SYLLABUS FOR THE TRADE OF MOTOR

MECHANIC VEHICLE

WEEK PRACTICAL WORK TRADE THEORY ENGINEERING W/S CAL. &

NO. DRAWING SCIENCE

27. Removing and fitting of Clutch lining- types- Isometric view of Logarithm-
new pilot bearing. materials used- clutch pedal- definition-
Removing and fitting of bonded and riveted clurtch release charecteristics
ring gear in fly wheel. lining clutch plate bearing- fork and and mantisa.
Relining a clutch plate- construction, purpose clutch plate- free Reading of
checking condition of of damper spring- hand sketching of logarithm and
flywheel and pressure precautions while clutch assembly. antilogarithm
plate surface for relining a clutch plate tables..
reconditioning. calculation of
multiplication,
division,
powers etc. by
using log.
Applied
problems on
work, energy
and power.

28. Assembling of pressure Fluid coupling- - ----do--- Applied

plate- adjusting the description operation problems on
fingers- checking run out and advantages of work energy
of fly wheel and aligning using fluid coupling- and power.
clutch assembly with common trouble and
flywheel. remedy.

29. Dismantling a four-speed The purpose of gear Free hand Explanation of

sliding mesh gear box. box in vehicle- sketching of the horse power-
Cleaning inspection of description and arrangements of brake
parts for wear/ damage. function of a sliding gears inside the horsepower
Assembling the gear box mesh gear box- sliding mesh gear and indicated
and filling in oil. common troubles in box in different horse power
gear box and their gear positions. electrical
remedies. equivalent of
horse power.

30 . Dismantling cleaning Lubrication of gear Free hand Applied

and assembling of gear box, constant mesh sketching of problems in
 shift mechanism-
changing oil in gearbox,
studying gear ratios in
the gearbox.
31. Removing open type
propeller shaft from
vehicle,. Removing
universal joints-
cleaning, inspecting-
replacing of worn out
parts, reassembling and
fitting to vehicle. Special
precautions while
removing torque tube
drive shaft.
32. Removing rear brake
drums and adjusting the
wheel bearings in full
floating rear axles and
semi- floating axles
replacing oil seals in rear
axles.
33. Removing rear axles
assembly from vehicle,
dismantling, cleaning,
inspecting parts for wear
and damage, cutting
packings/gaskets,
removing tail pinion and
bearings-cleaning and
inspection of oil-seals
and bearings.
34. Checking tooth contact
in crown and opinion and
adjusting backlash.
Assembling the rear axle
and fitting rear axle
assembly on vehicles
and testing.
gear box- description shifter horsepower.
and advantages. mechanism and Calculation of
gear shift lever. speed ratios in
the 4 speed
gear box.
Universal joints and Use of drawing Ratios and
propeller shaft- open instruments, T- proportions-
and closed type square and simple
propeller shaft. Types drawing board. problems.
of universal joints- Construction of Gear ratios in
care and simple figures. gear box and
maintenance, rear axles.
constant velocity
joints-special features
and advantages.
Description and Construction of ---do---
purpose of different simple solid
types of rear axles- figures with
special feature and dimensions and
advantages of each titles- use of
type, lubrications of different types of
rear axles-reasons for scales.
oil in brake drums.
Description and Free hand Calculation of
functions of final drive sketching of areas of
assembly-crown different types of square,
wheel and tail pinion- rear axles. rectangles,
hypoid gear and its triangles,
lubrication Description circles, and
of differential and its regular
principle of operation. polygons.
Description and Free hand Same as in
function of differential sketching of work 33.
gears- types- tooth universal joints,
contact and back silencer brackets
lash, preloading and spring
adjustment . common shackless.
trouble and their
 remedy in axle
assembly.

Trouble shooting in the Description and ----do---- Calculation of

transmissions system of purpose of optional volume of
.35 vehicle- detecting noises fittings such as square,
from clutch, gear box, transfer case-free rectangular
universal joints, and rear wheel- power take off- and conical
axles assembly. common troubles in blocks, volume
Dismantling transfer these units and their of cylinder
case from vehicle- remedy care and solid and
cleaning, inspecting, maintenance. hollow.
replacing worn parts,
reassembling and fitting
to vehicle.

ACHIEVEMENTS FOR 10 WEEKS OF TRAINING FROM 26TH TO 35TH WEEK:

TRAINEES SHOULD BE ABLE TO:

1. . Do relining of clutch plate and adjust clutch paddle free play

2. repair defects in clutch assembly, gear box universal joints and rear axle.

Identify defects and noises in the transmission system and rectify.

4. Overhaul differential and able to adjust and check and do preload bearings.

5. Observe safety precautions.

8. PRIMARY ENGINE WORK:

36. Dismantling of Description of Free hand Calculation of

unserviceable engine- internal and external sketching of 4 volumes and weight of
cleaning, studying the combustion engines stroke cycle and cubes, hexagonal
parts in the engine and different types of 2 stroke cycle. prisms- shop
assembling the engine, I.C.engines, problems.
 practice in the use of important working
correct tools and right parts in the engine
procedure. the 4-stoke cycle.

37. Dismantling an Two stroke cycle, ----do--- ---do---

unserviceable engine, difference between 4
cleaning of parts in the store and 2 stroke
engine, measuring of cycle engine.
cylinder bore- crank Description of valve
pins, main journals, operating
pistons, studying mechanism and
valve-operating valve timing.
mechanism. Description and
function of valve
springs , guide,
tappets, valve seals
and locks.

38. Checking compression Description and Drawing of 3 Calculation of cylinder

pressure in a running function of cylinder views stepped wear- ovality taper
engine, dismantling the block, cylinder head and taper blocks and compression
cylinder head from the cylinder liners. in the 3rd angle ratios- problems on
engine decarbonising Reconditioning of projection. compression ratios.
the cylinder head, cylinder heads.
removing the valves
cleaning reassembling
and adjusting tappets.

39. Removing pistons and Description and ----do--- Center of gravity-

connecting rods from function of different example- problems
engine- dismantling types of pistons , involving center. of
cleaning, inspecting piston rings and gravity in vehicles.
checking clearance, piston pins- common
installing rings and troubles and remedy.
piston pins.

40. Removing connecting Description and Drawing of plan, Heat and

rod assembly- function of elevation and temperature-
cleaning, checking connecting rods side and side thermometer-
bearing clearances materials used for views of tapered centigrade and
replacing bearing connecting rodsbig hollow objects. Fahrenheit scales
shells, setting correct and end main their conversion- use
clearance, measuring bearing shells- piston of temperature
wear in crank pins and pins and locking measuring
main journals in crank method of piston instruments- their
 shaft. pins crank shaft- description and uses.
description function
and types. Common
troubles and
remedies.

41 Assembling crankshaft, Firing order of the ---do--- ---do---

main bearing, engine , crankshaft
connecting, rods and balancing.
piston assembly in the Description of the fly
engine. Fitting cylinder wheel and its
head and starting the function, crank case
engine and tuning up and oil sump.
engine for smooth,
slow speed running.

42. Checking and cooling Engine cooling Drawing the 3 Geometry- properties
system for methods, air and views in 3rd angle of angles, triangles,
overheating, cleaning water cooling- projection of a and circles.
radiators, dismantling, radiators pump curved object.
cleaning, assembling themostat and fans-
and testing water their description,
pumps, reverse care and
flushing the system maintenance.
and adjusting the fan Reason for engine
belt tension. overheating.

43. Studying the Need for lubrication Free hand Properties of angles,
lubrication, oil flow of engine parts- sketching of oil triangles and circles
system in engine. Friction, lubricant filters oil flow continued.
Over-hauling oil filters, and its properties, circuits oil
oil pump and setting lubrication system, pumps.
the pressure release types- full flow and
valves for correct oil by-pass flow system,
pressure. Maintenance components in
and repair in the lubrication system,
lubrication system in oil filters and pump
engine. -types, their special
feature and uses.
Types of lubricants
and their properties.

44. Simple repair in fuel Fuel feed system in ---do--- ----do---

feed system motor vehicles
overhauling of petrol description and
 pump, carburetors, fuellayout of the system.
filters and air cleaners.
Description,
Introduction to petrol operation,
injector. maintenance of
petrol pump, petrol
Repair to solex and SU filters and
carburetors adjusting carburetors. Types of
float level and slow fuel and their
speed adjustments properties. Petrol
studying the fuel flow injection system.
circuit in carburetor.
Types of carburetors,
special features , -
advantages, different
adjustments and
their purposes. Reading of Reading of simple
simple blue graphs.
prints.

45. Practice in engine tune Explanation of Exercises in blue Plotting and reading of
up in a vehicle. engine tune up, job print reading. graphs.
testing vacuum and description of
compression of engine, compression and
adjusting tappets vacuum testing
setting ignition timing description of ignition
and adjusting timing setting and
carburetor for slow slow speed
speeds. adjustment.

ACHIEVEMENTS FOR 10 WEEKS OF TRAINING FROM 36TH TO 45TH WEEK;

TRAINEES SHOULD BE ABLE TO:

i. Dismantling and assembling of different components of the engine.

ii. Repair operations of engine, valve refacing, valve seat cutting,
Descarbonising, fitting of bearings, piston rings, gudgeon pins.
iii. Overhauling of water pump, oil pump and petrol pump.
iv. Follow safety precautions while doing the above repairs.
v. Locate trouble and rectify in cooling, lubrication and fuel feed system of
the engine.
9.BASIC ELECTICAL AND ELECTRONICS WORK:

46. Practice in jointing Simple electrical Freehand sketching Electricity and its
wires and soldering. circuits series and of electrical symbols effects, static and
Forming simple parallel circuits, and drawing of dynamic electricity
electrical circuits. Identification of simple circuits AC & DC
Measuring of current, alternating current differences.
voltage and and direct current
residence. Cleaning meters. Insulators,
and topping up of a conductors types of
lead acid battery. resistance ohms
Testing battery with law and its
hydrometer. Cell application, Common
tester. Connecting electrical terms and
battery to charger. symbols primary
and secondary cells-
lead acid battery
description
construction
common troubles
and remedies

47 Studying electrical Description of Freehand sketching Magnets natural

circuits in the engine electrical circuits of ignition circuits of and artificial types
assembly checking ignition system and a vehicle poles of magnets
loose, open and the components sketching the Magnetic fields
short circuit in purposes of induction circuits lines
ignition circuits. coil, condenser, diagram of magneto
Cleaning and testing spark plugs. ignition
spark plugs. Common troubles in
Overhauling of ignition circuits and
distributor assembly. remedies
Checking and setting
ignition timing

48 Removing dynamo Description of Free hand sketching Definition of ampers

from vehicle- charging circuits of charging system volt and Ohm
dismantling, cleaning operation of dynamo Units of current ,
, checking for defects and regulator Unit voltage and
assembling and Ignition warning lamp resistance-
testing for motoring trouble and remedy
action of dynamo and in charging system Ohms law
fitting to vehicle.
 Removing starter
Motor from vehicle
and overhauling the
starter motor testing
of starter motor

Description of starter
motor circuit
-constructional
details of starter
motor . Solenoid Sketching starter Calculations based
switches . Common motor circuit and on Ohms Law.
troubles and solenoid switch
remedies in starter circuit
circuit

49 Identification of Introduction to Sketching of various Advanced

different Electronic electronics electronic devices calculation relating
Devices, Testing of Definition of resistor, used in motor to electrical circuits.
electronic device, capacitor and vehicles
fault finding in inductor and their
Electronic circuits principles of working.
and remedies. Different types of
Diodes, transistors,
power supply for
electronic circuit

ACHIEVEMENT : - After 4 weeks of training from 46th to 49 th week Trainee should be able to do
i. Practice in making wire connections and soldering.
ii. Forming series and parallel circuits in the motor vehicle
iii. Maintain and testing battery.
iv. Trace and rectify defects in wiring circuits
v. Overhaul Dynamo self starter
vi. Recognize basic electronic components viz. Diodes, capacitors,
Resistors, etc. and locate and rectify faults

vii. Follow safety precautions while doing the above repair

50 REVISION

51
52

WEEK PRACTICAL WORK TRADE THEORY ENGINEERING W/S CAL. &

NO. DRAWING SCIENCE

53 Further practice on
petrol engine repair
work

Removing a petrol
engine from a motor
vehicle dismantling Methods of engine Drawing of Problems on
cylinder head, repair fitting new riveted joints straight and bell
decarbonising checking liners types and Lap and Butt crank levers.
valves cutting valve advantages of liners, joints A freehand
seats, replacing worn procedure of sketching valve
guides and weak decarbonising and operating
springs , assembling valve reconditioning mechanism.
valves and cylinder in an engine
head and adjusting common defects in
tappet clearance in a valves valves
side valve engine reface and seat
angles. Reasons for
valve bouncing
_importance of
correct tappet
clearances

54 Removing piston and Reasons for cylinder Drawing of Meaning of

connecting rods from wear methods of locking devices of stress, strain,
engine checking reconditioning worn different types modulus of
cylinder bore wear for out cylinders. with dimensions . elasticity ,
ovality and taper. Precautions to be Freehand ultimate strength
Checking piston ring observed while sketching of examples
grooves and cleaning removing and fitting piston and
measuring piston size piston and connecting rod
removing gudge-on pin connecting rod
and Bushes checking assembly in cylinder
wear refitting new bore
bushes and pins

55 Checking main and Bearing types- their Drawing of Problems

connecting rod bearing, special advantages different types of involving stress,
 Checking connecting and special features couplings strain modulus
rod alignment, fitting bearing metals, Freehand of Elasticity and
new bearing shells and their composition, sketching of oil ultimate
setting correct oil bearing spread nip pumps. strength.
clearances . Checking and crush their
and cleaning oil purpose, Lubricating
passages in crank shaft pumps. Types and
and engine block over their special features.
hauling and testing oil By pass and full flow
pumps . Cleaning oil oil filters
filters

56 Cleaning fuel tank and A.C. Mechanical Drawing of Factors of safety

checking for leaks in Petrol pump different types of examples of
fuel tank. Overhauling Description and couplings. different types of
petrol pumps testing operation electrical stresses.
petrol pumps for correct pump (S.U . Pump)
pressure vacuum and construction ,
delivery operation and care
and maintenance.

57 Further practice in Special feature of Problems

removing, dismantling, solex and S.U. involving factor
cleaning , inspecting, carburetors, petrol of safety and
replacing, worn parts flow circuits in these different types of
and assembling and carburetors stresses.
fitting of solex and S,U. functions of each
carburettors. Practice in component in the
adjusting the slow carburettors,
speed screw and setting common troubles and ------------
idling speed of engine remedies. do-------------

58 Removing valve timing Valve timing gears Drawing of Hydraulics-

cover checking and Timing marks, timing bearing pulleys elementary
correct setting of valve chains and chain with dimensions, principles
timing replacing timing tensioners effects Free hand incompressibility
chains. Checking of stretched chains sketches of valve of liquids-
camshaft, and play and checking backlash in timing diagram Pascals Law
correcting it timing gears and Archimedes
Principles, Law
of floatation
Problems
involving
properties of
fluids
59 Assembling piston and Engine Assemble Problems on
connecting rod procedure as various
assembly, crank shaft , recommended by Trigonometric
camshaft and timing Makers Precautions ratios , Reading
gears , fitting cylinder to be observed while of Trigonometric
head and checking assembling engine tables. Problems
valve tappet clearance , components, on height and
starting and adjusting checking and distance
engine speed adjusting engine idle ----do--------
speed with vacuum
gauge

60 Removing inlet and Inlet and exhaust Freehand

exhaust manifold manifold sketching of
cleaning carbon and description and sectionised view
checking for warpage purpose of manifolds, of silencer box
and crack checking exhaust pipes and exhaust pipes
heat control valve in silencer box. and tail pipe
exhaust manifold for Constructional details
proper working. and purpose and
Removing and replacing types of silencers.
of new manifold gaskets Common troubles in
and checking leakage of exhaust system and ----------
exhaust gases. The their remedy do------------
removing and cleaning
silencer and tail pipe
and refitting

2. Trouble shooting in
cooling Lubrication fuel
feed and ignition
systems,

61 Troubles shooting in Step by step method Freehand Properties of

cooling and lubrication of locating troubles in sketching of gases and
system. Checking up the lubrication and piston and composition of
and connecting oil and cooling system. connecting rod gases.
water leaks changing Reasons for engine Compression
defective packing and overheating flow test pressure
gaskets. Testing radiator rate recommended
for leaks testing for radiator . Crank
thermostat case dilution and
crank case ventilation

62 Trouble shooting in fuel Systematic ----------do---------- Applied

 feed and ignition system procedure of trouble problems on gas
starting engine- tracing in fuel feed pressure ,
checking air leaks. and ignition system in compression
Repairing of silencer automobile engine ratios and horse
and tail pipes. Adjusting Reasons for power
the slow speed of the excessive fuel and oil
engine with vacuum consumption
gauge.

ACHIEVEMENT FOR 10 WEEKS FROM 53RD TO 62ND WEEK

TRAINEES SHOULD BE ABLE TO ;-

i. Remove petrol engine from vehicle,. Dismantle cylinder head, piston connecting
rod, crank shaft camshaft etc.
ii. Decarbonise cylinder head, to cut, repair and grind valve seat
iii. Check main and connecting rod bearing. Fit new shell bearing in main and big end,
set oil clearance.
iv. Clean ring grooves , set piston rings and assemble
v. Overhaul oil pump , oil filters, fuel filter, fuel pump and to set correct pressure and
vacuum of fuel pump
vi. Overhaul carburetor repair , test and adjust.
vii. Locate troubles and rectify them in cooling , lubrication, fuel feed and ignition
system.
viii. Follow safety precautions

ix. Set ignition timing and valve timing

3. DISEL ENGINE
REPAIR WORK

63 Practice on History and Freehand Lubricants _

unserviceable diesel development of sketching of types specials
engine removing compression ignition combustion purpose,
jammed nuts, broken engines. chamber of viscosity , effects
studs and reconditioning Classification of C.I. different types of temperature
damaged threaded Engine , Advantages on viscosity High
holes removing and disadvantages detergent oil and
cylinder head, over petrol engines its applications
connecting rods and constructional details
pistons, cleaning, of single and Multi
inspecting and refitting cylinder engine
them, Writing reports of
damaged parts and
repairs to be carried out
 on engine,

64 Practice in starting and The four stroke and Freehand Lubricants

stopping of stationery two stroke diesel sketching of four types viscosity
and a transport vehicle engine uniflow and stroke cycles and and effects of
engine, General loop scavenging two stroke cycle temperature on
maintenance of engines constant pressure engines viscosity. High
checking oil, fuel, and constant volume detergent oils
water levels and cycles. Diesel cycle and their
accessories of diesel indicator diagrams. application
engines

65& 66 Removing cylinder Specification of Freehand Gear and belt

head, pistons diesel engine . sketching of fuel drives
connecting rods, Materials used for feed system in problems on
cleaning, decarbonising different engine parts diesel engine gear and belt
and cylinder head , working and diesel fuel drives
checking, piston clearances , filters
clearance, dismantling compression ratios
valve assemble , valve timing of diesel
cleaning , checking and engines crankshaft ,
reconditioning valves , connecting rods,
assembling valves and piston , valves and
adjusting tappet valve operation . The
clearances, assembling combustion
engine parts and chambers types ,
starting the engine after advantages and
repairs and adjusting disadvantages ,.
slow speeds. Heater plugs types
uses

67 Bleeding fuel lines for Fuels used in diesel Freehand gear and belt
Air locks. Repairing fuel engine specification sketching of drives
leaks in the pipe lines of diesel fuels diesel fuel feed problems on
and unions. Cleaning of importance of clean system and fuel gear and belt
oil and Air Filters in fuel general layout of filters drive
diesel engine the fuel feed system
in the stationary and
transport diesel
Engine

68 Cleaning and servicing Types of fuel injection Freehand Gear and bolt
of primary fuel filters systems air sketching of drives
and pressure , stage injection and air less diesel fuel feed problems on
filters removing feed injection . Fuel feed system and fuel gear and belt .
 pump dismantling, pumps description filters Torque
cleaning , reassembling operation common definition, its
refitting and testing and troubles and relation with
feed pump remedies forces on engine
mounting,
steering gear
box and torque
wrench

69 Dismantling an Need for governors Free hand and Inclined plane

unserviceable fuel types pneumatric and sketching of uses- example
injection pump clearing mechanical components from and applied
inspecting, studying governors. The assemblies . problems
parts and reassembling. pumps phasing and
Removing F.I pump from calibration of pumps.
running engine Checking and fixing
changing oil in it cutting injection timings.
back to engine testing Governors types their
the governor and setting description and
injection timing. operation. Starting
and adjusting slow
speed.

70. Testing injection for Injector nozzles- Free hand Screws and
missing on the vehicle- types description, sketching of fuel screw jack.
removing, dismantling, operation testing of injectors of Problems on a
cleaning, inspecting injectors. Special; different types. screw jack.
replacing defective parts features of pintle
reassembling the nozzles.
injectors and testing
them.

71. Trouble shooting with Need for governors- Free hand Area of circle,
special reference to types- pneumatic and sketching of fuel ellipses, volume
adjustments in the fuel mechanical injectors of and weight of
feed system- checking governors, different types. regular solids
exhaust gases- and maintenance of and spheres.
adjusting the governor governors reason for
slow speed adjustment black, white and blue
and venturi control smoke in exhaust.
adjustments. Checking
oil, fuel water and
exhaust gas leaks and
correcting them.
72.. Further practice on Timing of injection in Free hand -do-
cleaning and servicing single cylinder sketching of
of injectors, adjustment engine.flange type single element
of tappets and setting pumps and their flange mounted
injection timing in special features. pump.
engines(Both stationary Care and
and transport vehicles maintenance of
engines. single cylinder
pumps.

73. VISIT TO LOCAL GARAGES AND INDUSTRIES- DEMONSTRATION OF

SERVICE STATION EQUIPMENTS:

ACHIEVEMENTS FOR 11 WEEKS FROM 63RD TO 73RD WEEKS

TRAINEES SHOULD BE ABLE TO:

1. Bleed and air in the diesel fuel system, check and correct fuel leak and
service diesel fuel fitters..

2. Remove clean and test fuel injectors and find out the defective/ missing
injectors

3. Overhaul fuel feed pump.

4. Check and correct injection timing in single and multi-cylinder engine and
know service station equipment.

5. Follow necessary safety precautions.

5. ELECTRICAL/ ELECTRONIC ACCESSORIES REPAIR WORK:

74. Studying the light Description of light Free hand sketching Measurement of
circuit- test bulbs, circuits and different of light circuit of a electrical power-
align head lamps, components in light vehicle with watt and kilowatt
find out short and circuits- description electrical symbols. relationship with
open circuits in the and function of each. horse power.
 light wiring- replacing Prefocussed bubles
fuses testing the tail and sealed beams.
and brake lights in Fuses and their
vehicle. importance.

75. Removing and Electric horn circuit- Freehand sketching Applied problems
electrical horn from description of electric of horn circuit, involving watt,
vehicle- horn- operation of drawing the kilowatt, volt,
dismantling.,cleaning relay and horn sectional view of ampere and horse
point, testing wires, switches. Common horn. power.
assembling the horn troubles and their
and adjusting the remedies.
horn for correct
sound, tuning double
horn, repairing of
horn relay and horn
switches.

76. Removing a wiper Description and Free hand sketching Applied problems on
motor dismantling, operation of electric of wipier motor resistance in the
cleaning, inspecting, wiper motor care and circuit. series ands parallel
repairing electrical maintenance. circuits.
wiper motors, Common troubles
assembling and and remedies.
fitting, setting blades
for correct
functioning.

77. Studying the wiring Flasher circuit its Sketching the Problems on
circuit of traffic signal description and flasher light circuit resistance in series
flasher light circuit operation common, with parallel circuits.
tracing defects in the troubles in the circuit symbols.freehand conductors and
tracing defects in the and remedies sketching of insulators- example
flasher circuit .magnetors ignition magneto ignition and uses.
replacing fuse system- description circuit.
bulb.removing and operation
dismantling cleaning advantages rotating
and assembling armature and
magnetos- adjusting flywheel magnetos
gap in points- testing special features.
magnetos.

78. Studying the Description and Freehand sketching Conductors and

alternators in vehicle- operation of of alternator insulators- type and
removing and refitting alternators in vehicle. charging unit. uses.
 alternator in vehicle Advantages of using
precautions to be alternators. Common
observed while troubles and
connecting battery in remedies.
alternation circuit.
General
maitanence,adjusting
fan belt play/ tension

79. Further practice in Positive and negative Freehand sketching Explanation of open
dismasntling earthing of battery- of braker plate and short circuits-
cleaning, testing and advantages and assembly and locating short
reassembling of precautions. advance and retard circuits with the help
starter motor and Electrical measuring plate of meters.
generators . meters their use care
overhauling of and maintenance.
distributor assembly.

WEEK PRACTICAL WORK TRADE THEORY ENGINEERING W/S CAL.

NO. DRAWING &
SCIENCE

80 Trouble tracing in Iucas- color code for Free hand -do-

electrical wiring of the wiring in the ;motor sketching of
vehicle. Use of resistance vehicles. Binary complete wiring of
meter, voltmeter and numbers logic gates, the vehicle.
ammeter. Attending amplifiers and multi
mechanical repairs to vibrators.
electrical accessories
such as fuel gauge,
temprature gauge, brake
light switch, and solenoid
switch.

81 Tracing fault in different Principle of electronic -do- -do-

electronic ignition ignition advantages
systems and rectification types of electronic
ignition system as
capacitor discharge
ignition system
thyristor based ignition
system and
microprocessor based
 contactless ignition
system.

ACHIEVEMENTS FOR 8 WEEKS FROM 74TH TO 81ST WEEK:

TRAINEES SHOULD BE ABLE TO:

1. Trace fault in electrical wiring and accessories and rectify them.

2 Trace faults in electronic circuits and accessories and rectify them.

3 Follow necessary safety precautions.

1. DRIVING PRACTICE:

82 Practice in straight Motor vehicle Act :

to driving on wide
88 roads. Driving Driving road rules
through lanes and Road traffic signals
curves. Practice in hand signals.
reversing. Practice Precautions to be
overtaking another taken while
vehicle. Practice in overtaking, reversing
driving through sand driving through
and wet surface. narrow lanes, curves
Practice in parking and slopes.
vehicles, paralled
parking and diagonal
parking. Practice in
driving over slope
and down hill.
Practice in driving
over narrow bridges.

Achievements for 7 weeks from 82nd to 88th week :-

Trainees should be able to

i. Drive and road test a Motor vehicle.

ii. Follow necessary safety precautions.

7. SYNCHROMESH GEAR BOX AND TRANFER CASE 4 WHEEL DRIVE PREPARE WORK :

89 Dismantling a Synchromesh gear Free hand sketches Calculation of area ,

 Synchromesh gear boxes advantages of Synchromesh volume and weight o
box- cleaning, description , unit. f hollow and solid
inspecting parts operation in different bodies.
replacing worn out gear positions.
defective parts Common trouble and
assembling and remedies. Types of
testing for correct Synchromesh gear
performance, boxes- their special
identifying noises features.
from gear box and
rectifying.

90 Removing transfer Description and Free hand sketching Revision of ratio and
case from the vehicle operation of 4 wheel of intermediate shaft proportion applied
dismentling, drive. The purpose of and shifter problems in 4 wheel
cleaning, inspecting transfer case and the arrangement. drive.
parts, replacing worn/ arrangement of
damaged parts, re- shifting mechanism.
assembling, testing Common troubles
and fitting. Repairing and remedies.
of 4 wheel drive
shifter mechanism.
Overhauling of front
wheel drive propeller
shaft unit.

91 Trouble shooting in Systematic Free hand sketching Revision of ratio and

& the transmission procedure of locating of intermediate shift proportion, applied
92 system identifying noises from the and shifter problems in 4 wheel
the noises from transmission units arrangement. drive.
clutch, assembly, common troubles in
gearbox, universal the system and their
joints- rear axle drive remedies.
and the differential
unit. Checking oil
leaks and correcting.

Achievements for 4 weeks from 89th to 92nd week:-

Trainees should be able to

i. Overhaul a Synchromesh gear box.

ii. Overhaul a transfer case.
iii. Follow necessary safety precautions
8. ENGINE FAULT DYGNOSIS INCLUDING ENGINE SCANING :

93 Diagnosing noises Different types of Code of practice.

& and faults in engine noises coming from General
and rectifying them engine bearing Engineering
94 checking under knock, gudgeons pin Drawing.
carriage noises and knock, pinging,
rectifying them. Road tappet noise,
testing vehicle. chipping noise.

95 Test Duel angle, Introduction to

& Engine tuning and engine tuning, study
exhaust gases engine torque, fuel
96 analysis. consumption, duel
Demonstration of angle exhaust gases
engine efficiency with etc.
the help of
Dynamometer

Achievements for 4 weeks from 93rd to 96th week :

Trainees should be able to

i. Diagnose noises and faults in engine and rectifying them.

ii. Diagnose, faults in engine with the help of computerized machines.
iii. Follow necessary safety precautions.

9. SERVICESTATION EQUIPMENTS AND WHEEL BALANCING :

97 Repairs of jacks, Garage equipment Sketching of screw Description and

& grease guns, oil construction and jacks, grease guns operation of an
98 spray guns, other operation of air and oil spray guns. alternator.
spray guns and other compressor, spark
shop floor plug tester, valve
equipment. Care and refacer, injector
maintenance and tester, drilling
lubrication of air machine care and
compressor, valve maintenance.
refacer, drilling
machine, injector
tester , spark plug
tester.

99 Wheel balancing and Importance of wheel

 use of equipment. balancing. Details of
equipment and
method.

Achievements for 3weeks from 97th to 99th week :

Trainees should be able to

i. Repair jacks, grease guns, oil spray guns and other shop floor equipment.
ii. Operate the wheel balancer.
iii. Follow necessary safety precautions.

10. CAR AIR CONDITIONING SYSTEM REPAIR AND MAINTENANCE :

100 Fitting and repairing Introduction to Air

& air conditioning unit conditioning system
101 in motor vehicle. in Motor vehicle.
Tuning engine with Compatibility of Air
respect to the Air conditioning system
conditioning. with vehicle engine.

Achievements for 2 weeks from 100th to 101st week :

Trainees should be able to

i. Undertake servicing, rectification and installation of Air conditioning system in Motor

vehicles.

ii. Follow necessary safety precautions.

102 REVISION AND ALL INDIA TRADE TEST.

&
104