Neelkanth - ITI Mechanic Motor Vehicle Practical English  (English, Paperback, Manish Sharma)

I Year Week No. Practical 1-2 • Familiarisation with institute, Job opportunities in the automobile sector, Machinery used in Trade. Types of work done by the students in the shop floor. • Importance of maintenance and cleanliness of Workshop. • Interaction with health centre and fire service station to provide demo on First aid and Fire safety, Use of fire extinguishers. • Practice operation of different workshop equipments. • Demonstrate Energy saving Tips of ITI electricity Usage 3-5 • Practice using all marking aids, like steel rule with spring callipers, dividers, scriber, punches, Chisel etc. • Layout a work piece- for line, circle, arcs and circles. • Practice to measure a wheel base of a vehicle with measuring tape. • Practice to measure valve spring tension using spring tension tester. • Practice to remove wheel lug nuts with use of an air impact wrench. • Practice on General workshop tools & power tools. 6-7 • Carryout Measuring practice on Cam height, Camshaft Journal dia, crankshaft journal dia, Valve stem dia, piston diameter, and piston pin dia with outside Micrometers. • Carryout Measuring practice on the height of the rotor of an oil pump from the surface of the housing or any other auto component measurement with depth micrometer. • Carryout Measuring practice on valve spring free length. • Carryout Measuring practice on cylinder bore, Connecting rod bore, inside diameter (ID) of a camshaft bearing with Telescope gauges. • Carryout Measuring practice on cylinder bore for taper and outof-round with Dial bore gauges. • Perform Measuring practice to measure wear on crankshaft end play, crankshaft run out, and valve guide with dial indicator. • Perform Measuring practice to check the flatness of the cylinder head is warped or twisted with straightedge is used with a feeler gauge. • Perform Measuring practice to check the end gap of a piston ring, piston-to-cylinder wall clearance with feeler gauge. • Practice to check engine manifold vacuum with vacuum gauge. • Practice to check the air pressure inside the vehicle tires is maintained at the recommended setting. 8-9 • Practice on Marking and Drilling clear and Blind Holes, Sharpening of Twist Drills Safety precautions to be observed while using a drilling machine. • Practice on Tapping a Clear and Blind Hole, Selection of tape drill Size, use of Lubrication, Use of stud extractor. • Practice 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. 10-11 • Practice in joining wires using soldering Iron, Construction of simple electrical circuits, measuring of current, voltage and resistance using digital multimeter, practice continuity test for fuses, jumper wires, fusible links, and circuit breakers. 12 • Diagnose series, parallel, seriesparallel circuits using Ohm’s law, Check electrical circuit with a test lamp, perform voltage drop test in circuits using multimeter, measure current flow using multimeter /ammeter, use of service manual wiring diagram for troubleshooting. 13-14 • Carryout Cleaning and topping up of a lead acid battery, Testing battery with hydrometer, • Connect battery to a charger for battery charging, Inspecting & testing a battery after charging, Measure and Diagnose the cause(s) of excessive Key-off battery drain (parasitic draw) and do corrective action. Testing of relay and solenoids and its circuit. • Test diode for functionality. • Practice checking Transistors. 15-16 • Identify Hydraulic and pneumatic components used in vehicle. • Trace hydraulic circuit on hydraulic jack, hydraulic power steering, and Brake circuit. • Identify components in Air brake systems. 17-18 • Carryout Identification of different type of Vehicle. • Perform Demonstration of vehicle specification data • Perform Identification of vehicle information Number (VIN). Demonstration of Garage, Service station equipments.- Vehicle hoists - Two post and four post hoist, Engine hoists, Jacks, Stands. 19-21 • Identify parts in a Diesel engine of LMV/ HMV. • Identify parts in a Petrol engine of LMV/ HMV. • Practice on starting and stopping of engines. • Observe and report the reading of Tachometer, Odometer, temp and Fuel gauge under ideal and on load condition. • Practice identification of difference in components of Petrol and Diesel Engines. • Practice on dismantling engine of LMV/HMV as per procedure. 22-23 Project Work/ Industrial Visit Broad Area: (a) Simple electrical circuits (b) Testing of Battery (c) Testing of Ignition Circuit (d) Dismantling and assembling of Petrol and Diesel engines. 24-25 • Overhauling of cylinder head assembly, Use of service manual for clearance and other parameters, Practice on removing rocker arm assembly manifolds. • Practice on removing the valves and its parts from the cylinder head, cleaning. Inspection of cylinder head and manifold surfaces for warping, cracks and flatness. • Perform Checking valve seats & valve guide – Replacing the valve if necessary check valve overlap. Testing leaks of valve seats for leakage – Dismantle rocker shaft assembly -clean & check rocker shaft-and levers, for wear and cracks and reassemble. • Check valve springs, tappets, push rods, tappet screws an valve stem cap. • Reassemble valve parts in sequence, refit cylinder head and manifold & rocker arm assembly, adjustable valve clearances, starting engine after adjustments. 26 • Practice Overhauling piston and connecting rod Assembly. Use of service manual for clearance and other parameters • Practice on removing oil sump and oil pump – clean the sump. Practice on removing the big end bearing, connecting rod with the piston. • Practice on removing the piston rings; Dismantle the piston and connecting rod. Check the side clearance of piston rings in the piston groove & lands for wear. Check piston skirt and crown for damage and scuffing, clean oil holes. • 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. • Check connecting rod for bend and twist. Assemble the piston and connecting rod assembly. 27-28 • Carryout Overhauling of crankshaft by referring service manual for clearance and other parameters • Practice on removing damper pulley, timing gear/timing chain, flywheel, main bearing caps, bearing shells and crankshaft from engine checking oil retainer and thrust surfaces for wear • Measure crank shaft journal for wear, taper and ovality, Checking crankshaft for fillet radii, bend & twist. 29-30 • Perform Checking of flywheel and mounting flanges, spigot, bearing. • Check vibration damper for defects, Practice on removing cam shaft from engine block, Check for bend & twist of camshaft. • Perform Inspection of cam lobe, camshaft journals and bearings and measure cam lobe lift. • Practice 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. 31-32 • Practice Cleaning and Checking of cylinder blocks. • Check cylinder blocks Surface flatness visually. • Measure cylinder bore for taper & ovality, clean oil gallery passage and oil pipe line, Bore - descale water passages. • Practice Removing cylinder liners from scrap cylinder block, practice in measuring and refitting new liners as per maker’s recommendations precautions while fitting new liners. 33-34 • Practice on Checking &Top up coolant, • Drain & refill coolant, Checking / replacing a coolant hose, Testing cooling system pressure, Practice on Removing & replacing radiator/ thermostat. • Inspect the radiator pressure cap, testing of thermostat. • Perform Cleaning & reverse flushing. • Carryout overhauling water pump and refitting. • Practice on Checking engine oil, Draining engine oil, Replacing oil filter, Refilling engine oil. • Carryout Overhauling of oil pump, oil coolers, air cleaners and air filters and adjust oil pressure relief valves, repairs to oil flow pipe lines and unions if necessary.