Pump Operator cum Mechanic - Directorate General of Employment
Contents
1. e Dismantles pump using hand tools and examines mechanism to locate faults or damage Repairs defective parts or obtains replacements sets them in position and assembles pump e Tests reassembled or repaired unit for pressure leakage etc makes necessary adjustment and observes performance for appropriate yield of air oil or water e May erect and install pumps at site and connect to motor power e May locate faults to electric system motor repaired such as rewinding of field coils or armatures by Electrician or Armature Winder May specialise in repairing centrifugal or reciprocating pumps e Oil Engine Fitter repairs services and overhauls diesel or oil engines for efficient performance as prime mover to drive machinery and equipment Examines engine to locate defects using various tools and instruments e Dismantles or partly dismantles it to remove damaged or worn out parts and replaces or repairs them e Instals assembled or repaired engine in position and connects pulley or wheel to propulsion system Starts engine tunes it up and observes performance noting different meter readings such as temperature fuel level oil pressure etc and sets it to specified standard for optimum performance e Checks adjusts and lubricates engine periodically and performs such other functions to keep engine in good working order May solder or braze parts and service diesel fuel pumps and injectors Measures essential parts like cylind2. Heating expansion and compression of gases Absolute pressure Absolute temperature Laws relating to the compression and expansion of gases Heating a gas at constant volume Heating a gas at constant pressure Charles law Expansion or compression at constant temperature isothermal 17 18 20 Internal combustion engines Engine power Brake power Horsepower PS the DIN Indicated power Mean effective pressure Calculation of indicated power Cylinder pressure vs crank angle Mechanical efficiency of an engine Volumetric efficiency Torque vs engine speed Specific fuel consumption vs engine speed Brake power torque and sfc Specific fuel consumption compared Brake mean effective pressure Thermal efficiency Indicated thermal efficiency Brake thermal efficiency petrol vs Diesel 21 Fuels and combustion Calorific value Combustion Products of combustion Relevant combustion equations Air fuel ratio Petrol engine combustion Detonation Pre ignition Octane rating Diesel fuel Flash point Pour point Cloud point Biofuels Liquefied petroleum gas LPG Hydrogen Zero emissions vehicles ZEVs 18 Automobile Group 1 year Trade 2 Semester Engineering Drawing Syllabus for the trade of Syllabus for the trade of Pump operator cum Mechanic Week Engineering Drawing 3 Hrs week Nos 2 Semester 1 4 Read and interpret drawings Determ
3. Ohm s law Voltage Current Resistance Power Energy Voltmeter ammeter Ohmmeter Mulitmeter Conductors amp insulators Wires Shielding Length vs resistance Resistor ratings 14 Diagnose series parallel series parallel circuits using Ohm s law Check electrical circuit with a test lamp perform voltage drop test in circuits using multimeter measure current flow using multimeter ammeter use of service manual wiring diagram for troubleshooting Fuses amp circuit breakers Ballast resistor Stripping wire insulation cable colour codes and sizes Resistors in Series circuits Parallel circuits and Series parallel circuits Electrostatic effects Capacitors and its applications Capacitors in series and parallel 15 Cleaning and topping up of a lead acid battery Testing hydrometer battery with Description of Chemical effects Batteries amp cells Lead acid batteries amp Stay Maintenance Free SMF batteries Magnetic effects Heating effects _Thermo electric energy Thermisters Connecting battery to a charger for battery charging Inspecting amp testing a battery after charging Measure and Diagnose the cause s of excessive Key off battery drain parasitic draw and do corrective action Testing of relay and solenoids and its circuit Thermo couples Electrochemical energy Photo voltaic energy Piezo electric energy Electromagnetic induction Relays Solenoids
4. Primary amp Secondary windings Transformers stator and rotor coils 16 Identify and test power and signal Basic electronics Description of Semi connectors for continuity Identify conductors Solid state devices Diodes and test different type of Diodes oo a ee PE o Metal Oxide Fie ect Transistors ae i Thanstsioes orate MOSFETs Logic gates OR AND amp NOT and a a __ Logic gates using switches Construct and test simple logic circuits OR AND amp NOT and Logic gates using switches ree ene te make straight ne Introduction to welding and Heat Treatment 18 Butt Lap amp T joints Manual Metal Arc Welding Welding processes Principles of Arc welding brief Setting of Gas welding flames description eee Raan ane applications Manual i i Metal Arc welding principles power sources practice to make a straight beads and a i electrodes welding parameters edge preparation joints Oxy Acetylene welding j amp fit up and welding techniques Oxy Acetylene Film on Heat treatment process welding principles equipment welding parameters edge preparation amp fit up and welding techniques Heat Treatment Process Introduction Definition of heat treatment Definition of Annealing Normalizing Hardening and tempering Case hardening Nitriding Induction hardening and Flame Hardening process used in auto components with examples 19 amp Practice on Liquid penetrant testing Non de
5. x 1 2 19 Trainees locker 6 2 x 3 x 1 2 2 Nos to accommodate 20 Lockers List of tools amp Equipment for the Trade of Pump operator cum Mechanic Engineering Drawing Note Facilities available in Draughtsman trade can be utilized TRAINEE S TOOLS KIT SI No Name of the items Quantity l Draughtsman drawing instrument box 20 1 set 2 Set square celluloid 45 250 X 1 5 mm 20 1 set 3 Set square celluloid 30 60 250 X 1 5 mm 20 1 set 4 Mini drafter 20 1 set 5 Drawing board 700mm x500 mm IS 1444 20 1 set GENERAL MACHINERY SHOP OUTFIT Sl No Name amp Description of Machine Quantity l Draughtsman table 20 Nos 2 Draughtsman stool 20Nos 26 27
6. 1 181 Tube expander up to 62 mm 1 182 Universal puller for removing pulleys bearings 1 183 V Block 75 x 38 mm pair with Clamps 2 184 Vacuum gauge to read 0 to 760 mm of Hg 2 185 vernier caliper 0 300 mm with least count 0 02mm 4 186 Vibrometer 2 187 Vice grip pliers 2 188 Voltmeter AC to 500 V 2 189 Wall hoists 1 190 Water pump for dismantling and assembling 2 191 Wattmeter AC DC 0 to 10 Kw 2 192 Wire Gauge metric 5 193 Work bench 250 x 120 x 60 cm with 4 vices 12cm Jaw 1 C General Installation Machineries Sl No Item with specification Qty Nos l Arbor press hand operated 2 ton capacity 1 2 Back pull out type centrifugal pump 1 3 Bench lever shears 250mm Blade x 3mm Capacity 1 4 Centrifugal pump coupled with mono block set 1 5 Diesel engine 2 stroke vertical up to 10 KW ISHP 1 6 Diesel Engine 4 stroke vertical up to abouit 10 KW ISHP 1 T Diesel Engine Driven portable pump set 1 8 Diesel Engine upto 3 5 KW 4 5 HP fitted with pump 1 9 Discrete Component Trainer Basic Electronics Trainer 1 24 10 Drilling machine bench to drill up to 12mm dia along with accessories 1 11 Dual Magnetization Yoke AC HWDC 230 VAC 50Hz 1 set 12 Gas Welding Table 1220mm x760mm 2 13 Grinding machine general purpose D E pedestal with 300 mm 1 dia wheels rough and smooth 14 H
7. 5 pair 13 Holders lamp teakwood boards plug sockets As required 14 Hydrometer As required 15 Lapping abrasives As required 16 Leather Apron As required 17 Petrol As required 25 18 Power steering oil As required 19 Radiator Coolants As required 20 Safety glasses As required 21 Steel wire Brush 50mmx 150mm As required 22 Gloves for Welding Leather and Asbestos As required 23 Block of timber various sizes As required 24 Various type of seal required for pump assembly As required E Workshop Furniture Sl Description Quantity No l Book shelf glass panel 6 2 x 3 x 1 2 As required 2e Computer Chair 1 1 3 Computer Table 1 1 4 Desktop computer and related MS office software 1 1 5 Discussion Table 8 x 4 x 2 2 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 i As required 12 Online UPS 2KVA 1 13 Stools 21 14 Storage Rack 6 2 x 3 x 1 As required 15 Storage shelf 6 2 x 3 x 1 4 As required 16 Suitable class room furniture As required 17 Suitable Work Tables with vices As required 18 Tool Cabinet 6 2 x 3
8. Drift Punch Copper 15 Cm 4 41 Drill point angle gauge 1 42 Drill twist 1 5 mm to 15 mm various sizes by 0 5 mm 4 43 Electric Soldering Iron 230 V 60 watts 230 V 25 watts 2 each 44 Electric testing screw driver 2 45 Energy meter AC Single Phase 5 Amps 230 Volts 2 46 Engineers square 700 mm 4 47 Engineers stethoscope 1 48 Feeler gauge 20 blades metric 4 49 File flat 20 cm bastard 4 50 File half round 20 cm second cut 4 51 File Square 20 cm second cut 4 52 File Square 30 cm round 4 53 File triangular 15 cm second cut 4 54 Files assorted sizes and types including safe edge file 20 Nos 2 set 55 Flat File 25 cm second cut 4 56 Flat File 35 cm bastard 4 57 Flow meter 0 400 It min 2 58 Forks clips 02 tonnes copa 1 59 Forks clips 05 tonnes copa 1 60 Foundation bolt 4 61 Gasket hollow punches 5 6 8 10 12 19 25 mm dia lset 62 Glow plug tester 2 63 Granite surface plate 1600 x 1000 with stand and cover 1 64 Grease Gun 2 65 Growler 2 21 66 Hacksaw frame adjustable 20 30 cm 10 67 Hammer Ball Peen 0 75 Kg 4 68 Hammer Chipping 0 25 Kg 4 69 Hammer copper Kg with handle 4 70 Hammer Mallet 4 71 Hammer Plastic 4 12 Hand key way broacher l 73 Hand operated chain pulley block 1 74 Hand operated crimping tool i for crimping up to 4mm and ii f
9. allowable keyways tolerance clearances Key fitting procedure methods Procedure for removing keys Types amp uses of key pullers 19 Identifying selecting use of different Specification and use of different types of types of ropes such as hemp manila ropes such as hemp manila nylon wire etc nylon wire etc Practicing different types of knots and its Practicing different types of knots and its applications applications Method of joining two ropes Method of joining two ropes together for Together for extension Detection of extension Detection of unsafe defective unsafe defective conditions of ropes and conditions of ropes and knots Specification knots and correct use of slings Safety to be observed in use of ropes and slings 20 Use of different types lifting tackles both Description operation purpose application mechanical and hydraulic such as Screw jacks chain pulley block crabs and winches rollers and bars levers lashing and packing Use of inclined plane hydraulic trolleys etc Care and maintenance of lifting equipment and safety to be observed by care and use of Different types of lifting tackles for components of pump set Precaution to be observed while using lifting tackles 15 handling the equipment 21 Making different types of keys for fitting Types of pulleys solid split V groove step pulleys Assembling and dismantling of cone taper guid
10. and circumference Length of arc Timing marks Wheel revolutions and distance travelled Valve opening area Trigonometry Using sines cosines and tangents to solve vehicle problems Formulae for Perimeter and Area of Plane figure Rectangle Square Parallelogram Triangle Hexagon any regular polygon Trapezium Circle sector Fillet Ellipse segment of a circle Formulae for Volume and surface area of solids Rectangular solid Prism cylinder pyramids and cones Frustum of pyramid and cones sphere Hollow sphere segment of sphere circular ring spherical sector Calculation of volume and weight of simple solid bodies such as cubes square and hexagonal prism shop problem 11 13 Statistics Collecting and sorting raw data Definition of Discrete variable continuous Variable with Shop examples Constructing pictographs pie chart Bar chart Frequency and tally Charts Importance of the shape of a frequency distribution histogram frequency polygon Cumulative frequency plot Interpreting statistics sampling arithmetic mean median 14 amp 15 Heat and temperature Temperature Thermodynamic temperature scale Kelvin Cooling system temperature Standard temperature and pressure STP Thermal expansion with calculation Heat Sensible heat Latent heat Specific latent heat Specific heat capacity Quantity of heat with calculation Heat transfer Conduction Convection Radiation 16 amp 17
11. cm 2 22 113 Plumb bob 1 114 Pneumatic scraper with adjustable stroke 2 115 Portable electric drill Machine 1 116 Portable jack 1 117 Power Supply 0 12 v lamp 1 118 Pressure gauge 0 5 Kg cm2 2 119 Prick Punch 15 cm 4 120 Punch Letter 4mm Number 2 set 121 Radius Gauge Metric 2 122 Ratchet chain pulley 1 123 Rawl plug tool amp kit 124 Right cut snips 250mm 4 125 Rivet sets snap and Dolly combined 3mm 4mm 6mm 4 126 Rollers steel tubes from 40 to 65 mm dia 127 Rotary pump working for dismantling and assembling 128 Scientific Calculator 2 129 Scraper flat 25 cm 2 130 Scraper half round 25 cm 2 131 Scraper Triangular 25 cm 2 132 Screw jacks 1 133 Scriber 15 cm 2 134 Scriber with scribing black universal 2 135 Self alignment roller ball bearing 2 136 Set of stock and dies Metric 2 sets 137 Shear legs tripod 1 138 Shear Tin Man s 450 mm x 600mm 4 139 Sheet Metal Gauge 2 140 Sher Tinmans 300mm 4 141 Single Phase 220 V Capacitor type AC Meter squirrel gage Induction 1 motor 142 Soldering Copper Hatchet type 500gms 4 143 Solid Parallels in pairs Different size in Metric 2 144 Spanner Clyburn 15 cm 1 145 Spanner D E set of 12 pieces 6mm to 32mm 4 146 Spanner T flocks for screwing up and up screwing inaccessible 2 147 Spanner adju
12. SYLLABUS OF SEMESTER SYSTEM FOR THE TRADE OF Pump Operator cum Mechanic Under Craftsmen Training Scheme CTS One year T wo Semesters Redesigned in 2014 By Government of India Ministry of Labour amp Employment DGE amp T SYLLABUS FOR THE TRADE 1 Name of the Trade 2 N C O Code No 3 Duration of Craftsmen Training Power Norms 5 Space Norms 6 Entry Qualification T7 Unit strength 8 Instructors Qualification Note GENERAL INFORMATION Pump operator cum Mechanic 7233 40 1Year Two Semester having duration of six months each 11 KW 84 Sq mtr Passed 10th class examination under 10 2 system of education with Science and Mathematics or its equivalent 16 30 super Numeric a Degree in Automobile Mechanical Engg Electrical Eng from recognised college University with one year experience in the relevant field OR Diploma in Automobile Mechanical Engg Electrical Engg From recognized board of technical education with two years experience in the relevant field OR 10 Passed NTC NAC in the Trade of Pump Operator Cum Mechanic with 3 years post qualification experience in the relevant field and b With National Crafts Instructor Certificate 1 At least one Instructor must have Degree in Automobile Mechanical Engg Electrical Engg When applied for 02 units 2 Instructor Qualification for WCS amp E D as per the Training Manual 9 For Employability Skills On
13. TY SKILLS SEMESTER II Pl ref to www dget nic in 19 A TRAINEES TOOL KIT per 4 Trainees TRADE Pump Operator Cum Mechanic LIST OF TOOLS amp EQUIPMNT 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 6 mm set of 28 pieces with box 17 Steel rule 30 cm inch and metric 6 18 Steel tool box with lock and key folding type 400x200x150 mm 6 19 Wire cutter and stripper 6 B Tools Instruments and General Shop outfits Sl No Item with specification Qty Nos 1 Adjustable spanner pipe wrench 350 mm 2 2 Air blow gun with standard accessories 1 3 Air impact wrench with standard accessories 4 4 Air ratchet with standard acc
14. am of forces Triangle of forces Resolution of forces Mass Equilibrium Pressure Pressure in hydraulic systems Hooke s law Practical applications 20 21 Work energy power Definition and calculation of Work Power and Work done by a torque Definition and calculation of Energy Potential energy Chemical energy Conservation of energy Energy equation Kinetic energy Energy of a falling body Kinetic energy of rotation 11 Automobile Group 1 year Trade 1 Semester Engineering Drawing Syllabus for the trade of Syllabus for the trade of Pump operator cum Mechanic Week No Engineering Drawing 3 Hrs week 1 Semester 1 Importance of engineering drawing as a communication medium different types of drawing Machine Drawing Production Drawing Part Drawing Assembly Drawing Drawing instruments equipment and materials and their uses 2 amp 3 Scales Recommended scales reduced amp enlarged Drawing Sheet sizes AO Al A2 A3 A4 A5 Layout of drawing sheet sizes of title block and its contents Using drawing instruments to draw straight lines rectangles squares circles polygons 4 amp 5 Lettering and Dimensioning Types of Lettering Guide Lines for lettering Recommended sizes of letters and numbers Single stroke letters Dimensioning rules and systems of dimensioning dimensioning a given drawing 6 amp 7 Identify the alphabet of lines Read and Interpret the meani
15. ctioning Practice on troubleshooting in for Engine Not starting Mechanical amp 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 amp Electrical causes High fuel consumption Engine overheating Low Power Generation Excessive oil consumption Low High Engine Oil Pressure Engine Noise Familiarization with plain journal bearings anti friction bearings used on machine assembly Specification Mounting of bearing on shafts and in housing with proper fit amp axis alignment Use of proper tools Removal of bearings from shafts amp housing by using pullers Cleaning up amp removing old metal form bearing and replacing with new metal Checking of shafts for alignment with dial indicator Types of belt drives velocity ratio of belt drive Horse Power transmitted by belt Ratio amp driving tension in a belt Parallel amp cross belt drive open amp cross belt drive angular belt drive Methods of fixing and uses Description types and application of bushes bearing and couplings Procedure to fit bushes bearings and coupling safely Identification of different pumps its components prime movers Practice on operational safety Dismantling of reciprocating pumps valves pistons cranks seals etc for inspection repa
16. e Contract Part Time Guest Faculty for Generic Module 1 MBA BBA with two years experience OR Graduate in Sociology Social Welfare Economics with Two years experience OR Graduate Diploma with Two years experience and trained in Employability Skills from DGET institutes AND Must have studied English Communication Skills and Basic Computer at 12 Diploma level and above OR Existing Social Study Instructors duly trained in Employability Skills from DGET institutes Distribution of training on Hourly basis Total hours Trade practical Trade Work shop Engg Employability Extra week theory Cal amp Sc Drawing skills curricular activity 42 Hours 27 Hours 5 Hours 3 Hours 3 Hours 2 Hours 2 Hours COURSE INFORMATION PUMP OPERATOR CUM MECHANIC 1 Introduction gt An intensive industrial survey was made to ascertain the requirements of skill gap in the automobile sector a scientifically designed survey covering labour market survey web survey was conducted Based on the data obtained the skills are identified and accordingly the syllabus has been drafted Subsequently the Trade expert committed reviewed 2 Terminal Competencies Deliverables After successful completion of the above course the trainee shall be able to perform the following skills with proper sequence e Repairs all types of pumps such as centrifugal plunger types etc according to specifications for pumping water oil air etc
17. e Project NATRIP amp Automobile Garage Service station equipments Association Vebicle hoists J he pen and four Definition Classification of vehicles on the post hoist Engine hoists Jacks basis of load as per central motor vehicle rule Stands wheels final drive and fuel used axles position of engine and 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 10 Automobile Group 1 year Trade 1 Semster Workshop Calculation and Science Syllabus for the trade of Pump operator cum Mechanic Week Workshop calculation and No Science 3 Hrs week 1 Units Derived and fundamental types of system FPS CGS MKS and their conversion Metric weights and measurements units conversion factors 2 Fractions Addition and subtraction Fractions and whole numbers Combined addition and subtraction Multiplication and division of fractions Operations in problems involving fractions 3 Order of performing BODMAS Mathematical operators Integers Rules for dealing with integers Addition subtraction Multiplication and division 4 amp 5 Ratio and proportion Percentages Examples of ratios in Automotive technology 6 profit and loss Discount 7 simple interest and compound interest 8 depreciati
18. e and temperature measuring instruments Method to read and application of pressure and temperature measuring instruments Installation of seals leather polythene asbestos rope rubber and mechanical seals Maintenance of lubrication systems Fitting of flanges and assembling of pipe work leak testing and rectification Use of tee elbow bend socket rectifiers and other pipe fittings Cutting threads for pipes Various seals their use and places of application with advantages Lubrication types of lubricant use amp methods of lubrication Various tools and accessories used in pipe fitting with their details Use of protecting caps on threads Pipe fitting technique Procedure to fit flanges amp for leak testing 10 Installation of stationary amp coupled pumps checking and correcting of alignment of pump with its prime movers and its serviceability test Testing of pumps for their delivery flow amp pressure Method of install align and testing of pumps for their serviceability Concept of lightening torque for different sizes of bolts 11 Reconditioning of centrifugal pumps Principle of centrifugal pump Construction and operation of centrifugal pump in series and parallel Finding out defects and method to recondition centrifugal pump 12 Dismantling identifying of parts finding out defects repairing and replacement of components cleaning assembling installing and testing of subme
19. ed and jockey or rider bushes bearings and couplings pulleys their functions and uses Procedure to maintaining safety assemble and dismantle pulleys and impellers from shafts following safety precautions 22 23 In Plant Training 24 25 Revision and test 26 NCVT Exam 16 Automobile Group 1 year Trade 2 Semster Workshop Calculation and Science Syllabus for the trade of Pump operator cum Mechanic Week No Workshop calculation and Science 3 Hrs week 1 amp 2 Factorisation and quadratics multiply expressions in brackets by a number symbol or by another expression in a bracket by extraction of a common factor eg ax ay a x 2 b x 2 by grouping eg ax ay bx by quadratic expressions eg a 2ab b roots of an equation eg quadratic equations with real roots by factorisation and by the use of formula Geometry Use of scientific calculator logarithmic table Angles Angular measurement Angles and rotation Examples of angles in automotive work Adding and subtracting angles Types of angle Adjacent angles Opposite angles Corresponding angles Alternate angle 4 6 Trigonometry Types of triangle Acute angled triangle Obtuse angled triangle Equilateral triangle Isosceles triangle Scalene triangle Right angled triangle Labelling sides and angles of a triangle Sum of the three angles of a triangle Pythagoras theorem Circles Ratio of diameter
20. er bores piston sizes crank pins etc using gauges micrometer and other precision tools and gets cylinders re bored liners fitted valve seats refaced etc as necessary 3 Employment opportunities On successful completion of the course the candidates can either get employed or become a self employed Entrepreneur in any one of the following fields a Wage Employment b Self Employment 1 Pump operator 1 Pump Service Mechanic 2 Pump Service Mechanic 2 Pump Operator 3 Pump Fitter in Pump Manufacturing Concern in 3 Spare Parts Salesman Assembly Shop or Test Shop 4 Spare Parts Dealer 4 Dealers service mechanic 5 Spare Parts Sales Assistant Manufacturers Representative 6 Laboratory Assistant 4 Further learning pathways gt gt gt On successful completion of the course trainee can get themselves enrolled in Apprenticeship training in reputed Industrial organisation The qualified candidates have scope for lateral entry into the Diploma courses offered by some of the State Governments The qualified candidates can also get themselves upgraded by taking up the Second Semester at his own convenience in the CTS scheme since the first semester is common to the following trades Craftsman Training Scheme UA MBRWW Mechanic Motor Vehicle 2 Years 4 Sem Mechanic Diesel 1 Year 2 Sem Mechanic Motor Cycle 1 Year 2 Sem Mechanic Auto Electrical and Electronics 1 Year 2 Sem Mechanic Ag
21. eriodic testing of lifting equipment Energy conservation Definition Energy and Safety disposal of Used engine Conservation Opportunities ECOs Minor ECos oil and Medium ECOs Major ECOs Safety disposal Energy saving Tips of ITI electricity of Used engine oil Electrical safety tips Usage 3 5 Practice using all marking aids like Hand amp Power Tools steel rule with spring calipers Marking scheme Marking material chalk dividers scriber punches Chisel Prussian blue Cleaning tools Scraper wire brush etc Emery paper Description care and use of Surface Layout a work piece for line circle p latg 7 siel tule eens ap 2 oy i Calipers inside and outside Dividers surface arcs and circles gauges scriber punches prick punch center Practice to measure a wheel base ofa punch pin punch hollow punch number and letter vehicle with measuring tape punch Chisel flat cross cut Hammer ball pein Practice to measure valve spring lump mallet Screw drivers blade screwdriver tension using spring tension tester Phillips screw driver Ratchet screwdriver Allen Practice to remove wheel lug nuts key bench vice amp C clamps Sp ee ee oa spanner open end spanner amp the combination with use of an air impact wrench spanner universal adjustable open end spanner Practice on General workshop tools Sockets amp accessories Pliers Combination amp power tools pliers multi grip long nose flat nose Nippers
22. essories 4 5 Allen Key set of 12 pieces 2mm to 14mm 4 6 Ammeter 300A 60A DC with external shunt 4 7 Angle plate adjustable 250x150x175 1 8 Angle plate size 200x100x200mm 2 9 Anvil 50 Kgs with Stand l 10 Auto Electrical test bench l 11 Battery charger 2 12 Bearing and gear tester 2 13 Belt Tensioner gauge 1 14 Blow Lamp 1 litre 2 15 Bradawl 2 16 Caliper inside 15 cm Spring 4 20 17 Calipers outside 15 cm spring 4 18 Cam lock type screw driver 1 19 Car Jet washer with standard accessories 1 20 Carge winches 3 5 tonnes 1 21 Chain pipe wrench 65 m 2 22 Chain Pulley Block 3 ton capacity with tripod stand 1 23 Chisel 10 cm flat 4 24 Chisels cross cut 200 mm X 6mm 4 25 Circlip pliers Expanding and contracting type 15cm and 20cm each 4 26 Clamps C 100mm 2 21 Clamps C 150mm 2 28 Clamps C 200mm 2 29 Cleaning tray 45x30 cm 4 30 Compression testing gauge suitable for diesel Engine 2 31 Copper bit soldering iron 0 25 Kg 5 32 crab 1 33 Cylinder bore gauge capacity 20 to 160 mm 4 34 DC Ohmmeter 0 to 300 Ohms mid scales at 20 Ohms 4 35 Depth micrometer 0 25mm 4 36 Dial gauge type 1 Gr A complete with clamping devices and stand 4 37 Different type of Engine Bearing model l set 38 Digital Tonge Tester 0 20 A AC 2 39 Dividers 15 cm Spring 4 40
23. ine information from the title block Read and interpret industrial prints Read and interpret detailed and assembly drawings Identify casting drawings and machining drawings Read and interpret diagrams Distinguish between a monodetail and a multidetail drawing 5 8 Identify different drawing projections Interpret pictorial and multi view drawings Interpret auxiliary and section views Determine views in a drawing and the significance of the view being shown Identify missing lines and missing views 9 12 Free hand sketching of key and screw threads Read and interpret three Types of screw thread representation pictorial schematic and simplified presentation Terms used in describing a threaded Part Designation of Thread Specifications Left Hand Thread Notations read and interpret the different type of Finish Symbols Fillets and Rounds and Machine Slots 13 Drawing of I C engine Diesel and their parts 14 Free hand sketching of screw jack Free hand sketching assembly of pulleys 15 Free hand sketching of different type of bearing 16 Free hand sketching of reciprocating pump component 17 Free hand sketching of rotary pump component 18 Free hand sketching of centrifugal pump component 19 Free hand sketching of Submersible pump component 20 Drawing of electrical symbol as per IS 1248 Reading of the circuit diagram of electrical circuits 21 Electrical circuit diagram connecting A C motors SYLLABUS FOR EMPLOYABILI
24. ir amp replacement Cleaning of parts amp assembling Installing of reciprocating pumps Pumps its importance for agricultural amp industrial applications Classification of pumps its prime movers parts and operation safety Classification of reciprocating pump construction and operation Installation technique of reciprocating pump Tools and equipment required amp procedure 13 Dismantling of rotary pumps impeller shaft bearing etc for inspection Repair amp replacement Cleaning of parts and assembling Checking for alignment clearance etc Priming technique and its application Installing operating amp testing of rotary pumps Classification of rotary pumps Construction and operation repairing procedure Brief description of turbine amp stage pumps positive displacements and their advantages Meaning of priming and its effect Installation techniques of rotary pump procedure tools and equipments required Servicing of pumps and valves of general purpose and of corrosive fluids Selection of gasket packing amp gland materials marking amp cutting off gasket as per shape amp profile Using gasket cement to stop leakage amp for fixing Different types of valves their description advantages amp use Special pumps amp glands used for corrosive fluids Different gasket cement used to prevent leakage and advantages of each over the other Principle of direct reading pressur
25. lear 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 amp Seam Joints Fastening Methods Riveting soldering Brazing fluxes used on common joints Sheet and wire gauges The blow lamp its uses and pipe fittings 13 Practice in joining wires using soldering Iron Construction of simple electrical circuits Measuring of current voltage and resistance using digital multimeter practice continuity test for fuses jumper wires fusible links circuit breakers Basic electricity Electricity principles Ground connections
26. ng of various line types with examples Object Lines Hidden Lines Center Lines Phantom Lines Dimension Lines Extension Lines Leaders Break Lines Long break Line Round Solid Hollow Cross Section Section Lines Common Manufacturing Materials Cutting Plane Lines Geometric Construction Bisecting a line perpendiculars parallel lines division of a line Angles bisection trisection Tangent lines touching circles internally and externally Polygons Regular polygons circumscribed and inscribed in circles Conic sections Definitions of focus directrix eccentricity Construction of Ellipse by Concentric circles method Construction of parabola by rectangular method 12 amp 13 Orthographic Projection Definition Planes of Projection Four quadrants Reference Line First angle projection Third angle projection 14 17 Isometric Projection Definition Isometric axes lines and planes Isometric Scale Isometric view Drawing of isometric views of plane figures Drawing of isometric views of prisms and pyramids Drawing of isometric view of cylinders and cones 18 21 Development of Surfaces Need for preparing development of surface Concept of true length Principal methods of development Development of simple solids like cubes prisms cylinders pyramids cones SYLLABUS FOR EMPLOYABILITY SKILLS SEMESTER I pl ref to www dget nic in 12 Syllabus for the trade of Pump ope
27. ometer Micrometer adjustments Vernier calipers Telescope gauges Dial bore gauges Dial indicators straightedge feeler gauge thread pitch gauge vacuum gauge tire pressure gauge 8 amp 9 Practice on General cleaning checking and use of nut bolts amp 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 Fasteners Study of different types of screws nuts studs amp bolts locking devices Such as lock nuts cotter split pins keys circlips lock rings lock washers and locating where they are used Washers amp chemical compounds can be used to help secure these fasteners Function of Gaskets Selection of materials for gaskets and packing oil seals Cutting tools Study of different type of cutting tools like Hacksaw File Definition parts of a file specification Grade shape different type of cut and uses OFF hand grinding with sander given dimensions bench and pedestal grinders safety precautions while grinding Limits Fits amp Tolerances Definition of limits fits amp tolerances with examples used in auto components 10 amp 11 Practice on Marking and Drilling clear and Blind Holes Sharpening of Twist Drills Safety precautions to be observed while using a drilling machine Practice on Tapping a C
28. on calculation 9 10 Time and work problem Time and distance clocks and calendar 11 Brief description of manufacturing process of steel and aluminum 12 Meaning of elasticity malleability brittleness hardness compressibility amp ductility and their examples Properties and uses of cast iron ferrous metal gray cast iron white cast iron wrought iron and plain carbon steel high speed steel and alloy steel 13 Properties and uses in automobile industries copper zinc lead tin aluminum brass bronze solder bearing metals timber and rubber Nylon P V C PP poly prop line polymer 14 15 Materials Stress strain Definition of Stress Types of stress Tensile compressive shear Examples of the three basic stresses in automotive components calculation of stress and strain in automotive application Stress raisers Strain Tensile compressive Shear strain Tensile strength Factor of safety Torsional stress Strain energy 16 Definition of cold working and Hot working and its properties on sheet metal Advantage of Deep drawing material Importance of Iron carbon diagram in heat treatment process 17 Different Type of cutting fluids and their properties Calculation of cutting speed feed and drilling time 18 19 Forces Definition of Force Types of force examples Direct forces Attractive forces Explosive forces Describing forces Graphical representation of a force Addition of forces Parallelogr
29. or 2 crimping up to 10mm 75 Hand reamers adjustable 10 5 to 11 25 mm 11 25 to 12 75 mm 12 75 2sets to 14 25 mm and 14 25 to 15 75 mm 76 Hand Shear Universal 250mm 2 77 Hand vice 37 mm 2 78 Hollow Punch set of seven pieces 6mm to 15mm 2 sets each 79 Hydraulic wheel and bearing puller 2 80 Injector Multi hole type Pintle type 4 each 81 Injector cleaning unit l 82 Injector testing set Hand tester 1 83 Insulated Screw driver 20 cm x 9mm blade 4 84 Insulated Screw driver 30 cm x 9mm blade 4 85 Ladle 150mm Dia 1 86 Left cut snips 250mm 4 87 Level bottle sprit 150 ml 1 88 Lifting jack screw type 3 ton capacity 4 89 Magneto spanner set with 8 spanners 1 set 90 Magnifying glass 75mm 2 91 Manila ropes 12 20 30 mm dia 2 sets 92 Marking out table 90X60X90 cm 1 93 Masonary bit Assorted up to 12 mm 2set 94 Master test bars different size 1 95 Megger 500 V 2 96 Mobile crank 1 97 Multimeter digital 5 98 Oil can 0 5 0 25 liter capacity 2 99 Oil Stone 15 cm x 5 cm x 2 5 cm 1 100 Outside micrometer 0 to 25 mm 4 101 Outside micrometer 25 to 50 mm 4 102 Outside micrometer 50 to 75 mm 1 103 Outside micrometer 75 to 100 mm 1 104 Philips Screw Driver set of 5 pieces 100 mm to 300 mm 2 sets 105 Pin spanner set 2 106 Pipe cutting tool 2 107 Pipe flaring tool 2 108 Pipe wrench 45 mm 2 109 Pliers combination 20 cm 2 110 Pliers flat nose 15 cm 2 111 Pliers round nose 15 cm 2 112 Pliers side cutting 15
30. or pincer pliers Side cutters Tin snips Circlip pliers external circlips pliers Air impact wrench air ratchet wrenches Torque wrenches pipe wrenches car jet washers Pipe flaring amp cutting tool pullers Gear and bearing 6 amp 7 Measuring practice on Cam height Systems of measurement Description care amp 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 use of Micrometers Outside and depth mir
31. orizontal split casing pump 1 15 Hydraulic jack HI LIFT type 3 ton capacity 1 16 Hydraulic Leak Testing equipment 1 17 Injector Testing set Hand Tester 1 18 Liquid penetrant Inspection kit 1 set 19 Multi stage pump 1 20 Overhead tank pump minimum 5000 litres with level indicators 1 and piping layout 21 Pipe Bending Machine Hydraulic type 12mm to 30mm 1 22 Pneumatic rivet gun 2 23 Portable electric drill Machine 1 24 Reciprocating Pump working for dismantling and assembling 1 25 Spring tension tester 1 26 Submersible pump set eight stage upto 10 KW 15 HP 1 27 Tin smiths bench folder 600 x 1 6mm 1 28 Trolley type portable air compressor single cylinder with 45 liters 1 capacity Air tank along with accessories amp with working pressure 6 5 kg sq cm 29 Welding plant Oxy Acetylene complete high pressure 1 30 Welding Transformer 150 300 Amps 1 D List of consumable SI Description Quantity No 1 Battery SMF As required 2 Brake fluids As required 3 Chalk Prussian blue As required 4 Chemical compound for fasteners As required 5 Diesel As required 6 Different type gasket material As required 7 Different type of oil seal As required 8 Drill Twist assorted As required Engine coolant As required Engine oil As required 9 Emery paper 36 60 grit 80 120 As required 10 Gear oils As required 11 Hacksaw blade consumable As required 12 Hand rubber gloves tested for 5000 V
32. rator Cum Mechanic Second Semester Semester code No Duration Six Months Syllabus for Trade practical and Trade Theory Week NO Trade Practical 28 Hrs week Trade Theory 6 Hrs week 1 amp 2 Identification of different type of stationary Engine and their applications Familiarisation with diesel engines tools and equipment required for maintenance engine parts and their handling technique Starting and stopping of engines Running of engines and checking temperatures fuel oil pressure and consumption on load and engine speed Pump Industry in India manufacturers development in Industry trends new product Principle of Compression ignition engine Spark Ignition Engine differentiate between 4 stroke and 2 stroke C I engine and S I Engine Otto cycle and Diesel cycle Different type of starting and stopping method of Diesel Engine Technical terms used in engine Engine specification leading Pump Cleaning of fuel tank checking leaks in the fuel lines Cutting flaring of tubes to make T amp Elbow fitting using unions Fitting of lubrication pump oil filters air filters checking and adjusting of oil pressure Preventive maintenance amp repairing Procedure to clean fuel tank amp check leak in the fuel line Lubrication system types description and advantages of each over others Filters and oil coolers their description functions and method to overhaul for efficient fun
33. ricultural Machinery 2 Years 4 Sem Mechanic Tractor Year 2 Sem Pump Operator cum Mechanic 1 Year 2 Sem Syllabus for the trade of Pump operator Cum Mechanic First Semester Semester code No Duration Six Months Syllabus for Trade practical and Trade Theory Week Trade Practical 27 Hrs week Trade Theory 5 Hrs week No 1 Familiarisation with institute Job Admission amp introduction to the trade opportunities in the automobile Introduction to the Course duration course sector Machinery used in Trade Content study of the syllabus General rule ertaining to the Institute facilities available Types oh yor done DF Mhe tiden Hostel ok Medical and Library working in the shop floor hours and time table 2 Practical related to Safety and Occupational Safety amp Health Health Importance of Safety and general Importance of maintenance and Precautions to be observed in the shop Basic cleanliness of Workshop first aid safety signs for Danger Warning TheeaciGue wiih headh cenre and caution amp personal safety message Safe handling i of Fuel Spillage Fire extinguishers used for fire service station to provide demo different types of fire Safe disposal of toxic dust on First aid and Fire safety Use of safe handling and Periodic testing of lifting fire extinguishers equipment Authorization of Moving amp road Demonstration on safe handling and testing vehicles P
34. rsible pumps Finding out amp rectifying faults developed during operation Submersible pump construction operation and selection of appropriate type Procedure to recondition install and test of submersible pumps Causes of failures and remedial measures 13 Identifying and rectifying defects of pump sets Practice on preventive amp scheduled maintenance of pump sets Defects in pump sets procedure for detection of causes amp rectification Purpose and procedure for balancing of rotor Procedure to be followed for preventive amp scheduled maintenance planning for spares and other stores 14 Familiarization with the safety precautions to be followed for electrical work Treatment for electrical shock Use of hand tools connected with electrical Safety rules to be followed in connection with electrical work First aid when affected by electrical shock Purpose types description and method to use common electrical hand 14 work and maintenance of electrical machines tools 15 amp Verification of Ohm s law Building up of Description and method to use current 16 electrical series parallel and combination voltage and resistance measuring instruments of series amp parallel circuits Measurement and precaution to be taken Insulation Tester of current voltage resistance Exercise on description method to use and precautions to fixing and connecting
35. stable 15cm 2 148 Spanner ring set of 12 metric sizes 6 to 32 mm 2 149 Spanners socket with speed handle T bar ratchet and universal upto 2 150 Spark lighter 2 151 Spark plug spanner 14mm x 18mm x Size 2 152 Square box wrenches 1 153 Square T wrenches 1 154 SRDG ball bearing DRDG ball bearing self aligning ball bearing 155 Steel measuring tape 10 meter in a case 4 156 Steel rule 15 cm inch and metric 4 157 Steel rule 30 cm inch and metric 4 158 Steel wire Brush 50mmx 150mm 5 159 Straight edge gauge 2 ft 2 160 Straight edge gauge 4 ft 2 23 161 Stud extractor set of 3 2 sets 162 Stud remover with socket handle 1 163 Surface gauge with dial test indicator plunger type i e 0 01 mm 2 164 Tachometer Counting type 1 165 Taps and Dies complete sets 5 types 1 set 166 Taps and wrenches UNC UNF and metric 2 sets 167 Telescope gauge 4 168 Temperature gauge 0 100 deg c 2 169 Thermostat 2 170 Thimbles of different sizes 2 171 Thread pitch gauge Metric 1 172 Threaded fastener type B 2 173 Threaded fastener type C 2 174 Threaded fastener type F 2 175 Three cell torch 2 176 Three Phase 50 Hz 5 HP AC squirrel gage induction motor with star 1 delta starter 177 Timing lighter l 178 Torque wrenches 5 35 Nm 12 68 Nm amp 50 225 Nm 1 each 179 Trammel 30 cm 2 180 Travelling and gantry cranes
36. structive Testing Methods Importance 20 method and Magnetic particle testing of Non Destructive Testing In Automotive method Identification of Hydraulic and pneumatic components used in vehicle Tracing of hydraulic circuit on hydraulic jack hydraulic power steering and Brake circuit Identification of components in Air brake systems Industry Definition of NDT Liquid penetrant and Magnetic particle testing method Portable Yoke method Introduction to Hydraulics amp Pneumatics Definition of Pascal law pressure Force viscosity Description symbols and application in automobile of Gear pump Internal amp External single acting double acting amp Double ended cylinder Directional control valves 2 2 3 2 4 2 4 3 way valve Pressure relief valve Non return valve Flow control valve used in automobile Pneumatic Symbols Description and function of air Reciprocating Compressor Function of Air service unit FRL Filter Regulator amp Lubricator 21 Identification of different type of Auto Industry History leading manufacturers Vehicle development in automobile industry trends new Hemonseaton of vehicie product Brief about Ministry of Road transport amp dati aaa Highways specification data The Automotive Research Association of India Identification of vehicle information ARAD National Automotive Testing and R amp D Number VIN Demonstration of Infrastructur
37. switches holders be taken Alternating current Definition fuses plugs sockets Push buttons etc explanation and advantages over Direct Use of test lamp and neon tester current and vice versa Concept and Identification of live neutral and earthling application of phase star and delta wires Measurement of electrical power connection Procedure to identify live and energy consumed for a definite period neutral single phase and 3 phase power of time supply Method to measure power and energy consumed by electrical appliances using wattmeter and Energy meter 17 Identifying of A C motors their testing AC Motors related terminology Purpose identifying terminals connecting running type construction operation testing for amp reversing Measuring speed of A C correct functioning maintenance and motor using tachometer with stop watch industrial applications Trouble shooting amp Dismantling assembling of A C motors amp protection of induction motor identification of parts Starting a single phase A C motor with Direct on line D O L starter Starting a 3 phase motor with star delta starter Checking for proper running of motor overheating etc maintenance of motors use and connection of single phase preventor trouble shooting in circuit 18 Practice on making out key as per shaft Types of key and key ways their uses and hub keyways preparing keys to fit into applications Preparation of keys
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