SYLLABUS FOR THE TRADE

OF

MECHANIC REPAIR & MAINTENANCE OF LIGHT

VEHICLES
(Semester Pattern)

UNDER
CRAFTSMAN TRAINING SCHEME (CTS)

Designed in– 2005

By
Government of India
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE
Directorate General of Employment & Training
Ministry of Labour & Employment
EN-81, Sector-V, Salt Lake City
Kolkata-700 091

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List of members attended the Trade Committee Meeting to finalise the draft syllabus for the trade of
" MECHANIC REPAIR & MAINTENANCE OF LIGHT VEHICLES Under C.T.S.

Sl. Name and Representing Organisation Remarks

No. Designation
1 Sri M.S. Lingaiah, CSTARI, Salt Lake, Kol. Chairman
Director
2 Sri P. K. Roy, Sr. Envr. W.B.Pollution Control Board Member
Engineer
3 Sri T.S. Ramanathan, CSC Ltd. Kolkata Member
Dy. Manager (HRD)
4 Kashi Nath Karmakar, G.T.T.I. Member
Sr. Faculty Sealdah Branch
Automobile Engineering
5 Maj.(Retd.) D.K.Ghosh, Dewar’s Garage Kolkata Member
G.M.
6 Mr. Debabrata Halder, Rolta Motor (Bajaj Auto) Kolkata Member
Works Manager
7 Sri R. Senthil Kumar, CSTARS, Salt Lake, Kol. Member
JDT
8 Sri T. Mukhopadhyay, CSTARS, Salt Lake, Kol. Member
DDT
9 Sri A. Chakraborty, -DO- Member
ADT
10 Sri P.K. Koley, T.O. -DO- Member
11 Sri A.B. Dhara. T.O. -DO- Member
12 Sri S.B. Sarder, T.O. -DO- Member

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 List of members attended the Workshop to finalize the syllabi of existing CTS into Semester Pattern
held from 6th to 10th May’2013 at CSTARI, Kolkata.

Sl. No. Name & Designation Organisation Remarks

1. R.N. Bandyopadhyaya, Director CSTARI, Kolkata-91 Chairman
2. K. L. Kuli, Joint Director of Training CSTARI, Kolkata-91 Member
3. K. Srinivasa Rao, CSTARI, Kolkata-91 Member
Joint Director of Training
4. L.K. Muhkerjee, CSTARI, Kolkata-91 Member
Deputy Director of Training
5. Ashoke Rarhi, ATI-EPI, Dehradun Member
Deputy Director of Training
6. N. Nath, CSTARI, Kolkata-91 Member
Assistant Director of Training
7. S. Srinivasu, ATI-EPI, Hyderabad-13 Member
Assistant Director of Training
8. Sharanappa, ATI-EPI, Hyderabad-13 Member
Assistant Director of Training
9. Ramakrishne Gowda, FTI, Bangalore Member
Assistant Director of Training
10. Goutam Das Modak, RVTI, Kolkata-91 Member
Assistant Director of Trg./Principal
11. Venketesh. Ch. , Principal Govt. ITI, Dollygunj, Andaman & Member
Nicobar Island
12. A.K. Ghate, Training Officer ATI, Mumbai Member
13. V.B. Zumbre, Training Officer ATI, Mumbai Member
14. P.M. Radhakrishna pillai, CTI, Chennai-32 Member
Training Officer
15. A.Jayaraman, Training officer CTI Chennai-32, Member
16. S. Bandyopadhyay, Training Officer ATI, Kanpur Member
17. Suriya Kumari .K , Training Officer RVTI, Kolkata-91 Member
18. R.K. Bhattacharyya, Training Officer RVTI, Trivandrum Member
19. Vijay Kumar, Training Officer ATI, Ludhiana Member
20. Anil Kumar, Training Officer ATI, Ludhiana Member
21. Sunil M.K. Training Officer ATI, Kolkata Member
22. Devender, Training Officer ATI, Kolkata Member
23. R. N. Manna, Training Officer CSTARI, Kolkata-91 Member
24. Mrs. S. Das, Training Officer CSTARI, Kolkata-91 Member
25. Jyoti Balwani, Training Officer RVTI, Kolkata-91 Member
26. Pragna H. Ravat, Training Officer RVTI, Kolkata-91 Member
27. Sarbojit Neogi, Vocational Instructor RVTI, Kolkata-91 Member
28. Nilotpal Saha, Vocational Instructor I.T.I., Berhampore, Murshidabad, (W.B.) Member
29. Vijay Kumar, Data Entry Operator RVTI, Kolkata-91 Member

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 GENERAL INFORMATION

1. Name of the Trade : MECHANIC REPAIR & MAINTENANCE OF

LIGHT VEHICLES
2. N.C.O. Code No. :

3. Duration of Craftsmen :
1 year (Two Semester)
Training
4. Power Norms : 6KW
5. Space Norms : 280 sq. mtr.
(Vehicle parking in common garage)

6. Entry Qualification :
Passed in 10th Class Examination
7. Unit strength : 16
8. Instructors : a) Diploma in Mechanical/Automobile Engg From
Qualification recognized board of technical education with two years
experience in the relevant field with LMV Driving license
OR
10th Passed + NTC/NAC in the Trade with 3 Years post
qualification experience in the relevant field with LMV
Driving license

b) Preference will be given to a candidate with Crafts

Instructor Certificate (CIC)

* Note: At least one Instructor must have Degree/Diploma in Mechanical/Automobile Engg. when applied for
02 units.

OBJECTIVE :

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 The course is so designed that the trainee should have the knowledge about all
components of the vehicle. He should be able to lubricate the parts of the vehicle, locate
the defects and to attend the minor maintenance of the different types of light motor
Vehicles. To drive light motor vehicles on different kinds of roads and surfaces
observing the traffic rules. To check emission from vehicles tail pipe as per norms.

TRADE: " MECHANIC REPAIR & MAINTENANCE OF LIGHT VEHICLES”

FIRST SEMESTER
Semester Code – MLV;SEM-I

Week No. Trade Practical Trade Theory Engg. Drawing Workshop

Calculation &
Science
1 Familiarization with institute, Introduction to
Importance of the trade- Central Outer
Machinery used in Trade. Vehicle Acts &
Types of work done by the Rules.
students in the Institute-shop General
floor of the Institute. introduction to the
course-duration of
the course & course
content. Study of
the Syllabus
General Rules
pertaining to the
Institute Facilities
available hostel,
recreation and
medical facilities
library working
hours-time table
2. Description of safety Importance of Introduction to Common
equipment their use safety safety & general Engineering Drawing & fractions,
rules to be observed in an precautions to be Blue print reading. Free additions,
Automobiles repair shop. observed in the hand sketching of substation
Accident & their causes-up shop, fire straight lines, rectangles, multiplication
keep of fire extinguishers. extinguishers used squares and circles. & Divisions.
Familiarization of the tools for different types Applied
and machinery available in of fire storing & workshop
the shop. Their use and up- handling of problems
keep, importance of inflammable involving
cleanness of workshop, tools, materials fractions &
jacks, trays and horses. elementary first aid. vulgar
Different types of fractions
Fire Extinguishers
used for different

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 types of fires.
3. General servicing of vehicles General description Free hand sketching of Properties of
washing, cleaning, oiling, of motor vehicles- nuts bolts studs with ferrous & non-
greasing and lubrication of major assemblies- dimensions from ferrous metals
vehicle. description location samples. and their
and function of
each locking
methods and
devices used in
vehicles hydraulic
and screw jacks
hydraulic hoist &
air compressor-
their description &
uses.
4 Inspection of under carriage -do- Free hand sketching of Brief
& of vehicle. Tightening all solids and hollow bodies description of
5 loose bolts & nuts-use of such as square manufacturing
hydraulic jacks hoist and rectangular, cylinder, process of
horses used in the shop rings and cones. steel, copper &
selecting materials for aluminium
packing cutting packing’s
and gaskets practice in use of
locking devices such as lock
nuts, cotter and split pins-
keys, Circlip, lock rings, lock
washers-wire, locking
location where they are used.
6. Removing wheels from Description of Explanation of simple Metric system,
vehicle, dismantling tyres wheels and tyres- orthographic projection met weight &
st
and tubes checking puncture types selection of 1 angle. Free hand measurement
assembling inflating to tyres, ply rating, sketching of types and units used
correct pressure. Rotating the inflation pressure wheels. conversion
wheels in vehicle minor and carrying from FPS to
repairs to wheels and tyres. capacity, storage of Metric system
tyres. & vice versa.
7. Inspection the frame Frames-description Exercise in simple Exercise
checking alignment of frame and function orthographic projection. involving
servicing of spring replacing common troubles metric and FPS
new bushes in shackle pins conventional
changing hushes in shock suspension system.
absorbers-cleaning & Types of leaf
lubrication of wheel springs used
bearings, adjusting wheel different types of
bearings. shock absorbers.
Their description

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 operation &
maintenance.
rd
8. Removing king pins and Description of Explanation of 3 angle Shop problems
bushes replacing new bushes different types of projection. Free hand in metric
& plus after removing bushes independent sketching of front axle system.
& lubrication of king pin suspension system, assembly.
bushes in the front, special features in
independent suspension each system
system. maintenance and
lubrication of front
suspension system.
9 & 10 Inspection and overhaul front The front axle Views of simple hallow Meaning of
& rear suspension rear description & and solids bodies with tenacity,
springs, coil spring torsion functions types of dimensions sketching ofelasticity
bars, check up main axle for steering knuckles steering linkages. brittleness,
alignment. arrangement of hardness,
steering knuckle compressibility
joint general layout and ductility
of steering linkages. examples of
each
11. Inspect and adjust steering Description of Free hand sketching of Effect of
linkages, after replacement different types of different types of alloying
of worn parts alignment of steering boxes steering boxes elements and
steering wheels with respect (latest type of properties of
to front wheel, check and steering boxes), cast iron and
correct toe-in. special features of steel alloys.
each adjustments
repair and
maintenance of
steering and boxes
power steering
description and its
advantages.
12. Inspect and overhaul steering Description of Free hand sketching of Problems in
boxes adjusting steering gear Ackerman’s angle, caster, camber, king-pin steering
backlash, and end play check caster, camber toe- angle. Ackerman’s geometry-
and adjust toe-in, camber in and toe-out on angle toe-in & toe-out. calculation of
angles checking king-pin turns, purpose and caster, camber.
angle & caster angle with effects of these
special gauges. angles.
Inspect and overhauling of
different types of power
steering (Egg. Hydraulic and
Electronic Power Steering)
13. Adjusting brake pedal play Arrangement of Free hand sketching of Square root of
dismantling wheel break brakes in cars and break linings wheel perfect square,

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 assembly cleaning and trucks-description brake assembly square root of
inspecting adjusting brake of hand brakes, its sectioned views of whole numbers
shoes for proper clearances, purposes layout of master cylinder. and decimals
bleeding hydraulic brakes & mechanical and relating to
Disk brakes. hydraulic breaking braking
system in cars. distance.
14. Removing master cylinder, Master cylinders- -do- Simple levers,
dismantling cleaning and common troubles & problems
inspection of parts- remedy. related to as
assembling and testing Engine Exhaust applied to
bleeding the braking system brakes. T.B. Valves motor vehicles.
after cleaning the pipelines. used in light
Dismantling and Assembling vehicles.
of Vacuum Servo brakes.
15. Dismantling wheel brake Brake lining types Free hand sketching of Meaning of
assembly removing old of uses relining the brake wheel cylinders friction
lining & fitting new lining on brake shoes cam adjuster, brake shoe examples of
the brake shoe removing, precautions to be assembly and anchor useful and
cleaning of brake drums observed wheel pins. wasteful
inspecting wheel cylinders & cylinders friction in
brake drums-fitting new cups description function vehicles co
and brake hosepipes, re- and types brake efficient of
assembling adjusting wheel fluids. Description friction-simple
bearing ad testing adjusting and use types of problems on
all 4 wheel brakes. fluids used. friction
16 & 17 Trouble tracing in braking Brake testing Free hand sketching of Properties of
system of a vehicle adjusting efficiency of brakes the layout of the Air matter
brakes and balancing all four braking distance, Brake system & molecules and
wheel brakes, precautions to weight transference sketching of slake atoms-atomic
be observed while testing during braking a adjuster. Free hand symbols and
brakes points to be remember vehicle common sketching the layout of atomic
while preparing the vehicle trouble in brakes & vacuum assisted number, simple
for brake certificate. their remedies. Hydraulic braking chemical
system. formula.
Definition of
mass unit of
force weight of
a Body energy
and power
18. Adjusting clutch pedal play Layout of Isometric drawings of Shop problems
removing gear box and transmission system simple objects such as on force- work
clutch assembly from description of square, and rectangular done energy
vehicle. Dismantling clutch single plate clutch blocks with grooves key and power.
assembly, cleaning different types of ways.
inspecting parts. clutches used in
vehicle.

8
 Study of Hydraulic
clutches.
19. Removing & fitting of new Clutch linings types Isometric view of clutch Shop problems
pilot bearing, removing & materials used pedal clutch release on force, work
fitting of ring gear in fly bonded & riveted bearing fork and clutch done energy
wheel relining a clutch plate lining clutch plate plate free hand and power
checking condition of constructions, sketching of clutch
flywheel and pressure plate purpose of damper assembly.
surface for reconditioning. spring precautions
while relining a
clutch plate.
20. Assembling of pressure plate Fluid coupling -do- Applied
adjusting the fingers description problems on
checking run out of fly wheel operation & work, energy
and aligning clutch assembly advantage of using & power.
with flywheel. fluid coupling
common troubles
and remedy.
21 & 22 Dismantling a synchromesh Synchromesh gear Free hand sketching of Explanation of
gear box, cleaning, box advantages the arrangement of gears horse power
inspecting parts replacing description, inside the sliding mesh and indicated
worn out defective parts operation in gear box in different horse power
assembling & testing for different gear gear position. electrical
correct performance positions common equivalent of
identifying noises from gear trouble and remedy H.P.
boxes and rectifying. types of
synchromesh
gearboxes their
special features.
Study about
overdrives.
Transfer cause used
in 4 wheel drive
vehicles.
23. Dismantling cleaning and Lubrication of Free hand sketching of Applied
assembling of gear shift gearbox constant shifter mechanism and problems in
mechanism changing oil in mesh gearbox hear shift lever. horsepower
gear box studying gear ratios description and calculation of
in the gear box. advantages. speed ratios in
4-speed
gearbox & 25
speed gear box.
24. Removing open type Universal joints and Use of drawing Ratios and
propeller shaft from vehicle, propeller shaft-open instruments T-square proportions,
removing universal joints and closed type and drawing boards- simple
cleaning replacing worn out propellers shaft construction of simple problems gear

9
 parts, re-assembling & types of universal figures. ratios in gear
refitting to vehicle-special joints, care and box & rear
precautions while removing maintenance- axles.
torque tube drive shaft. constant velocity
joints special and
advantages.
Removing rear brake drums Description and Construction of simple
and adjusting the wheel purpose of different solid figures with
bearings in full floating rear types of rear axles dimensions and titles
axles & semi floating axles, special features and use of different types of
replacing oil seals in rear advantages in each scales.
axles. type lubrication of
rear axles-reasons
for oil in brake
drum.

25 i) Project work
ii) Industrial visit
(Optional)
26 Examination

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 TRADE: MECHANIC REPAIR & MAINTENANCE OF LIGHT VEHICLES
SECOND SEMESTER
Semester Code: MLV;SEM- II
Week No. Trade Practical Trade Theory Engg. Drawing Workshop
Calculation &
Science
1. Removing rear axle assembly Description & Free hand sketching of Calculations of
from vehicle, dismantling, functions of final different types of rear areas of square,
cleaning, inspecting parts for drive assembly- axles. rectangular,
wear and damage, cutting crown wheel and triangles,
packing’s/gaskets- removing tail pinion hypoid circles &
tail pinion and bearings gear and its regular
cleaning and inspection of lubrication polygons
oil-seals and bearings. descriptions of
differential and its
principle of
operation.
2. Checking tooth contact in Description and Free hand sketching of -do-
crown land pinion and function of universal joints, silencer
adjusting back-lash- differential gears brackets and spring
assembling the rear axle types tooth contact shackles.
assembly on vehicles and and back lash,
testing. preloading
adjustment.
Common troubles
and their remedy in
rear axle assembly.
3. Trouble shooting in the Description & -do- Calculation of
transmission system of purpose of optional volume of
vehicle detecting noises from fittings such as square,
clutch, gear box, universal transfer case free rectangular and
joints and rear axle assembly wheel power take conical blocks
dismantling transfer case off common volume of
from vehicle, cleaning, troubles in these cylinders solid
inspecting replacing worn unit and their and hollow.
parts, reassembling & fitting remedy care and
to vehicle. maintenance.
4. Dismantling of unserviceable Description of Free hand sketching of 4 Calculation of
engine cleaning studying the internal and stroke cycles and 2 volumes and
parts in the engine and external stroke cycles. weight of
reassembling the engine combustion cubes,
practice in the use of correct engineers, different hexagonal
tools and right procedure. types of I.C. prisms shop
engines. Important problems.

11
 working parts in the
engine, the 4-stroke
cycle of operation.
5. Dismantling an un- Two-stroke cycle -do- -do-
serviceable engine, cleaning operation difference
of parts in the engine, between 4 stroke &
measuring of cylinder bore- 2 stroke cycle
crank pins main journals engines.
pistons studying valve Description of
operating mechanism. valve operating
mechanism & valve
timing description
and function of
valve spring guide
tappets, valve seals
and locks.
6. Checking compression Description & Drawing of 3 views of Calculations of
pressure in a running engine function of cylinder stepped & taper blocks cylinder wear
dismantling the cylinder head block-cylinder head in 3rd angle projection. ovality taper
from the engine, cylinder liners and
decarbonising the cylinder reconditioning of compression
head, removing the valves cylinder heads. ratios problems
cleaning re assembling and on
adjusting tappets. compression
ratios.
7. Removing pistons and Description & -do- Center of
connecting rods from engine, functions of gravity
dismantling, cleaning, different types of examples
inspecting, checking pistons, piston rings problems
clearances installing rings and piston pins involving
and pistons pins. common troubles center of
and remedy. gravity in
vehicles.
8. Removing connecting rod Description & Drawing of plan, Heat and
assembly, cleaning & functions of elevation and side views temperature
checking bearing clearances, connecting rod. of tapered hollow thermometers
replacing bearing shells, Materials used for objects. centigrade &
setting correct clearances. connecting rods-big Fahrenheit
Measuring wear in crank end and main scales their
pins and main journals in bearings shells conversion.
crank shaft. piston pins and Use of
locking methods of temperature
piston-pins crank measuring
shaft description instruments
function & types their
common trouble & description &

12
 remedy. uses.
9. Assembling crankshaft, main Firing order of the -do- -do-
bearings, connecting rods different types
and piston assembly in the engine and crank
engine, fitting cylinder head shaft balancing
and starting the engine and description of the
tuning up engine for smooth fly wheel and its
slow speed running with the function crank case
help of using torque wrench, and oil sump.
at proper torque & sequence.
10. Checking cooling system for Engine cooling Drawing the 3 views in Geometry
rd
overheating cleaning methods air & 3 angle projection of a properties of
radiators, dismantling, water-cooling curved objects. angles,
cleaning, assembling and radiators, pump, triangles and
testing water pump, reverse thermostats and fan, circles.
flushing the system and their description,
adjusting the fan belt tension. function care and
maintenance
reasons for engine
overheating.
11. Studying the lubrication oil Need for Free hand sketching of Properties of
flow system in engine, lubrication of oil filters oil flow angles,
overhauling oil filters, oil engine parts- circuits oil pumps. triangles,
pump and setting the friction lubrication circles contd.
pressure release valve for oil and its
correct oil pressure properties,
maintenance and repairs in lubrication system
the lubrication system in types full flow and
engine. by pass flow
system,
components in
lubrication system
oil filters and
pumps, types their
special features and
uses.
12. Simple repairs in fuel feed Fuel feed system in -do- -do-
system overhauling of petrol motor vehicles
pump, carburetors, fuel description and
filters & air cleaners. layout of the system
description,
operation,
maintenance of fuel
pump & fuel
injector’s filters and
carburetors.

13
 Study of Diesel fuel
supply systems, FIP
timing setting,
Injector testing,
Diesel fitter
changing Air
bleeding from
Diesel supply
system, Engine
Idling speed
adjusting.
Study bout CRDI
(Common Rail
Diesel Injector
System)
Study about LPG
and CNG driving
vehicles.
Study about vehicle
Air-conditioning.
13. Repairs to solex and S.U. Types of Reading of simple Blue Reading of
carburetors adjusting float carburetors special Prints. simple graphs.
level and slow speed features advantages
adjustments studying the different
flow circuit in carburetors. adjustments & their
Function of E.C.M. system & purposes.
sensors Types of sensors
14. Practice in engine up in a Explanation of Exercise in Blue Print Plotting and
vehicle-testing vacuum and engine tunes up Reading. reading of
compression of engine, job-description of simple Blue
adjusting tappets setting, compressions & Prints.
ignition timing & adjusting vacuum testing
carburetors for slow speeds description of
by using of tachometer. ignition timing
setting and slow
speed adjustment.
15. Practice in joining wires and Simple electrical Free hand sketching of Electricity and
soldering forming simple circuit, series & electrical symbols and its effects static
electrical circuits measuring parallel, circuits drawing of simple & dynamic
of current, voltage & identification of electrical circuits. electricity –
resistance cleaning and alternating current AC & DC
topping up of a lead acid and direct/current differences
battery testing battery with meters insulators
hydrometer-cell tester, conductors types of
connecting battery to charge. resistance- ohm’s
law and its

14
 application
common electrical
terms and symbols
primary and
secondary cells lead
acid battery
description
construction
common troubles
and remedy.
16. Studying electrical circuit in Description of Free hand sketching of Magnets
the engine assembly electrical circuits- ignition circuit of a natural and
checking loose open and ignition system and vehicle sketching the artificial types
short circuits cleaning and the components circuit line diagram of poles of
testing spark plugs- purpose of magneto ignition. magnets
overhauling of distributor induction coil, Magnetic
assembly checking and condenser, spark fields.
setting ignition timing. plugs common
troubles in ignition
circuit & remedy.
17. Removing dynamo Description of Free hand sketching of Definition of
alternators from vehicle, charging circuit charging system. ampere, volt
dismantling cleaning, operation of and ohm-units
checking for defects, dynamo alternatives of ampere, volt
assembling and testing for regulator unit ohm, ohm’s
motoring action of dynamo ignition warning law.
& fitting to vehicles. Study lamp troubles and
of wiring harm ness of 1 or 2 remedy in charging
E.C.M. system(Euro – II system.
vehicle), Octane No. &
Ucten No.
18. Removing starter motor from Description of Sketching starter motor Calculations
vehicle and overhauling the starter motor circuit circuit and solenoid based on
starter motor testing of constructional switch circuit. Ohm’s.
starter motor. details of starter
motor solenoid
switches, common
troubles and
remedy in starter
circuit.
19. Practice on unserviceable History & Free hand sketching of Lubricants
diesel engine-removing Development of combustion chambers of types special
jammed nuts, broken studs compression different types. purpose
and reconditioning damaged ignition engines viscosity
threaded holes-removing classification of effects of
cylinder head connecting C.I. Engine temperature on

15
 rods, and pistons cleaning, Advantages and viscosity high
inspecting and refitting them dis- advantages detergent oil
over petrol engines, and its
constructional applications.
details of single and
multi-cylinder
engines.
20. Practice in starting & The four stroke and Free hand sketching of Lubricants
stopping of vehicle engines, two stroke diesels- four stroke cycles and types, viscosity
general maintenance of Engine- two stroke cycle and effects of
engines-checking oil, fuel, uni-flow and loop engines. temperature on
water levels and accessories scavenging constant viscosity high
of diesel engines. volume cycles the detergent oils
diesel cycle, and their
indicator-diagrams. application
21. Bleeding fuel lines for air Fuel used in diesel Free hand sketching of Gears & belt
locks repairing fuel leaks in engines, diesel fuel feed system drives,
the pipe lines and unions specification of and fuel filters. problems on
cleaning of oil and air filters diesel fuels, gear and belt
in diesel engines. importance of clean drive.
fuel, Air fuel ratio,
general layout of
the fuel feed system
in diesel engines.
22. Cleaning and servicing of Types of CRDI Free hand sketching of Gears and belt
primary fuel filters and system fuel diesel fuel feed system drives,
pressure stage filters, injection systems and fuel filters. problems on
removing feed pump air injection & gear and belt
dismantling cleaning, re- airless injection torque
assembling, re-fitting and fuel feed pumps definition its
testing the feed pump. description, relation to
operation-common forces on
troubles and engine
remedy. mounting,
steering gear
box and torque
wrench.
23. Dismantling an Fuel injection Free hand sketching of Inclined plane
unserviceable fuel injection pumps description components from its uses
pump, cleaning inspecting, & operation types assembly’s fuel pumps. examples and
studying parts and adjustments in the applied
reassembling. Removing F.I. pumps phasing and problems
pumps from running engine calibration of
changing oil in fitting back to pumps checking
engine, testing the governor and fixing
& setting injection timing. injection-timing

16
 governors types
their description
and operation
starting and
adjusting slow
speed.
24. Testing injectors for missing Injector nozzles Free hand sketching of Screws and
on the vehicle removing types description, fuel injectors of screw jacks
dismantling, cleaning, operation testing of different types. problems on
inspecting replacing injector’s special screw jacks.
defective parts reassembling features of pintle
the injectors and testing nozzles.
them.
Emission standard,
Demonstrating retrofitting of Catalyzing
vehicles CNG & LPG system converter, noise
Euro II, III, IV, pollution, Battery
operated vehicle,
Hy-bride vehicle

25 Revision
26 Examination

17
ACHIEVEMENT: At the end of this course trainee should be able to
1. Identify different vehicles and units on them
2. Wash and clean vehicle
3. Lubricate a vehicle
4. Drive light motor vehicles on different kinds of roads and surfaces independently.
5. Knowledge about CNG & LPG kits.
5. Check emission from the vehicle.

TRADE: “MECHANIC REPAIR & MAINTENANCE OF LIGHT VEHICLES”

LIST OF TOOLS AND EQUIPMENTS

A. TRAINEES TOOL KIT FOR 16 TRAINEES +1 INSTRUCTOR

Sl.No. Description Quantity
1. Hammer ball Peen 0.75 Kg. 17 Nos.
2. Chisel Cold Flat 19 mm. 17 Nos.
3. Centre Punch 10 mm. Dia x 100 mm. 17 Nos.
4. Steel Rule 15 cm English and Metric 17 Nos.
5. Screw Driver 30 cm x 9 mm. Blade 17 Nos.
6. Screw Driver 20 cm x 9 mm. Blade 17 Nos.
7. Spanner DE Set of 12 pieces (6 mm. - 32 mm.) 17 Nos.
8. Plier Combination 15 cm 17 Nos.
9. Hand File 20 cm second cut 17 Nos.
10. Feeler gauge 20 blades (Metric) 17 Nos.
11. Ring spanner set of 12 pieces (6 mm. - 32 mm.) 17 Nos.
12. Steel tool box with Lock and Key (folding type) size 400 x 200 x 150 mm. 17 Nos.
13. Allen Key set of 12 pieces ( 2 mm.-14 mm.) 5 sets
14. Circlip Plier (Ext. and Int.) 150 mm. And 200 (two each) 9 sets
15. Philips screw driver type set of 5 pieces 100 mm. - 300 mm. 5 sets

B. GENERAL SHOP OUTFIT

SL. Name of the items For instructor For Trainees

NO.
1 Rule Steel 300 mm 1no. 2 nos.
2 Divider Spring Joint 150 mm 1no. 2 nos.
3 Prick Punch 15 cm 1no. 2 nos.
4 Chisel cross cut 200 mm X 6 mm 1no. 1no.
5 Hammer Ball Peen 0.5 kg 1no. 2 nos.
6 Hammer copper 1 kg with handle 1no. 1no.
7 Engineering square 15 cm blade 1no. 2 nos.
8 Scriber 15 cm 1no. 2 nos.
9 Scriber block Universal 1no. 1no.
10 Marking out tables 90 x 60 x 90 CM (high) 1no. 1no.
11 Surface Plate 60 X 60 cm 1no. 1no.
12 Hacksaw frame for 30 cm blade 1no. 4 nos.

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13 ‘V’ Block 75 X 38 mm pair with clamps 1no. 2 nos.
14 Punch Hollow 6, 7, 8, 9, 10.5 and 12 mm set 1no. 1 set
15 Punch figure set 3 mm 1no. 1 set
16 Punch letters set 3 mm 1no. 1 set
17 Hand vice 37 mm 1no. 2 nos.
18 Screw Driver Electrician type 15 cm size 1no. 2 nos.
19 File, flat 35 cm bastard 1no. 2 nos.
20 File, flat 25 cm second cut 1no. 2 nos.
21 File, flat 20 cm smooth 1no. 2 nos.
22 File, flat safe edge 25 cm smooth 1no. 2 nos.
23 File, triangular 15 cm second cut 1no. 2 nos.
24 File, half round 20 cm second cut 1no. 2 nos.
25 File, square 30 cm rough 1no. 2 nos.
26 File, square 20 cm second cut 1no. 2 nos.
27 Twist Drill, metric 3 mm to 12 mm (1 mm step) 1no. 1 set
28 Tape and dies complete set in box B.A., B.S.W., B.S.F., 1no. 2 set
American and metric with handle
29 Hand reamer, adjustable 10.5 mm to 11.25 mm, 11.25 to 12.75 1no. 1 set
mm, 12.75 mm to 14.25 mm, and 14.25 mm to 15.75 mm
30 Scraper flat 25 cm 1no. 1no.
31 Scraper triangular 25 cm 1no. 1no.
32 Scraper half round 25 cm 1no. 1no.
33 Sets of Morse socket MT 0-1, 1-2, and 2-3 1no. 1no.
34 Micrometer outside 25 – 50 mm 1no. 1no.
35 Micrometer outside 0 – 25 mm 1no. 1no.
36 Micrometer outside 50-57 mm 1no. 1no.
37 Micrometer outside 75 – 100 mm 1no. 1no.
38 Micrometer inside 50 to 75 mm and 150 mm and 25 mm to 50 1no. 1 each
mm
39 Vernier Caliper set 250 or 200 mm inside, outside and depth 1no. 1no.
40 Safety goggles 1no. 2 pairs
41 Hammer, planishing 1no. 1no.
42 Setting hammer 1no. 1no.
43 Mallet (Wooden) 1no. 1no.
44 Trammel 30 cm 1no. 1no.
45 Blow Lamp 0.5 litre 1no. 1no.
46 Soldering iron 120 watts 1no. 2 nos.
47 Soldering iron Copper 225 gms (fire heated) 150 mm and 200 1no. 2 nos.
mm
48 Pliers nose (round and straight) 150 mm and 200 mm 1no. 2 each
49 Pliers nose (round and straight) 150 mm and 200 mm 1no. 1 no.
50 Spanners double ended set of 12 metric sizes 6 to 32 mm 1no. 1 set
51 Spanner off-set double ended set of 7 Pds. (6 mm to 17 mm) 1no. 1 set
52 Double open ended ignition spanner set of 5 (0 to 9 mm) 1no. 4 set
53 Spanners adjustable 20 cm 1no. 1 set

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54 Spanner Ring off-set of 6 (SAE) 1no. 1 set
55 Spanner for sparking plug 14 mm 1no. 1 set
56 Magneto spanner set of 8 spanners 1no. 1 set
57 Spanner socket set 6-32 mm sockets (complete set) 1no. 2 nos.
58 Spanner T.Flex for screwing up and unscrewing in inaccessible 1no. 1no.
position
59 Double open ended Tappet spanner 1no. 1set
60 Drift copper 10 mm dia X 150 mm 1no. 2 nos.
61 Spray Gun – Kerosene 1no. 1no.
62 Pressure Grease Gun 1no. 1no.
63 Chain Pulley Block – 3 ton capacity 1no. 1no.
64 Tray cleaning 45 X 30 cm 1no. 16 nos.
65 Drilling machine (bench) 12 mm dia. 1no. 1no.
66 Oil can 0.5 litre 1no. 1no.
67 Lifter, Valve spring 1no. 1no.
68 Tool, Valve grinding, suction type (consumable tool) 1no. 6 nos.
69 Valve seat cutting tools complete with Guides and Pilot 1no. 1set
bar (all angles) in Box
70 Extractor, Stud Ezy out type 1no. 1no.
71 Compression gauge to read 17.6 kg/Sq cm 1no. 1no.
72 Vacuum gauge 0 to 75 cm 1no. 1no.
73 Stone, Carborandum 15 X 5 X 3.75 cm rough and smooth 1no. 2 nos.
74 Cylinder Dial Gauge 1no. 1set
75 Torque wrench (0 to 67.5 Kg. Meter) set of 3 1no. 1 no.
76 Work bench 240 X 120 X75 cm with 4 vices 12.5 1no. 4 nos.
77 Lockers with 8 drawers (standard size) 1no. 2 nos.
78 Metal rack 180 X 150 X 45 cm 1no. 1no.
79 Fuel pump (old for practice) 1no. 2 nos.
80 Distributor (old for practice) 1no. 2 nos.
81 Carburetor (two different types) 1no. 2each
82 Water Pump and Oil Pump 1no. 1each
83 Filing jig for adjusting the piston ring gap 1no. 1no.
84 Steel almirah 180 X 90 X 50 cm 1no. 1no.
85 Black Board 180 X 90 1no. 1no.
86 Desk or table 90 X 60 cm (for Instructor) 1no. 1no.
87 Fire Extinguisher 1no. 2 nos.
88 Fire buckets with stand 1no. 4 nos.
89 Tachometer 1no. 1no.
90 Lifting Jack Screw type 1no. 1no.
91 Tester sparking plug “NEON” Type 1no. 1no.
92 Compressor Air piston type (vehicular) 1no. 1no.
93 Wheel alignment gauge – magnetic type with turn tables 1no. 1no.
94 Sectionised engine gear box and differential mounted on chassis 1no. 1no.
95 Brake Assembly, master cylinder, wheel cylinder and servo 1no. 1no.
96 Vacuum assisted hydraulics brake assembly with vacuum 1no. 1no.

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 booster
97 Airbrakeassembly 1no. 1no.
98 Brake lining riveting machine (foot operated) 1no. 1no.
99 Clutches, different types such as Cone type disc type diaphragm 1no. 1no.
type etc
100 Axle, Gear Boxes, steering boxes fount axle assembly 1no. 1no.
independent front wheel spring assembly
101 Full floating axle and semi – floating axle assembly 1no. 1each
102 Steering Assembly – Rack and Pinion type 1no. 1no.
103 Steering Assembly – Rack and Pinion type 1no. 1no.
104 Spring tension scale – 0 –4.5 Kg 1no. 1no.
105 Valve spring compressor 1no. 1no.
106 Carburetor repair tool Kit 1no. 1no.
107 Puller set steering wheel universal 1no. 1no.
108 Puller set universal bearing and bushes 1no. 1set
109 Lifting jack, screw type 1no. 4 nos.
110 Coil spring compressor for suspension spring 1no. 1no.
111 Hot patch clamp 1no. 2 nos.
112 Piston ring compressor 1no. 2 nos.
113 Valve key inserter 1no. 1no.
114 Wall charts (driving instructions) 1no. 1no.
115 Connecting rod alignment fixture 1no. 1no.
116 Valve refacer 1no. 1no.
117 Piston ring expander 1no. 1no.
118 High rate discharge tester 1no. 1no.
119 A.V.O.Meter /Digital Millimeter 1no. 1no.
120 Pneumatic tools 1no. 1set
121 Impact Screw Driver 1no. 1set
122 General purpose puller 1no. 1set
123 Stud Extractor 1no. 1set
124 Spring Pliers 150, 200 mm 1no. 1set
125 Torque Wrench (set of three nos) 1no. 1set
126 Growler 1no. 1no.
127 Battery Charger 1no. 1no.
128 Timing light 1no. 1no.
129 Hydrometer 1no. 1no.
130 Continuity meter 1no. 1no.
131 Tyre Changer 1no. 1no.
132 Sound Meter 1no. 1no.
133 Gas Analyzer 1no. 1no.
134 Smoke Meter – with Engine r.p.m. & Temp. Sensor 1no. 1no.
135 4- - gas analysis with temp. & Engine r.p.m. Sensors. 1no. 1no.
LIST OF OPTIONAL TOOLS AND EQUIPMENTS, SHOULD BE PROCURED IF
POSSIBLE

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 1. Car Washer with detergent and steam mixed facility.

2. V.C.R./V.C.P. along with the Video Cassettes in the field of Mechanic Motor Vehicle.

3. Engine Tuning Equipments, such as Exhaust Gas, analyzer, Duel Angle. Tester etc.

4. Car Air Conditioning Model.

5. Disc Break Model

6. Engine Model with Petrol Injection.

7. Engine Model equipped with Electronic Ignition System.

8. Car Scanner

9. Illuminated Magnifier 10 X

C. GENERAL MACHINERY
Sl. Description Quantity
No.
1 Grinder with two 7 ” wheel capacity 1 no.
2 Arbor press & operated 1 ton capacity 1 no.

3 Light Motor Vehicle in running condition (Diesel) 1 no.

( Indian make)
4 Motor Car (Petrol) in running condition (Indian 1 no.
make)
5 Petrol engine running condition (Car type) ( 2 nos.
Indian make)
6 Diesel engine running condition (Vehicle type) 2 nos.

7 Spark plug cleaning and tester equipment 1 set

8 Air compressor – 2 stage – 500 liter with 5 HP 1 no.
motor and air recover
9 Car washer – Reciprocating type electrically 1 no.
operated with 5 HP motor – 222 liter tank

10 Hydraulic Hoist 1 no.

11 l.P.G. / C.M.G. Retro-fitting Kit ( for Dens ant 1 no.
type)

D. WORKSHOP FURNITURE

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 Sl. Description Quantity
No.
1 Discussion Table 1 No.
2 Tool Cabinet 2 Nos.
3 Trainees locker Required to accommodate 16 lockers
4 Book shelf (glass panel) 1 No.
5 Storage Rack 2 Nos.
6 Storage shelf 2 Nos.
7 Computer table 1 No.
8 Computer chair 2 Nos.
9 Printer table 1 No.
10 Online UPS 2KVA 1 No.

N.B.: - The subject of Social Studies is common for all Trades is not incorporated in this
syllabus

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