Mechanic Diesel

GOVERNMENT OF INDIA
MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP
DIRECTORATE GENERAL OF TRAINING

COMPETENCY BASED CURRICULUM

MECHANIC DIESEL
(Duration: One Year)

CRAFTSMEN TRAINING SCHEME (CTS)

NSQF LEVEL- 4

SECTOR – AUTOMOTIVE
Mechanic Diesel

MECHANIC DIESEL
(Engineering Trade)

(Revised in 2018)

CRAFTSMEN TRAINING SCHEME (CTS)

NSQF LEVEL - 4

Developed By

Ministry of Skill Development and Entrepreneurship

Directorate General of Training
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE
EN-81, Sector-V, Salt Lake City,
Kolkata – 700 091
 Mechanic Diesel
ACKNOWLEDGEMENT

The DGT sincerely acknowledges contributions of the Industries, State Directorates,

Trade Experts, Domain Experts and all others who contributed in revising the curriculum.
Special acknowledgement is extended by DGT to the following expert members who had
contributed immensely in this curriculum.

List of Expert members contributed/ participated for finalizing the course curriculum of
Mechanic Diesel trade held on 16.05.17 at Govt. ITI- Aundh, Pune
Name & Designation
S No. Organization Remarks
Shri/Mr./Ms.
Industry Experts

1. Dr. K C Vora Sr. Dy. Director & The Automotive Research Association Chairman
Head Arai Academy Of India. S.No.102, Vetal Hill, Off Paud
Road, Kothrud, Pune
2. Jayanta Patra Sr. Manager Micromatic Machine Tools (P) Ltd. Member
240/241,11th Main , 3rd Phase,
Peenya Industrial Area, Bangalore.
3. Kashinath M. Patnasetty Head Ace Designers Ltd. Plot No. 7&8, Ii Member
- Application Support Group Phase Peenya Industrial Area,
Bangalore
4. Suyog Fulbadave, Executive HR Piaggio Vehicles Pvt. Ltd, Pune Member
5. Sunil Khodke Training Bobst India Pvt Ltd Pirangut, Mulashi, Member
Manager Pune
6. Lokesh Kumar Manger Volkswagen India Pvt Ltd Pune Member
Training Academy
7. Shriram Tatyaba Khaire Sulzer India Pvt Ltd. Kondhapuri, Member
Executive Engineering. Shirur, Pune
8. Milind P Desai Sr. Shift Atlas Copco (I) Ltd Dapodi, Pune Member
Engineer
9. Shrikant Mujumdar Dgm John Deere India Pvt Ltd. Pune - Nagar Member
Road, Sanaswadi, Pune
10. Milind Sanghai Team Manager Alfa Laval India Ltd. Dapodi, Pune. Member
11. Rajesh Menon Unit Manager Alfa Laval India Ltd. Dapodi, Pune. Member
12. N K A Madhuubalan DGM - Sandvik Asia Pvt.Ltd. Dapodi, Pune. Member
QC, QA & SMPS
13. Irkar Balaji, Sr. Engineer Mfg. Premium Transmission Ltd. Member
Chinchwad, Pune.
14. Rajendra Shelke Sr. Engineer Premium Transmission Ltd. Member
Mfg. Chinchwad, Pune - 19
15. Bhagirath Kulkarni Manager Tata Ficosa Auto Sys Ltd Hinjawadi, Member
Maintenance Pune
16. Rohan More Hr & Admin Tata Ficosa Auto Sys Ltd Hinjawadi, Member
 Mechanic Diesel
Pune
17. G. Venkateshwaran Cummins India Ltd Member
18. Mahesh Dhokale Engineer Tata Toyo Radiator Ltd Member
19. Pankaj Gupta DGM- HR & IR Tata Toyo Radiator Ltd Member
20. S K Joshi Head - Business Radheya Machining Ltd Pune- Nagar Member
Development. Road, Sanaswadi, Pune.
21. A L Kulkarni DGM Mfg. Pmt Machines Ltd Pimpri, Pune Member
22. S V Karkhanis DGM Planning Pmt Machines Ltd Pimpri, Pune Member
23. Kiran Shirsath Asso. Manager Burckhardt Compressioni Pvt Ltd, Member
M.E. Ranjangaon, Pune
24. Ajay Dhuri Manager Tata Motors Ltd Pimpri, Pune Member
25. Arnold Martin Godrej & Boyce Mfg Co Ltd, Mumbai Member
26. Ravindra L. More Mahindra CIE Automotive Ind. Ltd. Member
Ursc-Pune
27. Kushagra P. Patel NRB Bearings Ltd., Chiklthana Member
Aurongabad
28. M. M. Kulkarni NRB Bearings Ltd., Chiklthana Member
Aurongabad
DGT & Training Institute
29. NIRMALYA NATH CSTARI, Kolkata Member cum
Asst. Director of Trg. Co-
coordinator
30. Akhilesh Pandey ATI, Mumbai Expert
31. Amar Prabhu, Principal Don Bosco, Mumbai Expert
32. Indranil Mukherjee, Instructor ITI, Tollygaunj Expert
Mechanic Diesel
CONTENTS

S No. Topics Page No.

1. Course Information 1

2. Training System 2-5

3. Job Role 6

4. General Information 7-8

5. NSQF Level Compliance 9

6. Learning/ Assessable Outcome 10-11

7. Learning Outcome with Assessment Criteria 12-18

8. Trade Syllabus 19-36

9. Syllabus - Core Skill

9.1 Core Skill – Workshop Calculation Science & 37-40

Engineering Drawing

9.2 Core Skill – Employability Skill 41-45

10. Annexure I

List of Trade Tools & Equipment 46-55

List of Tools & Equipment for Employability Skill 56

11. Annexure II - Format for Internal Assessment 57

Mechanic Diesel
1. COURSE INFORMATION

During one year duration of “Mechanic Diesel” trade, a candidate is trained on

Professional Skill, Professional Knowledge and Employability Skill. In addition to this, a
candidate is entrusted to undertake project work, extracurricular activities and on-the-
job training to build up confidence. The broad components covered related to the trade
are categorized in two semesters each of six months duration. The semester wise course
coverage is categorized as below: -

Semester-I:- This semester will cover the safety aspect in general and specific to the
trade, identification of tools & equipment, raw materials used. In this semester the
trainee will perform Measuring & marking by using various Measuring & Marking tools.
The trainee will be able to plan and perform basic fastening and fitting operations.
Familiarize with basics of electricity, test and measure the electrical parameter. Skilling
practice on maintenance of batteries being done. Practice making various welding joints
by using Arc and gas welding. Trace and identify various hydraulics and pneumatics
components and identify components in Air and Hydraulic Brake system. Identify
various types of vehicle.

Semester-II:- In this semester the candidate will be able to perform practice on

dismantling Diesel Engine of LMV as per given standard procedures. Able to achieve skill
on Overhauling of Cylinder Head , valve train , Piston, connecting rod assembly,
crankshaft, flywheel and mounting flanges, spigot and bearings, camshaft etc. practice
reassembling all parts of engine in correct sequence as per workshop manual. Perform
testing on engine. Also the trainee practice on repair and maintenance of Cooling,
lubrication, Intake & Exhaust system of Engine. Perform maintenance of diesel fuel
system, FIP, Governor and monitor emission of vehicle. Practice on repair, maintenance
and overhaul of Starter, alternator and perform Execute troubleshooting in engine of
LMV/HMV

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Mechanic Diesel
2. TRAINING SYSTEM

2.1 GENERAL
The Directorate General of Training (DGT) under Ministry of Skill Development &
Entrepreneurship offers a range of vocational training courses catering to the need of different
sectors of the economy/ labour market. The vocational training programs are delivered under
the aegis of National Council of Vocational Training (NCVT). Craftsman Training Scheme (CTS)
and Apprenticeship Training Scheme (ATS) are two pioneer programs of NCVT for propagating
vocational training.

Mechanic Diesel trade under CTS is one of the popular courses delivered nationwide
through a network of ITIs. The course is of one-year (02 semester) duration. It mainly consists
of Domain area and Core area. In the Domain area, Trade Theory & Practical impart
professional skills and knowledge, while Core area (Employability Skills) imparts requisite core
skill, knowledge and life skills. After passing out of the training programme, the trainee is
awarded National Trade Certificate (NTC) by NCVT which is recognized worldwide.

Candidates broadly need to demonstrate that they are able to:

 Read & interpret technical parameters/documentation, plan work, identify necessary

materials and tools;
 Perform task with due consideration to safety rules, accident prevention regulations
and environmental protection stipulations;
 Apply professional knowledge, core skills & employability skills while performing the
job.
 Check the components as per workshop manual, identify and rectify errors and
repair/replace components.
 Document the technical parameters related to the task undertaken.

2.2 CAREER PROGRESSION PATHWAYS

 Can join Apprenticeship programme in different types of industries leading to National

Apprenticeship certificate (NAC).

 Can join Crafts Instructor Training Scheme (CITS) in the trade for becoming instructor in
ITIs.

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2.3 COURSE STRUCTURE

Table below depicts the distribution of training hours across various course elements
during a period of one-year (02 semesters):

Notional Training
S No. Course Element
Hours
1 1075
Professional Skill (Trade Practical)
2 258
Professional Knowledge (Trade Theory)
3 Workshop Calculation & Science 86
4 Engineering Drawing 129
5 Employability Skills 110
6 Library & Extracurricular Activities 62
7 Project Work 80
8 Revision & Examination 280
Total 2080

2.4 ASSESSMENT & CERTIFICATION

The trainee will be tested for his skill, knowledge and attitude during the period of the
course and at the end of the training program as notified by the Government of India (GoI) from
time to time. The employability skills will be tested in the first two semesters itself.

a) The Internal Assessment during the period of training will be done by Formative Assessment
Method by testing for assessment criteria listed against learning outcomes. The training
institute has to maintain an individual trainee portfolio as detailed in assessment guideline. The
marks of internal assessment will be as per the template (Annexure – II).

b) The final assessment will be in the form of summative assessment method. The All India
Trade Test for awarding NTC will be conducted by NCVT at the end of each semester as per the
guideline of Government of India. The pattern and marking structure is being notified by Govt.
of India from time to time. The learning outcome and assessment criteria will be the basis for
setting question papers for final assessment. The examiner during final examination will also
check the individual trainee’s profile as detailed in assessment guideline before giving marks for
practical examination.

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2.4.1 PASS REGULATION

The minimum pass percentage for practical is 60% & minimum pass percentage of
theory subjects is 40%. For the purposes of determining the overall result, 50% weightage is
applied to the result of each semester examination.

2.4.2 ASSESSMENT GUIDELINE

Appropriate arrangements should be made to ensure that there will be no artificial
barriers to assessment. The nature of special needs should be taken into account while
undertaking the assessment. Due consideration should be given while assessing for teamwork,
avoidance/reduction of scrap/wastage and disposal of scrap/waste as per procedure,
behavioral attitude, sensitivity to the environment and regularity in training. The sensitivity
towards OSHE and self-learning attitude are to be considered while assessing competency.

Assessment will be evidence based comprising the following:

 Job carried out in labs/workshop

 Record book/ daily diary
 Answer sheet of assessment
 Viva-voce
 Progress chart
 Attendance and punctuality
 Assignment
 Project work

Evidences of internal assessments are to be preserved until forthcoming semester

examination for audit and verification by examining body. The following marking pattern to be
adopted while assessing:

Performance Level Evidence

(a) Weightage in the range of 60%-75% to be allotted during assessment
For performance in this grade, the candidate  Demonstration of good skill in the use of
should produce work which demonstrates hand tools, machine tools and workshop
attainment of an acceptable standard of equipment.
craftsmanship with occasional guidance, and  Below 70% tolerance dimension
due regard for safety procedures and achieved while undertaking different
practices work with those demanded by the
component/job.
 A fairly good level of neatness and
consistency in the finish.
 Occasional support in completing the
project/job.

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Mechanic Diesel

(b) Weightage in the range of 75%-90% to be allotted during assessment

For this grade, a candidate should produce  Good skill levels in the use of hand tools,
work which demonstrates attainment of a machine tools and workshop equipment.
reasonable standard of craftsmanship, with  70-80% tolerance dimension achieved
little guidance, and regard for safety while undertaking different work with
procedures and practices those demanded by the component/job.
 A good level of neatness and consistency
in the finish.
 Little support in completing the
project/job.

(c) Weightage in the range of more than 90% to be allotted during assessment
For performance in this grade, the candidate,  High skill levels in the use of hand tools,
with minimal or no support in organization machine tools and workshop equipment.
and execution and with due regard for safety  Above 80% tolerance dimension
procedures and practices, has produced work achieved while undertaking different
which demonstrates attainment of a high work with those demanded by the
standard of craftsmanship. component/job.
 A high level of neatness and consistency
in the finish.
 Minimal or no support in completing the
project.

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Mechanic Diesel
3. JOB ROLE

Brief description of job roles:

Mechanic Diesel can learn about diesel engine fundamentals and power generation.
The trainees have to participate in hands-on work and begin repairing diesel engine vehicles.

Mechanic, Diesel Engine; Oil Engine, Fitter repairs services and overhauls diesel or oil
engines for efficient performance as prime mover to drive machinery and equipment. Examine
engine to locate defects, using various tools and instruments. Dismantles or partly dismantles it
to remove damaged or worn out parts and replaces or repairs them.

Grinds valve and assembles parts, doing supplementary tooling and other functions as
necessary to ensure accuracy of fit. Installs assembled or repaired engine in position and
connects pulley or wheel to propulsion system. Starts engine, tunes it up and observes
performance noting different meter readings such as temperature, fuel level, oil pressure, etc.
and sets it to specified standard for optimum performance. Checks, adjusts and lubricates
engine periodically and performs such other functions to keep engine in good working order.
May solder or braze parts and service diesel fuel pumps and injectors.

Additionally, since diesel engines are starting to incorporate electronic components,

programs usually give students a chance to take courses in electrical systems and computer
diagnostic software.

Plan and organize assigned work and detect & resolve issues during execution in his own
work area within defined limit. Demonstrate possible solutions and agree tasks within the
team. Communicate with required clarity and understand technical English. Sensitive to
environment, self-learning and productivity.

Reference NCO-2015: 7233.0400

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Mechanic Diesel
4. GENERAL INFORMATION

Name of the Trade

MECHANIC DIESEL
NCO - 2015 7233.0400

NSQF Level
Level-4
Duration of Craftsmen
Training One year (Two semesters each of six months duration)

Entry Qualification Passed 10th class examination with Mathematics and Science.

Unit Strength (No. Of 16 (Max. Supernumeraries seats: 5)

Student)
Space Norms Space Area 210 Sq. Mt. (Including parking area)

Power Norms
4.8 KW
Instructors Qualification for

1. Mechanic Diesel a) Degree in Automobile/ Mechanical Engg. (with specialization in

Trade Automobile) from recognized college/University with one year
experience in the automobile industry and should possess valid LMV
Driving license.
OR
Diploma in Automobile/Mechanical (specialization in automobile) from
recognized board of technical education with two years’ experience in
Automobile industry and should possess valid LMV driving license.
OR
NTC/NAC in the Trade of “Mechanic Diesel” with 3 years post
qualification experience in the relevant field and should possess valid
LMV driving license.
and
b) With “National Crafts Instructor Certificate”.

Note:
1) At least one Instructor must have Degree/Diploma in Automobile/
Mechanical Engg. (With specialization in Automobile) when applied for
02 units.
Out of two Instructors required for the unit of 2(1+1), one must have
Degree/Diploma and other must have NTC/NAC qualifications.
2. Workshop 2) Instructor Qualification for WCS & E.D, as per the Training Manual
Calculation & Science Degree in Engineering with one year experience.

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Mechanic Diesel

OR
Diploma in Engineering with two-year experience.

Desirable:
Craft Instructor Certificate in RoD&A course under NCVT.
3. Engineering Drawing 2) Instructor Qualification for WCS & E.D, as per the Training Manual
Diploma in Engineering with two-year experience.
OR
NTC/ NAC in the Draughtsman (Mechanical / Civil) with three-year
experience.

4. Employability Skill MBA OR BBA with two-year experience OR Graduate in Sociology/

Social Welfare/ Economics with two-year experience OR Graduate/
Diploma with two-year experience and trained in Employability Skills
from DGT institutes.
AND
Must have studied English/ Communication Skills and Basic Computer
at 12th / Diploma level and above.
OR
Existing Social Studies Instructors duly trained in Employability Skills
from DGT institutes.

List of Tools and

Equipment As per Annexure – I

Distribution of training on Hourly basis: (Indicative only)

Extra-
Total Trade Trade Workshop Engg. Employability
curricular
Hours/Week Practical Theory Cal. &Sc. Drawing Skills
Activity
40 Hours 25 Hours 6 Hours 2 Hours 3 Hours 2 Hours 2 Hours

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5. NSQF LEVEL COMPLIANCE

NSQF level for Mechanic Diesel trade under CTS: Level 4

As per notification issued by Govt. of India dated- 27.12.2013 on National Skill

Qualification Framework total 10 (Ten) Levels are defined.

Each level of the NSQF is associated with a set of descriptors made up of five outcome
statements, which describe in general terms, the minimum knowledge, skills and attributes
that a learner needs to acquire in order to be certified for that level.

Each level of the NSQF is described by a statement of learning outcomes in five

domains, known as level descriptors. These five domains are:

a. Process
b. Professional Knowledge
c. Professional Skill
d. Core Skill
e. Responsibility

The Broad Learning outcome of the Mechanic Diesel trade under CTS mostly matches
with the Level descriptor at Level- 4.

The NSQF level-4 descriptor is given below:

Professional
Level Process Required Professional Skill Core Skill Responsibility
Knowledge
Level 4 Job that requires Knowledge A range of Desired Responsibility
well developed of facts, cognitive and mathematical for own work
skill, with clear principles, practical skills skill, and
choice of processes and required to understanding of learning and
procedures in general accomplish tasks social, political some
familiar context. concepts, in a and solve and some skill of responsibility
field of work problem by collecting and for other’s
or study. selecting and organizing works and
applying basic information, learning.
methods, tools, communication.
materials and
information.

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6. LEARNING/ ASSESSABLE OUTCOME

Learning outcomes are a reflection of total competencies of a trainee and assessment will
be carried out as per the assessment criteria.

6.1. GENERIC LEARNINGOUTCOME

1. Recognize & comply with safe working practices, environment regulation and
housekeeping.
2. Understand and explain different mathematical calculation & science in the field of
study including basic electrical. [Different mathematical calculation & science-Work,
Power & Energy, Algebra, Geometry & Mensuration, Trigonometry, Heat &
Temperature, elasticity]
3. Interpret specifications, different engineering drawing and apply for different
application in the field of work. [Different engineering drawing-Geometrical
construction, Dimensioning, Layout, Method of representation, Symbol, Different
Projections, Assembly drawing, Sectional views, Estimation of material]
4. Select and measure dimension of components and record data.
5. Explain the concept in productivity, quality tools, and labour welfare legislation and
apply such in day-to-day work to improve productivity & quality.
6. Explain energy conservation, global warming and pollution and contribute in day-to-day
work by optimally using available resources.
7. Explain personnel finance, entrepreneurship and manage/organize related task in day-
to-day work for personal & societal growth.
8. Plan and execute the work related to the occupation.

6.2. SPECIFIC LEARNING OUTCOME

Semester – I
9. Check & perform Measuring & marking by using various Measuring & Marking tools
(Vernier Callipers, Micrometre, Telescope gauges, Dial bore gauges, Dial indicators,
straightedge, feeler gauge, thread pitch gauge, vacuum gauge, tire pressure gauge.)
10. Plan & perform basic fastening & fitting operation by using correct hand tools, Machine
tools & equipment.
11. Trace and Test all Electrical & Electronic components & circuits and assemble circuit to
ensure functionality of system.
12. Join components by using Arc & Gas welding.
13. Trace & Test Hydraulic and Pneumatic components

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14. Check & Interpret Vehicle Specification data and VIN. Select & operate various Service
Station equipment.

Semester – II
15. Understand basics of engine types construction, working.
16. Dismantle & assemble of Diesel Engine from vehicle (LMV/HMV) along with other
accessories (torqueing methods, handling parts).
17. Overhaul, service and testing Diesel Engine, its parts and check functionality.
18. Trace, Test & Repair Cooling and Lubrication System of engine (types of coolants and
oils relevant to the engines).
19. Trace & Test Intake and Exhaust system of engine.(cleaning egr valves, exhaust inlet
valves, ports and manifolds)
20. Service Diesel Fuel System and check proper functionality (calibration of mechanical and
electronic pumps, checking injectors, filters)
21. Plan & overhaul the stationary engine and Governor and check functionality.
22. Monitor emission of vehicle and execute different operation to obtain optimum
pollution as per emission norms.
23. Carryout overhauling of Alternator and Starter Motor.
24. Diagnose & rectify the defects in LMV/HMV to ensure functionality of vehicle
25. Checking the condition of hoses, mounts, radiators and fans.
26. Electronic control diagnostics of CR engines.

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7. LEARNING OUTCOME WITH ASSESSMENT CRITERIA

GENERIC LEARNING/ ASSESSABLE OUTCOME

LEARNING/ ASSESSABLE
ASSESSMENT CRITERIA
OUTCOME
1. Recognize & comply 1. 1. Follow and maintain procedures to achieve a safe working
with safe working environment in line with occupational health and safety
practices, environment regulations and requirements.
regulation and 1. 2. Recognize and report all unsafe situations according to site
housekeeping. policy.
1. 3. Identify and take necessary precautions on fire and safety
hazards and report according to site policy and procedures.
1. 4. Identify, handle and store/ dispose of
dangerous/unsalvageable goods and substances according
to site policy and procedures following safety regulations
and requirements.
1. 5. Identify and observe site policies and procedures withregard
to illness or accident.
1. 6. Identify safety alarms accurately.
1. 7. Report supervisor/ Competent of authority in the event of
accident or sickness of any staff and record accident details
correctly according to site accident/injury procedures.
1. 8. Identify and observe site evacuation procedures according to
site policy.
1. 9. Identify Personal Productive Equipment (PPE) and use the
same as per related working environment.
1. 10. Identify basic first aid and use them under different
circumstances.
1. 11. Identify different fire extinguisher and use the same as per
requirement.
1. 12. Identify environmental pollution & contribute to avoidance
of same.
1. 13. Take opportunities to use energy and materials in an
environmentally friendly manner.
1. 14. Avoid waste and dispose waste as per procedure.
1. 15. Recognize different components of 5S and apply the same in
the working environment.

2. Understand and explain 2.1 Explain concept of basic science related to the field such as

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different mathematical Material science, Mass, weight, density, heat & temperature,
calculation & science in heat treatment.
the field of study 2.2 Measure dimensions as per drawing
including basic 2.3 Use scale/ tapes to measure for fitting to specification.
electrical. [Different 2.4 Comply with given tolerance.
mathematical 2.5 Prepare list of appropriate materials by interpreting detail
calculation & science - drawings and determine quantities of such materials.
Work, Power & Energy, 2.6 Ensure dimensional accuracy of assembly by using different
Algebra, Geometry, instruments/gauges.
Mensuration, 2.7 Explain basic electricity, insulation and earthing.
Trigonometry, Heat &
Temperature, elasticity]

3. Interpret specifications, 3. 1. Read and interpret the information on drawings and apply in
different engineering executing practical work.
drawing and apply for 3. 2. Read & analyse the specification to ascertain the material
different application in requirement, tools, and assembly/maintenance parameters.
the field of work. 3. 3. Encounter drawings with missing/unspecified key information
[Different engineering and make own calculations to fill in missing dimension/
drawing-Geometrical parameters to carry out the work.
construction,
Dimensioning, Layout,
Method of
representation, Symbol,
Different Projections,
Assembly drawing,
Sectional views,
Estimation of material]

4. Select and measure 4.1 Select appropriate measuring scale/tape/gauges.

dimension of 4.2 Measure dimension of the components/assembly & compare
components and with given drawing/measurement.
record data.

5. Explain the concept in 5.1 Explain the concept of productivity and quality tools and apply
productivity, quality during execution of job.
tools, and labour 5.2 Understand the basic concept of labour welfare legislation and
welfare legislation and adhere to responsibilities and remain sensitive towards such
apply such in day-to- laws.

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day work to improve 5.3 Knows benefits guaranteed under various acts.
productivity & quality.

6. Explain energy 6.1 Explain the concept of energy conservation, global warming,
conservation, global pollution and utilize the available recourses optimally & remain
warming and pollution sensitive to avoid environment pollution.
and contribute in day-
to-day work by 6.2 Dispose waste following standard procedure.
optimally using
available resources.

7. Explain personnel 7. 1. Explain personnel finance and entrepreneurship.

finance, 7. 2. Explain role of various schemes and institutes for self-
entrepreneurship and employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/
manage/organize non-financing support agencies to familiarize with the
related task in day-to- Policies/Programmes & procedure & the available scheme.
day work for personal 7. 3. Prepare Project report to become an entrepreneur for
& societal growth. submission to financial institutions.

8. Plan and execute the 8. 1. Use documents, drawings and recognize hazards in the work
work related to the site.
occupation. 8. 2. Plan workplace/ assembly location with due consideration to
operational stipulation.
8. 3. Communicate effectively with others and plan project tasks.
8. 4. Execute the task effectively.

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SPECIFIC LEARNING/ ASSESSABLE OUTCOMES

SEMESTER-I
LEARNING/ ASSESSABLE
ASSESSMENT CRITERIA
OUTCOMES
9. Check & perform 9. 1 Plan the working principles of measuring instruments
Measuring & marking by and special tools required for auto workshop.
using various Measuring & 9. 2 Select, care and use of measuring instrument.
Marking tools (Vernier 9. 3 Set up the measured value with workshop manual and
Caliper, Micrometer, quality concepts and proper safety.
Telescope gauges, Dial 9. 4 Carry out decision on whether to replace or not.
bore gauges, Dial
indicators, straightedge,
feeler gauge, thread pitch
gauge, vacuum gauge, tire
pressure gauge.)

10. Plan & perform basic 10.1 Describe the purpose, use of auto hand tools.
fastening & fitting 10.2 List the safety rules for hand tools.
operation by using correct
hand tools, Machine tools 10.3 Select the correct tool for the job.
& equipments. 10.4 Set up the tacked pieces in specific position.
10.5 Joint components by Brazing, Soldering, Riveting as per
given drawing.
10.6 Produce components by different operation (Drilling,
Reaming, Taping, Dieting)

11. Trace and Test all 11.1 Plan and prepare as per procedure and safety methods
Electrical & Electronic of soldering the cable ends using an electric soldering
components & circuits and iron.
assemble circuit to ensure 11.2 Use crimping tool to make a circuit joint.
functionality of system. 11.3 Explain the connection of an ammeter, voltmeter, and
Charge and test batteries ohmmeter in a circuit trouble shooting.
used in vehicle. 11.4 State open & short circuit, series and parallel circuits.
11.5 Verify DC series & parallel circuits and its characteristics.
11.6 Check out the open and short circuits in the lighting
circuits.
11.7 Verify ohm’s law and measure resistance using rheostat.
11.8 Check the voltage drop in the auto electrical system by
using multimeter.
11.9 Trace the auto electrical components by using vehicle
wiring circuits.
11.10 Check the condition of the solenoid switch in the starting

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system.
11.11 Determine the forward to reverse resistance ratio of
diodes and identify good / bad diodes.
11.12 Perform battery charging and check

12. Join components by using 12.1. Determine the principles, process of different welding
Arc & Gas welding. process applicable in automobile industry.
12.2. Demonstrate the edge preparation for butt and fillets
welds.
12.3. Select the type and size of filler rod and flux/electrode,
size of nozzle and gas pressure/welding current,
preheating method and temperature as per
requirement.
12.4. Set and tack metals as per drawing.
12.5. Deposit the weld maintaining appropriate technique and
safety aspects.
12.6. Cool the welded joint by observing appropriate cooling
method. Use post heating, peening etc. as per
requirement.
12.7. Clean the joint and inspect the weld for its uniformity
and different types of surface defects.

13. Trace & Test Hydraulic and 13. 1 Demonstrate Brake System ( Hydraulic & Air).
Pneumatic components. 13. 2 Demonstrate Hydraulic Power Steering.

14. Check & Interpret Vehicle 14. 1 Identify of different type of vehicle.
Specification data and VIN. 14. 2 Identify the different vehicle specification data and
Select & operate various information
Service Station 14. 3 Demonstrate the garage, service station different
Equipments equipment
SEMESTER-II
15. Dismantle & assemble of 15. 1 Demonstrate safe handling of lifting equipments.
Diesel Engine from vehicle
15. 2 Identify the problems in the vehicle
(LMV/HMV) along with
other accessories. Vehicle 15. 3 Perform the periodic testing of lifting equipments.
performance Test
15. 4 Judge whether this Engine needs overhaul or not
15. 5 Perform dispose the used engine oil and safety measures
in disposal.
15. 6 Perform on vehicle Engine Tests to analyze need of
Overall

16
 Mechanic Diesel

15. 7 Perform sequencing and identifying parts at the time of

dismantle and assemble.
15. 8 Then Dismantle of Engine & Overhaul is ok, refer below
attached screen shot for your reference

16. Overhaul & service Diesel 16.1 Remove accessories fitted to the engine prior to engine
Engine, its parts and check removal.
functionality.(Judge 16.2 Align the left hook of the crane with engine lifting
weather this Engine needs bracket.
overhaul or not) 16.3 Remove the engine mountings
16.4 Remove the engine from vehicle.
16.5 Mount the engine on the vehicle.
16.6 Align and fit the gear box to the engine.
16.7 Refit the accessories to the engine.
16.8 Set the Timing of the Engine
16.9 Overhaul Valve Actuating Mechanism (Hydraulic latch
actuator).

17. Trace, Test & Repair 17.1 Overhauling of Radiator/ Recovery tank water pump, oil
Cooling and Lubrication pump, air cleaner
System of engine
17.2 Check the engine oil pressure at different r.p.ms.
17.3 Overhaul the Oil Pump.
17.4 Set Checking &Top up coolant, Draining & refilling
coolant.
17.5 Testing cooling system pressure & Thermostat
17.6 Cleaning & reverse flushing. Overhauling water pump
and refitting and repairs to oil flow pipe lines and unions
if necessary.
17.7 Check proper functioning of radiator fan (Mechanical/
Electrical / viscous / belt drive).

18. Trace & Test Intake and 18. 1 Overhauling of manifolds, silencer and tail pipe, air
Exhaust system of engine compressor, air exhauster and inspect parts of air
exhauster, turbo charger from vehicle.
18. 2 Overhauling of air filter, clean & refit air cooler, fuel
filter assembly and replace filter elements
18. 3 Remove and replace EGR valve, Use Smoke meter to
test emission from engine.

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 Mechanic Diesel

19. Service Diesel Fuel System 19. 1 Overhauling fuel feed pump, fuel injector pump.
and check proper 19. 2 Test injectors, check the injection timing by the spill cut
functionality. off method

20. Plan & overhaul the 20. 1 Start engine, adjust idling speed.
stationary engine and 20. 2 Overhaul the Governor (Mechanical & Pneumatic)
Governor and check
functionality 20. 3 Set the Engine Timing.

20. 4 Check performance of engine off load.

20. 5 Servicing of the cylinder and replace the defective parts.

21. Monitor emission of 21. 1 Check vacuum pump for its functioning.
vehicle and execute
different operation to 21. 2 Perform troubleshooting of EVAP Canister.
obtain optimum pollution 21. 3 Inspect PCV hose, inspect PCV Valve and check for
as per emission norms. vacuum.
21. 4 Clean the PCV valve and replace if required.
21. 5 Inspect & clean EGR.

22. Carryout overhauling of 22. 1 Trace the circuit from the alternator to the battery.
Alternator and Starter 22. 2 Perform servicing of starter motor.
Motor. 22. 3 Perform servicing of alternator and test its
performance.
22. 4 Check belt condition and replace as per requirement.

23. Diagnose & rectify the 23. 1 Plan and diagnose the problem if engine not starting.
defects in LMV/HMV to 23. 2 Diagnose high fuel consumption and engine
ensure functionality of overheating.
vehicle. 23. 3 Diagnose for excessive oil consumption and low/high
engine oil pressure.

23. 4 Diagnose for abnormal engine noise.

23. 5 Diagnose for engine’s poor performance.

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 Mechanic Diesel
8. SYLLABUS

SYLLABUS FOR MECHANIC DIESEL TRADE

FIRST SEMESTER - 6 MONTHS

Professional Skills
Week Professional Knowledge
Learning Outcome (Trade Practical)
No. (Trade Theory)
With Indicative Hours
1-2 Apply safe working 1. Demonstration of Machinery - Importance& scope of
practices in an used in the trade. (05 hrs) Mechanic Diesel Trade
automotive work shop. 2. Identify safety Gear/PPE Training.
(Personal Protective - General discipline in the
Equipments) and their uses (10 Institute
hrs) - Elementary First Aid,
3. Importance of maintenance and Occupational Safety & Health
cleanliness of Workshop. (05 - Knowledge of Personal Safety
hrs) &Safety precautions in
4. Demonstration on safe handling handling Diesel machine
and Periodic testing of lifting - Concept about House Keeping
equipment, and Safety disposal & 5S method.
of used engine oil. (10 hrs.) - Energy conservation process
5. Demonstration on health - Safety disposal of Used engine
hazards, occupational safety oil,
&first Aid. (05 hrs) - Electrical safety tips.
6. Demonstration fire service - Safe handling of Fuel Spillage,
station to provide demo on Fire - Knowledge of Fire Safety &Fire
safety. (05 hrs) extinguishers used for
7. Perform use of fire different types of fire.
extinguishers. (05 hrs) - Safe disposal of toxic dust,
8. Energy saving Tips of ITI - safe handling and Periodic
electricity Usage. (05 hrs) testing of lifting equipment
3-4 Check & perform 9. Perform marking using all Hand & Power Tools:-
Measuring & marking marking aids, like steel rule with - Marking scheme, marking
by using various spring callipers, dividers, material-chalk, Prussian blue.
Measuring & Marking scriber, punches, chisel etc. on - Cleaning tools- Scraper, wire
tools(Vernier Calliper, MS Flat/Sheet Metal. (17 hrs) brush, Emery paper,
Micrometer, Telescope 10. Measure a wheel base of a - Description, care and use of
gauges, Dial bore vehicle with measuring tape. Surface plates, steel rule,
gauges, Dial indicators, (08 hrs) measuring tape, try square.
straightedge, feeler 11. Measure valve spring tension Callipers-inside and outside.
gauge, thread pitch using spring tension tester (10 Dividers, surface gauges,
gauge, vacuum gauge, hrs) scriber,

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 Mechanic Diesel

tire pressure gauge.) 12. Perform to remove wheel lug - Punches-prick punch, centre
nuts with use of an air impact punch, pin punch, hollow
wrench (08 hrs) punch, number and letter
13. Operate General workshop punch. Chisel-flat, cross-cut.
tools & power tools. (07 hrs) Hammer- ball pein, lump,
mallet. Screw drivers-blade
- Screwdriver, Phillips screw
driver, Ratchet screwdriver.
Allen key, bench vice & C-
clamps,
- Spanners- ring spanner, open
end spanner & the
combination spanner,
universal adjustable open end
spanner. Sockets &
accessories,
- Pliers - Combination pliers,
multi grip, long nose, flat-
nose, Nippers or pincer pliers,
Side cutters, Tin snips, Circlip
pliers, external circlips pliers.
- Air impact wrench, air ratchet,
wrenches- Torque wrenches,
pipe wrenches, Pipe flaring &
cutting tool, pullers-Gear and
bearing.
5-6 -do- 14. Perform measuring practice on Systems of measurement,
Cam height, Camshaft Journal -Description, Least Count
dia, crankshaft journal dia, calculation, care & use of -
Valve stem dia, piston Micrometers- Outside, and
diameter, and piston pin dia depth micrometer,
with outside Micrometres. (05 - Micrometer adjustments,
hrs) - Description, Least Count
15. Perform measuring practice on calculation, care & use of
the height of the rotor of an oil Vernier Calliper.
pump from the surface of the - Telescope gauges, Dial bore
housing or any other auto gauges, Dial indicators,
component measurement with straightedge, feeler gauge,
depth micrometer. (05 hrs) thread pitch gauge, vacuum
16. Perform measuring practice on gauge, tire pressure gauge.
valve spring free length. (05
hrs)
17. Perform measuring practice on
cylinder bore, Connecting rod

20
 Mechanic Diesel

bore, inside diameter (ID) of a

camshaft bearing with
Telescope gauges. (05 hrs)
18. Perform measuring practice on
cylinder bore for taper and out-
of-round with Dial bore gauges.
(05 hrs)
19. Perform measuring practice to
measure wear on crankshaft
end play, crankshaft run out,
and valve guide with dial
indicator. (05 hrs)
20. Perform measuring practice to
check the flatness of the
cylinder head is warped or
twisted with straightedge is
used with a feeler gauge. (05
hrs)
21. Perform measuring practice to
check the end gap of a piston
ring, piston-to-cylinder wall
clearance with feeler gauge. (05
hrs)
22. Perform practice to check
engine manifold vacuum with
vacuum gauge. (05 hrs)
23. Perform practice to check the
air pressure inside the vehicle
tyre is maintained at the
recommended setting. (05 hrs)
7-8 Plan & perform basic 25. Perform practice on general - Different types of metal joint
fastening & fitting cleaning, checking and use of (Permanent, Temporary),
operation by using nut, bolts, & studs etc. (05 hrs) methods of Bolting, Riveting,
correct hand tools, 26. Perform removal of stud/bolt Soldering, Brazing, Seaming
Machine tools & from blind hole. (05 hrs) etc.
equipments. 27. Perform practice on cutting Fasteners
tools like Hacksaw, file, chisel, - Study of different types of
Sharpening of Chisels, center screws, nuts, studs & bolts,
punch, safety precautions while locking devices, Such as lock
grinding. (10 hrs) nuts, cotter, split pins, keys,
28. Perform practice on circlips, lock rings, lock washers
Hacksawing and filing to given and locating where they are
dimensions. (15 hrs) used. Washers & chemical
29. Perform on Soldering & Brazing. compounds can be used to help

21
 Mechanic Diesel

(10 hrs) secure these fasteners. Function

30. Perform practice on making of Gaskets, Selection of
various Gaskets like oil sump, materials for gaskets and
intake manifold, water pump, packing, oil seals. Types of
tappet cover etc. (05 hrs) Gaskets – paper, multilayered
metallic, liquid, rubber, copper
and printed.

Thread Sealants-Various types

like, locking, sealing,
temperature resistance,
antilocking, lubricating etc.

Cutting tools
-Study of different type of
cutting tools like Hacksaw, File-
Definition, parts of a file,
specification, Grade, shape,
different type of cut and uses.,
OFF-hand grinding with sander,
bench and pedestal grinders,
safety precautions while
grinding.

Limits, Fits & Tolerances

-Definition of limits, fits &
tolerances with examples used
in auto components
9-10 -do- 31. Perform practice on Marking Drilling machine
and Drilling clear and Blind - Description and study of
Holes, Sharpening of Twist Drills Bench type Drilling
Safety precautions to be machine, Portable
observed while using a drilling electrical Drilling machine,
machine. (10 hrs) drill holding devices, Work
32. Perform practice on Tapping a Holding devices, Drill bits.
Clear and Blind Hole, Selection Taps and Dies
of tape drill Size, use of - Hand Taps and wrenches,
Lubrication, Use of stud Calculation of Tap drill sizes for
extractor. (15 hrs) metric and inch taps. Different
33. Perform practice cutting type of Die and Die stock.
Threads on a Bolt/ Stud. Screw extractors.
Adjustment of two piece Die, Hand Reamers
Reaming a hole/ Bush to suit – Different Type of hand
the given pin/ shaft, scraping a reamers, Drill size for reaming,

22
 Mechanic Diesel

given machined surface. (25 Lapping, Lapping abrasives,

hrs) type of Laps.
11 -do- 34. Perform practice on making Sheet metal
Rectangular Tray. (08 hrs) - State the various common
metal Sheets used in Sheet
35. Perform pipe bending, fitting Metal shop Sheet metal
nipples union in pipes (08 hrs) operations
36. Perform Soldering and Brazing - Shearing, bending, Drawing,
of Pipes. (09 hrs) Squeezing
- Sheet metal joints
- Hem & Seam Joints Fastening
Methods - Riveting, soldering,
Brazing. fluxes used on
common joints. Sheet and
wire-gauges.
- The blow lamp its uses and
pipe fittings.
12 Trace and Test all 37. Perform practice in joining Basic electricity
Electrical & Electronic wires using soldering Iron. (08 - Electricity principles,
components & circuits hrs) - Ground connections,
and assemble circuit to 38. Prepare simple electrical - Ohm's law,
ensure functionality of circuits, measuring of current, - Voltage, Current,
system. voltage and resistance using Resistance, Power,
digital multimeter. (08 hrs) Energy.
39. Perform practice continuity test - Voltmeter, ammeter,
for fuses, jumper wires, fusible Ohmmeter, Multimeter,
links and circuit breakers. (09 - Conductors & insulators,
hrs) Wires, Shielding, Length vs.
resistance, Resistor ratings
13 -do- 40. Perform diagnose series, - Fuses & circuit breakers,
parallel, series-parallel circuits - Ballast resistor,
using Ohm’s law. (05 hrs) - Stripping wire insulation,
41. Check electrical circuit with a - cable colour codes and
test lamp. (05 hrs) sizes,
42. Perform voltage drop test in - Resistors in Series circuits ,
circuits using multimeter, - Parallel circuits and Series-
measure current flow using parallel circuits,
multimeter /ammeter. (07 hrs) - Electrostatic effects,
43. Check circuit using of service Capacitors and its
manual wiring diagram for applications,
troubleshooting (08 hrs) - Capacitors in series and
parallel.
14 -do- 44. Execute cleaning and topping - Description of Chemical

23
 Mechanic Diesel

up of a lead acid battery. (05 effects, Batteries & cells,

hrs) Lead acid batteries & Stay
45. Perform testing battery with Maintenance Free (SMF)
hydrometer. (02 hrs) batteries,
46. Perform connecting battery to a - Magnetic effects, Heating
charger for battery charging effects, Thermo-electric
and checking & testing a energy, Thermistors,
battery after charging. (08 hrs) Thermo couples,
47. Measure and Diagnose the - Electrochemical energy,
cause(s) of excessive Key-off Photo-voltaic energy,
battery drain (parasitic draw) Piezo-electric energy,
and do corrective action. (05 Electromagnetic induction,
hrs) - Relays, Solenoids, Primary
48. Perform test of relay and & Secondary windings,
solenoids and its circuit. (05 Transformers, stator and
hrs) rotor coils.
15 -do- 49. Identify and test power and Basic electronics:
signal connectors for continuity - Description of
(05 hrs) Semiconductors, Solid
50. Perform test and identify state devices- Diodes,
different type of Diodes, NPN & - Transistors, Thyristors, Uni
PNP Transistors for its Junction Transistors ( UJT),
functionality (10 hrs) - Metal Oxide Field Effect
51. Construct and test simple logic Transistors ( MOSFETs),
circuits OR, AND & NOT and - Logic gates-OR, AND &
Logic gates using switches. (10 NOT and Logic gates using
hrs) switches.
16-18 Join components by 52. Perform practice to make Introduction to welding and
using Arc & Gas straight beads and Butt, Lap & T Heat Treatment
welding. joints Manual Metal Arc Welding processes
Welding. (50 hrs) - Principles of Arc welding,
53. Set Gas welding flames and brief description,
perform practice to make a classification and
straight beads and joints by Oxy applications.
– Acetylene welding (25 hrs) - Manual Metal Arc welding
-principles, power sources,
electrodes, welding
parameters, edge
preparation & fit up and
welding techniques;
- Oxy – Acetylene welding -
principles, equipment,
welding parameters, edge
preparation & fit up and

24
 Mechanic Diesel

welding techniques;.
- Basic knowledge about
advance welding process &
equipments like MIG, TIG,
Spot Welding, Plasma
Cutter.
Heat Treatment Process
- Introduction, Definition of
heat treatment, -
- Definition of Annealing,
Normalizing, Hardening
and tempering. –
- Case hardening, Nitriding,
Induction hardening
- Flame Hardening process
used in auto components
with examples.
19-20 Trace & Test Hydraulic 54. Perform liquid penetrant Non-destructive Testing
and Pneumatic testing method and Magnetic Methods
components. particle testing method. (15 - Importance of Non-
hrs) Destructive Testing In
55. Identify of Hydraulic and Automotive Industry,
pneumatic components used in Definition of NDT,
vehicle. (10 hrs) - Liquid penetrant and
56. Tracing of hydraulic circuit on Magnetic particle testing
hydraulic jack, hydraulic power method – Portable Yoke
steering, and Brake circuit. (15 method
hrs) Introduction to Hydraulics &
57. Identify components in Air Pneumatics
brake systems (10 hrs) - Definition of Pascal law,
pressure, Force, viscosity.
Description, symbols and
application in automobile
of Gear pump-Internal &
External,
- single acting, double acting
& Double ended cylinder;
Directional control valves-
2/2, 3/2, 4/2, 4/3 way
valve, Pressure relief valve,
Non return valve, Flow
control valve used in
automobile.

25
 Mechanic Diesel

21 Check & Interpret 58. Identify of different types of - Auto Industry - History,
Vehicle Specification Vehicle. (05 hrs) leading manufacturers,
data and VIN 59. Demonstrate of vehicle - Development in
specification data . (05 hrs) automobile industry,
Select & operate
60. Identify of vehicle information trends, new product.
various Service Station
Number (VIN). (05 hrs). - Brief about Ministry of
Equipments.
61. Demonstrate of Garage, Service Road transport &
station equipments.- Vehicle Highways,
hoists – Two post and four post - The Automotive Research
hoist, Engine hoists, Jacks, Association of India (ARAI),
Stands. (10 hrs) National Automotive
Testing and R&D
Infrastructure Project
(NATRIP), & Automobile
Association.
- Classification of vehicles
on the basis of load as per
central motor vehicle rule,
wheels, final drive, and
fuel used, axles, position of
engine and steering
transmission, body and
load. Brief description
- Uses of Vehicle hoists –
Two post and four post
hoist, Engine hoists, Jacks,
Stands.
22-23 Project Work/ Industrial Visit-
Broad area:
a) Maintenance of cooling system (radiator leakage by brazing and precautionary
measures)
b) Maintenance of intake and exhaust system.
c) Maintenance of Battery.
d) Electrical Wiring harness of a vehicle
e) Vehicle brake system (Hydraulic & Air) & Hydraulic Power Steering
24-25 Revision

26 Examination

Note: More emphasis to be given on video/real-life pictures during theoretical classes. Some
real-life pictures/videos of welded items like boiler drum, ship building, heavy welded structures
etc., may be shown to the trainees to give a feel of Industry and their future assignment.

26
 Mechanic Diesel

SYLLABUS FOR MECHANIC DIESEL TRADE

SECOND SEMESTER – 06 Months
Professional Skills
Week Learning Outcome Professional Knowledge
(Trade Practical)
No. Reference (Trade Theory)
With Indicative Hours
27-28 Dismantle & assemble 62. Identify the different parts of Introduction to Engine:
of Diesel Engine from IC Engine(10 hrs) - Description of internal &
vehicle (LMV/HMV) 63. Identify the different parts in external combustion
along with other engines, Classification of IC
a diesel engine of LMV/ HMV
accessories. engines, Principle & working
(10 hrs) of 2&4-stroke diesel engine
64. Perform practice on starting (Compression ignition
and stopping of diesel Engine (C.I)),
engines. Observe and report - Principle of Spark Ignition
the reading of Tachometer, Engine(SI), differentiate
Odometer, temp and Fuel between 2-stroke and 4
stroke, C.I engine and S.I
gauge under ideal and on load
Engine,
condition. (10 hrs) - Main Parts of IC Engine
65. Practice on dismantling Diesel - Direct injection and indirect
engine of LMV/HMV as per injection, Technical terms
procedure. (20 hrs) used in engine, Engine
specification.
- Study of various gauges/
instrument on a dash board
of a vehicle- Speedometer,
Tachometer, Odometer and
Fuel gauge, and Indicators
such as gearshift position,
Seat belt warning light,
Parking-brake-engagement
warning light and an Engine-
malfunction light.
- Different type of starting
and stopping method of
Diesel Engine
- Procedure for dismantling
of diesel engine from a
vehicle.

27
 Mechanic Diesel

29-30 Overhaul & service 66. Perform Overhauling of Diesel Engine Components:
Diesel Engine, its parts cylinder head assembly, Use - Description and
and check functionality. of service manual for Constructional feature of
Cylinder head, Importance
clearance and other
of Cylinder head design,
parameters,(10 hrs) - Type of Diesel combustion
67. Perform practice on removing chambers,
rocker arm assembly - Effect on size of Intake &
manifolds. (07 hrs) exhaust passages, Head
68. Perform practice on removing gaskets.
the valves and its parts from - Importance of Turbulence
Valves & Valve Actuating
the cylinder head, cleaning.
Mechanism -
(07 hrs)
- Description and Function of
69. Inspection of cylinder head
Engine Valves, different
and manifold surfaces for
types, materials,
warping, cracks and flatness.
- Type of valve operating
Checking valve seats & valve
mechanism, Importance of
guide – Replacing the valve if
Valve seats, Valve seats
necessary. (07 hrs)
inserts in cylinder heads,
70. Check leaks of valve seats for
- importance of Valve
leakage – Dismantle rocker
rotation, Valve stem oil
shaft assembly -clean & check
seals, size of Intake valves,
rocker shaft-and levers, for
Valve trains, Valve- timing
wear and cracks and
diagram, concept of
reassemble. (07 hrs)
Variable valve timing.
71. Check valve springs, tappets,
- Description of Camshafts &
push rods, tappet screws and
drives ,
valve stem cap. Reassembling
- Description of Overhead
valve parts in sequence, refit
camshaft (SOHC and DOHC),
cylinder head and manifold &
importance of Cam lobes,
rocker arm assembly,
Timing belts & chains,
adjustable valve clearances,
Timing belts & tensioners.
starting engine after
adjustments. (12 hrs)
31 -do- 72. Perform Overhauling piston - Description & functions of
and connecting rod assembly. different types of pistons,
Use of service manual for piston rings and piston pins
and materials.
clearance and other
- Used recommended
parameters (05 hrs) clearances for the rings and

28
 Mechanic Diesel

73. Perform Practice on removing its necessity precautions

oil sump and oil pump – clean while fitting rings, common
the sump. troubles and remedy.
- Compression ratio.
74. Perform removing the big end
- Description & function of
bearing, connecting rod with connecting rod,
the piston. (05 hrs) - importance of big- end split
75. Perform removing the piston obliquely
rings; Dismantle the piston - Materials used for
and connecting rod. Check the connecting rods big end &
side clearance of piston rings main bearings. Shells piston
pins and locking methods of
in the piston groove & lands
piston pins.
for wear. Check piston skirt
and crown for damage and
scuffing, clean oil holes. (05
hrs)
76. 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. (05 hrs)
77. Check connecting rod for
bend and twist. Assemble the
piston and connecting rod
assembly. (05 hrs)
32 -do- 78. Perform Overhauling of - Description and function of
crankshaft, Use of service Crank shaft, camshaft,
manual for clearance and - Engine bearings-
classification and location –
other parameters (05 hrs)
materials used &
79. Perform removing damper composition of bearing
pulley, timing gear/timing materials- Shell bearing and
chain, flywheel, main bearing their advantages- special
caps, bearing shells and bearings material for diesel
crankshaft from engine(05 engine
hrs) - Application bearing failure &
its causes-care &
80. Inspect oil retainer and thrust
maintenance.
surfaces for wear. (05 hrs) - Crank-shaft balancing, firing
81. Measure crank shaft journal order of the engine.

29
 Mechanic Diesel

for wear, taper and ovality.

(05 hrs)
82. Demonstrate crankshaft for
fillet radii, bend & twist. (05
hrs)
33 -do- 83. Inspect flywheel and - Description and function of
mounting flanges, spigot and the fly wheel and vibration
bearing.(05 hrs) damper.
- Crank case & oil pump, gears
84. Check vibration damper for
timing mark, Chain
defect. (02 hrs) sprockets, chain tensioner
85. Perform removing cam shaft etc.
from engine block, Check for - Function of clutch &
bend & twist of camshaft. coupling units attached to
Inspection of cam lobe, flywheel.
camshaft journals and
bearings and measure cam
lobe lift. (07 hrs)
86. 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. (11 hrs)
34 -do- 87. Perform cleaning and - Description of Cylinder
checking of cylinder blocks. block,
(04 hrs) - Cylinder block construction,
- Different type of Cylinder
88. Surface for any crack, flatness
sleeves (liner).
measure cylinder bore for
taper & ovality, clean oil
gallery passage and oil pipe
line. (05 hrs)
89. Perform bore - descale water
passages and examine. (05
hrs)
90. Removing cylinder liners from

30
 Mechanic Diesel

scrap cylinder block. (04 hrs)

91. Perform practice in measuring
and refitting new liners as per
maker’s recommendations
precautions while fitting new
liners. (07 hrs)
35 -do- 92. Perform reassembling all parts - Engine assembly procedure
of engine in correct sequence with aid of special tools and
and torque all bolts and nuts gauges used for engine
assembling.
as per workshop manual of
- Introduction to Gas Turbine,
the engine. (12 hrs) Comparison of single and
93. Perform testing cylinder two stage turbine engine,
compression, Check idle - Different between gas
speed. (08 hrs) turbine and Diesel Engine.
94. Perform removing & replacing
a cam belt, and adjusting an
engine drive belt, replacing an
engine drive belt. (05 hrs)
36-38 Trace, Test & Repair 95. Perform practice on checking Need for Cooling systems
Cooling and Lubrication &top up coolant, draining & - Heat transfer method,
System of engine. refilling coolant, checking / Boiling point & pressure,
- Centrifugal force,
replacing a coolant hose. (10
- Vehicle coolant properties
hrs) and recommended change
96. Perform test cooling system of interval,
pressure. (05 hrs) - Different type of cooling
97. Execute on removing & systems,
replacing radiator/ thermostat Basic cooling system
check the radiator pressure components
- Radiator, Coolant hoses, -
cap. (10 hrs)
- Water pump,
98. Test of thermostat. (5 hrs) - Cooling system thermostat,
99. Perform cleaning & reverse Cooling fans,
flushing. (10 hrs) - Temperature indicators,
100. Perform overhauling water - Radiator pressure cap,
pump and refitting. (10 hrs) Recovery system, Thermo-
101. Perform checking engine oil, switch.
Need for lubrication system,
draining engine oil, replacing
- Functions of oil, Viscosity
oil filter, & refilling engine oil
and its grade as per SAE ,
(10 hrs)

31
 Mechanic Diesel

102. Execute overhauling of oil - Oil additives, Synthetic oils,

pump, oil coolers, air cleaners The lubrication system,
and air filters and adjust oil Splash system,
pressure relief valves, repairs - Pressure system
to oil flow pipe lines and - Corrosion/noise reduction in
unions if necessary. (15 hrs) the lubrication system.
- Lubrication system
components
- Description and function of
Sump, Oil collection pan, Oil
tank, Pickup tube,
- different type of Oil pump &
Oil filters Oil pressure relief
valve, Spurt holes & galleries, Oil
indicators, Oil cooler.
39 Trace & Test Intake and 103. Execute dismantling air Intake & exhaust systems –
Exhaust system of compressor and exhauster - Description of Diesel
engine. and cleaning all parts - induction & Exhaust
systems. Description &
measuring wear in the
function of air compressor,
cylinder, reassembling all exhauster, Super charger,
parts and fitting them in the Intercoolers, turbo charger,
engine. (6 hrs) variable turbo charger
104. Execute dismantling & mechanism.
assembling of turbocharger, Intake system components-
check for axial clearance as - Description and function of
Air cleaners, Different type
per service manual. (05 hrs)
air cleaner, Description of
105. Examine exhaust system for Intake manifolds and
rubber mounting for damage, material,
deterioration and out of Exhaust system components-
position; for leakage, loose - Description and function of
connection, dent and damage; Exhaust manifold, Exhaust
(05 hrs) pipe, Extractors, Mufflers-
Reactive, absorptive,
106. Perform practice on exhaust
Combination of Catalytic
manifold removal and converters, Flexible
installation, practice on connections, Ceramic
Catalytic converter removal coatings, Back-pressure,
and installation. (05 hrs) - Electronic mufflers.
107. Check Exhaust system for

32
 Mechanic Diesel

rubber mounting for damage,

deterioration and out of
position; for leakage, loose
connection, dent and damage.
(04 hrs)
40-42 Service Diesel Fuel 108. Perform work on removing Fuel Feed System in IC
System and check &cleaning fuel tanks, checking Engine(Petrol & Diesel)
proper functionality. leaks in the fuel lines. (10 hrs) - Gravity feed system, Forced
feed system, main parts,
109. Perform soldering & repairing
Fuel Pumps- Mechanical &
pipe lines and Unions, brazing Electrical Feed Pumps.
nipples to high pressure line - Knowledge about function,
studying the fuel feed system working & types of
in diesel engines, draining of Carburettor.
water separators. (10 hrs) Diesel Fuel Systems
110. Execute overhauling of Feed - Description and function of
Diesel fuel injection, fuel
Pumps (Mechanical &
characteristics, concept of
Electrical). (10 hrs) Quiet diesel technology
111. Perform bleeding of air from &Clean diesel technology.
the fuel lines, servicing Diesel fuel system components
primary & secondary filters. - Description and function of
(10 hrs) Diesel tanks & lines, Diesel
112. Execute removing a fuel fuel filters, water separator,
injection pump from an Lift pump, Plunger pump,
engine-refit the pump to the Priming pump,
engine re- set timing - fill - Inline injection pump,
lubricating-oil start and adjust Distributor-type injection
slow speed of the engine. (15 pump, Diesel injectors, Glow
hrs) plugs, Cummins & Detroit
113. Execute overhauling of Diesel injection.
injectors and testing of Electronic Diesel control-
injector. (10 hrs)
- Electronic Diesel control
114. General maintenance of Fuel
systems, Common Rail Diesel
Injection Pumps (FIP). (10 hrs)
Injection (CRDI) system,
hydraulically actuated
electronically controlled unit
injector (HEUI) diesel
injection system. Sensors,
actuators and ECU
(Electronic Control Unit)

33
 Mechanic Diesel

used in Diesel Engines.

43 Plan & overhaul the 115. Execute Start engine adjust Marine & Stationary Engine:-
stationary engine and idling speed and damping Types,
Governor and check device in pneumatic governor - double acting engines,
functionality. and venture control unit opposed piston engines,
checking. (06 hrs) starting systems, cooling
116. Verify performance of engine systems, lubricating systems,
with off load adjusting supplying fuel oil, hydraulic
timings. Start engine- coupling,
adjusting idle speed of the - Reduction gear drive,
engine fitted with mechanical electromagnetic coupling,
governor checking- high speed - Electrical drive, generators and
operation of the engine. (07 motors, supercharging.
hrs)
117. Check performance for
missing cylinder by isolating
defective injectors and test-
dismantle and replace
defective parts and
reassemble and refit back to
the engine. (12 hrs)
44 21.. Monitor emission 118. Monitor emissions procedures Emission Control:- Vehicle
of vehicle and execute by use of Engine gas analyser emissions
different operation to or Diesel smoke meter. (10 - Standards- Euro and Bharat II,
obtain optimum hrs) III, IV, V Sources of emission,
pollution as per 119. Checking & cleaning a Positive Combustion, Combustion
emission norms. crank case ventilation (PCV) chamber design. Types of
valve. Obtaining & emissions:
interpreting scan tool data. - Characteristics and Effect of
Inspection of EVAP canister Hydrocarbons, Hydrocarbons
purges system by use of scan in exhaust gases, Oxides of
Tool. (10 hrs) nitrogen, Particulates, Carbon
120. EGR /SCR Valve Remove and monoxide, Carbon dioxide,
installation for inspection. (05 Sulphur content in fuels
hrs) Description of Evaporation
emission control, Catalytic
conversion, Closed loop,
Crankcase emission control,

34
 Mechanic Diesel

- Exhaust gas recirculation (EGR)

valve, controlling air-fuel
ratios, Charcoal storage
devices, Diesel particulate
filter (DPF). Selective Catalytic,
Reduction (SCR), EGR VS SCR
45 Carryout overhauling of 121. Perform removing alternator Basic Knowledge about DC
Alternator and Starter from vehicle dismantling, Generator & AC Generator.
Motor. cleaning checking for defects, - Constructional details of
Alternator
assembling and testing for
- Description of charging
motoring action of alternator circuit operation of
& fitting to vehicles. (15 hrs) alternators, regulator
122. Practice on removing starter unit, ignition warning
motor Vehicle and lamp- troubles and
overhauling the starter motor, remedy in charging
testing of starter motor (10 system.
- Description of starter
hrs)
motor circuit,
- Constructional details of
starter motor solenoid
switches, common troubles
and remedy in starter circuit.
46-47 23. Diagnose & rectify 123. Execute troubleshooting in Troubleshooting :
the defects in LMV/HMV for Engine Not Causes and remedy for
LMV/HMV to ensure starting – Mechanical & - Engine Not starting
Mechanical & Electrical
functionality of vehicle. Electrical causes, High fuel
causes,
consumption, Engine - High fuel consumption,
overheating, Low Power Engine overheating,
Generation, Excessive oil - Low Power Generation,
consumption, Low/High - Excessive oil
Engine Oil Pressure, Engine consumption,
Noise. (50 hrs) - Low/High Engine Oil
Pressure, Engine Noise.
49-50 In-plant training / Project work Projects viz.
a. Overhauling of Pressure Lubrication system
b. Maintenance of cooling system.
c. Overhauling of FIP.
d. Cleaning & Testing of Injectors.
e. Overhauling of Alternator

35
 Mechanic Diesel

f. Overhauling of Starter Motor

g. Study on Diagnosis Tool/Scanner Tool for ECU of CRDI engine
51 Revision
52
Examination

Note: -

1. Some of the sample project works (indicative only) are given against each semester.

2. Instructor may design their own project and also inputs from local industry may be taken
for designing such new project.

3. The project should broadly covered maximum skills in the particular trade and must
involve some problem solving skill. Emphasis should be on Teamwork: Knowing the
power of synergy/ collaboration, Work to be assigned in a group (Group of at least 4
trainees). The group should demonstrate Planning, Execution, Contribution and
application of Learning. They need to submit Project report.

4. If the instructor feels that for execution of specific project more time is required than he
may plan accordingly to produce components/ sub-assemblies in appropriate time i.e.,
may be in the previous semester or during execution of normal trade practical.

5. More emphasis to be given on video/real-life pictures during theoretical classes. Some

real-life pictures/videos of welded items like boiler drum, ship building, heavy welded
structures etc., may be shown to the trainees to give a feel of Industry and their future
assignment.

36
 Mechanic Diesel
9. SYLLABUS - CORE SKILLS

9.1 WORKSHOP CALCULATION SCIENCE & ENGINEERING DRAWING

First Semester
Duration: Six Months
S No. Workshop Calculation and Science Engineering
Drawing
1. Unit: Systems of unit- FPS, CGS, MKS/SI Engineering Drawing: Introduction and its
unit, unit of length, Mass and time, importance
Conversion of units
- Relationship to other technical drawing
types
- Conventions
- Viewing of engineering drawing sheets
- Method of Folding of printed Drawing
Sheet as per BIS SP:46-2003
2. Fractions: Fractions, Decimal fraction, Drawing Instruments: their Standard and uses
L.C.M., H.C.F., Multiplication and Division
- Drawing board, T-Square, Drafter
of Fractions and Decimals, conversion of
(Drafting M/c), Set Squares, Protractor,
Fraction to Decimal and vice versa. Drawing Instrument Box (Compass,
Simple problems using Scientific Dividers, Scale, Diagonal Scales etc.),
Calculator. Pencils of different Grades, Drawing pins/
Clips.
3. Ratio &Proportion: Simple calculation on Lines:
related problems.
- Definition, types and applications in
Drawing as per BIS SP:46-2003
- Classification of lines (Hidden, centre,
construction, Extension, Dimension,
Section)
- Drawing lines of given length (Straight,
curved)
- Drawing of parallel lines, perpendicular line
- Methods of Division of line segment
4. Percentage: Free hand drawing of
Introduction, Simple calculation.
- Lines, polygons, ellipse, etc.
Changing percentage to fraction and - geometrical figures and blocks with
decimal & vice-versa. dimension
Transferring measurement from the given

37
 Mechanic Diesel

object to the free hand sketches.

5. Material Science: Properties -Physical & Lettering and Numbering as per BIS SP46-2003:
Mechanical, Types –Ferrous & Non-
- Single Stroke, Double Stroke, inclined,
Ferrous, difference between Ferrous and
Upper case and Lower case.
Non-Ferrous metals, introduction of Iron,
Cast Iron, Wrought Iron, Steel, difference
between Iron and Steel, Alloy steel,
carbon steel, stainless steel, Non-Ferrous
metals, Non-Ferrous Alloys.
6. Mass, Weight and Density: Mass, Unit of Drawing of Geometrical Figures: Definition,
Mass, Weight, difference between mass nomenclature and practice of :
and weight.
Density, unit of density. Relation between - Angle: Measurement and its types,
mass, weight & density. method of bisecting.
Simple problems related to mass, weight, - Triangle-different types
and density. - Rectangle, Square, Rhombus,
Parallelogram.
- Circle and its elements.
7. Work, Power and Energy: Work, unit of Sizes and Layout of Drawing Sheets
work, power, unit of power, Horse power
- Basic principle of Sheet Size
of engines, mechanical efficiency,
- Designation of sizes
energy, use of energy, potential and - Selection of sizes
kinetic energy, examples of potential - Title Block, its position and content
energyand kinetic energy. - Borders and Frames (Orientation marks
and graduations)
- Grid Reference
- Item Reference on Drawing Sheet (Item
List)
8. ----- Method of presentation of Engineering
Drawing
- Pictorial View
- Orthographic View
- Isometric view
9. ------ Symbolic Representation used in the related
trade (as per BIS SP:46-2003) of:
- Fastener (Rivets, Bolts and Nuts)
- Bars and profile sections
- Weld brazed and soldered joints
- Electrical and electronics element
- Piping joints and fittings

38
 Mechanic Diesel

Second Semester
Duration: Six Months

S No. Workshop Calculation and Science Engineering

Drawing
1. Basic Algebra: Dimensioning practice:
Addition, Subtraction, Multiplication, - Position of dimensioning (unidirectional,
Division, Algebraic formula, Linear aligned, as per BIS SP:46-2003)
equations - Types of arrowhead
(with two variables). - Leader Line with text
- Symbols preceding the value of
dimension and dimensional tolerance.
2. Mensuration: Drawing of Solid figures (Cube, Cuboids, Cone,
Area and perimeter of square, rectangle, Prism, Pyramid, Frustum of Cone and Pyramid)
parallelogram, triangle, circle, semi-circle, with dimensions.

Volume of solids – cube, cuboid, cylinder

and Sphere.

Surface area of solids – cube, cuboid,

cylinder and Sphere.
3. Trigonometry: Trigonometrical ratios, Free hand Drawing of Solid figures (Prism,
measurement of angles. Pyramid, Frustum of Cone and Pyramid) with
dimensions.
Trigonometric tables

4. Elasticity: Free Hand sketch of hand tools and measuring

Elastic & Plastic material. Stress & strain tools used in respective trades.
and their units. Young’s modules.
Ultimate stress and breaking stress.
5. Heat & Temperature: Projections:
Heat and temperature, their units, - Concept of axes plane and quadrant.
difference between heat and - Orthographic projections
temperature, boiling point, melting point, - Method of first angle and third angle
projections (definition and difference)
Scale of temperature, relation between - Symbol of 1st angle and 3rd angle
different scale of temperature. projection as per IS specification.

Thermometer, pyrometer.

Transmission of heat, conduction,

convection, radiation.
6. Basic Electricity: Introduction, use of Drawing of Orthographic projection in 3rd
electricity, how electricity is produced, angle.

39
Mechanic Diesel

Types of current_ AC, DC, their

comparison, voltage, resistance, their
units. Conductor, insulator, Types of
connections – series, parallel, electric
power, Horse power, energy, unit of
electrical energy.

- Electrical insulating materials.

- Basic concept of earthing.
7. - Area of irregular surfaces. Free hand Drawing of simple fastener (Rivet,
- Application related to shop problems. Bolts, Nuts & Screw)
8. - Material weight and cost problems Free hand sketching of simple objects related
related to trade. to trade.
9. - Temperature measuring instruments. - Riveted joints-Butt & Lap (Drawing one for
Specific heats of solids & liquids. each type).
10. - Thermal Conductivity, Heat loss and - Reading of drawing. Simple exercises related
heat gain. to missing lines, dimensions. How to make
queries.
11. - Heat treatment and advantages. - Simple exercises relating missing symbols.
- Missing views
12. ---------- - Concept of preparation of assembly drawing
and detailing. Preparation of simple
assemblies & their details of trade related
job/exercises with the dimensions from the
given sample or models.
13. ---------- Reading of fabricated engineering drawing

40
Mechanic Diesel

9.2 EMPLOYABILITY SKILLS

First Semester
Duration : 20 hrs
1. English Literacy
Marks : 09
Pronunciation Accentuation (mode of pronunciation) on simple words,
Diction (use of word and speech)

Functional Grammar Transformation of sentences, Voice change, Change of tense,

Spellings.

Reading Reading and understanding simple sentences about self, work and
environment

Writing Construction of simple sentences

Writing simple English

Speaking/ Spoken Speaking with preparation on self, on family, on friends/ classmates,

English on known people, picture reading, gain confidence through role-
playing and discussions on current happening, job description, asking
about someone's job, habitual actions.
Cardinal (fundamental) numbers, ordinal numbers.
Taking messages, passing on messages and filling in message forms,
Greeting and introductions, office hospitality, Resumes or curriculum
vita essential parts, letters of application reference to previous
communication.

Duration : 20 hrs
2. IT Literacy
Marks : 09
Basics of Computer Introduction, Computer and its applications, Hardware and
peripherals, Switching on-Starting and shutting down of the
computer.

Computer Operating Basics of Operating System, WINDOWS, The user interface of

System Windows OS, Create, Copy, Move and delete Files and Folders, Use
of External memory like pen drive, CD, DVD etc. Use of Common
applications.

Word Processing and Basic operating of Word Processing, Creating, Opening and Closing
Worksheet Documents, Use of shortcuts, Creating and Editing of Text,
Formatting the Text, Insertion &Creation of Tables. Printing
document. Basics of Excel worksheet, understanding basic

41
Mechanic Diesel

commands, creating simple worksheets, understanding sample

worksheets, use of simple formulas and functions, Printing of simple
excel sheets.

Computer Networking Basic of Computer Networks (using real life examples), Definitions of
and Internet Local Area Network (LAN), Wide Area Network (WAN), Internet,
Concept of Internet (Network of Networks),
Meaning of World Wide Web (WWW), Web Browser, WebsSite, Web
page and Search Engines. Accessing the Internet using Web Browser,
Downloading and Printing Web Pages, Opening an email account and
use of email. Social media sites and its implication.
Information Security and antivirus tools, Do's and Don'ts in
Information Security, Awareness of IT - ACT, types of cyber crimes.

Duration : 15 hrs
3. Communication Skills
Marks : 07
Introduction to Communication and its importance
Communication Skills Principles of effective communication
Types of communication - verbal, non-verbal, written, email, talking
on phone.
Non-verbal communication -characteristics, components-Para-
language
Body language
Barriers to communication and dealing with barriers.
Handling nervousness/ discomfort.

Listening Skills Listening-hearing and listening, effective listening, barriers to

effective listening, guidelines for effective listening.
Triple- A Listening - Attitude, Attention & Adjustment.
Active listening skills.

Motivational Training Characteristics essential to achieving success.

The power of positive attitude.
Self awareness
Importance of commitment
Ethics and values
Ways to motivate oneself
Personal goal setting and employability planning.

Facing Interviews Manners, etiquettes, dress code for an interview

Do's &don'ts for an interview

42
Mechanic Diesel

Behavioral Skills Problem solving

Confidence building
Attitude

Second Semester
Duration : 15 hrs
4. Entrepreneurship Skills
Marks : 06
Concept of Entrepreneur - Entrepreneurship - Enterprises: Conceptual issue
Entrepreneurship Entrepreneurship vs. management, Entrepreneurial motivation.
Performance &record, Role &function of entrepreneurs in relation to
the enterprise & relation to the economy, Source of business ideas,
Entrepreneurial opportunities, The process of setting up a business.

Project Preparation & Qualities of a good entrepreneur, SWOT and risk analysis. Concept
Marketing Analysis &Application of PLC, Sales &Distribution management. Difference
between small scale &large scale business, Market survey, Method
of marketing, Publicity and advertisement, Marketing mix.
Institution’s Support Preparation of project. Role of various schemes and institutes for
self-employment i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/
non-financing support agencies to familiarize with the policies /
programmes, procedure & the available scheme.

Investment Project formation, Feasibility, Legal formalities i.e., Shop act,

Procurement Estimation &costing, Investment procedure - Loan procurement -
Banking processes.

Duration : 10 hrs
5. Productivity
Marks : 05
Benefits Personal/ Workman - Incentive, Production linked Bonus,
Improvement in living standard.

Affecting Factors Skills, Working aids, Automation, Environment, Motivation - How it

improves or slows down productivity.

Comparison with Comparative productivity in developed countries (viz. Germany,

Developed Countries Japan and Australia) in select industries, e.g. Manufacturing, Steel,
Mining, Construction etc. Living standards of those countries, wages.

Personal Finance Banking processes, Handling ATM, KYC registration, safe cash
Management handling, Personal risk and insurance.

6. Occupational Safety, Health and Environment Education Duration : 15 hrs

43
Mechanic Diesel

Marks : 06
Safety & Health Introduction to occupational safety and health
Importance of safety and health at workplace.

Occupational Hazards Basic hazards, chemical hazards, vibroacoustic hazards, mechanical

hazards, electrical hazards, thermal hazards. occupational health,
occupational hygiene, occupational diseases/ disorders & its
prevention.

Accident &Safety Basic principles for protective equipment.

Accident prevention techniques - control of accidents and safety
measures.

First Aid Care of injured &sick at the workplaces, First-aid &transportation of

sick person.

Basic Provisions Idea of basic provision legislation of India.

Safety, health, welfare under legislative of India.

Ecosystem Introduction to environment. Relationship between society and

environment, ecosystem and factors causing imbalance.

Pollution Pollution and pollutants including liquid, gaseous, solid and

hazardous waste.

Energy Conservation Conservation of energy, re-use and recycle.

Global Warming Global warming, climate change and ozone layer depletion.
Ground Water Hydrological cycle, ground and surface water, Conservation and
harvesting of water.

Environment Right attitude towards environment, Maintenance of in-house

environment.
Duration : 05 hrs
7. Labour Welfare Legislation
Marks : 03
Welfare Acts Benefits guaranteed under various acts- Factories Act,
Apprenticeship Act, Employees State Insurance Act (ESI), Payment
Wages Act, Employees Provident Fund Act, The Workmen's
Compensation Act.

Duration : 10 hrs
8. Quality Tools
Marks : 05
Quality Consciousness Meaning of quality, Quality characteristic.

44
Mechanic Diesel

Quality Circles Definition, Advantage of small group activity, objectives of quality

circle, Roles and function of quality circles in organization, Operation
of quality circle. Approaches to starting quality circles, Steps for
continuation quality circles.

Quality Management Idea of ISO 9000 and BIS systems and its importance in maintaining
System qualities.

House Keeping Purpose of housekeeping, Practice of good housekeeping.

Quality Tools Basic quality tools with a few examples.

45
 Mechanic Diesel
ANNEXURE-I

MECHANIC DIESEL
LIST OF TOOLS AND EQUIPMENT
A. TRAINEES TOOL KIT per 4 Trainees ( FOR 20 TRAINEES + 1 ISTRUCTOR)

Name of the Tool &Equipments Specification Quantity

1. Allen Key set of 12 pieces 2mm to 14mm 5+1

2. Calliper inside with spring 15 cm 6 nos.
3. Callipers outside with spring 15 cm 6 nos.

4. Center Punch. 10 mm. Dia. x 100 mm 6 nos.

5. Dividers with spring 15 cm 6 nos.
6. Electrician Screw Driver 250mm 6 nos.
7. Hammer ball peen with handle 0.5 kg 6 nos.
8. Hands file for Second cut flat 20 cm. 6 nos.
9. Philips Screw Driver set of 5 pieces 100 mm to 300 mm 6 nos.
10. Pliers combination 20 cm. 6 nos.
11. Screw driver Blade 20cm.X 9mm. 6 nos.
12. Screw driver Blade 30 cm. X 9 mm. 6 nos.
13. Scriber 15 cm 6 nos.
14. Spanner D.E. set of 12 pieces 6mm to 32mm 6 nos.
15. Spanner, ring set of 12 6 to 32 mm. (metric) 6 nos.
Spanners socket with speed handle, T-bar, up to 32 mm 6 nos.
16. ratchet and universal set of 28 pieces with
box
17. Steel rule 30 cm inch and metric 6 nos.
18. Steel tool box with lock and key (folding type) 400x200x150 mm 6 nos.
19. Wire cutter and stripper 6 nos.
B. INSTRUMENTS AND GENERAL SHOP OUTFIT - For 2 (1+1) units no additional items are required
TOOLS & EQUIPMENT
20. Adjustable spanner (pipe wrench) 350 mm 2
21. Air blow gun with standard accessories 1

46
Mechanic Diesel

22. Allen Key set of 12 pieces 2mm to 14mm 4

23. Ammeter DC with external shunt 300A/ 60A 4
24. Air ratchet with standard accessories 4
Air impact wrench with standard 4
25.
accessories
26. Angle plate adjustable 250x150x175mm 1.
27. Angle plate size 200x100x200mm 2
28. Anvil with Stand 50 Kgs 1
29. Auto Electrical test bench 1
30. Battery –charger 5 meters flexible in case 2
31. Blow Lamp 1 litre 2
32. Belt Tensioner gauge 1
33. Caliper inside with Spring 15 cm 4
34. Calipers outside with spring 15 cm 4
35. Car Jet washer with standard accessories 1
Chain Pulley Block capacity with tripod 3 ton 1
36.
stand
37. Chisel flat 10 cm 4
38. Chisels cross cut 200 mm X 6mm 4
39. Circlip pliers Expanding and contracting 15cm and 20cm 4 each
40. Clamps C 100mm 2
41. Clamps C 150mm 2
42. Clamps C 200mm 2
43. Cleaning tray 45x30 cm. 4
Compression testing gauge suitable for
44. 2
diesel Engine with standard accessories
45. Connecting rod alignment fixture 1
46. Copper bit soldering iron 0.25 Kg 4
47. Cylinder bore gauge capacity 20 to 160 mm 4
Cylinder liner- Dry & wet liner, press fit &
48. 1 each
slidefit liner
49. DC Ohmmeter 0 to 300 Ohms 2
50. Depth micrometer 0-25mm 4

47
Mechanic Diesel

Dial gauge type 1 Gr. A (complete with

51. 4
clamping devices and with magnetic stand)
52. Different type of Engine Bearing model 1 set
53. Different type of piston model 1 set
54. Dividers with Spring 15 cm 4
55. Drift Punch Copper 15 Cm 4
56. Drill point angle gauge 1
1.5 mm to 15 mm by
57. Drill twist (various sizes) 4
0.5mm
230 V 60 watts 230 V 25
58. Electric Soldering Iron 2 each
watts
59. Electric testing screw driver 4
60. Engineer’s square Blade size 15 cm 4
61. Engineers stethoscope 1
62. Feeler gauge 20 blades (metric) 4
63. File flat , bastard 20 cm 4
64. File, half round ,second cut 20 cm 4
65. File, Square second cut 20 cm 4
66. File, Square round 30 cm 4
67. File, triangular , second cut 15 cm 4
Files assorted sizes and types including safe
68. 2each
edge file (20 No’s)
69. Flat File , second cut 25 cm 4
70. Flat File , bastard 35 cm 4
71. Fuel feed pump for Diesel 1
72. Fuel injection pump (Diesel) inline 1
Fuel injection pump dismantling tool kit
73. 1
/Universal Vice
Fuel injection pump VE pump / Distributor
74. fuel rotary pump (DPC) pumps / along with 1 each
special tools and accessories
75. Gloves for Welding (Leather and Asbestos) 5 sets
76. Glow plug tester 2
77. Granite surface plate with stand and cover 1600 x 1000mm 1

48
Mechanic Diesel

78. Grease Gun 2

79. Grease Gun heavy duty trolley type 10 kg capacity 1
80. Growler 2
81. Hacksaw frame adjustable 20-30 cm 10
82. Hammer Ball Peen 0.75 Kg 4
83. Hammer Chipping 0.25 Kg 5
84. Hammer copper with handle 1 Kg 4
85. Hammer Mallet 4
86. Hammer Plastic 4
(i) up to 4mm
87. Hand operated crimping tool 2 each
(ii) up to 10mm
10.5 to 11.25 mm, 11.25 to
12.75 mm, 12.75 to 14.25
88. Hand reamers adjustable 2 set
mm and 14.25 to 15.75
mm
89. Hand Shear Universal 250mm 2
90. Hand vice Up to 37 mm 2
91. Hollow Punch set of seven pieces 6mm to 15mm 2set
92. Injector – Multi hole type, Pintle type 4 each
93. Injector cleaning unit 1
94. Injector testing set (Hand tester) 1
95. Insulated Screw driver 20 cm x 9mm blade 4
96. Insulated Screw driver 30 cm x 9mm blade 4
97. Left cut snips 250mm 4
98. Lifting jack screw 3 ton, 5ton & 20 Ton 1 each
99. Magneto spanner set with 8 spanners 1set
100. Magnifying glass 75mm 2
101. Marking out table 90X60X90 cm. 1
102. Multimeter digital 5
103. Oil can 0.5/0.25 liter capacity 4
104. Oil pump for dismantling and assembling. 2
105. Oil Stone 15 cm x 5 cm x 2.5 cm 1
106. Oscilloscope 20MHz 2

49
Mechanic Diesel

107. Outside micrometer 0 to 25 mm 2

108. Outside micrometer 25 to 50 mm 2
109. Outside micrometer 50 to 75 mm 1
110. Outside micrometer 75 to 100 mm 1
111. Philips Screw Driver set of 5 pieces 100 mm to 300 mm 2
112. Pipe cutting tool 2
113. Pipe flaring tool 2
114. Piston ring compressor 2
115. Piston Ring expander and remover. 2
116. Piston Ring groove cleaner. 1
117. Pliers combination 20 cm. 2
118. Pliers flat nose 15 cm 2
119. Pliers round nose 15 cm 2
120. Pliers side cutting 15 cm 2
121. Portable electric drill Machine 1
122. Prick Punch 15 cm 4
123. Punch Letter 4mm (Number) 2 sets
124. Radiator cut section-cross flow 1
125. Radiator cut section-down flow 1
126. Radiator pressure cap 2
127. Right cut snips 250mm 2
128. Rivet sets snap and Dolly combined 3mm, 4mm, 6mm 2
129. Scraper flat 25 cm 2
130. Scraper half round 25 cm 2
131. Scraper Triangular 25 cm 2
132. Scriber 15 cm 2
133. Scriber with scribing black universal 2
134. Set of stock and dies -Metric 2sets
135. Tinnman’s Shear 450 mm x 600mm 2
136. Sheet Metal Gauge 2
137. Tinnman’sShear 300mm 4
138. Soldering Copper Hatchet type 500gms 2

50
Mechanic Diesel

Solid Parallels in pairs (Different size) in

139. 2
Metric
140. Spanner Clyburn 15 cm 1
141. Spanner D.E. set of 12 pieces 6mm to 32mm 4
Spanner T. flocks for screwing up and up-
142. 2
screwing inaccessible
143. Spanner, adjustable 15cm 2
144. Spanner, ring set of 12 metric sizes 6 to 32 mm. 4
Spanners socket with speed handle, T-bar,
145. 2
ratchet and universal
146. Spark lighter 2
147. Spark plug spanner 14mm x 18mm x Size 2
Starter motor axial type, pre-engagement
148. 1each
type & Co-axial type
149. Steel measuring tape in a case 10 meter 4
150. Steel rule 15 cm inch and metric 4
151. Steel rule 30 cm inch and metric 4
152. Straight edge gauge 2 ft. 2
153. Straight edge gauge 4 ft. 2
154. Stud extractor set of 3 2sets
155. Stud remover with socket handle 1
Surface gauge with dial test indicator
156. 0.01 mm 4
plunger type
157. Tachometer (Counting type) 1
158. Tandem master cylinder with booster 4
159. Taps and Dies complete sets (5 types) 1set
160. Taps and wrenches - Metric 2sets
161. Telescope gauge 4
0
162. Temperature gauge with sensor 0-100 C 2
163. Thermostat 2
164. Thread pitch gauge Metric 2
165. Timing lighter 2
5-35 Nm, 12-68 Nm & 50-
166. Torque wrenches 1each
225 Nm

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 Mechanic Diesel

167. Trammel 30 cm 2
168. Turbocharger cut sectional view 1
169. Tyre pressure gauge with holding nipple 2
Universal puller for removing pulleys,
170. 1
bearings
171. V’ Block 75 x 38 mm pair with Clamps 2
172. Vacuum gauge 0 to 760 mm of Hg. 2
173. Valve Lifter 1
174. Valve spring compressor universal 1
0-300 mm with least count
175. Vernier calliper 4
0.02mm
176. Vice grip pliers 2
Water pump for dismantling and
177. 4
assembling
178. Wire Gauge (metric ) 2
250 x 120 x 60 cm with 4
179. Work bench 4
vices 12cm Jaw
GENERAL SHOP OUTFIT
Air conditioned CRDI Vehicle in running 1
180.
condition -LMV
Arbor press hand operated 2 ton capacity 1
181.

Automotive exhaust 5 gas analyser 1

182.
(petrol & Diesel) or Diesel Smokemeter
183. Bench lever shears 250mm Blade x 3mm 1
Dismantling and 1
Diesel Engine – CRDI - 4 stroke
184. assembling with Swivelling
stand
Diesel engine ( Running condition ) 1
185.
Stationary type
Discrete Component Trainer / Basic 1
186.
Electronics Trainer
Drilling machine bench to drill up to 1
187.
12mm dia along with accessories
AC / HWDC, 230 VAC, 01 set
188. Dual Magnetization Yoke
50Hz

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 Mechanic Diesel

189. Gas Welding Table 1220mm x760mm 2

Grinding machine (general purpose) D.E. 1
190. pedestal with 300 mm dia. wheels rough
and smooth
Heavy Commercial vehicle type (without 1
191.
body on frame)
Hydraulic jack HI-LIFT type -3 ton 1each
192.
capacity, and 5 Ton capacity
193. Liquid penetrate Inspection kit 1set
194. Multi Scan Tool with oscilloscope 1
195. Pipe Bending Machine (Hydraulic type) 12mm to 30mm 1
Pneumatic rivet gun with standard 2
196.
accessories
197. Spring tension tester 1
198. Tin smiths bench folder 600 x 1.6mm 1
compressor single cylinder 1
with 45 litres capacity Air
199. Trolley type portable air tank, along with
accessories & with working
pressure 6.5 kg/sq. cm
Welding plant Oxy-Acetylene complete ( 1
200.
high pressure)
201. Welding Transformer 150-300 Amps 1
Working Condition of Diesel Engine – 1
202. CRDI - 4 stroke Engine, Assembly with
fault simulation board
Cut section of 4/6 cylinder diesel engine 1
203. with moving condition to show
momentum of internal parts
Fuel injection test bench for calibration 1
204.
of fuel pump
205. Electrical test bench 1
Diesel Engine six Cylinder in running 1
206.
condition
CONSUMABLE

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 Mechanic Diesel

207. Battery- SMF As required

208. Brake fluids As required
209. Chalk, Prussian blue As required
210. Chemical compound for fasteners As required
211. Diesel As required
212. Different type gasket material As required
213. Different type of oil seal As required
214. Drill Twist (assorted) As required
215. Emery paper - 36–60 grit , 80–120 As required
216. Engine oil & Engine coolant As required

217. Gear oils As required

Gloves for Welding (Leather and As required

218.
Asbestos)

219. Hacksaw blade (consumable) As required

220. Hand rubber gloves tested for 5000 V 5 pairs

Holders, lamp teakwood boards, plug As required

221.
sockets,

222. Hydrometer 8

223. Lapping abrasives As required

224. Leather apron 5

225. Petrol As required

226. Power steering oil As required

227. Radiator Coolants As required

228. Safety glasses As required

229. Steel wire Brush 50mmx150mm 5

CLASS ROOM FURNITURE FOR TRADE THEORY

230. Instructor’s table and Chair (Steel) 1 set

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 Mechanic Diesel

231. Students chairs with writing pads 20

232. White board size 1200mm X 900 mm 1

Instructors lap top with latest(vista &

above) configuration pre-loaded with
233. 1
operating system. and MS Office
package.

234. LCD projector with screen. 1

1 set each
235. Trainees locker 6½ ‘ x 3’ x 1½’
(optional)

TOOLS & EQUIPMENTS FOR ENGINEERING DRAWING HALL

236. Drawing board (700mm x500 mm) IS: 1444 20+1

237. Mini drafter 20+1

Set square celluloid 45⁰ (250 X 1.5 20+1

238.
mm)

239. Stool for trainees 20+1

240. Cupboard (big) 01

241. White Board 8ft. x 4ft. 01

242. Trainer’s Table 01

243. Trainer’s Chair 01

244. Draughtsman drawing instrument box 20+1

245. Draughtsman table 20

NOTE:
1. No additional items are required to be provided for unit or batch working in the Second
shift except the items under trainee's tool kit and steel lockers.

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Mechanic Diesel

TOOLS &EQUIPMENTS FOR EMPLOYABILITY SKILLS

S No. Name of the Equipment Quantity
1. Computer (PC) with latest configurations and Internet connection with 10 nos.
standard operating system and standard word processor and
worksheet software
2. UPS - 500Va 10 nos.
3. Scanner cum Printer 1 no.
4. Computer Tables 10 nos.
5. Computer Chairs 20 nos.
6. LCD Projector 1 no.
7. White Board 1200mm x 900mm 1 no.

Note: Above Tools &Equipments not required, if Computer LAB is available in the institute.

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 Mechanic Diesel
ANNEXURE-II

FORMAT FOR INTERNAL ASSESSMENT

Name & Address of the Assessor: Year of Enrollment:

Name & Address of ITI (Govt./Pvt.): Date of Assessment:

Name & Address of the Industry: Assessment location: Industry / ITI

Trade Name: Semester: Duration of the Trade/course:

Learning Outcome:
Maximum Marks (Total 100 Marks) 15 5 10 5 10 10 5 10 15 15

Assessment Marks
Safety Consciousness

Speed in Doing Work

Skills to Handle tools
Workplace Hygiene

Economical Use of
Manuals/ Written

Total Internal

Result (Y/N)
Ability to Follow

Workmanship
Application of

&Equipment
Attendance/

Instructions
Punctuality

Knowledge

Quality in
Materials
SNo

Father's/Mother’s

VIVA
Candidate Name
Name

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