TRADE: MECHANIC (DIESEL)
DURATION OF TRAINING: - ONE YEAR
Syllabus For First Year
Week No. 1-26

QUALIFICATION: PASSED CLASS 10TH EXAMINATION UNDER 10+2 SYSTEM OF EDUCATION OR ITS EQUIVALE NT

Weekwise Syllabus:1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21,
                             22, 23, 24, 25, 26

  1. Introduction and Safety Training :
  2. Achievement expected.

    Awareness on the role of I.T.I in national building activity.
    Scopes of trade –mechanic (diesel) Safety rules and safety precautions to be observed
    in the shop floors. Awareness on disciplinary rules and communication channel in the shop
    floor or working area.

    Week No. Theory Practical Engg.Drg

    .

    Workshop cal & science
    1.

    General introduction to the course-duration of the course and course content. Study of the syllabus general rules pertaining to the institute facilities available Hostel .Recreation and medical facilities- library working hours. Time table.

    Familiarization with the institutes. Importance of the trade machinery used in the trade – types of work done by students in the institute shoo floor of the institute.

       
    2.

    Importance Safety or general precautions to be observed in the shop – fire Extinguishers used for different types of fire storing and handling of inflammable materials – Elementary First Aid.

     

     

     

     

    Description of safety Equipment their use – safety rules to be observed in an Automobiles repair shoo. Accidents their causes works of fire. Fire Extinourshers – Familiarization of the tools machinery available in the shop their use and up keep importance of maintenance cleanliness of workshop. Tools, Jacks. Trays and Hoses.

       
  3. Allied trade work – fitting
Week No.

Theory

Practical

Engg. Drg.

Workshop cal & science

3.

Systems of measurement conversion of English into metric measurement and vice versa – marking media – Chalk mechanic Blue Red lead and Tools used for marking steel rule. Try Square, caliper and dividers, scriber prick and centre punch- Hammer and Chisel – uses and maintenance – safety precautions in handling Grinding machines.

Demonstration of the use of Fitter’s Hand Tools marking off with steel rules calipers, scriber, dividers Dot and center punch – Chipping in marked lines in a given piece Sharpening of Chisels. Center punch and Dot punch to correct Angles.

Introduction to Engineering drawing and Blue Print Reading, Free Hand Sketching of Straight Lines. Rectangles Squares and circles.

Simple workshop Problems involving addition Subtraction multiplication and Division of whole numbers.

4.

Types of hacksaw frames and Blades-Their selection and uses- types of files and their uses. Care and Maintenance of files . Types and sizes of Drills- cutting Angles and speeds of Drills – Calculation of Tap drills sizes.

Hacksawing Filling to given Dimensions – Filling True and square – Practice different types of filling operations – marking and drilling clear and Blinds Holes sharpening of Twist Drills Safety precautions to be observed while using a drilling machine.

Free Hand Sketching with Dimensions and proportionate sketching of circles Rectangles squares Parellograms, Rhombus, Polygons.

Common Fractions, additions, subtraction, multiplication and division of common Fractions – Vulgar Fractions – single Shop problems involving Fractions.

         
5.

Tapes and Dies – Description use of different types Tapes and Dies – Use of ‘V’ Threads – precautions while using taps and Dies – Description and use of different types of Scrapers. Reamers and Emery papers.

Tapping a Clear and Blind Hole – Selection of tape drill Size – use of Lubrication – Cutting Threads on a Bolt/ Stud – Adjustment of two piece Die – Reaming a hole/ Bush to suit the given pin/ shaft – scraping a given machined surface.

Reading of simple Blue Prints Sketching of simple solids such as cubes. Rectangular Blocks, Cylinders.

Applied workshop problems involving Fractions and vulgar Fractions

6.

Construction and method of reading micrometers ( Internal and external ) and Vernier Caliper correct handling of micrometers and vernier Calipers, Reading of vernier Scale – Description and use of combination set care and maintenance of micrometers, vernier calipers, combination set.

Measuring diameter of pistons main journals, Crank – pins, king pin big end and main bearings cylinder Bores with micrometers and Vernier Calipers – measuring with and Thickness of machined flat and round bars – measuring of valves angles with protractor head locating centers of a round bar with center head.

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Properties of Ferrous Metals – Their uses – Cast Iron. Wrought plain and High carbon Steel – High speed steel and Alloy steel.

ALLIED TRADE SHEET METAL WORK

7.

Sheet metal workers hand tools their description and uses – description of simple soldering and brazing, Fluxes used for common joints – Types of sheet metal joints – their uses.

Joining of metal parts by Soft Soldering – Simple marking out on sheet metal and cutting – Bending and folding.

Free hand sketching of Nuts – Bolts – Studs – with dimensions from samples.

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8.

Sheet and wire gauges the blow lamp and its uses pipe fitting Explanation of various common metal sheets used in sheet metal shop.

Practice in silver soldering pipe bending, Annealing of pipes fitting Nipples Unions soldering and Brazing of pipes.

Sketching of views of solid bodies such as square and Rectangular Blocks – Hollow cylinders rings cones.

Properties of non Ferrous metals and Their uses copper, zinc, lead, tin, brass, Aluminum, Bronze, solder, wearing metals.

 

 

Week No.

Theory

Practical

Engg. Drg.

Workshop cal and science

9.

General description and construction of diesel engine – Characteristics and Classification working principles of 4 stocks cycle diesel and Petrol engine comparison between petrol and diesel engine.

Exercise involving use of wrenches, pliers, screw drivers and pliers – cleaning and lubrication of engine parts, location and identification of engine components.

Freehand sketching of rivets washers with dimensions from Samples.

Brief description of manufacturing process of non – ferrous metals i.e. . copper, aluminum, zinc and tin.

10.

Two stroke cycle diesel engine types of scavenging uniflow and 1oop flow Scavenge opposed copper piston engine differences between two strokes and 4 stroke cycle diesel engines.

Practice on unserviceable diesel engine, removing jammed nuts and broken studs reconditioning and damaged stud hole fitting oversized studs.

Free hand sketching of Bolts and Nuts with dimensions from Samples.

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11.

Engine details – cylinder materials – cylinder liners and their advantages, cylinder heads, description function, cares and maintenance – Location combustion chamber in cylinder heads and also heater plugs and port and valve arrangements.-

Selection of materials for gaskets and packing – use of locking devices lock nuts . cotters, split pins and circlips lock rings- location where they are used inspection and checking leakage of air, fuel oil and exhaust in the engine

Explanation of simple orthographic projection hand sketching of 4 stroke- 2 stroke cycles

F.P.S. & C.G.S. system Metric weights and measurements, conversion factors

12

Combustion chambers pumps , open and closed types, advantages, and disadvantages compression ratio & compression pressures, compression testing of cylinders and analysis of results & its importance

Practice on starting and stopping of diesel engines Use of speed counter in determining the engine speed – running of engine on load checking temperature fuel and oil compression testing of cylinders

Explanation of simple orthographic projection in 3rd angle

Shop problems on metric system of weights and measurements.

13

Need for maintenance check up in diesel engine- preparation of maintenance schedule from charts of popular makes of engine

Maintenance check – daily weekly monthly for different types of engines writing up of inspection schedules—Maintenance of log sheets details of maintenance

Views of simple hollow and solid bodies with dimensions

Meaning of tenacity elasticity, malleability brittleness hardness compressibility and ductility with example

ACHIEVEMENTS : THE TRAINEE SHOULD BE ABLE TO DO:

  1. Simple fitting operation of marking, chipping, hacksawing, filing, drilling and tapping, dieing, reaming and scraping
  2. Simple sheet metal joints , soldering , pipe bending and use of simple sheet metal tools
  3. Remove jammed bolts, nuts, and prepare maintenance schedule
  4. Start and stop diesel engine and observe its performance
  5. Compression testing of cylinders and analyze results

14

valves & valves operation- Mechanism- parts & function of each valve timing diagram camshaft and timing gears – types of drives used in engines chain tension and its importance cylinder head and manifold construction and function – water jackets passages

Remove , rocker arm assembly manifolds- and cylinder head- removing valves and its parts – cleaning & decarbonising - checking valve seats & valve guide – reconditioning valve seats and refacing valves- lapping valves on its seat- testing leaks of valve seats for leakage – inspection of cylinder head and manifold surfaces for warping and cracks

Free hand sketching of valve, valve springs, valve assembly with dimension

Effect of alloying elements on properties of cast iron and steel

15

Description and function of valve parts-maintenance Materials used –necessity of valve clearances prescribed by makers of engine – effects of incorrect clearances- common troubles and remedy –reason for wrapping of cylinder head

Dismantle rocker arm assembly clean & check shaft- bushes , posts and rocker arm for wear and cracks and reassemble. Check valve springs, tappets, push rods, tappet screws and valve stem cap. Reassembling valve parts in sequence , refit cylinder head and manifold & rockarm assembly , adjustable valve clearances, starting engine after decarbonising

Simple isometric view of objects such as square, rectangle and cubes

Square root of perfect square and whole number square root of decimal

16

Piston and piston rings Function-types and material . used recommended clearances for the rings and its necessity-precautions while fitting rings- connecting rods-types function and material used- methods of fixing gudgeon pin on small end method of lubrication provided for small end bushes

Removing piston & connecting rod from engine-examine-piston ring lands for wear- examine piston skirt for cracks & distortions, clean oil holes - check connecting rod for bend and twist and parent bore for taper and ovality and gudgeon pin bushes for wear-check elongation of cap fixing bolts

Free hand sketching of piston gudgeon pins rings and connecting rod with dimensions from samples

Shop problems involving square roots

17

Crankshaft- construction & functions material used - arrangement of crank pins and main journals-balancing methods- fly wheel - construction & its function and material used Rim marks and balancing. Elementary knowledge of function of clutch & coupling units attached to flywheel.

Removing crankshaft and camshaft from engine -checking crankshaft for bend & twist -checking oil retainer and thrust surfaces for wear-measure crank shaft journal for wear -checking flywheel and mounting flanges, spigot, bearing-check vibration damper for defects -check cam shaft for bend & crank

Free hand sketching of crankshaft and flywheels with dimensions from samples

Ratio and proportions. shop problems

18

Description & function of cylinder block- material used - cylinder liners -& details crank case and oil pan and their construction water jacket passages & wall thickness bolt hole dimensions for cylinder head fixing provision for mounting accessories like oil pump, water pump filters - oil flow passages and cleaning plugs

Checking cylinder blocks surface -measure cylinder bore for taper & ovality- check main bearing parent bore for taper & ovality clean oil gallery passage and oil pipe line- check main bearing cap bolt holes check cam shaft, bearings and tappet bore - descale water passages and examine Welsch plugs check cylinder head for warping.

Free hand sketching of cylinder block and cylinder head

Mass , unit of mass, force-absolute unit of force-weight of a body . Shop problems

19

Engine Bearings-classification and location materials used & composition of bearing materials - Shell bearing and their advantages - special bearings material for diesel engine application bearing failure & its causes - care & maintenance.

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.

Free hand sketching of bearing with dimensions from sample

Mass, unit of mass, force-absolute unit of force weight of a body , shop problem

20

Friction - its meaning and impo0rtance, methods to reduce friction in engines - use of lubricants - oil grease high detergent oil for diesel engine lubrication - properties of lubricants.

Overhauling oil pump , oil filters oil coolers aircleaners and airfilters and adjust oil pressure relief valves - changing oil in the sump, repairs to oil flow pipe lines and unions.

Freehand sketching of oil filters oil pumps, oil coolers with dimensions from samples.

Example of useful and wasteful friction.

21

Need for lubrication system for diesel engines - types used and layout of the system by pass & full flow arrangement-types of oil pumps oil filters, oil coolers, common troubles - care and maintenance

. Reassemble all parts of engine in correct sequence and torque all bolts and nuts as per makers recommendations for engines.

Freehand sketching of Examples of oil pumps oil coolers with dimensions from samples.

Example of useful and waste friction in engine, applied problems.

22

Engine assembly procedure need for cleanliness and special tools and gauges used for engine assembling, practice - periods of decarbonising and overhauling engine interms of hours of run or mileage - running in procedure of overhauled engines.

Reassemble all parts of engine in correct sequence and torque all bolts & nuts as per markers, recommendations for the engine - Fit accessories & start and run the engine on stands

 

 

 

 

 

 

 

Free hand sketching of cylinder liners with dimensions form sample

Work, Unit of work Energy Power, Unit of power.

23

Cylinder liners - construction & purpose - material used and finish provided types of liners in use - methods used to fit the same in cylinder bore, advantages of wet and dry liners wear pattern & allowable wear cylinder wear and its causes.

Removing cylinder liners from scrap cylinder block, practice in measuring and refitting new liners as per makers recommendations precautions while fitting new liners.

Freehand sketching of cylinder liners with dimensions from sample.

Work, Unit of work energy power - unit of power - shop problems.

24

Need for cooling an engine general description & types of air and liquids - cooling used in engine - layout of cooling system and parts in the layout-function of parts like radiator -thermostat & need to maintain engine working temperature.

Removing radiator and water pump from engine, cleaning & reverse flushing. Radiator, testing thermostat and refitting on engine-overhauling -water pump refitting - adjusting fan belt tension and connecting water pump with radiator with hoses & flushing cooling system of the engine.

Freehand sketching of water pump thermostatic valve & water jackets in the cylinder block.

Ratio & proportion.

25

Description & operation of Air compressor and exhauster attached to transport vehicle engines - common troubles & maintenance of both their specific application for the brakes of the vehicle.

Dismantling air compressor and exhauster-cleaning all parts - measuring wear in the cylinder and blades-reassembling all parts and fitting them in the engine.

 

 

 

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Ratio and proportion problems.

26

Description of internal & external engines - different types of I C Engines parts of an IC Engine-4 stroke O T T O cycle engine - 2 stroke petrol engine - deference's between the two k- importance of valve timings and parts of valve operating system description and operation.

Dismantling a petrol engine in a systematic procedure - clean & inspect all parts for wear & reusage - check oil clearance reset main and connecting rod bearings - check cylinder wear & examine piston and rings connecting rods-and crank shaft reconditioning if necessary - reassemble all parts in sequence as per makers, recommendation - adjusting valve tappets-start & adjust slow speed of the engine.

Freehand sketching of 4 stroke cycle 2 stroke cycle valve timing diagram.

Different forms of heat energy-mechanical and electrical