Documente Academic
Documente Profesional
Documente Cultură
Under
Redesigned in
2014
By
Government of India
Ministry of Labour & Employment (DGE&T)
1
GENERAL INFORMATION
2. N.C.O. & NOS Code No. : 7231.10, ASC/ Q 1401, ASC/ Q 1402
3. Duration of Craftsmen : 2 Year (Four Semester having duration of six months each)
Training
4. Power Norms : 4.8 KW
5. Space Norms : Space Area 210 Sq. Mt. (Including parking area)
6. Entry Qualification : Passed 10th class examination with maths and Science.
7. Unit strength : 16 + 30% super Numeric
8. Instructors : a) Degree in Automobile/ Mechanical Engg. (with specialization in
Qualification Automobile) from recognised college/University with one year
experience in the automobile industry and should possess valid LMV
driving license.
OR
Diploma in Automobile/Mechanical (specialization in automobile)
from recognized board of technical education with two years
experience in the automobile industry and should posses valid
LMV driving license.
OR
10th Passed + NTC/NAC in the Trade of “Mechanic
Motor Vehicle)” with 3 years post qualification experience in
the relevant field and should possess valid LMV driving license.
and
b) With “National Crafts Instructor Certificate”.
* Note:
1) At least one Instructor must have Degree/Diploma in
Automobile/ Mechanical Engg. (with specialization in
Automobile) when applied for 02 units.
2) Instructor Qualification for WCS & E.D, as per the Training
Manual
2
9. For Employability Skills One Contract/Part Time/Guest Faculty for Generic Module .
i) MBA/ BBA with two years experience OR Graduate in Sociology / Social
Welfare / Economics with Two years experience OR Graduate / Diploma with
Two years experience and trained in Employability Skills from DGET institutes
AND
Must have studied English / Communication Skills and Basic Computer at 12th /
Diploma level and above
OR
Existing Social Study Instructors duly trained in Employability Skills from DGET
institutes
3
COURSE INFORMATION (MECHANIC MOTOR VEHICLE)
1.Introduction :
2. Terminal Competencies/Deliverables:
After successful completion of the above course, the trainee shall be able to perform
the following skills with proper sequence.
Mechanic, Automobile repairs overhauls and services motor vehicles to keep them in
good running condition.
Examines vehicle to ascertain nature and location of defects either by running engine
or driving vehicle on road.
Measures essential parts like cylinder, bores piston, sizes crank pins etc. using gauges,
micrometer and other precision tools and gets cylinders rebored, liners filled, valve
seats refaced, bearings replaced etc. as necessary.
Replaces or repairs defective parts of gear box, rear axle, steering mechanism etc. and
sets them right ensuring correct alignment, clearance, meshing of gears, specified
movements and operations.
Relines and builds brakes, sets wheel alignment, adjust, steering, clutch, hand brakes
etc fits new or repaired accessories and body parts, makes electrical connection, and
performs other tasks to effect repairs.
Lubricates, joints, tightens loose parts, tests performance of vehicle by driving on road
and makes necessary adjustments to attain desired standard.
4
3. Employment opportunities:
On successful completion of the course the candidates can either get employed, or
become a self-employed Entrepreneur in any one of the following fields.
5
Syllabus for the trade of Mechanic Motor Vehicle
First Semester (Semester code No. )
Duration: Six Months.
Syllabus for Trade practical and Trade Theory
6
6&7 Measuring practice on Cam height, Systems of measurement, Description, care &
Camshaft Journal dia, crankshaft use of - Micrometers- Outside and depth
journal dia, Valve stem dia, piston mirometer, Micrometer adjustments, Vernier
diameter, and piston pin dia with calipers, Telescope gauges, Dial bore gauges, Dial
outside Micrometers. indicators, straightedge, feeler gauge, thread pitch
Measuring practice on the height of gauge, vacuum gauge, tire pressure gauge.
the rotor of an oil pump from the
surface of the housing or any other
auto component measurement with
depth micrometer.
Measuring practice on valve spring
free length.
Measuring practice on cylinder bore,
Connecting rod bore, inside diameter
(ID) of a camshaft bearing with
Telescope gauges.
Measuring practice on cylinder bore
for taper and out-of-round with Dial
bore gauges.
Measuring practice to measure wear
on crankshaft end play, crankshaft
run out, and valve guide with dial
indicator.
Measuring practice to check the
flatness of the cylinder head is
warped or twisted with straightedge
is used with a feeler gauge.
Measuring practice to check the end
gap of a piston ring, piston-to-
cylinder wall clearance with feeler
gauge.
Practice to check engine manifold
vacuum with vacuum gauge.
Practice to check the air pressure
inside the vehicle tires is maintained
at the recommended setting.
8&9 Practice on General cleaning, Fasteners- Study of different types of screws,
checking and use of nut, bolts, & nuts, studs & bolts, locking devices, Such as lock
studs etc., nuts, cotter, split pins, keys, circlips, lock rings,
lock washers and locating where they are used.
Removal of stud/bolt from blind Washers & chemical compounds can be used to
hole. help secure these fasteners. Function of Gaskets,
Selection of materials for gaskets and packing, oil
Practice on cutting tools like seals.
Hacksaw, file, chisel, Sharpening of Cutting tools :- Study of different type of cutting
Chisels, center punch, safety
tools like Hacksaw, File- Definition, parts of a
precautions while grinding.
7
file, specification, Grade, shape, different type of
Practice on Hacksawing and filing to cut and uses., OFF-hand grinding with sander,
given dimensions. bench and pedestal grinders, safety precautions
while grinding.
Limits, Fits & Tolerances:-Definition of limits,
fits & tolerances with examples used in auto
components
10 & Practice on Marking and Drilling Drilling machine - Description and study of
11 clear and Blind Holes, Sharpening of Bench type Drilling machine, Portable electrical
Twist Drills Safety precautions to be Drilling machine, drill holding devices, Work
Holding devices, Drill bits.
observed while using a drilling
Taps and Dies: Hand Taps and wrenches,
machine. Practice on Tapping a Calculation of Tap drill sizes for metric and inch
Clear and Blind Hole, Selection of taps. Different type of Die and Die stock. Screw
tape drill Size, use of Lubrication, extractors. Hand Reamers – Different Type of
Use of stud extractor. hand reamers, Drill size for reaming, Lapping,
Cutting Threads on a Bolt/ Stud. Lapping abrasives, type of Laps.
Adjustment of two piece Die,
Reaming a hole/ Bush to suit the
given pin/ shaft, scraping a given
machined surface.
12 Practice on making Rectangular Sheet metal - State the various common metal
Tray. Sheets used in Sheet Metal shop
Pipe bending, Fitting nipples unions Sheet metal operations - Shearing, bending,
in pipes. Soldering and Brazing of Drawing, Squeezing
Pipes. 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.
8
15 Cleaning and topping up of a lead Description of Chemical effects, Batteries &
acid cells, Lead acid batteries & Stay Maintenance
battery, Testing battery with Free (SMF) batteries, Magnetic effects, Heating
hydrometer, effects, Thermo-electric energy, Thermisters,
Connecting battery to a charger for Thermo couples, Electrochemical energy, Photo-
battery charging, Inspecting & voltaic energy, Piezo-electric energy,
testing a battery after charging, Electromagnetic induction, Relays, Solenoids,
Measure and Diagnose the cause(s) Primary & Secondary windings, Transformers,
of excessive Key-off battery drain stator and rotor coils.
(parasitic draw) and do corrective
action. Testing of relay and solenoids
and its circuit.
16 Identify and test power and signal Basic electronics: Description of Semi
connectors for continuity, Identify conductors, Solid state devices- Diodes,
and test different type of Diodes, Transistors, Thyristors, Uni Junction Transistors (
UJT), Metal Oxide Field Effect Transistors (
NPN & PNP Transistors for its
MOSFETs), Logic gates-OR, AND & NOT and
functionality, Logic gates using switches.
Construct and test simple logic
circuits OR, AND & NOT and Logic
gates using switches.
17& Practice to make straight beads and
Introduction to welding and Heat Treatment
18 Butt, Lap & T joints Manual Metal
Arc Welding. Welding processes – Principles of Arc welding, brief
description, classification and applications. Manual
Setting of Gas welding flames,
Metal Arc welding -principles, power sources,
practice to make a straight beads and
electrodes, welding parameters, edge preparation
joints Oxy – Acetylene welding
& fit up and welding techniques; Oxy – Acetylene
Film on Heat treatment process welding - principles, equipment, welding
parameters, edge preparation & fit up and welding
techniques;.
9
Identification of components in Air single acting, double acting & Double ended
brake systems. cylinder; Directional control valves-2/2, 3/2, 4/2,
4/3 way valve, Pressure relief valve, Non return
valve, Flow control valve used in automobile.
Pneumatic Symbols, Description and function of
air Reciprocating Compressor. Function of Air
service unit (FRL-Filter, Regulator & Lubricator).
21 Identification of different type of Auto Industry - History, leading manufacturers,
Vehicle. development in automobile industry, trends, new
Demonstration of vehicle product. Brief about Ministry of Road transport &
Highways,
specification data; The Automotive Research Association of India
Identification of vehicle information (ARAI), National Automotive Testing and R&D
Number (VIN). Demonstration of Infrastructure Project (NATRIP), & Automobile
Garage, Service station equipments.- Association.
Vehicle hoists – Two post and four Definition: - Classification of vehicles on the
post hoist, Engine hoists, Jacks, basis of load as per central motor vehicle rule,
Stands. wheels, final drive, and fuel used, axles, position
of engine and steering transmission, body and
load. Brief description and uses of Vehicle hoists
– Two post and four post hoist, Engine hoists,
Jacks, Stands.
22-23 In-plant Training
24-25 Revision and Test
26 NCVT Exam
10
Workshop Calculation and Science
Syllabus for the trade of
1. Mechanic Motor Vehicle
11
Syllabus for Engineering Drawing- Ist Semester
Syllabus for the trade of
1. Mechanic Motor Vehicle
Week Engineering Drawing (3 Hrs/week)
No. 1st Semester
1 Importance of engineering drawing as a communication medium, different types of
drawing - Machine Drawing, Production Drawing, Part Drawing, Assembly
Drawing, Drawing instruments, equipment and materials and their uses
2&3 Scales - Recommended scales, reduced & enlarged Drawing Sheet sizes: A0, A1,
A2, A3, A4, A5, Layout of drawing sheet, sizes of title block and its contents. Using
drawing instruments to draw straight lines, rectangles, squares, circles, polygons.
4&5 Lettering and Dimensioning - Types of Lettering, Guide Lines for lettering,
Recommended sizes of letters and numbers, Single stroke letters, Dimensioning -
rules and systems of dimensioning – dimensioning a given drawing.
6&7 Identify the alphabet of lines- Read and Interpret the meaning of various line types
with examples- Object Lines, Hidden Lines, Center Lines, Phantom Lines,
Dimension Lines, Extension Lines, Leaders, Break Lines -Long-break Line, Round,
Solid, Hollow Cross Section, Section Lines – Common Manufacturing Materials,
Cutting Plane Lines
8-11 Geometric Construction - Bisecting a line - perpendiculars - parallel lines - division
of a line; Angles - bisection, trisection, Tangent lines touching circles internally and
externally Polygons - Regular polygons - circumscribed and inscribed in circles.
Conic sections - Definitions of focus, directrix, eccentricity, Construction of Ellipse
by Concentric circles method, Construction of parabola by rectangular method.
12&13 Orthographic Projection - Definition - Planes of Projection - Four quadrants –
Reference Line, First angle projection - Third angle projection.
14-17 Isometric Projection - Definition - Isometric axes, lines and planes, Isometric Scale -
Isometric view. Drawing of isometric views of plane figures, Drawing of isometric
views of prisms and pyramids, Drawing of isometric view of cylinders and cones
18-21 Development of Surfaces - Need for preparing development of surface, Concept of
true length - Principal methods of development, Development of simple solids like
cubes, prisms, cylinders, pyramids, cones.
12
Syllabus for the trade of Mechanic Motor Vehicle
Second Semester (Semester code No. )
Duration: Six Months.
Syllabus for Trade practical and Trade Theory
Week Trade Practical (27 Hrs/week) Trade Theory (5 Hrs/week)
No.
1&2 Identification of parts in a diesel engine of Introduction to Engine:
LMV/ HMV Description of internal & external
combustion engines, Classification of IC
Practice on starting and stopping of diesel
engines, Principle & working of 2&4-stroke
engines.
diesel engine (Compression ignition Engine
Observe and report the reading of (C.I)), Principle of Spark Ignition
Tachometer, Odometer, temp and Fuel Engine(SI), differentiate between 2-stroke
gauge under ideal and on load condition. and 4 stroke, C.I engine and S.I Engine,
Direct injection and Indirect injection,
Practice on dismantling Diesel engine of Technical terms used in engine, Engine
LMV/HMV as per procedure. 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 Diesel Engine
Procedure for dismantling of diesel engine
from a vehicle..
13
5 Overhauling piston and connecting rod Description & functions of different types
Assembly. Use of service manual for of pistons, piston rings and piston pins and
clearance and other parameters:- materials. Used recommended clearances
Practice on removing oil sump and oil for the rings and its necessity precautions
pump – clean the sump. Practice on while fitting rings, common troubles and
removing the big end bearing, connecting remedy. Compression ratio.
rod with the piston. Practice on removing
Description & function of connecting
the piston rings; Dismantle the piston
rod, importance of big- end split
and connecting rod. Check the side
obliquely, Materials used for connecting
clearance of piston rings in the piston
rods big end & main bearings. Shells
groove & lands for wear. Check piston
piston pins and locking methods of piston
skirt and crown for damage and
pins.
scuffing, clean oil holes.
Measure -the piston ring close gap in the
cylinder, clearance between the piston and
the liner, clearance between crank pin and
the connecting rod big end bearing.
Check connecting rod for bend and twist.
Assemble the piston and connecting rod
assembly.
14
Removing cylinder liners from scrap
cylinder block, practice in measuring and
refitting new liners as per maker’s
recommendations precautions while fitting
new liners.
9 Reassemble all parts of engine in correct Engine assembly procedure with aid of
Sequence and torque all bolts and nuts special tools and gauges used for engine
as per workshop manual of the engine. assembling. Introduction to Gas Turbine,
Engine component procedures- Testing Comparison of single and two stage turbine
cylinder compression, Checking idle engine, Different between gas turbine and
speed, Removing & replacing a cam Diesel Engine.
belt, Inspecting & adjusting an engine
drive belt, Replacing an engine drive
belt.
10-12 Practice on Checking &Top up coolant, Need for Cooling systems, Heat transfer
Draining & refilling coolant, Checking / method, Boiling point & pressure,
replacing a coolant hose, Testing Centrifugal force, Vehicle coolant
cooling system pressure, Practice on properties and recommended change of
Removing & replacing radiator/ interval, Different type of cooling systems,
thermostat. Inspect the radiator pressure Basic cooling system components-
cap, Testing of thermostat. Cleaning & Radiator, Coolant hoses, Water pump,
reverse flushing. Overhauling water Cooling system thermostat, Cooling fans,
pump and refitting. Temperature indicators, Radiator pressure
Practice on Checking engine oil, Draining cap, Recovery system, Thermo-switch.
engine oil, Replacing oil filter, Refilling Need for lubrication system, Functions of
engine oil. Overhauling of oil pump, oil oil, Viscosity and its grade as per SAE , Oil
coolers, air cleaners and air filters and additives, Synthetic oils, The lubrication
adjust oil pressure relief valves, repairs to system, Splash system, Pressure system,
oil flow pipe lines and unions if necessary. Corrosion/noise reduction in the lubrication
system. Lubrication system components -
Description and function of Sump, Oil
collection pan, Oil tank, Pickup tube,
different type of Oil pump & Oil filters Oil
pressure relief valve, Spurt holes &
galleries, Oil indicators, Oil cooler.
13. Practice on Dismantling air compressor and Intake & exhaust systems – Description
exhauster and cleaning all parts - measuring of Diesel induction & Exhaust systems.
wear in the cylinder, reassembling all parts Description & function of air compressor,
exhauster, Super charger, Intercoolers,
and fitting them in the engine.
turbo charger, variable turbo charger
Dismantling & assembling of turbocharger, mechanism.
check for axial clearance as per service Intake system components- Description
manual.
and function of Air cleaners, Different
Check Exhaust system for rubber mounting type air cleaner, Description of Intake
for damage, deterioration and out of position; manifolds and material,
for leakage, loose connection, dent and
damage; Exhaust system components- Description
Practice on Exhaust manifold removal and
15
installation. and function of Exhaust manifold,
Practice on Catalytic converter removal and Exhaust pipe, Extractors, Mufflers-
installation. Reactive, absorptive, Combination.,
Catalytic converters, Flexible connections,
Ceramic coatings, Back-pressure,
Electronic mufflers.
14 - Practice on removing & Cleaning fuel Diesel Fuel Systems- Description and
16 tanks, checking leaks in the fuel lines, function of Diesel fuel injection, fuel
soldering & repairing pipe lines and characteristics, concept of Quiet diesel
Unions, brazing nipples to high pressure technology & Clean diesel technology.
line studying the fuel feed system in Diesel fuel system components –
diesel engines, draining of water Description and function of Diesel tanks &
separators. lines, Diesel fuel filters, water separator,
Lift pump, Plunger pump, Priming pump,
Bleeding of air from the fuel lines, Inline injection pump, Distributor-type
Servicing primary & secondary filters. injection pump, Diesel injectors, Glow
Removing a fuel injection pump from plugs, Cummins & Detroit Diesel injection.
an engine-refit the pump to the engine Electronic Diesel control- Electronic
re- set timing - fill lubricating-oil start Diesel control systems, Common Rail
and adjust slow speed of the engine. Diesel Injection (CRDI) system,
Practice on overhauling of injectors and Hydraulically actuated electronically
testing of injector. controlled unit injector (HEUI) diesel
General maintenance of Fuel Injection injection system. Sensors, actuators and
Pumps (FIP). ECU (Electronic Control Unit) used in
Diesel Engines.
17 Practice on Start engine adjust idling Marine & Stationary Engine:- Types,
speed and damping device in pneumatic double acting engines, opposed piston
governor and venture control unit checking engines, starting systems, cooling systems,
Performance of engine with off load lubricating systems, supplying fuel oil,
adjusting timings. Start engine- adjusting hydraulic coupling, reduction gear drive,
idle speed of the engine fitted with electromagnetic coupling, electrical drive,
mechanical governor checking- high generators and motors, supercharging.
speed operation of the engine.
Checking performance for missing
cylinder by isolating defective injectors
and test- dismantle and replace defective
parts and reassemble and refit back to the
engine
18 Monitoring emissions procedures by use of Emission Control:- Vehicle emissions
Engine gas analyser or Diesel smoke meter. Standards- Euro and Bhart II, III, IV, V Sources
Checking & cleaning a Positive crank case of emission, Combustion, Combustion
ventilation (PCV) valve. Obtaining & chamber design. Types of emissions:
interpreting scan tool data. Inspection of Characteristics and Effect of Hydrocarbons,
EVAP canister purge system by use of scan Hydrocarbons in exhaust gases, Oxides of
Tool. nitrogen, Particulates, Carbon monoxide,
EGR /SCR Valve Remove and installation Carbon dioxide, Sulfur content in fuels
for inspection. Description of Evaporation emission
control, Catalytic conversion, Closed loop,
16
Crankcase emission control, Exhaust gas
recirculation (EGR) valve, , Controlling air-
fuel ratios, Charcoal storage devices, Diesel
particulate filter (DPF). Selective Catalytic
Reduction (SCR), EGR VS SCR
19 Practice on removing alternator from Description .of charging circuit operation
vehicle dismantling, cleaning checking for of alternators, regulator unit, ignition
defects, assembling and testing for warning lamp- troubles and remedy in
motoring action of alternator & fitting to charging system.
vehicles.
Description of starter motor circuit,
Practice on removing starter motor Vehicle
Constructional details of starter motor
and overhauling the starter motor, testing of
solenoid switches, common troubles and
starter motor
remedy in starter circuit.
20 & Practice on troubleshooting in Troubleshooting : Causes and remedy for
21 LMV/HMV for Engine Not starting – Engine Not starting – Mechanical &
Mechanical & Electrical causes, High Electrical causes, High fuel consumption,
Engine overheating, Low Power
fuel consumption, Engine overheating,
Generation, Excessive oil consumption,
Low Power Generation, Excessive oil Low/High Engine Oil Pressure, Engine
consumption, Low/High Engine Oil Noise.
Pressure, Engine Noise.
17
Automobile Group – 2 years Trade
2nd Semester
Workshop Calculation and Science
Syllabus for the trade of
1. Mechanic Motor Vehicle
18
18-20 Internal combustion engines- Engine power-Brake power, Horsepower, PS – the DIN,
Indicated power, Mean effective pressure, Calculation of indicated power, Cylinder
pressure vs. crank angle, Mechanical efficiency of an engine, Volumetric efficiency,
Torque vs. engine speed, Specific fuel consumption vs. engine speed, Brake power,
torque and sfc( Specific fuel consumption) compared, Brake mean effective pressure,
Thermal efficiency, Indicated thermal efficiency, Brake thermal efficiency petrol vs.
Diesel.
21 Fuels and combustion- Calorific value, Combustion-Products of combustion, Relevant
combustion equations. Air–fuel ratio-Petrol engine combustion, Detonation, Pre-
ignition, Octane rating, Diesel fuel, Flash point , Pour point, Cloud point, Biofuels,
Liquefied petroleum gas (LPG) ,Hydrogen, Zero emissions vehicles (ZEVs)
19
Automobile Group – 2 years Trade
2nd Semester
Engineering Drawing
Syllabus for the trade of Mechanic Motor Vehicle
Week Engineering Drawing (3 Hrs/week)
Nos. 2nd Semester
1-4 Read and interpret drawings- Determine information from the title block, Read and
interpret industrial prints, Read and interpret detailed and assembly drawings,
Identify casting drawings and machining drawings, Read and interpret diagrams,
Distinguish between a monodetail and a multidetail drawing.
5-8 Identify different drawing projections - Interpret pictorial and multi-view drawings.
Interpret auxiliary and section views, Determine views in a drawing and the
significance of the view being shown. Identify missing lines and missing views.
9-12 Free hand sketching of key and screw threads. Read and interpret three Types of
screw thread representation: pictorial, schematic and simplified presentation. Terms
used in describing a threaded Part, Designation of Thread Specifications, Left-Hand
Thread Notations, read and interpret the different type of Finish Symbols, Fillets and
Rounds and Machine Slots.
13 Drawing of I .C engine – Diesel and their parts.
14 Sketching of otto cycle, Diesel cycle, valves and valve timing diagram.
15 Free hand sketch of piston assembly, Free hand sketching of piston gudgeon pins
rings and connecting rod .
16 Free hand sketching of crank shaft and cam shaft showing all parts.
17 Free hand sketching of cylinder block and cylinder head, cylinder liners.
18 Free hand sketching of different cooling system -showing all necessary parts such as
water pump, thermostatic valve, Radiator etc.
19 Free hand sketching of lubrication system, showing all necessary parts such as filters ,
oil pump, pressure release valve etc.
20 Freehand sketching of staring system.
21 Freehand sketching of charging system and solenoid switch circuit.
SEMESTER-II
(Pl ref to www.dget.nic.in)
20
Syllabus for the trade of Mechanic Motor Vehicle
Third Semester (Semester code No. )
Duration: Six Months.
Syllabus for Trade practical and Trade Theory
Week Trade Practical (27 Hrs/week) Trade Theory (5 Hrs/week)
No.
1 Identification of different major components Introduction: Study of different major
of Heavy vehicle and their function & components & assemblies of heavy vehicle,
placement study of different make and different make (indigenous). Name
lorry/bus/tractor in Institute with different plate-constructional differences and their
dealers or organizations. merits. leading manufacturers in Heavy
vehicle Industry
2 -4 Practice on adjusting clutch pedal play- Clutches & Manual Transmissions-Clutch
removing gearbox and clutch assembly from principles, Single-plate clutches, Multi-plate
Light & Heavy Vehicle. Dismantling clutch clutches, Dual mass flywheels, Operating
assembly, cleaning inspecting parts. mechanisms
Removing & fitting of new pilot bearing, Clutch components- Pressure plate, Driven/
removing & fitting of ring gear in fly wheel center plate, Throw-out bearing.
relining a clutch plate, checking condition of Manual transmissions- Gear ratios,
flywheel and pressure plate surface for Compound gear trains, Gear selection,
reconditioning. Bearings, Oil seals & gaskets, Brief about
Assembling of pressure plate adjusting the Automated Manual Transmission (AMT)
fingers checking run out of fly wheel and Gearbox layout & operation-
aligning clutch assembly with flywheel. Gearbox layouts, Transaxle designs,
Dismantling cleaning and assembling of Gearbox operation, Baulk-ring synchromesh
gearshift mechanism changing oil in gear unit, Transaxle synchromesh unit. Gear shift
box. mechanism.
Dismantling a synchromesh gear box,
cleaning, inspecting parts replacing worn out
defective parts assembling & testing for
correct performance identifying noises from
gear boxes and rectifying.
5-7 Practice on Removing open type propeller Final Drive & Drive Shafts - Basic layouts
shaft from vehicle, Practice on removing Front-wheel drive layout, Rear-wheel drive
universal joints, cleaning replacing worn out layout, Four-wheel drive layout, All-wheel
parts, re-assembling & refitting to vehicle- drive layout, 4WD v/s AWD
and their alignment special precautions Front-wheel drive, Front-wheel drive shafts,
while removing torque tube drive shaft. Front-wheel final drives, Front-wheel
Practice on FWD Driveshaft Removal differentials
and Replacement. Rear-wheel drive- Propeller shaft, Type of
Practice on overhauling & inspection of rear Universal joints, Type of Constant velocity
axle. Joints, Rear-wheel final drives, Salisbury
Practice on overhauling & inspection of axles, Rear-wheel drive differentials,
differential assembly. Limited slip differentials.
Trouble shooting – causes and remedy for Four-wheel drive- Four-wheel drive shafts,
clutch slip, clutch noise, clutch binding, hard Four-wheel final drive, Four-wheel drive
clutch, gearbox noise, gear slip, rear axle transfer case, Freewheeling hubs, Four-
noise, propeller shaft noise, universal joint wheel drive differentials
noise, differential noise. All-wheel drive- four wheel final drives,
21
All-wheel drive transfer case, Transfer case
differential action.
8&9 Identification of Automatic transmission Automatic Transmissions - Torque
components converters, Torque converter principles,
drive plate, Converter operation, Torque
Checking automatic transmission fluid, multiplication, Fluid flow, Heat exchanger,
Changing transmission fluid & filter. Lock-up converters, clutches.
Checking automatic transmission fluid, Planetary gearing- Planetary gears, Simple
Changing transmission fluid & filter. planetary gear sets, Compound planetary
Practice on oil pressure control cable play gear sets, Automatic transmission brake
bands, Multi-disc clutches,
adjustments, Inspection of shift lever switch,
Electronic control transmission -
throttle position sensor, speed sensor and Electronic control Unit, Fully hydraulically
automatic transmission wiring harness controlled transmission, Electronic shift
coupler. programs, Manual selection.
Layout & operation for P,R,N&D (1st & 2nd)
Selector positions, Planetary gear set, High
range power flow, Low range power flow
Servos & clutches-Rear servo, Front servo,
One way clutch, Multi-plate front clutch,
Clutch pack, Rear clutch.
Hydraulic system & controls-Hydraulic
system components, Spool valves,
Regulating or flow control valves, Control
valves, Orifices
Valve types & functions- Basic valve
action, Regulator & control valves, Shift &
governor valves
Pressure regulation- The primary
regulating valve, Line pressure variation,
Modulator valve pressure, The governor,
Governor pressure, Kickdown pressure.
Flow control- Gear position 1, 1-2 shift
valve, 2-3 shift valve assembly, The servo
orifice control valve, 3-2 kick down
Continuously variable transmission
(C.V.T.)- Continuously variable
transmission, Drive or reverse, The steel
belt, Secondary pulley shaft.
22
10-12 Following practical to be Practiced On Light Steering Systems:- Description and
& Heavy Vehicle. function of Steering systems, Principles of
steering, Rack-and-pinion steering system,
Practice on removing the drop arm, Check Recirculation ball & nut steering system,
and adjust the turning angle, align the drop Four-wheel steering systems, collapsible
arm and steering wheel with the front wheel. steering system.
Check and correct toe-in. Steering boxes & columns - Description
Practice on removing steering wheel, and function of Steering columns, Rack-and-
steering gearbox. pinion gearbox, Helix, Variable ratio
Inspect and overhaul steering boxes, steering, Worm gearbox, Power Assisted
adjusting steering gear backlash, pre-load steering, Steering process, Flow-control
and adjust toe-in, toe-out, camber angle, valve, Electric power assisted steering,
castor angle, kingpin inclination and wheel Basic electric power steering operation
run out. Checking & adjusting power Steering arms & components- Forward
steering fluid, Pressure testing a power control vehicle steering, Steering linkages,
steering system, Flushing a power steering Joints, Bushes/bushings
system, Inspecting & adjusting an engine Wheel alignment fundamentals:-
drive belt, Servicing a steering system, Basic principles of wheel alignment,
Servicing wheel bearings. wheel base, wheel track, king pin
Troubleshooting- Causes and remedy for inclination, Caster, Camber, Scrub radius,
abnormal wear of tyre, wheel wobbling, Toe-in & toe out, Toe-out on turns,
poor self centering, hard steering, and Turning radius, Thrust angle &
vehicle pulling to one side. centerlines.
13-15 Following practical to be Practiced On Light Suspension Systems:-
& Heavy Vehicle Principles of suspension, Suspension force,
Unsprung weight, Wheel unit location,
Practice on visual Inspection of chassis Dampening. Types of suspension-
frame for crack, bent and twists. Suspension systems, Solid axle, Dead axle,
Overhauling and Inspection of shackle, Description, function and advantages of non
leaf spring, front & rear suspension. independent suspension Independent
suspension, Rear independent suspension,
Practice on removing, inspection and Rear-wheel drive independent suspension,
assembling of shock absorber electronically controlled air suspension
Lubricating a suspension system. (ECAS), Adaptive air suspension operation.
Trouble shooting for Suspension system Types of springs - Description and function
defects : of Coil springs, Leaf springs, Torsion bars,
wheel hop, ride height (unequal and low), Rubber springs.
noises under operation, fluid leakage, Shock absorber types- Description and
excessive travel, bounce, worn dampers, function of Hydraulic shock absorbers, Gas-
worn joints/damaged linkages, vehicle pressurized shock absorbers, Load-
“crabbing”. adjustable shock absorbers, Manual
adjustable-rate shock absorbers, Electronic
adjustable-rate shock absorbers, Automatic
load-adjustable shock absorbers
Front suspension types & components-
Mc person Strut suspension, Short/long arm
suspension, Torsion bar suspension
Rear suspension types & components-Rigid
axle leaf spring suspension, Rigid axle coil
23
spring suspension, Independent type
suspension, Rigid non-drive suspension
16 Practice on removing wheels from light & Wheels & Tyres-Wheel types & sizes
Heavy vehicle, dismantling tyres and tubes Wheels, Rim sizes & designations, Types of
checking puncture. wheels
Assembling inflating to correct pressure. Tyre types & characteristics- Tyres,
Checking & adjusting tire pressure by use of Radial ply tyres, Radial ply tyre sidewalls,
air or by Nitorgen Tyre pressure monitoring systems, Run flat
Rotating the wheels in vehicle minor repairs tyres, Space-saver tyres, Tyre distortion,
to wheels and tyres, wheel balancing & Center of gravity.
alignment. Tyre construction-Tyre construction, Types
Checking for tyre wear patterns. of tyre construction, Tyre materials,
Caution: vehicle equipped with ABS while Hysteresis, Tyre sizes & designations, Tyre
removing the wheel and using on vehicle information, Tyre tread designs, Tyre ratings
balancing never ignition switch on (Follow for temperature & traction. Descriptions
the service manual procedure) Tirewear Patterns and causes
Nitrogen vs atmospheric air in tyres
17-19 Practice on Adjusting brake pedal play, Braking Systems :- Principles of braking,
Overhauling and inspection of tandem Drum & disc brakes, Lever/mechanical
master cylinder assembly, advantage, Hydraulic pressure & force,
Overhauling and inspection of front and rear Brake pad, Regenerative braking.
brake assembly, overhauling and inspection Braking systems - Brake type - principles,
of wheel cylinder assembly. Air brakes, Exhaust brakes, Electric brakes,
Bleeding hydraulic brakes & Disk brakes. Parking brakes, Engine brakes, Regenerative
Overhauling and inspection of vacuum braking
assisted brake assembly. Braking system components-Park brake
Overhauling and inspection of disc brake. system, Brake pedal, Brake lines, Brake
Adjusting Air brakes- repair to tank unit, air fluid, Bleeding, Master cylinder, Divided
compressor, wheel brake adjuster- locating systems, Tandem master cylinder, Power
air leaks in the brake lines and rectifying – booster or brake unit, Hydraulic brake
general maintenance and care. booster, Electro hydraulic braking (EHB),
Brakes procedures-Checking & adjusting Applying brakes, Brake force, Brake light
brake fluid, Replacing brake fluid, Checking switch
brake pads, Replacing brake pads, Drum brakes & components -Drum brake
Removing & replacing a rotor, Replacing system, Drum brake operation, Brake linings
brake linings, Adjusting a parking brake & shoes, Back plate, Wheel cylinders
cable. Disc brakes & components -Disc brake
system, Disc brake operation, Disc brake
Trouble tracing in braking system of a heavy rotors, Disc brake pads, Disc brake calipprs,
vehicle adjusting brakes and balancing all Proportioning valves, Proportioning valve
four wheel brakes, precautions to be operation, Brake friction materials
observed while testing brakes points to be Antilock braking system & components-
remember while preparing the vehicle for ABS brake system, Antilock braking system
brake certificate. operation, Principles of ABS braking, ABS
Practice of maintaining of ABS system. master cylinder, Hydraulic control unit,
Wheel speed sensors, ABS with EBD
electronic control unit.
The construction and operation of heavy
vehicle Anti-Slip Regulation / Traction
Control (ASR) system.
24
20 & Trouble shooting Practice with Heavy Study of Motor Vehicle act Rules &
21. vehicle for Regulation-Laws governing to use of motor
Engine Not starting – Mechanical & vehicle & vehicle transport, Licensing of
Electrical causes, drivers & conductors, Registration of
High fuel consumption, vehicle, Traffic rules, Signals & controls,
Engine overheating, Accidents, Causes & analysis,
Low Power Generation, Responsibility of driver, Offences, penalties
Excessive oil consumption, & procedures, Different types of forms,
Low/High Engine Oil Pressure, Government administration structure,
Engine Noise. Personnel, Authorities & duties, Rules
regarding construction of motor vehicles,
Tax exemption & tax renewal, Insurance
types & significance -Comprehensive
Third party insurance, Duty of driver in case
of accident
25
Automobile Group – 2 years Trade
3rd Semester
Workshop Calculation and Science
Syllabus for the trade of
1. Mechanic Motor Vehicle
26
Automobile Group – 2 years Trade
3rd Semester Engineering Drawing
Syllabus for the trade of Mechanic Motor Vehicle
27
Syllabus for the trade of Mechanic Motor Vehicle
Fourth Semester (Semester code No. )
Duration: Six Months.
Syllabus for Trade practical and Trade Theory
Week Trade Practical (27 Hrs/week) Trade Theory (5 Hrs/week)
No.
1 & Identification of petrol Engine components. Petrol Engine Basics:
2 Practice on starting and stopping of petrol 4-stroke spark-ignition engines- Basic 4-
engines. Observe and report the reading of stroke principles.
Tachometer, Odometer, temp and Fuel Spark-ignition engine components- Basic
gauge under ideal and on load condition. engine components, Engine cams & camshaft,
Removing a petrol engine from a motor Engine power transfer, Scavenging, Counter
vehicle. Dismantling cylinder head for weights, Piston components.
Inspection.
Intake & exhaust systems -Carbureted
Practice on Removing of piston and systems, Electronic fuel injection systems,
connecting rods from engine checking Exhaust systems.
Cylinder bore wear for ovality and taper. Intake system components, Air cleaners,
Piston ring, Piston as per service manual. Carburetor air cleaners, EFI air cleaners, Intake
Checking valves - replacing worn guides manifolds, Intake air heating.
and weak springs, assembling valves and Gasoline Fuel Systems : Description of
cylinder head and adjusting tappet clearance Gasoline fuel, Gasoline fuel characteristics,
in engine. Controlling fuel burn, Stoichiometric ratio, Air
density, Fuel supply system, Pressure &
vacuum.
4&5 Practice on Cleaning fuel tank, checking for Introduction to Electronic fuel injection
leaks in Fuel tank. Identification of various (EFI) fuel supply system , Basic EFI
components of MPFI system. principles, Air supply, Air volume, Multi-point
Testing of MPFI components and injection systems (MPI/MPFI), Simultaneous
replacement if necessary. Check delivery injection, Efficient combustion
from fuel Pump. Replacing a fuel filter. EFI fuel supply system components - Fuel
pumps, Fuel filters, Tanks & lines, Fuel lines,
Fuel rail, Fuel pressure regulator, Injectors,
Tachometric relay, Thermotime switch, EFI
sensors, Potentiometer, Auxiliary air valves,
Idle speed control devices, Inertia sensors.
6&7 Identification of Electronic control Unit. Introduction to EFI Engine Management -
Set up for testing, Testing of Electronic EFI operation Modes of EFI, Electronic fuel
28
Control Circuit. Fault finding in Electronic injection, Idle speed control systems, Feedback
circuit and remedies using scan tool. & looping, Cold start systems, Air
Identification of various sensors installed in measurement, Air-flow monitoring, Variable
engine & it’s mounting. Checking intake manifold system, Electrical functions,
instruments & Gauges on dash board. EFI wiring diagram
Rectify replace defective gauges. Electronic control unit (ECU) - EFI system
Testing of Temperature sensor, Pressure ECU, Electronic control unit settings, Engine
senor, potentiometer, magnetic induction speed limiting, Malfunction indicator lamp.
sensor, cam shaft sensor, crankshaft position Importance of Diagnostic Trouble Code (DTC)
sensor. & its general format. Use of scan tool and
retrievals of codes.
EFI sensors- 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,
8 Diagnosis- Possible causes and remedy for Ignition principles and Faraday’s laws,
Engine cranks, but will not or hard to start, Primary and secondary winding of transformer,
Poor fuel economy or engine performance. Ignition components, Spark plugs, Spark plug
Checking ignition timing, Checking & components, Vacuum & centrifugal units, Plug
changing a spark plug, Identification and firing voltage,
testing of Hall effect sensor, Optical sensor. Induction, Inductive system operation,
Tracing and testing of sensor circuits. Induction wiring, Hall effect sensors, Hall effect
operation, Optical type sensors
Distributor less ignition systems, Insulated coils,
Distributor less ignition system timing.
9& Checking a charging system for the cause of Charging system- The purpose of Charging
10 undercharge, No charge, and over charge system, charging system components, charging
conditions. Removing & replacing an system circuit, Alternator principles,
alternator, Inspection of rotor for ground, Alternating current, Alternator components,
open circuit – field coil resistance, slip ring Rectification, Phase winding connections, Rotor
surface, Fan, bearing. Inspection of stator circuit, Voltage regulation, System operating
for ground, open circuit, Inspection of Drive voltage, High voltage charging systems, Rotor,
end bearing rotation, Rectifier, brush length Stator, Alternator end frames, Slip ring & brush
compare with service manual. slip ring assembly, Rectifier assembly, Alternator
surface. Inspecting & adjusting an engine cooling fan.
drive belt, Replacing an engine drive belt /
pulleys / Tesnionsers and their alignments.
Trouble shooting, possible causes and
remedy for warning lamp does not glow
when ignition switch is on, Warning lamp
glows dim when ignition switch is on,
warning lamp ‘on’ while the alternator is
running, Warning lamp glows ‘dim’ while
the alternator is running, warning lamp
flickers considerably.
11 & Removing starter motor from vehicle, and Starting system- purpose of starting system,
12 Performance test for pull-in test, Hold-in Staring system components, Starter motor
test, pinion (plunger) return test, No-load principles, study of starter control circuits.
29
performance test. Starter motor construction, Starter magnet
Solenoid test for Hold in coil open circuit, types, Starter motor engagement, Commutation,
Armature test – Ground test, Open circuit Switching, solenoid construction.
test, pull-in coil open circuit test, field coil
test. Inspections of brush length wear as per
service manual.
Trouble shooting , possible causes and
remedy for starter motor not running,
Starting motor running but too slow (small
torque), staring motor running, but not
cranking engine. Noise, starting motor does
not stop running. Growler testing for rotors.
Checking a starting system, Jump-starting a
vehicle
13 & Trace the light circuit - test bulbs, align head Lighting system, Lamps/light bulbs,
14 lamps, Aiming headlights. Changing a Lamp/light bulb information, LED lighting,
headlight bulb, Checking of a head light Headlights-description of standard sealed beam,
switch and to replace if faulty. halogen sealed beam, composite and High
Trouble shooting and remedy for Headlight intensity discharge (HID) headlights. Headlight
- headlight do not light up, only one & dimmer circuits, Park & tail light circuits,
headlight does not light up, Only one beam Brake light circuits, turn signal circuit,
(“Hi” or “Lo”) does not light.. Cornering lights, Fog lights circuit, interior
Trouble shooting and remedy for turn signal lights- courtesy, reading and instrument panel
and hazard warning lights -Flash rate high or lights, Smart lighting , Reverse lights
one side only flashes, No Flashing, flash rate
low.
Trouble shooting and remedy for clearance,
tail and license plate lights - All lights do
not light up, some lights do not light up.
Trouble shooting and remedy for Back-up
light - Back-up lights do not light up.
Trouble shooting and remedy for Brake
lights -Brake lights do not light up, Brake
light stay on.
Trouble shooting and remedy for fuel meter
and fuel gauge unit - Fuel meter shows no
operation or incorrect operation.
Trouble shooting and remedy for Engine
coolant Temp (ECT) meter and ECT Sensor
– Engine coolant temp meter shows no
operation or incorrect operation.
Trouble shooting and remedy for oil
pressure light – Oil pressure warning light
does not light up when ignition switch is on
at engine off.
Trouble shooting and remedy for brake and
parking brake warning light- Brake warning
light does not light up when fluid flow level,
Brake warning light does not light up when
30
parking brake pull up, Brake warning lights
stay on.
Trouble shooting and remedy for interior
light- Interior light do not light up.
Trace the wiring circuit of traffic signal
flashers light circuit-tracing
defects in the flasher circuits, replacing fuse
bulb.
15 & Identification of Air conditioning Heating Ventilation Air Conditioning
16 components, Performance test on A/c unit, (HVAC) legislation, Vehicle heating,
Checking Charged state of refrigerant, ventilation & cooling systems, Basic air-
Inspecting & adjusting an engine drive belt, conditioning principles, Air-conditioning
Replacing an engine drive belt. capacity, Air-conditioning refrigerant, Humidity
Checking a heating system, Compressor Description and function of Fixed orifice,
rotation test, air Gap check, Control devices, Thermostatic expansion valve
Refrigerant recovery –evacuating –charging system, Thermal expansion valves, Air-
of A/c system. Replenishing compressor oil conditioning compressors, Condensers &
level. Troubles diagnose and remedy for No evaporators, Receiver drier, Lines & hoses, TX
cooling or warm air, Cool air comes out valve construction, Temperature monitoring
only intermittently, Insufficient cooling, thermostat, Refrigerants, Pressure switches,
Abnormal noise from compressor, Magnetic Heating elements
clutch, condenser, evaporator, Blower
motor. Diagnosis test for High pressure Air-conditioning ECU, Ambient air temperature
gauge –pressure high and low, Low pressure sensor, Servo motors, Electric servo motors,
gauge for pressure high and low. Automatic climate control sensors, Evaporator
temperature sensor, Blower speed control,
Ventilation systems.
17 & Trouble shooting and remedy for Horn- No Accessories: Horn circuit, wiper circuit, power
18 horn operation, poor sound quality, horn window components and circuit. Power door
sounds continuously and to replace the horn lock circuit, automatic door lock circuit, remote
if faulty. keyless entry system circuit, antitheft system,
Remove and install wiper motors and wiper immobilizer system. Navigation system, Car
switches. Checking & replacing wiper radio and cassette player, car videos.
blades. Description and function of Airbags, Seatbelt,
Trouble shooting and remedy for windshield Vehicle safety systems, Crash sensors, Seat belt
wiper and washer - no operation, pre-tensioners, Tire pressure monitoring
intermittent operation, continuous operation, systems
and wipers will not park. Integrated communications, Proximity sensors,
Diagnose causes for improper operation of Reflective displays, Global positioning
the windshield washer system and to replace satellites, Triangulation/trilateration,
the pump if faulty. Telematics. Networking & multiplexing
Diagnose the power window system for – all .
power window motors do not operate, some
switches do not operate.
Diagnose the power door lock control for –
All power door locks do not operate, only
one power door lock not operate.
Diagnose for remote keyless entry and
immobilizer system.
Familiarization of car radio wiring and
31
speaker circuits
Diagnose automatic seat belt systems,
Diagnose air bag system and service
warnings.
19-21 Driving Practice. Locating vehicle information, Obtaining &
Practice in straight driving on wide roads. interpreting scan tool data, Using a repair
Driving through lanes and curves. manual, Using a shop manual, Using an owner's
Practice in reversing. Practice overtaking manual, Using a labor guide, Using a parts
another vehicle. Practice in driving through program, Using a service information program
sand and wet surfaces. Practice in parking
and Diagonal parking.
22-23 Project work
24-25 Revision and Test
26 NCVT Exam
32
Automobile Group – 2 years Trade
4th Semester
Workshop Calculation and Science
Syllabus for the trade of
1. Mechanic Motor Vehicle
18 & 19 Filter circuits, Voltage divider, Integrated circuits, Sensors and actuators, Control unit
(computer) inputs and outputs, Logic gates-The RTL NOR gate, Truth tables, Bits, bytes
and baud.
20 & 21 Properties of refrigerants, refrigerant oil, Fluorinated refrigerants, Refrigeration process –
pressure/enthalpy diagram
33
Automobile Group – 2 years Trade
4th Semester Engineering Drawing
Syllabus for the trade of Mechanic Motor Vehicle
34
TRADE: Mechanic Motor Vehicle
LIST OF TOOLS & EQUIPMNT
35
21. Carburetor – Solex, Mikuny for dismantling and assembling 1 each
22. Carburetor repair tool kit 1
23. Chain Pulley Block-3 ton capacity with tripod stand 1
24. Chisel 10 cm flat 4
25. Chisels cross cut 200 mm X 6mm 4
26. Circlip pliers Expanding and contracting type 15cm and 20cm each 4
27. Clamps C 100mm 2
28. Clamps C 150mm 2
29. Clamps C 200mm 2
30. Cleaning tray 45x30 cm. 4
31. Coil spring compressor for suspension spring 1
32. Compression testing gauge suitable for diesel Engine with standard 2
accessories
33. Connecting rod alignment fixture 1
34. Constant Mesh Gear box with stand for Dismantling and assembly. 1
35. Copper bit soldering iron 0.25 Kg 4
36. Cut section Model of Mock layout of a motor car –electrical system 1 set
working model
37. Cut section models of shock absorbers 1
38. Cut section of cross ply and radial tyres 1
39. Cut section working model of automatic transmission Gear box 1
40. Cut section working model of centrifugal clutch assembly. 1
41. Cut section working model of Diaphragm clutch assembly. 1
42. Cut section working model of Single plate clutch assembly. 1
43. Cylinder bore gauge capacity 20 to 160 mm 4
44. Cylinder liner- Dry & wet liner, press fit & slidefit liner 1 each
45. DC Ohmmeter 0 to 300 Ohms, mid scales at 20 Ohms 2
46. Demonstration board of 2W Ignition system, ignition coil 1
47. Demonstration board of electronic Ignition system, ignition coil 1
48. Demonstration board of MPFI system 1
49. Depth micrometer 0-25mm 4
50. Dial gauge type 1 Gr. A (complete with clamping devices and with 4
magnetic stand)
51. Different type of Engine Bearing model 1 set
52. Different type of piston model 1each
53. Disk brake with caliper assembly 2
54. Distributor –Duel advance type, reluctance type 1 each
55. Dividers 15 cm Spring 4
56. Drift Punch Copper 15 Cm 4
57. Drill point angle gauge 1
58. Drill twist 1.5 mm to 15 mm (various sizes) by 0.5 mm 4
59. Drum brake assembly 1
60. Electric Soldering Iron 230 V 60 watts 230 V 25 watts 2 each
61. Electric testing screw driver 4
62. Engineer’s square 15 cm. Blade 4
63. Engineers stethoscope 1
64. Executive Auto Electrical tool kit 1
65. Feeler gauge 20 blades (metric) 4
36
66. File flat 20 cm bastard 4
67. File, half round 20 cm second cut 4
68. File, Square 20 cm second cut 4
69. File, Square 30 cm round 4
70. File, triangular 15 cm second cut 4
71. Files assorted sizes and types including safe edge file (20 Nos) 2 set
72. Flat File 25 cm second cut 4
73. Flat File 35 cm bastard 4
74. Front axle ( Rzeeppa Joint) with stand for Dismantling and assembly 1
75. Fuel feed pump for diesel 1
76. Fuel injection pump (Diesel) inline 1
77. Fuel injection pump dismantling tool kit /Universal Vice 1
78. Fuel injection pump, VE pump / Distributor fuel rotary pump (DPC) 1 each
pumps / along with special tools and accessories.
79. Full floating axle and semi-floating axle assembly 1
80. Functional/experiment model of different type of sensors. 1 set
81. Garage stand 4
82. Gloves for Welding (Leather and Asbestos) 5 sets
83. Glow plug tester 2
84. Granite surface plate 1600 x 1000 with stand and cover 1
85. Grease Gun 2
86. Grease Gun heavy duty trolley type 10 kg capciaty 1
87. Growler 2
88. Hacksaw frame adjustable 20-30 cm 10
89. Hammer Ball Peen 0.75 Kg 4
90. Hammer Chipping 0.25 Kg 5
91. Hammer copper 1 Kg with handle 4
92. Hammer Mallet 4
93. Hammer Plastic 4
94. Hand operated crimping tool (i) for crimping up to 4mm and (ii) for 2
crimping up to 10mm
95. Hand reamers adjustable 10.5 to 11.25 mm, 11.25 to 12.75 mm, 12.75 1 sets
to 14.25 mm and 14.25 to 15.75 mm
96. Hand Shear Universal 250mm 2
97. Hand vice – 37 mm 2
98. Hollow Punch set of seven pieces 6mm to 15mm 2 sets each
99. Horn and Horn relay 2
100. Impact screw driver 2
101. Injector – Multi hole type, Pintle type 4 each
102. Injector cleaning unit 1
103. Injector testing set (Hand tester) 1
104. Insulated Screw driver 20 cm x 9mm blade 4
105. Insulated Screw driver 30 cm x 9mm blade 4
106. Left cut snips 250mm 4
107. Lifting jack screw type 3 ton, 5ton & 20 Ton capacity 1 each
108. Magneto spanner set with 8 spanners 1 set
109. Magnifying glass 75mm 2
37
110. Marking out table 90X60X90 cm. 1
111. Multimeter digital 5
112. Multi-point fuel injection pump 2
113. Oil can 0.5/0.25 liter capacity 4
114. Oil pump for dismantling and assembling. 2
115. Oil Stone 15 cm x 5 cm x 2.5 cm 1
116. Oscilloscope 20MHz 1
117. Outside micrometer 0 to 25 mm 4
118. Outside micrometer 25 to 50 mm 4
119. Outside micrometer 50 to 75 mm 1
120. Outside micrometer 75 to 100 mm 1
121. Petrol nozzle 2
122. Philips Screw Driver set of 5 pieces (100 mm to 300 mm) 2
123. Pipe cutting tool 2
124. Pipe flaring tool 2
125. Piston ring compressor 2
126. Piston Ring expander and remover. 2
127. Piston Ring groove cleaner. 2
128. Pliers combination 20 cm. 2
129. Pliers flat nose 15 cm 2
130. Pliers round nose 15 cm 2
131. Pliers side cutting 15 cm 2
132. Portable electric drill Machine 1
133. Prick Punch 15 cm 4
134. Punch Letter 4mm (Number) 2 set
135. Radiator cut section-cross flow 1
136. Radiator cut section-down flow 1
137. Radiator pressure cap 2
138. Rear axle full floating type with stand for Dismantling and assembly 1
139. Right cut snips 250mm 2
140. Rivet sets snap and Dolly combined 3mm, 4mm, 6mm 2
141. Scraper flat 25 cm 2
142. Scraper half round 25 cm 2
143. Scraper Triangular 25 cm 2
144. Scriber 15 cm 2
145. Scriber with scribing black universal 2
146. Set of stock and dies – Metric 2 sets
147. Shear Tin Man’s 450 mm x 600mm 2
148. Sheet Metal Gauge 2
149 Sher Tinmans 300mm 4
150 Soldering Copper Hatchet type 500gms 2
151 Solid Parallels in pairs (Different size) in Metric 2
152 Spanner Clyburn 15 cm 1
153 Spanner D.E. set of 12 pieces (6mm to 32mm) 4
154 Spanner T. flocks for screwing up and up-screwing inaccessible 2
155 positions
Spanner, adjustable 15cm. 2
156 Spanner, ring set of 12 metric sizes 6 to 32 mm. 4
157 Spanners socket with speed handle, T-bar, ratchet and universal upto 2
32 mm set of 28 pieces with box
38
158 Spark lighter 2
159 Spark plug spanner 14mm x 18mm x Size 2
160 Starter motor axial type, pre-engagement type & Co-axial type 1each
161 Steel measuring tape 10 meter in a case 4
162 Steel rule 15 cm inch and metric 4
163 Steel rule 30 cm inch and metric 4
164 Steering assembly - 1.Rack & pinion, 2.Worm & roller 3. Recirculating 1 each
ball, 4.Power steering
39
204 Working Model of power windows 1
205 Working model of torque converter 1
206 4 Point relays 2
207 5 Point relays 2
C. General Installation/ Machineries
40
29. Tube/ tyre vulcanizing machine 1
30. Two post car lift – capacity 4000 kg 1
31. Tyer Changer Machine 1
32. Ultrasonic Injection cleaning equipment 1
33. Welding plant Oxy-Acetylene complete ( high pressure) 1
34. Welding Transformer ( 150-300 Amps) 1
35. Wheel alignment Machine –computerised 3D 1
36. Wheel balancing machine 1
37. Working Condition of Diesel Engine – CRDI - 4 stroke Engine 1
Assembly with fault simulation board
38. Working Condition of Petrol MPFI Engine Assembly with fault 1
simulation board
D. List of consumable:
Sl. Description Quantity
No.
1. Automatic Transmission oils As required
2. Battery- SMF As required
3. Brake fluids As required
4. Chalk, Prussian blue. As required
5. Chemical compound for fasteners As required
6. Diesel As required
7. Different type gasket material As required
8. Different type of oil seal As required
9. Drill Twist (assorted) As required
10. Emery paper - 36–60 grit , 80–120 As required
11. Engine coolant As required
12. Engine oil As required
13. Gear oils As required
14. Gloves for Welding (Leather and Asbestos) 5 sets
15. Hacksaw blade (consumable) As required
16. Hand rubber gloves tested for 5000 V 5 pair
17. Holders, lamp teakwood boards, plug sockets, As required
solders, flux wires and cables batteries round
consumable blocks and other consumables as
required
18. Hydrometer 4
19. Lapping abrasives As required
20. Leather Apron 5
21. Petrol As required
22. Power steering oil As required
23. Radiator Coolants As required
24. Safety goggles As required
25. Steel wire Brush 50mmx150mm 5
41
E. Workshop Furniture
42
43