SYLLABUS OF SEMESTER SYSTEM

FOR THE TRADE

OF
Mechanic Basic Engineering (Automobile Trae!
(1
st
semester)
U"DER
#RAFTSME" TRA$"$"% S#HEME (#TS!
YEAR 2012
Designed By
Government of India
Ministry of Labour (D.G.E.&T.)
#E"TRAL STAFF TRA$"$"% A"D RESEAR#H $"ST$TUTE
EN-Blo!" #etor-$" #alt La!e
%ol!ata-&'' '()

Automobile Trade_ Mechanic Basic Engineering_1
st
semester _common *a+e & of '(
Mechanic Basic Engineering (Automobile Trae!
,nder -raftsmen Trainin+ #.eme (-T#)
()
st
semester)
-ommon to
) Mechanic Diesel ) Marine Diesel
/ Mechanic Motor *ehicle
0 Mechanic Autotronics
1 Mechanic T+o +heelers
2 Mechanic Three +heelers
3 Mechanic Hea,- *ehicle
& Tractor Mechanic
4 Mechanic Agricultural Machiner-
( .um/ O/erator #um Mechanic
Automobile Trade_ Mechanic Basic Engineering_1
st
semester _common *a+e ( of '(
List o0 trae committee members a//ro,e the s-llabus o0 semester s-stem 0or the
trae o0 Mechanic Basic Engineering hel at AT$1 #hennai
Sl2
"o2
"ame 3 Designation Re/resenting
Organisation
Remar4s
' Shri R2 Senthil 5umar1 Director AT$1 #hennai #hairman
& Shri S2Harinath Babu1 6oint Director o0
Training
AT$1 #hennai Member
( Shri E2Bala4rishna1 E786oint Director o0
Training
"$M$1 #hennai Member
9 Shri A2Suganthan1 Assistant Training o00icer %o,t1 $T$1 Ara44onam Member
: Shri "2 Ramesh 5umar1 Training O00icer #T$1 #hennai Member
; Shri T "anago/al1 Anna Uni,ersit-1 #hennai Member
< Shri 52 Thani-arasau1 Assistant Training o00icer %o,t 2 $T$1 Trich- Member
= Shri .252 Rama4rishnan "air Ram international
$nustrial Acaem- (/!
Lt1 #hennai
Member
> Shri S2Arul Sel,an 1 Assistant /ro0essor De/t Auto Engg1 M2$2T1
Anna Uni,ersit-1
#hennai2
Member
'? Shri S2 6a-ara@1 Associate .ro0essor De/t Auto Engg1 M2$2T1
Anna Uni,ersit-1
#hennai2
Member
'' Shri R2 La4shmanan Bosch Lt1 Bangalore Member
'& Shri *2#hanraMohan "ATR$.1 %lobal
Automoti,e Research
centre1 #hennai
Member
'( Shri *2*ai,elan "ATR$.1 %lobal
Automoti,e Research
centre1 #hennai
Member
'9 Shri A2D2She+ale Training O00icer #T$1 chennai Member
': Shri B2 %riharan *isa Diesel Ser,ice1
#hennai
Member
'; Shri 5242*alasara@an 1 *ice /resient T+o Aheeler +or4sho/
o+ners Association1
#hennai
Member
Automobile Trade_ Mechanic Basic Engineering_1
st
semester _common *a+e 9 of '(
'< Shri 6a-a/al1 T+o Aheeler +or4sho/
o+ners Association1
#hennai
Member
'= Shri *2 *ai,elan T+o Aheeler +or4sho/
o+ners Association1
#hennai
Member
'> Shri S-esh+ath T+o Aheeler +or4sho/
o+ners Association1
#hennai
Member
&? .2 Mar,elass1 Assistant Director o0 Training
(Electronics!
AT$1 #hennai Member
&' 52 ArulSel,i1 Training O00icer (Electronics! AT$1 #hennai Member
&& Shri %urcharan Singh1 Assistant Director o0
Training
AT$1 Luhiana Member
&( Shri O2R2 Ar@un Mohan1 Assistant E7ecuti,e
Engineer
Agricultural Engg2 De/t1
#hennai
Member
&9 Shri R2Murugesan1 Assistant E7ecuti,e Engineer Agricultural Engg2 De/t1
#hennai
Member
&: Shri Rama4rishne %o+a1 Assistant Director o0
Training
FT$1 Bangalore Member
&; #2Yu,ara@1 Assistant Director o0 Training AT$1 #hennai Member
Automobile Trade_ Mechanic Basic Engineering_1
st
semester _common *a+e : of '(
%E"ERAL $"FORMAT$O"
). Name of t.e Trade 5 Mechanic Basic Engineering2
/. N.-.6. -ode No. 5
0. Duration of -raftsmen Trainin+ 5 '3 mont.s ()
st
#emester)
1. Entry 7ualifiation 5 *ass in )'
t.
-lass under )'8/ system of Eduation
2. ,nit stren+t. 5 /'
3. #9ae norms 5 a) :or!s.o95 )/' #;r meter.
b) -lass room5 0' s;.meter.
&. *o<er norms 5 1.' %:
4. Instrutors 7ualifiation 5 De+ree in Me.anial=>utomobile En+ineerin+ from
reo+ni?ed en++. olle+e=university <it. one year e@9eriene in
t.e relevant field 6A
Di9loma in Me.anial=>utomobile En++
Brom reo+ni?ed board of te.nial eduation <it. t<o years
e@9eriene in t.e relevant field
6A
NT- in t.e relevant trade <it. 2 years 9ost ;ualifiation e@9eriene.
6r" N>- in t.e relevant trade <it. 1 years 9ost ;ualifiation e@9eriene.

(. Desirable ;ualifiation 5 *referene <ill be +iven to a andidate <it. -IT#.
(If not done -IT# t.an must be trained <it.in
'/yrs on Coinin+)
Automobile Trade_ Mechanic Basic Engineering_1
st
semester _common *a+e ; of '(
S-llabus 0or the Trae o0 B Mechanic Basic Engineering (Automobile Trae! uner
#2T2S2
Duration C Si7 Month
First Semester
Automobile Trade_ Mechanic Basic Engineering_1
st
semester _common *a+e < of '(
:ee!s Trade T.eory Trade *ratial $oational #iene
and -alulation
En+ineerin+
Dra<in+
) &
/
Amission 3 introuction
to the traeC
Bamiliarisation <it.
institute" Dob o99ortunities
in t.e automobile setor"
Ma.inery used in Trade.
Ty9es of <or! done by t.e
students in t.e s.o9 floor.
-ommon Brations
addition" subtration
Multi9liation and
Division of
-ommon
Brations #im9le
#.o9 9roblems
Involvin+ Brations.
0 &
1
Occu/ational Sa0et- 3
Health
Basi safety introdution"
*ersonal 9rotetion5-
Basi inCury 9revention"
Basi first aid" Ea?ard
identifiation and
avoidane" safety si+ns for
Dan+er" :arnin+" aution &
9ersonal safety messa+e.
emer+eny evauation
9roedure" #afe .andlin+
of Buel #9illa+e" ,se of Bire
e@tin+uis.ers" safe dis9osal
of to@i dust" safe .andlin+
and *eriodi testin+ of
liftin+ e;ui9ment"
>ut.ori?ation of Movin+ &
road testin+ ve.iles"
Environment ontrol of
Aunnin+ indoors en+ines"
#afety dis9osal of ,sed
en+ine oil" Eletrial safety
9raties.
Eouse %ee9in+ F 2#
-one9t.
*ratial related
to #afety and
Eealt. "
Demonstration on
**E (*ersonal
*rotetion
E;ui9ments)
Interation <it.
.ealt. enter and
fire servie
station to 9rovide
demo on Birst aid
and Bire safety"
,se of fire
e@tin+uis.ers.
,nits" Derived and
fundamental" ty9es
of system B*#"
-G#" M%# and
t.eir onversion.
Metri <ei+.ts and
measurements" units
onversion fators.
Introdution to
En+ineerin+
dra<in+ and
Blue *rint
Aeadin+"
Bree .and
s!et.in+ of
strai+.t lines"
retan+les"
s;uares" irles"
9oly+ons et
2 S-stems o0 measurement"
onversion of En+lis. into
metri #ystems of
measurement & vie- versa.
Desri9tion" are & use
of 5-
Mirometers- Inside"
6utside and de9t.
measurements" T.read
Mirometer" Mirometer
adCustments" $ernier
ali9ers" veriner de9t.
+au+e" vernier .ei+.t +au+e
Teleso9e +a+es" Dial bore
+au+es" Dial indiators"
vauum +au+e" tire 9ressure
+au+e.
Measurin+
9ratie on
en+ine
om9onents <it.
aid of instrument
studied.
Aedution of
ommon frations to
deimal frations-
s.o9 9roblems.
Definition of least
ount" >uray"
-alibration"
Derive t.e least
ount for $ernier
ali9er and
Mirometer.
Bree .and
s!et.in+ of
$ernier ali9er
and
Mirometer"
Dial +au+e
3 Han 3 .o+er ToolsCD
Mar!in+ s.eme" Mar!in+
material" Desri9tion" are
and use of #urfae 9lates"
steel rule" measurin+ ta9e"
*ratie usin+ all
mar!in+ aids" li!e
steel rule <it.
s9rin+ ali9ers"
dividers" surfae
*ro9erties and uses
of ast iron" ferrous
metal" +ray ast
iron" <.ite ast iron"
<rou+.t iron" and
Bree .and
s!et.in+ of
!ey and sre<
t.reads <it.
dimensions
Automobile Trade_ Mechanic Basic Engineering_1
st
semester _common *a+e = of '(
L$ST OF TOOLS 3 EEU$.M"T FOR SEMESTERD$
FOR THE TRADE OF Mechanic Basic Engineering (Automobile Trae!
(Unit SiFe C &?!
Mechanic Basic Engineering (Automobile Trae! D '
st
Semester
#ommon to
) Mechanic Diesel ) Marine Diesel
/ Mechanic Motor *ehicle
0 Mechanic Autotronics
1 Mechanic T+o +heelers
2 Mechanic Three +heelers
Automobile Trade_ Mechanic Basic Engineering_1
st
semester _common *a+e > of '(
3 Mechanic Hea,- *ehicle
& Tractor Mechanic
4 Mechanic Agricultural Machiner-
( .um/ O/erator #um Mechanic
Sl2"o $tem +ith s/eci0ication Et-
Trainees Tool 4it
) #teel rule )2 m in. and metri /'8)
/ #teel rule 0' m in. and metri /'8)
0 #teel measurin+ ta9e )' meter in a ase /'8)
1 Try #;uare )' m Blade /'8)
2 -ali9ers outside )2 m s9rin+ /'8)
3 -ali9er inside )2 m #9rin+ /'8)
& Dividers )2 m #9rin+ /'8)
4 #afety +lasses /'8)
( #riber )2 m /'8)
)' %nife double Blade Eletriian /'8)
)) :ire insulation #tri99er for s.innin+ ondutors from '.1mm to 1mm /'8)
)/ Eletriian testin+ *enil (Line = Neon tester) /'8)
)0 Eletriian #re< Driver /2'mm /'8)
)1 -entre 9un. )' m. /'8)
)2 -.isel old flat /' mm @ )2' mm /'8)
)3 Eammer ball 9een '.2 !+ <it. .andle /'8)
)& #re< driver /'m.G (mm. Blade /'8)
)4 #re< driver 0' m. G ( mm. Blade /'8)
)( #9anner D.E. set of )/ 9iees (3mm to 0/mm) /'8)
/' *liers ombination /' m. /'8)
/) *liers side uttin+ )2 m /'8)
// *liers round nose )2 m /'8)
/0 *liers flat nose )2 m /'8)
/1 Eands file /' m. #eond ut flat /'8)
/2 Eand file /' m. #eond ut .alf-round /'8)
/3 Eand file /' m. smoot. trian+ular /'8)
/& Eand file 0' m. bastard /'8)
/4 Eand file 0' m. round bastard /'8)
/( Bile ard or leaner /'8)
0' :ire utter and stri99er /'8)
0) #teel tool bo@ <it. lo! and !ey (foldin+ ty9e) 1''@/''@)2' mm /'8)
Tools $nstruments an %eneral Sho/ out0its
0/ 6utside mirometer ' to /2 mm /
00 6utside mirometer /2 to 2' mm /
01 6utside mirometer 2' to &2 mm /
02 6utside mirometer &2 to )'' mm /
03 Internal mirometer 2 to 0' mm /
0& De9t. mirometer '-/2mm /
04 T.read Mirometer '-/2mm /
0( >dCustable mirometer s9rit level to measure flatness" indiation and
ta9er <it. 9rismati measurin+ base
/
1' $ernier ali9er > /'' <it. inside and de9t. measurement /
Automobile Trade_ Mechanic Basic Engineering_1
st
semester _common *a+e '? of '(
1) Diret readin+ vernier ali9er B 0'' (diret readin+ <it. dial) /
1/ $ernier de9t. Gau+e '-)2' mm /
10 $ernier .ei+.t +au+e 2'' mm /
11 Teleso9e +au+e )
12 Dial +au+e ty9e ) Gr. > (om9lete <it. lam9in+ devies and stand) 1
13 #urfae +au+e <it. dial test indiator 9lun+er ty9e i.e. '.') mm /
1& -ylinder bore +au+e a9aity /' to )3' mm /
14 -om9ression testin+ +au+e. )
1( $auum +au+e to read ' to &3' mm of E+. )
2' Tyre 9ressure +au+e )
2) Mar!in+ Material (-onsumable) >s re;uired
2/ Mar!in+ out table ('G3'G(' m. /
20 Granite surfae 9late )3'' @ )''' <it. stand and over. )
21 -I surfae 9late 1'' @ 1'' mm <it. stand and over )
22 #teel rule )2 m in. and metri /
23 #teel rule 0' m in. and metri /
2& #teel measurin+ ta9e )' meter in a ase /
24 Try #;uare )' m Blade /
2( En+ineerHs s;uare )2 m. Blade 1
3' -ali9ers outside )2 m s9rin+ /
3) -ali9er inside )2 m #9rin+ /
3/ -ali9ers )2 m Eerma9.rodite 1
30 Dividers )2 m #9rin+ /
31 #afety +lasses /
32 #riber )2 m /
33 #riber <it. sribin+ bla! universal 1
3& *un. Letter 1mm / set
34 Eollo< 9un. set of seven 9iees 3mm to )2mm / set ea.
3( Drift 9un. o99er )2 m 1
&' *ri! 9un. )2 m. 1
&) -.isels ross ut /'' mm G 3mm 1
&/ -.isel )' m flat 1
&0 Ball *een Eammer '.&2 %+ 1
&1 Eammer o99er ) %+ <it. .andle /
&2 Eammer Mallet 1
&3 Eammer *lasti 1
&& Eammer ball 9een './2 !+ <it. .andle 1
&4 *.ili9s #re< Driver set of 2 9iees ()'' mm to 0'' mm) / sets
&( Insulated #re< driver 0' m @ (mm blade /
4' Insulated #re< driver /' m @ (mm blade /
4) Eletri testin+ sre< driver /
4/ >llen %ey set of )/ 9iees (/mm to )1mm) /
40 Eand vie F 0& mm /
41 :or! ben. /2' @ )/' @ 3' m <it. 1 vies )/m Da< 1
42 Ma+nifyin+ +lass &2mm /
43 I$H Blo! &2 @ 04 mm 9air <it. -lam9s /
4& -lam9s - )''mm /
44 -lam9s - )2'mm /
4( -lam9s - /''mm /
(' #9anner D.E. set of )/ 9iees (3mm to 0/mm) )
() #9anner" adCustable )2m. )
(/ #9anner" rin+ set of )/ metri si?es 3 to 0/ mm. )
Automobile Trade_ Mechanic Basic Engineering_1
st
semester _common *a+e '' of '(
(0 #9irit level /$ /2'" '2 metre /
(1 >n+le 9late si?e /''@)''@/''mm /
(2 >n+le 9late adCustable /2'@)2'@)&2 )
(3 #olid 9arallels in 9airs (Different si?es) in Metri )/ 9airs
(& *liers ombination /' m. /
(4 *liers side uttin+ )2 m /
(( *liers round nose )2 m /
)'' *liers flat nose )2 m /
)') $ie +ri9 9liers /
)'/ -irli9 9liers E@9andin+ and ontratin+ ty9e )2m and /'m ea. /
)'0 Gri9 :ren. /''mm /
)'1 Tor;ue <ren.es 2-02 Nm )
)'2 >ir im9at <ren. )
)'3 >ir rat.et )
)'& >ir .isel )
)'4 >ir blo< +un )
)'( -ar Det <as.er )
))' *i9e flarin+ tool )
))) *i9e uttin+ tool )
))/ ,niversal 9uller for removin+ 9ulleys" bearin+s )
))0 -leanin+ tray 12@0' m. )
))1 -leanin+ tray- >luminum 12 @ 0' m )
))2 #tud e@trator set of 0 / sets
))3 #tud remover <it. so!et .andle )
))& -.emial om9ound for fasteners (-onsumable) >s re;uired
))4 *araffin 9ressure Gun /
))( Grease Gun /
)/' *o9rivet +un /
)/) Aivet sets sna9 and Dolly ombined 0mm" 1mm" 3mm 1 ea.
)// Ea!sa< frame adCustable /'-0' m 4
)/0 Ea!sa< blade (onsumable) >s re;uired
)/1 Blat Bile 02 m bastard 1
)/2 Blat Bile /2 m seond ut 1
)/3 Bile flat /' m bastard 1
)/& Biles assorted si?es and ty9es inludin+ safe ed+e file (/' Nos) / set
)/4 Drill T<ist (assorted) (-onsumables) )' Nos
)/( Drill t<ist ).2 mm to )2 mm (various si?es) by '.2 mm 1
)0' Drill 9oint an+le +au+e )
)0) #et of sto! and dies - ,N-" ,NB and metri / sets
)0/ Ta9s and <ren.es - ,N-" ,NB and metri / sets
)00 Eand reamers adCustable )'.2 to ))./2 mm" ))./2 to )/.&2 mm" )/.&2
to )1./2 mm and )1./2 to )2.&2 mm
/sets
)01 La99in+ abrasives (onsumable) >s re;uired
)02 6il an '.2='./2 liter a9aity /
)03 6il #tone )2 m @ 2 m @ /.2 m )
)0& Different ty9e +as!et material (onsumable) >s re;uired
)04 Different ty9e of oil seal (onsumable) >s re;uired
)0( #.eet Metal Gau+e /
)1' Beeler +au+e /' blades (metri) /
)1) #trai+.t ed+e +au+e / ft. )
)1/ #trai+.t ed+e +au+e 1 ft. )
)10 T.read 9it. +au+e metri" B#G" B#B" M-" MB & #>E )
Automobile Trade_ Mechanic Basic Engineering_1
st
semester _common *a+e '& of '(
)11 Ladle )2'mm Dia )
)12 Blo< Lam9 ) litre /
)13 -ro< bar ()' @/2mm /
)1& $oltmeter 2'$=D- 2
)14 >mmeter 0''>= 3'> D- <it. e@ternal s.unt 2
)1( #tandard variable resistanes as used in t.e lab 2
)2' D- 6.mmeter ' to 0'' 6.ms" mid sales at /' 6.ms )
)2) Eletri #olderin+ Iron /0' $ 3' <atts /0' $ /2 <atts / ea.
)2/ -o99er bit solderin+ iron './2 %+ 2
)20 T.imbles of different si?es /
)21 :ire Gau+e (metri) )'
)22 Eand o9erated rim9in+ tool (i) for rim9in+ u9 to 1mm and (ii) for
rim9in+ u9 to )'mm
/
)23 Eand rubber +loves tested for 2''' $ 2 9air
)2& Eolders" lam9 tea!<ood boards" 9lu+ so!ets" solders" flu@ <ires and
ables batteries round onsumable blo!s and ot.er onsumables as
re;uired
>s re;uired
)24 Multimeter di+ital 2
)2( #ientifi -alulator 1
)3' Eydrometer /
)3) Ei+. rate dis.ar+e tester (ell tester) )
)3/ #9ray Gun (*aintin+) 2''ml )
%eneral Machiner-)$nstallation
)30 Trolley ty9e 9ortable air om9ressor sin+le ylinder <it. 12 liters
a9aity >ir tan!" alon+ <it. aessories & <it. <or!in+ 9ressure
3.2 !+=s; m
)
)31 Lat.e +eneral 9ur9ose all +eared .ei+.t of enter )2' mm to
belo<" Ga9 bed bet<een enters )''' mm <it. all aessories <it.
all atta.ment.
1
)32 Grindin+ ma.ine (+eneral 9ur9ose) D.E. 9edestal <it. 0'' mm dia
<.eels rou+. and smoot.
)
)33 Drillin+ ma.ine ben. to drill u9 to )/mm dia alon+ <it. aessories /
)3& *ortable eletri drill Ma.ine )
)34 Eletrial furnae u9 to )/'' de+ )
)3( >.- <eldin+ transformer 0'' >m9s <it. om9lete aessories / set
)&' 6@y-aetylene <eldin+ e;ui9ment <it. om9lete aessories ( Lo< &
.i+. 9ressure)
/
)&) #9ot <eldin+ ma.ine <it. om9lete aessories )
)&/ Guillotine s.earin+ Ma.ine foot o9eration
()mt @ )4G -a9aity)
)
)&0 Bly 9ress = Ball 9ress No.1 sin+le body )
)&1 *i9e Bendin+ Ma.ine (Eydrauli ty9e) )/mm to 0'mm )
)&2 #9rin+ tension tester )
)&3 Ben. lever s.ears /2'mm Blade @ 0mm -a9aity )
)&& Gas :eldin+ Table )//'mm @&3'mm )
)&4 Eydrauli Trainer %it FBasi alon+ <it. aessories )
)&( *neumati Trainer %it- Basi alon+ <it. aessories )
)4' Eletroni om9onent trainer !it )
Sl2
"o2
#lass Room) Aor4sho/ Furniture Euantit-
). #uitable lass room furniture >s re;uired
Automobile Trade_ Mechanic Basic Engineering_1
st
semester _common *a+e '( of '(
/. #tools >s re;uired.
0. Disussion Table ) No.
1. Tool -abinet / Nos.
2. Trainees lo!er / Nos. to aommodate /'
lo!ers
3. Bire E@tin+uis.ers" first- aid bo@ >s re;uired
&. Boo! s.elf (+lass 9anel) ) No.
4. #tora+e Aa! >s re;uired
(. #tora+e s.elf >s re;uired.
)' L-D 9roCetor ) no
)) Des!to9 om9uter and related M# offie soft<are 1 No
)/ 6nline ,*# /%$> ) No
)0 Laser 9rinter ) No