Mechanic Auto Electrical & Electronics
Contents
1. 64 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 65 Hand Shear Universal 250mm 2 66 Hand vice 37 mm 2 67 High rate discharge tester cell tester 1 68 Holders lamp teakwood boards plug sockets solders flux wires and As required cables batteries round consumable blocks and other consumables as required 69 Hollow Punch set of seven pieces 6mm to 15mm 2 sets each 70 Insulated Screw driver 20 cm x 9mm blade 4 71 Insulated Screw driver 30 cm x 9mm blade 4 yea Left cut snips 250mm 4 73 Lifting jack screw type 3 ton 5ton amp 20 Ton capacity 1 each 74 Magneto spanner set with 8 spanners 1 set 75 Magnifying glass 75mm 2 76 Marking out table 90X60X90 cm 1 71 Multimeter digital 5 78 Multi point fuel injection pump 1 79 Oil can 0 5 0 25 liter capacity 2 80 Oil Stone 15 cm x 5 cm x 2 5 cm 1 81 Oscilloscope 20MHz 2 82 Outside micrometer 0 to 25 mm 4 83 Outside micrometer 25 to 50 mm 4 84 Outside micrometer 50 to 75 mm 1 85 Outside micrometer 75 to 100 mm 1 86 Philips Screw Driver set of 5 pieces 100 mm to 300 mm 2 sets 87 Pipe cutting tool 2 88 Pipe flaring tool 2 89 Pliers combination 20 cm 2 90 Pliers flat nose 15 cm 2 91 Pliers round nose 15 cm 2 92 Pliers side cutting 15 cm 2 93 Portable electric drill Machine 1 94 Portable headlight aiming kit ji 952. 1 Year 2 Sem Mechanic Motor Cycle 1 Year 2 Sem Mechanic Auto Electrical and Electronics 1 Year 2 Sem Mechanic Agricultural Machinery 2 Years 4 Sem Mechanic Tractor 1 Year 2 Sem Pump Operator cum Mechanic 1 Year 2 Sem Syllabus for the trade of Mechanic Auto Electrical amp Electronics First Semester Semester code No Duration Six Months Syllabus for Trade practical and Trade Theory Week No Trade Practical 27 Hrs week Trade Theory 5 Hrs week Familiarisation with institute Job opportunities in the automobile sector Machinery used in Trade Types of work done by the students in the shop floor Admission amp introduction to the trade Introduction to the Course duration course content study of the syllabus General rule pertaining to the Institute facilities available Hostel Recreation Medical and Library working hours and time table Practical related Health Importance of maintenance cleanliness of Workshop Interaction with health centre and fire service station to provide demo on First aid and Fire safety Use of fire extinguishers Demonstration on safe handling and Periodic testing of lifting equipment and Safety disposal of Used engine oil Energy saving Tips of ITI electricity Usage to Safety and and Occupational Safety amp Health Importance of Safety and general Precautions to be observed in the shop Basic first aid safety signs for Danger
3. Practice on Marking and Drilling clear and Blind Holes Sharpening of Twist Drills Safety precautions to be observed while using a drilling machine Practice on Tapping a Clear and Blind Hole Selection of tape drill Size use of Lubrication Use of stud extractor Cutting Threads on a Bolt Stud Adjustment of two piece Die Reaming a hole Bush to suit the given pin shaft scraping a given machined surface Drilling machine Description and study of Bench type Drilling machine Portable electrical Drilling machine drill holding devices Work Holding devices Drill bits Taps and Dies Hand Taps and wrenches Calculation of Tap drill sizes for metric and inch taps Different type of Die and Die stock Screw extractors Hand Reamers Different Type of hand reamers Drill size for reaming Lapping Lapping abrasives type of Laps 12 Practice on making Rectangular Tray Pipe bending Fitting nipples unions in pipes Soldering and Brazing of Pipes Sheet metal State the various common metal Sheets used in Sheet Metal shop Sheet metal operations Shearing bending Drawing Squeezing Sheet metal joints Hem 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 resistanc
4. Prick Punch 15 cm 4 96 Punch Letter 4mm Number 2 set 97 Right cut snips 250mm 4 98 Rivet sets snap and Dolly combined 3mm 4mm 6mm 4 99 Scriber 15 cm 2 100 Scriber with scribing black universal 2 101 Set of stock and dies Metric 2 sets 102 Shear Tin Man s 450 mm x 600mm 4 103 Sheet Metal Gauge 2 104 Sher Tinmans 300mm 8 105 Soldering Copper Hatchet type 500 gms 5 106 Spanner Clyburn 15 cm 1 107 Spanner D E set of 12 pieces 6mm to 32mm 4 108 Spanner T flocks for screwing up and up screwing inaccessible 2 positions 24 109 Spanner adjustable 15cm 2 110 Spanner ring set of 12 metric sizes 6 to 32 mm 2 111 Spanners socket with speed handle T bar ratchet and universal upto 2 32 mm set of 28 pieces with box 112 Spark lighter 2 113 Spark plug spanner 14mm x 18mm x Size 2 114 Steel measuring tape 10 meter in a case 2 115 Steel rule 15 cm inch and metric 2 116 Steel rule 30 cm inch and metric 2 117 Straight edge gauge 2 ft 1 118 Straight edge gauge 4 ft 1 119 Stud extractor set of 3 2 sets 120 Stud remover with socket handle 1 121 Surface gauge with dial test indicator plunger type i e 0 01 mm 2 122 Tachometer Counting type 1 123 Taps and Dies complete sets 5 types 1 set 124 Taps and wrenches Metric 2 sets 125 Telescope gauge 4 126 Tem
5. components with examples 19 amp Practice on Liquid penetrant testing Non destructive Testing Methods Importance 20 method and Magnetic particle testing of Non Destructive Testing In Automotive method Industry Definition of NDT Liquid penetrant Identification of Hydraulic and and Magnetic particle testing method Portable pneumatic components used in Yoke method vehicle Introduction to Hydraulics amp Pneumatics Tracing of hydraulic circuit on Definition of Pascal law pressure Force hydraulic jack hydraulic power viscosity Description symbols and application in steering and Brake circuit automobile of Gear pump Internal amp External Identification of components in Air single acting double acting amp Double ended brake systems 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 Demonstration of specification data Identification of vehicle information Number VIN Demonstration of Garage Service station equipments Vehicle hoists Two post and four post hoist Engine hoists Jacks Stands vehicle development in automobile industry trends new product
6. Brief about Ministry of Road transport amp Highways The Automotive Research Association of India ARAD National Automotive Testing and R amp D Infrastructure Project NATRIP amp Automobile Association Definition Classification of vehicles on the basis of load as per central motor vehicle rule wheels final drive and fuel used axles position of engine and steering transmission body and load Brief description and uses of Vehicle hoists Two post and four post hoist Engine hoists Jacks Stands 22 23 In plant Training 24 25 Revision and Test 26 NCVT Exam Automobile Group 1 year Trade 1 Semster Workshop Calculation and Science Syllabus for the trade of Mechanic Auto Electrical amp Electronics 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
7. I pl ref to www dget nic in 11 Syllabus for the trade of Mechanic Auto Electrical amp Electronics Second 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 Identification of parts in a diesel engine Introduction to Engine of LMV HMV Principle amp working of 4 stroke diesel engine Practice on starting and stopping of Compression ignition Engine C I Principle diesel engines of Spark Ignition Engine SI difference Observe and report the reading of between C I engine and S I Engine Technical Tachometer Odometer temp and Fuel terms used in engine Engine specification gauge under ideal and on load Study of various gauges instrument on a dash condition board of a vehicle Speedometer Tachometer Odometer and Fuel gauge and Indicators such as gearshift position Seat belt warning light Parking brake engagement warning light and an Engine malfunction light Different type of starting and stopping method of Petrol Diesel Engine 2 Practice to identify components and Electrical and Electronic Components their locations indicated on the wiring diagram Practice to identify the power source ground connection and controls for electrical circuits using a wiring diagram Switches Description of Normally open Normally closed single pole single throw switch SPST gange
8. Warning caution amp personal safety message Safe handling of Fuel Spillage Fire extinguishers used for different types of fire Safe disposal of toxic dust safe handling and Periodic testing of lifting equipment Authorization of Moving amp road testing vehicles Energy conservation Definition Energy Conservation Opportunities ECOs Minor ECos and Medium ECOs Major ECOs Safety disposal of Used engine oil Electrical safety tips 3 5 Practice using all marking aids like steel rule with spring calipers dividers scriber punches Chisel etc Layout a work piece for line circle arcs and circles Practice to measure a wheel base of a vehicle with measuring tape Practice to measure valve spring tension using spring tension tester Practice to remove wheel lug nuts with use of an air impact wrench Practice on General workshop tools amp power tools Hand amp Power Tools Marking scheme Marking material chalk Prussian blue Cleaning tools Scraper wire brush Emery paper Description care and use of Surface plates steel rule measuring tape try square Calipers inside and outside Dividers surface gauges scriber punches prick punch center punch pin punch hollow punch number and letter punch Chisel flat cross cut Hammer ball pein lump mallet Screw drivers blade screwdriver Phillips screw driver Ratchet screwdriver Allen key bench vice amp C clamps Spanners ring spanner
9. of Mechanic Auto Electrical amp Electronics Week Engineering Drawing 3 Hrs week Nos 2 Semester 1 4 Read and interpret drawings Determine 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 Make a simple sketch in plan view of a front engine FWD vehicle Label the main components engine clutch gearbox drive shafts driving wheels radiator fuel tank 14 Free hand Sketching of Fuel supply High Pressure system Control unit ingoing outgoing information diagram 15 Drawing of schematic diagram of ABS hydraulic circuit Engine control module assembly 16 Free hand sketch of Torque co
10. open end spanner amp the combination spanner universal adjustable open end spanner Sockets amp accessories Pliers Combination pliers multi grip long nose flat nose Nippers or pincer pliers Side cutters Tin snips Circlip pliers external circlips pliers Air impact wrench air ratchet wrenches Torque wrenches pipe wrenches car jet washers Pipe flaring amp cutting tool pullers Gear and bearing 6 amp 7 Measuring practice on Cam height Camshaft Journal dia crankshaft journal dia Valve stem dia piston diameter and piston pin dia with outside Micrometers Measuring practice on the height of the rotor of an oil pump from the surface of the housing or any other auto component measurement with depth micrometer Measuring practice on valve spring free length Measuring practice on cylinder bore Connecting rod bore inside diameter ID of a camshaft bearing with Telescope gauges Measuring practice on cylinder bore for taper and out of round with Dial bore gauges Measuring practice to measure wear on crankshaft end play crankshaft run out and valve guide with dial indicator Measuring practice to check the flatness of the cylinder head is warped or twisted with straightedge is used with a feeler gauge Measuring practice to check the end gap of a piston ring piston to cylinder wall clearance with feeler gauge Practice to check engine manifold vacuum with vacuum gauge Practice to check th
11. test for Hold in coil open circuit Armature test Ground test Open circuit test pull in coil open circuit test field coil test Inspections of brush length wear as per service manual Trouble shooting possible causes and remedy for starter motor not running Starting motor running but too slow small torque staring motor running but not cranking engine Noise starting motor does not stop running Growler testing for rotors Checking a starting system Jump Starting system purpose of starting system Staring system components Starter motor principles study of starter control circuits Starter motor construction Starter magnet types Starter motor engagement Commutation Switching solenoid construction 13 starting a vehicle 8 amp 9 Checking a charging system for the Charging system The purpose of Charging cause of undercharge No charge and system charging system components charging over charge conditions Removing amp system circuit Alternator principles replacing an alternator Inspection of Alternating current Alternator components rotor for ground open circuit field Rectification Phase winding connections coil resistance slip ring surface Fan Rotor circuit Voltage regulation System bearing Inspection of stator for operating voltage High voltage charging ground open circuit Inspection of systems Rotor Stator Alternator end frames Drive end b
12. up Only one beam Hi or Lo does not light Trouble shooting and remedy for turn signal and hazard warning lights Flash rate high or one side only flashes No Flashing flash rate low Trouble shooting and remedy for clearance tail and license plate lights All lights do not light up some lights do not light up Trouble shooting and remedy for Back up light Back up lights do not light up Trouble shooting and remedy for Brake lights Brake lights do not light up Brake light stay on Trouble shooting and remedy for fuel meter and fuel gauge unit Fuel meter shows no operation or incorrect operation Trouble shooting and remedy for Engine coolant Temp ECT meter and ECT Sensor Engine coolant temp meter shows no operation or incorrect operation Trouble shooting and remedy for oil pressure light Oil pressure warning light does not light up when ignition switch is on at engine off Trouble shooting and remedy for brake and parking brake warning light Brake warning light does not light up when fluid flow level Brake warning light does not light up when parking brake pull up Brake warning lights stay on Trouble shooting and remedy for interior light Interior light do not light up Trace the wiring circuit of traffic signal flashers light circuit tracing defects in the flasher circuits replacing fuse bulb circuits Brake light circuits turn signal circuit Cornering lights Fog lights circ
13. 6 17 Spanners socket with speed handle T bar ratchet and universal upto 32 6 mm set of 28 pieces with box 18 Steel rule 30 cm inch and metric 6 19 Steel tool box with lock and key folding type 400x200x150 mm 6 20 Test light 6 21 Wire cutter and stripper 6 B Tools Instruments and General Shop outfits Sl No Item with specification Qty Nos 1 AC alternator slip ring puller 1 2 Adjustable spanner pipe wrench 350 mm 2 3 Air blow gun with standard accessories 1 4 Air impact wrench with standard accessories 4 5 Air ratchet with standard accessories 4 6 Allen Key set of 12 pieces 2mm to 14mm 2 T Ammeter 300A 60A DC with external shunt 4 8 Angle plate adjustable 250x150x175 1 9 Angle plate size 200x100x200mm 2 10 Anti theft device 2 11 Anvil 50 Kgs with Stand 1 12 Auto Electrical test bench 1 13 Battery charger 2 14 Battery terminal cleaner tool 2 15 Battery tester 1 22 16 Belt Tensioner gauge 1 17 Blow Lamp 1 litre 2 18 Caliper inside 15 cm Spring 4 19 Calipers outside 15 cm spring 4 20 Car Jet washer 1 21 Car stereo 1 22 Chisel 10 cm flat 4 23 Chisels cross cut 200 mm X 6mm 4 24 Circlip pliers Expanding and contracting type 15cm and 20cm each 2 25 Clamps C 100mm 2 26 Clamps C 150mm 2 2T Clamps C 200mm 2 28 Cleaning tray 45x30 cm 4 29 Cop
14. 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 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 expansio
15. SYLLABUS OF SEMESTER SYSTEM FOR THE TRADE OF Mechanic Auto Electrical amp Electronics Under Craftsmen Training Scheme CTS One year Two Semesters Redesigned in 2014 By Government of India Ministry of Labour amp Employment DGE amp T GENERAL INFORMATION 1 Name of the Trade 2 N C O Code No 3 Duration of Craftsmen Training 4 Power Norms 5 Space Norms 6 Entry Qualification 7 Unit strength 8 Instructors Qualification Mechanic Auto Electrical amp Electronics 7241 70 7242 10 ASC Q 1408 1Year Two Semester having duration of six months each 3 KW Space Area 100 Sq Mt Including parking area Passed 10 class examination with maths and Science 16 30 super Numeric a Degree in Automobile Mechanical Engg Electrical Electronics amp communication Engg Engineering with specialization in Automobile from recognised college University with one year experience in the automobile industry and should possess valid LMV driving license OR Diploma in Automobile Mechanical specialization in automobile Electrical Engineering Electronics amp communication Engg from recognized board of technical education with two years experience in the automobile industry and should posses valid LMV driving license OR 10 Passed NTC NAC in the Trade of Mechanic Auto Electrical amp Electronics with 3 years post qualification experience in the relevant field and should p
16. binet 6 2 x 3 x 1 2 19 Trainees locker 6 2 x 3 x 1 2 Nos to accommodate 20 Lockers 27 List of tools amp Equipment for the Trade of Mechanic Auto Electrical amp Electronics Engineering Drawing Note Facilities available in Draughtsman trade can be utilized TRAINEE S TOOLS KIT SI No Name of the items Quantity 1 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 Draughtsman stool 20Nos 28
17. bing forces Graphical representation of a force Addition of forces Parallelogram 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 10 Automobile Group 1 year Trade 1 Semster Engineering Drawing Syllabus for the trade of Mechanic Auto Electrical amp Electronics Week No Engineering Drawing 3 Hrs week 1 Semester 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 am
18. c equipment in factory or workshop or at place of use Examines drawings and wiring diagrams checks parts for accuracy of fit and minor adjustments assembles parts or mounts them on chassis or panels with aid of hand tools Installs and connects wiring soldering joints equipment diagnoses faults with aid of electronic testing equipment Dismantles equipment if required and replaces faulty parts or wiring 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 Auto Electrician 1 Diagnostic Mechanic 2 Spare Parts Sales Assistant Manufacturers 2 Spare Parts Salesman Representative 3 Spare Parts Dealer 3 Laboratory Assistant 4 Diagnostic Mechanic 5 Car AC Mechanic 4 Further learning pathways gt On successful completion of the course trainee can get themselves enrolled in Apprenticeship training in reputed Industrial organisation gt The qualified candidates have scope for lateral entry into the Diploma courses offered by some of the State Governments gt 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 SAP Ae Mechanic Motor Vehicle 2 Years 4 Sem Mechanic Diesel
19. d and mercury switches used in Automobile circuit Description of Relay ISO Relays Solenoids Buzzers Resistors Description of different type of resistors and their colour codes Fixed stepped and variable _ resistors Rheostat Potentiometer Description of Diodes Diode identification and ratings zener diodes Avalanche diodes Light emitting diodes photo diodes and clamping diodes Transistors Description of NPN PNP field effect transistor FET phototransistors Description of Integrated circuits Circuit protection devices Description of fuses different type of fuses glass or ceramic blade and bullet or cartridge fuses Fusible links maxi fuses circuit breaker Positive Temperature coefficient PTC resistor device 12 Diagnosis and remedy for Speedometer shows no operation fuel level meter shows no operation coolant temp meter shows no operation Oil pressure light shows no lighting Wiring and circuit diagrams Automotive Wiring difference between primary wiring and secondary wiring Comparison between solid and stranded primary wire Description of wire size Metric and American wire gauge AWG Importance of ground straps used in automotive wiring Description of different type of terminals and connectors Molded multiple wire hard shell bulkhead weather pack metri pack heat shrink covered butt connectors Importance of printed circuit boards wiring harnesses wiring diagra
20. e using digital multimeter practice continuity test for fuses jumper wires fusible links circuit breakers Basic electricity Electricity principles Ground connections Ohm s law Voltage Current Resistance Power Energy Voltmeter ammeter Ohmmeter Mulitmeter Conductors 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 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 battery with Description of Chemical effects Batteries amp cells Lead acid batteries amp Stay Maintenance Free SMF batteries Magnetic effects Heating effects Thermo e
21. e air pressure inside the vehicle tires is maintained at the recommended setting Systems of measurement Description care amp use of Micrometers Outside and depth mirometer Micrometer adjustments Vernier calipers Telescope gauges Dial bore gauges Dial indicators straightedge feeler gauge thread pitch gauge vacuum gauge tire pressure gauge 8 amp 9 Practice on General checking and use of nut studs etc cleaning bolts amp Removal of stud bolt from blind hole Practice on cutting tools like Hacksaw file chisel Sharpening of Chisels center punch safety precautions while grinding Practice on Hacksawing and filing to given dimensions 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 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
22. earing rotation Rectifier Slip ring amp brush assembly Rectifier assembly brush length compare with service Alternator cooling fan manual slip ring surface Inspecting amp adjusting an engine drive belt Replacing an engine drive belt pulleys Tesnionsers and their alignments Trouble shooting possible causes and remedy for warning lamp does not glow when ignition switch is on Warning lamp glows dim when ignition switch is on warning lamp on while the alternator is running Warning lamp glows dim while the alternator is running warning lamp flickers considerably 10 Identification of EDC components Electronic Diesel control Electronic Diesel 12 sensors Testing of sensors and control systems Common Rail Diesel Injection actuators Identification of various components of MPFI system Testing of MPFI components and replacement if necessary Check delivery from fuel Pump Replacing a fuel filter Identification of Electronic control Unit Set up for testing Testing of Electronic Control Circuit Fault finding in Electronic circuit and remedies using scan tool CRDI system Hydraulically actuated electronically controlled unit injector HEUI diesel injection system Sensors actuators and ECU Electronic Control Unit used in Diesel Engines Introduction to Electronic fuel injection EFI fuel supply system Miulti point injection systems MPI MPFI EFI air cleaners Electronic m
23. ed 14 Fender cover As required 15 Gear oils As required 16 Hacksaw blade consumable As required 17 Hand rubber gloves tested for 5000 V 5 pair 26 18 Holders lamp teakwood boards plug sockets As required solders flux wires and cables batteries round consumable blocks and other consumables as required 19 Hydrometer 8 20 Jumper wires As required 21 Lapping abrasives As required 22 Leather Apron 5 23 Petrol As required 24 Power steering oil As required 25 Radiator Coolants As required 26 Safety glasses As required 27 Steel wire Brush 50mmx150mm 5 E Workshop Furniture SI Description Quantity No l Book shelf glass panel 6 2 x 3 x 1 2 As required 2 Computer Chair 1 1 3 Computer Table 1 1 4 Desktop computer and related MS office software 1 1 5 Discussion Table 8 x 4 x 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 14 As required 16 Suitable class room furniture As required 17 Suitable Work Tables with vices As required 18 Tool Ca
24. entified 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 Installs repairs replaces and overhauls wiring starters generators distributors and other electrical equipment of motor vehicles e Examines vehicle battery checks voltage and specific gravity using special equipment such as voltmeter hydrometer heavy discharge tester etc and ensures that battery is in good condition e Checks vehicle wiring locates faults and rectifies defects by replacing damaged wire or connecting ends with insulation tape e Starts engine to check whether alternator is charging correctly and if distributor condenser coil and cut out are functioning properly e Estimates nature of defects and reports components to be replaced or repaired e Dismantles and repairs electrical units and components such s generator distributor etc where required Replaces repaired kit or unit in vehicle and connects it with battery Conducts thorough examination of various electrical fittings such as lights panel indicators fuel pumps etc and rectifies defects Checks condition and makes necessary adjustments May do armature winding May drive vehicles on road May charge batteries Fits assembles and repairs various kinds of electroni
25. lectric energy Thermisters Thermo couples Electrochemical energy Photo voltaic energy Piezo electric energy Electromagnetic induction Relays Solenoids Primary amp Secondary windings Transformers stator and rotor coils 16 Identify and test power and signal connectors for continuity Identify and test different type of Diodes NPN amp PNP Transistors for its functionality Construct and test simple logic circuits OR AND amp NOT and Logic gates using switches Basic electronics Description of Semi conductors Solid state devices Diodes Transistors Thyristors Uni Junction Transistors UJT Metal Oxide Field Effect Transistors MOSFETs Logic gates OR AND amp NOT and Logic gates using switches a ste en Introduction to welding and Heat Treatment Arc Welding Welding processes Principles of Arc welding Seine or Gane times ea eas So and y aac practice to make a straight beads and ice Ce ee A A a i sources electrodes welding parameters edge Taa See e ve wekaae preparation amp fit up and welding techniques Oxy Film on Heat treatment process Acetylene 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
26. m Flushing a Electronic adjustable rate shock absorbers power steering system Electric brakes Electro hydraulic braking Trouble shooting and remedy for EHB ABS brake system Antilock braking steering wheel feels heavy at low speed system operation Principles of ABS braking poor recovery from turns Vehicle pulls ABS master cylinder Hydraulic control unit to one side during straight driving Wheel speed sensors ABS with Electronic Identification of ABS components Brake force Distribution EBD control unit checking of ABS warning lamp Electronic control transmission Electronic Identification of Automatic control Unit Fully hydraulically controlled transmission components transmission Electronic shift programs Inspection of shift lever switch throttle Manual selection position sensor speed sensor and automatic transmission wiring harness coupler 16 amp Identification of Air conditioning Heating Ventilation Air Conditioning 17 components Performance test on A c HVAC legislation Vehicle heating unit Checking Charged state of ventilation amp cooling systems Basic air refrigerant Inspecting amp adjusting an conditioning principles Air conditioning engine drive belt Replacing an engine capacity Air conditioning refrigerant drive belt Humidity Description and function of Fixed Checking a heating system orifice Control devices Thermostatic Compressor rotation test air Gap check expansi
27. ms and color codes and circuit numbering Study of common electrical and electronic symbols used in wiring diagrams Check and replace ignition overhauling Distributor Assembly Checking ignition timing Checking amp changing a spark plug Removing amp replacing contact points Diagnosis Possible causes and remedy for Engine cranks but will not or hard to start Poor fuel economy or engine performance Identification and testing of Hall effect sensor Optical sensor Tracing and testing of sensor circuits Tracing of Distributor less ignition systems circuit coil Ignition principles and _ Faraday s laws Primary and secondary winding of transformer Ignition components Spark plugs Spark plug components Vacuum amp centrifugal units Plug firing voltage Contact breaker system ballast resistor coil Dwell angle Spark timing Battery power source Description and function of Capacitor condenser Distributors Distributor types High tension leads Advance amp retard mechanisms Principle of Induction Mutual induction self Induction Inductive system operation Induction wiring Hall effect sensors Hall effect operation Optical type sensors Distributor less ignition systems Insulated coils Distributor less ignition system timing 6 amp 7 Removing starter motor from vehicle and Performance test for pull in test Hold in test pinion plunger return test No load performance test Solenoid
28. n 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 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 18 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 19 Automobile Group 2 Semester Engineering Drawing Syllabus for the trade
29. nverter Lay out for gearbox Selector positions Planetary gear set High range power flow Low range power flow 17 Block diagram of MPFI system Sketching of various Electronic devices used in motor vehicle 18 Free hand sketching of sensors Free hand cut sectional view of petrol nozzle 19 Sketching of Exploded view of alternator 20 Sketching of Exploded view of starter motor 21 Sketching of Air conditioning system using an expansion valve and orifice tube SYLLABUS FOR EMPLOYABILITY SKILLS SEMESTER II Pl ref to www dget nic in 20 21 TRADE MECHANIC AUTO ELECTRICAL amp ELECTRONICS LIST OF TOOLS amp EQUIPMNT A TRAINEES TOOL KIT per 4 Trainees FOR 20 TRAINEES 1 ISTRUCTOR Sl No Item with specification Qty Nos l Allen Key set of 12 pieces 2mm to 14mm 5 1 2 Back probe tools 6 3 Caliper inside 15 cm Spring 6 4 Calipers outside 15 cm spring 6 5 Center Punch 10 mm Dia x 100 mm 6 6 Dividers 15 cm Spring 6 7 Electrician Screw Driver 250mm 6 8 Hammer ball peen 0 5 kg with handle 6 9 Hands file 20 cm Second cut flat 6 10 Logic probe 6 11 Pliers combination 20 cm 6 12 Screw driver 20cm X 9mm Blade 6 13 Screw driver 30 cm X 9 mm Blade 6 14 Scriber 15 cm 6 15 Spanner D E set of 12 pieces 6mm to 32mm 6 16 Spanner ring set of 12 metric sizes 6 to 32 mm
30. o 12mm dia along with accessories 1 14 Dual Magnetization Yoke AC HWDC 230 VAC 50Hz 1 15 Electronic engine control module 1 set 16 Grinding machine general purpose D E pedestal with 300 mm dia 1 17 Liquid penetrant Inspection kit 1 set 18 Memory keeper Battery backups 1 19 Multi scan tool ECU diagnostics kit 1 20 Petrol Engine 4 stroke Motor Cycle Scooter along with special tools 1 and accessories 21 Pipe Bending Machine Hydraulic type 12mm to 30mm 1 22 Pneumatic rivet gun 2 23 Spring tension tester 1 24 Starter motor axial type pre engagement type amp Co axial type leach 25 Trolley type portable air compressor single cylinder with 45 liters 1 26 Ultrasonic Injection cleaning equipment 1 27 Welding plant Oxy Acetylene complete high pressure 2 28 Welding Transformer 150 300 Amps 1 29 Wiper motor assembly 2 30 Working Model of power windows 1 D List of consumable SI No Description Quantity 1 Assortment of diodes electronic components As required 2 Automatic Transmission oils As required 3 Backing Soda As required 4 Battery cleaner spray As required 5 Battery SMF As required 6 Brake fluids As required 7 Chalk Prussian blue As required 8 Chemical compound for fasteners As required 9 Diesel As required 10 Different type gasket material As required 11 Different type of oil seal As required 12 Drill Twist assorted As required 13 Emery paper _ 36 60 grit 80 120 As requir
31. on valve system Thermal expansion Refrigerant recovery evacuating valves Air conditioning compressors charging of A c system Condensers amp evaporators Receiver drier Replenishing compressor oil level Lines amp hoses TX valve construction Trouble diagnose and remedy for Temperature monitoring thermostat No cooling or warm air Cool air comes Refrigerants Pressure switches Heating out only intermittently cool air comes elements out only at high Insufficient cooling Air conditioning ECU Ambient air Abnormal noise from compressor temperature sensor Servo motors Electric Magnetic clutch condenser evaporator servo motors Automatic climate control Blower motor sensors Evaporator temperature sensor Blower Diagnosis test for High pressure gauge speed control Ventilation systems pressure high and low Low pressure gauge for pressure high and low 18 amp Trace the light circuit test bulbs align Lighting system Lamps light bulbs 19 head lamps Aiming headlights Lamp light bulb information LED lighting Changing a headlight bulb Checking of a head light switch and to replace if faulty Trouble shooting and remedy for Headlights description of standard sealed beam halogen sealed beam composite and High intensity discharge HID headlights Headlight amp dimmer circuits Park amp tail light 15 Headlight headlight do not light up only one headlight does not light
32. osses valid LMV driving license and b With National Crafts Instructor Certificate Note 1 At least one Instructor must have Degree Diploma in Automobile Mechanical Engg Electrical Engineering Electronics amp communication when applied for 02 units 2 Instructor Qualification for WCS amp E D as per the Training Manual 9 For Employability Skills One 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 Trade Work Engg Employability Extra week practical theory shop Cal Drawing skills curricular amp Sc activity 42 Hours 27 Hours 5 Hours 3 Hours 3 Hours 2 Hours 2 Hours COURSE INFORMATION MECHANIC AUTO ELECTRICAL AND ELECTRONICS 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 id
33. p 7 Identify the alphabet of lines Read and Interpret the meaning 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 8 11 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 S YLLABUS FOR EMPLOYABILITY SKILLS SEMESTER
34. per bit soldering iron 0 25 Kg 4 30 Cylinder bore gauge capacity 20 to 160 mm 4 31 DC Ohmmeter 0 to 300 Ohms mid scales at 20 Ohms 4 32 Depth micrometer 0 25mm 4 33 Dial gauge type 1 Gr A complete with clamping devices and stand 4 34 Distributor Duel advance type reluctance type e 35 Dividers 15 cm Spring 4 36 Drift Punch Copper 15 Cm 4 37 Drill point angle gauge 1 38 Drill twist 1 5 mm to 15 mm various sizes by 0 5 mm 4 39 Electric Soldering Iron 230 V 60 watts 230 V 25 watts 40 Electric testing screw driver 41 Electrical horn different types 42 Engineer s square 15 cm Blade 4 43 Executive Auto Electrical tool kit 1 44 Feeler gauge 20 blades metric 1 45 File flat 20 cm bastard 4 46 File half round 20 cm second cut 4 47 File Square 20 cm second cut 4 48 File Square 30 cm round 4 49 File triangular 15 cm second cut 4 50 Files assorted sizes and types including safe edge file 20 Nos 2 set 51 Flat File 25 cm second cut 4 52 Flat File 35 cm bastard 4 53 Glow plug tester 2 54 Granite surface plate 1600 x 1000 with stand and cover 1 55 Grease Gun 1 56 Growler 4 57 Hacksaw frame adjustable 20 30 cm 10 58 Hammer Ball Peen 0 75 Kg 2 59 Hammer Chipping 0 25 Kg 2 60 Hammer copper 1 Kg with handle 2 6l Hammer Mallet 2 62 Hammer Plastic 2 63 Hand operated crimping tool i for crimping up to 4mm and ii for 2 crimping up to 10mm 23
35. perature gauge 0 100 deg c 2 127 Tester sparking plug NEON Type 1 128 Thermostat 2 129 Thread pitch gauge metric BSW 1 130 Timing lighter 1 131 Torque wrenches 5 35 Nm 12 68 Nm amp 50 225 Nm 1 each 132 Trammel 30 cm 2 133 Universal puller for removing pulleys bearings 1 134 V Block 75 x 38 mm pair with Clamps 2 135 Vrnier caliper 0 300 mm with least count 0 02mm 4 136 Vice grip pliers 2 137 Voltmeter 50V DC 5 138 Wire Gauge metric 5 139 Work bench 250 x 120 x 60 cm with 4 vices 12cm Jaw 1 140 4 Point relays 2 141 5 Point relays 2 C General Installation Machineries SLNo Item with specification Qty Nos l Air bag simulator 1 2 Air conditioned MPFI vehicle with auto transmission and accessories 1 3 Air conditioning service Unit Car 1 4 Air conditioning trainer kit 1 5 Alternator assembly used for LMV 2 6 Arbor press hand operated 2 ton capacity 1 7 Bench lever shears 250mm Blade x 3mm Capacity 1 8 Cut section Model of Mock layout of a motor car electrical system 1 working model 9 Demonstration board Ignition system ignition coil 1 set 25 10 Demonstration board of CRDI system working model 1 11 Demonstration board of MPFI system working model 1 12 Discrete Component Trainer Basic Electronics Trainer 1 13 Drilling machine bench to drill up t
36. profit and loss Discount 7 simple interest and compound interest 8 depreciation 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 ofi 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 Descri
37. rs Tire pressure monitoring systems Integrated communications Proximity sensors Reflective displays Global positioning satellites Triangulation trilateration Telematics Application of Automotive bus system currently used in cars CAN Control Area Network LIN Local Interconnect Network FlexRay and MOST Media Oriented Systems Transport Importance of E E Architecture 22 23 Industrial Training Project 24 25 Revision and Test 26 NCVT Exam 17 Automobile Group 1 year Trade 2 1 Semster Workshop Calculation and Science Syllabus for the trade of Mechanic Auto Electrical amp Electronics 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 Trigonometry Types of triangle Acute angled triangle Obtuse angled triangle
38. ufflers EFI fuel supply system components Description of Fuel pumps EFI sensors Potentiometer Auxiliary air valves Idle speed control devices Inertia sensors Introduction to EFI Engine Management EFI operation Modes of EFI Idle speed control systems Feedback amp looping Cold start systems Air measurement Air flow monitoring Variable intake manifold system Electrical functions EFI wiring diagram Electronic control unit ECU EFI system ECU Electronic control unit settings Engine speed limiting Malfunction indicator lamp Importance of Diagnostic Trouble Code DTC amp its general format Use of scan tool and retrievals of codes 14 13 Identification of various sensors installed in engine amp its mounting Testing of Temperature sensor Pressure senor potentiometer magnetic induction sensor cam shaft sensor crankshaft position sensor EFI sensors Description location and function of Intake Temperature sensor Mass airflow sensor Manifold absolute pressure sensor Air vortex sensor Fuel system sensor Throttle position sensor Exhaust gas oxygen sensor Crank angle sensor Hall effect voltage sensor 14 amp Inspection of power steering control Steering suspension and Brakes 15 module circuit Checking amp adjusting Description of Electric power assisted steering power steering fluid Pressure testing a Basic electric power steering operation power steering syste
39. uit interior lights courtesy reading and instrument panel lights Smart lighting Reverse lights 20 amp 21 Trouble shooting and remedy for Horn No horn operation poor sound quality horn sounds continuously and to replace the horn if faulty Remove and install wiper motors and wiper switches Checking amp replacing wiper blades Trouble shooting and remedy for Accessories Horn circuit wiper circuit power window components and circuit Power door lock circuit automatic door lock circuit remote keyless entry system circuit antitheft system immobilizer system Navigation system Car radio and cassette player car videos Description and function of Airbags Seatbelt Vehicle safety systems Crash sensors Seat belt 16 windshield wiper and washer no operation intermittent operation continuous operation and wipers will not park Diagnose causes for improper operation of the windshield washer system and to replace the pump if faulty Diagnose the power window system for all power window motors do not operate some switches do not operate Diagnose the power door lock control for All power door locks do not operate only one power door lock not operate Diagnose for remote keyless entry and immobilizer system Familiarization of car radio wiring and speaker circuits Diagnose automatic seat belt systems Diagnose air bag system and service warnings pre tensione
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