Mechanic Diesel Trade Theory PDF

MECHANIC DIESEL NSQF LEVEL - 4 Volume I of II TRADE THEORY SECTOR: AUTOMOTIVE DIRECTORATE GENERAL OF TRAINING MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP GOVERNMENT OF INDIA NATIONAL INSTRUCT...

MECHANIC DIESEL NSQF LEVEL - 4 Volume I of II TRADE THEORY SECTOR: AUTOMOTIVE DIRECTORATE GENERAL OF TRAINING MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP GOVERNMENT OF INDIA NATIONAL INSTRUCTIONAL MEDIA INSTITUTE, CHENNAI Post Box No. 3142, CTI Campus, Guindy, Chennai - 600 032 (i) Sector : Automotive Duration : 1 - Year Trade : Mechanic Diesel - Volume I of II - Trade Theory - (NSQF Level - 4) Developed & Published by National Instructional Media Institute Post Box No.3142 Guindy, Chennai - 32 INDIA Email: [email protected] Website: www.nimi.gov.in Printed by National Instructional Media Institute Chennai - 600 032 First Edition : November 2018 Copies : 1,000 Second Edition : March 2019 Copies : 1,000 First Reprint : December 2019 Copies : 500 Rs.285/- © (ii)  FOREWORD The Government of India has set an ambitious target of imparting skills to 30 crores people, one out of every four Indians, by 2020 to help them secure jobs as part of the National Skills Development Policy. Industrial Training Institutes (ITIs) play a vital role in this process especially in terms of providing skilled manpower. Keeping this in mind, and for providing the current industry relevant skill training to Trainees, ITI syllabus has been recently updated with the help of Mentor Councils comprising various stakeholder's viz. Industries, Entrepreneurs, Academicians and representatives from ITIs. The National Instructional Media Institute (NIMI), Chennai, an autonomous body under Ministry of Skill Development & Entrepreneurship is entrusted with developing producing and disseminating Instructional Media Packages (IMPs) required for ITIs and other related institutions. The institute has now come up with instructional material to suit the revised curriculum for Mechanic Diesel (Volume I of II) Trade Theory NSQF Level - 4 in Automotive Sector under annual Pattern. The NSQF Level - 4 Trade Theory will help the trainees to get an international equivalency standard where their skill proficiency and competency will be duly recognized across the globe and this will also increase the scope of recognition of prior learning. NSQF Level - 4 trainees will also get the opportunities to promote life long learning and skill development. I have no doubt that with NSQF Level - 4 the trainers and trainees of ITIs, and all stakeholders will derive maximum benefits from these IMPs and that NIMI's effort will go a long way in improving the quality of Vocational training in the country. The Executive Director & Staff of NIMI and members of Media Development Committee deserve appreciation for their contribution in bringing out this publication. Jai Hind RAJESH AGGARWAL Director General/ Addl.Secretary Ministry of Skill Development & Entrepreneurship, Government of India. New Delhi - 110 001 (iii)  PREFACE The National Instructional Media Institute (NIMI) was established in 1986 at Chennai by then Directorate General of Employment and Training (D.G.E & T), Ministry of Labour and Employment, (now under Ministry of Skill Development and Entrepreneurship) Government of India, with technical assistance from the Govt. of the Federal Republic of Germany. The prime objective of this institute is to develop and provide instructional materials for various trades as per the prescribed syllabi under the Craftsman and Apprenticeship Training Schemes. The instructional materials are created keeping in mind, the main objective of Vocational Training under NCVT/NAC in India, which is to help an individual to master skills to do a job. The instructional materials are generated in the form of Instructional Media Packages (IMPs). An IMP consists of Theory book, Practical book, Test and Assignment book, Instructor Guide, Audio Visual Aid (Wall charts and Transparencies) and other support materials. The trade practical book consists of series of exercises to be completed by the trainees in the workshop. These exercises are designed to ensure that all the skills in the prescribed syllabus are covered. The trade theory book provides related theoretical knowledge required to enable the trainee to do a job. The test and assignments will enable the instructor to give assignments for the evaluation of the performance of a trainee. The wall charts and transparencies are unique, as they not only help the instructor to effectively present a topic but also help him to assess the trainee's understanding. The instructor guide enables the instructor to plan his schedule of instruction, plan the raw material requirements, day to day lessons and demonstrations. In order to perform the skills in a productive manner instructional videos are embedded in QR code of the exercise in this instructional material so as to integrate the skill learning with the procedural practical steps given in the exercise. The instructional videos will improve the quality of standard on practical training and will motivate the trainees to focus and perform the skill seamlessly. IMPs also deals with the complex skills required to be developed for effective team work. Necessary care has also been taken to include important skill areas of allied trades as prescribed in the syllabus. The availability of a complete Instructional Media Package in an institute helps both the trainer and management to impart effective training. The IMPs are the outcome of collective efforts of the staff members of NIMI and the members of the Media Development Committees specially drawn from Public and Private sector industries, various training institutes under the Directorate General of Training (DGT), Government and Private ITIs. NIMI would like to take this opportunity to convey sincere thanks to the Directors of Employment & Training of various State Governments, Training Departments of Industries both in the Public and Private sectors, Officers of DGT and DGT field institutes, proof readers, individual media developers and coordinators, but for whose active support NIMI would not have been able to bring out this materials. R. P. DHINGRA Chennai - 600 032 EXECUTIVE DIRECTOR (iv)  ACKNOWLEDGEMENT National Instructional Media Institute (NIMI) sincerely acknowledges with thanks for the co-operation and contribution extended by the following Media Developers and their sponsoring organisations to bring out this Instructional Material (Trade Theory) for the trade of Mechanic Diesel under Automotive Sector for ITIs. MEDIA DEVELOPMENT COMMITTEE MEMBERS Shri. S. Devakumar _ Principal (Retd) G.I.T.I. Nettapakkam -Pdy. Shri. K. Thaniyarasu _ Principal G.I.T.I. Viralimalai Shri. W. Nirmal Kumar _ Training Officer G.I.T.I. Manikandan Shri. A. Thangavelu _ Asst. Training Officer (Retd) Govt.I.T.I. Guindy Shri. A. Duraichamy _ Asst. Training Officer Govt. I.T.I. Coonoor NIMI CO-ORDINATORS Shri. K. Srinivasa Rao _ Joint Director, NIMI, Chennai - 32 Shri. S. Gopalakrishnan _ Assitant Manager, NIMI, Chennai - 32 NIMI records its appreciation for the Data Entry, CAD, DTP operators for their excellent and devoted services in the process of development of this Instructional Material. NIMI also acknowledges with thanks the invaluable efforts rendered by all other NIMI staff who have contributed towards the development of this Instructional Material. NIMI is also grateful to everyone who has directly or indirectly helped in developing this Instructional Material. (v)  INTRODUCTION TRADE THEORY The manual of trade theory consists of theoretical information. The contents are sequenced according to the practical exercise contained in NSQF LEVEL - 4 syllabus on Trade Practical. Attempt has been made to relate the theoretical aspects with the skill covered in each exercise to the extent possible. This correlation is maintained to help the trainees to develop the perceptional capabilities for performing the skills. The trade theory has to be taught and learnt along with the corresponding exercise contained in the manual on trade practical. The indications about the corresponding practical exercises are given in every sheet of this manual. It will be preferable to teach/learn trade theory connected to each exercise at least one class before performing the related skills in the shop floor. The trade theory is to be treated as an integrated part of each exercise. The material is not for the purpose of self-learning and should be considered as supplementary to class room instruction. TRADE PRACTICAL The trade practical manual is intended to be used in practical workshop. It consists of a series of practical exercises to be completed by the trainees supplemented and supported by instructions / informations to assist in performing the exercises. These exercises are designed to ensure that all the skills in compliance with NSQF LEVEL - 4 syllabus are covered. The manual is divided into seven modules. The distribution of time for the practical in the seven modules are given below: Module 1 Safety workshop practice 25 Hrs Module 2 Measuring and marking & practice 100 Hrs Module 3 Fastening and fitting 125 Hrs Module 4 Electrical and electronics 100 Hrs Module 5 Arc & Gas welding 75 Hrs Module 6 Hydraulics and pneumatics 50 Hrs Module 7 Specifications and service equipments 25 Hrs Total 525 Hrs The skill training in the shop floor is planned through a series of practical exercises centered around some practical project. However, there are few instances where the individual exercise does not form a part of project. While developing the practical manual, a sincere effort was made to prepare each exercise which will be easy to understand and carry out even by below average trainee. However the development team accept that there is a scope for further improvement. NIMI looks forward to the suggestions from the experienced training faculty for improving the manual. (vi)  CONTENTS Lesson No. Title of the Lesson Page No. Module 1 : Safety workshop practices 1.1.01 Organization of ITI’s and scope of the mechanic diesel trade 1 1.1.02 Knowledge of personal safety and safety precautions in handling diesel machines. 3 1.1.03 Concept of house keeping & 5S method 6 1.1.04 Safe handling and periodic testing of lifting equipments 8 Safety disposal of used engine oil 8 Safe handling of fuel spillage 9 Safe disposal of toxic dust 9 1.1.05 Elementary first-aid 11 Occupational health and safety 12 1.1.06 Safety practice - fire extinguishers 14 Electrical safety tips 16 1.1.07 Types of fire extinguishers 18 1.1.08 Energy conservation process 20 Module 2 : Measuring and marking practice 1.2.09 Marking material 21 Cleaning tools 21 Scrapper 23 Surface plates 24 Try Square 25 Types of calipers 26 Jenny calipers 27 Dividers 28 Surface Gauges 28 Scriber 29 1.2.10 Wheelbase, wheeltrack and measuring tape 30 1.2.11 Length measurement 31 Engineer’s steel rule 31 1.2.12 Air impact wrench, air ratchet 32 1.2.13 Hand tools 33 Chisel 35 Angles of chisels 36 Hammers 37 Wooden mallet 39 Screwdrivers 40 (vii) Lesson No. Title of the Lesson Page No. Allen keys 44 Bench vice 45 Types of vices 45 C - Clamps and toolmaker’s clamps 46 Spanners and their uses 47 Pliers 52 SNIPS (Straight & Bent) 54 Wrenches 55 Flaring, flare fittings and testing the joints 57 Puller 59 1.2.14 Least count calculation, care and use of micrometer 62 Precision measuring instruments - Outside metric micrometer 65 1.2.15 Depth micrometer 67 1.2.16 Description least count, calculation, care and use of vernier caliper 69 The universal vernier caliper and its application 71 1.2.17 Telescopic gauge 73 1.2.18 Bore dial gauge 74 1.2.19 Dial test indicators 76 1.2.20 Straight edges 78 1.2.21 Feeler gauge & uses 79 1.2.22 Vacuum gauge 80 1.2.23 Tyre pressure gauge 81 Module 3 : Fastening and fitting 1.3.25 Rivets - types & uses 82 Rivet proportions 82 Riveted joints 84 Tools for hand riveting 85 Spacing of rivets in joints 86 Defects in riveted joints 87 Caulking and fullering 87 Special sheet metal rivets and their applications 89 Bolts, studs and nuts 90 Locking Devices 91 Keys and splines 96 Circlips 98 Washers - Types and uses 99 Different types of screws, nuts, studs and bolts 101 Thumb screws 103 Types of Nuts 104 (viii)  Lesson No. Title of the Lesson Page No. 1.3.26 Methods of removing broken studs 106 Screw pitch gauge 107 1.3.27 - 1.3.28 Hacksaw frame and blade 108 Elements of a file 109 Cut of files 110 File specifications and grades 111 File - Applications 112 Shapes of files 112 Off - hand grinding with bench and pedestal grinders 113 Safe working on off - hand grinders 115 Indian standard system of limits & fits - terminology 115 Fits and their classification as per the indian standard 119 1.3.29 Soldering 122 Brazing 124 1.3.30 Gasket 125 Oil seal 125 1.3.31 Drilling machine (portable type) 127 Drilling machines (Bench and pillar type) 128 Cutting speed and RPM 130 Work - holding devices 130 Drill - holding devices 131 Drill bits 133 Drill Angles 134 1.3.32 Hand taps and dies 137 Tap drill size 138 Die and die stock 140 1.3.33 Hand Reamers 142 Hole size for reaming 143 Lapping 144 Lap materials and lapping compounds 145 1.3.34 Types of sheet metals and their applications 146 Properties of an auto body sheet metal 146 Notches in sheet metal 147 Edge stiffening 148 Sheet metal joints 149 Folding and joining allowances 150 Groovers 151 Standard wire gauge 152 Sheet metal shearing, drawing, squeezing 153 (ix)  Lesson No. Title of the Lesson Page No. Bending sheet metal 155 Manual bending 156 Bending metals to an angle 158 1.3.35 Pipe bending machines 160 Pipes and pipe fittings 161 1.3.36 Blow lamp and Flux 163 Brazing techniques 164 Module 4 : Electrical and electronics 1.4.37 Electricity principles 167 Earthing and its importance 169 1.4.38 Ohm’s Law 170 1.4.39 Basic types of electrical meters 173 Multimeter 175 1.4.40 Fuse 177 1.4.41 Cable colour codes and size 179 1.4.42 - 1.4.43 Law of Resistances 181 Resistors and capacitots 182 Capacitors 184 Grouping of capacitors 185 DC series - parallel - series and parallel combination circuits 187 Potential difference and polarity of IR voltage drops 189 DC parallel circuit 191 Series parallel combination 193 1.4.44 - 1.4.47 Battery 196 Electricity effects 200 Electromagnetic induction, self-induced emf - inductors 202 1.4.48 Tracing auto electrical components in circuit - solenoid & relay 203 Primary and secondary winding, transformers, stator and rotor coil 204 1.4.49 - 1.4.50 Diodes 206 Transistors and classification 208 Uni -junction transistor (UJT) 211 Field effect Transistors 211 Metal oxide field effect transistor (MOSFET) 213 1.4.51 Basic logic gates 215 Module 5 : Arc & Gas Welding 1.5.52 Principles of arc welding brief description classification and applications 217 Arc -welding machines 219 A.C. Arc - welding machine 220 D.C. Arc - welding machines 221 (x)  Lesson No. Title of the Lesson Page No. Edge preparation 222 1.5.53 Tools and equipment used in oxy - acetylene gas welding 223 Systems of oxy - acetylene welding 226 TIG welding process and equipment 226 GMAW equipment and accessories 229 GMAW (MIG/MAG) torches 230 Cutting processes - plasma arc cutting 233 Heat Treatment 236 Module 6 : Hydraulics and pneumatics 1.6.54 Non - destructive testing methods 239 1.6.55 Introduction to the hydraulics and pneumatics 241 Pascal’s law - pressure viscosity 242 1.6.56 - 1.6.57 Hydraulics 245 Hydraulic actuators and valves 247 Pneumatic System 251 Module 7 : Specifications and service equipments 1.7.58 Recent trends and developments 255 1.7.59 Classification of vehicles 257 1.7.60 Ministry of road transport & high ways 259 1.7.61 Uses of hoists, jacks and stands 261 LEARNING / ASSESSABLE OUTCOME On completion of this book you shall be able to Check & perform measuring & marking by using various measuring & marking tools. ( Vernier callipers, micrometre, tele- scope gauges, dial bore gauges, dial indicators, straightedge, feeler gauge, thread pitch gauge, vaccum gauge, tire pressure gauge.) Plan & perform basic fastening & fitting operation by using correct hand tools, machine tools & equipment. Trace and test all electrical & electronic components & circuits and assemble circuit to ensure functionality of system. Join components by using Arc & Gas welding. Trace & test hydraulic and pneumatic components Check & interpret vehicle specification data and VIN, select & opearte various service station equipment. (xi)  SYLLABUS FOR MECHANIC DIESEL TRADE Duration: 06 Months Learning Professional Skills Week Professional Knowledge Outcome (Trade Practical) No. (Trade Practical) with Indicative hrs. Apply saf e working 1. Demonstration of Machinery used in - Importance& scope of 1-2 practices in an automotive the trade. (05 hrs) Mechanic Diesel Trade work shop. 2. Identify safety Gear/PPE (Personal Training. Protective Equipments) and their - General discipline in the uses (10 hrs) Institute 3. Importance of maintenance and - Elementary First Aid, cleanliness of Workshop. (05 hrs) Occupational Safety & Health 4. Demonstration on safe handling and - Knowledge of Personal Safety Periodic testing of lifting equipment, &Safety precautions in and Safety disposal of used engine handling Diesel machine oil. (10 hrs.) - Concept about House Keeping 5. Demonstration on health hazards, & 5S method. occupational safety &first Aid. (05 - Energy conservation process hrs) - Safety disposal of Used engine 6. Demonstration fire service station to oil, - Electrical safety tips. provide demo on Fire safety. (05 hrs) - Safe handling of Fuel Spillage, 7. Perform use of fire extinguishers. (05 - Knowledge of Fire Safety hrs) &Fire extinguishers used for 8. Energy saving Tips of ITI electricity different types of fire Usage. (05 hrs) Hand tools and their.- Safe disposal of toxic dust, uses - safe handling and Periodic testing of lifting equipment 3-4 Check & perform Measuring 9. Perform marking using all marking Hand & Power Tools:- & marking by using various aids, like steel rule with spring - Marking scheme, marking callipers, dividers, scriber, punches, material-chalk, Prussian blue. Measuring & Marking chisel etc. on MS Flat/Sheet Metal. - Cleaning tools- Scraper, wire tools(Vernier Calliper, (17 hrs) brush, Emery paper, Micrometer, Telescope 10. Measure a wheel base of a vehicle - Description, care and use of gauges, Dial bore gauges, with measuring tape. (08 hrs) Surface plates, steel rule, Dial indicators, straightedge, 11. Measure valve spring tension using measuring tape, try square. feeler gauge, thread pitch spring tension tester (10 hrs) Callipers-inside and outside. gauge, vacuum gauge, tire 12. Perform to remove wheel lug nuts Dividers, surface gauges, pressure gauge.) with use of an air impact wrench (08 scriber, hrs) - Punches-prick punch, centre 13. Operate General workshop tools & punch, pin punch, hollow power tools. (07 hrs) punch, number and letter punch. Chisel-flat, cross-cut. Hammer- ball pein, lump, mallet. Screw drivers-blade - Screwdriver, Phillips screw driver, Ratchet screwdriver. Allen key, bench vice & Cclamps, - Spanners- ring spanner, open end spanner & the combination spanner, universal adjustable open end spanner. Sockets & accessories, - Pliers - Combination pliers, multi grip, long nose, flatnose, Nippers or pincer pliers, Side cutters, Tin snips, xii  Circlip pliers, external circlips pliers. - Air impact wrench, air ratchet, wrenches- Torque wrenches, pipe wrenches, Pipe flaring & cutting tool, pullers-Gear and bearing. 5-6 -do- 14. Perform measuring practice on Cam height, Systems of measurement, Camshaft Journal dia, crankshaft journal - Description, Least Count dia, Valve stem dia, piston diameter, and calculation, care & use of - piston pin dia with outside Micrometres. Micrometers- Outside, and (05 hrs) depth micrometer, 15. Perform measuring practice on the height - Micrometer adjustments, of the rotor of an oil pump from the surface - Description, Least Count of the housing or any other auto calculation, care & use of component measurement with depth Vernier Calliper. micrometer. (05 hrs) - Telescope gauges, Dial bore 16. Perform measuring practice on valve spring gauges, Dial indicators, free length. (05 hrs) straightedge, feeler gauge, 17. Perform measuring practice on cylinder thread pitch gauge, vacuum bore, Connecting rod bore, inside diameter gauge, tire pressure gauge. (ID) of a camshaft bearing with Telescope gauges. (05 hrs) 18. Perform measuring practice on cylinder bore for taper and outof-round with Dial bore gauges. (05 hrs) 19. Perform measuring practice to measure wear on crankshaft end play, crankshaft run out, and valve guide with dial indicator. (05 hrs) 20. Perform measuring practice to check the flatness of the cylinder head is warped or twisted with straightedge is used with a feeler gauge. (05 hrs) 21. Perform measuring practice to check the end gap of a piston ring, piston-to-cylinder wall clearance with feeler gauge. (05 hrs) 22. Perform practice to check engine manifold vacuum with vacuum gauge. (05 hrs) 23. Perform practice to check the air pressure inside the vehicle tyre is maintained at the 7-8 Plan & perform basic recommended setting. (05 hrs) - Different types of metal joint fastening & fitting 25. Perform practice on general cleaning, (Permanent, Temporary), operation by using checking and use of nut, bolts, & studs etc. methods of Bolting, Riveting, correct hand tools, (05 hrs) Soldering, Brazing, Seaming Machine tools & 26. Perform removal of stud/bolt from blind hole. etc. equipments. (05 hrs) Fasteners 27. Perform practice on cutting tools like - Study of different types of Hacksaw, file, chisel, Sharpening of Chisels, screws, nuts, studs & bolts, center punch, safety precautions while locking devices, Such as lock grinding. (10 hrs) nuts, cotter, split pins, keys, 28. Perform practice on Hacksawing and filing circlips, lock rings, lock to given dimensions. (15 hrs) washers and locating where 29. Perform on Soldering & Brazing. (10 hrs) they are used. Washers & 30. Perform practice on making various Gaskets chemical compounds can be like oil sump, intake manifold, water pump, used to help secure these tappet cover etc. (05 hrs) fasteners. Function of xiii  Gaskets, Selection of materials for gaskets and packing, oil seals. Types of Gaskets – paper, multilayered metallic, liquid, rubber, copper and printed. Thread Sealants-Various types like, locking, sealing, temperature resistance, antilocking, lubricating etc. Cutting tools - Study of different type of cutting tools like Hacksaw, File- Definition, parts of a file, specification, Grade, shape, different type of cut and uses., OFF-hand grinding with sander, bench and pedestal grinders, safety precautions while grinding. Limits, Fits & Tolerances - Definition of limits, fits & tolerances with examples used in auto components 31. Perform practice on Marking and Drilling Drilling machine clear and Blind Holes, Sharpening of - Description and study of Bench type Twist Drills Safety precautions to be Drilling machine, Portable electrical observed while using a drilling machine. Drilling machine, drill holding devices, (10 hrs) Work Holding devices, Drill bits. 9-10 -do- 32. Perform practice on Tapping a Clear and Taps and Dies Blind Hole, Selection of tape drill Size, - Hand Taps and wrenches, Calculation use of Lubrication, Use of stud extractor. of Tap drill sizes for metric and inch (15 hrs) taps. Different type of Die and 33. Perform practice cutting Threads on a Die stock. Screw extractors. Bolt/ Stud. Adjustment of two piece Die, Hand Reamers Reaming a hole/ Bush to suit the given – Different Type of hand reamers, Drill pin/ shaft, scraping a given machined size for reaming, surface. (25 hrs) Lapping, Lapping abrasives, type of Laps. 11 34. Perform practice on making Rectangular Sheet metal -do- Tray. (08 hrs) - State the various common metal Sheets used in Sheet Metal shop Sheet metal 35. Perform pipe bending, fitting nipples union operations in pipes (08 hrs) - Shearing, bending, Drawing, Squeezing 36. Perform Soldering and Brazing of Pipes. - Sheet metal joints (09 hrs) - Hem & Seam Joints Fastening Methods - Riveting, soldering, Brazing. fluxes used on common joints. Sheet and wire- gauges. Trace and Test 37. Perform practice in joining wires using Basic electricity 12 all Electrical & soldering Iron. (08 hrs) - Electricity principles, E l e c t r o n i c 38. Prepare simple electrical circuits, - Ground connections, components & measuring of current, voltage and - Ohm's law, - Voltage, Current, circuits and resistance using digital multimeter. (08 Resistance, Power, Energy. assemble hrs) - Voltmeter, ammeter, Ohmmeter, circuit to 39. Perform practice continuity test for fuses, Multimeter, e n s u r e jumper wires, fusible links and circuit - Conductors & insulators, W ires, functionality of breakers. (09 hrs) Shielding, Length vs. resistance, system. Resistor ratings - The blow lamp its uses and pipe fittings. xiv  -do- 40. Perform diagnose series, parallel, series- - Fuses & circuit breakers, 13 parallel circuits using Ohm’s law. (05 hrs) - Ballast resistor, 41. Check electrical circuit with a test lamp. - Stripping wire insulation, (05 hrs) - cable colour codes and sizes, 42. Perform voltage drop test in circuits using - Resistors in Series circuits , multimeter, measure current flow using - Parallel circuits and Seriesparallel multimeter /ammeter. (07 hrs) circuits, 43. Check circuit using of service manual - Electrostatic effects, Capacitors and its wiring diagram for troubleshooting (08 hrs) applications, - Capacitors in series and parallel. 44. Execute cleaning and topping up of a lead - Description of Chemical effects, Batteries 14 -do- acid battery. (05 hrs) & cells, Lead acid batteries & Stay Maintenance Free (SMF) batteries, 45. Perform testing battery with hydrometer. - Magnetic effects, Heating effects, Thermo- (02 hrs) electric energy, Thermistors, Thermo 46. Perform connecting battery to a charger couples, for battery charging and checking & - Electrochemical energy, Photo-voltaic testing a battery after energy, Piezo-electric energy, charging. (08 hrs) Electromagnetic induction, 47. Measure and Diagnose the cause(s) of - Relays, Solenoids, Primary & Secondary excessive Key-off battery drain (parasitic windings, Transformers, stator and rotor draw) and do corrective action. (05 hrs) coils. 48. Perform test of relay and solenoids and its circuit. (05 hrs) 15 49. Identify and test power and signal Basic electronics: -do- connectors for continuity (05 hrs) - Description of Semiconductors, Solid 50. Perform test and identify different type of state devices - Diodes, Diodes, NPN & PNP Transistors for its - Transistors, Thyristors, Uni Junction functionality (10 hrs) Transistors ( UJT), 51. Construct and test simple logic circuits - Metal Oxide Field Effect Transistors ( OR, AND & NOT and Logic gates using MOSFETs), switches. (10 hrs) - Logic gates-OR, AND & NOT and Logic gates using switches. 16-18 J o i n 52. Perform practice to make straight beads Introduction to welding and Heat components and Butt, Lap & T joints Manual Metal Treatment by using Arc Arc Welding. (50 hrs) Welding processes & Gas 53. Set Gas welding flames and perform - Principles of Arc welding, brief description, welding. practice to make a straight beads and classification and applications. joints by Oxy – Acetylene welding (25 hrs) - Manual Metal Arc welding -principles, power sources, electrodes, welding parameters, edge preparation & fit up and welding techniques; - Oxy – Acetylene welding - principles, equipment, welding parameters, edge preparation & fit up and welding techniques;. - Basic knowledge about advance welding process & equipments like MIG, TIG, Spot Welding, Plasma Cutter. Heat Treatment Process - Introduction, Definition of heat treatment, - - Definition of Annealing, Normalizing, Hardening and tempering. – - Case hardening, Nitriding, Induction hardening xv  - Flame Hardening process used in auto components with examples. Trace & Test 54. Perform liquid penetrant testing 19-20 Hydraulic and method and Magnetic particle Non-destructive Testing Methods Pneumatic testing method. (15 hrs) - Importance of NonDestructive Testing In components. 55. Identify of Hydraulic and pneumatic Automotive Industry, Definition of NDT, components used in vehicle. (10 - Liquid penetrant and Magnetic particle hrs) testing method – Portable Yoke method 56. Tracing of hydraulic circuit on Introduction to Hydraulics & Pneumatics hydraulic jack, hydraulic power - Definition of Pascal law, pressure, Force, steering, and Brake circuit. (15 hrs) viscosity. Description, symbols and 57. Identify components in Air brake application in automobile of Gear pump- systems (10 hrs) Internal & External, - single acting, double acting & Double ended cylinder; Directional control valves2/ 2, 3/2, 4/2, 4/3 way valve, Pressure relief valve, Non return valve, Flow control valve used in automobile. Check & Interpret 58. Identify of different types of Vehicle. - Auto Industry - History, leading 21 V e h i c l e (05 hrs) manufacturers, Specification data 59. Dem onstrate of vehicle - Development in automobile industry, and VIN specification data. (05 hrs) trends, new product. Select & operate 60. Identify of vehicle information Number - Brief about Ministry of Road transport & various Service (VIN). (05 hrs). Highways, S t a t i o n 61. Demonstrate of Garage, Service - The Automotive Research Association of Equipments. station equipments.- Vehicle hoists India (ARAI), National Automotive Testing – Two post and four post hoist, and R&D Infrastructure Project (NATRIP), Engine hoists, Jacks, Stands. (10 & Automobile Association. hrs) - Classification of vehicles on the basis of load as per central motor vehicle rule, wheels, final drive, and fuel used, axles, position of engine and steering transmission, body and load. Brief description - Uses of Vehicle hoists – Two post and four post hoist, Engine hoists, Jacks, Stands. 22-23 Project Work/ Industrial Visit- Broad area: a) Maintenance of cooling system (radiator leakage by brazing and precautionary measures) b) Maintenance of intake and exhaust system. c) Maintenance of Battery. d) Electrical Wiring harness of a vehicle e) Vehicle brake system (Hydraulic & Air) & Hydraulic Power Steering 24-25 Revision xvi Automobile Related Theory for Exercise 1.1.01 Mechanic Diesel - Safety workshop practices Organization of ITI’s and scope of the mechanic diesel trade Objectives: At the end of this lesson you shall be able to state brief introduction about Industrial Training Institutes (ITI) state about the organized structure of the Institute. Brief Introduction of Industrial Training Institute (ITIs) They are giving training about 132 trades including Engineering and Non-engineering trades with the duration Industrial Training Institute plays a vital role in economy of of 1 or 2 years. The minimum eligibility for admission in the country, especially interms of providing skilled ITIs 8th, 10th and 12th pass with respect to the trades manpower. and admission process will be held in every year in July. The Directorate General of Training (DGT) comes under At the end of each semester year. All India Trade Test Ministry of Skill Development and Entrepreneurship (AITT) will be conducted in every July and January, with (MSDE) offers a range of vocational training trades in OMR answer sheet pattern and multiple choice type different sectors based on economy /labour market. The questions. After passing, National trade certificates (NTC), vocational training programmes are delivered under the will be issued by DGT which is authorized and recognized aegis of National Council of Vocational Training internationally. In 2017, for few trades they have introduced (NCVT). Craftsmen Training scheme (CTS) and and implemented National Skill Qualification Frame work Apprenticeship Training Scheme (ATS) and two pioneer (NSQF) with Level 4 & 5. programmes of NCVT for Propagatory Vocational Training. Scope of the mechanic diesel trade Objectives: At the end of this lesson you shall be able to importance and scope of the diesel mechanic trade training general discipline in the institute. Scope of the diesel mechanic trade training : Me- Self-employment opportunities chanic diesel trade under craftsmen training scheme (CTS) Service centre in rural and urban areas. is one of the most popular trade delivered nation wide through the network of ITI. This trade one year (2 semes- Maintenance contractor ter) duration. Manufacturer of sub-assembly Identify the various types of tools equipment, raw Dealership/agency for automobile spare parts materials, spares used in mechanic diesel trade, Own repair shop or garrage. Practice to measuring, fitting, welding, sheet metal works, mechanical and electrical and hydraulic system General discipline in the institute : Always be polite, fault diagnosis and rectification courteous while in institue Practice to indent and repairing various type of diesel Do not arguments with others, on matters of related to engines, your training or with the office while seeking clarifications Carrier Progress Pathways: Can join the apprenticeship Do not bring bad name to your institute by your improper training in different types of industries and often National habitude. Apprenticeship Certificate (NAC) Do not waste your precious time in gossips with your Can join Craftsman Instructor Training Scheme (CITS) to friends and on activities other than training. become an instructor in ITIs Do not be late to the theory practical and other classes. Job Opportunities Do not unnecessarily interfere in other’s activities. Mechanic diesel can join in central and state Do very attentive and listen to the lecture carefully during government establishments, like railway, airport, the theory classes and practical demonstration given by marine, military, joins as a service technician in dealer the training staff. of agricultural machinery minining, trucks, bus, car, stationary engines, compressors, diesel generators, Give respect to your trainer and all other training staff, construction equipments, etc. office staff and co-trainees. employment. opportunities in overseas. Be interested in all the training activities. Do not make noise or be playful while undergoing training. 1 Keep the institute premises neat and clean avoid poluting Avoid any malpractice during the test/examination. the environment. Write your theory and practical records regularly and Do not take away any material from the institute which submit them on time for correction does not belong to you. Take care of your safety as well as other’s safety while Always attend the institute well dressed and good physical doing the practicals. appearance. Be regular to attend the training without fail and avoid absent from the theory or practical classes for simple reasons. Prepare well before writing a test/examination. 2 Automobile : Mechanic Diesel (NSQF LEVEL - 4) Related Theory for Exercise 1.1.01 Automobile Related Theory for Exercise 1.1.02 Mechanic Diesel - Safety workshop practices Knowledge of personal safety and safety precautions in handling diesel machines. Objectives: At the end of this lesson you shall be able to state the is personal protective equipment and its purpose name the two categories of personal protective equipment list the most common type of personal protective equipment list the conditions for selection of personal protective equipment state the safety precaution in handling diesel machines. Personal Protective Equipment (PPE) Categories of PPEs Devices, equipment, clothing are used by the employees, Depending upon the nature of hazard, the PPE is broadly as a last resort, to protect against hazards in the divided into the following two categories: workplace. The primary approach in any safety effort is that the hazard to the workmen should be eliminated or 1 Non-respiratory: Those used for protection against controlled by engineering methods rather than protecting injury from outside the body, i.e. for protecting the head, the workmen through the use of personal protective eye, face, hand, arm, foot, leg and other body parts equipment (PPE). Engineering methods could include 2 Respiratory: Those used for protection from harm due design change, substitution, ventilation, mechanical to inhalation of contaminated air. handling, automation, etc. They are to meet the applicable BIS (Bureau of Indian The Factories Act, 1948 and several other labour legislations Standards) standards for different types of PPE. 1996 have provisions for effective use of appropriate types The guidelines on 'Personal Protective Equipment' is issued of PPE. to facilitate the plant management in maintaining an effective programme with respect to protection of persons Ways to ensure workplace safety and use personal against hazards, which cannot be eliminated or controlled protective equipment (PPE) effectively. by engineering methods listed in table1. Workers to get up-to-date safety information from the regulatory agencies that workplace safety in their Table1 specific area. No. Title To use all available text resources that may be in work area and for applicable safety information on how to PPE1 Helmet use PPE best. When it comes to the most common types of personal PPE2 Safety footwear protective equipment, like goggles, gloves or bodysuits, PPE3 Respiratory protective these items are much less effective if they are not worn equipment at all times, or whenever a specific danger exists in a work process. Using PPE consistent will help to avoid PPE4 Arms and hands protection some common kinds of industrial accidents. PPE5 Eyes and face protection Personal protective gear is not always enough to protect workers against workplace dangers. Knowing more PPE6 Protective clothing and coverall about the overall context of your work activity can help to fully protect from anything that might threaten health PPE7 Ears protection and safety on the job. PPE8 Safety belt and harnesses Inspection of gear thoroughly to make sure that it has the standard of quality and adequately protect the user should be continuously carried out. 3 Common type of personal protective equipments and their uses and hazards are as follows: Types of protection Hazards PPE to be used Head protection (Fig 1) 1. Falling objects Helmets 2. Striking against objects 3. Spatter Foot protection (Fig 2) 1. Hot spatter Leather leg guards 2. Falling objects Safety shoes 3. Working wet area Gum boots Nose (Fig 3) 1. Dust particles Nose mask 2. Fumes/ gases/ vapours Hand protecion (Fig 4) 1. Heat burn due to direct contact Hand gloves 2. Blows sparks moderate heat 3. Electric shock Eye protection (Fig 5, Fig 6) 1. Flying dust particles Goggles 2. UV rays, IR rays heat and Face shield High amount of visible Hand shield radiation Head shield Face Protection (Fig 6, Fig 7) 1. Spark generated during Face shield Welding, grinding Head shield with or 2. Welding spatter striking without ear muff 3. Face protection from Helmets with welders UV rays screen for welders Ear protection (Fig 7) 1. High noise level Ear plug Ear muff Body protection (Fig 8, Fig 9) 1. Hot particles Leather aprons 4 Automobile : Mechanic Diesel (NSQF LEVEL - 4) Related Theory for Exercise 1.1.02  Safety operation of diesel machine: Don't operate the machine with loose engine mounting Don't operate the machine without lubricant Don't spill diesel during fill in to the fuel tank Keep the empty diesel /lubricant can away from the machine. Ensure stationary engine exhaust gas outlet should be far away from work place otherwise it will be harm full to human health Use preheat before start the diesel engine Use safe guard around rotating part of the engine Maintain the coolant and lubricant level in the engine. Always keep engine in an upright places for easy handling and safety. use specified grade lubricant and coolant in an engine safety of rubber hose and pipes: Inspect the rubber hose periodically and replace the Safety precaution in handling diesel machine: damaged parts Diesel mechanic must know the safety rules first and Inspect the fuel leaks in fuel system and rectify the then practice to handling diesel machine as well as we leakages known, when accident starts means safety rules are not followed during the handling of diesel machine. So Inspect the exhaust gas leaks and rectify the leakages safety precautions are always based on good sense. Check the engine performance if any air lock in fuel The following precautions are to be observed to keep a system, bleed the fuel system. diesel mechanic/personal accident free. Safety of engine operation: General safety: Check the coolant circulation and pressure cap function Do not spill the fuel and lubricant on work place, the spills may cause for the risk of slipping. Check the oil pressure Keep all flammable material away from the diesel Check the tappet noise and rectify the noise/adjust machine. the defective tappet Always keep clean hand and tools while work on Check the abnormal noise in the engine machine Check leakages of lubricant and coolant in the engine Keep the diesel machines operating area free from any and rectify the leakages. form of fire. Ensure free air circulation in engine operating place Automobile : Mechanic Diesel (NSQF LEVEL - 4) Related Theory for Exercise 1.1.02 5 Automobile Related Theory for Exercise 1.1.03 Mechanic Diesel - Safety workshop practices Concept of house keeping & 5S method Objectives: At the end of this lesson you shall be able to elements of house keeping and cleanliness at work place state the concept of 5‘S’ techniques. Concept of house keeping Aisles and stairways: Aisles and stairways are to be kept clear and not to be used for storage. It is also House keeping is the systematic process of making home/ important to maintain adequate lighting in stairways. work place neat and clean. House keeper is responsible for Further stairways need to have railings preferably round systematic administration of activities that provide railings for adequate grip. segregation, storage, transfer, processing treatment and disposal of solid waste (which is collected during cleaning) Spill control: The best method to control spills is to prevent them from happening. Regular cleaning and Scope of house keeping maintenance maintenance on machines and equipment is an The scope of work hieghly depend on where the house essential practice. When cleaning a spill, it is required keeping activity is performed in general, maintains clean to use the proper cleaning agents or absorbent liness and orderliness, Furnishes the room, office, materials. It is also to be ensured that the waste workplace, house keeping supervisor assisted by an products are disposed of properly. assistant house keeper. Waste disposal: The regular collection of the waste - eye appeal materials contribute to good housekeeping and cleanliness practices. Placing containers for wastes - safety near the place where the waste is produced encourages - maintenance orderly waste disposal and makes collection easier. All recyclable wastes after their collection are to be Elements of housekeeping and cleanliness at transferred to their designated places so that the waste workplace materials can be dispatched to the point of use or sold. The major elements which are normally included in the Tools and equipment: Tools and equipment are housekeeping and cleanliness practices at the workplace required to be inspected prior to their use. Damaged or are described below. worn tools are to be taken out of service immediately. Dust and dirt removal: Working in dusty and dirty Tools are to be cleaned and returned to their storage area is unhygienic as well as unhealthy for the place after use. employees, regular sweeping the workplace for the Maintenance: One of the most important elements of removal of dust and dirt is an essential housekeeping good housekeeping and cleanliness practices is the and cleanliness practice. Further, compressed air is maintenance of the equipment and the buildings housing not to be used for removing dust or dirt off employees them. This means keeping buildings, equipment and or equipment. Compressed air can caused dirt and dust machinery in safe and efficient working condition. When paticles to be embedded under the skin or in the eye. a workplace looks neglected means there are broken Employees facilities: Adequate employees facilities windows, defective plumbing, broken floor surfaces and such as drinking water, wash rooms, toilet blocks, and dirty walls etc. These conditions can cause accidents rest rooms are to be provided for the employees at the and affect work practices. workplace so that employees can use them when there Storage: Proper storage of materials is essential in a is a need. Cleanliness at the place of these facilities is good housekeeping and cleanliness practice. All an important aspect of the facilities. storage areas need to be clearly marked. Also it is Flooring: Floors are to be cleaned regularly and important that all containers be labeled properly. If immediately if liquids or other materials are spilled. materials are being stored correctly, then the incidents Poor floor conditions are a leading cause of accidents of strain injuries, chemical exposures and fires get in the workplace. It is also important to replace worn, reduced drastically. ripped or damaged flooring that poses a trip hazard. Clutter control: Cluttered workplaces typically happen Lighting: Adequate lighting reduces the potential for because of poor housekeeping practices. This type of accidents. It is to be ensured that inoperative light workplace can lead to a number of issues which include fixtures are repaired and dirty light fixtures are cleaned ergonomic as well as injuries. It is important to develop regularly so that the light intensity levels are maintained practices where items like tools, chemicals, cords, and at the workplace. containers are returned to their appropriate storage location when not in use. 6  Individual workspace: Individual workspace need to Reduction in cost. be kept neat, cleared of everything not needed for work. People tend to be more disciplined. It is necessary to make a checklist which is to be used by the employees to evalute their workspace. Delay is avoided. It can be said that a clean work area demonstrate the Less absenteeism. pride employees have with the job and the culture of safety Better use of floor space. at the workplace. Less accidents. 5 Steps (5s) - Concept (Fig 1) High productivity with quality etc. 5s is a people-oriented and practice-oriented approach. 5s expects every one to participate in it. It becomes a basic for continuous improvement in the organisation. The terms (5s) 5 steps are Step 1: SEIRI (Sorting out) Step 2: SEITON (Systematic arrangement) Step 3: SEISO (Shine cleanliness) Step 4: SEIKTSU (Stanardization) Step 5: SHITSURE (Self discipline) Fig 1 shows the 5s concept wheel. The list describes how to organize a work space for efficiency and effectiveness by identifying and storing the items used, maintaining the area and items and sustaining the new order. Benefits of 5s Work place becomes clear and better organised. Working in working place becomes easier. Automobile : Mechanic Diesel (NSQF LEVEL - 4) Related Theory for Exercise 1.1.03 7 Automobile Related Theory for Exercise 1.1.04 Mechanic Diesel - Safety workshop practices Safe handling and periodic testing of lifting equipments Objectives: At the end of this lesson you shall be able to state the periodic testing of lifting equipments state the handling of lifting equipments Safe and successful lifting operations depends on periodical Never improvise lifting tackle. testing of lifting equipment, maintenance and handling of operation, failure of this equipment may result in significant Periodic testing of lifting equipment loss and fatal accident. Visually inspect the component of the lifting equipment such as lifting chain, slings chain hoist before operating Lifts and cranes the equipment. Safety precautions for handling of lifts and cranes. In Hydraulic function of lift (or) cranes check the oil level Never exceed the safe working load (SWL) of the and top up the oil level periodically. equipment you are using. The Hydraulic oil used in the lifts or cranes should be Always support vehicles with axle stands before working replaced periodically. underneath them. The lifting equipment should be over hauled once (or) There is always a danger when loads are lifted or twice a year. suspended. Never work under an unsupported, Check the electrical connections of the lifting equipment Suspended or raised load such as a suspended engine. periodically. Always ensure that lifting equipment such as jacks, The calibration of the lifting equipment should be done hoists, axle stands, slings, etc, are adequate and once in a year and calibration certificate must to suitable for the job, In good condition and regularly obtained from the authorized testing center. maintained. Safety disposal of used engine oil Objectives: At the end of this lesson you shall be able to state the purpose of used oil disposal state the method of safety disposal of used oil Waste oil This procedure applies to the disposal of any used oil that is collected during normal work functions at work place. The waste oil, derived from fuels or lubricants, originally Used oil may include: come from petroleum oil, sometimes known as mineral oils. Many lubricants may also contain synthetic 1 Gasoline. Volatile, flammable, it can be ignited by components. sparks and flames even at cold temperatures. Vapors can migrate to distant ignition sources and in poorly ventilated Waste oil is harmful to the environment and some, for spaces, can accumulate to explosive levels. Typical example used engine oils, may cause cancer. so it needs gasoline contains about 150 different chemicals including to be managed carefully. You may need to account for benzence, toluene and xylene. Health and Safety guidance as well as the environment. Used Oil Disposal Purpose 2 Fuel oils. Fuel oils such as diesel fuel are petroleum Oils are defined as greasy, viscous substances from plant, based fluids which are some what volatile and flammable animal, mineral sources (petroleum), and synthetics that and can be ignited only when heated above 100°F. Vapors are not soluble in water, and are usually flammable. These can travel and flash from ignition sources and can accumlate oils which have been used could be contaminated by to explosive levels in poorly ventilated areas. All fuel oils physical or chemical impurities such as dirt, metal scrapings, consist of complex mixtures of aliphatic and aromatic and water. Oils that enter storm drains or waterways are a hydrocarbons such as kerosene, benzene, and styrene. serious environmental hazard. used oil can pollute fresh water. The purpose of this procedure is to describe the 3 Lubricating oils. Lubricating oils such as motor oil proper means for handling and disposing of used oil from and hydraulic fluids are not volatile but are combustible. For equipment maintenance operations, process procedures, lubricating oil to catch fire some other intense heat source and any other activities where used oils are generated. (i.e., other materials on fire, hot engine manifold, etc.) must be present. Mineral-based lube oils are refined from 8 petroleum or crude oil and contain additives such as lead 1 Wear gloves because oil contains chemicals and or metal sulphide and other polymers. contaminants that are not good for skin contact. 4 Transformer oil. Tranformer oil conducts heat away 2 Put used oil in a clean plastic or metal container in from and insulates equipment used to convert electricity good condition and with a tight lid. from high amperage to low amperage lines. Transformer oil 3 If the oil is hot, avoid sudden contact with other is a liquid by product of the distillation of petrolem to substances because mixing may cause ignition or the produce gasoline. receiving container to fracture due to thermal shock. Cooking oils and grease: Cooking oils and grease are 4 Do not allow used fuel and used oils to mix with any not volatile but they are combustible. With a 400°F flash other substances because unknown and dangerous point, another heat source must be present for cooking oils chemical reactions may occur. or grease to catch fire. Vegetable oils contain chemical solvents that are strong enough to dissolve engine seals 5 Keep used oils away from gas cylinders and gasoline. and gaskets. 6 Do not fill container to the top but allow a couple inches below the rim. Note: for all other waste chemicals, please refer SOP regarding Used Chemical Disposal. 7 Label the container with contents,and department. Procedures Products saturated with petroleum products require special handling and disposal by licensed transporters. During the collection of used oil for disposal, some basic principles should be followed: Safe handling of fuel spillage Objectives: At the end of this lesson you shall be able to state the safe handling of fuel spillage state the effect of fuel spillage in workplace. Diesel fuel is a flammable liquid and fuel spillage or leaks 5 Don't spill the fuel during refilling the fuel in fuel tank or in work place maybe cause for slippage or fire hazard. fuel container. Safe handling of fuel: 6 Use funnel during filling the fuel in fuel tank to avoid 1 Improper handling of fuel may cause for fuel spillage fuel spillage and explosion, so fuel handling should be use 7 Use tray during air bleeding from the fuel system to appropriate method. avoid fuel spillage 2 Fuel should not be stored near the working hot engine 8 Fuel leaks and spills near the engine may cause for 3 Don't refueling, when it is hot, fuel tank vapor may accident so it should be clean and mopped up quickly cause for fire. as soon as the spillage. 4 No smoking is allowed when refueling to the engine. 9 Stationary engine fuel tank should be position away from any source of direct heat to the fuel tank Safe disposal of toxic dust Objectives: At the end of this lesson you shall be able to list the waste material in a work shop explain the methods of disposal of waste material. Introduction The Automobile produces fumes containing unburnt gases Brake and clutch components produces dust, when used such as carbon-monoxide, nitrogen oxide and other gases compressed air jet to clean them. While cleaning which are harmful to human health. Hence a systematic conforming the PPE to safety regulation & policies. This and scientifically designed methods are adopted for safe includes overall coat, Face mask, safety goggles for eyes disposal of such toxic waste. earmuffs & earplug for ear protection, rubber gloves &barrier Dust from vehicle components to be blown into the air, cream for hand and valved respirator for breathing. since such dust floating in air for many hours, may cause harm to people who breath unknowingly. Automobile : Mechanic Diesel (NSQF LEVEL - 4) Related Theory for Exercise 1.1.04 9 Some auto parts having asbestos, is a toxic material, which Use grease which can not re-used is stored in a separate cause lung cancer. Airborne dust in workshop leads to container and stored with unique identification. In a similar asthma and throat infections. Do not use compressed air manner waste oil is stored in separate container, labeled to clean dust from various components & parts of the ‘Waste oil’ and stored in different location, meant for Vehicle. Solvent used for cleaning can also form a toxic disposal used diesel oil and kerosene are also stored in waste. Wash work cloths separately from other cloths so separate containers and kept at disposal area. that toxic dust does not get transfer to other clothes. After cleaning a vehicle, there are certain chemicals present in this vehicle diet which turns toxic. To eliminate the toxic waste, create small diet piles and dispose them spontaneous rather than waiting for big diet pile till the end of the day. Workshop diet is best cleaned using a water hose, which does not allow diet to fully. But the waste water must be caught in a sledge pit and not into the storm water drain. Vacuum cleaner is a best device control toxic waste. Providing high speed exhaust ventillation can solve toxic diet. 10 Automobile : Mechanic Diesel (NSQF LEVEL - 4) Related Theory for Exercise 1.1.04 Automobile Related Theory for Exercise 1.1.05 Mechanic Diesel - Safety workshop practices Elementary first-aid Objectives: At the end of this lesson you shall be able to define first aid list out the first aid key points describe the responsiveness First aid is defined as the immediate care and support Important guideline for first aiders given to an acutely injured or ill person, primarily to save Evaluate the situation life, Are there things that might put the first aider at risk. When First aid procedure often consists of simple and basic life faced with accidents like fire, toxic smoke, gasses, an saving techniques that an individual performs with proper unstable building, live electrical wires or other dangerous training and knowledge. scenario, the first aider should be very careful not to rush The key aims of first aid can be summarized in three into a situation, which may prove to be fatal. key points: Avoid moving the victim - Preserve life: If the patient was breathing, a first aider Avoid moving the victim unless they are immediate danger. would normally place them in the recovery position, Moving a victim will often make injuries worse, especially with the patient leant over on their side, which also in the case of spinal cord injuries. has the effect of clearing the tongue from the pharynx. The first aider will be taught to deal with this through a Call emergency services combination of 'back slaps' and 'abdominal thrusts'. Call for help or tell someone else to call for help as soon Once the airway has been opened, the first aider would as possible. If alone at the accident scene, try to establish assess to see if the patient is breathing. breathing before calling for help, and do not leave the victim - Prevent further harm: Also sometimes called prevent alone unattended. the condition from worsening, or danger of further injury, Determine responsiveness this covers both external factors, such as moving a patient away from any cause of harm, and applying If a person is unconscious, try to rouse them by gently first aid techniques to prevent worsening of the condition, shaking and speaking to them. such as applying pressure to stop a bleed becoming If the person remains unresponsive, carefully roll dangerous. them on the side (recovery position) and open his - Promote recovery: First aid also involves trying to airway. start the recovery process from the illness or injury, - Keep head and neck aligned. and in some cases might involve completing a treatment, such as in the case of applying a plaster to - Carefully roll them onto their back while holding hishead. a small wound. First aid ABC of first aid - Call EMERGENCY number. ABC stands for airway, breathing and circulation. - Check the person's airway, breathing, and pulse - Airway: Attention must first be brought to the airway frequently. If necessary, begin rescue breathing and to ensure it is clear. Obstruction (choking) is a life- CPR. threatening emergency. - If the person is breathing and lying on the back and - Breathing: Breathing if stops, the victim may die soon. after ruling out spinal injury, carefully roll the person Hence means of providing support for breathing is an onto the side, preferably left side. Bend the top leg so important next steps. There are several methods both hip and knee are at right angles. Gently tilt the practiced in first aid. head back to keep the airway open. If breathing or pulse stops at any time, roll the person on to his back - Circulation: Blood circulation is vital to keep person and begin CPR. alive. The first aiders now trained to go straight to chest compressions through CPR methods. - If there is a spinal injur