NSQF LEVEL- 6

SECTOR- AUTOMOTIVE

GOVERNMENT OF INDIA
Ministry of Skill Development & Entrepreneurship
Directorate General of Training
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE
EN-81, Sector-V, Salt Lake City, Kolkata – 700091
MECHANIC (DIESEL)
(Engineering Trade)

SECTOR –AUTOMOTIVE

(Revised in 2019)

Version 1.1

CRAFT INSTRUCTOR TRAINING SCHEME (CITS)

NSQF LEVEL - 6

Developed By
Government of India
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
www.cstaricalcutta.gov.in
 MECHANIC (DIESEL) (CITS)

CONTENTS

S No. Topics Page No.

1. Course Overview 1
2. Training System 2
3. General Information 6
4. Job Role 8
5. Learning Outcome 9
6. Course Content 10
7. Assessment Criteria 23
8. Infrastructure 26
Annexure I –List of Trade Experts 34
 MECHANIC (DIESEL) (CITS)

1. COURSEOVERVIEW

The Craft Instructor Training Scheme is operational since inception of the Craftsmen
Training Scheme. The first Craft Instructor Training Institute was established in 1948.
Subsequently, 6 more institutes namely, Central Training Institute for Instructors (now called as
National Skill Training Institute (NSTI)), NSTI at Ludhiana, Kanpur, Howrah, Mumbai, Chennai
and Hyderabad were established in 1960’s by DGT. Since then the CITS course is successfully
running in all the NSTIs across India as well as in DGT affiliated institutes viz. Institutes for
Training of Trainers (IToT). This is a competency based course for instructors of one year
duration. “Mechanic (Diesel)” CITS trade is applicable for Instructors of “Mechanic (Diesel)” CTS
Trade.

The main objective of Craft Instructor training programme is to enable Instructors

explore different aspects of the techniques in pedagogy and transferring of hands-on skills so as
to develop a pool of skilled manpower for industries, also leading to their career growth &
benefiting society at large. Thus promoting a holistic learning experience where trainee
acquires specialized knowledge, skills & develops attitude towards learning & contributing in
vocational training ecosystem.

This course also enables the instructors to develop instructional skills for mentoring the
trainees, engaging all trainees in learning process and managing effective utilization of
resources. It emphasizes on the importance of collaborative learning & innovative ways of
doing things. All trainees will be able to understand and interpret the course content in right
perspective, so that they are engaged in & empowered by their learning experiences and above
all, ensure quality delivery.

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2. TRAINING SYSTEM

2.1 GENERAL

CITS courses are delivered in National Skill Training Institutes (NSTIs) & DGT affiliated
institutes viz., Institutes for Training of Trainers (IToT). For detailed guidelines regarding
admission on CITS, instructions issued by DGT from time to time are to be observed. Further
complete admission details are made available on NIMI web portal
http://www.nimionlineadmission.in. The course is of one-year duration. It consists of Trade
Technology (Professional skills and Professional knowledge), Training Methodology and
Engineering Technology/ Soft skills. After successful completion of the training programme, the
trainees appear in All India Trade Test for Craft Instructor. The successful trainee is awarded
NCIC certificate by DGT.

2.2 COURSE STRUCTURE

Table below depicts the distribution of training hours across various course elements
during a period of one year:

S No. Course Element Notional Training Hours

1. Trade Technology
Professional Skill (Trade Practical) 640
Professional Knowledge (Trade Theory) 240
2. Engineering Technology
Workshop Calculation & Science 80
Engineering Drawing 120
3. Training Methodology
TM Practical 320
TM Theory 200
Total 1600

2.3 PROGRESSION PATHWAYS

 Can join as Instructor in Vocation Training Institute/ Technical Institute.
 Can join as a supervisor in Industries.

2.4 ASSESSMENT & CERTIFICATION

The CITS trainee will be assessed for his/her Instructional skills, knowledge and attitude
towards learning throughout the course span and also at the end of the training program.

a) The Continuous Assessment (Internal) during the period of training will be done by
Formative Assessment Method to test competency of instructor with respect to assessment
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criteria set against each learning outcomes. The training institute has to maintain an individual
trainee portfolio in line with assessment guidelines. The marks of internal assessment will be as
per the formative assessment template provided on www.bharatskills.gov.in.

b) The Final Assessment will be in the form of Summative Assessment Method. The All India
Trade Test for awarding National Craft Instructor Certificate will be conducted by DGT at the
end of the year as per the guidelines of DGT. The learning outcome and assessment criteria will
be the basis for setting question papers for final assessment. The external examiner during final
examination will also check the individual trainee’s profile as detailed in assessment guideline
before giving marks for practical examination.

2.4.1 PASS CRITERIA

Pass Marks
Sl. Ma Internal Full
Subject Internal
No. rks Assessment Marks Exam
Assessment
Trade
100 40 140 40 24
Trade Theory
1
Technology Trade
200 60 260 120 36
Practical
Worksho
p Cal. & 50 25 75 20 15
Engineering Sc.
2
Technology Engineeri
ng 50 75 20 15
25
Drawing
TM
200 30 230 120 18
Training Practical
3
Methodology TM
100 20 120 40 12
Theory
Total Marks 700 200 900 360 120

The minimum pass percent for Trade Practical, TM practical Examinations and Formative
assessment is 60% & for all other subjects is 40%.There will be no Grace marks.

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. While assessing, the major factors to be considered are
approaches to generate solutions to specific problems by involving standard/non-standard
practices.

Due consideration should also be given while assessing for teamwork,

avoidance/reduction of scrap/wastage and disposal of scrap/waste as per procedure,
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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 of the following:

 Demonstration of Instructional Skills (Lesson Plan, Demonstration Plan)

 Record book/daily diary
 Assessment Sheet
 Progress chart
 Video Recording
 Attendance and punctuality
 Viva-voce
 Practical work done/Models
 Assignments
 Project work

Evidences and records of internal (Formative) assessments are to be preserved until

forthcoming yearly 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  Demonstration of fairly good skill to
candidate should be well versed with establish a rapport with audience,
instructional design, implement presentation in orderly manner and
learning programme and assess establish as an expert in the field.
learners which demonstrates  Average engagement of students for
attainment of an acceptable standard learning and achievement of goals while
of crafts instructorship with occasional undertaking the training on specific topic.
guidance and engage students by  A fairly good level of competency in
demonstrating good attributes of a expressing each concept in terms the
trainer. student can relate, draw analogy and
summarize the entire lesson.
 Occasional support in imparting effective
training.
(b) Weightage in the range of 75%-90% to be allotted during assessment
For performance in this grade, the  Demonstration of good skill to establish a
candidate should be well versed with rapport with audience, presentation in
instructional design, implement orderly manner and establish as an expert
learning programme and assess in the field.
learners which demonstrates  Above average engagement of students
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attainment of a reasonable standard for learning and achievement of goals

of crafts instructorship with little while undertaking the training on specific
guidance and engage students by topic.
demonstrating good attributes of a  A good level of competency in expressing
trainer. each concept in terms the student can
relate, draw analogy and summarize the
entire lesson.
 Little support in imparting effective
training.
(c) Weightage in the range of more than 90% to be allotted during assessment
For performance in this grade, the  Demonstration of high skill level to
candidate should be well versed with establish a rapport with audience,
instructional design, implement presentation in orderly manner and
learning programme and assess establish as an expert in the field.
learners which demonstrates  Good engagement of students for
attainment of a high standard of crafts learning and achievement of goals while
instructorship with minimal or no undertaking the training on specific topic.
support and engage students by  A high level of competency in expressing
demonstrating good attributes of a each concept in terms the student can
trainer. relate, draw analogy and summarize the
entire lesson.
 Minimal or no support in imparting
effective training.

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3. GENERAL INFORMATION

Name of the Trade Mechanic (Diesel)-CITS

Trade Code DGT/ 4007
NCO – 2015 2356.0100,7233.0400
NSQF Level Level-6
Duration of Craft One Year
Instructor Training
Unit Strength (No. Of
25
Student)
Entry Qualification Degree in appropriate branches of Mechanical/ Automobile
Engineering from AICTE/ UGC recognized Engineering College /
University.
OR
Diploma in appropriate branches of Mechanical / Automobile
Engineering from AICTE/ recognized board / Institution.
OR
National Trade Certificate in Mechanic (Diesel) or related trades.
OR
National Apprenticeship Certificate in Mechanic (Diesel) or related
trades.
AND
Essential:
Valid MCWG & LMV driving License Mandatory for all.
Minimum Age 18 years as on first day of academic session.
Space Norms 120 sq. m + 80 Sq. m (Parking area)
Power Norms 5.5 KW
Instructors Qualification for
1. Mechanic (Diesel) - B.Voc/Degree in Automobile or Mechanical Engineering from
CITS Trade recognized University with two years experience in relevant field.
OR
03 years Diploma in Automobile or Mechanical from
AICTE/recognized Board/ Institution or relevant Advanced Diploma
(Vocational) from DGT with five years experience in relevant field.
OR
NTC/ NAC in Mechanic (Diesel) with seven years of experience in
relevant field.
AND
Essential:
Valid MCWG & LMV driving License Mandatory for all.
Essential Qualification:
National Craft Instructor Certificate (NCIC) in Mechanic (Diesel)
trade, in any of the variants under DGT.
2. Workshop B.Voc/Degree in any Engineering from AICTE/ UGC recognized
Calculation & Science Engineering College/ university with two years experience in
relevant field.
OR
03 years Diploma in Engineering from AICTE /recognized board of
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technical education or relevant Advanced Diploma (Vocational)

from DGT with five years’ experience in the relevant field.
OR
NTC/ NAC in any Engineering trade with seven years experience in
relevant field.

Essential:
National Craft Instructor Certificate (NCIC) in relevant trade
OR
NCIC in RoDA or any of its variants under DGT.
3. Engineering B.Voc/Degree in Engineering from AICTE/ UGC recognized
Drawing Engineering College/ university with two years experience in
relevant field.
OR
03 years Diploma in Engineering from AICTE /recognized board of
technical education or relevant Advanced Diploma (Vocational)
from DGT with five years’ experience in the relevant field.
OR
NTC/ NAC in any one of the ‘Mechanical group (Gr-I) trades
categorized under Engg. Drawing’/ D’man Mechanical / D’man
Civil’ with seven years experience.

Essential Qualification:
National Craft Instructor Certificate (NCIC) in relevant trade
OR
NCIC in RoDA / D’man (Mech /civil) or any of its variants under
DGT
4. Training B.Voc/Degree in any discipline from AICTE/ UGC recognized
Methodology College/ university with two years experience in training/ teaching
field.
OR
Diploma in any discipline from recognized board / University with
five years experience in training/teaching field.
OR
NTC/ NAC passed in any trade with seven years experience in
training/ teaching field.

Essential Qualification:
National Craft Instructor Certificate (NCIC) in any of the variants
under DGT / B.Ed /ToT from NITTTR or equivalent.
5. Minimum Age for 21 Years
Instructor
Distribution of training on Hourly basis: (Indicative only)
Trade Trade Workshop Engg. TM TM
Total Hrs /week
Practical Theory Cal. & Sc. Drawing Practical Theory

40 Hours 16 Hours 6Hours 2 Hours 3 Hours 8 Hours 5 Hours

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4. 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.

Manual Training Teacher/Craft Instructor; instructs students in ITIs/Vocational Training

Institutes in respective trades as per defined job role. Imparts theoretical instructions for the
use of tools & equipment of related trades and related subjects. Demonstrate process and
operations related to the trade in the workshop; supervises, assesses and evaluates students in
their practical work. Ensures availability & proper functioning of equipment and tools in stores.

Reference NCO 2015:

a) 7233.0400 – Mechanic, Diesel Engine
b) 2356.0100 – Manual Training Teacher/ Craft Instructor.

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5. LEARNING OUTCOME

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

5.1 TRADE TECHNOLOGY

1. Explain Quality Management tools- 5S, 7QC etc. & ensure compliance of safety practice
and handling of hand tools, special tools and maintenance of them.
2. Analyse diagnosis of problems in various Engine system (viz. Lubrication system,
emission control system and control system) and troubleshoot engine.
3. Evaluate maintenance, diagnosis and servicing of fuel supply system in Petrol/diesel
engines.
4. Evaluate maintenance, diagnosis and troubleshooting of Electrical and Electronics
systems.
5. Monitor emission of vehicle and execute different operation to obtain optimum
pollution as per emission norms.
6. Plan, Diagnose & rectify the defects in HMV to ensure functionality of vehicle.
7. Evaluate diagnosis and troubleshooting of CNG, LPG & hybrid system.
8. Assess Service of Diesel Fuel System and check proper functionality (calibration of
mechanical and electronic pumps, checking injectors, filters).
9. Analyse diagnosis and troubleshooting of Electric and Electronic related to CRDI.
10. Analyse diagnosis Repair and Overhauling of CRDI Engine.
11. Plan & overhaul the stationary engine check functionality of various sub-systems
attached.

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6. COURSE CONTENT

SYLLABUS FOR MECHANIC (DIESEL) –CITS TRADE

TRADE TECHNOLOGY

Reference Learning Professional Skills Professional Knowledge

Duration
Outcome (Trade Practical) (Trade Theory)
Practical Explain Quality 1. Practice 5s techniques in the  Admission, introduction,
32Hrs Management tools- automobile work shop. facility available in the
5S, 7QC etc. & 2. Practice 7QC techniques in institute.
Theory
ensure compliance the automobile work shop.  Importance of safety,
12Hrs
of safety practice 3. Precautions to be observed safety precautions& first
and handling of while working in the aid.
hand tools, special automobile work shop and  Concept of 5S & 7QC tools,
tools and garage equipments. time management as
maintenance of 4. Familiarization with employed for quality circle.
them. computer. Importance of healthy
environment.
 Application of computers
& its Features.
5. Handling & maintenance of  Application and safety to
hand tools, special tools, be observed while
equipment & machineries. handling hand tools,
6. Maintenance of garage special tools, equipment &
equipment in the workshop. machineries Importance
7. Preventive maintenance of and types of
vehicle/engines. maintenance of
vehicles/engines.
Practical Analyse diagnosis 8. Checking engine vacuum  Explanation of Principle of
96Hrs of problems in & compression pressure. All types of SI and CI
various Engine 9. Taking Cylinder leakage test Engines with respect to
Theory
system (viz. with compressed air. pressure, volume and
36Hrs
Lubrication 10. Measure the cubic capacity of temperature.
system, emission a given engine.  Thermodynamic cycles
control system and with respect to pv&ts
control system) diagrams.
and troubleshoot  Valve timing diagram of all
engine. types of Engine.
11. Servicing cylinder head  Importance of servicing
assembly. cylinder head-Precautions
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 MECHANIC (DIESEL) (CITS)

12. Remove all accessories to be observed while

attached with the engine servicing cylinder head.
dismantling the head  Reasons for frequently
components and its visual occurring abnormal wear in
inspection. cylinder head components
13. Measuring components for and its Effects on engine
wear with precision performance.
measuring instruments-  Constructional details,
suggestions for remedy and Advantages and
taking remedial measures. disadvantages of variable
14. Reassembling cylinder head valve timing
components.
15. Servicing cylinder block  Importance of servicing
assembly. cylinder block-Precautions
16. Removing and dismantling to be observed while
piston and connecting rod servicing cylinder block.
assembly, crank shaft and  Reason for measuring
flywheel, vibration damper cylinder block for various
from the engine. parameters to find out its
17. Visual inspection of cylinder serviceability and
block for various parameters suggestions for remedial
such as bore, main journal measures. Reasons for
etc. for wear and suggest frequently occurring
remedial measures. abnormal wear in cylinder
18. Visual inspection of the block components and its
cylinder blocks components Effects on engine
(piston and connecting rod performance.
assembly, crank shaft,
flywheel etc.)
19. Measuring cylinder block &  Importance of measuring
components for wear with cylinder block components
precision measuring for actual wear to
instruments-suggestions for decide serviceability.
remedy and taking remedial  Engine assembly procedure
measures. as recommended by
20. Reassembling the engine manufacturers.
block and its components.  Importance and correct
21. Refit cylinder head assembly. procedure of setting valve
22. Setting valve timing. timing.
23. Checking and setting valve  Importance of correct valve
clearance. clearance Precautions to be
24. Practice on checking and observed while assembling

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setting variable valve timing. engine components.

25. Maintenance, diagnosis and  Study about intake system
Servicing intake systems. components such as air
26. Servicing of different types of cleaner, different types of
air cleaner, turbocharger, turbo charger, super
intercooler, throttle body, charger, throttle body,
intake manifold. intake manifold etc.
27. Maintenance, diagnosis and  Importance of
Servicing exhaust systems. maintenance, diagnosis
28. Servicing of exhaust and Servicing intake
manifold, catalytic converter, systems.
resonator, muffler.  Causes of failure of the
components of intake
system.
 Trouble shooting in an
intake system. Study about
exhaust system
components such as
exhaust manifold, muffler,
types of catalytic converter
etc.
 Importance of
maintenance, diagnosis
and Servicing exhaust
systems.
 Causes of failure of the
components of exhaust
system.
 Trouble shooting in an
intake system.
Practical Evaluate 29. Maintenance, diagnosis and  FUEL SUPPLY SYSTEM IN
96Hrs maintenance, servicing of basic petrol fuel PETROL ENGINE Gasoline
diagnosis and system components. Fuel: properties of
Theory
servicing of fuel 30. Overhauling of fuel tank, Gasoline fuel -combustion
36 Hrs
supply system in mechanical fuel Pump, processes.
Petrol/diesel electrical pump, fuel filters,  Study about carburetor
engines. carburetors Testing of fuel fuel system and its
pumps for proper components such as fuel
functioning. tank, mechanical fuel
Pump, electrical pump,
fuel filters, carburetors and
its circuits etc.

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 Importance of
maintenance, diagnosis
and Servicing carburetor
fuel system and its
components.
 Causes of failure of the
carburetor fuel system and
its components.
 Trouble shooting in
carburetor fuel system and
its components.
 Importance of testing of
fuel pumps.
31. Maintenance, diagnosis and  Fuel supply system in
servicing of conventional diesel engines.
diesel fuel system and its  Diesel fuel& its properties -
components. combustion processes.
32. Overhauling of fuel tank, fuel  Study about conventional
feed Pump, electrical pump, diesel fuel system and its
fuel filters, types of fuel components such as fuel
injection pumps, governors, tank, fuel feed Pump,
injector. electrical pump, fuel filters,
33. Testing of fuel feed water separators, fuel
pumps for proper injection pumps, governors,
functioning. injectors etc. Importance
34. Servicing of fuel tanks, of maintenance, diagnosis
Checking leaks in the fuel and Servicing diesel fuel
lines, draining of water system and its components.
separators. Causes of failure of the
35. Replacing of primary& diesel fuel system and its
secondary filters. components.
36. Phasing and calibration of  Importance of testing of
fuel injection pump. fuel feed pumps, FIP and
37. Testing of injectors for its injectors.
proper functioning.  Importance of setting
38. Setting fuel injection timing correct FIP timing.
Bleeding diesel fuel system. Importance of bleeding the
fuel system. Trouble
shooting in diesel fuel
system and its components.
39. Maintenance, diagnosis and Engine lubrication system
servicing of lubrication  Lubricant, types, application

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system. and its properties. Study

40. Changing engine oil and filter. about lubrication systems
41. Tracing oil leak from the and its components such as
engine. oil sump, oil strainer, oil
42. Overhauling of oil pump, pump, relief valve, filter,
checking oil pressure relief bypass valve, oil cooler etc.
valves for proper functioning.  Study about oil filtering
43. Servicing oil coolers. systems.
44. Checking oil galleries.  Importance of
45. Oil pressure testing. maintenance, diagnosis and
46. Removing of sludge by using Servicing lubricating system
flushing oil. and its components.
 Causes of failure of the
lubricating system and its
components.
 Importance of testing of oil
pumps.
 Importance of servicing oil
filter.
 Importance of checking and
setting correct oil pressure.
 Reasons for sludge
formation and its
prevention Trouble
shooting in lubricating
system and its components.
47. Maintenance, diagnosis and Engine cooling system
servicing of cooling system.  Coolant, types, and its
48. Flushing cooling system properties.
replacing coolant.  Importance of maintaining
49. Tracing coolant leakage from correct coolant-water ratio.
the engine.  Study about cooling
50. Checking cooling system for systems and its components
proper functioning. such as radiator, pressure
51. Replacing/overhauling of cap, types of hoses, types of
water pump. water pump, electric fan,
52. Checking thermostat valve. thermostat, fan belts,
53. Adjusting fan belt tension. temperature gauge,
54. Checking radiator pressure temperature sensor etc.
cap for proper functioning.  Study about oil filtering
55. Replacing/Servicing radiator. systems.
56. Diagnosis of improper  Importance of

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operating temperature. maintenance, diagnosis

and Servicing cooling
system and its components.
 Causes of failure of the
cooling system and its
components.
 Importance of testing of
pressure cap.
 Importance of servicing
radiator.
 Trouble shooting in cooling
system and its components.
Practical Evaluate 57. Maintenance, diagnosis and  Battery/accumulator: -
96Hrs maintenance, servicing battery Checking of types, construction,
diagnosis and battery condition using working. Battery capacity
Theory
troubleshooting of hydrometer and battery &rating, Booster starting.
36 Hrs
Electrical and tester. IBS, Disposal of waste
Electronics 58. Charging batteries in series battery.
systems. and parallel.  Advantages of slow
59. Maintenance of battery. charging. Advantages of
60. Jump starting a battery. solidification of electrolyte
61. Preparation of electrolyte. by adding salicylic acid or
Reconditioning of terminal introducing absorbed glass
post. mat (AGM) - VRLA batteries
Electrolyte-definition,
percentage of sulphuric
acid and water effects of
improper ratio of acid and
water on battery life.
 Specific gravity of water,
acid and electrolyte.
Temperature effect on
specific gravity. Battery
troubles and their remedies
62. Maintenance, diagnosis and  Study about starting
servicing of starting system. system and its
63. Checking starter circuit for components. Importance
proper functioning. of checking starter circuit
64. Checking solenoid for proper functioning.
switches for proper  Role of solenoid switch and
functioning. relay, importance of its
65. Overhauling all types of checking.

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starter.  Importance of testing

66. Checking of starter for proper starter components.
functioning. Troubles and remedies in
starting system.
67. Maintenance, diagnosis and  Study about Charging
servicing of charging system. system and its
68. Checking charging circuit components.
voltage drop test for proper  Importance of checking
functioning. charging circuit for proper
69. On vehicle inspection of functioning.
alternator for proper  Importance of voltage
functioning. regulation
70. Overhauling of alternator  Importance of testing
Testing voltage regulator. charging system
components.
 Troubles and remedies in
charging system.
71. Maintenance, diagnosis and  Study about types of
servicing of conventional conventional Ignition
ignition system. system and its
72. Checking ignition circuit for components.
proper functioning.  Importance of checking
73. Checking magneto coil for ignition circuit.
proper functioning.  Importance of checking
74. Checking magneto for proper and setting correct
strength. ignition timing.
75. Checking and Setting of
magneto ignition timing using
Ignition Timing light.
76. Overhauling distributor.  Study about distributor and
77. Checking vacuum & its components.
centrifugal advance  Importance of checking
mechanism for proper distributor for proper
functioning. functioning.
78. Testing ignition coil, spark  Importance of testing
plug, condenser for proper ignition coil, spark plug,
functioning using testing condenser for proper
equipment. functioning. Common
79. Setting ignition timing. troubles in Ignition system.
Checking of Ignition timing
using Ignition Timing light
Practical Monitor emission 80. Checking of exhaust gas in Emission control system

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16 Hrs of vehicle and petrol engine using exhaust  Definition, Sources of

execute different gas analyser. emission (such as Exhaust
Theory operation to obtain 81. Checking of exhaust gas in system, crank case, fuel
06 Hrs
optimum pollution diesel engine using Smoke tank and carburetor).
as per emission meter. Methods to control
norms. 82. Maintenance of crank case emission, (1. exhaust
ventilation system. system with EGR OR Air
83. Maintenance of EGR system. injection system in to
exhaust manifold with
catalytic converter 2.
Positive crank case
ventilation. 3. Evaporative
control system i.e. charcoal
canister. ). Vehicle emission
standards- Euro and Bharat
standards. Emission control
Practical Plan, Diagnose & 84. Trouble tracing in engines  Digital panel board gauges
64Hrs rectify the defects through dashboard gauges and their circuit. details
in HMV to ensure such as Mal function about MIL indicator, cooling
Theory
functionality of Indicator Lamp , cooling system indicator, oil level
24Hrs
vehicle. system indicator, oil level indicator, battery charging
indicator, battery charging indicator, glow plug
indicator, glow plug indicator indicator etc.
etc.
85. Engine tune up procedure,  Tune up the engine with
diagnosing abnormal noises the help of multi scan tool,
coming from engine and its adjusting of valve tappet
causes. clearance checking and
86. Troubleshooting of engine- setting at injection timing &
mechanical and electrical valve timing.
problems.
87. Determining the mechanical Engine performance tests
efficiency of the engine by  Purpose of testing an I.C
Morse test using engine. Classification of
dynamometer and test, fault finding tests,
tachometer. routine tests. Measurement
of IHP, indicative mean
effective pressure, BHP,
Mechanical efficiency, fuel
consumption, thermal
efficiency, volumetric
efficiency, relative

17
 MECHANIC (DIESEL) (CITS)

efficiency, air consumption,

lubricating oil consumption.
 Dynamometers and its
types.
 Preparation of heat balance
sheet.
Practical Evaluate diagnosis 88. Find out the location of CNG  Alternative fuels, types,
16 Hrs and kit components in vehicle. PROPERTIES, Advantages &
troubleshooting of 89. Overhauling of CNG kit disadvantages of each type of
Theory
CNG, LPG & hybrid components.(conventional fuel. CNG engine and its
06 Hrs
system. type). advantages. CNG conversion
90. Overhauling of CNG kit kit, function, constructional
components.(Gas injection details. (conventional type)
type ) CNG conversion kit, function,
91. Find out the location of L P G constructional details. (Gas
kit components in vehicle. injection type) L P G engine and
92. Overhauling of L P G kit its advantages. LPG Conversion
components. kit, function, constructional
93. Maintenance, diagnosis and details. Comparison between
servicing of electric and petrol, diesel, LPG and CNG.
hybrid car.  Electric car and Hybrid car.
Practical Asses Service of 94. Maintaining fuel injection test  Importance of testing the
32Hrs Diesel Fuel System bench further practice on pumps.
and check proper overhauling.  Procedure for testing
Theory
functionality 95. Testing of different types before dismantling.
12Hrs
(calibration of inline fuel injection pump  Procedure as per the
mechanical and manufacturer for
electronic pumps, dismantling, inspecting and
checking injectors, assembling inline pump.
filters) 96. Further practice on servicing  Detailed description of
and testing different types of procedure of servicing
inline FIP, governors and mechanically controlled
injectors. distributor type,
97. Servicing and testing different electronically controlled
types of distributor type fuel distributor type and
injection pumps. solenoid valve controlled
distributor type pumps-
details of start assist
systems.
 Procedure as per the
manufacturer for
dismantling, inspecting and

18
 MECHANIC (DIESEL) (CITS)

assembling distributor
pumps.
Practical Analyse diagnosis 98. Trouble tracing in engine Engine management system
80 Hrs and using multi scan tool such as  Definition, Function, Types
troubleshooting of Engine management system, of system available,
Theory
Electric and electronic fuel injection, Air  Parts of Engine
30Hrs
Electronic related flow measurement, Variable Management System. (All
to CRDI. intake manifold system, types sensors, actuators,
of EFI wiring system, pumps.) & their function.
Electronic control unit,  Closed and open loop
malfunction indicating lamp, system, cold start system,
Data link connector, Onboard Air flow measurement,
diagnostic system Checking of Variable intake manifold
sensors. system, EFI wiring system,
99. Checking of actuators. Electronic control unit, pre
Checking of pumps. heaters for inlet manifold,
Data link connector,
Onboard diagnostic system.
100. Diesel Engine diagnostic  Precautions to be observed
information and procedures. while working with engine
101. Engine and emission control emission control systems-
system-analyzing the details of OBD-description
complaint. of data link connector-
102. Handling of scan tool- study about schematic and
checking freeze frame data- routing diagram of
recording freeze frame data emission control system-
and clearance. flow diagram of control
103. Visual inspection- systems-terminal
confirmation of trouble arrangement of ECM.
system- rechecking freeze
frame data.
104. Trouble shooting for DTC-  Details of trouble codes-
checking DTC circuits. functions of sensors and
105. Identifying the trouble by actuators-details of scan
scan tool. tool-precautions while
106. Tracing the faults by trouble working with sensors and
code. actuators.
107. Checking intermittent
problems-final confirmation
test.
Practical Analyse diagnosis Servicing CRDI fuel system:  Description of CRDI systems
48Hrs Repair and 108. Checking low pressure fuel and its components.

19
 MECHANIC (DIESEL) (CITS)

Overhauling of supply circuit-preliminary Precautions to be observed

Theory CRDI Engine. check. before removing the CRDI
18 Hrs 109. Checking fuel pump fuel system-study about the
operation. low and high pressure fuel
110. Checking fuel pressure. supply circuits.
111. Checking high pressure fuel
supply circuit.
112. Checking fuel injector leak.
113. Checking fuel regulator.
114. Removing a high pressure Electronic Diesel control-
CRDI pump from an engine.  Electronic Diesel
115. Refit the pump to the engine, control systems, Common
start and adjusting for proper Rail Diesel Injection (CRDI)
functioning. system, Hydraulically
116. Servicing and testing of actuated electronically
various types of electronic controlled unit injector
injectors. (HEUI) diesel injection
117. Checking and replacing the system.
components of CRDI system.  Sensors, actuators and ECU
(Electronic Control Unit)
used in Diesel Engines.
118. Servicing CRDI diesel engines  Importance of measuring/
Dismantling, inspecting, inspecting the engine
measuring the engine components for wear to
components for wear, decide serviceability.
suggestions for remedy.
119. Replacement of worn
out/unserviceable parts and
reassembling.
120. Starting engine and tune up
for better performance.
Practical Plan & overhaul the 121. Servicing stationary diesel  Study about PT fuel system.
64Hrs stationary engine engine-PT injection system. definition, function,
check functionality 122. Dismantling, inspecting, components, function and
Theory
of various sub- measuring the engine working of each
24 Hrs
systems attached. components for wear, component and advantages
suggestions for remedy. and disadvantages of PT
123. Replacement of worn system.
out/unserviceable parts and  Importance of measuring/
reassembling. inspecting the engine
124. Starting and adjusting for components for wear to
better performance decide serviceability.

20
 MECHANIC (DIESEL) (CITS)

125. Servicing PT fuel system.

overhauling components of
PT fuel system
126. Identify terminals of 3 phase  Read and interpret the
generator set-determine dc name plate details-selecting
excitation/field winding ohmmeter for proper
terminals. range-advantages of using
127. Testing gen set for continuity- megger-residual
connect start, run the gen set magnetism-residual voltage
& measure build up voltage. and current
128. Determine the load
performance.
129. Dismantling of reciprocating  Importance of pumps in
pumps-valves, pistons, agricultural & industrial
cranks, seals etc. for applications. Classification
inspection, repair & of pumps, parts,
replacement. constructional details and
130. Cleaning of parts & its working.
assembling.  Classification of
131. Installing of reciprocating reciprocating pump,
pumps. construction and operation.
Installation technique of
reciprocating pump. Tools
and equipment required &
procedure.
132. Dismantling of rotary pumps-  Classification of rotary
impeller, shaft, bearing etc, pumps-Construction and
for inspection, Repair & operation- repairing
replacement. procedure. Brief
133. Cleaning of parts and description of turbine &
assembling. stage pumps, positive
134. Checking for alignment, displacements and their
clearance, etc., Priming advantages.
technique and its application.  Meaning of priming and its
135. Installing, operating & effect. Installation
testing of rotary pumps. techniques of rotary
pump-procedure, tools
and equipments required.

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 MECHANIC (DIESEL) (CITS)

SYLLABUS FORCORE SKILLS

1. Workshop Calculation & Science(Common for all Engineering CITS trades) (80 Hrs)
2. Engineering Drawing (Group I) (120Hrs)
3. Training Methodology (Common for all trades) (320Hrs + 200Hrs)

Learning outcomes, assessment criteria, syllabus and Tool List of above Core Skills subjects
which is common for a group of trades, provided separately in www.bharatskills.gov.in

22
 MECHANIC (DIESEL) (CITS)

7. ASSESSMENT CRITERIA

LEARNING OUTCOME ASSESSMENT CRITERIA

TRADE TECHNOLOGY
1. Explain Quality Explain 5s & 7QC techniques in the automobile work shop.
Management tools- 5S, 7QC Ensure precautions to be observed while working in the
etc. & ensure compliance of automobile work shop and garage equipments.
safety practice and handling Evaluate handling & maintenance of hand tools, special tools,
of hand tools, special tools equipment & machineries.
and maintenance of them. Ensure compliance of safety precautions while handling hand
tools, special tools, equipment & machineries.
Evaluate Preventive maintenance of garage equipment in the
workshop.

2. Analyse diagnosis of Assess planning and executing of dismantling & assembling of

problems in various Engine Engine from vehicle (LMV/HMV) along with other accessories.
system (viz. Lubrication Evaluate Overhauling of Engine and check functionality.
system, emission control Evaluate Tracing, Testing& Repairing of Cooling and Lubrication
system and control system) System of engine, Intake and Exhaust system of engine.
and troubleshoot engine. Assess servicing of different types of air cleaner, turbocharger,
intercooler, throttle body and intake manifold.
Assess servicing of exhaust manifold, catalytic converter,
resonator and muffler.
Check and propose possible optimization and compare their cost
effectiveness.
Contribute to continuous improvement of work process in the
related area.
Evaluate Engine Performance and set idling speed.
Analyse emission of vehicle and execution of different operation
to obtain optimum pollution as per emission norms.
Monitor, evaluate and document work result.

3. Evaluate maintenance, Evaluate dismantling & assembling of fuel feed system along
diagnosis and servicing of with other accessories.
fuel supply system in Evaluate Servicing of Fuel System and check proper functionality.
Petrol/diesel engines.
Check and propose possible optimization and compare their cost
effectiveness.
Contribute to continuous improvement of work process in the
related area.
Evaluate Engine Performance and set idling speed.

4. Evaluate maintenance, Evaluate diagnosis of problems and maintenance of batteries.

diagnosis and Evaluate Service & repair of charging and starting System
troubleshooting of Electrical components.
23
 MECHANIC (DIESEL) (CITS)

and Electronics systems. Assess overhauling and assembling of distributor.

Evaluate Servicing of ignition system, vacuum & centrifugal
advance mechanism and check proper functionality.
Check and propose possible optimization and compare their cost
effectiveness.
Contribute to continuous improvement of work process in the
related area.
Evaluate Performance of serviced units for functionality.

5. Monitor emission of vehicle Check vacuum pump for its functioning.

and execute different Perform troubleshooting of EVAP Canister.
operation to obtain Inspect PCV hose, inspect PCV Valve and check for vacuum.
optimum pollution as per Clean the PCV valve and replace if required.
emission norms. Inspect & clean EGR.

6. Plan, Diagnose & rectify the Plan and diagnose the problem if engine not starting.
defects in HMV to ensure Diagnose high fuel consumption and engine overheating.
functionality of vehicle. Diagnose for excessive oil consumption and low/high engine oil
pressure.
Diagnose for abnormal engine noise.
Diagnose for engine’s poor performance.

7. Evaluate diagnosis and Evaluate dismantling & assembling of CNG, LPG& hybrid system
troubleshooting of CNG, components.
LPG & hybrid system. Analyse rectification of the defects following the vehicle
manufacture`s standard procedure.
Select and use of testing methods that comply with the
manufacturer’s requirements.
Check and propose possible optimization and compare their cost
effectiveness.
Evaluate Performance of serviced units for functionality.

8. Assess Service of Diesel Fuel Overhauling fuel feed pump, fuel injector pump.
System and check proper Test injectors, check the injection timing by the spill cut off
functionality (calibration of method.
mechanical and electronic
pumps, checking injectors,
filters).

9. Analyse diagnosis and Evaluate dismantling and assembling of CRDI pump for servicing.
troubleshooting of Electric Plan and execute dismantling & assembling and evaluate
and Electronic related to servicing of CRDI system components.
CRDI. Analyse Rectify rectification of the defects following the vehicle
manufacture`s standard procedure.
Select and use testing methods that comply with the
manufacturer’s requirements.
Check and propose possible optimization and compare their cost
effectiveness.
24
 MECHANIC (DIESEL) (CITS)

Evaluate Performance of serviced units for functionality.

Assess trouble shooting for Diagnostic Trouble Code (DTC) and
check DTC circuits.
Monitor, evaluate and document work result.

10. Analyse diagnosis Repair Illustrate Dismantling, inspecting, measuring the engine
and Overhauling of CRDI components for wear.
Engine. Align the left hook of the crane with engine lifting bracket.
Remove the engine mountings.
Remove the engine from vehicle
Analyse Engine Overhauling procedure.
Mount the engine on the vehicle.
Align and fit the gear box to the engine.
Refit the accessories to the engine.
Overhaul Valve Actuating Mechanism (Hydraulic latch actuator).

11. Plan & overhaul the Start engine, adjust idling speed.
stationary engine check Overhaul the Governor (Mechanical & Pneumatic).
functionality of various sub- Set the Engine Timing.
systems attached. Check performance of engine off load.
Servicing of the cylinder and replace the defective parts.

25
 MECHANIC (DIESEL) (CITS)

8. INFRASTRUCTURE

LIST OF TOOLS AND EQUIPMENT FOR MECHANIC (DIESEL) - CITS

For batch of 25 candidates

S No. Name of the Tool &Equipment Specification Quantity

A. TRAINEES TOOL KIT

1. Allen Key set of 12 pieces 2mm to 14mm 6+1 Nos.
2. Calliper inside with spring 15 cm 6 +1 Nos.
3. Callipers outside with spring 15 cm 6 +1 Nos.

4. Center Punch. 10 mm. Dia. x 100 mm 6 +1 Nos.

5. Dividers with spring 15 cm 6 +1 Nos.
6. Electrician Screw Driver 250mm 6 +1 Nos.
7. Hammer ball peen with handle 0.5 kg 6 +1 Nos.
8. Hands file for Second cut flat 20 cm. 6 +1 Nos.
9. Philips Screw Driver set of 5 pieces 100 mm to 300 mm 6 +1 Nos.
10. Pliers combination 20 cm. 6 +1 Nos.
11. Screw driver Blade 20cm. x 9mm. 6 +1 Nos.
12. Screw driver Blade 30 cm. x 9 mm. 6 +1 Nos.
13. Scriber 15 cm 6 +1 Nos.
14. Spanner D.E. set of 12 pieces 6mm to 32mm 6 +1 Nos.
15. Spanner, ring set of 12 6 to 32 mm. (metric) 6 +1 Nos.
Spanners socket with speed handle, T-bar, up to 32 mm 6 +1 Nos.
16.
ratchet and universal set of 28 pieces with box
17. Steel rule 30 cm inch and metric 6 +1 Nos.
18. Steel tool box with lock and key (folding type) 400x200x150 mm 6 +1 Nos.
19. Wire cutter and stripper 6 +1 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 Nos.
21. Air blow gun with standard accessories 1 No.
22. Allen Key set of 12 pieces 2mm to 14mm 4 Nos.
23. Ammeter DC with external shunt 300A/ 60A 4 Nos.
24. Air ratchet with standard accessories 4 Nos.
25. Air impact wrench with standard accessories 4 Nos.

26
 MECHANIC (DIESEL) (CITS)

26. Angle plate adjustable 250x150x175mm 1 No.

27. Angle plate size 200x100x200mm 2 Nos.
28. Anvil with Stand 50 Kgs 1 No.
29. Auto Electrical test bench 1 No.
30. Battery –charger 5 meters flexible in case 2 Nos.
31. Blow Lamp 1 litre 2 Nos.
32. Belt Tensioner gauge 1 No.
33. Caliper inside with Spring 15 cm 4 Nos.
34. Caliper outside with spring 15 cm 4 Nos.
35. Car Jet washer with standard accessories 1 No.
36. Chain Pulley Block capacity with tripod stand 3 ton 1 No .
37. Chisel flat 10 cm 4 Nos.
38. Chisels cross cut 200 mm x 6mm 4 Nos.
39. Circlip pliers Expanding and contracting 15cm and 20cm 4 each
40. Clamps C 100mm 2 Nos.
41. Clamps C 150mm 2 Nos.
42. Clamps C 200mm 2 Nos.
43. Cleaning tray 45x30 cm. 4 Nos.
Compression testing gauge suitable for diesel
44. 2 Nos.
Engine with standard accessories
45. Connecting rod alignment fixture 1 No.
46. Copper bit soldering iron 0.25 Kg 4 Nos.
47. Cylinder bore gauge capacity 20 to 160 mm 4 Nos.
Cylinder liner- Dry & wet liner, press fit &
48. 1 Each
slidefit liner
49. DC Ohmmeter 0 to 300 Ohms 2 Nos.
50. Depth micrometer 0-25mm 4 Nos.
Dial gauge type 1 Gr. A (complete with
51. 4 Nos.
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 Nos.
55. Drift Punch Copper 15 Cm 4 Nos.
56. Drill point angle gauge 1 No.
1.5 mm to 15 mm by
57. Drill twist (various sizes) 4 Nos.
0.5mm
230 V, 60 watts
58. Electric Soldering Iron 2 Each
230 V, 25 watts

27
 MECHANIC (DIESEL) (CITS)

59. Electric testing screw driver 4 Nos.

60. Engineer’s square Blade size 15 cm 4 Nos.
61. Engineers stethoscope 1 No.
62. Feeler gauge 20 blades (metric) 4 Nos.
63. File flat , bastard 20 cm 4 Nos.
64. File, half round ,second cut 20 cm 4 Nos.
65. File, Square second cut 20 cm 4 Nos.
66. File, Square round 30 cm 4 Nos.
67. File, triangular , second cut 15 cm 4 Nos.
Files assorted sizes and types including safe
68. 2Each
edge file (20 No’s)
69. Flat File , second cut 25 cm 4 Nos.
70. Flat File , bastard 35 cm 4 Nos.
71. Fuel feed pump for Diesel 1 No.
72. Fuel injection pump (Diesel) inline 1 No.
Fuel injection pump dismantling tool kit
73. 1 No.
/Universal Vice
Fuel injection pump VE pump / Distributor
74. fuel rotary pump (DPC) pumps / along with 1 Each
special tools and accessories
75. Glow plug tester 2 Nos.
76. Granite surface plate with stand and cover 1600 x 1000mm 1 No.
77. Grease Gun 2 Nos.
78. Grease Gun heavy duty trolley type 10 kg capacity 1 No.
79. Growler 2 Nos.
80. Hacksaw frame Adjustable 20-30 cm 10 Nos.
81. Hammer Ball Peen 0.75 Kg 4 Nos.
82. Hammer Chipping 0.25 Kg 5 Nos.
83. Hammer copper with handle 1 Kg 4 Nos.
84. Hammer Mallet 4 Nos.
85. Hammer Plastic 4 Nos.
(i) up to 4mm
86. Hand operated crimping tool 2 Each
(ii) up to 10mm
10.5 to 11.25 mm, 11.25 to
87. Hand reamers adjustable 12.75 mm, 12.75 to 14.25 2 Set
mm and 14.25 to 15.75 mm
88. Hand Shear Universal 250mm 2 Nos.
89. Hand vice Up to 37 mm 2 Nos.
90. Hollow Punch set of seven pieces 6mm to 15mm 2Set
28
 MECHANIC (DIESEL) (CITS)

91. Injector – Multi hole type, Pintle type 4 each

92. Injector cleaning unit 1 No.
93. Injector testing set (Hand tester) 1 No.
94. Insulated Screw driver 20 cm x 9mm blade 4 Nos.
95. Insulated Screw driver 30 cm x 9mm blade 4 Nos.
96. Left cut snips 250mm 4 Nos.
97. Lifting jack screw 3 Ton, 5Ton & 20 Ton 1 Each
98. Magneto spanner set with 8 spanners 1Set
99. Magnifying glass 75mm 2 Nos.
100. Marking out table 90 x 60 x 90 cm. 1 No.
101. Multimeter digital 5 Nos.
102. Oil can 0.5/0.25 liter capacity 4 Nos.
103. Oil pump for dismantling and assembling. 2 Nos.
104. Oil Stone 15 cm x 5 cm x 2.5 cm 1 No.
105. Oscilloscope 20MHz 2 Nos.
106. Outside micrometer 0 to 25 mm 2 Nos.
107. Outside micrometer 25 to 50 mm 2 Nos.
108. Outside micrometer 50 to 75 mm 1 No.
109. Outside micrometer 75 to 100 mm 1 No.
110. Philips Screw Driver set of 5 pieces 100 mm to 300 mm 2 Nos.
111. Pipe cutting tool 2 Nos.
112. Pipe flaring tool 2 Nos.
113. Piston ring compressor 2 Nos.
114. Piston Ring expander and remover. 2 Nos.
115. Piston Ring groove cleaner. 1 No.
116. Pliers combination 20 cm. 2 Nos.
117. Pliers flat nose 15 cm 2 Nos.
118. Pliers round nose 15 cm 2 Nos.
119. Pliers side cutting 15 cm 2 Nos.
120. Portable electric drill Machine 1 No.
121. Prick Punch 15 cm 4 Nos.
122. Punch Letter 4mm (Number) 2 Sets
123. Radiator cut section-cross flow 1 No.
124. Radiator cut section-down flow 1 No.
125. Radiator pressure cap 2 Nos.
126. Right cut snips 250mm 2 Nos.
29
 MECHANIC (DIESEL) (CITS)

127. Rivet sets snap and Dolly combined 3mm, 4mm, 6mm 2 Nos.
128. Scraper flat 25 cm 2 Nos.
129. Scraper half round 25 cm 2 Nos.
130. Scraper Triangular 25 cm 2 Nos.
131. Scriber 15 cm 2 Nos.
132. Scriber with scribing black universal 2 Nos.
133. Set of stock and dies -Metric 2 Sets
134. Tinnman’s Shear 450 mm x 600mm 2 Nos.
135. Sheet Metal Gauge 2 Nos.
136. Tinnman’s Shear 300mm 4 Nos.
137. Soldering Copper Hatchet type 500gms 2 Nos.
Solid Parallels in pairs (Different size) in
138. 2 Nos.
Metric
139. Spanner Clyburn 15 cm 1 No.
140. Spanner D.E. set of 12 pieces 6mm to 32mm 4 Nos.
Spanner T. flocks for screwing up and up-
141. 2 Nos.
screwing inaccessible
142. Spanner, adjustable 15cm 2 Nos.
143. Spanner, ring set of 12 metric sizes 6 to 32 mm. 4 Nos.
Spanners socket with speed handle, T-bar,
144. 2 Nos.
ratchet and universal
145. Spark lighter 2 Nos.
146. Spark plug spanner 14mm x 18mm x Size 2 Nos.
Starter motor axial type, pre-engagement
147. 1Each
type & Co-axial type
148. Steel measuring tape in a case 10 meter 4 Nos.
149. Steel rule 15 cm inch and metric 4 Nos.
150. Steel rule 30 cm inch and metric 4 Nos.
151. Straight edge gauge 2 ft. 2 Nos.
152. Straight edge gauge 4 ft. 2 Nos.
153. Stud extractor set of 3 2Sets
154. Stud remover with socket handle 1 No.
Surface gauge with dial test indicator plunger
155. 0.01 mm 4 Nos.
type
156. Tachometer (Counting type) 1 No.
157. Tandem master cylinder with booster 4 Nos.
158. Taps and Dies complete sets (5 types) 1 Set
159. Taps and wrenches - Metric 2 Sets

30
 MECHANIC (DIESEL) (CITS)

160. Telescope gauge 4 Nos.

161. Temperature gauge with sensor 0-100 0C 2 Nos.
162. Thermostat 2 Nos.
163. Thread pitch gauge Metric 2 Nos.
164. Timing lighter 2 Nos.
5-35 Nm, 12-68 Nm & 50-
165. Torque wrenches 1Each
225 Nm
166. Trammel 30 cm 2 Nos.
167. Turbocharger cut sectional view 1 No.
168. Tyre pressure gauge with holding nipple 2 Nos.
Universal puller for removing pulleys,
169. 1 No.
bearings
170. V’ Block 75 x 38 mm pair with Clamps 2 Nos.
171. Vacuum gauge 0 to 760 mm of Hg. 2 Nos.
172. Valve Lifter 1 No.
173. Valve spring compressor universal 1 No.
0-300 mm with least count
174. Vernier calliper 4 Nos.
0.02mm
175. Vice grip pliers 2 Nos.
176. Water pump for dismantling and assembling 4 Nos.
177. Wire Gauge (metric ) 2 Nos.
250 x 120 x 60 cm with 4
178. Work bench 4 Nos.
vices 12cm Jaw
GENERAL SHOP OUTFIT
Air conditioned CRDI Vehicle in running 1 No.
179.
condition -LMV
Arbor press hand operated 2 ton capacity 1 No.
180.

181. Bench lever shears 250mm Blade x 3mm 1 No.

Dismantling and 1No .
Diesel Engine – CRDI - 4 stroke
182. assembling with Swivelling
stand
Diesel engine ( Running condition ) Stationary 1 No.
183.
type
Discrete Component Trainer / Basic 1 No.
184.
Electronics Trainer
Drilling machine bench to drill up to 12mm 1 No.
185.
dia along with accessories
AC / HWDC, 230 VAC, 50Hz 01 Set
186. Dual Magnetization Yoke
Grinding machine (general purpose) D.E. 1 No.
187.
pedestal with 300 mm dia. wheels rough and

31
 MECHANIC (DIESEL) (CITS)

smooth
Heavy Commercial vehicle type (without 1 No.
188.
body on frame)
Hydraulic jack HI-LIFT type -3 ton capacity, 1 Each
189.
and 5 Ton capacity
190. Liquid penetrate Inspection kit 1 Set
191. Multi Scan Tool 1 No.
192. Pipe Bending Machine (Hydraulic type) 12mm to 30mm 1 No.
Pneumatic rivet gun with standard 2 Nos.
193.
accessories
194. Spring tension tester 1 No.
195. Tin smiths bench folder 600 x 1.6mm 1 No.
compressor single cylinder 1 No.
with 45 litres capacity Air
196. Trolley type portable air tank, along with accessories
& with working pressure
6.5 kg/sq. cm
Working Condition of Diesel Engine – CRDI - 4 1 No.
197. stroke Engine, Assembly with fault simulation
board
Cut section of 4/6 cylinder diesel engine with 1 No.
198. moving condition to show momentum of
internal parts
Fuel injection test bench for calibration of 1 No.
199.
fuel pump
200. Electrical test bench 1 No.
Diesel Engine six Cylinder in running 1 No.
201.
condition
CONSUMABLE
202. Battery- SMF As required
203. Brake fluids As required
204. Chalk, Prussian blue As required
205. Chemical compound for fasteners As required
206. Diesel As required
207. Different type gasket material As required
208. Different type of oil seal As required
209. Drill Twist (assorted) As required
210. Emery paper - 36–60 grit , 80–120 As required
211. Engine oil & Engine coolant As required
212. Gear oils As required
213. Hacksaw blade (consumable) As required

32
 MECHANIC (DIESEL) (CITS)

214. Hand rubber gloves tested for 5000 V 5 Pairs

Holders, lamp teakwood boards, plug As required
215.
sockets,
216. Hydrometer 8 Nos.
217. Lapping abrasives As required
218. Leather apron 5 Nos.
219. Petrol As required
220. Power steering oil As required
221. Radiator Coolants As required
222. Safety glasses As required
223. Steel wire Brush 50mmx150mm 5 Nos.
C. CLASS ROOM FURNITURE FOR TRADE THEORY
224. Instructor’s table and Chair (Steel) 1 Set
225. Students chairs with writing pads 25 Nos.
226. White board size 1200mm X 900 mm 1 No.
Instructors lap top with latest configuration
227. pre-loaded with operating system and MS 1 No.
Office package.
228. LCD projector with screen. 1 No.
1 Set each
229. Trainees locker 6½ ‘ x 3’ x 1½’
(optional)

33
 MECHANIC (DIESEL) (CITS)

ANNEXURE – I

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 participated for finalizing the course curriculum of Mechanic (Diesel)
(CITS) trade.
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. SuyogFulbadave, 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 TatyabaKhaire 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
Pune
17. G. Venkateshwaran Cummins India Ltd Member
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 MECHANIC (DIESEL) (CITS)

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 ShirsathAsso. 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., Member
ChiklthanaAurongabad
28. M. M. Kulkarni NRB Bearings Ltd., Member
ChiklthanaAurongabad
DGT & Training Institute
29. Nirmalya Nath CSTARI, Kolkata Member
Asst. Director of Trg. cum Co-
coordinato
r
30. Akhilesh Pandey ATI, Mumbai Expert
31. Amar Prabhu, Principal Don Bosco, Mumbai Expert
32. Indranil Mukherjee, Instructor ITI, Tollygaunj Expert

35
 MECHANIC (DIESEL) (CITS)

36