ITI's which provides courses for Mechanic Repair & Maintenance of Heavy Vehicles

Sem. I

Sr. No.

Subjects of Study

Trade Practical

Trade Theory

1

Familiarization with institute, Importance of the trade Machinery used in Trade. Types of work done by the students in the Institute-shop floor of the Institute.

Introduction to Central Outer Vehicle Acts & Rules. General introduction to the course-duration of the course & course content. Study of the Syllabus General Rules pertaining to the Institute Facilities available hostel recreation and medical facilities library working hours-time table.

2

Description of safety equipment their use safety rules to be observed in an Automobiles repair shop. Accident & their causes-up keep of fire extinguishers.

Importance of safety & general precautions to be observed in the shop, fire extinguishers used for different types of fire storing & handling of inflammable materials elementary first aid.

3

General servicing of vehicles washing, cleaning, oiling, greasing and lubrication of vehicle.

General description of motor vehicles-major assemblies description location and function of each locking methods and devices used in vehicles hydraulic and screw jacks hydraulic hoist & air compressor- their description & uses.

4

Inspection of under carriage of vehicle

-do-

5

Removing wheels from vehicle, dismantling tyres and tubes checking puncture assembling inflating to correct pressure.

Description of wheels and tyres-types selection of tyres, ply rating, inflation pressure and carrying capacity, storage of tyres.

6

Inspection the frame checking alignment of frame servicing of spring replacing new bushes in shackle pins changing hushes in shock absorbers

Frames-description and function common troubles conventional suspension system.

7

Removing kingpins and bushes replacing new bushes & plus after removing bushes & rings, lubrication of king pin bushes in the front, independent suspension system.

Description of different types of independent suspension system, special features in each system maintenance and lubrication of front suspension system.

8

Inspect and adjust steering linkages, after replacement of worn parts alignment of steering wheels with respect to front wheel, check and correct toe-in.

Description of different types of steering boxes (latest type of steering boxes), special features of each adjustments repair and maintenance of steering and boxes power steering description and its advantages

9

Inspect and overhaul steering boxes adjusting steering gear backlash, and end play check and adjust toe-in, camber angles checking kingpin angle & caster angle with special gauges.

Description of Ackerman's angle, caster, camber toe-in and toe-out on turns, purpose and effects of these Angles.

10

Adjusting brake pedal play dismantling wheel break assembly cleaning and inspecting adjusting brake shoes for proper clearances, bleeding hydraulic brakes & Disk brakes.

Arrangement of brakes in cars and trucks-description of hand brakes, its purposes layout of mechanical and hydraulic breaking system in cars.

11

Removing master cylinder, dismantling cleaning and inspection of parts assembling and testing bleeding the braking system after cleaning the pipelines.

Master cylinders including the tandem master cylinder, special features of each function- common troubles & remedy.

12

Dismantling wheel brake assembly removing old lining & fitting new lining on the brake shoe removing, cleaning of brake drums inspecting wheel cylinders & brake drums-fitting new cups and brake hosepipes, reassembling adjusting wheel bearing ad testing adjusting all 4 wheel brakes.

Brake lining types of uses relining the brake shoes precautions to be observed wheel cylinders description function and types brake fluids. Description and use types of fluids used.

13

Bleeding of vacuum assisted hydraulic brakes removing & refitting of vacuum boosters-repairs to pipelines-adjusting the brakes in vacuum assisted hydraulic brakes.

Description and advantages of vacuum assisted hydraulic brakes - special features -common troubles in vacuum assisted hydraulic brakes.

14

Adjusting Air brake srepair to tank unit, air compressor, wheel brake adjuster locating air leaks in the brake lines and rectifying – general maintenance and care

Description of air brake system. Major components in Air brake system.

15

Trouble tracing in braking system of a heavy vehicle adjusting brakes and balancing all four wheel brakes, precautions to be observed while testing brakes points to be remember while preparing the vehicle for brake certificate.

Brake testing efficiency of brakes braking distance, weight transference during braking a vehicle common trouble in brakes & their remedies.

16

Adjusting clutch pedal play-removing gearbox and clutch assembly from Heavy Vehicle. Dismantling clutch assembly, cleaning inspecting parts.

Lay out of transmission system-description of single plate clutch-different types of clutches used in Vehicles their description, special features and advantages.

17

Removing & fitting of new pilot bearing, removing & fitting of ring gear in fly wheel relining a clutch plate checking condition of flywheel and pressure plate surface for reconditioning.

Clutch linings types materials used bonded & riveted lining clutch plate constructions, purpose of damper spring precautions while relining a clutch plate.

18

Assembling of pressure plate adjusting the fingers checking run out of fly wheel and aligning clutch assembly with flywheel.

Fluid coupling description operation & advantage of using fluid coupling common troubles and remedy.

19

Dismantling cleaning and assembling of gearshift mechanism changing oil in gear box studying gear ratios in the gear box.

Lubrication of gearbox constant mesh gearbox description and advantages.

20

Dismantling a synchromesh gear box, cleaning, inspecting parts replacing worn out defective parts assembling & testing for correct performance identifying noises from gear boxes and rectifying.

Synchromesh gear box advantages description, operation in different gear positions common trouble and remedy types of synchromesh gearboxes their special features.

21

Removing rear brake drums and adjusting the wheel bearings in full floating rear axles & semi floating axles, replacing oil seals in rear axles.

Description and purpose of different types of rear axles special features and advantages in each type lubrication of rear axles reasons for oil in brake drum

Project Work

Sem. II

Trade Practical

Trade Theory

 1

Removing rear axle assembly from vehicle, dismantling, cleaning, inspecting parts for wear and damage, cutting packings/gaskets removing tail pinion and bearings cleaning and inspection of oilseals and bearings

Description & functions of final drive assembly crown wheel and tail pinion hypoid gear, Bevel type and worm & worm wheel and its lubrication descriptions of differential and its principle of operation.

 2

Checking tooth contact in crown land pinion and adjusting back-lash-assembling the rear axle assembly on vehicles and testing.

Description and function of differential gears types tooth contact and back lash, preloading adjustment. Common troubles and their remedy in rear axle assembly.

 3

Trouble shooting in the transmission system of vehicle, detecting noises from clutch, gear box, universal joints and rear axle assembly.

Description and function of differential gears types tooth contact and back lash, preloading adjustment.

 4

Dismantling of unserviceable engine of heavy vehicle cleaning studying the parts in the engine and reassembling the engine.

Description of internal and external combustion engineers, different types of I.C. engines. Important working parts in the engine, the 4-stroke cycle of operation.

 5

Dismantling an unserviceable engine, cleaning of parts in the engine, measuring of cylinder bore-crank pins main journals pistons studying valve-operating mechanism.

Description of valve operating mechanism & valve timing description and function of valve spring guide tappets, valve seals and locks.

 6

Checking compression pressure & vacuum in a running engine of heavy vehicle dismantling the cylinder.

Description & function of cylinder block-cylinder head cylinder liners reconditioning of cylinder heads.

 7

Removing pistons and connecting rods from engine, dismantling, cleaning, inspecting, checking clearances installing rings and pistons pins.

Description & functions of different types of pistons & connecting rod attachment, piston rings and piston pins common troubles and remedy

 8

Removing connecting rod assembly, cleaning & checking bearing clearances, replacing bearing shells, setting correct clearances.

Description & functions of connecting rod. Materials used for connecting rods-big end and main bearings shells piston pins and locking methods of piston-pins crank shaft description function & types common trouble & remedy.

 9

Assembling crankshaft, main bearings, connecting rods and piston assembly in the engine, fitting cylinder head and starting the engine and tuning up engine for smooth slow speed running with the help of using torque wrench, at proper torque & sequence.

Firing order of the different types engine and crankshaft balancing description of the flywheel and its function crankcase and oil sump.

 10

Checking cooling system for overheating cleaning radiators, dismantling, cleaning, assembling and testing water pump, reverse flushing the system and adjusting the fan belt tension.

Engine cooling methods air & water-cooling & coolants radiators, pump, thermostats and fan, their description, function care and maintenance reasons for engine overheating.

 11

Studying the lubrication oil flow system in engine, overhauling oil filters; oil pump and setting the pressure release valve for correct oil pressure maintenance and repairs in the lubrication system in engine.

Need for lubrication of engine parts-friction lubrication oil and its properties, lubrication system types full flow and by pass flow system, components in lubrication system oil filters and pumps, types their special features and uses.

 12

Practice in joining wires and soldering forming simple electrical circuits measuring of current, voltage & resistance cleaning and topping up of a lead acid battery testing battery with hydrometer-cell tester, connecting battery to charger.

Simple electrical circuit, series & parallel, circuits identification of alternating current and direct/current meters insulators conductors types of resistance- ohm's law and its application common electrical terms and symbols primary and secondary cells lead acid battery description construction common troubles and remedy.

 13

Studying different electrical circuits in a heavy vehicle checking loose open and short circuits.

Description of different electrical circuits in a heavy vehicle.

 14

Removing dynamo alternators from vehicle, dismantling cleaning, checking for defects, assembling and testing for motoring action of dynamo & fitting to vehicles.

Description of charging circuit operation of dynamo alternatives regulator unit ignition warning lamp troubles and remedy in charging system.

 15

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 switches, common troubles and remedy in starter circuit.

 16

Practice on unserviceable diesel engine-removing jammed nuts, broken studs and reconditioning damaged threaded holes-removing cylinder head connecting rods, and pistons cleaning, inspecting and refitting them.

History & Development of compression ignition engines classification of C.I. Engine Advantages and disadvantages over petrol engines, constructional details of single and multi-cylinder engines

 17

Practice in starting & stopping of vehicle engines, general maintenance of engines-checking oil, fuel, water levels and accessories of diesel engines. Working of each components used in CNG engine.

The four stroke and two stroke diesels- Engineunit-flow and loop scavenging constant volume cycles the diesel cycle, indicator diagrams. Study about various components used in conversion of Diesel Engine to CNG Engine.

 18

Bleeding fuel lines for air locks repairing fuel leaks in the pipelines and unions cleaning of oil and air filters in diesel engines.

Fuel used in diesel engines, specification of diesel fuels, and importance of clean fuel, Air fuel ratio, and generally out of the fuel  feed system in diesel engines.

 19

Cleaning and servicing of primary fuel filters and pressure stage filters, removing feed pump dismantling cleaning, reassembling, refitting and testing the feed pump.

Types of CRDI system fuel injection systems air injection & airless injection fuel feed pumps description, operation common troubles and Remedy.

 20

Dismantling an unserviceable fuel injection pump, cleaning inspecting, studying parts and reassembling.

Fuel injection pumps description & operation types adjustments in the pumps phasing and calibration of pumps checking and fixing injection-timing governors types their description and operation starting and adjusting slow speed.

 21

Testing injectors for missing on the vehicle Removing dismantling, cleaning, inspecting replacing defective parts reassembling the injectors and testing them.

Injector nozzles types’ description, operation testing of injector's special features of pintle nozzles.

 22

Demonstrating retrofitting of vehicles CNG & LPG system Euro II, III, IV.

Emission standard, Catalytine converter, noise pollution, Battery operated vehicle, Hy-bride vehicle.