ITI's which provides courses for Mechanic Auto Electrical & Electronics

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. Interaction with health centre and fire service station to provide demo on First aid and Fire safety, Use of fire extinguishers

Occupational Safety & Health Importance of Safety and general Precautions to be observed in the shop. Basic first aid, safety signs - for Danger, Warning, caution & personal safety message.

3

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

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.

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 Sheet metal joints - Hem & Seam Joints Fastening Methods - Riveting, soldering, Brazing. Fluxes used on common joints.

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, circuit breakers.

Basic electricity, Electricity principles, Ground connections, Ohm's law, Voltage, Current, Resistance, Power, Energy.

9

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 and Diagnose the cause(s) of excessive Key-off battery drain (parasitic draw) and do corrective action.

Description of Chemical effects, Batteries & cells, Lead acid batteries & Stay Maintenance Free (SMF) batteries, Magnetic effects, Heating effects, Thermo-electric energy, Thermisters, Thermo couples, Electrochemical energy, Photovoltaic energy, Piezo-electric energy, Electromagnetic induction, Relays, Solenoids, Primary & Secondary windings, Transformers, stator and rotor coils.

10

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.

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.

11

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

Introduction to welding and Heat Treatment. 

12

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 Introduction to Hydraulics & Pneumatics

13

Identification of different type of Vehicle. Demonstration of vehicle specification data; Identification of vehicle information Number (VIN).

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. Observe and report the reading of Tachometer, Odometer, temp and Fuel gauge under ideal and on load condition. 

Introduction to Engine: Principle & working of 4-stroke diesel engine (Compression ignition Engine (C.I)), Principle of Spark Ignition Engine (SI), difference between C.I engine and S.I Engine, Technical terms used in engine, Engine specification.

2

Practice to identify components and their locations indicated on the wiring diagram. Practice to identify the power source, ground connection, and controls for electrical circuits using a wiring diagram.

Electrical and Electronic Components: Switches- Description of Normally open, Normally closed, single pole single throw switch (SPST), ganged, and mercury switches used in Automobile circuit. Description of Relay, ISO Relays, Solenoids, Buzzers.

3

Diagnosis and remedy for-Speedometer shows no operation, fuel level meter shows no operation, coolant temp meter shows no operation, Oil pressure light shows no lighting. 

Wiring and circuit diagrams- Automotive Wiring- difference between primary wiring and secondary wiring. Comparison between solid and stranded primary wire.

4

Check and replace ignition coil, overhauling Distributor Assembly. Checking ignition timing, Checking & changing a spark plug, Removing & replacing contact points Diagnosis- Possible causes and remedy for Engine cranks, but will not or hard to start, Poor fuel economy or engine performance.

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, Contact breaker system, ballast resistor coil, Dwell angle, Spark timing.

5

Removing starter motor from vehicle, and Performance test for pull-in test, Hold-in test, pinion (plunger) return test, No-load performance test.

Starting system- purpose of starting system, Staring system components, Starter motor principles, study of starter control circuits

6

Checking a charging system for the cause of undercharge, No charge, and over charge conditions. Removing & replacing an alternator, Inspection of rotor for ground, open circuit – field coil resistance, slip ring surface, Fan, bearing.

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. 

7

Identification of EDC components, sensors, Testing of sensors and actuators. Identification of various components of MPFI system

Electronic Diesel control- Electronic Diesel control systems, Common Rail Diesel Injection (CRDI) system, Hydraulically actuated electronically controlled unit injector (HEUI) diesel injection system. Sensors, actuators and ECU (Electronic Control Unit) used in Diesel Engines

8

Identification of various sensors installed in engine & its mounting. Testing of Temperature sensor, Pressure senor, potentiometer, magnetic induction sensor, cam shaft sensor, crankshaft position sensor. 

EFI sensors- Description, location and function of 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.

9

Inspection of power steering control module circuit. Checking & adjusting power steering fluid, Pressure testing a power steering system, Flushing a power steering system.

Steering, suspension and Brakes, Electronic control transmission

10

Identification of Air conditioning components, Performance test on A/c unit, Checking Charged state of refrigerant, Inspecting & adjusting an engine drive belt, Replacing an engine drive belt.

Heating Ventilation Air Conditioning (HVAC)

11

Trace the light circuit - test bulbs, align head lamps, Aiming headlights. Changing a headlight bulb, Checking of a head light switch and to replace if faulty.

Lighting system, Lamps/light bulbs, Lamp/light bulb information, LED lighting, Headlights-description of standard sealed beam, halogen sealed beam, composite and High intensity discharge (HID) headlights

12

Trouble shooting and remedy for Horn No horn operation, poor sound quality, horn sounds continuously and to replace the horn if faulty. Familiarization of car radio wiring and speaker circuits Diagnose automatic seat belt systems, Diagnose air bag system and service warnings.

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. Importance of E/E Architecture.