MECHANIC AUTO ELECTRICAL & ELECTRONICScstaricalcutta.gov.in/images/CTS MECHANIC AUTO ELECTRICAL and... · Mechanic Auto Electrical & Electronics The DGT sincerely acknowledges contributions

Mechanic Auto Electrical & Electronics

GOVERNMENT OF INDIA MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP

DIRECTORATE GENERAL OF TRAINING

COMPETENCY BASED CURRICULUM

MECHANIC AUTO ELECTRICAL & ELECTRONICS

(Duration: One Year)

CRAFTSMEN TRAINING SCHEME (CTS) NSQF LEVEL - 4 NSQF LEVEL- 4

SECTOR – AUTOMOTIVE


MECHANIC AUTO ELECTRICAL &

ELECTRONICS

(Engineering Trade)

(Revised in 2015)

Version: 1.1

CRAFTSMEN TRAINING SCHEME (CTS)

NSQF LEVEL- 4

Developed By

Ministry of Skill Development and Entrepreneurship Directorate General of Training

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE EN-81, Sector-V, Salt Lake City,

Kolkata – 700 091


The DGT sincerely acknowledges contributions of the Industries, State Directorates, Trade

Experts, Domain Experts and all others who contributed in revising the curriculum. Special

acknowledgement is extended by DGT to the following expert members who had contributed

immensely in this curriculum.

List of Expert members participated for finalizing the course curriculum of Mechanic Auto Electrical & Electronics Trade

S No. Name & Designation

Shri/Mr./Ms. Organization Remarks

1. V Krishna Shankar, Gen. Manager,

Ashok Leyland Chairman

2. G Satish Kumar, Manager Ashok Leyland Member

3. GM Cholanrajan, Sr. Manager, Training

Lansun Toyota, Chennai Member

4. M Shanavas Khan, Hinduja Foundries Member

5. Dr. Abhijit KR Mandal, National Automotive Testing and R&D Infrastructure Project, Global, Automotive Research center, Chennai

Member

6. Vadivelan -Do- Member

7. Anatharaman, Proprietor, Care Care Center, Chennai Member

8. M. K. Gupta Maruthi Suzuki Member

9. Pandey, Director, SRFMTTI, Anathapur Member

10. P. Thangapalam, DM- Trg, Dailmer India Member

11. S. Gopinath, Sr. Manager Crompton Greaves Member

12. R. A. Armstrong TAFE Member

13. B. Muthukumar, Toyoto Kirloskar, New

Delhi

Member

14. J. Dharsan, Asst. Mgr, Toyoto Kirloskar, Bangalore Member

15. C. Prakash, Sr. Gen. Manager Ashok Leyland Member

16. P. Palanivelan, Manger TVS Sundram Fasteners ltd. Member

17. T. N.Umashankar, Head Manufacturing

Delphi TVS Ltd. Member

18. K. Aravind, Regional Trainer, Bosch Ltd., Chennai Member

19. K. Mohankumar TAFE Member

20. M. Sivaraman, Consultant Delphi TVS Member

Representatives from Academic/Professional Institutions

21. Dr. Ramesh A, Professor D/o Mechanical Engineering IIT Madras

Member

22. Dr. A.R. Mohanty Professor, D/o Mechanical Engg Member

ACKNOWLEDGEMENT


IIT Kharagpur 23. Dr. Shankar Ram C S, Assistant

Profesor

D/o Engineering Design IIT Madras

Member

24. Prof. Nilesh J Vasa, Professor IIT Chennai Member

25. Prof. G. Balaganesh, Professor IIT Chennai Member

26. J. Rajakumar, Principal Brakes India Member

27. S HorlyokChelladurai, Retd. ITI Principal

Member

DGT Coordinator

28. Shri T.C. Saravanabava,Deputy Director General (AT)

DGET Headquarters Coordinator/ Member

Core Group

29. K.S. Rao, JDT, NIMI, Chennai Member

30. Yuvraj, DDT ATI Chennai Member

31. G. Venktesh, ADT ATI Hyd Member

32. S.P. Rewaskar, ATI, Hyd Member

33. T.N. Rudra, TO ATI, Howrah Member

34. N. Ramesh Kumar, TO ATI, Chennai Member

35. Akhilesh Pandey, TO ATI, Mumbai Member

36. Vijayaraju, TO ATI, Hyd Member

37. R. Rajesh Kanna, TO ATI Chennai Member

Champion ITIs

38. H.S. Kalara, Principal Govt. ITI, Chandigarh Member

39. A. Duraiswamy, ATO, Govt. ITI, Coimbattore Member

40. W. Nirmal Kumar Isarael, ATO Govt. ITI, Trichy Member

41. K. Thaniarasu, ATO Govt. ITI, Trichy Member

42. N. Durimurugan, TO Govt. ITI, Chengalpattu Member

43. Ravindernath, Govt. ITI, Ambattur Member

44. Palanikumar Govt. ITI, Pudukotai, TN Member


S No. Topics Page No.

1. Course Information 1

2. Training System 2-5

3. Job Role 6

4. General Information 7-8

5. NSQF Level Compliance 9

6. Learning Outcome 10-11

7. Learning Outcome with Assessment Criteria 12-20

8. Syllabus 21-38

9. Syllabus - Core Skill

9.1 Core Skill – Workshop Calculation & Science and Engineering Drawing

39-42

9.2 Core Skill – Employability Skill 43-46

10. Annexure I

List of Trade Tools & Equipment 47-54

List of Tools & Equipment for Employability Skill 55

11. Annexure II - Format for Internal Assessment 56

CONTENTS

1


During the one-year duration a candidate is trained on subjects Professional Skill,

Professional Knowledge, Engineering Drawing, Workshop Calculation Science and Employability

Skills. In addition to this a candidate is entrusted to make/do project work and extra-curricular

activities to build up confidence. The practical skills are imparted in simple to complex manner &

simultaneously theory subject is taught in the same fashion to apply cognitive knowledge while

executing task. The broad components covered under Professional Skill subject are as below:-

The trainee begins with safety aspect in general and specific to the trade, identification of

tools & equipment, raw materials used. The trainee will perform precision measurements on the

components and compare parameters with specifications used in automotive workshop. He learns

to carry out basic fitting operations used in the workshop practices and inspection of dimensions.

The trainee performs grinding of cutting tools and surface finishing operations in the given job. He

learns to inspect the auto component using Non-destructive testing methods, to identify the

hydraulic and pneumatic components in a vehicle. Constructs electrical circuits and performs basic

electrical testing in a vehicle. Apply safe working practices and environment regulation in an

automotive workshop. He identifies the major components of LMV/HMV and dashboard gauges.

Performs the wiring circuits and the electrical components in the vehicle, troubleshoots different

wiring circuits in vehicle and prepare different electrical joints. He learns to check and overhaul

the ignition system, service and test battery, inspects power steering control module and

troubleshoot. He identifies and checks ABS components, troubleshoots in all electrical circuits,

diagnosis for all comfort system. He also understands the constructional features and working

principles of MPFI system and different types of sensors in engine. The trainee identifies EDC

components, sensors, actuators, major components of car AC, automotive lighting system and

carries out repair & maintenance.

1. COURSE INFORMATION

2


2.1 GENERAL

The Directorate General of Training (DGT) under Ministry of Skill Development &

Entrepreneurship offers a range of vocational training courses catering to the need of different

sectors of the economy/ labour market. The vocational training programs are delivered under the

aegis of National Council of Vocational Training (NCVT). Craftsman Training Scheme (CTS) and

Apprenticeship Training Scheme (ATS) are two pioneer programs of NCVT for propagating

vocational training.

Mechanic Auto Electrical & Electronics trade under CTS is one of the courses delivered

nationwide through network of ITIs. The course is of one year duration. It mainly consists of

Domain area and Core area. The Domain area (Trade Theory & Practical) imparts professional

skills and knowledge, while Core area (Workshop Calculation science, Engineering Drawing and

Employability Skills) imparts requisite core skills, knowledge and life skills. After passing out the

training program, the trainee is awarded National Trade Certificate (NTC) by NCVT which is

recognized worldwide.

Candidates need broadly to demonstrate that they are able to:

Read & interpret technical parameters/document, plan and organize work processes, identify necessary materials and tools;

Perform task with due consideration to safety rules, accident prevention regulations and environmental protection stipulations;

Apply professional skill, knowledge, core skills & employability skills while performing jobs and repair & maintenance work.

Document the technical parameters related to the task undertaken.

2.2 CAREER PROGRESSION PATHWAYS

Can join Apprenticeship programme in different types of industries leading to a National

Apprenticeship certificate (NAC).

Can join Crafts Instructor Training Scheme (CITS) in the trade for becoming instructor in

ITIs.

Can join various industries of the relevant field.

2. TRAINING SYSTEM

3


2.3 COURSE STRUCTURE

Table below depicts the distribution of training hours across various course elements during

a period of one year:-

SNo. Course Element Notional Training

Hours

1 Professional Skill (Trade Practical) 1050

2 Professional Knowledge (Trade Theory) 252

3 Workshop Calculation & Science 84

4 Engineering Drawing 126

5 Employability Skills 110

6 Library & Extracurricular activities 58

7 Project work 160

8 Revision & Examination 240

Total 2080

2.4 ASSESSMENT & CERTIFICATION

The trainee will be tested for his skill, knowledge and attitude during the period of the

course and at the end of the training program as notified by the Government of India (GoI) from

time to time. The employability skills will be tested in the first year itself.

a) The Internal Assessment during the period of training will be done by Formative Assessment

Method by testing for assessment criteria listed against learning outcomes. The training institute

has to maintain an individual trainee portfolio as detailed in assessment guideline. The marks of

internal assessment will be as per the template (Annexure – II).

b) The final assessment will be in the form of summative assessment method. The All India Trade

Test for awarding NTC will be conducted by NCVT as per the guideline of Government of India.

The pattern and marking structure is being notified by Govt. of India from time to time. The

learning outcome and assessment criteria will be the basis for setting question papers for final

assessment. The examiner during final examination will also check the individual trainee’s profile

as detailed in assessment guideline before giving marks for practical examination.

2.4.1 PASS REGULATION

For the purposes of determining the overall result, weightage of 100% is applied for six

months and one year duration courses and 50% weightage is applied to each examination for two

years courses. The minimum pass percent for Practical is 60% & minimum pass percent for Theory

subjects is 33%.

4


2.4.2 ASSESSMENT GUIDELINE Appropriate arrangements should be made to ensure that there will be no artificial

barriers to assessment. The nature of special needs should be taken into account while

undertaking the assessment. Due consideration should be given while assessing for teamwork,

avoidance/reduction of scrap/wastage and disposal of scrap/waste as per procedure, behavioral

attitude, sensitivity to the environment and regularity in training. The sensitivity towards OSHE

and self-learning attitude are to be considered while assessing competency.

Assessment will be evidence based comprising the following:

Job carried out in labs/workshop

Record book/ daily diary

Answer sheet of assessment

Viva-voce

Progress chart

Attendance and punctuality

Assignment

Project work

Evidences of internal assessments are to be preserved until forthcoming examination for

audit and verification by examining body. The following marking pattern to be adopted while

assessing:

Performance Level Evidence

(a) Weightage in the range of 60%-75% to be allotted during assessment

For performance in this grade, the candidate

should produce work which demonstrates

attainment of an acceptable standard of

craftsmanship with occasional guidance, and

due regard for safety procedures and

practices

Demonstration of good skill in the use of

hand tools, machine tools and workshop

equipment.

60-70% accuracy achieved while undertaking

different work with those demanded by the

component/job.

A fairly good level of neatness and

consistency in the finish.

Occasional support in completing the

project/job.

(b) Weightage in the range of 75%-90% to be allotted during assessment

For this grade, a candidate should produce work which demonstrates attainment of a reasonable standard of craftsmanship, with

Good skill levels in the use of hand tools, machine tools and workshop equipment.

70-80% accuracy achieved while undertaking

5


little guidance, and regard for safety procedures and practices

different work with those demanded by the component/job.

A good level of neatness and consistency in the finish.

Little support in completing the project/job.

(c) Weightage in the range of more than 90% to be allotted during assessment

For performance in this grade, the candidate, with minimal or no support in organization and execution and with due regard for safety procedures and practices, has produced work which demonstrates attainment of a high standard of craftsmanship.

High skill levels in the use of hand tools, machine tools and workshop equipment.

Above 80% accuracy achieved while undertaking different work with those demanded by the component/job.

A high level of neatness and consistency in the finish.

Minimal or no support in completing the project.

6


Brief description of job roles:

After successful completion of the above course, the trainee shall be able to perform the

following skills with proper sequence.

• Installs, repairs replaces and overhauls wiring, starters, generators, distributors and other

electrical equipment of motor vehicles.

• 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.

• Checks vehicle wiring, locates faults and rectifies defects by replacing damaged wire or

connecting ends with insulation tape.

• Starts engine to check whether alternator is charging correctly, and if distributor, condenser

coil and cut out are functioning properly.

• Estimates nature of defects and reports components to be replaced or repaired.

• 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 electronic 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 Employment

opportunities:

Reference NCO-2015:

a) 7412.0701 - Electrician, Automobile

3. JOB ROLE

7


Name of the Trade Mechanic Auto Electrical & Electronics

NCO - 2015 7412.0701

NSQF Level Level – 4

Duration of Craftsmen Training

One year

Entry Qualification Passed 10th class examination with Mathematics and Science

Unit Strength (No. Of Student)

20

Space norms 100 Sq. m (Including parking area)

Power norms 3 KW

Instructors Qualification for:

1. Mechanic Auto Electrical & Electronics Trade

Degree in Automobile/ Mechanical Engg./ Electrical /Electronics & communication Engg Engineering (with specialization in Automobile) from recognized 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 & communication Engg from recognized board of technical education with two years experience in the automobile industry and should posses valid LMV driving license.

OR NTC/NAC passed in the Trade of "Mechanic Auto Electrical & Electronics" with 3 years’ post qualification experience in the relevant field, and should posses valid LMV driving license. Essential Qualification: Craft Instructor Certificate in relevant trade under NCVT. Note: Out of two Instructors required for the unit of 2(1+1), one must have Degree/Diploma and other must have NTC/NAC qualifications.

2. Workshop Calculation & Science

Degree in Engineering with one year experience. OR

Diploma in Engineering with two years experience.

4. GENERAL INFORMATION

8


Essential Qualification: Craft Instructor Certificate in RoD& A course under NCVT.

3. Engineering Drawing Degree in Engineering with one year experience. OR

Diploma in Engineering with two years experience. OR

NTC/ NAC passed in the Draughtsman (Civil) with three years experience. Essential Qualification: Craft Instructor Certificate in RoD& A course under NCVT.

4. Employability Skill MBA OR BBA with two years experience OR Graduate in Sociology/ Social Welfare/ Economics with Two years experience OR Graduate/ Diploma with Two years experience and trained in Employability Skills from DGT institutes.

AND Must have studied English/ Communication Skills and Basic Computer at 12th / Diploma level and above.

OR Existing Social Studies Instructors duly trained in Employability Skills from DGT institutes.

List of Tools and Equipment As per Annexure – I

Distribution of training on Hourly basis: (Indicative only)

Total hours /week

Trade practical

Trade theory

Work shop Cal.

&Sc.

Engg. Drawing

Employability skills

Extra-curricular

activity

40 Hours 25 Hours 6 Hours 2 Hours 3 Hours 2 Hours 2 Hours

9


NSQF level for Mechanic Auto Electrical & Electronics trade under CTS: Level 4 As per notification issued by Govt. of India dated- 27.12.2013 on National Skill Qualification Framework total 10 (Ten) Levels are defined. Each level of the NSQF is associated with a set of descriptors made up of five outcome statements, which describe in general terms, the minimum knowledge, skills and attributes that a learner needs to acquire in order to be certified for that level. Each level of the NSQF is described by a statement of learning outcomes in five domains, known as level descriptors. These five domains are:

a. Process b. professional knowledge c. professional skill d. core skill e. Responsibility

The Broad Learning outcome of Mechanic Auto Electrical & Electronics trade under CTS mostly matches with the Level descriptor at Level- 4. The NSQF level-4 descriptor is given below:

Level Process Required Professional Knowledge

Professional Skill

Core Skill Responsibility

Level 4 Work in familiar, predictable, routine, situation of clear choice

Factual knowledge of field of knowledge or study

Recall and demonstrate practical skill, routine and repetitive in narrow range of application, using appropriate rule and tool, using quality concepts

Language to communicate written or oral, with required clarity, skill to basic Arithmetic and algebraic principles, basic understanding of social political and natural environment

Responsibility for own work and learning

5. NSQF LEVEL COMPLIANCE

10


Learning outcomes are a reflection of total competencies of a trainee and assessment will

be carried out as per the assessment criteria.

6.1 GENERIC LEARNINGOUTCOME

1. Recognize & comply safe working practices, environment regulation and housekeeping.

2. Work in a team, understand and practice soft skills, technical English to communicate

with required clarity.

3. Demonstrate knowledge of concept and principles of basic arithmetic & algebraic and

apply knowledge of specific area to perform practical operations.

4. Understand basic science in the field of study.

5. Read and understand engineering drawing for different application in the field of work.

6. Understand the concept in productivity, quality tools, and labour welfare legislation.

7. Explain energy conservation, global warming and pollution.

8. Explain time management, entrepreneurship and manage/organize related task in day to

day work for personal & societal growth.

9. Understand and apply basic computer working, basic operating system and uses internet

services to get accustomed & take benefit of IT developments in the industry.

6.2 SPECIFIC LEARNING OUTCOME

10. Use different types of tools and work shop equipment in the Auto work shop.

11. Perform precision measurements on the components and compare parameters with

specifications used in automotive work shop practices.

12. Use of different type of fastening and locking devices in a vehicle.

13. Perform basic fitting operations used in the work shop practices and inspection of

dimensions.

14. Produce components using bending process in the given work piece.

15. Construct electrical circuits and test its parameters by using electrical measuring

instruments.

16. Perform basic electrical testing in a vehicle.

17. Perform battery testing and charging operations.

18. Construct basic electronic circuits and testing.

19. Manufacture components with different types of welding processes in the given job.

20. Identify the hydraulic and pneumatic components in a vehicle.

21. Check & Interpret Vehicle Specification data and VIN, Select & operate various Service

Station Equipments.

6. LEARNING OUTCOME

11


22. Identify the major components of LMV/HMV and dashboard gauges.

23. Perform the wiring circuits and the electrical components in the vehicle.

24. Trace /troubleshoot different wiring circuits in vehicle and prepare different electrical

joints.

25. Check and overhaul the ignition system.

26. Apply appropriate rule and tools for starting and charging system and diagnose & rectify

faults.

27. Understand the constructional features and working principles of EDC/MPFI system.

28. Inspect power steering control module and troubleshoot in power steering.

29. Diagnosis for all comfort system.

30. Demonstrate the skill of automotive lighting system and their troubleshooting.

31. Troubleshoots in all electrical circuits.

12


GENERIC LEARNING OUTCOME

LEARNING OUTCOME ASSESSMENT CRITERIA

1. Recognize & comply safe

working practices,

environment regulation and

housekeeping.

1.1 Follow and maintain procedures to achieve a safe working

environment in line with occupational health and safety

regulations and requirements and according to site policy.

1.2 Recognize and report all unsafe situations according to site

policy.

1.3 Identify and take necessary precautions on fire and safety

hazards and report according to site policy and

procedures.

1.4 Identify, handle and store / dispose off dangerous goods

and substances according to site policy and procedures

following safety regulations and requirements.

1.5 Identify and observe site policies and procedures in regard

to illness or accident.

1.6 Identify safety alarms accurately.

1.7 Report supervisor/ Competent of authority in the event of

accident or sickness of any staff and record accident

details correctly according to site

accident/injuryprocedures.

1.8 Identify and observe site evacuation procedures according

to site policy.

1.9 Identify Personal Productive Equipment (PPE) and use

the same as per related working environment.

1.10 Identify basic first aid and use them under different

circumstances.

1.11 Identify different fire extinguisher and use the same as

per requirement.

1.12 Identify environmental pollution & contribute to the

avoidance of instances of environmental pollution.

1.13 Deploy environmental protection legislation

&regulations.

1.14 Take opportunities to use energy and materials in

an environmentally friendly manner

1.15 Avoid waste and dispose waste as per procedure.

7. LEARNING OUTCOME WITH ASSESSMENT CRITERIA

13


1.16 Recognize different components of 5S and apply the

same in the working environment.

2. Work in a team,

understand and practice

soft skills, technical English

to communicate with

required clarity.

2.1 Obtain sources of information and recognize

information.

2.2 Use and draw up technical drawings and documents.

2.3 Use documents and technical regulations and

occupationally related provisions.

2.4 Conduct appropriate and target oriented discussions

with higher authority and within the team.

2.5 Present facts and circumstances, possible solutions &use

English special terminology.

2.6 Resolve disputes within the team

2.7 Conduct written communication.

3. Demonstrate knowledge of

concept and principles of

basic arithmetic, algebraic,

trigonometric, statistics,

coordinate system and apply

knowledge of specific area to

perform practical operations.

3.1 Examination to test basic skills on arithmetic, algebra,

trigonometry and statistics.

3.2 Their applications will also be assessed during execution

of assessable outcome and also tested during theory and

practical examination.

4. Understand and explain basic

science in the field of study

including basic electrical, and

hydraulics & pneumatics.

4.1 Final examination to test basic skills on science in the

field of study including basic electrical and hydraulics &

pneumatics.




5. Read and apply engineering

drawing for different

application in the field of

work.

5.1 Final examination to test basic skills on engineering

drawing.




14


6. Understand and explain the

concept in productivity,

quality tools, and labour

welfare legislation and apply

such in day to day work to

improve productivity &

quality.

6.1 Final examination to test the concept in productivity,

quality tools and labour welfare legislation.


of assessable outcome.

7. Explain energy conservation,

global warming and pollution

and contribute in day to day

work by optimally using

available resources.

7.1 Final examination to test knowledge on energy

conservation, global warming and pollution.

7.2 Their applications will also be assessed during

execution of assessable outcome.

8. Explain personnel finance,

entrepreneurship and

manage/organize related task

in day to day work for

personal & societal growth.

8.1 Final examination to test knowledge on personnel

finance, entrepreneurship.

8.2 Their applications will also be assessed during

execution of assessable outcome.

9. Understand and apply basic

computer working, basic

operating system, and uses

internet services to get

accustomed & take benefit of

IT developments in the

industry.

9.1 Final examination to test knowledge on basic computer

working, basic operating system and uses internet

services.


of assessable outcome.

15


SPECIFIC LEARNING OUTCOME

LEARNING OUTCOME ASSESSMENT CRITERIA

10. Use different types of

tools and work shop

equipment in the work

shop.

10.1 Identify the different types of hand and power tools used in

the automotive work shop.

10.2 Operate various tools and work shop equipment.

11. Perform precision

measurements on the

components and

compare parameters

with specifications used

in automotive work shop

practices.

11.1 Measure all dimensions in accordance with standard

specifications and tolerances by using precision measuring

instruments.

11.2 Measure the parameters related with the vehicle

components for its effective operation by matching with

manufacturer's specification using different gauges

12. Use of different type of

fastening and locking

devices in a vehicle.

12.1 Identify the different type of fasteners and locking devices

used in the vehicle.

12.2 Use different types of locking devices correctly.

12.3 Specify the bolt and nut threads.

12.4 Practice on removing the damaged studs and bolts

13. Perform basic fitting

operations used in the

work shop practices and

inspection of

dimensions.

13.1 Mark according to drawing by using marking tools on flat

surfaces.

13.2 Hack saw and file the job using different methods and

perform in accordance with the standard specifications and

tolerances.

13.3 Drilling and reaming on flat surfaces.

13.4 Identify and use hand tools for internal and external

threading with taps and dies.

13.5 Measure all dimensions in accordance with standard

specification and tolerances.

14. Produce components

using bending process in

the given work piece.

14.1 Ascertain and select tools, equipment and materials for the

job and make this available for use in a timely manner.

14.2 Plan and organize the work for pipe bending operations.

14.3 Perform bending, soldering and brazing operations in

16


accordance with standard operating procedure using

appropriate tools.

14.4 Check accuracy/correctness of the job using appropriate

measuring instruments.

15. Construct electrical

circuits and test its

parameters by using

electrical measuring

instruments.

15.1 Plan and organize the work for basic electrical operations.

15.2 Select the tools, instruments and materials required to do

the job.

15.3 15.3 Comply with safety rules when performing the basic

electrical operations.

15.4 Perform electrical wire joints, form electrical circuits and

test basic electrical parameters as per the circuit drawings

and operating procedures.

16. Perform basic electrical

testing in a vehicle.

16.1 Plan and organize the work for auto electrical component

testing.

16.2 Tracing the auto electrical components in a vehicle.

16.3 Test continuity and voltage drop in the electrical circuits.

16.4 Operate the electrical components in a vehicle and test

lamps.

17. Perform battery testing

and charging operations.

17.1 Ascertain and select tools and materials for the job.

17.2 Comply with safety rules when performing the following

operations.

17.3 Plan and select different methods for charging the battery.

17.4 Perform battery testing as per the operating procedure.

18. Construct basic

electronic circuits and

testing.

18.1 Plan and select different types of basic electronic

components and measuring instruments.

18.2 Construct and test the basic electronic gate circuits and its

components as per the standard procedure.

19. Manufacture

components with

different types of

welding processes in the

given job.

19.1 Plan and select appropriate method to produce components

with welding process.

19.2 Comply with safety rules when performing the above

operations.

19.3 Mark according to the drawing using marking tools on the

job.

17


19.4 Select appropriate tools and equipment to perform the

above operations.

19.5 Set up and produce component as per standard operating

procedure.

20. Identify the hydraulic

and pneumatic

components in a vehicle.

20.1 Comply with safety rules when performing the following

operations.

20.2 Locate and identify the hydraulic components in a vehicle.

20.3 Locate and identify the pneumatic components in a vehicle.

21. Check & Interpret

Vehicle Specification

data and VIN, Select &

operate various Service

Station Equipments

21.1 Identify of different type of vehicle.

21.2 Identify the different vehicle specification data and information

21.3 Demonstrate the garage, service station different equipment

22. Identify the major

components of LMV/HMV

and dashboard gauges.

22.1 Ascertain and select tools and materials for the job and

make this available for use in a timely manner.

22.2 Plan work in compliance with standard safety norms.

22.3 Identify the parts of Diesel/Petrol engine.

22.4 Identify different gauges fitted on the dashboard and check

for proper functioning.

22.5 Perform daily checks before starting the engine.

22.6 Start the engine and allow it to warm up.

22.7 Identify the problem in functionality of particular Gauge

fitted on dashboard and record the reading and compare it

with standard reading.

22.8 Repair / Replace the defective gauges as per standard

operating practice

22.9 Check for proper functionality.

22.10 Stop the engine

22.11 Comply with safety rules when performing the above

jobs.

23. Perform the wiring

circuits and the electrical

components in the



23.2 Plan work in compliance with standard safety norms.

18


vehicle. 23.3 Identify Personal Protective Equipment and use the same

as per related working environment.

23.4 Locate and identify the electrical components in a vehicle

by using wiring diagram.

23.5 Locate and identify the power sources of various controls of

electrical circuits.

24. Trace /troubleshoot

different wiring circuits

in vehicle and prepare

different electrical joints.

24.1 Diagnosis and remedy for-Speedometer shows no

operation., ,

24.2 Diagnosis and remedy for fuel level meter shows no

operation

24.3 Diagnosis and remedy for coolant temp meter shows no

operation

24.4 Diagnosis and remedy for Oil pressure light shows no lighting

25. Check and overhaul the

ignition system.


make

this available for use in a timely manner.

25.2 Identify Personal Protective Equipment and use the same as

per related working environment.

25.3 Plan and organize work for overhaul the ignition system.

25.4 Check all components of ignition system physically,

electrically and replace if required.

25.5 Diagnosis the possible causes for hard or no start of engine

related to ignition system.

25.6 Diagnosis the possible causes for hard or no start of engine

related to fuel system.

26. Apply appropriate rule and

tools for starting and

charging system and

diagnose & rectify faults.

26.1 Check Charging system for proper functioning as per manufacturer guidelines.

26.2 Check alternator for proper functioning

26.3 Remove alternator from the vehicle

26.4 Overhaul and check alternator for proper function

26.5 Refit Alternator to the vehicle and check for functioning

26.6 Check starting system for proper functioning as per manufacturer guidelines.

26.7 Check starter for proper functioning

26.8 Remove starter from the vehicle.

26.9 Overhaul and check starter for proper function

19


26.10 Refit starter to the vehicle and check for functioning

27. Understand the

constructional features

and working principles

of EDC/MPFI system.

27.1 Identify EDC components/ sensors,

27.2 Test sensors /actuators.

27.3 Identify various components of MPFI system.

27.4 Test MPFI components and replace if necessary.

27.5 Check delivery from fuel Pump.

27.6 Replace fuel filter.

27.7 Fault finding in Electronic circuit and remedies using scan

tool.

28. Inspect power steering

control module and

troubleshoot in power

steering.



28.2 Plan and organize work for overhaul the starting system with

safety norms.

28.3 Check power steering and its components for proper

functioning.

28.4 Flush power steering.

28.5 Check fluid and fluid pressure of power steering circuit.

28.6 Diagnosis and trouble for power steering system.

29. Diagnosis for all comfort

system.



29.2 Plan and organize work to check the components of

automatic transmission system with safety norms.

29.3 Identify and locate the components of Carr AC system in a

given vehicle.

29.4 Check charge state of refrigerant.

29.5 Check AC system and its components for proper functioning.

29.6 Check and replace/adjust compressor belt tension.

29.7 Carry out the diagnostic procedure for the following trouble.

a) No cooling. b) Intermittent cooling. c) Insufficient cooling. d) Abnormal noise from compressor, magnetic clutch,

condenser, evaporator, and blower. e) High pressure gauge—Pressure high and low. f) Low pressure gauge Pressure high and low.

20


30. Demonstrate the skill of

automotive lighting system

and their troubleshooting.



30.2 Plan and organize work to check the components of lighting

circuit.

30.3 Read the wiring circuit of lighting of the given vehicle.

30.4 Operate and check the function of combination switch and

other light switches.

30.5 Check the lights whether glow or not.

30.6 Replace the defective bulbs/fuse/faulty wire/electrical or

electronic components.

30.7 Check fluid level light, engine oil pressure light, brake

warning light.

30.8 Align head light for proper focus.

30.9 Repair and rectify any other faults in the light circuit.

31. Trouble shoots in all




31.2 Plan and organize work to check the components of lighting

circuit.

31.3 Carry out the diagnostic procedure for the following troubles

in the improper functioning electrical accessories.

a) Improper functioning of horn. b) Improper functioning of wiper and washer circuit. c) Improper functioning of power window. d) Improper functioning of flasher circuit. e) Improper functioning of immobilizer system. f) Improper functioning of seat belt circuit. g) Improper functioning of air bag system. h) Improper functioning of car radio wiring.

21


SYLLABUS – MECHANIC AUTO ELECTRICAL & ELECTRONICS

Duration: One Year

Week No.

Reference Learning Outcome

Professional Skills (Trade Practical)

With Indicative Hours

Professional Knowledge (Trade Theory)

1 Apply safe working

practices and

environment

regulation in an

automotive work

shop.

1. Familiarization with institute,

Job opportunities in the

automobile sector, Machinery

used in Trade.(10 hrs)

2. Types of work done by the

students in the shop floor.

(15 hrs)

Admission & introduction to the

trade: Introduction to the Course

duration, course content, study

of the syllabus. General rule

pertaining to the Institute,

facilities available- Hostel,

Recreation, Medical and Library

working hours and time table

2 -do- 3. Practical related to Safety and

Health, Importance of

maintenance and cleanliness

of Workshop. (08 hrs)

4. Interaction with health centre

and fire service station to

provide demo on First aid and

Fire safety, Use of fire

extinguishers.(07 hrs)

5. Demonstration on safe

handling and Periodic testing

of lifting equipment, and

Safety disposal of Used engine

oil.(08 hrs)

6. Energy saving Tips of ITI

electricity Usage.(02 hrs)

Occupational Safety & Health

Importance of Safety and

general Precautions to be

observed in the shop. Basic first

aid, safety signs - for Danger,

Warning, caution & personal

safety message. Safe handling of

Fuel Spillage, Fire extinguishers

used for different types of fire.

Safe disposal of toxic dust, safe

handling and Periodic testing of

lifting equipment, Authorization

of Moving &road testing

vehicles.

Energy conservation-Definition,

Energy Conservation

Opportunities (ECOs)-Minor ECos

and Medium ECOs, Major ECOs),

Safety disposal of Used engine

oil, Electrical safety tips.

3-5 Use different types of

tools and work shop

7. Practice using all marking aids,

like steel rule with spring

Hand & Power Tools:-

Marking scheme, Marking

8. SYLLABUS

22


equipment in the Auto

work shop.

calipers, dividers, scriber,

punches, Chisel etc., Layout a

work piece- for line, circle, arcs

and circles.(40hrs)

8. Practice to measure a wheel

base of a vehicle with

measuring tape.(12hrs)

9. Practice to measure valve

spring tension using spring

tension tester.(08hrs)

10. Practice to remove wheel lug

nuts with use of an air impact

wrench Practice on General

workshop tools & power

tools.(15hrs)

material-chalk, Prussian blue.

Cleaning tools- Scraper, wire

brush, Emery paper, Description,

care and use of Surface plates,

steel rule, measuring tape, try

square. Calipers-inside and

outside. Dividers, surface gauges,

scriber, punches-prick punch,

center punch, pin punch, hollow

punch, number and letter punch.

Chisel-flat, cross-cut. Hammer-

ball pein, lump, mallet. Screw

drivers-blade screwdriver,

Phillips screw driver, Ratchet

screwdriver. Allen key, bench

vice & C-clamps, Spanners- ring

spanner, open end spanner &

the combination spanner,

universal adjustable open end

spanner. Sockets & accessories,

Pliers - Combination pliers, multi

grip, long nose, flat-nose,

Nippers or pincer pliers, Side

cutters, Tin snips, Circlip pliers,

external circlips pliers. Air impact

wrench, air ratchet, wrenches-

Torque wrenches, pipe

wrenches, car jet washers Pipe

flaring & cutting tool, pullers-

Gear and bearing.

6-7 Perform precision

measurements on the

components and

compare parameters

with specifications

used in automotive

work shop practices.

11. Measuring practice on Cam

height, Camshaft Journal dia,

crankshaft journal dia, Valve

stem dia, piston diameter, and

piston pin dia with outside

Micrometers.(12 hrs)

12. Measuring practice on the

height of the rotor of an oil

Systems of measurement,

Description, care & use of -

Micrometers- Outside and

depth micrometer, Micrometer

adjustments, Vernier calipers,

Telescope gauges, Dial bore

gauges, Dial indicators,

straightedge, feeler gauge,

23


pump from the surface of the

housing or any other auto

component measurement with

depth micrometer.(04 hrs)

13. Measuring practice on valve

spring free length.(02 hrs)

14. Measuring practice on cylinder

bore, Connecting rod bore,

inside diameter (ID) of a

camshaft bearing with

Telescope gauges.(04 hrs)

15. Measuring practice on cylinder

bore for taper and out-of-

round with Dial bore

gauges.(04 hrs)

16. Measuring practice to measure

wear on crankshaft end play,

crankshaft run out, and valve

guide with dial indicator.(06

hrs)

17. Measuring practice to check

the flatness of the cylinder

head is warped or twisted with

straightedge is used with a

feeler gauge.(04 hrs)

18. Measuring practice to check

the end gap of a piston ring,

piston-to-cylinder wall

clearance with feeler

gauge.(06 hrs)

19. Practice to check engine

manifold vacuum with vacuum

gauge.(04 hrs)

20. Practice to check the air

pressure inside the vehicle

tires is maintained at the

recommended setting.(04 hrs)

thread pitch gauge, vacuum

gauge, tire pressure gauge.

24


8-9 Use different types of

tools and work shop

equipment in the Auto

work shop.

Use of different type

of fastening and

locking devices in a

vehicle.

21. Practice on General cleaning,

checking and use of nut, bolts,

& studs etc.(16 hrs)

22. Removal of stud/bolt from

blind hole. (06 hrs)

23. Practice on cutting tools like

Hacksaw, file, chisel,

Sharpening of Chisels, center

punch, safety precautions

while grinding. (20 hrs)

24. Practice on Hacksawing and

filing to given dimensions.

(08 hrs)

Fasteners- Study of different

types of screws, nuts, studs &

bolts, locking devices, Such as

lock nuts, cotter, split pins, keys,

circlips, lock rings, lock washers

and locating where they are

used. Washers & chemical

compounds can be used to help

secure these fasteners. Function

of Gaskets, Selection of materials

for gaskets and packing, oil seals.

Cutting tools Study of different

type of cutting tools like

Hacksaw, File- Definition, parts

of a file, specification, Grade,

shape, different type of cut and

uses., OFF-hand grinding with

sander, bench and pedestal

grinders, safety precautions

while grinding.

Limits, Fits &Tolerances:-

Definition of limits, fits &

tolerances with examples used in

auto components

10-11 Perform basic fitting

operations used in the

work shop practices

and inspection of

dimensions.

25. Practice on Marking and

Drilling clear and Blind Holes,

Sharpening of Twist Drills

Safety precautions to be

observed while using a drilling

machine.(16 hrs)

26. Practice on Tapping a Clear

and Blind Hole, Selection of

tape drill Size, use of

Lubrication, Use of stud

extractor. (16 hrs)

27. Cutting Threads on a Bolt/

Stud. (08 hrs)

28. Adjustment of two piece Die,

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.

25


Reaming a hole/ Bush to suit

the given pin/ shaft, scraping a

given machined surface.

(10 hrs)

12 Produce components

using bending process

in the given work

piece.

29. Practice on making

Rectangular Tray.(10 hrs)

30. Pipe bending, Fitting nipples

unions in pipes. Soldering and

Brazing of Pipes.(15hrs)

Sheet metal - State the various

common metal Sheets used in

Sheet Metal shop

Sheet metal operations -

Shearing, bending, Drawing,

Squeezing

Sheet metal joints - Hem & Seam

Joints Fastening Methods -

Riveting, soldering, Brazing.

fluxes used on common joints.

Sheet and wire-gauges. The blow

lamp- its uses and pipe fittings.

13 Construct electrical

circuits and test its

parameters by using

electrical measuring

instruments.

31. Practice in joining wires using

soldering Iron, Construction of

simple electrical

circuits.(16hrs)

32. Measuring of current, voltage

and resistance using digital

multimeter, practice continuity

test for fuses, jumper wires,

fusible links, circuit

breakers.(09 hrs)

Basic electricity, Electricity

principles, Ground connections,

Ohm's law, Voltage, Current,

Resistance, Power, Energy.

Voltmeter, ammeter, Ohmmeter

Mulitmeter, Conductors &

insulators, Wires, Shielding,

Length vs. resistance, Resistor

ratings

14 Perform basic

electrical testing in a

vehicle.

33. 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.(25 hrs)

Fuses & circuit breakers, Ballast

resistor, Stripping wire

insulation, cable colour codes

and sizes, Resistors in Series

circuits , Parallel circuits and

Series-parallel circuits,

Electrostatic effects, Capacitors

and its applications, Capacitors in

series and parallel.

15 Perform battery

testing and charging

34. Cleaning and topping up of a

lead acid battery, testing

Description of Chemical effects,

Batteries & cells, Lead acid

26


operations. battery with hydrometer.

(08 hrs)

35. Connecting battery to a

charger for battery charging,

Inspecting & testing a battery

after charging.(08 hrs)

36. Measure and Diagnose the

cause(s) of excessive Key-off

battery drain (parasitic draw)

and do corrective action.

(05 hrs)

37. Testing of relay and solenoids

and its circuit.(04 hrs)

batteries & Stay Maintenance

Free (SMF) batteries, Magnetic

effects, Heating effects, Thermo-

electric energy, Thermisters,

Thermo couples, Electrochemical

energy, Photo-voltaic energy,

Piezo-electric energy,

Electromagnetic induction,

Relays, Solenoids, Primary &

Secondary windings,

Transformers, stator and rotor

coils.

16 Construct basic

electronic circuits and

testing.

38. Identify and test power and

signal connectors for

continuity, Identify and test

different type of Diodes, NPN

& PNP Transistors for its

functionality.(15 hrs)

39. Construct and test simple logic

circuits OR, AND & NOT and

Logic gates using switches.

(10 hrs)

Basic electronics: Description of

Semi conductors, Solid state

devices- Diodes, Transistors,

Thyristors, Uni-Junction

Transistors ( UJT), Metal Oxide

Field Effect Transistors (

MOSFETs), Logic gates-OR, AND

& NOT and Logic gates using

switches.

17-18 Manufacture

components with

different types of

welding processes in

the given job.

40. Practice to make straight

beads and Butt, Lap & T joints

Manual Metal Arc Welding.

(32 hrs)

41. Setting of Gas welding flames,

practice to make a straight

beads and joints Oxy -

Acetylene welding Film on

Heat treatment process (18

hrs)

Introduction to welding and

Heat Treatment Welding

processes - Principles of Arc

welding, brief description,

classification and applications.

Manual Metal Arc welding -

principles, power sources,

electrodes, welding parameters,

edge preparation & fit up and

welding techniques; Oxy -

Acetylene welding - principles,

equipment, welding

parameters, edge preparation &

fit up and welding techniques;.

Heat Treatment Process-

27


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.

19-20 Identify the hydraulic

and pneumatic

components in a

vehicle.

42. Practice on Liquid penetrant

testing method and Magnetic

particle testing method.24 hrs)

43. Identification of Hydraulic and

pneumatic components used

in vehicle.(06 hrs)

44. Tracing of hydraulic circuit on

hydraulic jack, hydraulic

power steering, and Brake

circuit. (14 hrs)

45. Identification of components

in Air brake systems.(06 hrs)

Non-destructive Testing

Methods- Importance of Non-

Destructive Testing In

Automotive Industry, Definition

of NDT, Liquid penetrant and

Magnetic particle testing method

- Portable Yoke method

Introduction to Hydraulics &

Pneumatics: - Definition of

Pascal law, pressure, Force,

viscosity. Description, symbols

and application in automobile

of Gear pump-Internal &

External, single acting, double

acting & Double ended

cylinder; Directional control

valves-2/2, 3/2, 4/2, 4/3 way

valve, Pressure relief valve, Non

return valve, Flow control valve

used in automobile.

Pneumatic Symbols, Description

and function of air Reciprocating

Compressor. Function of Air

service unit (FRL-Filter, Regulator

& Lubricator).

21 Check & Interpret

Vehicle Specification

data and VIN. Select &

operate various

Service Station

46. Identification of different type

of Vehicle. (04 hrs)

47. Demonstration of vehicle

specification data.(06 hrs)

48. Identification of vehicle

Auto Industry - History, leading

manufacturers, development in

automobile industry, trends, new

product. Brief about Ministry of

Road transport & Highways, The

28


Equipments. information Number (VIN).

(04 hrs)

49. Demonstration of Garage,

Service station equipments.

(04 hrs)

50. Vehicle hoists - Two post and

four post hoist, Engine hoists,

Jacks, Stands.(07 hrs)

Automotive Research

Association of India (ARAI),

National Automotive Testing and

R&D Infrastructure Project

(NATRIP), & Automobile

Association. Definition: -

Classification of vehicles on the

basis of load as per central motor

vehicle rule, wheels, final drive,

and fuel used, axles, position of

engine and steering

transmission, body and load.

Brief description and uses of

Vehicle hoists -Two post and four

post hoist, Engine hoists, Jacks,

Stands.

22-24 In-plant Training

25-26 Revision

27 Identify the major

components of

LMV/HMV and

dashboard gauges.

51. Identification of parts in a

diesel engine of LMV/

HMV.(08 hrs)

52. Practice on starting and

stopping of diesel engines. (12

hrs)

53. Observe and report the

reading of Tachometer,

Odometer, temp and Fuel

gauge under ideal and on load

condition.(05 hrs)

Introduction to Engine:

Principle & working of 4-stroke

diesel engine (Compression

ignition Engine (C.I)), Principle of

Spark Ignition Engine(SI),

difference between C.I. engine

and S.I Engine, Technical terms

used in engine, Engine

specification. Study of various

gauges/instrument on a dash

board of a vehicle-Speedometer,

Tachometer, Odometer and Fuel

gauge, and Indicators such as

gearshift position, Seat belt

warning light, Parking-brake-

engagement warning light and

an Engine-malfunction light.

Different type of starting and

stopping method of Petrol/Diesel

Engine

29


28 Perform the wiring

circuits and the

electrical components

in the vehicle.

54. Practice to identify

components and their

locations indicated on the

wiring diagram.(10 hrs)

55. Practice to identify the power

source, ground connection,

and controls for electrical

circuits using a wiring

diagram.(15 hrs)

Electrical and Electronic

Components:-Switches-

Description of Normally open,

Normally closed, single pole

single throw switch (SPST),

ganged, 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

29 Trace /troubleshoot

different wiring

circuits in vehicle and

prepare different

electrical joints.

56. 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.(25 hrs)

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),

30


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

diagrams and color codes and

circuit numbering.

Study of common electrical and

electronic symbols used in wiring

diagrams.

30-31 Check and overhaul

the ignition system.

57. Check and replace ignition

coil, overhauling Distributor

Assembly.(08 hrs)

58. Checking ignition timing,

Checking & changing a spark

plug, Removing & replacing

contact points.(12 hrs)

59. Diagnosis- Possible causes

and remedy for Engine cranks,

but will not or hard to start,

Poor fuel economy or engine

performance.(12 hrs)

60. Identification and testing of

Hall effect sensor, Optical

sensor. (08 hrs)

61. Tracing and testing of sensor

circuits.(05 hrs)

62. Tracing of Distributor less

ignition systems circuit. (05

hrs)

Ignition principles and Faraday's

laws, Primary and secondary

winding of transformer, Ignition

components, Spark plugs, Spark

plug components, Vacuum &

centrifugal units, Plug firing

voltage, 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 &

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

31


32-33 Apply appropriate rule

and tools for starting

and charging system

and diagnose & rectify

faults.

63. Removing starter motor from

vehicle, and Performance test

for pull-in test, Hold-in test,

pinion (plunger) return test,

No-load performance test.

(16 hrs)

64. Solenoid test for Hold in coil

open circuit, Armature test -

Ground test, Open circuit test,

pull-in coil open circuit test,

field coil test. (10 hrs)

65. Inspections of brush length

wear as per service manual.

(06 hrs)

66. 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.(12

hrs)

67. Checking a starting system,

Jump-starting a vehicle.(06

hrs)

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.

34-35 -do- 68. Checking a charging system for

the Cause of undercharge, No

charge, and over charge

conditions. (04 hrs)

69. Removing & replacing an

alternator, Inspection of rotor

for ground, open circuit - field

coil resistance, slip ring

surface, Fan, bearing.(12 hrs)

70. Inspection of stator for

ground, open circuit,

Charging system- The purpose

of Charging system, charging

system components, charging

system circuit, Alternator

principles, Alternating current,

Alternator components,

Rectification, Phase winding

connections, Rotor circuit,

Voltage regulation, System

operating voltage, High voltage

charging systems, Rotor, Stator,

32


Inspection of Drive end

bearing rotation, Rectifier,

brush length compare with

service manual.(10 hrs)

71. Slip ring surface. Inspecting &

adjusting an engine drive

belt, replacing an engine drive

belt / pulleys / Tesnionsers

and their alignments.(12 hrs)

72. 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.(12

hrs)

Alternator end frames, Slip ring

& brush assembly, Rectifier

assembly, Alternator cooling fan.

36-38 Understand the

constructional

features and working

principles of

EDC/MPFI system.

73. Identification of EDC

components, sensors, Testing

of sensors and actuators. (12

hrs)

74. Identification of various

components of MPFI

system.(10 hrs)

75. Testing of MPFI components

and replacement if necessary.

(06 hrs)

76. Check delivery from fuel

Pump. (04 hrs)

77. Replacing a fuel filter.(06 hrs)

78. Identification of Electronic

control Unit.(10 hrs)

79. Set up for testing, Testing of

Electronic Control Circuit.

Electronic Diesel control-

Electronic Diesel control systems,

Common Rail Diesel Injection

(CRDI) system, Hydraulically

actuated electronically

controlled unit injector (HEUI)

diesel injection system. Sensors,

actuators and ECU (Electronic

Control Unit) used in Diesel

Engines.

Introduction to Electronic fuel

injection (EFI) fuel supply system,

Multi-point injection systems

(MPI/MPFI), EFI air cleaners,

Electronic mufflers, EFI fuel

supply system components-

Description of Fuel pumps, EFI

33


(12 hrs)

80. Fault finding in Electronic

circuit and remedies using

scan tool.(15hrs)

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 & looping,

Cold start systems, Air

measurement, Air-flow

monitoring, Variable intake

manifold system, Electrical

functions, EFI wiring

diagram,Electronic control unit -

ECU, EFI system ECU, Electronic

control unit settings, Engine

speed limiting, Malfunction

indicator lamp. Importance of

Diagnostic Trouble Code (DTC) &

its general format. Use of scan

tool and retrievals of codes.

39 -do- 81. Identification of various

sensors installed in engine &its

mounting.(10 hrs)

82. Testing of Temperature

sensor, Pressure senor,

potentiometer, magnetic

induction sensor, cam shaft

sensor, crankshaft position

sensor.(15 hrs)

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.

40-41 Inspect power

steering control

module and

troubleshoot in power

steering.

83. Inspection of power steering

control module circuit. (04 hrs)

84. Checking & adjusting power

steering fluid, Pressure testing

a power steering system,

Flushing a power steering

system.(08 hrs)

85. Trouble shooting and remedy

Steering, suspension and

Brakes:-

Description of Electric power

assisted steering, Basic electric

power steering operation,

Electronic adjustable-rate shock

absorbers, Electric brakes,

Electro hydraulic braking (EHB),

34


for steering wheel feels heavy

at low speed, poor recovery

from turns, Vehicle pulls to

one side during straight

driving.(06 hrs)

86. Identification of ABS

components, checking of ABS

warning lamp.(08 hrs)

87. Identification of Automatic

transmission components.

(08 hrs)

88. Inspection of shift lever switch,

throttle position sensor, speed

sensor and automatic

transmission wiring harness

coupler.(16 hrs)

ABS brake system, Antilock

braking system operation,

Principles of ABS braking, ABS

master cylinder, Hydraulic

control unit, Wheel speed

sensors, ABS with Electronic

Brake force Distribution (EBD)

control unit.

Electronic control transmission -

Electronic control Unit, Fully

hydraulically controlled

transmission, Electronic shift

programs, Manual selection

42-43 Diagnosis for all

comfort system.

89. Identification of Air

conditioning components,

Performance test on A/c unit,

Checking Charged state of

refrigerant, Inspecting &

adjusting an engine drive belt,

replacing an engine drive belt.

90. Checking a heating system,

Compressor rotation test, air

Gap check, Refrigerant

recovery -evacuating -charging

of A/c system.

91. Replenishing compressor oil

level Trouble diagnose and

remedy for No cooling or

warm air, Cool air comes out

only intermittently, cool air

comes out only at high,

Insufficient cooling, Abnormal

noise from compressor

Magnetic clutch, condenser,

evaporator, blower motor.

Heating Ventilation Air

Conditioning (HVAC)

legislation, Vehicle heating,

ventilation & cooling systems,

Basic air-conditioning principles,

Air-conditioning capacity, Air-

conditioning refrigerant,

Humidity, Description and

function of Fixed orifice, Control

devices, Thermostatic expansion

valve system, Thermal expansion

valves, Air-conditioning

compressors, Condensers &

evaporators, Receiver drier, Lines

& hoses, TX valve construction,

Temperature monitoring

thermostat, Refrigerants,

Pressure switches, Heating

elements.

Air-conditioning ECU, Ambient

air temperature sensor, Servo

motors, Electric servo motors,

35


92. Diagnosis test for high

pressure gauge pressure high

low, pressure gauge for

pressure high low.

Automatic climate control

sensors, Evaporator temperature

sensor, Blower speed control,

Ventilation systems.

44-45

Demonstrate the skill

of automotive lighting

system and their

troubleshooting.

93. Trace the light circuit - test

bulbs, align head lamps,

Aiming headlights.(02 hrs)

94. Changing a headlight bulb,

Checking of a head light switch

and to replace if faulty.(02 hrs)


for Headlight - headlight do

not light up, only one

headlight does not light up,

Only one beam ("Hi" or "Lo")

does not light.(04 hrs)


for turn signal and hazard

warning lights -Flash rate high

or one side only flashes, No

Flashing, flash rate low.(04 hrs)


for clearance, tail and license

plate lights -All lights do not

light up, some lights do not

light up.(02hrs)


for Back-up light - Back-up

lights do not light up.(02 hrs)


for Brake lights -Brake lights

do not light up, Brake light stay

on.(02 hrs)


for fuel meter and fuel gauge

unit - Fuel meter shows no

operation or incorrect

operation.(02hrs)

Discharge (HID) headlights.

Headlight & dimmer circuits,

Park & tail light circuits, Brake

light circuits, turn signal circuit,

Cornering lights, Fog lights

circuit, interior lights- courtesy,

reading and instrument panel

lights, Smart lighting , Reverse

lights.

36



for Engine coolant Temp (ECT)

meter and ECT Sensor - Engine

coolant temp meter shows no

operation or incorrect

operation.(04 hrs)

102. Lighting system, Lamps/light

bulbs, Lamp/light bulb

information, LED lighting,

Headlights-description of

standard sealed beam,

halogen sealed beam,

composite and High intensity

discharge (HID) headlights. (08

hrs)

103. Headlight & dimmer circuits,

Park & tail light circuits, Brake

light circuits, turn signal circuit,

Cornering lights, Fog lights

circuit, interior lights-

courtesy, reading and Trouble

shooting and remedy for oil

pressure light - Oil pressure

warning light does not light up

when ignition switch is on at

engine off.(08 hrs)


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.(06hrs)


for interior light- Interior light

do not light up.(02hrs)

106. Trace the wiring circuit of

37


traffic signal flashers light

circuit-tracing defects in the

flasher circuits, replacing fuse

bulb.(02hrs)

46-47 Trouble shoots in all



for Horn- No horn operation,

poor sound quality, horn

sounds continuously and to

replace the horn if faulty.(12

hrs)

108. Remove and install wiper

motors and wiper switches.(08

hrs)

109. Checking & replacing wiper

blades.(08 hrs)


for windshield wiper and

washer - no operation,

intermittent operation,

continuous operation, and

wipers will not park.(06 hrs)

111. Diagnose causes for improper

operation of the windshield

washer system and to replace

the pump if faulty.(08 hrs)

112. Diagnose the power window

system for - all power window

motors do not operate, some

switches do not operate.(08

hrs)

Accessories: Horn circuit, wiper

circuit, power window

components and circuit. Power

door lock circuit, automatic door

lock circuit, remote keyless entry

system circuit, antitheft system,

immobilizer system. Navigation

system, Car radio and cassette

player, car videos.

Description and function of

Airbags, Seatbelt, Vehicle safety

systems, Crash sensors, Seat belt

pre-tensioners, Tire pressure

monitoring systems

Integrated communications,

Proximity sensors, Reflective

displays, Global positioning

satellites, Triangulation/

trilateration, Telematics.

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

48-49 In plant Training/Project Work

50-52 Revision & Examination

Note: -

1. Instructor may design their own project and also inputs from local industry may be taken

for designing such new project.

38


2. The project should broadly cover maximum skills in the particular trade and must involve

some problem solving skill. Emphasis should be on Teamwork: Knowing the power of

synergy/ collaboration, work to be assigned in a group (Group of at least 4 trainees). The

group should demonstrate Planning, Execution, Contribution and Application of Learning.

They need to submit Project report.

3. If the instructor feels that for execution of specific project more time is required then he

may plan accordingly in appropriate time during the execution of normal trade practical.

39


9.1 WORKSHOP CALCULATION SCIENCE & ENGINEERING DRAWING

S No. Workshop Calculation and Science Engineering Drawing

Duration: One Year

1. Unit: Systems of unit- FPS, CGS, MKS/SI unit, unit of length, Mass and time, Conversion of units

Engineering Drawing: Introduction and its importance - Relationship to other technical drawing

types - Conventions - Viewing of engineering drawing sheets. - Method of Folding of printed Drawing

Sheet as per BIS SP:46-2003 2. Fractions: Fractions, Decimal fraction,

L.C.M., H.C.F., Multiplication and Division of Fractions and Decimals, conversion of Fraction to Decimal and vice versa. Simple problems using Scientific Calculator.

Drawing Instruments : their Standard and uses - Drawing board, T-Square, Drafter (Drafting

M/c), Set Squares, Protractor, Drawing Instrument Box (Compass, Dividers, Scale, Diagonal Scales etc.), Pencils of different Grades, Drawing pins / Clips.

3. Square Root: Square and Square Root, method of finding out square roots, Simple problem using calculator.

Lines :

- Definition, types and applications in Drawing as per BIS SP:46-2003

- Classification of lines (Hidden, centre, construction, Extension, Dimension, Section)

- Drawing lines of given length (Straight, curved)

- Drawing of parallel lines, perpendicular line - Methods of Division of line segment

4. Ratio & Proportion: Simple calculation on related problems.

Drawing of Geometrical Figures: Definition, nomenclature and practice of - Angle: Measurement and its types, method

of bisecting. - Triangle -different types - Rectangle, Square, Rhombus,

Parallelogram. - Circle and its elements.

5. Percentage: Introduction, Simple calculation. Changing percentage to

Lettering and Numbering as per BIS SP46-2003:

9. SYLLABUS - CORE SKILLS

40


decimal and fraction and vice-versa. - Single Stroke, Double Stroke, inclined, Upper case and Lower case.

6. Material Science : properties -Physical & Mechanical, Types -Ferrous & Non-Ferrous, difference between Ferrous and Non-Ferrous metals, introduction of Iron, Cast Iron, Wrought Iron, Steel, difference between Iron and Steel, Alloy steel, carbon steel, stainless steel, Non-Ferrous metals, Non-Ferrous Alloys.

Dimensioning:

- Definition, types and methods of dimensioning (functional, non-functional and auxiliary)

- Types of arrowhead - Leader Line with text

7. Mass, Weight and Density : Mass, Unit of Mass, Weight, difference between mass and weight, Density, unit of density, specific gravity of metals.

Free hand drawing of - Lines, polygons, ellipse, etc. - geometrical figures and blocks with

dimension - Transferring measurement from the given

object to the free hand sketches. 8. Speed and Velocity: Rest and motion,

speed, velocity, difference between speed and velocity, acceleration, retardation, equations of motions, simple related problems.

Sizes and Layout of Drawing Sheets - Basic principle of Sheet Size - Designation of sizes - Selection of sizes - Title Block, its position and content - Borders and Frames (Orientation marks

and graduations) - Grid Reference - Item Reference on Drawing Sheet (Item

List) 9. Work, Power and Energy: work, unit of

work, power, unit of power, Horse power of engines, mechanical efficiency, energy, use of energy, potential and kinetic energy, examples of potential energy and kinetic energy.

Method of presentation of Engineering Drawing - Pictorial View - Orthogonal View - Isometric view

10.

--------------

Symbolic Representation (as per BIS SP:46-2003) of : - Fastener (Rivets, Bolts and Nuts) - Bars and profile sections - Weld, brazed and soldered joints. - Electrical and electronics element - Piping joints and fittings

11. Algebra: Addition, Subtraction, Multiplication, Division, Algebraic formula, Linear equations (with two variables).

Construction of Scales and diagonal scale

12. Mensuration :Area and perimeter of Practice of Lettering and Title Block

41


square, rectangle, parallelogram,

triangle, circle, semi circle,

Volume of solids - cube, cuboids,

cylinder and Sphere.

Surface area of solids - cube, cuboids,

cylinder and Sphere. 13. Trigonometry: Trigonometrical ratios,

measurement of angles. Trigonometric tables

Dimensioning practice: - Position of dimensioning (unidirectional,

aligned, oblique as per BIS SP:46-2003) - Symbols preceding the value of dimension

and dimensional tolerance. - Text of dimension of repeated features,

equidistance elements, circumferential objects.

14. Heat & Temperature: Heat and

temperature, their units, difference

between heat and temperature, boiling

point, melting point, scale of temperature,

relation between different scale of

temperature, Thermometer, pyrometer,

transmission of heat, conduction,

convection, radiation.

Construction of Geometrical Drawing Figures: - Different Polygons and their values of

included angles. Inscribed and Circumscribed polygons.

- Conic Sections (Ellipse& Parabola)

15. Basic Electricity: Introduction, use of

electricity, how electricity is produced,

Types of current_ AC, DC, their

comparison, voltage, resistance, their

units. Conductor, insulator, Types of

connections - series, parallel, electric

power, Horse power, energy, unit of

electrical energy.

Drawing of Solid figures (Cube, Cuboids,

Cone, Prism, Pyramid, Frustum of Cone and

Pyramid.) with dimensions.

16. Levers and Simple Machines: levers and

its types.

Simple Machines, Effort and Load,

Mechanical Advantage, Velocity Ratio,

Efficiency of machine, Relationship

between Efficiency, velocity ratio and

Mechanical Advantage.

Free Hand sketch of hand tools and

measuring tools used in respective trades.

17.

--------------

Projections: - Concept of axes plane and quadrant. - Orthographic projections - Method of first angle and third angle

projections (definition and difference)

42


- Symbol of 1st angle and 3rd angle projection as per IS specification.

18. --------------

Drawing of Orthographic projection from

isometric/3D view of blocks

19. --------------

Orthographic Drawing of simple fastener

(Rivet, Bolts, Nuts & Screw) 20.

-------------- Drawing details of two simple mating

blocks and assembled view.

43


9.2 CORE SKILL – EMPLOYABILITY SKILL

Duration: 110 Hrs.

1. English Literacy Duration : 20 Hrs. Marks : 09

Pronunciation Accentuation (mode of pronunciation) on simple words, Diction (use of word and speech)

Functional Grammar Transformation of sentences, Voice change, Change of tense, Spellings.

Reading Reading and understanding simple sentences about self, work and environment

Writing Construction of simple sentences Writing simple English

Speaking / Spoken English

Speaking with preparation on self, on family, on friends/ classmates, on know, picture reading gain confidence through role-playing and discussions on current happening job description, asking about someone's job habitual actions. Cardinal (fundamental) numbers ordinal numbers. Taking messages, passing messages on and filling in message forms Greeting and introductions office hospitality, Resumes or curriculum vita essential parts, letters of application reference to previous communication.

2. I.T. Literacy Duration : 20 Hrs. Marks : 09

Basics of Computer Introduction, Computer and its applications, Hardware and peripherals, Switching on-Starting and shutting down of computer.

Computer Operating System

Basics of Operating System, WINDOWS, The user interface of Windows OS, Create, Copy, Move and delete Files and Folders, Use of External memory like pen drive, CD, DVD etc, Use of Common applications.

Word processing and Worksheet

Basic operating of Word Processing, Creating, opening and closing Documents, use of shortcuts, Creating and Editing of Text, Formatting the Text, Insertion & creation of Tables. Printing document. Basics of Excel worksheet, understanding basic commands, creating simple worksheets, understanding sample worksheets, use of simple formulas and functions, Printing of simple excel sheets.

Computer Networking and Internet

Basic of computer Networks (using real life examples), Definitions of Local Area Network (LAN), Wide Area Network (WAN), Internet, Concept of Internet (Network of Networks), Meaning of World Wide Web (WWW), Web Browser, Web Site, Web page and Search Engines. Accessing the Internet using Web Browser,

44


Downloading and Printing Web Pages, Opening an email account and use of email. Social media sites and its implication.

Information Security and antivirus tools, Do's and Don'ts in Information Security, Awareness of IT - ACT, types of cyber crimes.

3. Communication Skills Duration : 15 Hrs. Marks : 07

Introduction to Communication Skills

Communication and its importance Principles of Effective communication Types of communication - verbal, non verbal, written, email, talking on phone. non verbal communication -characteristics, components-Para-language Body language Barriers to communication and dealing with barriers. Handling nervousness/ discomfort.

Listening Skills Listening-hearing and listening, effective listening, barriers to effective listening guidelines for effective listening. Triple- A Listening - Attitude, Attention & Adjustment. Active Listening Skills.

Motivational Training Characteristics Essential to Achieving Success. The Power of Positive Attitude. Self awareness Importance of Commitment Ethics and Values Ways to Motivate Oneself Personal Goal setting and Employability Planning.

Facing Interviews Manners, Etiquettes, Dress code for an interview Do's & Don'ts for an interview.

Behavioral Skills Problem Solving Confidence Building Attitude

4. Entrepreneurship Skills Duration : 15 Hrs. Marks : 06

Concept of Entrepreneurship

Entrepreneur - Entrepreneurship - Enterprises:-Conceptual issue Entrepreneurship vs. management, Entrepreneurial motivation. Performance & Record, Role & Function of entrepreneurs in relation to the enterprise & relation to the economy, Source of business ideas, Entrepreneurial opportunities, The process of setting up a business.

Project Preparation & Qualities of a good Entrepreneur, SWOT and Risk Analysis. Concept &

45


Marketing analysis application of PLC, Sales & distribution Management. Different Between Small Scale &Large Scale Business, Market Survey, Method of marketing, Publicity and advertisement, Marketing Mix.

Institutions Support Preparation of Project. Role of Various Schemes and Institutes for self-employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/ non financing support agencies to familiarizes with the Policies /Programmes& procedure & the available scheme.

Investment Procurement Project formation, Feasibility, Legal formalities i.e., Shop Act, Estimation & Costing, Investment procedure - Loan procurement - Banking Processes.

5. Productivity Duration : 10 Hrs. Marks : 05

Benefits Personal / Workman - Incentive, Production linked Bonus, Improvement in living standard.

Affecting Factors Skills, Working Aids, Automation, Environment, Motivation - How improves or slows down.

Comparison with developed countries

Comparative productivity in developed countries (viz. Germany, Japan and Australia) in selected industries e.g. Manufacturing, Steel, Mining, Construction etc. Living standards of those countries, wages.

Personal Finance Management

Banking processes, Handling ATM, KYC registration, safe cash handling, Personal risk and Insurance.

6. Occupational Safety, Health and Environment Education Duration : 15 Hrs. Marks : 06

Safety & Health Introduction to Occupational Safety and Health importance of safety and health at workplace.

Occupational Hazards Basic Hazards, Chemical Hazards, Vibroacoustic Hazards, Mechanical Hazards, Electrical Hazards, Thermal Hazards. Occupational health, Occupational hygienic, Occupational Diseases/ Disorders & its prevention.

Accident & safety Basic principles for protective equipment. Accident Prevention techniques - control of accidents and safety measures.

First Aid Care of injured & Sick at the workplaces, First-Aid & Transportation of sick person.

Basic Provisions

Idea of basic provision legislation of India.

safety, health, welfare under legislative of India.

Ecosystem Introduction to Environment. Relationship between Society and Environment, Ecosystem and Factors causing imbalance.

46


Pollution Pollution and pollutants including liquid, gaseous, solid and hazardous waste.

Energy Conservation Conservation of Energy, re-use and recycle.

Global warming Global warming, climate change and Ozone layer depletion.

Ground Water Hydrological cycle, ground and surface water, Conservation and Harvesting of water.

Environment Right attitude towards environment, Maintenance of in -house environment.

7. Labour Welfare Legislation Duration : 05 Hrs. Marks : 03

Welfare Acts Benefits guaranteed under various acts- Factories Act, Apprenticeship Act, Employees State Insurance Act (ESI), Payment Wages Act, Employees Provident Fund Act, The Workmen's compensation Act.

8. Quality Tools Duration : 10 Hrs. Marks : 05

Quality Consciousness Meaning of quality, Quality characteristic.

Quality Circles Definition, Advantage of small group activity, objectives of quality Circle, Roles and function of Quality Circles in Organization, Operation of Quality circle. Approaches to starting Quality Circles, Steps for continuation Quality Circles.

Quality Management System

Idea of ISO 9000 and BIS systems and its importance in maintaining qualities.

House Keeping Purpose of House-keeping, Practice of good Housekeeping.

Quality Tools Basic quality tools with a few examples.

47


LIST OF TOOLS AND EQUIPMENT

Mechanic Auto Electrical & Electronics (for Batch of 20 Candidates)

S. No. Name of the Tools & Equipment Specification Quantity

A. TRAINEES TOOL KIT

1. Allen Key set of 12 pieces 2 mm to 14 mm (5+1) nos.

2. Back probe tools 6 nos.

3. Caliper inside 15 cm Spring 6 nos.

4. Calipers outside 15 cm spring 6 nos.

5. Center Punch 10 mm. Dia. x 100 mm. 6 nos.

6. Dividers 15 cm Spring 6 nos.

7. Electrician Screw Driver 250mm 6 nos.

8. Hammer ball peen 0.5 kg with handle 6 nos.

9. Hands file 20 cm. Second cut flat 6 nos.

10. Logic probe 6 nos.

11. Pliers combination 20 cm. 6 nos.

12. Screw driver 20cm.X 9mm. Blade 6 nos.

13. Screw driver 30 cm. X 9 mm. Blade 6 nos.

14. Scriber 15 cm 6 nos.

15. Spanner D.E. set of 12 pieces 6mm to 32mm 6 nos.

16. Spanner, ring set of 12 metric sizes 6 to 32 mm. 6 nos.

17. Spanners socket with speed handle, T-

bar, ratchet and universal

upto 32 mm set of 28 pieces with box

6 nos.

18. Steel rule 30 cm inch and metric 6 nos.

19. Steel tool box with lock and key (folding type)

400x200x150 mm 6 nos.

20. Test light 6 nos.

21. Wire cutter and stripper 6 nos.

B. TOOLS, INSTRUMENTS AND GENERAL SHOP OUTFIT

25. AC alternator slip ring puller 1 no.

26. Adjustable spanner pipe wrench 350 mm 2 nos.

27. Air blow gun with standard accessories

1 no.

28. Air impact wrench with standard accessories

4 nos.

ANNEXURE-I

48


29. Air ratchet with standard accessories 4 nos.

30. Allen Key set of 12 pieces 2mm to 14mm 2 nos.

31. Ammeter 300A/ 60A DC with external shunt 4 nos.

32. Angle plate adjustable 250x150x175 1 no.

33. Angle plate size 200x100x200mm 2 nos.

34. Anti theft device 2 nos.

35. Anvil 50 Kgs with Stand 1 no.

36. Auto Electrical test bench 1 no.

37. Battery -charger 2 nos.

38. Battery terminal cleaner tool 2 nos.

39. Battery tester 1 no.

40. Belt Tensioner gauge 1 no.

41. Blow Lamp 1 litre 2 nos.

42. Caliper inside 15 cm Spring 4 nos.

43. Calipers outside 15 cm spring 4 nos.

44. Car Jet washer 1 no.

45. Car stereo 1 no.

46. Chisel 10 cm flat 4 nos.

47. Chisels cross cut 200 mm X 6mm 4 nos.

48. Circlip pliers Expanding and contracting type

15cm and 20cm each 2 nos.

49. Clamps C 100mm 2 nos.



52. Cleaning tray 45x30 cm. 4 nos.

53. Copper bit soldering iron 0.25 Kg 4 nos.

54. Cylinder bore gauge capacity 20 to 160 mm 4 nos.

55. DC Ohmmeter 0 to 300 Ohms, mid scales at 20 Ohms

4 nos.

56. Depth micrometer 0-25mm 4 nos.

57. Dial gauge type 1 Gr. A (complete with clamping devices and stand)

4 nos.

58. Distributor -Duel advance type, reluctance type

1 each

59. Dividers 15 cm Spring 4 nos.

60. Drift Punch Copper 15 Cm 4 nos.

61. Drill point angle gauge 1 no.

62. Drill twist 1.5 mm to 15 mm (various sizes) by 0.5 mm

4 nos.

49


63. Electric Soldering Iron 230 V 25 watts 230 V 60 watts 2 each

64. Electric testing screw driver 4 nos.

65. Electrical horn ( different types ) 1 each

66. Engineer's square 15 cm. Blade 4 nos.

67. Executive Auto Electrical tool kit 1 no.

68. Feeler gauge 20 blades (metric) 1 no.

69. File flat 20 cm bastard 4 nos.

70. File, half round 20 cm second cut 4 nos.

71. File, Square 20 cm second cut 4 nos.

72. File, Square 30 cm round 4 nos.

73. File, triangular 15 cm second cut 4 nos.

74. Files assorted sizes and types including safe edge file (20 Nos)

2 set

75. Flat File 25 cm second cut 4 nos.

76. Flat File 35 cm bastard 4 nos.

77. Glow plug tester 2 nos.

78. Granite surface plate 1600 x 1000 with stand and cover 1 no.

79. Grease Gun 1 no.

80. Growler 4 nos.

81. Hacksaw frame adjustable 20-30 cm 10 nos.

82. Hammer Ball Peen 0.75 Kg 2 nos.

83. Hammer Chipping 0 .25 Kg 2 nos.

84. Hammer copper 1 Kg with handle 2 nos.

85. Hammer Mallet 2 nos.

86. Hammer Plastic 2 nos.

87. Hand operated crimping tool (i) for crimping up to 4mm and (ii) for crimping up to 10mm

2 nos.

88. Hand reamers adjustable 10.5 to 11.25 mm, 11.25 to 12.75 mm, 12.75 to 14.25 mm and 14.25 to 15.75 mm

2 sets

89. Hand Shear Universal 250mm 2 nos.

90. Hand vice - 37 mm 2 nos.

91. High rate discharge tester (cell tester) 1 no.

92. Holders, lamp teakwood boards, plug sockets, solders, flux wires and cables batteries round consumable blocks and other consumables as required

As required

93.

94. Hollow Punch set of seven pieces 6mm to 15mm

2 sets each

95. Insulated Screw driver 20 cm x 9mm blade 4 nos.

96. Insulated Screw driver 30 cm x 9mm blade 4 nos.

50


97. Left cut snips 250mm 4 nos.

98. Lifting jack screw type 3 ton, 5ton & 20 Ton capacity 1 each

99. Magneto spanner set with 8 spanners 1 set

100. Magnifying glass 75mm 2 nos.

101. Marking out table 90X60X90 cm. 1 no.

102. Multimeter digital 5 nos.

103. Multi-point fuel injection pump 1 no.

104. Oil can 0.5/0.25 liter capacity 2 nos.

105. Oil Stone 15 cm x 5 cm x 2.5 cm 1 no.

106. Oscilloscope 20MHz 2 nos.

107. Outside micrometer 0 to 25 mm 4 nos.

108. Outside micrometer 25 to 50 mm 4 nos.

109. Outside micrometer 50 to 75 mm 1 no.

110. Outside micrometer 75 to 100 mm to 300 mm 100 mm 1 no.

111. Philips Screw Driver set of 5 pieces 2 sets

112. Pipe cutting tool 2 nos.

113. Pipe flaring tool 2 nos.

114. Pliers combination 20 cm. 2 nos.

115. Pliers flat nose 15 cm 2 nos.

116. Pliers round nose 15 cm 2 nos.

117. Pliers side cutting 15 cm 2 nos.

118. Portable electric drill Machine 1 no.

119. Portable headlight aiming kit 1 no.

120. Prick Punch 15 cm 4 nos.

121. Punch Letter 4mm (Number) 2 set

122. Right cut snips 250mm 4 nos.

123. Rivet sets snap and Dolly combined 3mm, 4mm, 6mm 4 nos.

124. Scriber 15 cm 2 nos.

125. Scriber with scribing black universal 2 nos.

126. Set of stock and dies - Metric 2 sets

127. Shear Tin Man's 450 mm x 600mm 4 nos.

128. Sheet Metal Gauge 2 nos.

129. Sher Tinmans 300mm 8 nos.

130. Soldering Copper Hatchet type 500gms 5 nos.

131. Spanner Clyburn 15 cm 1 no.

132. Spanner D.E. set of 12 pieces 6mm to 32mm 4 nos.

133. Spanner T. flocks for screwing up and up-screwing inaccessible positions

2 nos.

134. Spanner, adjustable 15cm. 2 nos.

135. Spanner, ring set of 12 metric sizes 6 to 32 mm. 2 nos.

136. Spanners socket with speed handle, T-bar, ratchet and universal upto 32 mm set of 28 pieces with box

2 nos.

51


137. Spark lighter 2 nos.

138. Spark plug spanner 14mm x 18mm x Size 2 nos.

139. Steel measuring tape 10 meter in a case 2 nos.



142. Straight edge gauge 2 ft. 1 no.

143. Straight edge gauge 4 ft. 1 no.

144. Stud extractor set of 3 2 sets

145. Stud remover with socket handle 1 no.

146. Surface gauge with dial test indicator plunger type i.e. 0.01 mm

2 nos.

147. Tachometer (Counting type) 1 no.

148. Taps and Dies complete sets (5 types) 1 set

149. Taps and wrenches - Metric 2 sets

150. Telescope gauge 4 nos.

151. Temperature gauge 0-100 deg c 2 nos.

152. Tester sparking plug 'NEON' Type 1 no.

153. Thermostat 2 nos.

154. Thread pitch gauge metric, BSW 1 no.

155. Timing lighter 1 no.

156. Torque wrenches 5-35 Nm, 12-68 Nm & 50-225 Nm 1 each

157. Trammel 30 cm 2 nos.

158. Universal puller for removing pulleys, bearings

1 no.

159. V' Block 75 x 38 mm pair with Clamps 2 nos.

160. Vrnier caliper 0-300 mm with least count 0.02mm

4 nos.

161. Vice grip pliers 2 nos.

162. Voltmeter 50V/DC 5 nos.

163. Wire Gauge (metric) 5 nos.

164. Work bench 250 x 120 x 60 cm with 4 vices 12cm Jaw

1 no.

165. 4 Point relays 2 nos.

166. 5 Point relays 2 nos.

C. GENERAL INSTALLATION/ MACHINERIES

167. Air bag simulator 1 no.

168. Air conditioned MPFI vehicle with auto transmission and accessories

1 no.

169. Air conditioning service Unit (Car) 1 no.

170. Air conditioning trainer kit 1 no.

171. Alternator assembly used for LMV 1 no.

172. Arbor press hand operated 2 ton 1 no.

52


capacity

173. Bench lever shears 250mm Blade x 3mm Capacity

1 no.

174. Cut section Model of Mock layout of a motor car -electrical system -working model

1 no.

175. Demonstration board Ignition system, ignition coil

1 set

176. Demonstration board of CRDI system working model

1 no.

177. Demonstration board of MPFI system working model

1 no.

178. Discrete Component Trainer / Basic Electronics Trainer

1 no.

179. Drilling machine bench to drill up to 12mm dia along with accessories

1 no.

180. Dual Magnetization Yoke : AC / HWDC, 230 VAC, 50Hz

1 no.

181. Electronic engine control module 1 set

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

1 no.

183. Liquid pengtrant Inspection kit 1 set

184. Memory keeper / Battery backups 1 no.

185. Multi scan tool /ECU diagnostics kit 1 no.

186. Petrol Engine(4-stroke) Motor Cycle/Scooter along with special tools and accessories

1 no.

187. Pipe Bending Machine (Hydraulic type) 12mm to 30mm

1 no.

188. Pneumatic rivet gun 2 nos.

189. Spring tension tester 1 no.

190. Starter motor axial type, pre-engagement type & Co-axial type

1each

191. Trolley type portable air compressor single cylinder with 45 liters capacity Air

1 no.

192. Ultra sonic Injection cleaning e quipment

1 no.

193. Welding plant Oxy-Acetylene complete ( high pressure)

2 nos.

194. Welding Transformer ( 150-300 Amps) 1 no.

195. Wiper motor assembly 2 nos.

196. Working Model of power windows 1 no.

53


D. LIST OF CONSUMABLE:

197. Assortment of diodes / electronic components

As required

198. Automatic Transmission oils As required

199. Backing Soda As required

200. Battery cleaner spray As required

201. Battery- SMF As required

202. Brake fluids As required

203. Chalk, Prussian blue. As required

204. Chemical compound for fasteners As required

205. Diesel As required

206. Different type gasket material As required

207. Different type of oil seal As required

208. Drill Twist (assorted) As required

209. Emery paper - 36-60 grit , 80-120 As required

210. Fender cover As required

211. Gear oils As required

212. Hacksaw blade (consumable) As required

213. Hand rubber gloves tested for 5000 V 5 pair

214. Holders, lamp teakwood boards, plug sockets, solders, flux wires and cables batteries round consumable blocks and other consumables as required

As required

215. Hydrometer 8 nos.

216. Jumper wires As required

217. Lapping abrasives As required

218. Leather Apron 5 nos.

219. Petrol As required

220. Power steering oil As required

221. Radiator Coolants As required

222. Safety glasses As required

223. Steel wire Brush 50mmx150mm 5 nos.

E. WORKSHOP FURNITURE

224. Book shelf (glass panel) 6.5’ x 3' x 1.5' As required

225. Computer Chair 1+1

226. Computer Table 1+1

227. Desktop computer and related MS office software

1+1

228. Discussion Table 8' x 4' x 2.5' 2 nos.

229. Fire Extinguishers, first- aid box As required

230. Instructional Material - NIMI Books/Ref. books

As required

54


231. Internet connection with all accessories

As required

232. Laser printer 1 no.

233. LCD projector/ LED /LCD TV (42") 1 no.

234. Multimedia DVD for Automotive application/subjects

As required

235. Online UPS 2KVA 1 no.

236. Stools 21 nos.

237. Storage Rack 6.5’ x 3' x 1.5' As required

238. Storage shelf 6.5’ x 3' x 1.5' As required.

239. Suitable class room furniture As required

240. Suitable Work Tables with vices As required

241. Tool Cabinet - 6.5’ x 3' x 1.5' 2 nos.

242. Trainees locker 6.5’ x 3' x 1.5' 2 Nos. to accommodate

20

Note: - 1. All the tools and equipment are to be procured as per BIS specification. 2. Quantity marked with * has been increased as per the batch size. 3. Internet facility is desired to be provided in the class room.

55


Tools & Equipment for Employability Skills

S No. Name of the Equipment Quantity

1. Computer (PC) with latest configurations and Internet connection with standard operating system and standard word processor and worksheet software

10 Nos.

2. UPS - 500VA 10 Nos.

3. Scanner cum Printer 1 No.

4. Computer Tables 10 Nos.

5. Computer Chairs 20 Nos.

6. LCD Projector 1 No.

7. White Board 1200mm x 900mm 1 No.

Note: - Above Tools & Equipment not required, if Computer LAB is available in the institute.

56


Name & Address of the Assessor: Year of Enrollment:

Name & Address of ITI (Govt./Pvt.): Date of Assessment:

Name & Address of the Industry: Assessment location: Industry / ITI

Trade Name: Examination: Duration of the Trade/course:

Learning Outcome:

S N

o.

Maximum Marks (Total 100 Marks) 15 5 10 5 10 10 5 10 15 15

Tota

l In

tern

al

Ass

ess

men

t M

arks

Res

ult

(Y

/N)

Candidate Name Father's/Moth

er’s Name

Safe

ty C

on

scio

usn

ess

Wo

rkp

lace

Hyg

ien

e &

Ec

on

om

ical

use

of

mat

eria

ls

Att

end

ance

/ P

un

ctu

alit

y

Ab

ility

to

fo

llow

Man

ual

s/ W

ritt

en

inst

ruct

ion

s

Ap

plic

atio

n o

f

Kn

ow

led

ge

Skill

s to

Han

dle

To

ols

/ Eq

uip

men

t/

Inst

rum

ents

/ D

evic

es

Eco

no

mic

al u

se o

f

Mat

eri

als

Wo

rkin

g St

rate

gy

Qu

alit

y in

W

ork

man

ship

/ P

erfo

rman

ce

VIV

A

1

2

ANNEXURE-II

FORMAT FOR INTERNAL ASSESSMENT