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CURRICULUM, , FOR THE TRADE OF, , MECHANIC MOTOR VEHICLE, (Dual Mode), , UNDER, DUAL TRAINING SYSTEM, , BY, , GOVERNMENT OF INDIA, MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP, DIRECTORATE GENERAL OF TRAINING, , 1

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PROPOSED TIME DISTRIBUTION FOR MECHANIC MOTOR VECHILCE, TRADE UNDER INDUSTRY INSTITUTE - TRAINING SCHEME, BLOCK, WITH, DURATION, , THEORY, , BLOCK – I, , 510 hrs., , PRAC., , WSC/, CAL, , ENGG. EMP., DRG. SKILL, , ECA,, LIB. &, , REM., , OTHERS, 830 hrs., , 170, hrs., , (12, months/52, Weeks, duration ), , 250, hrs., , 110, hrs., , 50 hrs., , 160 hrs., Revision, & Test, , Institute, level trg., BLOCK – II, , ---, , 1560 HRS., , ---, , ---, , ---, , ---, , ---, , ---, , 20 hrs., , Last 2, weeks, revision, & exam., , 110, HRS., , 70 HRS., , 240, , (09 months, /39 weeks, duration), Industry, level trg., BLOCK – III, , 100 hrs., , 210 hrs., (Practical, practice and, submission of, report related, to industry, training), , 50, hrs., , 60 hrs., , 610, HRS., , 2600 HRS., , 220, HRS., , 310, HRS., , (3 months/, 13 Weeks, duration), Institute, level trg., GRAND, TOTAL, , HRS., , Total duration of training inclusive of Industry & Institute is 2 years (4160 HRS.), , 2

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GENERAL INFORMATION FOR INSTITUTE (ITI), 1. Name of the Trade, , : Mechanic Motor Vehicle (Dual mode), , 2. N.C.O. Code No., , : 7231.10, ASC/ Q 1401, ASC/ Q 1402, ASC/ Q 1408, , 3. Duration of Craftsmen Training: Two years (Three Blocks)., 4. Power norms, , : 4.8KW, , 5. Space norms, , :.workshop Area – 130 Sq.m and Parking Area-20 Sqm, , 6. Entry Qualification, 7. Trainees per unit, , : Passed 10th class examination with Maths and Science, :16 (Max. supernumeraries seats: 5), , 8a. Qualification for Instructors:, a) Degree in Automobile/ Mechanical Engg. (with, specialization in Automobile) from recognised, college/University with one year experience in the, automobile industry and should possess valid LMV, driving license., OR, Diploma in Automobile/Mechanical (specialization, in automobile) from recognized board of technical, education with two years experience in the, automobile industry and should posses valid LMV, driving license., OR, th, 10 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”., 8b. Desirable qualification: Preference will be given to a candidate with Craft, Instructor Certificate (CIC) in MMV Trade., Note:, (i), Out of two Instructors required for the unit of 2(1+1), one must have, Degree/Diploma and other must have NTC/NAC qualifications., (ii) Instructor qualification for WCS and E.D, as per the training manual., Distribution of training on Hourly basis:, Total hours, /week, , Trade practical, , Trade, theory, , Work shop, Cal. &Sc., , Engg., Drawing, , Employability, skills, , 40 Hours, , 25 Hours, , 6 Hours, , 2 Hours, , 3 Hours, , 2 Hours, , 3, , Extra, curricular, activity, 2 Hours

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SYLLABUS CONTENT WITH TIME STRUCTURE FOR MECHANIC, MOTOR VEHCILE TRADE, Block – I, Duration- 12 Months (52 weeks), Institute Level Training: Sl., No., 1, , Practical, Duration:- 830 hrs., Familiarisation, with, institute,, Job, opportunities in the automobile sector,, Machinery used in Trade. Types of work, done by the students in the shop floor., , 2., , Practical related to Safety and Health,, Importanceofmaintenanceandcleanliness, ofWorkshop., Interaction with health centre and fire, service station to provide demo on First aid, and Fire safety, Use of fire extinguishers., Demonstration on safe handling and Periodic, testing of lifting equipment, and Safety, disposal of Used engine oil., Energy saving Tips of ITI electricity Usage, , 3., , Measuring practice on Cam height,, Camshaft Journal dia, crankshaft journal dia,, Valve stem dia, piston diameter, and piston, pin dia with outside Micrometers., Measuring practice on the height of the rotor, of an oil pump from the surface of the, housing or any other auto component, measurement with depth micrometer., Measuring practice on valve spring free, length., , 4, , Theory, Duration:- 510 hrs., Admission & introduction to the trade:, Introductiontothe, Courseduration,, coursecontent, studyofthe syllabus. General rule, pertainingto theInstitute, facilitiesavailable–, Hostel, Recreation, Medicaland Libraryworking, hours andtime table, AutoIndustry- History, leading manufacturers,, developmentin, automobileindustry,, trends,newproduct. Brief about Ministry of, Road transport & Highways, The Automotive, Research Association of India (ARAI), National, Automotive Testing and R&D Infrastructure, Project (NATRIP), & Automobile Association., Occupational Safety & Health, ImportanceofSafetyandgeneral, Precautionstobeobservedintheshop. 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., Systems of measurement:Description, care & use of - MicrometersOutside and depth micrometer, Micrometer, adjustments,, Vernier calipers, Telescope, gauges, Dial bore gauges, Dial indicators,, straightedge, feeler gauge, thread pitch gauge,, vacuum gauge, tire pressure gauge.

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4., , 5., , 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., Practice using all marking aids, like steel, rule with spring calipers, dividers, scriber,, punches, Chisel etc.,, Layout a work piece- for line, circle, arcs, and circles., Practice to measure a wheel base of a vehicle, with measuring tape., Practice to measure valve spring tension, using spring tension tester, Practice to remove wheel lug nuts with use, of an air impact wrench, Practice on General workshop tools & power, tools., , Hand & Power Tools:Marking scheme, Marking material-chalk,, Prussian blue. Cleaning tools- Scraper, wire, brush, Emery paper, Description, care and use, of Surface plates, steel rule, measuring tape, try, square. Calipers-inside and outside. Dividers,, surface gauges, scriber, punches-prick punch,, center punch, pin punch, hollow punch, number, and letter punch. Chisel-flat, cross-cut., Hammer- ball pein, lump, mallet. Screw, drivers-blade screwdriver, Phillipsscrew driver,, Ratchet screwdriver. Allenkey,bench vice & Cclamps, 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, Nippersor pincer, pliers, Side cutters, Tin snips, Circlip pliers,, external, circlips, pliers.Airimpactwrench,, airratchet, wrenches- Torque wrenches, pipe, wrenches, car jet washersPipeflaring&cutting, tool, pullers-Gear and bearing., Practice on General cleaning, checking and Fasteners:- Study of different types of screws,, use of nut, bolts, & studs etc.,, nuts, studs & bolts, locking devices, Such as, Removal of stud/bolt from blind hole., 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, , 5

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Gaskets,Selection of materials for gaskets and, packing, oil seals., 6., , Practice on cutting tools like Hacksaw, file,, chisel, Sharpening of Chisels, center, punch,safety precautions while grinding, Practice on Hacksawing and filing to given, dimensions, , 7., , Practice on Marking and Drilling clear and, Blind Holes, Sharpening of Twist Drills, Safety precautions to be observed while, using a drilling machine. Practice on, Tapping a Clear and Blind Hole, Selection of, tape drill Size, use of Lubrication, Use of, stud extractor., Cutting Threads on a Bolt/ Stud. Adjustment, of two piece Die, Reaming a hole/ Bush to, suit the given pin/ shaft, scraping a given, machined surface., , 8., , Practice on making Rectangular Tray., Sheet metal :- State the various common metal, Pipe bending, Fitting nipples unions in pipes. Sheets used in Sheet Metal shop, Soldering and Brazing of Pipes., 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., Practice in joining wires using soldering Basic electricity:- Electricityprinciples, Ground, Iron, Construction of simple electrical connections, Ohm's law, Voltage, Current,, circuits, Measuring of current, voltage and Resistance,Power, Energy. Voltmeter, ammeter,, resistance using digital multimeter, practice Ohmmeter Mulitmeter,Conductors & insulators,, continuity test for fuses, jumper wires, Wires, Shielding, Length vs. resistance,, fusible links, circuit breakers., Resistor ratings, Diagnose series, parallel, series-parallel Fuses & circuit breakers:- Ballast resistor,, circuits using Ohm‟s law, Check electrical Stripping wire insulation, cable colour codes, circuit with a test lamp, perform voltage and sizes, Resistors in Series circuits , Parallel, drop test in circuits using multimeter, circuitsandSeries-parallel circuits, Electrostatic, measure current flow using multimeter effects, Capacitors and its applications,, /ammeter, use of service manual wiring Capacitors in series and parallel., diagram for troubleshooting., , 9., , 10., , 6, , 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, 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

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11., , Cleaning and topping up of a lead acid, battery, Testing battery with hydrometer,, Connecting battery to a charger for battery, charging, Inspecting & testing a battery after, charging,Measure andDiagnosethe cause(s), of excessive Key-off battery drain (parasitic, draw) and do corrective action. Testing of, relay and solenoids and its circuit, , 12., , Identify and test power and signal, connectors for continuity, Identify and test, different type of Diodes, NPN & PNP, Transistors for its functionality,, Construct and test simple logic circuits OR,, AND & NOT and Logic gates using, switches., Practice to make straight beads and Butt,, Lap & T joints Manual Metal Arc Welding., Setting of Gas welding flames, practice to, make a straight beads and joints Oxy –, Acetylene welding, , 13., , Film on Heat treatment process, , 14., , Practice on Liquid penetrant testing method, and Magnetic particle testing method., Identification of Hydraulic and pneumatic, components used in vehicle., , 15., , Tracing of hydraulic circuit on hydraulic, jack, hydraulic power steering, and Brake, circuit. Identification of components in Air, brake systems., , 7, , Batteries & cells, Description of Chemical, effects, Lead acid 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., Basic, electronics:, Description, of, Semiconductors, 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., 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– 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., Non-destructive, Testing, MethodsImportance 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 ofPascal 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

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16., , 17., , Identification of different type of Vehicle., Demonstration of vehicle specification data;, Identification of vehicle information Number, (VIN). Demonstration of Garage, Service, station equipment.- Vehicle hoists – Two post, and four post hoist, Engine hoists,, Jacks,Stands., Identificationofparts inadieselengine of, LMV/ HMV, Practiceonstarting and stoppingofdiesel, engines., Observe and report the reading of, Tachometer, Odometer, temp and Fuel, gauge under ideal and on load condition., PracticeondismantlingDiesel, LMV/HMV asper procedure., , 18., , engineof, , Overhaulingof, cylinderheadassembly,, Useofservice, manualforclearance, andotherparameters, Practiceonremoving, rockerarmassembly manifolds., Practiceonremoving thevalvesandits parts, fromthecylinder head, cleaning., Inspectionofcylinder head andmanifold, surfacesforwarping, cracksand flatness., Checkingvalveseats&valveguide–, Replacing the valve if necessary.Testing, leaksofvalveseatsfor leakage–, Dismantlerockershaft assemblyclean&checkrockershaft-and, levers,forwearand cracksandreassemble., , 8, , automobile., Pneumatic Symbols, Description and function, of air Reciprocating Compressor. Function of, Air service unit (FRL-Filter, Regulator &, Lubricator)., 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., Introduction to Engine:, Description of internal & external combustion, engines,, Classification of IC engines,, Principle & working of 2&4-stroke diesel, engine (Compression ignition Engine, (C.I)),Principle of Spark Ignition Engine(SI),, differentiate between 2-stroke and 4 stroke, C.I, engine and S.I Engine, Direct injection and, Indirect injection, Technical terms used in, engine, Engine specification. Study of various, gauges/instrument on a dash board of a vehicleSpeedometer, Tachometer, Odometer and Fuel, gauge, and Indicators such as gearshift, position, Seat belt warning light, Parkingbrake-engagement warning light and an, Engine-malfunction light., Different, typeof, startingandstopping, methodofDiesel Engine, Procedure for dismantling of diesel engine from, a vehicle.., Diesel EngineComponents: Descriptionand, Constructional, featureofCylinder, head,Importanceof, Cylinderhead, design,, Typeof Dieselcombustion chambers,Effecton, sizeofIntake&exhaust passages, Headgaskets., Importanceof Turbulence, Valves &Valve Trains- Descriptionand, FunctionofEngine, Valves,different, types,materials,, Typeofvalve, operating, mechanism,, ImportanceofValve, seats,Valveseats, insertsincylinder, heads,, importance ofValverotation, Valve stemoilseals,, sizeofIntakevalves,, Valvetrains,Valve-

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center plate, Throw-out bearing., Manual transmissions- Gear ratios,, Compound gear trains, Gear selection,, Bearings, Oil seals & gaskets, Brief about, Automated Manual Transmission (AMT), Gearbox layout & operation- Gearbox, layouts, Transaxle designs, Gearbox operation,, Baulk-ring synchromesh unit, Transaxle, synchromesh unit. Gear shift mechanism., Final Drive & Drive Shafts - Basic layouts,, Front-wheel drive layout, Rear-wheel drive, layout, Four-wheel drive layout, All-wheel, drive layout, 4WD v/s AWD, Front-wheel drive, Front-wheel drive shafts,, Front-wheel, final, drives,, Front-wheel, differentials, Rear-wheel drive- Propeller shaft, Type of, Universal joints, Type of Constant velocity, Joints, Rear-wheel final drives, Salisbury axles,, Rear-wheel drive differentials, Limited slip, differentials., Four-wheel drive- Four-wheel drive shafts,, Four-wheel final drive, Four-wheel drive, transfer case, Freewheeling hubs, Four-wheel, drive differentials, All-wheel drive- four wheel final drives, Allwheel drive transfer case, Transfer case, differential action., Automatic Transmissions - Torque converters,, Torque converter principles, drive plate,, Converter operation, Torque multiplication,, Fluid flow, Heat exchanger, Lock-up, converters, clutches., , 33., , Planetary gearing- Planetary gears, Simple, planetary gear sets, Compound planetary gear, sets, Automatic transmission brake bands,, Multi-disc clutches,, Electronic control transmission -Electronic, control Unit, Fully hydraulically controlled, transmission, Electronic shift programs, Manual, , 14

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selection. Layout & operation for P,R,N&D, (1st& 2nd) Selector positions, Planetary gear set,, High range power flow, Low range power flow, Continuously variable transmission (C.V.T.)Continuously variable transmission, Drive or, reverse, The steel belt, Secondary pulley shaft., , Steering Systems:- Description and function of, Steering systems, Principles of steering, Rackand-pinion steering system, Recirculation ball, & nut steering system, Four-wheel steering, systems, collapsible steering system., , 34., , Steering boxes & columns - Description and, function of Steering columns, Rack-and-pinion, gearbox, Helix, Variable ratio steering, Worm, gearbox, Power Assisted steering, Steering, process, Flow-control valve, Electric power, assisted steering, Basic electric power steering, operation, Steering arms & components- Forward, control vehicle steering, Steering linkages,, Joints, Bushes/bushings, Wheel, alignment, fundamentals:-Basic, principles of wheel alignment, wheel base,, wheel track, king pin inclination, Caster,, Camber, Scrub radius, Toe-in & toe out, Toeout on turns, Turning radius, Thrust angle &, centerlines., Suspension Systems:- Principles of, suspension, Suspension force, Un-sprung, weight, Wheel unit location, Dampening., Types of suspension-Suspension systems,, Solid axle, Dead axle, Description, function, and advantages of non-independent suspension, Independent suspension, Rear independent, suspension, Rear-wheel drive independent, suspension, electronically controlled air, suspension (ECAS), Adaptive air suspension, operation., Types of springs - Description and function of, , 35., , 15

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Coil springs, Leaf springs, Torsion bars,, Rubber springs., Shock absorber types- Description and, function of Hydraulic shock absorbers, Gaspressurized shock absorbers, Load-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, coilspring suspension, Independent type, suspension, Rigid non-drive suspension, Wheels & Tyres-Wheel types & sizes Wheels,, Rim sizes & designations, Types of wheels, , 36., , Tyre types & characteristics- Tyres, Radial, ply tyres, Radial ply tyre sidewalls, Tyre, pressure monitoring systems, Run flat tyres,, Space-saver tyres, Tyre distortion, Center of, gravity., Tyre construction-Tyre construction, Types of, tyre construction, Tyre materials, Hysteresis,, Tyre sizes & designations, Tyre information,, Tyre tread designs, Tyre ratings for temperature, & traction. Descriptions Tirewear Patterns and, causes Nitrogen vs atmospheric air in tyres, Braking Systems :- Principles of braking,, Drum & disc brakes, Lever/mechanical, advantage, Hydraulic pressure & force, Brake, pad, Regenerative braking., , 37., , Braking systems - Brake type - principles, Air, brakes, Exhaust brakes, Electric brakes, Parking, brakes, Engine brakes, Regenerative braking, Braking system components-Park brake, system, Brake pedal, Brake lines, Brake fluid,, Bleeding, Master cylinder, Divided systems,, Tandem master cylinder, Power booster or, , 16

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brake unit, Hydraulic brake booster, Electro, hydraulic braking (EHB), Applying brakes,, Brake force, Brake light switch, Drum brakes & components -Drum brake, system, Drum brake operation, Brake linings &, shoes, Back plate, Wheel cylinders, Disc brakes & components-Disc brake system,, Disc brake operation, Disc brake rotors, Disc, brake pads, Disc brake calipprs, Proportioning, valves, Proportioning valve operation, Brake, friction materials, Antilock braking system & components-ABS, brake system, Antilock braking system, operation, Principles of ABS braking, ABS, 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., Petrol Engine Basics: 4-stroke spark-ignition, engines- Basic 4-stroke principles., , 38., , Spark-ignition engine components- Basic, engine components, Engine cams & camshaft,, Engine power transfer, Scavenging, Counter, weights, Piston components., Intake & exhaust systems -Carbureted, systems, Electronic fuel injection systems,, Exhaust systems., Intake system components, Air cleaners,, Carburetor air cleaners, EFI air cleaners, Intake, manifolds, Intake air heating., Gasoline Fuel Systems: Description of, Gasoline fuel, Gasoline fuel characteristics,, Controlling fuel burn, Stoichiometric ratio, Air, density, Fuel supply system, Pressure &, vacuum., , 17

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39., , Carburetor operation-Carburation, Carburetor, systems,, Metering, jets,, Accelerating,, Carburetor, barrelsCarbureted, system, components, The carburetor, Mechanical fuel, pumps, Electric fuel pumps, Tanks & lines,, Fuel lines, Charcoal canister, Carburetor filters, , 40., , Introduction to Electronic fuel injection, (EFI) fuel supply system , Basic EFI principles,, Air supply, Air volume, Multi-point injection, systems (MPI/MPFI), Simultaneous injection,, Efficient combustion, 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, Introduction to EFI Engine Management - EFI, operation Modes of EFI, Electronic fuel, injection, Idle speed control systems, Feedback, & looping, Cold start systems, Air, measurement, Air-flow monitoring, Variable, intake manifold system, Electrical functions,, EFI wiring diagram, , 41., , 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., 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., 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, Induction, Inductive system, , 42., , 18

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operation, Induction wiring, Hall effect sensors,, Hall effect operation, Optical type sensors,, Distributor less ignition systems, Insulated, coils, Distributor less ignition system timing., 43., , 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,, Alternator end frames, Slip ring & brush, assembly, Rectifier assembly, Alternator, cooling fan, , 44., , 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., , 45., , Lighting system,Lamps/light bulbs, Lamp/light, bulb information, LED lighting, Headlightsdescription of standard sealed beam, halogen, sealed beam, composite and High intensity, 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, , 46., , Heating Ventilation Air Conditioning, (HVAC), legislation,, Vehicle, heating,, ventilation & cooling systems, Basic airconditioning, principles,, Air-conditioning, capacity,, Air-conditioning, refrigerant,, HumidityDescription and function ofFixed, 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,, , 19

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Refrigerants,, elements, , Pressure, , switches,, , Heating, , Air-conditioning ECU, Ambient air temperature, sensor, Servo motors, Electric servo motors,, Automatic climate control sensors, Evaporator, temperature sensor, Blower speed control,, Ventilation systems, 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,, Carradio andcassetteplayer, car videos., , 47., , 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. Networking & multiplexing, Locating vehicle information, Obtaining &, interpreting scan tool data, Using a repair, manual, Using a shop manual, Using an owner's, manual, Using a labor guide, Using a parts, program, Using a service information program, , 48., , 49., , Revision & Examination, , NOTE: - Maximum uses of video demonstration and other IT based, teaching aids may be adopted to deliver the theoretical knowledge., , 20

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GENERAL INFORMATION, (Employability Skill), , 1. Name of the subject: EMPLOYABILITY SKILLS, 2. Hours of Instruction: 110 Hrs., 3. Examination: The examination will be held at the end of the training., 4. Instructor Qualification:, 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 DGET 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 DGET, institutes, 5. Instructor:, One full time regular instructor shall be engaged on every 240 numbers of trainees, for teaching the subject “Employability Skills”. One additional full time regular, instructor would be required on increase in every 240 trainees. Wherever the, trainees are less than 240 or part thereof, a part-time instructor may be engaged to, teach the subject., , 22

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ALLOTMENT OF TIME AND MARKS AMONG THE TOPICS, , Sl., No., , Topics, , Allotted Hours, , 1., 2., 3., , English Literacy, I.T. Literacy, Communication Skills, , 20 hrs., 20 hrs., 15 hrs., , Marks, Allotted, 9, 9, 7, , 4., , SUB TOTAL:, , 55, , 25, , 5., , Entrepreneurship Skills, Productivity, Occupational safety , health and, Environment Education, Labour Welfare Legislation, Quality Tools, , 15 hrs., , 6, , 10 hrs., 15 hrs., , 5, 6, , 05 hrs., 10 hrs., , 3, 5, , 55, 110 hrs., , 25, 50, , 6., 7., 8., 9., , Sub Total:, TOTAL, , 23, , To be, covered in, , Block – I

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Detail of Syllabus, 1. English Literacy, Hours of Instruction: 20 Hrs., Marks Allotted: 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 with preparation on self, on family, on friends/ classmates,, Speaking / Spoken, on know, picture reading gain confidence through role-playing and, English, 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, Hours of Instruction: 20 Hrs., Marks Allotted: 09, Basics of Computer Introduction, Computer and its applications, Hardware and, peripherals, Switching on-Starting and shutting down of computer., Computer Operating Basics of Operating System, WINDOWS, The user interface of, Windows OS, Create, Copy, Move and delete Files and Folders, Use, System, of External memory like pen drive, CD, DVD etc, Use of Common, applications., Word processing and Basic operating of Word Processing, Creating, opening and closing, Documents, use of shortcuts, Creating and Editing of Text,, Worksheet, 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, Basic of computer Networks (using real life examples), Definitions of, Computer, Networking and Local Area Network (LAN), Wide Area Network (WAN), Internet,, Concept of Internet (Network of Networks),, INTERNET, Meaning of World Wide Web (WWW), Web Browser, Web Site,, Web page and Search Engines. Accessing the Internet using Web, Browser, 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., , 24

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3. Communication Skills Hour of Instruction: 15 Hrs., Marks, Allotted: 07, Topic, Contents, Communication and its importance, Introduction to, Principles of Effective communication, Communication Skills, Types of communication - verbal, non verbal,, written, email, talking on phone., Non verbal communication -characteristics, componentsPara-language, Body - language, Barriers to communication and dealing with barriers., Handling nervousness/ discomfort., Listening Skills, , Motivational Training, , Facing Interviews, , Listening-hearing and listening, effective listening,, barriers to effective listening guidelines for effective, listening., Triple- A Listening - Attitude, Attention &, Adjustment., Active Listening Skills., 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., Manners, Etiquettes, Dress code for an interview, Do's & Don'ts for an interview, , Problem Solving, Confidence Building, Attitude, 4. Entrepreneurship Skills Hour of Instruction: 15 Hrs., Marks, Allotted: 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 & application of PLC, Sales & distribution, Marketing analysis, 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, Behavioral Skills, , 25

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Investment Procurement, , 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., Project formation, Feasibility, Legal formalities i.e., Shop Act,, Estimation & Costing, Investment procedure - Loan, procurement - Banking Processes., , 5. Productivity, Hour of Instruction: 10 Hrs., Marks Allotted: 05, Benefits, Personal / Workman - Incentive, Production linked Bonus,, Improvement in living standard., Industry, Nation., Affecting Factors, Skills, Working Aids, Automation, Environment, Motivation How, improves or slows down., Comparison with, Comparative productivity in developed countries (viz. Germany,, developed countries Japan and Australia) in selected industries e.g. Manufacturing, Steel,, Mining, Construction etc. Living standards of those countries, wages., Personal Finance, Banking processes, Handling ATM, KYC registration, safe cash, Management, handling, Personal risk and Insurance., 7. Occupational Safety, Health and Environment Education Hour of, Instruction: 15 Hrs., Safety & Health, Occupational, Hazards, , Accident & safety, , First Aid, Basic Provisions, , Marks Allotted: 06, Introduction to Occupational Safety and Health importance of, safety and health at workplace., Basic Hazards, Chemical Hazards, Vibroacoustic Hazards,, Mechanical Hazards, Electrical Hazards, Thermal Hazards., Occupational health, Occupational hygienic, Occupational, Diseases/ Disorders & its prevention., Basic principles for protective equipment., Accident Prevention techniques - control of accidents and, safety measures., Care of injured & Sick at the workplaces, First-Aid &, Transportation of sick person, Idea of basic provision of safety, health, welfare under legislative, of India., , 26

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Introduction to Environment. Relationship between Society and, Environment, Ecosystem and Factors causing imbalance., 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 Hour of Instruction: 05 Hrs., Marks Allotted: 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., Hour of Instruction: 10 Hrs., 8. Quality Tools, Marks Allotted: 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., Idea of ISO 9000 and BIS systems and its importance in, Quality, maintaining qualities., Management, System, House Keeping, Purpose of House keeping, Practice of good Housekeeping., Basic quality tools with a few examples, Quality Tools, Ecosystem, , 27

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Tools & Equipments for Employability Skills:, Sl., No., 1, , 2, 3, 4, 5, 6, 7, , Name of the Equipment, Computer (PC) with latest configurations and Internet, connection with standard operating system and standard word, processor and worksheet software, UPS - 500Va, Scanner cum Printer, Computer Tables, Computer Chairs, LCD Projector, White Board 1200mm x 900mm, , Quantity, 10 nos., , 10 nos., 1 no., 10 nos., 20 nos., 1 no., 1 no., , * Note: Above Tools & Equipments not required, if Computer LAB is available in the institute., , 28

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Syllabus for, , ENGINEERING DRAWING, , 29

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GENERAL INFORMATION, (Engineering Drawing), 1. Name of the Subject : ENGINEERING DRAWING, 2. Hours of Instruction: 310 hrs., , 3. Instructor Qualification:, , Degree in Engineering with one year experience, OR, Diploma in Engineering with two years experience, OR, NCVT / NAC in the Draughtsman (Mechanical / Civil), with three years experience., , 4. Desirable: Craft Instructor Certificate in RoD & A course under NCVT., 5. Instructor:, , • One full time instructor is required for 144Engineering seats, sanctioned in the institute. Additional instructor will be required, on increase in every 144 students., • For seats less than 144, the instructor may be out sourced/ hired, on contract basis., , 30

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Details of syllabus, Sl., No., , 1., , 2., , 3., , 4., , 5., 6., , 7., , 8., , 9., , 10., , Topics, (Total duration – 310 hrs.), , 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, 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., 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, 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., Lettering and Numbering as per BIS SP46-2003: - Single Stroke, Double Stroke,, inclined, Upper case and Lower case., Dimensioning:, - Definition, types and methods of dimensioning (functional, nonfunctional and, auxiliary), Types of arrowhead, Leader Line with text, 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., 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), Method of presentation of Engineering Drawing, - Pictorial View, - Orthogonal View, - Isometric view, Symbolic Representation (as per BIS SP:46-2003) of :, Fastener (Rivets, Bolts and Nuts) - Bars and profile sections, - Weld, brazed and soldered joints., , 31

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11., 12., 13., , 14., , 15., 16., 17., , 18., 19., 20., 21., 22., 23., 24., 25., 26., 27., 28., 29., , 30., 31., 32., 33., 34., 35., 36., 37., 38., , - Electrical and electronics element, - Piping joints and fittings, Construction of Scales and diagonal scale, Practice of Lettering and Title Block, 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., Construction of Geometrical Drawing Figures:, - Different Polygons and their values of included angles. Inscribed and, Circumscribed polygons., - Conic Sections (Ellipse & Parabola), Drawing of Solid figures (Cube, Cuboids, Cone, Prism, Pyramid, Frustum of Cone and, Pyramid.) with dimensions., Free Hand sketch of hand tools and measuring tools used in respective trades., Projections:, - Concept of axes plane and quadrant., - Orthographic projections, - Method of first angle and third angle projections (definition and difference), - Symbol of 1st angle and 3rd angle projection as per IS specification., Drawing of Orthographic projection from isometric/3D view of blocks, Orthographic Drawing of simple fastener (Rivet, Bolts, Nuts & Screw), Drawing details of two simple mating blocks and assembled view., - Machined components; concept of fillet & chamfer; surface finish symbols., - Screw thread, their standard forms as per BIS, external and internal thread,, conventions on the features for drawing as per BIS., - Free hand Sketches for bolts, nuts, screws and other screwed members., - Free hand Sketching of foundation bolts and types of washers., - Standard rivet forms as per BIS (Six types)., - Riveted joints-Butt & Lap (Drawing one for each type)., - Orthogonal views of keys of different types, - Free hand Sketches for simple pipe, unions with simple pipe line drawings., - Concept of preparation of assembly drawing and detailing. Preparation of simple, assemblies & their details of trade related tools/job/exercises with the dimensions from the, given sample or models., -Free hand sketch of trade related components / parts (viz., single tool post for the lathe,, etc.), - Study of assembled views of Vee-blocks with clamps., - Study of assembled views of shaft and pulley., - Study of assembled views of bush bearing., - Study of assembled views of a simple coupling., - Free hand Sketching of different gear wheels and nomenclature., - Free hand Details and assembly of simple bench vice., - Reading of drawing. Simple exercises related to missing lines, dimensions. How to make, queries., - Simple exercises relating missing symbols., - Missing views, , 32

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39., 40., 41., 42., , 43., 44., 45., 46., , - Simple exercises related to missing section., -Free hand sketching of different types of bearings and its conventional representation., - Free hand sketching of different gear wheels and nomenclature/ Simple duct (for RAC)., Free hand sketch of Reciprocating compressor - open type (for RAC), - Solution of NCVT test., - Simple exercises related to trade related symbols., - Basic electrical and electronic symbols, - Study of drawing & Estimation of materials., - Solution of NCVT test papers., Revision, Examination, , 33

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LIST OF TOOLS & EQUIPMENTS, Sl., No., 1., 2., 3., 4., 5., 6., 7., 8., , NAME OF TOOLS / EQUIPMENTS, Drawing Board, Models : Solid & cut section, Table for trainees, Stool for trainees, Cupboard (big), White Board (size: 8ft. x 4ft.), Trainer's Table, Trainer's Chair, , QUANTITY, 20, as required, 20, 20, 01, 01, 01, 01, , 34

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Syllabus for, , Workshop Calculation & Science, , 35

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GENERAL INFORMATION, (Workshop Calculation & Science), , 1. Name of the subject : WORKSHOP CALCULATION & SCIENCE, 2. Hours of Instruction: 220 hrs., 3. Examination: The examination for the subject will be held at the end of, training., 4. Instructor Qualification: Degree in Engineering with two years, experience OR, Diploma in Engineering with one year experience, 5. Desirable:, , Craft Instructor Certificate in RoD & A course under NCVT., , 6. Instructor:, One full time instructor is required for 144Engineering seats, sanctioned in the institute. Additional instructor will be required on, increase in every 144 students., For seats less than 144, the instructor may be out sourced/ hired on, contract basis., , 36

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SYLLABUS FOR WORKSHOP CALCULATION AND SCIENCE, (Total duration – 220 hrs.), , Topic, Workshop Calculation, No, 1. Unit: Systems of unit- FPS, CGS, MKS/SI unit, unit of, , Workshop Science, 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., Fractions : Fractions, Decimal fraction, L.C.M.,, Mass .Weight and Density :, H.C.F., Multiplication and Division of Fractions and, Mass, Unit of Mass, Weight, difference between mass, Decimals, conversion of Fraction to Decimal and vice, and weight, Density, unit of density, specific gravity of, versa. Simple problems using Scientific Calculator., metals., Square Root:Square and Square Root, method of, Speed and Velocity: Rest and motion, speed,, finding out square roots, Simple problem using calculator. velocity, difference between speed and velocity,, acceleration, retardation, equations of motions, simple, related problems., Ratio & Proportion :, Work, Power and Energy: work, unit of work,, Simple calculation on related problems., power, unit of power, Horse power of engines,, Percentage : Introduction, Simple calculation., mechanical efficiency, energy, use of energy, potential, Changing percentage to decimal and fraction and viceand kinetic energy, examples of potential energy and, versa., kinetic energy., Heat & Temparature: Heat and temperature,, Algebra : Addition, Subtraction, Multiplication,, Division, Algebraic formula, Linear equations (with two their units, difference between heat and temperature,, boiling point, melting point, scale of temperature,, variables)., relation between different scale of temperature,, Thermometer, pyrometer, transmission of heat,, conduction, convection, radiation., Basic Electricity: Introduction, use of electricity,, Mensuration : Area and perimeter of square,, how electricity is produced, Types of current_ AC, DC,, rectangle, parallelogram, triangle, circle, semi circle,, their comparison, voltage, resistance, their units., Volume of solids - cube, cuboid, cylinder and Sphere., Conductor, insulator, Types of connections - series,, Surface area of solids -cube, cuboid, cylinder and, parallel, electric power, Horse power, energy, unit of, Sphere., electrical energy., length, Mass and time, Conversion of units, , 2., , 3., , 4., 5., , 6., , 7., , Levers and Simple Machines:, , 8. Trigonometry:, , levers and its types. Simple Machines, Effort and Load,, Mechanical Advantage, Velocity Ratio, Efficiency of, machine, Relationship between Efficiency, velocity, ratio and Mechanical Advantage., , Trigonometrical ratios, measurement of angles., Trigonometric tables, , 9. - Geometrical construction & theorem: division, of line segment, parallel lines, similar angles,, perpendicular lines, isosceles triangleand right, angled triangle., , - Forces definition., - Compressive, tensile, shear forces and, simple problems., -Stress,strain, ultimate strength, factor of, safety., -Basic study of stress-strain curve for MS., - Temperature measuring instruments. Specific, heats of solids & liquids., - Thermal Conductivity, Heat loss and heat, gain., - Average Velocity, Acceleration &, Retardation., - Related problems., , 10. - Area of cut-out regular surfaces: circle and, segment and sector of circle., 11. - Area of irregular surfaces., - Application related to shop problems., 12. - Volume of cut-out solids: hollow cylinders,, frustum of cone, block section., - Volume of simple machine blocks., 37

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13. - Material weight and cost problems related to, trade., , - Circular Motion: Relation between circular, motion and Linear motion, Centrifugal force,, Centripetal force, , 14. - Finding the value of unknown sides and angles, of a triangle by Trigonometrical method., 15. - Finding height and distance by, trigonometry., 16. - Application of trigonometry in shop problems., (viz. taper angle calculation)., 17. Graph:, - Read images, graphs, diagrams, - bar chart, pie chart., - Graphs: abscissa and ordinates, graphs of, straight line, related to two sets of varying, quantities., 18. Simple problem on Statistics:, - Frequency distribution table, - Calculation of Mean value., - Examples on mass scale productions. Cumulative frequency -Arithmetic mean, 19. Acceptance of lot by sampling method, (within specified limit size) with simple, examples (not more than 20 samples)., 20., , 21., 22., , 23., , 38, , - Friction- co-efficient of friction,, application and effects of friction in, Workshop practice., Centre of gravity and its practical, application., - Magnetic substances- natural and artificial, magnets., - Method of magnetization. Use of magnets., , - Electrical insulating materials., - Basic concept of earthing., - Transmission of power by belt, pulleys &, gear drive., - Calculation of Transmission of power by belt, pulley and gear drive., - Heat treatment and advantages., Concept of pressure - units of pressure,, atmospheric pressure, absolute pressure,, gauge pressure -gauges used for measuring, pressure, Introduction to pneumatics & hydraulics, systems.

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BLOCK – II, DURATION: 09MONTHS (39 weeks), Industry level training, BROAD LEARNING TO BE COVERED IN INDUSTRY FOR, MECHANIC MOTOR VEHICLE TRADE:, 1., 2., 3., 4., 5., 6., 7., , Safety and best practices /Basic Industrial Culture (5S, KAIZEN, etc.), Record keeping and documentation, Repair, maintenance and Overhauling of Diesel engine (CRDI), Repair, maintenance and Overhauling of petrol engine (MPFI), Maintenance & overhauling of vehicle (Light & Heavy), Diagnosis/Troubleshooting of Engine, Carryout repair & maintenance work of different aggregates of, vehicle., 8. Inspection & testing of Engine and vehicle, DETAILS OF PRACTICAL SKILLS TO BE COVERED DURING, INDUSTRY TRAINING FOR MECHANIC MOTOR VEHICLE TRADE, Duration of training: - 09 Months, Actual training will depend on the existing facilities available in the establishments., The candidate should be competent to execute following operation/ skills after completion of, the industrial training: 1., 2., 3., 4., 5., 6., 7., 8., 9., 10., 11., 12., 13., 14., , Apply safe working practices in an automotive work shop, Comply environment regulations and housekeeping in the work shop., Identify and check functionality of major components and assemblies of heavy, vehicle., Carry Out overhauling light vehicle /Heavy vehicle transmission system and record, the information, Trouble shooting of transmission system, Identify and check functionality of auto transmission components and to Carry out, automatic transmission adjustments., Carryout overhauling of light vehicle /Heavy vehicle chassis system including, steering, suspension and braking system and record the information, Carry out steering and Brake adjustments., Trouble shooting of Steering, suspension and braking system, Carry out removal and replacement activities of tyres and tubes of light & Heavy, vehicle, Balance wheels and carry out final checks on the vehicle and record the information, Trouble shooting of wheel and tyres, Identify and check functionality of MPFI Components, Overhaul the Petrol Engine, 39

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15. Perform engine tune up, 16. Identify and check functionality of various sensors installed in engine, Gauges and, instruments on dashboard, 17. Find the trouble in electronic circuit and rectify using scan tool, 18. Diagnose and Troubleshoot Petrol Engines, 19. Troubleshoot the Charging System, 20. Troubleshoot the Starting System, 21. Troubleshoot the Lighting circuit, 22. Diagnose and Troubleshoot the AC system, 23. Diagnose and Troubleshoot the electrical system accessories, , NOTE: 1. In addition to the above mentioned skills/ operations industry may impart training on, any other skills/ operations related to the trade., 2. Assignment should be planned so that the trainees may spend 20% of the total time of, production/service type of work (using gauges, instruments etc.) for developing their, skill and confidence about manufacturing/servicing which will help ever in selfemployment, if found necessary in the future., , 40

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BLOCK – III, DURATION: 3 months (13 weeks), Institute level training, For last three months candidates will be engaged in following works: 1. Revision of theoretical components covered during Block – I., 2. Practical practice and report submission, 3. Preparing candidate to face interview, preparation of bio-data,, awareness about different jobs in the related field and grooming to, be an entrepreneur., 4. Self study and final AITT examination, Note:1. The training may be conducted in Block mode i.e. few months in ITI &, few in Industry., 2. The training may be conducted in flexible mode i.e. few days of a, week in ITI& few days in Industry., 3. Nine months industrial training is mandatory., 4. Last three months of training in ITI is mandatory., 5. No admission of trainees without signing MOU with industry by the, Institute (ITI)., 6. To sign MOU with ITI, industry must ensure that, training facility is, available to impart all skill sets as indicated in Block-II. Industry, should make arrangements to provide all the Skill set as in Block-II, for MMV Diesel in the Industry either by itself or through its ancillary, units or in association with some other Industries., 7. If the industry ensures delivery of skill training as per Sl. 6 then 2nd, MOU is not necessary., 8. However, Industry should ensure 100% skill training indicated in Block-II, & necessary arrangement to be made to cover training on rest skill set, (beyond the % indicated in sl.6) in collaboration with any other related, industries. Extensive use of E-learning process may also be adopted., 41

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TRADE: Mechanic Motor Vehicle (Dual, , mode), , LIST OF TOOLS & EQUIPMENTS FOR 16 TRAINEES, A. TRAINEESTOOLKIT per 4 Trainees, Sl.No., 1., 2., 3., 4., 5., 6., 7., 8., 9., 10., 11., 12., 13., 14., 15., 16., 17., 18., 19., Sl.No., 1., 2., 3., 4., 5., 6., 7., 8., 9., 10., 11., 12., 13., 14., 15., 16., 17., 18., 19., 20., 21., , Item with specification, Qty (Nos.), 5, Allen Key set of 12 pieces (2mm to 14mm), Caliper inside 15 cm Spring, 6, Calipers outside 15 cm spring, 6, Center Punch 10 mm. Dia. x 100 mm., 6, Dividers 15 cm Spring, 6, Electrician Screw Driver 250mm, 6, Hammer ball peen 0.5 kg with handle, 6, Hands file 20 cm. Second cut flat, 6, Philips Screw Driver set of 5 pieces (100 mm to 300 mm), 6, Pliers combination 20 cm., 6, Screw driver 20cm.X 9mm. Blade, 6, Screw driver 30 cm. X 9 mm. Blade, 6, Scriber 15 cm, 6, Spanner D.E. set of 12 pieces (6mm to 32mm), 6, Spanner, ring set of 12 metric sizes 6 to 32 mm., 6, Spanners socket with speed handle, T-bar, ratchet and universal upto 32, 6, mm set of 28 pieces with box, Steel rule 30 cm inch and metric, 6, Steeltoolboxwithlockandkey(foldingtype) 400x200x150mm, 6, Wire cutter and stripper, 6, B. Tools Instruments and General Shop outfits (at ITI), Itemwith specification, Qty. (Nos), AC alternator slip ring puller, 1, Adjustable spanner (pipe wrench 350 mm), 2, Air blow gun with standard accessories, 1, Air impact wrench with standard accessories, 4, Air ratchet with standard accessories, 4, Allen Key set of 12 pieces (2mm to 14mm), 4, Alternator assembly used for LMV, 2, Ammeter 300A/ 60A DC with external shunt, 4, Angle plate adjustable 250x150x175, 1, Angle plate size 200x100x200mm, 2, Anti theft device, 1, Anvil 50 Kgs with Stand, 1, Auto Electrical test bench, 1, Battery –charger, 2, Belt Tensioner gauge, 1, Blow Lamp 1 litre, 2, Caliper inside 15 cm Spring, 4, Calipers outside 15 cm spring, 4, Car Jet washer with standard accessories, 1, Carburetor – Solex, Mikuny for dismantling and assembling, 1 each, Carburetor repair tool kit, 1, 42

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22., 23., 24., 25., 26., 27., 28., 29., 30., 31., 32., 33., 34., 35., 36., 37., 38., 39., 40., 41., 42., 43., 44., 45., 46., 47., 48., 49., 50., 51., 52., 53., 54., 55., 56., 57., 58., 59., 60., 61., 62., 63., 64., 65., 66., 67., 68., 69., 70., , Chain Pulley Block-3 ton capacity with tripod stand, Chisel 10 cm flat, Chisels cross cut 200 mm X 6mm, Circlip pliers Expanding and contracting type 15cm and 20cm each, Clamps C 100mm, Clamps C 150mm, Clamps C 200mm, Cleaning tray 45x30 cm., Coil spring compressor for suspension spring, Compression testing gauge suitable for diesel Engine with standard, accessories, Copper bit soldering iron 0.25 Kg, Cut section models of shock absorbers, Cut section of cross ply and radial tyres, Cut section working model of automatic transmission Gear box, Cut section working model of centrifugal clutch assembly., Cut section working model of Diaphragm clutch assembly., Cut section working model of Single plate clutch assembly., Cylinder bore gauge capacity 20 to 160 mm, DC Ohmmeter 0 to 300 Ohms, mid scales at 20 Ohms, Depth micrometer 0-25mm, Dial gauge type 1 Gr. A (complete with clamping devices and with, magnetic stand), Different type of Engine Bearing model, Dividers 15 cm Spring, Drift Punch Copper 15 Cm, Drill point angle gauge, Drill twist 1.5 mm to 15 mm (various sizes) by 0.5 mm, Electric Soldering Iron 230 V 60 watts 230 V 25 watts, Electric testing screw driver, Engineer‟s square 15 cm. Blade, Executive Auto Electrical tool kit, Feeler gauge 20 blades (metric), File flat 20 cm bastard, File, half round 20 cm second cut, File, Square 20 cm second cut, File, Square 30 cm round, File, triangular 15 cm second cut, Files assorted sizes and types including safe edge file (20 Nos), Flat File 25 cm second cut, Flat File 35 cm bastard, Fuel feed pump for diesel, Garage stand, Gloves for Welding (Leather and Asbestos), Glow plug tester, Granite surface plate 1600 x 1000 with stand and cover, Grease Gun, Grease Gun heavy duty trolley type 10 kg capciaty, Growler, Hacksaw frame adjustable 20-30 cm, Hammer Ball Peen 0.75 Kg, 43, , 1, 4, 4, 4, 2, 2, 2, 4, 1, 2, 4, 1, 1, 1, 1, 1, 1, 4, 2, 4, 4, 1 set, 4, 4, 1, 4, 2 each, 4, 4, 1, 4, 4, 4, 4, 4, 4, 2 set, 4, 4, 1, 4, 5 sets, 2, 1, 2, 1, 2, 10, 4

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71., 72., 73., 74., 75., , 77., 78., 79., , Hammer Chipping 0.25 Kg, Hammer copper 1 Kg with handle, Hammer Mallet, Hammer Plastic, Hand operated crimping tool (i) for crimping up to 4mm and (ii) for, crimping up to 10mm, 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, Hand Shear Universal 250mm, Hand vice – 37 mm, Hollow Punch set of seven pieces 6mm to 15mm, , 80., 81., 82., 83., 84., 85., 86., 87., 88., 89., , Horn and Horn relay, Impact screw driver, Injector – Multi hole type, Pintle type, Injector cleaning unit, Injector testing set (Hand tester), Insulated Screw driver 20 cm x 9mm blade, Insulated Screw driver 30 cm x 9mm blade, Left cut snips 250mm, Lifting jack screw type 3 ton, 5ton & 20 Ton capacity, Magneto spanner set with 8 spanners, , 90., 91., 92., 93., 94., 95., 96., 97., 98., 99., 100., 101., 102., 103., 104., 105., 106., 107., 108., 109., 110., 111., 112., 113., 114., 115., 116., 117., 118., , Magnifying glass 75mm, Marking out table 90X60X90 cm., Multimeter digital, Multi-point fuel injection pump, Oil can 0.5/0.25 liter capacity, Oil pump for dismantling and assembling., Oil Stone 15 cm x 5 cm x 2.5 cm, Oscilloscope 20MHz, Outside micrometer 0 to 25 mm, Outside micrometer 25 to 50 mm, Outside micrometer 50 to 75 mm, Outside micrometer 75 to 100 mm, Petrol nozzle, Philips Screw Driver set of 5 pieces (100 mm to 300 mm), Pipe cutting tool, Pipe flaring tool, Piston ring compressor, Piston Ring expander and remover., Piston Ring groove cleaner., Pliers combination 20 cm., Pliers flat nose 15 cm, Pliers round nose 15 cm, Pliers side cutting 15 cm, Portable electric drill Machine, Prick Punch 15 cm, Punch Letter 4mm (Number), Right cut snips 250mm, Rivet sets snap and Dolly combined 3mm, 4mm, 6mm, Scraper flat 25 cm, , 76., , 44, , 5, 4, 4, 4, 2, 1 sets, 2, 2, 2 sets each, 2, 2, 4 each, 1, 1, 4, 4, 4, 1 each, 1 set, 2, 1, 5, 2, 4, 2, 1, 1, 4, 4, 1, 1, 2, 2, 2, 2, 2, 2, 2, 2, 2, 2, 2, 1, 4, 2 set, 2, 2, 2

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119., 120., 121., 122., 123., 124., 125., 126., 127., 128., 129., 130., 131., 132., 133., 134., 135., 136., 137., 138., 139., 140., 141., 142., 143., 144., 145., 146., 147., 148., 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, , Scraper half round 25 cm, Scraper Triangular 25 cm, Scriber 15 cm, Scriber with scribing black universal, Set of stock and dies – Metric, Shear Tin Man‟s 450 mm x 600mm, Sheet Metal Gauge, Sher Tinmans 300mm, Soldering Copper Hatchet type 500gms, Solid Parallels in pairs (Different size) in Metric, Spanner Clyburn 15 cm, Spanner D.E. set of 12 pieces (6mm to 32mm), Spanner T. flocks for screwing up and up-screwing inaccessible, positions, Spanner, adjustable 15cm., Spanner, ring set of 12 metric sizes 6 to 32 mm., Spanners socket with speed handle, T-bar, ratchet and universal upto, 32 mm set of 28 pieces with box, Spark lighter, Spark plug spanner 14mm x 18mm x Size, Starter motor axial type, pre-engagement type & Co-axial type, Steel measuring tape 10 meter in a case, Steel rule 15 cm inch and metric, Steel rule 30 cm inch and metric, Straight edge gauge 2 ft., Straight edge gauge 4 ft., Stud extractor set of 3, Stud remover with socket handle, Surface gauge with dial test indicator plunger type i.e. 0.01 mm, Synchronous Gear box with stand for Dismantling and assembly., Tachometer (Counting type), Tandem master cylinder with booster, Taps and Dies complete sets BSF, Taps and wrenches - metric, Telescope gauge, Temperature gauge with sensor 0-100 deg c, Tester sparking plug „NEON‟ Type, Thermostat, Thread pitch gauge metric, BSW, Timing lighter, Toe-in, toe-out gauge, Torque wrenches 5-35 Nm, 12-68 Nm & 50-225 Nm, Trammel 30 cm, Tread wear indicator, Tubed tyre of car, trucks & motorcycle, Tubeless tyre of cars & trucks, Tubeless tyre repair kit, Tyre & split rim wheel assembly, Tyre pressure gauge with holding nipple, Universal puller for removing pulleys, bearings, V‟ Block 75 x 38 mm pair with Clamps, Vacuum gauge to read 0 to 760 mm of Hg., Valve Lifter, 45, , 2, 2, 2, 2, 2 sets, 2, 2, 4, 2, 2, 1, 4, 2, 2, 4, 2, 2, 2, 1each, 4, 4, 4, 2, 2, 2 sets, 1, 4, 1, 1, 4, 1 set, 2 sets, 4, 2, 1, 2, 2, 2, 1set, 1 each, 2, 1, 1, 1, 1, 2, 1, 2, 2, 1

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170, 171, 172, 173, 174, 175, 176, 177, 178, , Valve spring compressor universal., vernier caliper 0-300 mm with least count 0.02mm, Vice grip pliers, Water pump for dismantling and assembling, Wheel cylinder, Wire Gauge (metric), Work bench 250 x 120 x 60 cm with 4 vices 12cm Jaw, 4 Point relays, 5 Point relays, , 1, 4, 2, 4, 4, 2, 4, 2, 2, , C. General Installation/Machineries at ITI, Sl.No., 1., 2., 3., 4., 5., 6., 7., , Item with specification, Air conditioned CRDI Vehicle in running condition -LMV, Arbor press hand operated 2 ton capacity, Automotive exhaust 5 gas analyzer (petrol & Diesel) or Diesel Smoke, Meter, Bench lever shears 250mm Blade x 3mm Capacity, Drilling machine bench to drill up to 12mm dia along with accessories, , Qty (Nos.), 1, 1, 1, , Grinding machine (general purpose) D.E. pedestal with 300 mm dia, wheels rough and smooth, Hydraulic jack HI-LIFT type -3 ton capacity, and 5 Ton capacity, , 1, 1, 1, 1 each, , 8., , MPFI petrol engine with swiveling stand along with special tools for, dismantling and assembling, , 1, , 9., 10., 11., , Pneumatic rivet gun with standard accessories, Tin smiths bench folder 600 x 1.6mm, Trolley type portable air compressor single cylinder with 45 liters, capacity Air tank, along with accessories & with working pressure 6.5, kg/sq cm, Working Condition of Diesel Engine – CRDI - 4 stroke Engine, Assembly with fault simulation board, , 2, 1, 1, , Working Condition of Petrol MPFI Engine Assembly with fault, simulation board, , 1, , 12., 13., , Sl., No., 1., 2., 3., 4., 5., 6., 7., 8., 9., 10., 11., 12., 13., , D. List of consumable:, Description, , 1, , Quantity, , Automatic Transmission oils, Battery- SMF, Brake fluids, Chalk, Prussian blue., Chemical compound for fasteners, Diesel, Different type gasket material, Different type of oil seal, Drill Twist (assorted), Emery paper - 36–60 grit , 80–120, Engine coolant, Engine oil, Gear oils, , As required, As required, As required, As required, As required, As required, As required, As required, As required, As required, As required, As required, As required, 46

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14., 15., 16., 17., , Gloves for Welding (Leather and Asbestos), Hacksaw blade (consumable), Hand rubber gloves tested for 5000 V, Holders, lamp teakwood boards, plug sockets,, solders, flux wires and cables batteries round, consumable blocks and other consumables as, required, , 5 sets, As required, 5 pair, As required, , 18., 19., 20., 21., 22., 23., 24., 25., , Hydrometer, Lapping abrasives, Leather Apron, Petrol, Power steering oil, Radiator Coolants, Safety goggles, Steel wire Brush 50mmx150mm, , 4, As required, 5, As required, As required, As required, As required, 5, , E. Workshop Furniture, Sl., No., 1., 2., 3., 4., 5., 6., 7., 8., 9., 10., 11., 12., 13., 14., 15., 16., 17., 18., 19., , Description, , Quantity, , Book shelf(glasspanel) 6½ „ x 3‟ x 1½‟, ComputerChair, ComputerTable, Desktopcomputerand relatedMSofficesoftware, Discussion Table 8‟ x 4‟ x 2½ „, FireExtinguishers,first-aidbox, Instructional Material – NIMI Books/Ref.books, Internet connection with all accessories, Laserprinter, LCDprojector/LED/LCDTV(42”), Multimedia DVD for Automotive, application/subjects, OnlineUPS2KVA, Stools, Storage Rack 6½ „ x 3‟ x 1½‟, Storage shelf 6½ „ x 3‟ x 1½‟, Suitable class room furniture, Suitable Work Tables with vices, Tool Cabinet - 6½ „ x 3‟ x 1½‟, Traineeslocker 6½ „ x 3‟ x 1½‟, , 47, , As required, 1+1, 1+1, 1+1, 2, As required, As required, As required, 1, 1, As required, 1, 21, As required, Asrequired., As required, As required, 2, 2Nos.toaccommodate20, Lockers

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ALLOTMENT OF TIME &MARKS AMONG, THE SUBJECTS FOR EXAMINATION, Sl., No., , SUBJECTS, , Duration, of exam, (in Hrs.), 3, , Full Marks, , Pass Marks, , 200, , 80, , 1., , Trade Theory + E/S, (150+50), , 2., , Workshop Cal. & Sc., , 3, , 50, , 20, , 3., , Engineering Drawing, , 4, , 50, , 20, , 4., , Internal Marks (ITI), , --, , 50, , 30, , 5., , Trade Practical –I*, , 4, , 50, , 30, , 6., , Internal Marks, (Industry), , --, , 50, , 30, , 8, , 250, , 150, , 700, , 360, , 7., , Trade Practical-II** +, Project work (200+50), GRAND TOTAL, , Note:1. “*” represents practical conducted at ITI, 2. “**” represents practical conducted at Industry at the end of training, 3. 40% pass marks for theory subjects and 60% pass marks for practical, 4. The project work will be conducted at industry and industry will allot marks, for the same., , 48

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Format for Internal Assessment, 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 :, , Block:, , Duration of the Trade/course:, , 1, 2, , 49, , 15, Result (Y/N), , 15, , Total internal, assessment Marks, , Economical use of, materials, , 10, , VIVA, , 5, , Quality in, workmanship, , 10, , Speed in doing work, , 10, , Skills to handle tools, & equipment, , 5, Ability to follow, Manuals/ Written, instructions, , 10, Attendance/, Punctuality, , Father's/Mother’s, Name, , 5, Workplace hygiene, , Candidate Name, , 15, Safety consciousness, , Sl. No, , Maximum Marks (Total 100 Marks), , Application of, Knowledge, , Operation/Skill: