduction in thelubrication system Lubrication systemcomponents -Description and

function of Sump , Oil collection pan ,Oil tank , Pickuptube , different typeof Oil pump & Oilfilters Oil pressurerelief valve , Spurtholes & galleries ,Oil indicators , Oilcooler.

Free hand sketchingof lubricationsystem, filters anddifferent types of oil

pump, pressurerelease valve.

Properties ofDiesel enginecylinderlubricatingoil.Definition ofemulsion,viscosityindex.

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


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21

16 Practice onDismantling aircompressor andexhauster and cleaningall parts - measuringwear in the cylinder,

reassembling all partsand fitting them in theengine.Dismantling &assembling ofturbocharger, check foraxial clearance as perservice manual.

Intake & exhaustsystems – Description of Diesel induction &Exhaust systems. Description &

function of aircompressor,exhauster, Supercharger,Intercoolers, turbocharger, variableturbo chargermechanism.Intake systemcomponents - Description andfunction of Aircleaners, Differenttype air cleaner,Description ofIntake manifolds andmaterial ,Exhaust systemcomponents -Description andfunction of Exhaustmanifold , Exhaust

pipe , Extractors ,Mufflers , Catalyticconverters , Flexibleconnections ,Ceramic coatings ,Back-pressure,Electronic mufflers .

Free hand sketchingof air cleaner &Turbochargersystem.

Machines- basic principles,determinationof velocityratio,

mechanicaladvantageandefficiency.

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


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




22

17 & 18 Practice on removing& Cleaning fuel tanks,checking leaks in thefuel lines,soldering & repairing

pipe lines and Unions,

brazing nipples to high pressure line studyingthe fuel feed system indiesel engines,draining of waterseparators.

Bleeding of air fromthe fuel lines,Servicing primary &secondary filters.

Dismantling fuelinjection pump, feed

pump governorstudying the parts andreassemble generalmaintenance of FuelInjection Pumps (FIP).

Removing a fuelinjection pump froman engine-refit the

pump to the engine re-set timing - filllubricating-oil start andadjust slow speed ofthe engine.

Practice onoverhauling ofinjectors and testing of

injector.

Diesel FuelSystems-Description andfunction of Dieselfuel injection, , fuelcharacteristics ,

concept of Quietdiesel technology &Clean dieseltechnology Diesel fuel systemcomponents – Description andfunction of Dieseltanks & lines , Dieselfuel filters , waterseparator, Lift pump ,Plunger pump ,Priming pump ,Inline injection

pump , Mechanicalor pneumaticgovernors ,Distributor-typeinjection pump ,Diesel injectors ,Glow plugs ,Cummins & DetroitDiesel injection.Electronic Dieselcontrol- ElectronicDiesel controlsystems , CommonRail Diesel Injection(CRDI) system ,Hydraulicallyactuatedelectronically

controlled unitinjector (HEUI)diesel injectionsystem. Sensors,actuators and ECU(Electronic ControlUnit) used in DieselEngines.

Free hand sketchingof fuel feed systemin diesel engines andfuel filters.

Free hand sketchingof different types ofinjectors.

Free hand sketchingof single element

plunger of fuelinjection pump

Freehand sketchingof water separatorsand fuel tanks withdimension fromsample.

Freehand sketchingof Distributor fuelinjection pump withdimension fromsamples.

Freehand sketchingof a pneumaticgovernor withdimensions fromsamples

Freehand sketchingof mechanicalgovernor withdimensions from

sample.

AlternateFuelSystems :-Bio -dieselfuel ,Importance of

Alternativefuels-Ethanol,Methanol,LiquefiedPetroleumGasCompressed

Natural Gas,Liquefied

Natural Gas, Fuel cells , solar , Hybrid system .

19 & 20 Practice on Startengine adjust idlingspeed and damping

device in pneumatic

Marine & StationaryEngine:- Types,double acting

engines, opposed

-do- Problems onEquations ofmotion

(v = u+at

http://www.cdxetextbook.com/fuelSys/alternate/fuelBatt/fuelcells.html


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23

governor and venturecontrol unit checking

performance of enginewith off load adjustingtimings.Start engine- adjusting

idle speed of theengine fitted withmechanical governorchecking- high speedoperation of theengine.Checking performancefor missing cylinder byisolating defectiveinjectors and test-dismantle and replacedefective parts andreassemble and refit

back to the engineVisit to marine engineservice station.

piston engines,starting systems,cooling systems,lubricating systems,supplying fuel oil,hydraulic coupling,

reduction gear drive,electromagneticcoupling, electricaldrive, generators andmotors,supercharging.

s = (u+v)t /2v2 = u 2+2ass = ut+ (at 2 )/2u = initialvelocity in

m/s;v =final velocityin m/s;a =

accelerationin m/s 2;t = time inseconds;s = distance.)

and theirapplication tovehicletechnology

21 On-board diagnostics-OBD systems ,Diagnostic troublecodes , Monitoringemissions Emissions procedures Checking & cleaning aPositive crank caseventilation (PCV)valve . Obtaining &interpreting scan tooldata.

Emission Control:-Vehicle emissionsstandards.Sources of emission, Combustion ,Combustionchamber design. Types of emissions: Characteristics andEffect ofHydrocarbons ,Hydrocarbons inexhaust gases ,Oxides of nitrogen ,Particulates , Carbonmonoxide , Carbon

dioxide , Sulfurcontent in fuels Description ofEvaporationemission control ,Catalyticconversion , Closedloop , Crankcaseemission control ,Exhaust gasrecirculation (EGR)

valve , Controlling

Views of simplesolid and hollow

bodies cut by section plane.

Determination ofefficiency ofsimplemachines likewinch, pulleylocks, wheelandcompoundaxles.



24

air-fuel ratios ,Charcoal storagedevices, Diesel

particulate filter(DPF).

22 Practice on removing

alternator from vehicledismantling, cleaningchecking for defects,assembling and testingfor motoring action ofalternator & fitting tovehicles.

Description of

charging circuitoperation ofalternators, regulatorunit, ignitionwarning lamp-troubles and remedyin charging system.

Freehand sketching

of charging system.

Magnets-

natural andartificialtypes-poles ofmagnets-magneticfields.

23 Practice on removingstarter motor vehicleand overhauling thestarter motor, testingof starter motor.

Description ofstarter motor circuit,comparison of wirethickness in startermotor circuit,constructionaldetails of startermotor solenoidswitches, commontroubles and remedyin starter circuit.

Sketching startermotor circuit andsolenoid switchcircuit.

Principle ofSolenoid andrelay,Electromagnetic induction.Fleming’srule.

24 Practice ontroubleshooting forEngine Not starting –Mechanical &Electrical causes,High fuelconsumption,Engine overheating,Low PowerGeneration,Excessive oilconsumption,Low/High Engine Oil

Pressure,Engine Noise.

Troubleshooting :Causes and remedyforEngine Not starting

– Mechanical &Electrical causes,High fuelconsumption,Engine overheating,Low PowerGeneration,Excessive oilconsumption,

Low/High EngineOil Pressure,Engine Noise.

Reading of simple blue print.

Study ofEnginespecification.

25 Project Work / Industrial Visit (Optional)

26 Examination



25

TRADE: “MECHANIC MOTOR VEHICLE ”THIRD SEMESTERSemester Code: MMV;SEM-III

WeekNo.

Trade Practical Trade Theory EngineeringDrawing

Workshopcalculation and

science1 Identification of different

major components ofHeavy vehicle and theirfunction & placementstudy of different makelorry/bus/tractor inInstitute with differentdealers or organizations.

Study of different majorcomponents & assembliesof heavy vehicle, anddifferent make(indigenous). Name plate-constructional differencesand their merits.leading manufacturers inHeavy vehicle Industry

2 Trouble shooting Practicewith Heavy vehicle.

Review of Troubleshooting:Causes and remedy forEngine Not starting –Mechanical &Electrical causes,High fuel consumption,Engine overheating,Low Power Generation,Excessive oil consumption,Low/High Engine OilPressure,Engine Noise.

Simple Blue PrintReading and I.S.I.symbols ofdifferentmaterials

Materials usedin theconstruction ofdifferent parts ofHeavy vehicle.

3-5 Practice on adjustingclutch pedal play-removing gearbox andclutch assembly fromLight & Heavy Vehicle.Dismantling clutchassembly, cleaninginspecting parts.Removing & fitting of

new pilot bearing,removing & fitting ofring gear in fly wheelrelining a clutch platechecking condition offlywheel and pressure

plate surface forreconditioning.Assembling of pressure

plate adjusting thefingers checking run out

of fly wheel and aligning

Clutches & ManualTransmissions-ClutchesClutch principles , Single-

plate clutches , Multi-plateclutches , Dual massflywheels , Operatingmechanisms Clutch components-Pressure plate ,

Driven/center plate ,Throw-out bearing Manual transmissions -Gearratios , Compound geartrains , Gear selection ,Bearings , Oil seals &gaskets Gearbox layout &operationGearbox layouts , Transaxledesigns , Gearbox

operation , Baulk-ring

Isometric drawingof simple objectssuch as squire andrectangular

blocks withgrooves-keyways.

Isometric view of

clutch pedal-clutch release bearing-fork andclutch plate-freehand sketching ofclutch assembly.Free handsketching ofshiftermechanism andhear shift lever.

Free hand

Study of Gearnomenclature.

Applied problems inforce, work-done, energy &

power.

Applied problems inhorsepowercalculation ofspeed ratios in4-speed gearbox& 5-speedgearbox.

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







26

clutch assembly withflywheel.Dismantling cleaning andassembling of gearshiftmechanism changing oilin gear box

Dismantling asynchromesh gear box,cleaning, inspecting partsreplacing worn outdefective parts assembling& testing for correct

performance identifyingnoises from gear boxesand rectifying.

synchromesh unit ,Transaxle synchromeshunit

sketching of thearrangement ofgears inside thesliding mesh gear

box in differentgear positions.

6-8 Practice on Removingopen type propeller shaftfrom vehicle, Practice onremoving universal jointscleaning replacing wornout parts, re-assembling& refitting to vehicle-special precautions whileremoving torque tubedrive shaft.Practice on Removingand refitting rear axleassembly.Practice on overhauling& inspection of rear axle.Practice on overhauling& inspection ofdifferential assembly.Trouble shooting –causes and remedy forclutch slip, clutch noise,clutch binding, hardclutch, gearbox noise,

gear slip, rear axle noise, propeller shaft noise,universal joint noise,differential noise.

Final Drive & Drive Shafts- Basic layoutsFront-wheel drive layout ,Rear-wheel drive layout ,Four-wheel drive layout ,All-wheel drive layout ,4WD v/s AWD Front-wheel driveFront-wheel drive shafts ,Front-wheel final drives ,Front-wheel differentials Rear-wheel drive-Propeller shaft , Universal

joints , Rear-wheel finaldrives , Salisbury axles ,Rear-wheel drivedifferentials , Limited slipdifferentials .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- fourwheel final drives , All-wheel drive transfer case ,Transfer case differentialaction .

Free handsketching ofFront-wheel drivelayout , Rear-wheel drivelayout , Four-wheel drivelayout , All-wheeldrive layout,

joints &Universal Joint.

Study of Gearterminology,Belt drives,Problems ongear and beltdrives.Gear ratiocalculation,

9-11 Identification ofAutomatic transmissioncomponents. Checkingautomatic transmissionfluid , Changing

transmission fluid & filter.

Automatic Transmissions-Torque convertersTorque converter

principles , drive plate ,Converter operation ,

Torque multiplication ,

Free hand sketchof Torqueconverter

Lay out for

gearbox , Selector

Properties oftransmissionfluid.

Gear ratio

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Fluid flow , Heatexchanger , Lock-upconverters , clutches Planetary gearing -Planetary gears , Simple

planetary gear sets ,

Compound planetary gearsets , Automatictransmission brake bands ,Multi-disc clutches ,Electronic controltransmission -Electroniccontrol Unit , Fullyhydraulically controlledtransmission , Electronicshift programs , Manualselection Layout & operation for P,R,N&D (1 st & 2 nd)Selector positions ,Planetary gear set , Highrange power flow , Lowrange power flow Servos & clutches -Rearservo , Front servo , Oneway clutch , Multi-platefront clutch , Clutch pack ,Rear clutch .Hydraulic system &controls -Hydraulic systemcomponents , Spool valves ,Regulating or flow controlvalves , Control valves ,Orifices Valve types & functions Basic valve action ,Regulator & controlvalves , Shift & governor

valves Pressure regulation -The primary regulating valve ,Line pressure variation ,Modulator valve pressure ,The governor , Governor

pressure , Kickdown pressure .Flow control -Gear position1, 1-2 shift valve , 2-3 shiftvalve assembly , The servo

orifice control valve , 3-2

positions ,Planetary gearset , High range

power flow , Lowrange power flow

calculation forAutomatictransmission.

http://www.cdxetextbook.com/trans/auto/layoutOp/planetarygearset.html

http://www.cdxetextbook.com/trans/auto/layoutOp/highpowerflow.html

http://www.cdxetextbook.com/trans/auto/layoutOp/highpowerflow.html

http://www.cdxetextbook.com/trans/auto/layoutOp/planetarygearset.html

http://www.cdxetextbook.com/trans/auto/layoutOp/selectposition.html



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kick down Continuously variabletransmission (C.V.T.)Continuously variabletransmission , Drive orreverse , The steel belt ,

Secondary pulley shaft . 12-14 Following practical to be

Practiced On Light &Heavy Vehicle.

Practice on removing thedrop arm, Check andadjust the turning angle,align the drop arm andsteering wheel with thefront wheel. Check andcorrect toe-in.

Practice on removingsteering wheel, steeringgearbox.Inspect and overhaul

steering boxes, adjustingsteering gear backlash,

pre-load and adjust toe-in, toe-out, camber angle,castor angle, kingpininclination and wheel runout. Checking &adjusting power steeringfluid , Pressure testing a

power steering system ,Flushing a powersteering system ,Inspecting & adjustingan engine drive belt ,Servicing a steering

system , Servicing wheel bearings.Troubleshooting- Causesand remedy for abnormalwear of tyre, wheelwobbling, poor selfcentering, hard steering,and vehicle pulling toone side.

Steering Systems:-Description and function

of Steering systems ,Principles of steering ,Rack-and-pinion steeringsystem , Recirculation ball& nut steering system ,Four-wheel steeringsystems , collapsiblesteering system. Steering boxes & columnsDescription and function ofSteering columns , Rack-and-pinion gearbox , Helix , Variable ratio steering ,Worm gearbox , PowerAssisted steering , Steering

process , Flow-controlvalve , Electric powerassisted steering , Basicelectric power steeringoperation Steering arms &components Forwardcontrol vehicle steering ,Steering linkages ,Joints , Bushes/bushings Wheel alignmentfundamentals:-Basic principles of wheelalignment, wheel base,

wheel track, king pininclination , Caster ,Camber , Scrub radius ,Toe-in & toe out , Toe-outon turns , Turning radius ,Thrust angle & centerlines.

Free handsketching ofdifferent types ofsteering boxes

Free handsketching ofcaster, camber,king-pin angle.Ackerman’s angletoe-in & toe-out.

Problems insteeringgeometry-calculation ofcaster, camber.

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


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15-17 Following practical to bePracticed On Light &Heavy Vehicle

Practice on visualInspection of chassis

frame for crack, bent andtwists.

Overhauling andInspection of shackle,leaf spring, front & rearsuspension.

Practice on removing,inspection andassembling of shockabsorber

Lubricating a suspensionsystem .

Suspension Systems:-Principles of suspension ,Suspension force ,Unsprung weight , Wheelunit location , Dampening Types of suspension -

Suspension systems , Solidaxle , Dead axle ,Independent suspension ,Rear independentsuspension , Rear-wheeldrive independentsuspension , Adaptive airsuspension operation Types of springs -Description and function of Coil springs , Leaf springs ,Torsion bars , Rubbersprings Shock absorber types - Description and function ofHydraulic shock absorbers ,Gas-pressurized shockabsorbers , Load-adjustableshock absorbers , Manualadjustable-rate shockabsorbers , Electronicadjustable-rate shockabsorbers , 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 leafspring suspension , Rigid

axle coil spring suspension ,Independent typesuspension , Rigid non-drive suspension

Free handsketching ofSuspensionsystem layouts. Driven rearsuspension

layouts , Non-driven rearsuspensionlayouts ,Independent rearsuspensionlayouts , Frontsuspensionlayouts ,Bushes/bushings , Arms & linkages

Definition oflongitudinalvibration,Transversevibration andtorsional

vibrations.Simple problemon frequency ofTransversevibration andtorsionalvibrations.

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30

18-19 Practice on removingwheels from light &Heavy vehicle,dismantling tyres andtubes checking puncture.Assembling inflating to

correct pressure.Rotating the wheels in

vehicle minor repairs towheels and tyres, wheel

balancing & alignment.Checking for tyre wear

patterns .

Wheels & Tyres-Wheeltypes & sizes Wheels , Rimsizes & designations ,Types of wheels Tyre types &characteristics Tyres ,

Radial ply tyres , Radial plytyre sidewalls , Tyre

pressure monitoringsystems , Run flat tyres ,Space-saver tyres , Tyredistortion , Center ofgravity Tyre construction -Tyreconstruction , Types of tyreconstruction , Tyrematerials , Hysteresis , Tyresizes & designations , Tyreinformation , Tyre treaddesigns , Tyre ratings fortemperature & traction.

Free handsketching ofdifferent type oftyre threaddesign.

Rounding of Numbers, Power& roots –General rule forindices,Multiplying and

dividingnumbers instandard form.

20-22 Practice on Adjusting brake pedal play,Overhauling andinspection of tandemmaster cylinderassembly,Overhauling andinspection of front andrear brake assembly,overhauling andinspection of wheelcylinder assemblyBleeding hydraulic

brakes & Disk brakes.Overhauling andinspection of vacuumassisted brake assembly.

Overhauling andinspection of disc brake.Adjusting Air brake s-

repair to tank unit, aircompressor, wheel brakeadjuster- locating airleaks in the brake linesand rectifying – generalmaintenance and care.Brakes procedures -Checking & adjusting

brake fluid , Replacing

Braking Systems :-Principles of braking ,Drum & disc brakes ,Lever/mechanicaladvantage , Hydraulic

pressure & force , Brakefade , Regenerative braking . Braking systems - Braketype - principles , Air

brakes , Exhaust brakes ,Electric brakes , Parking

brakes , Engine brakes ,Regenerative brakingBraking systemcomponents- Park brakesystem , Brake pedal , Brakelines , Brake fluid ,

Bleeding , Master cylinder ,Divided systems , Tandemmaster cylinder , Power

booster or brake unit ,Hydraulic brake booster ,Electro hydraulic braking(EHB) , Applying brakes ,Brake force , Brake lightswitch Drum brakes &components -Drum brake

system , Drum brake

Free handsketching of

brake liningswheel brakeassemblysectioned viewsof mastercylinder.

Free handsketching of

brake wheelcylinders camadjuster, brakeshoe assemblyand anchor pins.Freehand

sketching – thelayout of vacuumassisted.Hydraulic brakesystemFreehandsketching of thelay out of Air

brake system andsketching ofslacken adjuster.

Square root of perfect square,square root ofwhole numbersand decimalsrelating to

braking distance.

Simple levers, problems relatedto as applied tomotor vehicles

Meaning offrictionexamples ofuseful and

wasteful frictionin vehicles coefficient offriction-simple

problems onfrication.

Definition ofmass, unit offorce-weight ofa body- energy

and power.

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

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31

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 aheavy vehicle adjusting

brakes and balancing allfour wheel brakes,

precautions to beobserved while testing

brakes points to beremember while

preparing the vehicle for brake certificate.

Practice of maintainingof ABS system.

operation , Brake linings &shoes , Backing plate ,Wheel cylinders Disc brakes & components -Disc brake system , Disc

brake operation , Disc brake

rotors , Disc brake pads ,Disc brake calipers ,Proportioning valves ,Proportioning valveoperation , Brake frictionmaterials Antilock braking system &components-ABS brakesystem , Antilock brakingsystem operation ,Principles of ABS braking ,ABS master cylinder ,Hydraulic control unit ,Wheel speed sensors , ABSwith EBD electroniccontrol unit .

Applied problems inforce, work doneenergy and

power.

23-24 Study of Motor Vehicle actRules & Regulation.

Exercise indriving aLorry/Bus withdifferentimplements

25 Project Word / Industrial Visit(Optional)26 Examination

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32

TRADE: “MECHANIC MOTOR VEHICLE ”FOURTH SEMESTERSemester Code: MMV; SEM-IV

Week No

Practical Trade Theory EngineeringDrawing

WorkshopCalculation and

Science1 Identification of

petrol Enginecomponents.

Auto Industry in India -History, leadingmanufacturers,development inautomobile industry,trends, new product.

Statistics- definition,collecting andsorting raw data-tally chart.

2 Removing a petrolengine from a motorvehicle -dismantlingcylinder head,decorbonising,checking valves -cutting valves seats,replacing wornguides and weaksprings, assemblingvalves and cylinderhead and adjustingtappet clearance inengine.

Petrol Engine Basics:4-stroke spark-ignitionengines- Basic 4-stroke

principles, 4-stroke enginecycle.2-stroke principles, 2-

stroke engine cycle,Spark-ignition enginecomponents- Basic enginecomponents , 4 & 2-strokeengine differences ,Engine cams & camshaft ,Engine power transfer ,Scavenging , Counterweights , Pistoncomponents .

Make a simple sketchin plan view of a frontengine FWD vehicle.Label the maincomponents:engine, clutch,gearbox, drive shafts,driving, wheels,radiator, fuel tank.

.

Constructing pictograph –piechart, bar chart,arithmetic mean, themedian, and themode.

3 Practice onRemovingassembling of

piston andconnecting rodsfromenginecheckingcylinder bore wear

forovality and taperand finding nextoversize-Piston ring, Pistonas per servicemanual.Checking &changing an airfilter

Intake & exhaustsystems - Carburetedsystems , Electronic fuelinjection systems ,Exhaust systems .Intake systemcomponents , Air cleaners ,Carburetor air cleaners ,EFI air cleaners , Intake

manifolds , Intake airheating .

A free hand sketchingof 2 stroke and 4stroke engines.

Free hand sketchingofIntake system andexhaust system,Air cleaners.

Circle, length of arc,Timing marks,wheel revolutionsand distancetravelled, calculationof valve openingarea.



33

4 & 5 Simple repairs infuelfeed system –overhauling of fuel

pump, carburetors,fuel

Filters and aircleaners.Repair to a carcarburetors –adjustingfloat level and slowspeed adjustments –studying the fuelflowcircuit in carburetor

Practice in enginetuneup in a vehicle –testingvacuum andcompression ofengine,adjusting tappetssettingignition timing andadjusting carburetorFor slow speeds.

Gasoline Fuel Systems : Description of Gasolinefuel , Gasoline fuelcharacteristics ,Controlling fuel burn ,Stoichiometric ratio , Air

density , Fuel supplysystem , Pressure &vacuum Carburetor operation -Carburation ,Carburetor systemcomponents , Carburetorsystems , Metering jets ,Accelerating , Carburetor

barrels Carbureted systemcomponents The carburetor ,Mechanical fuel pumps ,Electric fuel pumps ,Tanks & lines , Fuel lines ,Charcoal canister ,Carburetor filters

Free hand sketchingof valve Operatingmechanism s, Free hand sketchingofCarburetor,

Block diagram ofPetrol fuel feedsystem

Calculation of piston, Enginedisplacement.Swept volume,clearance volume,total volume,

Compression ratioCheck your results

by looking in themanufacturersmanual.

Units of Heat,Temp, Pressure andits conversion.Basic of calorificvalue calculation.Comparison ofvarious fuel w.r.tocalorific values.Relevantcombustionequation,Detonation.

6 & 7 Practice onCleaning fuel tank,checking for leaksinFuel tank.Identification ofvarious componentsof MPFI system.Testing of MPFI

components andreplacement ifnecessary.Check deliveryfrom fuelPump.Replacing a fuelfilter .

Introduction to Electronicfuel injection (EFI) fuelsupply system , Basic EFI

principles , Air supply , Airvolume , Multi-pointinjection systems (MPI/MPFI),Simultaneous injection ,Efficient combustion

EFI fuel supply system -components Fuel pumps , Fuel filters ,Tanks & lines , Fuel lines ,Fuel rail , Fuel pressureregulator , Injectors ,Tachometric relay ,Thermotime switch , EFIsensors , Potentiometer ,Auxiliary air valves , Idlespeed control devices ,

Inertia sensors.

Block diagram ofMPFI system.

International standardand norms for testingof MPFI.

Free hand sketchingof wiring diagram of

MPFI systemFree hand sketchingof symbols used invehicle electricalsystems.

Angels & rotationType of angels,adding andsubtracting angle,Examples of anglesin automotive workType of triangle,Pythagoras’stheorem

Trignometery-Using scientificcalculator to find thevalue of sin, cos,tangent withexamples inautomotiveapplication,

http://www.cdxetextbook.com/fuelSys/gasoline/fuelSystem/repfuelfilter.html

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8 & 9 Identification ofElectronic controlUnit.Set up for testing,Testing ofElectronic

Control Circuit.Fault finding inElectronic circuitand remedies

Introduction to EFIEngine Management - EFIoperation Modes of EFI , Electronicfuel injection , Idle speedcontrol systems , Feedback

& looping , Cold startsystems , Air measurement ,Air-flow monitoring ,Variable intake manifoldsystem , Electricalfunctions , EFI wiringdiagram Electronic control unit –ECU EFI system ECU ,Electronic control unitsettings , Engine speedlimiting , Malfunctionindicator lamp.

Sketching of variousElectronic devicesused in motorvehicle.

Free hand sketching

of wiring diagram ofEFI system

Binary system, Mostsignificant Bit(MSB), Leastsignificant Bit(LSB),hexadecimal,

converting base 10numbers to binary,uses of binarynumbers in vehiclesystems .Binary codes-ASCII

10 Identification ofvarious sensorsinstalled in engine& its mounting.Checking

instruments &Gauges on dash

board.Rectify replacedefective gauges.

EFI sensors- IntakeTemperature sensor,Mass airflow sensor ,Manifold absolute

pressure sensor , Airvortex sensor , Fuelsystem sensor , Throttle

position sensor , Exhaustgas oxygen sensor , Crankangle sensor , Hall effectvoltage sensor

Free hand sketchingof sensors.Free hand cutsectional view of

petrol nozzle.

Directed numbers-Addition,subtraction,multiplication andDivision.Active sensors,Passive sensors.

11 Check andreplace ignitioncoil, overhaulingDistributorAssembly.Diagnosis- Possiblecauses and remedyfor Engine cranks,

but will not or hardto start, Poor fueleconomy or engine

performance.

Ignition principles andFaraday’s laws, Primaryand secondary winding oftransformer, Ignitioncomponents , Spark plugs ,Spark plug components ,Vacuum & centrifugalunits , Plug firing voltage ,

Contact breaker system , ballast resistor coil , Dwellangle , Spark timing .

Free hand sketchingofTransformerwindings, Ignitioncircuit of avehicle,Sketching varioustype of spark plugs.

Algebra-Multiplying two

binomialexpressionsin brackets,Algebraicexpressions andsimplification,

finding thevalue of theunknown quantity.

12 Checking ignitiontiming , Checking &changing a spark

plug , Removing &replacing contact

points.

Battery power source ,Description and functionof Capacitor/condenser ,Distributors , Distributortypes , High-tension leads ,Advance & retardmechanisms .

Sketching of batteryand assortedcapacitor/condenser.

Calculation of timeconstant forcapacitance circuit.Calculation relatingto capacitor in seriesand parallel.

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http://www.cdxetextbook.com/fuelSys/efi/sensors/title.html



35

13 Identification andtesting of Hall effectsensor, Opticalsensor. Tracing andtesting of sensorcircuits.

Induction , Inductivesystem operation ,Induction wiring , Halleffect sensors , Hall effectoperation , Optical typesensors

Distributor less ignitionsystems , Insulated coils ,Distributor less ignitionsystem timing .

Sketching of sensorssymbols, sketching ofHall effect sensor,Optical sensor.

Calculation of timeconstant forinductive circuit.

14 Checking acharging system forthe cause ofundercharge, Nocharge, and overcharge conditions. Removing &replacing analternator ,Inspecting &adjusting an enginedrive belt ,Replacing an enginedrive belt / pulleys /Tesnionsers andtheir alignments.

Charging system, Alternator principles ,Alternating current ,Alternator components ,Rectification , Phasewinding connections ,Rotor circuit , Voltageregulation , Systemoperating voltage , Highvoltage charging systems Rotor , Stator , Alternatorend frames , Slip ring &

brush assembly . ,Rectifier assembly ,Alternator cooling fan .

Sketching ofExploded view ofalternator.

Sketching ofCharging circuitalong with symbols init.

Lenz’s law, simplecalculation of backemf.

15 Perform startermotor current drawtest, Perform startervoltage drop test,test starter motorrelay, solenoidswitch, connectorsand wires.Removing starter

motorfrom vehicle ,overhauling and

testingOf starter motor.Differentiate

between electricaland mechanical

problems that causeslow crank and nocrank.Growler testing forrotors.

Starting system, Startermotor principles , Startermotor construction ,Starter magnet types ,Starter motor engagement ,Commutation , Switching ,solenoid construction.Checking a startingsystem , Jump-starting avehicle

Sketching ofExploded view ofstarter motor.

Sketching of startermotor circuit alongwith symbols in it.

Permanent magnet,The magnetic effectof an electriccurrent,Direction of themagnetic fielddue to an electriccurrent in astraight conductor,Magnetic fieldcaused by a coil ofwire.

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





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16 &17

Trace the lightcircuit -test bulbs align headlamps,replacing fusestesting the tail and

brakelights in vehicle.Checking &changing an exteriorlight bulb ,Checking incorrectturn signal or hazardlight operation.Checking &changing aheadlight bulb ,Aiming headlights .Identify systemvoltage and safety

precautionassociated with highintensity dischargelight. Removing anelectricalhorn from vehicle -assembling the hornandadjusting the hornforcorrect sound,tuningdouble horn,repairing ofhorn relay and hornswitches.Removing a wipermotor

dismantling,cleaning,inspecting, andrepairingelectrical wipermotors,assembling andfitting,Diagnose wiperspeed control and

park problem.

setting blades for

Lighting system ,Lamps/light bulbs ,Lamp/light bulbinformation , LED lighting

Stop lights , Reverse

lights , Indicators ,Headlights , High intensitydischarge (HID) lights ,

Driving lights , Fog lights ,Cornering lights , Smartlighting

Park & tail light circuits ,Headlight & dip circuits ,Circuit diagrams ,

Networking &multiplexing

Sketching of1. Head lamp, Park

& Tail lightcircuit.

2. Interior lightingcircuit

3. Hazard light andturn light

4. Horn & Wipercircuit

Graph-scales,variablescoordinates, straightline graphsGeometry andtrigonometry:-

Angles- angularmeasurements, theradian.



37

correct functioning.Trace the wiringcircuit of trafficsignal flasherslight circuit-tracingdefects in the

flasher circuits,replacing fuse

bulb. Removing,dismantlingmagnetos adjustinggap in points-testingmagnetos.

18 Identification ofAir conditioningcomponents,Performance test onA/c unit,Checking Chargedstate of refrigerant,Inspecting &adjusting an enginedrive belt ,Replacing an enginedrive belt.

Heating Ventilation AirConditioning (HVAC)legislation , Vehicleheating, ventilation &cooling systems , Basicair-conditioning

principles , Air-conditioning capacity ,Air-conditioningrefrigerant , Humidity

Sketching of Airconditioning systemusing an expansionvalve and orifice tube.

Definition – Absolutehumidity, Boiling

point, Heat transfer,convection,conduction, radiation,Latent heat ofvaporization, superheat, the effect of

pressure on boiling orcondensation.

19 &20

Checking a heatingsystem ,Compressor rotationtest, air Gap check,Refrigerantrecovery – evacuating – charging of A/csystem.Replenishingcompressor oil levelTrouble diagnoseand remedy for

No cooling or warmair,Cool air comes outonly intermittently,Insufficient cooling,Abnormal noisefrom compressor,Magnetic clutch,condenser,evaporator, Blowermotor.

Description and functionof Fixed orifice , Controldevices , Thermostaticexpansion valve system ,Thermal expansionvalves , Air-conditioningcompressors , Condensers& evaporators , Receiverdrier , Lines & hoses , TXvalve construction ,Temperature monitoringthermostat , Refrigerants ,Pressure switches ,

Heating elements

Air-conditioning ECU ,Ambient air temperaturesensor , Servo motors ,Electric servo motors ,Automatic climate controlsensors , Evaporatortemperature sensor ,Blower speed control ,Ventilation systems.

Drawing of A/cwiring circuit motorvehicle.

Sketching of TXvalve construction.

Sketching of blockdiagram of ACcompressor.

Properties ofrefrigerants,refrigerant oil,Fluorinatedrefrigerants,Refrigeration

process – pressure/enthalpydiagram.

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


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






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21 Carrying out avisual inspection ,Inspecting under

body components ,Measuring awheelbase ,

Checkingwindshield washerliquid , Checking &replacing wiper

blades , Checking asecurity system ,Checking doorhinges ,Diagnose automaticseat belt systems, Checking interiortrim , Checkingdriver's seat fabric ,Vehicle valetservice , Routinevehicle checks

Description and functionof Airbags, Seatbelt ,Vehicle safety systems ,Crash sensors , Seat belt

pre-tensioners , Tire pressure monitoring

systems

Air bag safety and servicewarnings. Security systems , Remotecontrol keys , Theftdeterrent systems Integratedcommunications , Bodycontrolled lightingsystems , Proximitysensors , Reflectivedisplays

Global positioningsatellites ,Triangulation/trilateration ,Satellite navigation ,Telematics.

Drawing ofAutomatic door locksystem circuit.

Drawing of powerwindow system

circuit.

22-24 Driving PracticePractice in straightdriving on wideroads.Driving throughlanesand curves.Practice inreversing.Practice overtakinganother vehicle.Practice in drivingthrough sand and

wetsurfaces.Practice in parkingandDiagonal parking.

Locating vehicleinformation , Obtaining &interpreting scan tooldata , Using a repairmanual , Using a shopmanual , Using an owner'smanual , Using a laborguide , Using a parts

program , Using a serviceinformation program

Free handsketching ofdifferent trafficSignals.

Applied workshopProblemscalculationFuel average, gearratios.

25 Revision26 Examination



39

Trade: Mechanic Motor VehicleLIST OF TOOLS & EQUIPMNT

A. TRAINEES TOOL KIT FOR 16 TRAINEES +1 INSTRUCTOR

Sl.No. Item with specification Qty.

1. Steel rule 15 cm inch and metric 17 nos.2. Steel rule 30 cm inch and metric 17 nos.3. Steel measuring tape 10 meter in a case 17 nos.4. Try Square 10 cm Blade 17 nos.5. Calipers outside 15 cm spring 17 nos.6. Caliper inside 15 cm Spring 17 nos.7. Dividers 15 cm Spring 17 nos.8. Safety glasses 17 nos.9. Scriber 15 cm 17 nos.10. Knife double Blade Electrician 17 nos.11. Wire insulation Stripper for shinning conductors from 0.4mm to

4mm17 nos.

12. Electrician testing Pencil (Line / Neon tester) 17 nos.13. Electrician Screw Driver 250mm 17 nos.14. Centre punch 10 cm. 17 nos.15. Chisel cold flat 20 mm x 150 mm 17 nos.16. Hammer ball peen 0.5 kg with handle 17 nos.17. Screw driver 20cm.X 9mm. Blade 17 nos.18. Screw driver 30 cm. X 9 mm. Blade 17 nos.19. Spanner D.E. set of 12 pieces (6mm to 32mm) 17 nos.20. Pliers combination 20 cm. 17 nos.

21. Pliers side cutting 15 cm 17 nos.22. Pliers round nose 15 cm 17 nos.23. Pliers flat nose 15 cm 17 nos.24. Hands file 20 cm. Second cut flat 17 nos.25. Hand file 20 cm. Second cut half-round 17 nos.26. Hand file 20 cm. smooth triangular 17 nos.27. Hand file 30 cm. bastard 17 nos.28. Hand file 30 cm. round bastard 17 nos.29. File card or cleaner 17 nos.30. Wire cutter and stripper 17 nos.31. Steel tool box with lock and key (folding type) 400x200x150 mm 17 nos.



40

B. Tools Instruments and General Shop outfitsSl. No. Item with specification Qty.1. Outside micrometer 0 to 25 mm 1no.2. Outside micrometer 25 to 50 mm 1no. 3. Outside micrometer 50 to 75 mm 1no. 4. Outside micrometer 75 to 100 mm 1no.

5. Internal micrometer 5 to 30 mm 1no. 6. Depth micrometer 0-25mm 1no. 7. Thread Micrometer 0-25mm 1no. 8. Drift Punch Copper 15 Cm 4 nos.9. Prick Punch 15 cm 4 nos.10. Adjustable micrometer sprit level to measure flatness, indication

and taper with prismatic measuring base1no.

11. Vernier caliper A 200 with inside and depth measurement 1no. 12. Direct reading vernier caliper B 300 (direct reading with dial) 1no. 13. Vernier depth Gauge 0-150 mm 1no.

14.

Vernier height gauge 500 mm 1no. 15. Telescope gauge 1no. 16. Dial gauge type 1 Gr. A (complete with clamping devices and

stand)4 nos.

17. Surface gauge with dial test indicator plunger type i.e. 0.01 mm 2 nos. 18. Cylinder bore gauge capacity 20 to 160 mm 2 nos. 19. Compression testing gauge suitable for petrol engine. 2 nos. 20. Vacuum gauge to read 0 to 760 mm of Hg. 2 nos. 21. Tyre pressure gauge with holding nipple 2 nos. 22. Marking Material (Consumable) As required23. Marking out table 90X60X90 cm. 1no.

24. CI surface plate 400 x 400 mm with stand and cover 1no. 25. Granite surface plate 1600 x 1000 with stand and cover 1no. 26. Steel rule 15 cm inch and metric 2 nos. 27. Steel rule 30 cm inch and metric 2 nos. 28. Steel measuring tape 10 meter in a case 2 nos. 29. Try Square 10 cm Blade 2 nos. 30. Engineer’s square 15 cm. Blade 2 nos. 31. Calipers outside 15 cm spring 2 nos. 32. Caliper inside 15 cm Spring 2 nos. 33. Calipers 15 cm Hermaphrodite 2 nos.

34. Dividers 15 cm Spring 2 nos. 35. Scriber 15 cm 2 nos. 36. Scriber with scribing black universal 2 nos. 37. Punch Letter 4mm 2 set38. Chisels cross cut 200 mm X 6mm 2 nos. 39. Chisel 10 cm flat 2 nos. 40. Safety Goggles 2 nos. 41. Hollow Punch set of seven pieces 6mm to 15mm 2 sets each42. Ball Peen Hammer 0.75 Kg 2 nos. 43. Hammer copper 1 Kg with handle 2 nos. 44. Hammer Mallet 2 nos.



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45. Hammer Plastic 2 nos. 46. Hammer ball peen 0.25 kg with handle 2 nos. 47. Philips Screw Driver set of 5 pieces (100 mm to 300 mm) 2 sets48. Insulated Screw driver 30 cm x 9mm blade 2 nos. 49. Insulated Screw driver 20 cm x 9mm blade 2 nos. 50. Electric testing screw driver 2 nos.

51. Allen Key set of 12 pieces (2mm to 14mm) 2 nos. 52. Hand vice – 37 mm 2 nos. 53. Work bench 250 x 120 x 60 cm with 4 vices 12cm Jaw 1no.54. Magnifying glass 75mm 2 nos. 55. ‘V’ Block 75 x 38 mm pair with Clamps 2 nos. 56. Clamps C 100mm 2 nos. 57. Clamps C 150mm 2 nos. 58. Clamps C 200mm 2 nos. 59. Spanner D.E. set of 12 pieces (6mm to 32mm) 4 nos.60. Spanner, adjustable 15cm. 2 nos.

61.

Spark plug spanner 14mm x 18mm x Size 2 nos. 62. Spanners socket with speed handle, T-bar, ratchet and universalupto 32 mm set of 28 pieces with box

2 nos.

63. Adjustable spanner (pipe wrench 350 mm) 2 nos. 64. Spanner, ring set of 12 metric sizes 6 to 32 mm. 2 nos. 65. Spanner T. flocks for screwing up and up-screwing inaccessible

positions2 nos.

66. Spanner Clyburn 15 cm 1no.67. Magneto spanner set with 8 spanners 1 set68. Spirit level 2V 250, 05 metre 2 nos. 69. Angle plate size 200x100x200mm 2 nos.

70. Angle plate adjustable 250x150x175 1no.71. Solid Parallels in pairs (Different size) in Metric 2 nos. 72. Pliers combination 20 cm. 2 nos. 73. Pliers side cutting 15 cm 2 nos. 74. Pliers round nose 15 cm 2 nos. 75. Pliers flat nose 15 cm 2 nos. 76. Vice grip pliers 2 nos. 77. Circlip pliers Expanding and contracting type 15cm and 20cm

each2 nos.

78. Grip Wrench 200mm 2 nos.

79. Torque wrenches 5-35 Nm, 12-68 Nm & 50-225 Nm 1 each80. Workshop plain goggles 17 nos.81. Air impact wrench 1no. 82. Air ratchet 1no. 83. Air chisel 1no. 84. Air blow gun 1no. 85. Car Jet washer 1no. 86. Pipe flaring tool 1no. 87. Pipe cutting tool 1no.

88. Universal puller for removing pulleys, bearings 1no.

89. Cleaning tray 45x30 cm. 4 nos.



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90. Cleaning tray- Aluminum 45 x 30 cm 4 nos.91. Stud extractor set of 3 2 sets92. Stud remover with socket handle 1no.93. Rivets sets snap and dolly combined 3mm, 4mm, 6mm 2 each94. Chemical compound for fasteners (Consumable) As required95. Paraffin pressure Gun 2 nos.

96. Grease Gun 2 nos.

97. Hacksaw frame adjustable 20-30 cm 2 nos.

98. Hacksaw blade (consumable) As required99. Flat File 35 cm bastard 4 nos.100. Flat File 25 cm second cut 4 nos.101. File flat 20 cm bastard 4 nos.102. Files assorted sizes and types including safe edge file (20 Nos) 2 set103. Drill Twist (assorted) (Consumables) 10 Nos104. Drill twist 1.5 mm to 15 mm (various sizes) by 0.5 mm 4 nos.105. Drill point angle gauge 1no.106. Set of stock and dies - UNC, UNF and metric 2 sets107. Taps and wrenches - UNC, UNF and metric 2 sets108. Taps and Dies complete sets (5 types) 1 set109. 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 mm2sets

110. Lapping abrasives (consumable) As required111. Oil can 0.5/0.25 liter capacity 2 nos.112. Oil Stone 15 cm x 5 cm x 2.5 cm 1no.113. Different type gasket material (consumable) As required114. Different type of oil seal (consumable) As required

115.

Sheet Metal Gauge 2 nos. 116. Feeler gauge 20 blades (metric) 2 nos. 117. Straight edge gauge 2 ft. 1no. 118. Straight edge gauge 4 ft. 1no. 119. Thread pitch gauge metric, BSX, BSF, MC, MF & SAE 1no. 120. Valve Lifter 1no. 121. Ladle 150mm Dia 1no. 122. Blow Lamp 1 litre 2 nos. 123. Crow bar 910 x25mm 2 nos. 124. Voltmeter 50V/DC 5 nos.125. Ammeter 300A/ 60A DC with external shunt 5nos.126. DC Ohmmeter 0 to 300 Ohms, mid scales at 20 Ohms 1no.127. Electric Soldering Iron 230 V 60 watts 230 V 25 watts 2 each128. Copper bit soldering iron 0.25 Kg 5 nos.129. Thimbles of different sizes 2 nos.130. Wire Gauge (metric) 5 nos.131. Hand operated crimping tool (i) for crimping up to 4mm and (ii)

for crimping up to 10mm2 nos.

132. Hand rubber gloves tested for 5000 V 5 pair133. Holders, lamp teakwood boards, plug sockets, solders, flux wires

and cables batteries round consumable blocks and other

consumables as required

As required



43

134. Multimeter digital 5 nos.135. Growler 1no. 136. Scientific Calculator 1no. 137. Hydrometer 2 nos.138. High rate discharge tester (cell tester) 1no. 139. Spray Gun (Painting) 500ml 1no.

140. Techometer 1no. 141. Valve Timing Diagram 1no. 142. Belt Tensioner Gauge 1no. 143. Portable electric drill Machine 1no. 144. Spring tension tester 1no. 145. Carburetor repair kit 1no. 146. Hot patch clamp 1no.

C. General Installation/ Machineries

1. Lathe general purpose all geared height of center 150 mm to below, Gap bed between centers 1000mm with all accessorieswith all attachment

1no.

2. Drilling machine bench to drill up to 12mm dia along withaccessories

1no.

3. Cut section working model of Single plate clutch assembly. 1no. 4. Cut section working model of Diaphragm clutch assembly. 1no. 5. Cut section working model of centrifugal clutch assembly. 1no. 6. Front axle ( Rzeeppa Joint) with stand for Dismantling and

assembly1no.

7. Rear axle with stand for Dismantling and assembly 1no. 8. Constant Mesh Gear box with stand for Dismantling and

assembly.1no.

9. Sliding mesh Gear box with stand for Dismantling and assembly. 1no. 10. Synchronous Gear box with stand for Dismantling and assembly. 1no. 11. Transfer case with stand for Dismantling and assembly. 1no. 12. Cut section model of synchronous gear box working 1no. 13. Cut section model of sliding mesh gearbox working 1no. 14. Cut section model of constant mesh gearbox working 1no. 15. Full floating axle and semi-floating axle assembly 1no. 16. Cut section working model of automatic transmission Gear box 1no. 17. Working model of fluid fly wheel 1no. 18. Working model of torque converter 1no. 19. Steering assembly -

1.Rack & pinion2.Worm & roller3. Recirculating ball4.Power steering

1 each

20. Suspension and steering system trainer 1no. 21. Cut section models of shock absorbers 1no. 22. Stock absorber testing bench 1no.

23. Spring Tension scale – 0-4.5 kg. 1no.



45

67. Cylinder Block, CI Engine, Overhead camshaft & camshaft in block, air cooled

1each

68. Carburetor – Solex, Mikuny for dismantling and assembling 1 each69. Carburetor repair tool kit 1no. 70. Demonstration board of 2W Ignition system, ignition coil 1no. 71. Demonstration board of electronic Ignition system, ignition coil 1no.

72. Spark Plug cleaning and testing equipment 1no. 73. Starter motor axial type, pre-engagement type & Co-

axial type1each

74. Distributor –Duel advance type, reluctance type 1 each75. Tester sparking plug ‘NEON’ Type 1no.76. Alternator assembly used for LMV 2 nos. 77. Starter motor assembly used for LMV 2 nos. 78. Electronic engine control module 1no.79. Working Condition of Petrol MPFI Engine Assembly with fault

simulation board1no.

80.

MPFI petrol engine with swiveling stand along with special toolsfor dismantling and assembling 1no.

81. Demonstration board of MPFI system 1no. 82. Ultrasonic Injection cleaning equipment 1no. 83. Fuel feed pump 1no. 84. Multi-point fuel injection pump 1no. 85. Petrol nozzle 4 nos.86. Air conditioning trainer kit 1no. 87. Air conditioning service Unit (Car) 1no. 88. Working Model of power windows 1no. 89. Petrol Engine(2-stroke) Motor Cycle/Scooter along with special

tools and accessories1no.

90. Cut model of 4 stroke Petrol engine on stand 1no. 91. Cut model of 2 stroke Petrol engine on stand 1no. 92. Mechanical Hoist/Plate Form Type 1no. 93. Multi scan tool /ECU diagnostics kit 1no. 94. Four stroke petrol engine with CNG setup-working condition 1no. 95. AC alternator slip ring puller 1no. 96. Functional/experiment model of different type of sensors. 1 set97. Executive Auto Electrical tool kit 1no. 98. Auto Electrical test bench 1no.

99.

Cut section Model of Mock layout of a motor car –electricalsystem – working model 1 set

100. Car stereo 1no.101. Battery 12V (Lead acid & Alkaline ) 2 nos.102. Battery charger 6V – 24 V 1no.103. Electrical horn ( different types ) 2 nos. 104. Wiper motor assembly 2 nos. 105. Anti theft device 2 nos. 106. Horn and Horn relay 2 nos. 107. Air conditioned MPFI vehicle with accessories 1no.108. 5 Point relays 2 nos.109. 4 Point relays 2 nos.



110. Air bag simulator 1no. 111. Driving Simulator 1no. 112. Trolley type portable air compressor single cylinder with 45

liters capacity Air tank, along with accessories & with working pressure 6.5 kg/sq cm

1no.

113. Grinding machine (general purpose) D.E. pedestal with 300 mm

dia wheels rough and smooth

1no.

114. Tyer Changer Machine 1no.

D. Workshop Furniture

Sl.No.

Description Quantity

1. Suitable class room furniture As required2. Suitable Work Tables with vices As required3. Stools 17 nos.4. Discussion Table 1 no.5. Tool Cabinet 2 nos.6. Trainees locker 2 Nos. to accommodate 16

lockers7. Fire Extinguishers, first- aid box As required8. Book shelf (glass panel) 1 no.9. Storage Rack As required10 Storage shelf As required.11 LCD projector/ LED /LCD TV (big size) 1 no.12 Multimedia CD for Automotive application As required

13 Desktop computer and related MS office software 5+1 no.14 Online UPS 2KVA 1 no.15 Laser printer 1 no.16 Computer Table 1 no.17 Computer Chair 2 no.

mech motor vech

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