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SYLLABUS OF SEMESTER SYSTEM

FOR THE TRADE

OF

1. Mechanic Diesel /Marine Diesel

2. Mechanic Motor Vehicle

(common syllabus)

(Automobile Trade)

(2nd semester)

UNDER

CRAFTSMEN TRAINING SCHEME (CTS)

YEAR – 2012

Designed By

Government of India

Ministry of Labour (D.G.E.&T.)

CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE

EN-Block, Sector-V, Salt Lake

Kolkata

List of trade committee members approved the syllabus of semester system for the

trade of “Mechanic Diesel / Marine Diesel & Mechanic Motor Vehicle (Automobile Trade)” held at ATI, Chennai

|Sl. No.|Name & Designation |Representing Organisation |Remarks |

|1 |Shri R. Senthil Kumar, Director |ATI, Chennai |Chairman |

|2 |Shri S.Harinath Babu, Joint Director of Training |ATI, Chennai |Member |

|3 |Shri E.Balakrishna, Ex_ Joint Director of Training |NIMI, Chennai |Member |

|4 |Shri A.Suganthan, Assistant Training Officer |Govt, ITI, Arakkonam |Member |

|5 |Shri N. Ramesh Kumar, Training Officer |CTI, Chennai |Member |

|6 |Shri T Nandagopal, |Anna University, Chennai |Member |

|7 |Shri K. Thaniyarasau, Assistant Training Officer |Govt . ITI, Trichy |Member |

|8 |Shri P.K. Ramakrishnan Nair |Ram international Industrial Academy |Member |

| | |(p) Ltd, Chennai | |

|9 |Shri S.Arul Selvan, Assistant professor |Dept Auto Engg, M.I.T, Anna University,|Member |

| | |Chennai. | |

|10 |Shri S. Jayaraj, Associate Professor |Dept Auto Engg, M.I.T, Anna University,|Member |

| | |Chennai. | |

|11 |Shri R. Lakshmanan |Bosch Ltd, Bangalore |Member |

|12 |Shri V.ChandraMohan |NATRIP, Global Automotive Research |Member |

| | |centre, Chennai | |

|13 |Shri V.Vadivelan |NATRIP, Global Automotive Research |Member |

| | |centre, Chennai | |

|14 |Shri A.D.Shewale Training Officer |CTI, chennai |Member |

|15 |Shri B. Gridharan |Visa Diesel Service, Chennai |Member |

|16 |Shri K.k.Valasarajan , Vice president |Two Wheeler workshop owners |Member |

| | |Association, Chennai | |

|17 |Shri Jayapal, | Two Wheeler workshop owners |Member |

| | |Association, Chennai | |

|18 |Shri V. Vadivelan |Two Wheeler workshop owners |Member |

| | |Association, Chennai | |

|19 |Shri Syedshwath |Two Wheeler workshop owners |Member |

| | |Association, Chennai | |

|20 |P. Marveldass, Assistant Director of Training |ATI, Chennai |Member |

| |(Electronics) | | |

|21 |K. ArulSelvi, Training Officer (Electronics) |ATI, Chennai |Member |

|22 |Shri Gurcharan Singh, Assistant Director of Training |ATI, Ludhiana |Member |

|23 |Shri O.R. Arjun Mohan, Assistant Executive Engineer |Agricultural Engg Dept,Chennai |Member |

|24 |Shri R.Murugesan, Assistant Executive Engineer |Agricultural Engg Dept,Chennai |Member |

|25 |Shri Ramakrishne Gowda, Assistant Director of Training |FTI, Bangalore |Member |

|26 |C.Yuvaraj, Assistant Director of Training |ATI, Chennai |Member |

GENERAL INFORMATION

1. Name of the Trade : Mechanic Diesel / Marine Diesel.

2. N.C.O. Code No. :

3. Duration of Craftsmen Training : 06 months -2nd Semester ( 01 year course.)

4. Entry Qualification : Pass in 10th Class under 10+2 system of Education &

completed Mechanic Basic Engineering.

5. Unit strength : 20

6. Space norms : a) Workshop: 120 Sq. Mtrs

+ Parking area 152 Sq.mtrs separate

b) Class room: 30 sq.meter.

7. Power norms : 4.0 KW

|8. Instructors Qualification : Degree in Mechanical/Automobile Engineering from |

|recognized engg. college/university with one year experience in the |

|relevant field OR |

|Diploma in Mechanical/Automobile Engg from recognized board of |

|technical education with two years experience in the relevant field |

| OR |

| 10th/Madhyamic pass + NTC/NAC in the relevant Trade |

|With 3 years post qualification experience in the relevant field. |

| |

9. Desirable qualification : Preference will be given to a candidate with CITS. (If not done CITS

than must be trained within 02yrs on joining)

Syllabus for the Trade of “Mechanic Diesel / Marine Diesel & Mechanic Motor Vehicle.(Automobile Trade)” under C.T.S.

Duration : Six Month

Second Semester

|Week No.|Trade Theory |Practical |Vocational Science and |Engineering Drawing |

| | | |Calculation | |

|1 |Auto Industry in India -History, leading | |Mensuration -area of |Use of drawing instruments, |

| |manufacturers, development in automobile | |rectangles, squares, |T-square and drawing board. |

| |industry, trends, new product. | |tri-angles, circles, regular |Use of different types of |

| | | |polygons etc. calculation of |scales in inches and |

| | | |areas. |millimeters |

|2 |Diesel Engine Basics: Introduction, |Identification of parts in a |Calculation of Horse Power- |Lettering number & alphabet |

| |Compression-ignition engines- |diesel engine. |IHP, FHP and applied shop | |

| |Description of |Practice on starting and |problem. | |

| |Basic 4-stroke diesel principles and cycle , |stopping of diesel engines. | | |

| |Basic 2-stroke diesel principles and cycle, Three|Use of speed counter in |Simple problems straight and |Free hand sketching of 4 |

| |phases of combustion |determining the engine speed –|ball-cranked levers. |stroke cycles & 2 stroke |

| |Compression-ignition engine components – |running of engine on load, | |cycles of engine |

| |Basic diesel engine components, Diesel engine |checking temperature fuel and | | |

| |passages, |oil. | | |

| |Diesel fuel delivery, Direct injection, Indirect | | | |

| |injection, Diesel valves & components, | | | |

| |scavenging, Crankshaft rotation, | | | |

| |crankshaft, Diesel engine pistons | | | |

|3 |Principle of Spark Ignition engine, |Practice on Diesel engine |Calculation of volume and |Explanation of simple |

| |Differentiate between C.I engine and S.I Engine, |cleaning, dismantling as per |weight of simple solid bodies|Orthographic projection- lst.|

| |4-stroke and 2 strokes, |procedure. |such as cubes, square and |angle |

| |Otto cycle and Diesel cycle. | |hexagonal prism-shop problem.| |

| |Different type of starting and stopping method of| | |Views of simple hollow and |

| |Diesel Engine. | | |solid bodies with dimensions.|

| |Engine output, Power range. | | | |

|4 |Engine Components – |Overhauling of cylinder head |Heat and temperature |Explanation of simple |

| |Description and Constructional feature of |assembly with use of service |thermometric scale Fahrenheit|orthographic projection 3rd |

| |Cylinder head, Importance of Cylinder head |manual for clearance and other|and centigrade scales & their|angle. |

| |design, Type of Diesel combustion chambers, |parameters:- |conversion. Name & use of |Simple isometric drawings, |

| |Effect on size of Intake & exhaust passages, Head|Practice on removing rocker |temperature measuring |isometric views of simple |

| |gaskets. Importance of Turbulence. |arm assembly manifolds, |instruments normally used in |objects, such as square, |

| | |cylinder head from the engine.|Workshop. |rectangles, cubes , |

| | | | |rectangular blocks etc |

|5 |Valves & Valve Trains |Practice on removing the |Calculation of Engine |Sketching valve timing |

| |Description and Function of Engine Valves, |valves and its parts from the |displacement. |diagram. |

| |different types, materials, Type of valve |cylinder head, cleaning & |Calculation of spring | |

| |operating mechanism, Importance of Valve seats, |decarbonising. |stiffness |Free hand sketch of |

| |Valve seats inserts in cylinder heads, |Inspection of cylinder head | |Different types of cams and |

| |importance of Valve rotation, Valve stem oil |and manifold surfaces for |Shop problems on |followers |

| |seals, size of Intake valves, Valve trains, |warping, cracks and flatness. |determination of volume & | |

| |Valve-timing diagram, concept of Variable valve |checking valve seats & valve |weight of simple bodies. |Free hand sketching of crank |

| |timing. |guide – reconditioning valve | |shaft showing all parts. |

| |Description of Camshafts & drives , Description |seats and re-facing valves- | | |

| |of Overhead camshaft, importance of Cam lobes, |lapping valves on its seat- | | |

| |Timing belts & chains, Timing belts & tensioners.|testing leaks of valve seats | | |

| | |for leakage – | | |

| | |Dismantle rocker shaft | | |

| | |assembly -clean & check rocker| | |

| | |shaft-and levers, for wear and| | |

| | |cracks and reassemble. | | |

| | |Check valve springs, tappets, | | |

| | |push rods, tappet screws and | | |

| | |valve stem cap. Reassembling | | |

| | |valve parts in sequence, refit| | |

| | |cylinder head and manifold & | | |

| | |rocker arm assembly, | | |

| | |adjustable valve clearances, | | |

| | |starting engine after | | |

| | |decarbonising. | | |

|6 & 7 |Description & functions of different types of |Overhauling piston and |Calculation of volume, |Free hand sketch of piston |

| |pistons, piston rings and piston pins and |connecting rod assembly with |compression ratio, force on |assembly, valve assembly. |

| |materials. Used recommended clearances for the |use of service manual for |the piston due to combustion | |

| |rings and its necessity precautions while fitting|clearance and other |pressure, average piston |Free hand isometric sketching|

| |rings, common troubles and remedy. Compression |parameters:- |velocity, internal power of |of simple objects with |

| |ratio. |Practice on removing oil sump |engine respecting two or four|dimensions. |

| | |and oil pump – clean the sump |stroke, | |

| |Description & function of connecting rod, |Practice on removing the big | |Free hand sketching of piston|

| |importance of big-end split obliquely, Materials |end bearing, connecting rod | |gudgeon pins rings and |

| |used for connecting rods big end & main bearings.|with the piston. | |connecting rod with |

| |Shells piston pins and locking methods of piston |Practice on removing the | |dimensions from samples |

| |pins. |piston rings; Dismantle the | | |

| | |piston and connecting rod. | | |

| | |Check the side clearance of | | |

| | |piston rings in the piston | | |

| | |groove & lands for wear. | | |

| | |Check piston skirt and crown | | |

| | |for damage and 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. | | |

|8 |Description and function of Crank shaft, |Overhauling of crankshaft |calculation of effective |Free hand sketching of |

| |camshaft, Engine bearings-classification and |with use of service manual for|power on crank shaft by using|crankshaft and flywheels with|

| |location – materials used & composition of |clearance and other |mechanical efficiency |dimensions from samples |

| |bearing materials-Shell bearing and their |parameters:- | | |

| |advantages-special bearings material for diesel |Practice on removing damper | |Drafting of |

| |engine application bearing failure & its |pulley, timing gear/timing | |- Bush bearing |

| |causes-care & maintenance. Crank-shaft |chain, flywheel, main bearing |Centre of gravity of |- Split bearing |

| |balancing, Firing order of the engine. |caps, bearing shells and |bodies-stable & unstable, |- Thrust bearing, |

| | |crankshaft t from engine |Neutrals & |- Ball bearing |

| | |checking oil retainer and |equilibrium-Examples & |- Roller bearing – straight |

| | |thrust surfaces for wear, |Problems on Centre of |and needle. |

| | |Measure crank shaft journal |gravity. | |

| | |for wear, taper and ovality, | | |

| | |Checking crankshaft for fillet| | |

| | |radii, bend & twist. | | |

|9 |Description and function of the fly wheel and |Checking of flywheel and |Simple levers with examples |Free hand sketching of gears |

| |vibration damper. Crank case & oil pump, gears |mounting flanges, spigot, |i. e. bell - crank lever & |timing mark. |

| |timing mark, Chain sprockets, chain tensioner |bearing. |other used in engine – | |

| |etc. |Check vibration damper for |Advantage in using them. | |

| |Function of clutch & coupling units attached to |defects, |Problems on lever. | |

| |flywheel. |Practice on removing | | |

| | |cam shaft from engine block, | | |

| | |Check for bend & twist of | | |

| | |camshaft. | | |

| | |Inspection of cam lobe, | | |

| | |camshaft journals and bearings| | |

| | |and measure cam lobe lift. | | |

| | | | | |

| | |Fixing bearing inserts in | | |

| | |cylinder block & cap check nip| | |

| | |and spread clearance & oil | | |

| | |holes & locating lugs fix | | |

| | |crank shaft on block-torque | | |

| | |bolts - check end play remove | | |

| | |shaft - check seating, repeat | | |

| | |similarly for connecting rod | | |

| | |and Check seating and refit. | | |

|10 |Description of Cylinder block, Cylinder block |Cleaning and Checking of |Definition of stress, strain |Free hand sketching of |

| |construction, |cylinder blocks surface for |and modulus of elasticity |cylinder block and cylinder |

| |Different type of Cylinder sleeves (liner). |any crack, flatness, |ultimate strength types of |head |

| | |Measure cylinder bore for |stresses- factor of safety |Free hand sketching of |

| | |taper & ovality, clean oil |examples. |cylinder liners with |

| | |gallery passage and oil pipe | |dimensions form sample |

| | |line, Bore - descale water | | |

| | |passages and examine | | |

| | |Removing cylinder liners from | | |

| | |scrap cylinder block, practice| | |

| | |in measuring and refitting new| | |

| | |liners as per maker’s | | |

| | |recommendations precautions | | |

| | |while fitting new liners. | | |

|11 |Engine assembly procedure with aid of special |Reassemble all parts of engine|Simple calculation of stress,|Free hand sketching of plain |

| |tools and gauges used for engine assembling. |in correct sequence and torque|compressive Strain, |and elevation of simple |

| |Introduction to Gas Turbine, Comparison of single|all bolts and nuts as workshop|compressive stress (E), Shear|objects like hexagonal bar, |

| |and two stage turbine engine, Different between |manual of the engine. |stress (G), Tensile strength,|square bar, circular bar, |

| |gas turbine and Diesel Engine. |Engine component procedures- |Factor of safety, and The |tapered bar, hollow bar etc. |

| | |Testing cylinder compression, |allowable working stress. | |

| | |Checking idle speed, Removing | | |

| | |& replacing a cam belt, | | |

| | |Inspecting & adjusting an | | |

| | |engine drive belt, Replacing | | |

| | |an engine drive belt. | | |

|12&13 |Need for Cooling systems, Heat transfer method, |Practice on Checking & |Calculation of Volumetric |Free hand sketching of |

| |Boiling point & pressure, Centrifugal force, |adjusting coolant, Draining &|efficiency, Torque Vs Engine |different cooling system |

| |Vehicle coolant properties and recommended change|refilling coolant, |speed, Specific fuel |showing all necessary parts. |

| |of interval, Different type of cooling systems, |Checking & replacing a coolant|consumption vs. engine speed.| |

| |Basic cooling system components- Radiator, |hose, | |Freehand sketching of water |

| |Coolant hoses, Water pump, Cooling system |Testing cooling system | |pump thermostatic valve & |

| |thermostat, Cooling fans, Temperature indicators,|pressure, | |water jackets in the cylinder|

| |Radiator pressure cap, Recovery system, |Practice on Removing & | |block. |

| |Thermo-switch. |replacing a radiator, | | |

| | |thermostat. | | |

| | |Inspect the radiator pressure | | |

| | |cap, Testing of thermostat. | | |

| | |Cleaning & reverse flushing. | | |

| | |Overhauling water pump and | | |

| | |refitting. | | |

|14 & 15 |Need for lubrication system, Functions of oil, |Practice on Checking engine |Properties of Diesel engine |Free hand sketching of |

| |Viscosity and its grade as per SAE , Oil |oil, Draining engine oil, |cylinder lubricating oil. |lubrication system, filters |

| |additives, Synthetic oils, The lubrication |Replacing oil filter, |Definition of emulsion, |and different types of oil |

| |system, Splash system, Pressure system, |Refilling engine oil. |viscosity index. |pump, pressure release valve.|

| |Corrosion/noise reduction in the lubrication |Overhauling of oil pump, oil | | |

| |system |filters, oil coolers, air | | |

| |Lubrication system components - |cleaners and air filters and | | |

| |Description and function of Sump, Oil collection |adjust oil pressure relief | | |

| |pan, Oil tank, Pickup tube, different type of Oil|valves, repairs to oil flow | | |

| |pump & Oil filters Oil pressure relief valve, |pipe lines and unions if | | |

| |Spurt holes & galleries, Oil indicators, Oil |necessary. | | |

| |cooler. | | | |

|16 |Intake & exhaust systems – Description of Diesel |Practice on Dismantling air |Machines-basic principles, |Free hand sketching of air |

| |induction & Exhaust systems. Description & |compressor and exhauster and |determination of velocity |cleaner & Turbocharger |

| |function of air compressor, exhauster, Super |cleaning all parts - measuring|ratio, mechanical advantage |system. |

| |charger, Intercoolers, turbo charger, variable |wear in the cylinder, |and efficiency. | |

| |turbo charger mechanism. |reassembling all parts and | | |

| |Intake system components- Description and |fitting them in the engine. | | |

| |function of Air cleaners, Different type air |Dismantling & assembling of | | |

| |cleaner, Description of Intake manifolds and |turbocharger, check for axial | | |

| |material, |clearance as per service | | |

| |Exhaust system components- Description and |manual. | | |

| |function of Exhaust manifold, Exhaust pipe, | | | |

| |Extractors, Mufflers, Catalytic converters, | | | |

| |Flexible connections, Ceramic coatings, | | | |

| |Back-pressure, Electronic mufflers. | | | |

|17 & 18 |Diesel Fuel Systems- |Practice on removing & | Alternate Fuel Systems:- | |

| |Description and function of Diesel fuel |Cleaning fuel tanks, |Bio-diesel fuel, |Free hand sketching of fuel |

| |injection,, fuel characteristics, concept of |checking leaks in the fuel |Importance of Alternative |feed system in diesel engines|

| |Quiet diesel technology & Clean diesel technology|lines, |fuels- Ethanol, Methanol, |and fuel filters. |

| |Diesel fuel system components – Description and |soldering & repairing pipe |Liquefied Petroleum Gas | |

| |function of Diesel tanks & lines, Diesel fuel |lines and Unions, brazing |Compressed Natural Gas, |Free hand sketching of |

| |filters, water separator, Lift pump, Plunger |nipples to high pressure line |Liquefied Natural Gas, Fuel |different types of injectors.|

| |pump, Priming pump, Inline injection pump, |studying the fuel feed system |cells, solar, Hybrid system. | |

| |Mechanical or pneumatic governors, |in diesel engines, draining of| | |

| |Distributor-type injection pump, Diesel |water separators. | |Free hand sketching of single|

| |injectors, Glow plugs, Cummins & Detroit Diesel | | |element plunger of fuel |

| |injection. |Bleeding of air from the fuel | |injection pump |

| |Electronic Diesel control- Electronic Diesel |lines, | | |

| |control systems, Common Rail Diesel Injection |Servicing primary & secondary | |Freehand sketching of water |

| |(CRDI) system, Hydraulically actuated |filters. | |separators and fuel tanks |

| |electronically controlled unit injector (HEUI) | | |with dimension from sample. |

| |diesel injection system. Sensors, actuators and |Dismantling fuel injection | | |

| |ECU (Electronic Control Unit) used in Diesel |pump, feed pump governor | |Freehand sketching of |

| |Engines. |studying the parts and | |Distributor fuel injection |

| | |reassemble general maintenance| |pump with dimension from |

| | |of Fuel Injection Pumps (FIP).| |samples. |

| | | | | |

| | |Removing a fuel injection pump| |Freehand sketching of a |

| | |from an engine-refit the pump | |pneumatic governor with |

| | |to the engine re-set timing - | |dimensions from samples |

| | |fill lubricating-oil start and| | |

| | |adjust slow speed of the | |Freehand sketching of |

| | |engine. | |mechanical governor with |

| | | | |dimensions from sample. |

| | |Practice on overhauling of | | |

| | |injectors and testing of | | |

| | |injector. | | |

|19 & 20|Marine & Stationary Engine:- Types, double acting|Practice on Start engine |Problems on Equations of | -do- |

| |engines, opposed piston engines, starting |adjust idling speed and |motion | |

| |systems, cooling systems, lubricating systems, |damping device in pneumatic |(v = u+at | |

| |supplying fuel oil, hydraulic coupling, reduction|governor and venture control |s = (u+v)t /2 | |

| |gear drive, electromagnetic coupling, electrical |unit checking performance of |v2 = u2+2as | |

| |drive, generators and motors, supercharging. |engine with off load adjusting|s = ut+ (at2 ) /2 | |

| | |timings. |u = initial velocity in m/s; | |

| | |Start engine- adjusting idle |v = | |

| | |speed of the engine fitted |final velocity in m/s; | |

| | |with mechanical governor |a = acceleration in m/s2; | |

| | |checking- high speed operation|t = time in seconds; | |

| | |of the engine. |s = distance.) | |

| | |Checking performance for |and their application to | |

| | |missing cylinder by isolating |vehicle technology | |

| | |defective injectors and | | |

| | |test-dismantle and replace | | |

| | |defective parts and reassemble| | |

| | |and refit back to the engine | | |

| | |Visit to marine engine service| | |

| | |station. | | |

|21 |Emission Control:- |On-board diagnostics- |Determination of efficiency |Views of simple solid and |

| |Vehicle emissions standards. |OBD systems, Diagnostic |of simple machines like |hollow bodies cut by section |

| |Sources of emission, Combustion, Combustion |trouble codes, Monitoring |winch, pulley locks, wheel |plane. |

| |chamber design. |emissions |and compound axles. | |

| |Types of emissions: |Emissions procedures | | |

| |Characteristics and Effect of Hydrocarbons, |Checking & cleaning a Positive| | |

| |Hydrocarbons in exhaust gases, Oxides of |crank case ventilation (PCV) | | |

| |nitrogen, Particulates, Carbon monoxide, Carbon |valve. Obtaining & | | |

| |dioxide, Sulfur content in fuels |interpreting scan tool data. | | |

| |Description of Evaporation emission control, | | | |

| |Catalytic conversion, Closed loop, Crankcase | | | |

| |emission control, Exhaust gas recirculation (EGR)| | | |

| |valve, Controlling air-fuel ratios, Charcoal | | | |

| |storage devices, Diesel particulate filter (DPF).| | | |

|22 |Description of charging circuit operation of |Practice on removing |Magnets-natural and |Freehand sketching of |

| |alternators, regulator unit, ignition warning |alternator from vehicle |artificial types-poles of |charging system. |

| |lamp- troubles and remedy in charging system. |dismantling, cleaning checking|magnets-magnetic fields. | |

| | |for defects, assembling and | | |

| | |testing for motoring action of| | |

| | |alternator & fitting to | | |

| | |vehicles. | | |

|23 |Description of starter motor circuit, comparison |Practice on removing starter |Principle of Solenoid and |Sketching starter motor |

| |of wire thickness in starter motor circuit, |motor vehicle and overhauling |relay, Electromagnetic |circuit and solenoid switch |

| |constructional details of starter motor solenoid |the starter motor, testing of |induction. Fleming’s rule. |circuit. |

| |switches, common troubles and remedy in starter |starter motor. | | |

| |circuit. | | | |

|24 |Troubleshooting : Causes and remedy for |Practice on troubleshooting |Study of Engine |Reading of simple blue print.|

| |Engine Not starting – Mechanical & |for |specification. | |

| |Electrical causes, |Engine Not starting – | | |

| |High fuel consumption, |Mechanical & | | |

| |Engine overheating, |Electrical causes, | | |

| |Low Power Generation, |High fuel consumption, | | |

| |Excessive oil consumption, |Engine overheating, | | |

| |Low/High Engine Oil Pressure, |Low Power Generation, | | |

| |Engine Noise. |Excessive oil consumption, | | |

| | |Low/High Engine Oil Pressure, | | |

| | |Engine Noise. | | |

|25 |Industrial training OR Project work preferably in cross sectoral trades |

|26 |Revision & Test |

LIST OF TOOLS & EQUIPMNT FOR SEMESTER-II

FOR THE TRADE OF “Mechanic Diesel / Marine Diesel & Mechanic Motor Vehicle. (Automobile Trade)”

(Unit Size : 20)

|Sl.No |Item with specification |Qty |

|Trainees Tool kit | |

|1 |Steel rule 15 cm inch and metric |20+1 |

|2 |Steel rule 30 cm inch and metric |20+1 |

|3 |Steel measuring tape 10 meter in a case |20+1 |

|4 |Try Square 10 cm Blade |20+1 |

|5 |Calipers outside 15 cm spring |20+1 |

|6 |Caliper inside 15 cm Spring |20+1 |

|7 |Dividers 15 cm Spring |20+1 |

|8 |Safety glasses |20+1 |

|9 |Scriber 15 cm |20+1 |

|10 |Knife double Blade Electrician |20+1 |

|11 |Wire insulation Stripper for shinning conductors from 0.4mm to 4mm |20+1 |

|12 |Electrician testing Pencil (Line / Neon tester) |20+1 |

|13 |Electrician Screw Driver 250mm |20+1 |

|14 |Centre punch 10 cm. |20+1 |

|15 |Chisel cold flat 20 mm x 150 mm |20+1 |

|16 |Hammer ball peen 0.5 kg with handle |20+1 |

|17 |Screw driver 20cm.X 9mm. Blade |20+1 |

|18 |Screw driver 30 cm. X 9 mm. Blade |20+1 |

|19 |Spanner D.E. set of 12 pieces (6mm to 32mm) |20+1 |

|20 |Pliers combination 20 cm. |20+1 |

|21 |Pliers side cutting 15 cm |20+1 |

|22 |Pliers round nose 15 cm |20+1 |

|23 |Pliers flat nose 15 cm |20+1 |

|24 |Hands file 20 cm. Second cut flat |20+1 |

|25 |Hand file 20 cm. Second cut half-round |20+1 |

|26 |Hand file 20 cm. smooth triangular |20+1 |

|27 |Hand file 30 cm. bastard |20+1 |

|28 |Hand file 30 cm. round bastard |20+1 |

|29 |File card or cleaner |20+1 |

|30 |Wire cutter and stripper |20+1 |

|31 |Steel tool box with lock and key (folding type) 400x200x150 mm |20+1 |

|Tools Instruments and General Shop outfits |

|32 |Outside micrometer 0 to 25 mm |1 |

|33 |Outside micrometer 25 to 50 mm |1 |

|34 |Outside micrometer 50 to 75 mm |1 |

|35 |Outside micrometer 75 to 100 mm |1 |

|36 |Internal micrometer 5 to 30 mm |1 |

|37 |Depth micrometer 0-25mm |1 |

|38 |Thread Micrometer 0-25mm |1 |

|39 |Adjustable micrometer sprit level to measure flatness, indication and taper with prismatic |1 |

| |measuring base | |

|40 |Vernier caliper A 200 with inside and depth measurement |1 |

|41 |Direct reading vernier caliper B 300 (direct reading with dial) |1 |

|42 |Vernier depth Gauge 0-150 mm |1 |

|43 |Vernier height gauge 500 mm |1 |

|44 |Telescope gauge |1 |

|45 |Dial gauge type 1 Gr. A (complete with clamping devices and stand) |4 |

|46 |Surface gauge with dial test indicator plunger type i.e. 0.01 mm |2 |

|47 |Cylinder bore gauge capacity 20 to 160 mm |2 |

|48 |Compression testing gauge suitable for diesel engine. |2 |

|49 |Vacuum gauge to read 0 to 760 mm of Hg. |2 |

|50 |Pressure gauge |2 |

|51 |Marking Material (Consumable) |As required |

|52 |Marking out table 90X60X90 cm. |1 |

|53 |CI surface plate 400 x 400 mm with stand and cover |1 |

|54 |Steel rule 15 cm inch and metric |2 |

|55 |Steel rule 30 cm inch and metric |2 |

|56 |Steel measuring tape 10 meter in a case |2 |

|57 |Try Square 10 cm Blade |2 |

|58 |Engineer’s square 15 cm. Blade |2 |

|59 |Calipers outside 15 cm spring |2 |

|60 |Caliper inside 15 cm Spring |2 |

|61 |Calipers 15 cm Hermaphrodite |2 |

|62 |Dividers 15 cm Spring |2 |

|63 |Scriber 15 cm |2 |

|64 |Scriber with scribing black universal |2 |

|65 |Punch Letter 4mm |2 set |

|66 |Chisels cross cut 200 mm X 6mm |2 |

|67 |Chisel 10 cm flat |2 |

|68 |Ball Peen Hammer 0.75 Kg |2 |

|69 |Hammer copper 1 Kg with handle |2 |

|70 |Hammer Mallet |2 |

|71 |Hammer Plastic |2 |

|72 |Hammer ball peen 0.25 kg with handle |2 |

|73 |Philips Screw Driver set of 5 pieces (100 mm to 300 mm) |2 sets |

|74 |Insulated Screw driver 30 cm x 9mm blade |2 |

|75 |Insulated Screw driver 20 cm x 9mm blade |2 |

|76 |Electric testing screw driver |2 |

|77 |Allen Key set of 12 pieces (2mm to 14mm) |2 |

|78 |Hand vice – 37 mm |2 |

|79 |Work bench 250 x 120 x 60 cm with 4 vices 12cm Jaw |1 |

|80 |Magnifying glass 75mm |2 |

|81 |‘V’ Block 75 x 38 mm pair with Clamps |2 |

|82 |Clamps C 100mm |2 |

|83 |Clamps C 150mm |2 |

|84 |Clamps C 200mm |2 |

|85 |Spanner D.E. set of 12 pieces (6mm to 32mm) |2 |

|86 |Spanner, adjustable 15cm. |2 |

|87 |Spanners socket with speed handle, T-bar, ratchet and universal upto 32 mm set of 28 pieces with |2 |

| |box | |

|88 |Adjustable spanner (pipe wrench 350 mm) |2 |

|89 |Spanner, ring set of 12 metric sizes 6 to 32 mm. |2 |

|90 |Spanner T. flocks for screwing up and up-screwing inaccessible positions |2 |

|91 |Spanner Clyburn 15 cm |1 |

|92 |Magneto spanner set with 8 spanners |1 set |

|93 |Spirit level 2V 250, 05 metre |2 |

|94 |Angle plate size 200x100x200mm |2 |

|95 |Angle plate adjustable 250x150x175 |1 |

|96 |Pliers combination 20 cm. |2 |

|97 |Pliers side cutting 15 cm |2 |

|98 |Pliers round nose 15 cm |2 |

|99 |Pliers flat nose 15 cm |2 |

|100 |Vice grip pliers |2 |

|101 |Circlip pliers Expanding and contracting type 15cm and 20cm each |2 |

|102 |Grip Wrench 200mm |2 |

|103 |Torque wrenches 5-35 Nm, 12-68 Nm & 50-225 Nm |1 each |

|104 |Workshop plain goggles |17 |

|105 |Air impact wrench |1 |

|106 |Air ratchet |1 |

|107 |Air chisel |1 |

|108 |Air blow gun |1 |

|109 |Car Jet washer |1 |

|110 |Pipe flaring tool |1 |

|111 |Pipe cutting tool |1 |

|112 |Universal puller for removing pulleys, bearings |1 |

|113 |Cleaning tray 45x30 cm. |4 |

|114 |Cleaning tray- Aluminum 45 x 30 cm |4 |

|115 |Stud extractor set of 3 |2 sets |

|116 |Stud remover with socket handle |1 |

|117 |Chemical compound for fasteners (Consumable) |As required |

|118 |Paraffin pressure Gun |2 |

|119 |Grease Gun |2 |

|120 |Hacksaw frame adjustable 20-30 cm |2 |

|121 |Hacksaw blade (consumable) |As required |

|122 |Flat File 35 cm bastard |4 |

|123 |Flat File 25 cm second cut |4 |

|124 |File flat 20 cm bastard |4 |

|125 |Files assorted sizes and types including safe edge file (20 Nos) |2 set |

|126 |Drill Twist (assorted) (Consumables) |10 Nos |

|127 |Drill twist 1.5 mm to 15 mm (various sizes) by 0.5 mm |4 |

|128 |Drill point angle gauge |1 |

|129 |Set of stock and dies - UNC, UNF and metric |2 sets |

|130 |Taps and wrenches - UNC, UNF and metric |2 sets |

|131 |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 |2sets |

| |mm | |

|132 |Lapping abrasives (consumable) |As required |

|133 |Oil can 0.5/0.25 liter capacity |2 |

|134 |Oil Stone 15 cm x 5 cm x 2.5 cm |1 |

|135 |Different type gasket material (consumable) |As required |

|136 |Different type of oil seal (consumable) |As required |

|137 |Sheet Metal Gauge |2 |

|138 |Feeler gauge 20 blades (metric) |2 |

|139 |Straight edge gauge 2 ft. |1 |

|140 |Straight edge gauge 4 ft. |1 |

|141 |Thread pitch gauge metric, BSX, BSF, MC, MF & SAE |1 |

|142 |Ladle 150mm Dia |1 |

|143 |Blow Lamp 1 litre |2 |

|144 |Crow bar 910 x25mm |2 |

|145 |Voltmeter 50V/DC |1 |

|146 |Ammeter 300A/ 60A DC with external shunt |1 |

|147 |DC Ohmmeter 0 to 300 Ohms, mid scales at 20 Ohms |1 |

|148 |Electric Soldering Iron 230 V 60 watts, 230 V 25 watts |1 each |

|149 |Copper bit soldering iron 0.25 Kg |2 |

|150 |Thimbles of different sizes |2 |

|151 |Wire Gauge (metric) |1 |

|152 |Hand operated crimping tool (i) for crimping up to 4mm and (ii) for crimping up to 10mm |1 |

|153 |Hand rubber gloves tested for 5000 V |2 pair |

|154 |Holders, lamp teakwood boards, plug sockets, solders, flux wires and cables batteries round |As required |

| |consumable blocks and other consumables as required | |

|155 |Multimeter digital |1 |

|156 |Scientific Calculator |1 |

|157 |Hydrometer |1 |

|158 |High rate discharge tester (cell tester) |1 |

|159 |Spray Gun (Painting) 500ml |1 |

|160 |Scrapper, half round 25 cm. |4 |

|161 |Scrapper, triangular 25 cm. |4 |

|162 |Scrapper, bearing. |4 |

|163 |Tachometer (Counting type) |1 |

|164 |Valve Timing Diagram Model |1 |

|165 |Belt Tensioner gauge |1 |

|166 |Cylinder block- CI Engine, Overhead camshaft & camshaft in block, air cooled |1each |

|167 |Cylinder liner- Dry & wet liner, press fit & slidefit liner |1 each |

|168 |Different type of piston model |1each |

|169 |Crankshaft, camshaft, connecting rod –different type |1 each |

|170 |Cooling system components-with & without expansion tank including components |1 each |

|171 |Different type of Engine Bearing model |1 set |

|172 |Radiator cut section-cross flow |1 |

|173 |Radiator cut section-down flow |1 |

|174 |Water pump for dismantling and assembling |2 |

|175 |Radiator pressure cap |2 |

|176 |Thermostat |2 |

|177 |Temperature gauge 0-100 deg c |2 |

|178 |Cut section model of fuel filter |1 |

|179 |Oil pump for dismantling and assembling. |2 |

|180 |Portable oil monitoring Indicator |1 |

|181 |Turbocharger cut sectional view |1 |

|182 |Catalytic converter for diesel |1 |

|183 |Decarbanising Machine |1 |

|184 |Fuel feed pump |1 |

|185 |Fuel injection pump with pneumatic governor, with Maximum and minimum speed governor (Bosch-RQV ),|1 each |

| |with variable speed flyweight governor (Bosch-RSV), VE pump / Distributor fuel rotary pump (DPC) | |

| |pumps /Pressure Time (PT ) pump along with special tools and accessories. | |

|186 |Fuel injection pump dismantling tool kit /Universal Vice |1 |

|187 |Fuel injection pump (Diesel) inline |1 |

|188 |Diesel phasing & calibration machine |1 |

|189 |Injector – Multi hole type, Pintle type |4 each |

|190 |Injector cleaning unit |1 |

|191 |Injector testing set (Hand tester) |1 |

|192 |CRDI cut section model |1 |

|193 |Common rail pressure tester |1 |

|194 |Valve spring compressor universal. |1 |

|195 |Auto Electrical test bench |1 |

|196 |Tool, valve grinding, suction type. |6 |

|197 |Tool, valve grinding, screw in type. |1 |

|198 |Valve seat cutting, tools complete with guides and pilot bar (All angles) |1 |

|199 |Valve grinding machine. |1 |

|200 |Engineers stethoscope |2 |

|201 |Stone, carborandum 15 x 5 x 4 cm smooth and rough. |1each |

|202 |Cylinder gauge capacity 6 to 15 cm. |1 |

|203 |Ring expander and remover. |2 |

|204 |Ring groove cleaner. |1 |

|205 |Starter motor for Light vehicle –different type |2 |

|206 |Alternator for Light vehicle – different type |2 |

|207 |Glow plug tester |1 |

|208 |Timing lighter |1 |

|209 |Battery-12 volt /24 V |1 |

|210 |Piston ring compressor |2 |

|211 |Valve key inserter |1 |

|212 |Connecting rod alignment fixture |1 |

|213 |Chain Pulley Block-3 ton capacity |1 |

|214 |Growler |1 |

|215 |Lifting jack screw type 3 ton capacity |4 |

|General Installation/ Machineries |

|216 |Trolley type portable air compressor single cylinder with 45 liters capacity Air tank, along with|1 |

| |accessories & with working pressure 6.5 kg/sq cm | |

|217 |Grinding machine (general purpose) D.E. pedestal with 300 mm dia wheels rough and smooth |1 |

|218 |Portable electric drill Machine |1 |

|219 |Spring tension tester |1 |

|220 |CRDI Vehicle in running condition |1 |

|221 |Diesel Engine – CRDI - 4 stroke for Dismantling and assembling with swiveling stand |2 |

|222 |Diesel Engine – 2 stroke for Dismantling and assembling with swiveling stand |2 |

|223 |Marine Diesel Engine running condition for Dismantling and assembling with swiveling stand |1 |

|224 |Multi Scan Tool |1 |

|225 |Hydraulic jack HI-LIFT type -3 ton capacity, |1 |

|226 |Arbor press hand operated 2 ton capacity |1 |

|227 |Battery charger |1 |

|228 |Automotive exhaust 5 gas analyzer (petrol & Diesel) or Diesel Smoke meter |1 |

|Sl. No. |Class Room/ Workshop Furniture |Quantity |

|1. |Suitable class room furniture |As required |

|2. |Stools |As required |

|3. |Discussion Table |1 No. |

|4. |Tool Cabinet |2 Nos. |

|5. |Trainees locker |2 Nos. to accommodate 20 lockers |

|6. |Fire Extinguishers, first- aid box |As required |

|7. |Book shelf (glass panel) |1 No. |

|8. |Storage Rack |As required |

|9. |Storage shelf |As required. |

|10 |LCD projector |1 no |

|11 |Multimedia CD for Automotive application |As required |

|12 |Desktop computer and related MS office software |4 No |

|13 |Online UPS 2KVA |1 No |

|14 |Laser printer |1 No |

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