ITI's which provides courses for Mechanic (Diesel)

Sem. I

Sr. No.

Subjects of Study

Trade Practical

Trade Theory

1

Familiarisation with institute, Job opportunities in the automobile sector, Machinery used in Trade. Types of work done by the students in the shop floor

Admission & introduction to the trade: Introduction to the Course duration, course content, study of the syllabus. General rule pertaining to the Institute, facilities available–Hostel, Recreation, Medical and Library working hours and time table

2

Practical related to Safety and Health, Importance of maintenance and cleanliness of Workshop.

Occupational Safety & Health: Importance of Safety and general Precautions to be observed in the shop.

3

Practice using all marking aids, like steel rule with spring calipers, dividers, scriber, punches, Chisel etc.,

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.

4

Measuring practice on Cam height, Camshaft Journal dia, crankshaft journal dia, Valve stem dia, piston diameter, and piston pin dia with outside Micrometers.

Systems of measurement, Description, care & use of - Micrometers- Outside and depth mirometer, Micrometer adjustments, Vernier calipers, Telescope gauges, Dial bore gauges, Dial indicators, straightedge, feeler gauge, thread pitch gauge, vacuum gauge, tire pressure gauge.

5

Practice on General cleaning, checking and use of nut, bolts, & studs etc., Removal of stud/bolt from blind hole.

Fasteners- Study of different types of screws, nuts, studs & bolts, locking devices, Such as lock nuts, cotter, split pins, keys, circlips, lock rings, lock washers and locating where they are used.

6

Practice on Marking and Drilling clear and Blind Holes, Sharpening of Twist Drills Safety precautions to be observed while using a drilling machine.

Drilling machine - Description and study of Bench type Drilling machine, Portable electrical Drilling machine, drill holding devices, Work Holding devices, Drill bits.

7

Practice on making Rectangular Tray. Pipe bending, Fitting nipples unions in pipes. Soldering and Brazing of Pipes. 

Sheet metal - State the various common metal Sheets used in Sheet Metal shop Sheet metal operations - Shearing, bending, Drawing, Squeezing

8

Practice in joining wires using soldering Iron, Construction of simple electrical circuits, Measuring of current, voltage and resistance using digital multimeter, practice continuity test for fuses, jumper wires, fusible links, and circuit breakers.

Basic electricity, Electricity principles, Ground connections, Ohm's law, Voltage, Current, Resistance, Power, Energy. Voltmeter, ammeter, Ohmmeter Mulitmeter, Conductors & insulators, Wires, Shielding, Length vs. resistance, Resistor ratings 

9

Diagnose series, parallel, series parallel circuits using Ohm’s law, Check electrical circuit with a test lamp, perform voltage drop test in circuits using multimeter, measure current flow using multimeter/ ammeter, use of service manual wiring diagram for troubleshooting

Fuses & circuit breakers, Ballast resistor, Stripping wire insulation, cable colour codes and sizes, Resistors in Series circuits , Parallel circuits and Series-parallel circuits, Electrostatic effects, Capacitors and its applications, Capacitors in series and parallel.

10

Cleaning and topping up of a lead Acid battery, Testing battery with hydrometer, Connecting battery to a charger for battery charging

Description of Chemical effects, Batteries & cells, Lead acid batteries & Stay Maintenance Free (SMF) batteries, Magnetic effects, Heating effects,

11

Identify and test power and signal connectors for continuity, Identify and test different type of Diodes, NPN & PNP Transistors for its functionality

Basic electronics: Description of Semi conductors, 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.

12

Practice to make straight beads and Butt, Lap & T joints Manual Metal Arc Welding.

Introduction to welding and Heat Treatment

13

Practice on Liquid penetrates testing method and Magnetic particle testing method.

Non-destructive Testing Methods- Importance of Non-Destructive Testing In Automotive Industry, Definition of NDT, Liquid penetrate and Magnetic particle testing method – Portable Yoke method

14

Identification of different type of Vehicle.

Auto Industry - History, leading manufacturers, development in automobile industry, trends, new product.

Sem. II

Trade Practical

Trade Theory

1

Identification of parts in a diesel engine of LMV/ HMV. Practice on starting and stopping of diesel engines.

Introduction to Engine

2

Overhauling of cylinder head assembly, Use of service manual for clearance and other parameters, Practice on removing rocker arm assembly manifolds.

Diesel Engine Components, Valves & Valve Trains

3

Overhauling piston and connecting rod Assembly. Use of service manual for clearance and other parameters

Description & functions of different types of pistons, piston rings and piston pins and materials.

4

Overhauling of crankshaft, Use of service manual for clearance and other parameters

Description and function of Crank shaft, camshaft, Engine bearings- classification and location – materials used & composition of bearing materials- Shell bearing and their advantages

5

Checking of flywheel and mounting flanges, spigot, bearing. Check vibration damper for defects, Practice on removing cam shaft from engine block, Check for bend & twist of camshaft.

Description and function of the fly wheel and vibration damper. Crank case & oil pump, gears timing mark, Chain sprockets, chain tensioner etc.

6

Cleaning and Checking of cylinder blocks Surface for any crack, flatness, Measure cylinder bore for taper & ovality, clean oil gallery passage and oil pipe line, Bore

Description of Cylinder block, Cylinder block construction, and Different type of Cylinder sleeves (liner).

7

Reassemble all parts of engine in correct Sequence and torque all bolts and nuts as per workshop manual of the engine. Engine component procedure

Engine assembly procedure with aid of special tools and gauges used for engine assembling. Introduction to Gas Turbine, Comparison of single and two stage turbine engine, Different between gas turbine and Diesel Engine.

8

Practice on Checking &Top up coolant, Draining & refilling coolant, Checking /replacing a coolant hose, Testing cooling system pressure, Practice on Removing & replacing radiator/thermostat. Inspect the radiator pressure cap, Testing of thermostat.

Need for Cooling systems, Basic cooling system components, Need for lubrication system

9

Practice on Dismantling air compressor and exhauster and cleaning all parts – measuring wear in the cylinder, reassembling all parts and fitting them in the engine

Intake & exhaust systems, Intake system components, Exhaust system components

10

Practice on removing & Cleaning fuel tanks, checking leaks in the fuel lines, soldering & repairing pipe lines and Unions, brazing nipples to high pressure line studying the fuel feed system in diesel engines, draining of water separators.

Diesel Fuel Systems, Diesel fuel system components, Electronic Diesel control,

11

Practice on Start engine adjust idling speed and damping device in pneumatic governor and venture control unit checking Performance of engine with off load adjusting timings.

Marine & Stationary Engine

12

Monitoring emissions procedures by use of Engine gas analyser or Diesel smoke meter

Emission Control, Types of emissions

13

Practice on removing alternator from vehicle dismantling, cleaning checking for defects, assembling and testing for motoring action of alternator & fitting to vehicles.

Description .of charging circuit operation of alternators, regulator unit, ignition warning lamp- troubles and remedy in charging system

14

Practice on troubleshooting in LMV/HMV for Engine Not starting –Mechanical & Electrical causes, High fuel consumption, Engine overheating, Low Power Generation, Excessive oil consumption, Low/High Engine Oil Pressure, Engine Noise.

Troubleshooting : Causes and remedy for Engine Not starting – Mechanical & Electrical causes, High fuel consumption, Engine overheating, Low Power Generation, Excessive oil consumption, Low/High Engine Oil Pressure, Engine Noise.