Mechanical Tech with sp in construction Machinery.pdf

Government of Pakistan Ministry of Communication

CURRICULUM

for

REVISED SYLLABUS

of

3-Years Diploma of Associate Engineer Mechanical Technology with Specialization in

Construction Machinery

In

Construction Technology Training Institute

Sector I-12, Islamabad

2007

1

CURRICULUM FOR DIPLOMA OF ASSOCIATE ENGINEER (DAE) IN MECHANICAL TECHNOLOGY

WITH SPECIALIZATION IN CONSTRUCTION MACHINERY

REVISED SEPTEMBER 2007

SCHEME OF STUDIES

1st Year

Ser Code No Name of Subj Period

Page T P C

1 Gen-111 Islamiat/Pak Studies 1 0 1 2-10

2 Eng-112 English 2 0 2 11-12

3 Math-113 Applied Mathematics – I (A+B 75+75) 3 0 3 13-18

4 Phy-122 Applied Physics 1 3 2 19-23

5 Comp-122 Computer Applications 1 3 2 24-28

6 AD-123 Internal Combustion Engines 2 3 3 29-35

7 MT-143 Basic Engineering Drawing and CAD I 1 6 3 36-43

8 MT-164

Workshop Practice-I a. Machine Shop and Safety Practice Procedures

b. Metal shop, Welding Practice and Foundry

1

1

3

3

2

2

44-54

9 AD-113 Automotive Electrics and Electronics 2 3 3 55-63

10 OHSE-101 Occupational Health, Safety and Environment 1 0 1 64-74

Total 16 24 24

2nd Year


Page T P C


2 Ch-213 Applied Chemistry 2 3 3 82-88

3 Math-212 Applied Mathematics – II 2 0 2 89-92

4 Phy-212 Applied Mechanics 1 3 2 93-98

5 AD-212 Applied Thermodynamics 1 3 2 99-106

6 AD-234 Workshop Practice – II 2 6 4 107-113

7 AD-243 Problems in IC Engines-II 2 3 3 114-121

8 CMT-213 Fuel System 2 3 3 122-126

9 CMT-224 Operation of Construction Machinery 2 6 4 127-132

Total 15 27 24

3rd Year


Page T P C


2 MGM-321 Business Communication 1 0 1 140-143

3 CMT-315 Transmission of Construction Machinery

a. Mechanical Transmission

b. Hydramatic Transmission

3 6 5 144-153

4 CMT-323 Steering & Brake System of Construction Machinery 2 3 3 154-160

5 CMT-333 Final Drive, Undercarriage and Power Line 2 3 3 161-166

6 CMT-343 Hydraulic System of Construction Machinery 2 3 3 167-173

7 CMT-353 Hydraulic Excavator 2 3 3 174-179

8 CMT-363 Planning and Management of Construction Machinery 2 3 3 180-184

9 CMT-372 Project 0 6 2 185

Total 15 27 24

2

DAE TECHNOLOGY

11

Eng-112 ENGLISH

Total contact hours Theory 64 T P C

Practical 0 2 0 2

AIM:- At the end of the course, the students will be equipped with cognitive skill to enable them to

present facts in a systematic and logical manner to meet the language demands of dynamic field

of commerce and industry for functional day-to-day use and will inculcate skills of reading,

writing and comprehension.

COURSE CONTENTS

ENGLISH PAPER "A"

1 PROSE/TEXT 16 hours 1.1 First eight essays of Intermediate English Book-II

2 CLOZE TEST 4 hours 2.1 A passage comprising 50-100 words will be selected from the text. Every 11th word or

any word for that matter will be omitted. The number of missing word will range

between 5-10. The chosen word may or may not be the one used in the text, but it

should be an appropriate word.

ENGLISH PAPER "B"

3 GRAMMAR 26 hours 3.1 Sentence Structure.

3.2 Tenses.

3.3 Parts of speech.

3.4 Punctuation.

3.5 Change of Narration.

3.6 One word for several

3.7 Words often confused

4. COMPOSITION 8 hours 4.1 Letters/Messages

4.2 Job application letter

4.3 For character certificate/for grant of scholarship

4.4 Telegrams, Cablegrams and Radiograms, Telexes, Facsimiles

4.5 Essay writing 4 hours

4.6 Technical Education, Science and Our life, Computers, Environmental

Pollution, Duties of a Student.

5. TRANSLATION 6 hours 5.1 Translation from Urdu into English.

For Foreign Students: A paragraph or a dialogue.

RECOMMENDED BOOKS 1. Intermediate English Book-II.

2. An English Grammar and Composition of Intermediate Level.

3. A Hand Book of English Students By Gatherer.

12

Eng-112 ENGLISH

INSTRUCTIONAL OBJECTIVES

PAPER-A

1. DEMONSTRATE BETTER READING, COMPREHENSION AND VOCABULARY 1.1 Manipulate, skimming and scanning of the text.

1.2 Identify new ideas.

1.3 Reproduce facts, characters in own words

1.4 Write summary of stories

2. UNDERSTAND FACTS OF THE TEXT 2.1 Rewrite words to fill in the blanks recalling the text.

2.2 Use own words to fill in the blanks.

PAPER-B

3. APPLY THE RULES OF GRAMMAR IN WRITING AND SPEAKING 3.1 Use rules of grammar to construct meaningful sentences containing a subject and a

predicate.

3.2 State classification of time, i.e. present, past and future and use verb tense correctly in

different forms to denote relevant time.

3.3 Identify function words and content words.

3.4 Use marks of punctuation to make sense clear.

3.5 Relate what a person says in direct and indirect forms.

3.6 Compose his writings.

3.7 Distinguish between confusing words.

4. APPLY THE CONCEPTS OF COMPOSITION WRITING TO PRACTICAL

SITUATIONS 4.1 Use concept to construct applications for employment, for character certificate, for

grant of scholarship.

4.2 Define and write telegrams, cablegrams and radiograms, telexes, facsimiles

4.3 Describe steps of a good composition writing.

4.4 Describe features of a good composition.

4.5 Describe methods of composition writing

4.6 Use these concepts to organize facts and describe them systematically in practical

situation.

5. APPLIES RULES OF TRANSLATION 5.1 Describe confusion.

5.2 Describe rules of translation.

5.3 Use rules of translation from Urdu to English in simple paragraph and sentences.

13

Math-113 APPLIED MATHEMATICS-I

T P C

3 0 3

Total Contact Hours Theory 96 Hours.

Pre-requisite: Must have completed a course of Elective Mathematics at Matric level.

AIM:- After completing the course the students will be able to

1. Solve problems of Algebra, Trigonometry, vectors, Mensuration, Matrices and

Determinants.

2. Develop skill, mathematical attitudes and logical perception in the use of

mathematical instruments as required in the technological fields.

3. Acquire mathematical clarity and insight in the solution of technical problems.

COURSE CONTENTS

1. QUADRATIC EQUATIONS 6 Hours 1.1 Standard Form

1.2 Solution

1.3 Nature of roots

1.4 Sum & Product of roots

1.5 Formation

1.6 Problems

2. ARITHMETIC PROGRESSION AND SERIES. 3 Hours 2.1 Sequence

2.2 Series

2.3 nth term

2.4 Sum of the first n terms

2.5 Means

2.6 Problems

3. GEOMETRIC PROGRESSION AND SERIES. 3 Hours 3.1 nth term

3.2 Sum of the first n terms

3.3 Means

3.4 Infinite Geometric progression

3.5 Problems

4. BINOMIAL THEOREM 6 Hours 4.1 Factorials

4.2 Binomial Expression

4.3 Binomial Co-efficient

4.4 Statement

4.5 The General Term

4.6 The Binomial Series

4.7 Problems.

5. PARTIAL FRACTIONS 6 Hours 5.1 Introduction

5.2 Linear Distinct Factors Case I

5.3 Linear Repeated Factors Case II

5.4 Quadratic Distinct Factors Case III

5.5 Quadratic Repeated Factors Case IV

5.6 Problems

14

6. FUNDAMENTALS OF TRIGONOMETRY 6 Hours 6.1 Angles

6.2 Quadrants

6.3 Measurements of Angles

6.4 Relation between Sexagesimal & circular system

6.5 Relation between Length of a Circular Arc & the Radian Measure of its central Angle

6.6 Problems

7. TRIGONOMETRIC FUNCTIONS AND RATIOS 6 Hours 7.1 Trigonometric functions of any angle

7.2 Signs of trigonometric Functions

7.3 Trigonometric Ratios of particular Angles

7.4 Fundamental Identities

7.5 Problems

8. GENERAL IDENTITIES 6 Hours 8.1 The Fundamental Law

8.2 Deductions

8.3 Sum & Difference Formulae

8.4 Double Angle Identities

8.5 Half Angle Identities

8.6 Conversion of sum or difference to products

8.7 Problems

9. SOLUTION OF TRIANGLES 6 Hours 9.1 The law of Sines

9.2 The law of Cosines

9.3 Measurement of Heights & Distances

9.4 Problems

10. MENSURATION OF SOLIDS 30 Hours 10.1 Review of regular plane figures and Simpson's Rule

10.2 Prisms

10.3 Cylinders

10.4 Pyramids

10.5 Cones

10.6 Frusta

10.7 Spheres

15

11. VECTORS 9 Hours 11.1 Scalers & Vectors

11.2 Addition & Subtraction

11.3 The unit Vectors i, j, k

11.4 Direction Cosines

11.5 Scaler or Dot Product

11.6 Deductions

11.7 Dot product in terms of orthogonal components

11.8 Vector or cross Product

11.9 Deductions

11.10 Analytic Expression for a x b.

11.11 Problems

12. MATRICES AND DETERMINANTS 9 Hours 12.1 Definition of Matrix

12.2 Rows & Columns

12.3 Order of a Matrix

12.4 Algebra of Matrices

12.5 Determinants

12.6 Properties of Determinants

12.7 Solution of Linear Equations

12.8 Problems

REFERENCE BOOKS 1. Ghulam Yasin Minhas - Technical Mathematics Vol-I, Ilmi Kitab Khana, Lahore.

2. Prof. Riaz Ali Khan - Polytechnic Mathematic Series Vol I & II, Majeed Sons, Faisalabad

3. Prof. Sana Ullah Bhatti - A Text Book of Algebra and Trigonometry, Punjab Text Book Board,

Lahore.

16

Math-113 APPLIED MATHEMATICS-I


1. USE DIFFERENT METHODS FOR THE SOLUTION OF QUADRATIC

EQUATIONS. 1.1 Define a standard quadratic equation.

1.2 Use methods of factorization and method of completing the square for solving the

equations.

1.3 Derive quadratic formula.

1.4 Write expression for the discriminant.

1.5 Explain nature of the roots of a quadratic equation.

1.6 Calculate sum and product of the roots.

1.7 Form a quadratic equation from the given roots.

1.8 Solve problems involving quadratic equations.

2. UNDERSTAND APPLY CONCEPT OF ARITHMETIC PROGRESSION AND

SERIES. 2.1 Define an Arithmetic sequence and a series.

2.2 Derive formula for the nth term of an A.P.

2.3 Explain Arithmetic Mean between two given numbers.

2.4 Insert n Arithmetic means between two numbers.

2.5 Derive formulas for summation of an Arithmetic series.

2.6 Solve problems on Arrthimetic Progression and Series..

3. UNDERSTAND GEOMETRIC PROGRESSION AND SERIES. 3.1 Define a geometric sequence and a series.

3.2 Derive formula for nth term of a G.P.

3.3 Explain geometric mean between two numbers.

3.4 Insert n geometric means between two numbers.

3.5 Derive a formula for the summation of geometric Series.

3.6 Deduce a formula for the summation of an infinite G.P.

3.7 Solve problems using these formulas.

4. EXPAND AND EXTRACT ROOTS OF A BINOMIAL. 4.1 State binomial theorem for positive integral index.

4.2 Explain binomial coefficients: (n,0), (n,1).....,(n,r)......, (n,n)

4.3 Derive expression for the general term.

4.4 Calculate the specified terms.

4.5 Expand a binomial of a given index.

4.6 Extract the specified roots.

4.7 Compute the approximate value to a given decimal place.

4.8 Solve problems involving binomials.

17

5. RESOLVE A SINGLE FRACTION INTO PARTIAL FRACTIONS USING

DIFFERENT METHODS. 5.1 Define a partial fraction, a proper and an improper fraction.

5.2 Explain all the four types of partial fractions.

5.3 Set up equivalent partial fractions for each type.

5.4 Explain the methods for finding constants involved.

5.5 Resolve a single fraction into partial fractions.

5.6 Solve problems involving all the four types.

6. UNDERSTAND SYSTEMS OF MEASUREMENT OF ANGLES. 6.1 Define angles and the related terms.

6.2 Illustrate the generation of an angle.

6.3 Explain sexagesimal and circular systems for the measurement of angles.

6.4 Derive the relationship between radian and degree.

6.5 Convert radians to degrees and vice versa.

6.6 Derive a formula for the circular measure of a central angle.

6.7 Use this formula for solving problems.

7. APPLY BASIC CONCEPTS AND PRINCIPLES OF TRIGONOMETRIC

FUNCTIONS. 7.1 Define the basic trigonometric functions/ratios of an angle as ratios of the sides of a

right triangle.

7.2 Derive fundamental identities.

7.3 Find trigonometric ratios of particular angles.

7.4 Draw the graph of trigonometric functions.

7.5 Solve problems involving trigonometric functions.

8. USE TRIGONOMETRIC IDENTITIES IN SOLVING TECHNOLOGICAL

PROBLEMS. 8.1 List fundamental identities.

8.2 Prove the fundamental law.

8.3 Deduce important results.

8.4 Derive sum and difference formulas.

8.5 Establish half angle,double angle & triple angle formulas.

8.6 Convert sum or difference into product & vice versa.

8.7 Solve problems.

9. USE CONCEPTS, PROPERTIES AND LAWS OF TRIGONOMETRIC FUNCTIONS

FOR SOLVING TRIANGLES. 9.1 Define angle of elevation and angle of depression.

9.2 Prove the law of sines and the law of cosines.

9.3 Explain elements of a triangle.

9.4 Solve triangles and the problems involving heights and distances.

18

10. USE PRINCIPLES OF MENSURATION IN FINDING SURFACES, VOLUMES AND

WEIGHTS OF SOLIDS. 10.1 Define mensuration of plane and solid figures.

10.2 List formulas for perimeters & areas of plane figure.

10.3 Define pyramid and cone.

10.4 Define frusta of pyramid and cone.

10.5 Define a sphere and a shell.

10.6 Calculate the total surface and volume of each type of solid.

10.7 Compute weight of solids.

10.8 Solve problems of these solids.

11. USE THE CONCEPT AND PRINCIPLES OF VECTORS IN SOLVING

TECHNOLOGICAL PROBLEMS. 11.1 Define vector quantity.

11.2 Explain addition and subtraction of vector.

11.3 Illustrate unit vectors i, j, k.

11.4 Express a vector in the component form.

11.5 Explain magnitude, unit vector, direction cosines of a vector.

11.6 Derive analytic expression for dot product and cross product of two vector.

11.7 Deduce conditions of perpendicularity and parallelism of two vectors.

11.8 Solve problems

12. USE THE CONCEPT OF MATRICES & DETERMINANTS IN SOLVING

TECHNOLOGICAL PROBLEMS. 12.1 Define a matrix and a determinant.

12.2 List types of matrices.

12.3 Define transpose, adjoint and inverse of a matrix.

12.4 State properties of determinants.

12.5 Explain basic concepts.

12.6 Explain algebra of matrices.

12.7 Solve linear equation by matrices.

12.8 Explain the solution of a determinant.

12.9 Use Crammers Rule for solving linear equations.

19

Phy-122 APPLIED PHYSICS

Total Contact Hours Theory 32 T P C

Practicals 96 1 3 2

AIM:- The students will be able to understand the fundamental principles and concept of physics,

use these to solve problems in practical situations/technological courses and understand

concepts to learn advance physics/technical courses.

COURSE CONTENTS

1 MEASUREMENTS. 2 Hours 1.1 Fundamental units and derived units

1.2 Systems of measurement and S.I. units

1.3 Concept of dimensions, dimensional formula

1.4 Conversion from one system to another

1.5 Significant figures

2 SCALARS AND VECTORS. 4 Hours 2.1 Revision of head to tail rule

2.2 Laws of parallelogram, triangle and polygon of forces

2.3 Resolution of a vector

2.4 Addition of vectors by rectangular components

2.5 Multiplication of two vectors, dot product and cross product

3 MOTION 4 Hours 3.1 Review of laws and equations of motion

3.2 Law of conservation of momentum

3.3 Angular motion

3.4 Relation between linear and angular motion

3.5 Centripetal acceleration and force

3.6 Equations of angular motion

4 TORQUE, EQUILIBRIUM AND ROTATIONAL INERTIA. 4 Hours 4.1 Torque

4.2 Centre of gravity and centre of mass

4.3 Equilibrium and its conditions

4.4 Torque and angular acceleration

4.5 Rotational inertia

5 WAVE MOTION. 5 Hours 5.1 Review Hooke's law of elasticity

5.2 Motion under an elastic restoring force

5.3 Characteristics of simple harmonic motion

5.4 S.H.M. and circular motion

5.5 Simple pendulum

5.6 Wave form of S.H.M.

5.7 Resonance

5.8 Transverse vibration of a stretched string

20

6 SOUND. 5 Hours 6.1 Longitudinal waves

6.2 Intensity, loudness, pitch and quality of sound

6.3 Units of Intensity of level and frequency response of ear

6.4 Interference of sound waves silence zones, beats

6.5 Acoustics

6.6 Doppler effect.

7 LIGHT. 5 Hours 7.1 Review laws of reflection and refraction

7.2 Image formation by mirrors and lenses

7.3 Optical instruments

7.4 Wave theory of light

7.5 Interference, diffraction, polarization of light waves

7.6 Applications of polarization in sunglasses, optical activity and stress analysis

8 OPTICAL FIBER. 2 Hours 8.1 Optical communication and problems

8.2 Review total internal reflection and critical angle

8.3 Structure of optical fiber

8.4 Fiber material and manufacture

8.5 Optical fiber - uses.

9 LASERS. 3 Hours 9.1 Corpuscular theory of light

9.2 Emission and absorption of light

9.3 Stimulated absorption and emission of light

9.4 Laser principle

9.5 Structure and working of lasers

9.6 Types of lasers with brief description.

9.7 Applications (basic concepts)

9.8 Material processing

9.9 Laser welding

9.10 Laser assisted machining

9.11 Micro machining

9.12 Drilling, scribing and marking

9.13 Printing

9.14 Lasers in medicine

RECOMMENDED BOOKS 1 Tahir Hussain, Fundamentals of Physics Vol-I and II

2 Farid Khawaja, Fundamentals of Physics Vol-I and II

3 Wells and Slusher, Schaum's Series Physics .

4 Nelkon and Oyborn, Advanced Level Practical Physics

5 Mehboob Ilahi Malik and Inam-ul-Haq, Practical Physics

6 Wilson, Lasers - Principles and Applications

7 M. Aslam Khan and M. Akram Sandhu, Experimental Physics Note Book

21



1 USE CONCEPTS OF MEASUREMENT TO PRACTICAL SITUATIONS AND

TECHNOLOGICAL PROBLEMS.

1.1 Write dimensional formulae for physical quantities

1.2 Derive units using dimensional equations

1.3 Convert a measurement from one system to another

1.4 Use concepts of measurement and Significant figures in problem solving.

2 USE CONCEPTS OF SCALARS AND VECTORS IN SOLVING PROBLEMS

INVOLVING THESE CONCEPTS. 2.1 Explain laws of parallelogram, triangle and polygon of forces

2.2 Describe method of resolution of a vector into components

2.3 Describe method of addition of vectors by rectangular components

2.4 Differentiate between dot product and cross product of vectors

2.5 Use the concepts in solving problems involving addition resolution and multiplication

of vectors.

3 USE THE LAW OF CONSERVATION OF MOMENTUM AND CONCEPTS OF

ANGULAR MOTION TO PRACTICAL SITUATIONS. 3.1 Use law of conservation of momentum to practical/technological problems.

3.2 Explain relation between linear and angular motion

3.3 Use concepts and equations of angular motion to solve relevant technological problems.

4 USE CONCEPTS OF TORQUE, EQUILIBRIUM AND ROTATIONAL INERTIA TO

PRACTICAL SITUATION/PROBLEMS. 4.1 Explain Torque

4.2 Distinguish between Centre of gravity and centre of mass

4.3 Explain rotational Equilibrium and its conditions

4.4 Explain Rotational Inertia giving examples

4.5 Use the above concepts in solving technological problems.

5 USE CONCEPTS OF WAVE MOTION IN SOLVING RELEVANT PROBLEMS. 5.1 Explain Hooke's Law of Elasticity

5.2 Derive formula for Motion under an elastic restoring force

5.3 Derive formulae for simple harmonic motion and simple pendulum

5.4 Explain wave form with reference to S.H.M. and circular motion

5.5 Explain Resonance

5.6 Explain Transverse vibration of a stretched string

5.7 Use the above concepts and formulae of S.H.M. to solve relevant problems.

6 UNDERSTAND CONCEPTS OF SOUND. 6.1 Describe longitudinal wave and its propagation

6.2 Explain the concepts: Intensity, loudness, pitch and quality of sound

6.3 Explain units of Intensity of level and frequency response of ear

6.4 Explain phenomena of silence zones, beats

6.5 Explain Acoustics of buildings

6.6 Explain Doppler effect giving mathematical expressions.

7 USE THE CONCEPTS OF GEOMETRICAL OPTICS TO MIRRORS and LENSES. 7.1 Explain laws of reflection and refraction

7.2 Use mirror formula to solve problems

22

7.3 Use the concepts of image formation by mirrors and lenses to describe working of

optical instruments, e.g. microscopes, telescopes, camera and sextant.

8 UNDERSTAND WAVE THEORY OF LIGHT 8.1 Explain wave theory of light

8.2 Explain phenomena of interference, diffraction, polarization of light waves

8.3 Describe uses of polarization given in the course contents.

9 UNDERSTAND THE STRUCTURE, WORKING AND USES OF OPTICAL FIBER. 9.1 Explain the structure of the Optical Fiber

9.2 Explain its principle of working

9.3 Describe use of optical fiber in industry and medicine.

10. UNDERSTANDING THE PRINCIPLE, STRUCTURE TYPES OF LASER AND

APPLICATION OF LASER 10.1 Explain the basics theories of light.

10.2 Describe principle, structure and working of LASER.

10.3 Explain Applications/uses of LASER.

23


LIST OF PRACTICALS. 1 Draw graphs representing the functions:

a) y=mx for m=0, 0.5, 1, 2

b) y=x2

c) y=1/x

2 Find the volume of a given solid cylinder using vernier callipers.

3 Find the area of cross-section of the given wire using micrometer screw gauge.

4 Prove that force is directly proportional to (a) mass, (b) acceleration, using fletchers' trolley.

5 Verify law of parallelogram of forces using Grave-sands apparatus.

6 Verify law of triangle of forces and Lami's theorem

7 Determine the weight of a given body using

a) Law of parallelogram of forces

b) Law of triangle of forces

c) Lami's theorem

8 Verify law of polygon of forces using Grave-sands apparatus.

9 Locate the position and magnitude of resultant of like parallel forces.

10 Determine the resultant of two unlike parallel forces.

11 Find the weight of a given body using principle of moments.

12 Locate the centre of gravity of regular and irregular shaped bodies.

13 Find Young's Modules of Elasticity of a metallic wire.

14 Verify Hooke's Law using helical spring.

15 Study of frequency of stretched string with length.

16 Study of variation of frequency of stretched string with tension.

17 Study resonance of air column in resonance tube and find velocity of sound.

18 Find the frequency of the given tuning fork using resonance tube.

19 Find velocity of sound in rod by Kundt's tube.

20 Verify rectilinear propagation of light and study shadow formation.

21 Study effect of rotation of plane mirror on reflection.

22 Compare the refractive indices of given glass slabs.

23 Find focal length of concave mirror by locating centre of curvature.

24 Find focal length of concave mirror by object and image method

25 Find focal length of concave mirror with converging lens.

26 Find refractive index of glass by apparent depth.

27 Find refractive index of glass by spectrometer.

28 Find focal length of converging lens by plane mirror.

29 Find focal length of converging lens by displacement method.

30 Find focal length of diverging lense using converging lens.

31 Find focal length of diverging lens using concave mirror.

32 Find angular magnification of an astronomical telescope.

33 Find angular magnification of a simple microscope (magnifying glass)

34 Find angular magnification of a compound microscope.

35 Study working and structure of camera.

36 Study working and structure of sextant.

37 Compare the different scales of temperature and verify the conversion formula.

38 Determine the specific heat of lead shots.

39 Find the coefficient of linear expansion of a metallic rod.

40 Find the heat of fusion of ice.

41 Find the heat of vaporization.

42 Determine relative humidity using hygrometer.

24

Comp-122 COMPUTER APPLICATIONS

Total contact hours Theory 32 Hours T P C

Practicals 96 Hours 1 3 2

Pre-requisite None

AIM:- This subject will enable the student to be familiar with the operation of a Micro-computer. He

will also learn DOS, BASIC language and word processing to elementary level.

COURSE CONTENTS

1. ELECTRONIC DATA PROCESSING (EDP) 6 Hours 1.1 Basics of computers

1.2 Classification of computers

1.3 Block diagram of a computer system

1.4 Binary number system

1.5 BIT, BYTE, RAM, ROM, EROM, EPROM

1.6 Input and output devices

1.7 Secondary storage media details

1.8 Processors and types

1.9 Using computer for system software

1.10 Using computers for application software.

1.11 Common types of software and their application.

2. DISK OPERATING SYSTEM (DOS) 6 Hours 2.1 Internal commands

2.2 External commands

2.3 Batch files

2.4 Advance features.

3. BASIC LANGUAGE 10 Hours 3.1 Introduction to high level languages

3.2 Introduction to BASIC

3.3 REM Statement

3.4 Assignment statement

3.5 Input statement

3.6 Read-Data statement

3.7 IF-THEN statement

3.8 IF-THEN Else statement

3.9 FOR-NEXT statement

3.10 DIM statement

3.11 LPRINT statement

3.12 STOP statement

3.13 END statement

3.14 Logic of a BASIC Programme

3.15 Running a BASIC Programme

3.16 Saving and Retrieving a Programme

3.17 Advance features

25

4. WORD PROCESSING 7 Hours 4.1 Starting word processor session

4.2 Opening a document

4.3 Saving a document

4.4 Ending word processor session (Temporarily)

4.5 Retrieving a document

4.6 Spell check

4.7 Margins and tab setting

4.8 Aligning Paragraph

4.9 Printing a document

4.10 Advance features

5. COMPUTER GRAPHIC IN BASIC 3 hours 5.1 Graphic fundamentals

5.2 Points and lines

5.3 Dots in space

5.4 A lightening blot

5.5 Shapes

5.6 Expanding circles and rectangles

RECOMMENDED BOOKS 1. Ron S. Gottfrid, Programming with BASIC,

2. Any Word Processor Latest Release (e.g., Word, Word-Perfect etc).

3. ABC'S of DOS (latest release).

4. Judd Robbins, Mastering DOS 6.0 and 6.2

26



1. UNDERSTAND ELECTRONIC DATA PROCESSING (EDP). 1.1 Describe basics of computers.

1.2 Enlist different classification of computers.

1.3 Explain block diagram of a computer system.

1.4 Describe binary number system.

1.5 State the terms used in computers such as BIT, BYTE, RAM, ROM, EROM, EPROM.

1.6 Identify input and output devices.

1.7 Describe secondary storage media.

1.8 Explain processor.

1.9 Name different types of processors.

1.10 Explain the use of computer for system software.

1.11 Explain the use of computer for application software.

1.12 Enlist common types of software and their application.

1.13 Explain various applications of above softwares mentioned in 1.12

2. UNDERSTAND DISK OPERATING SYSTEM (DOS). 2.1 Explain the use of various internal commands of DOS.

2.2 Explain the use of various external commands of DOS.

2.3 Describe batch files.

2.4 Identify advanced features

3. UNDERSTAND BASIC LANGUAGE. 3.1 Explain high level languages.

3.2 Explain Basic language.

3.3 Describe Rem statement

3.4 Describe assignment statement

3.5 Explain Input statement

3.6 Explain Read-Data statement

3.7 Explain If-Then Statement

3.8 Explain If-then-Else Statement

3.9 Explain For-Next Statement

3.10 Explain DIM Statement

3.11 Explain LPRINT statement

3.12 Explain stop statement

3.13 Explain end Statement

3.14 Describe Logic of Basic program

3.15 Describe running a Basic Program

3.16 Describe saving & retrieving Basic Program

3.17 Describe some Advance features of Basic program

4. UNDERSTAND WORD PROCESSING SESSION

4.1. Describe word-processing

4.2 Name command to be entered on Dos-prompt to load word-processor

4.3 Identify initial screen

4.4 Describe the command to open a document

4.5 Describe the procedure for naming the document

4.6 Explain importance of giving extension to a document

4.7 Describe saving and retrieving a document

4.8 Explain importance of saving the work at regular intervals

27

4.9 State temporarily Ending word-processing session & document retrieval

4.10 State procedure to re-enter word processor

4.11 State procedure to re-open the document and editing

4.12 Describe spell-check facility

4.13 Describe Margins & Tab Setting

4.14 Describe to align paragraph

4.15 Describe Re-editing techniques

4.16 Describe procedure to set-up printer

4.17 Describe command for printouts

4.18 Explain multiple-copy printout procedure

4.19 Explain some advance features

4.20 Describe procedure of condensed printing

4.21 Describe procedure for change of fonts

5. UNDERSTAND PROGRAMMING INSTRUCTIONS FOR COMPUTER GRAPHIC

IN BASIC LANGUAGE 5.1 Identify graphic fundamentals in basic language

5.2 Explain to draw points and lines

5.3 Explain to draw dot in space

5.4 Explain to draw lighting blot

5.5 Explain to draw shapes

5.6 Explain to draw expanding circles and rectangles

28


LIST OF PRACTICALS 96 hours

DOS 1 Identify key board, mouse, CPU, disk drives, disks, monitor & printer

2 Practice for booting up of a computer system with DOS system disk and power off system at

DOS prompt

3 Practice for CLS, VER, VOL, DATE & TIME commands

4 Practice for COPY, REN commands

5 Practice for DEL, TYPE, PATH, PROMPT, COPY CON, MD, CD, RD commands

6 Practice of the practicals at S. No. 3, 4, 5

7 Practice for FORMAT command with /s, /4, /u switches

8 Practice for DISKCOPY, DISKCOMP commands

9 Practice for SCANDISK, XCOPY, DELTREE, TREE, LABEL commands

10 Practice for PRINT, UNDELETE commands

11 Practice for the practicals at S. No. 8, 9, 10, 11

12 Practice for creating a batch file

BASIC 1 Practice for loading & unloading BASIC software and identify role of function keys in Basic

2 Identify role of various keys in continuation with ALT key in BASIC programming

3 Practice for CLS, LOAD, SAVE, FILE, RENUM command by loading any existing BASIC

Program

4 Practice for editing any existing BASIC Program

5 Prepare BASIC Program to display sum of two numbers using INPUTS

6 Prepare BASIC Program to display sum of two numbers using READ-DATA

7 Prepare BASIC Program to multiply two numbers

8 Prepare BASIC Program to calculate Area of Rectangle, when length and width are given

9 Prepare BASIC Program to calculate area of a circle when radius/diameter is given

10 Prepare very simple BASIC Programs using IF-THEN-ELSE and FOR-NEXT statement

11 Identify DIM statement

12 Practice for LPRINT statement for various Programs hard-copy output

WORD PROCESSING 1 Practice for loading & unloading a word processor

2 Practice for creating document & saving it

3 Practice for spell-check facility of the word-processor

4 Practice for editing an existing document

5 Practice for various word-processing Menu Options

6 Practice for printing a document

7 Practice for margin and TAB setting and document alignment

8 Practice for some advance features

29

AD-123 INTERNAL COMBUSTION ENGINE

TOTAL CONTACT HOURS: Theory: 64 hours T P C

Practical: 96 hours 2 3 3

Pre-requisite: None

AIM:- 1. Understand the principles of petrol and diesel engines

2. Understand the working of engine systems

3. Understand the systems based upon pressure and volume

4. Recognize the importance of proper relationship between different parts and

components

5. Build up self confidence and creative logical thinking

6. Identify petrol and diesel engine

7. Know different types of engines

8. Understand design, working engine systems

9. Compare petrol and diesel engine

COURSE CONTENTS:

1. HISTORY OF AUTOMOBILE AND DEVELOPMENT 2 hours 1.1 History and development of I.C Engine

2. AUTOMOBILE MAIN COMPONENTS 2 hours 2.1 Chassis and Frame

3. I.C. ENGINES FUNDAMENTALS 2 hours 3.1 Compression ratio

4. ENGINE OPERATION 3 hours 4.1 Stroke operation TDC and BDC

4.2 Suction stroke

4.3 Compression stroke

4.4 Working stroke or power stroke.

4.5 Exhaust stroke

5. I.C. ENGINES CONSTRUCTION 4 hours 5.1 Engine block

5.2 Cylinder head

5.3 Crank shaft

5.4 Cam shaft

5.5 Cylinder

5.6 Piston

6. ENGINE VALVES 4 hours 6.1 Inlet valve

6.2 Exhaust valve

6.3 Valve spring

6.4 Valve guide

6.5 Valve arrangement

6.6 Valve action (operation)

30

7. CLASSIFICATION OF ENGINES 5 hours 7.1 Classification w.r.t number of stroke i.e. four strokes, two strokes

7.2 Classification w.r.t number cylinder arrangement

7.3 Classification w.r.t valve arrangement

7.4 Classification w.r.t fuel used

7.5 Classification w.r.t ignition

7.6 Classification w.r.t cooling

7.7 Classification w.r.t engine displacement

7.8 Classification w.r.t lubrication

7.9 Operation i.e reciprocating rotary (Wankel)

8. ENGINE CONSTRUCTION NOMENCLATURE 4 hours 8.1 Manifolds

8.2 Oil pan

8.3 Gasket

8.4 Vibration damper

8.5 Fly wheel

8.6 Oil cleaner

8.7 Air cleaner

9. ENGINE BEARING TYPES 4 hours 9.1 Main bearing

9.2 Big end bearing

9.3 Piston pins

9.4 Cam shaft bush

9.5 Thrust bearing

10. PISTON & CYLINDER ARRANGEMENT 5 hours 10.1 Liners types i.e wet and dry

10.2 Piston types

10.3 Piston ring types, shape and characteristics

10.4 Piston expansion control gap

10.5 Oil control, Blow-by

10.6 Attaching piston to connecting rod

11. TYPES OF VALVE TRAIN & THEIR COMPONENTS 5 hours 11.1 Valve assembly

11.2 Rocker arm assembly

11.3 Valve lifters

11.4 Valve seat

11.5 Cam & camshaft and its location, drive and speed timing marks

11.6 Valve timing diagram

11.7 Tappet clearance and purpose

11.8 Valve lead, lag, over lap

12. INTRODUCTION TO ENGINE SYSTEMS 5 hours 12.1 Intake System

12.2 Exhaust system

12.3 Lubrication System

12.4 Ignition system

12.5 Injection System

12.6 Lubrication System

12.7 Cooling System

31

13. INTAKE SYSTEM (I.C. ENGINE) 3 hours 13.1 Air cleaner

13.2 Carburetor

13.3 Inlet manifold

13.4 Piston displacement

14. LUBRICATION SYSTEM 6 hours 14.1 Function

14.2 Types of lubrication

14.3 Components

14.4 Oil pumps types, working and service

14.5 Relief valve, oil filter types

14.6 Oil pressure indicator working light

14.7 Dipstick

14.8 Oil changing

15. COOLING SYSTEM 6 hours 15.1 Purpose and types

15.2 Components

15.3 Water jcket

15.4 Water pump and types

15.5 Fan types

15.6 Radiator types

15.7 Thermostat types

15.8 Water hose

15.9 Radiator pressure cap

15.10 Antifreeze purpose

15.11 Cooling fins

15.12 Temperature gauge for cooling system

16. COMPARISON 4 hours 16.1 Between Petrol and Diesel Engines

a. w.r.t Construction

b. w.r.t Fuel System

c. w.r.t Working

16.2 Between two stroke and four stroke engine

BOOK RECOMMENDED:

Automotive Engines

By: William H. Crouse

32

AD-123 INTERNAL COMBUSTION ENGINE


On the completion of this course, the student will be able to

1. KNOW THE HISTORY AND DEVELOPMENT OF AUTOMOBILE. 1.1 State the history of Automobile.

1.2 State the history of I.C. Engine.

2. KNOW THE VEHICLE MAIN COMPONENTS. 2.1 Identify the vehicle main components.

2.2 Define chassis and frame.

3. UNDERSTAND THE ENGINE FUNDAMENTALS. 3.1 Define clearance volume.

3.2 Define stroke.

3.3 Define total cylinder volume.

3.4 Explain compression ratio.

4. UNDERSTAND THE ENGINE OPERATION. 4.1 Define stroke.

4.2 Define TDC an BDC.

4.3 Discuss four strokes.

5. UNDERSTAND ENGINE UNITS. 5.1 Explain Engine block.

5.2 Explain cylinder head.

5.3 Explain crank shaft.

5.4 Explain cam shaft.

5.5 Explain cylinders, piston.

6. UNDERSTAND THE WORKING OF VALVE. 6.1 Explain the working of engine valves.

6.2 Explain the valve arrangement.

7. UNDERSTAND CLASSIFICATION OF ENGINES. 7.1 Compare 4-stroke and 2-stroke engine.

7.2 Explain the types of engines w.r.t numbers of cylinders and cylinder arrangement.

7.3 Explain the types of engines w.r.t valve arrangement.

7.4 Classify engines with respect to fuels used, ignition, cooling, engine displacement and

lubrication

7.5 Discuss reciprocating and Wankel engines.

7.6 Discuss gas turbine.

8. UNDERSTAND ENGINE PARTS. 8.1 Explain manifolds.

8.2 Describe oil pan.

8.3 Describe gasket.

8.4 Explain vibration damper.

8.5 Explain fly wheel.

8.6 Explain oil cleaner.

8.7 Describe Air cleaners.

8.8 Identify engine parts.

33

9. UNDERSTAND THE ENGINE BEARING. 9.1 State the purpose of bearing.

9.2 Enslist the types of bearings

9.3 Discuss the working of different types of bearing.

9.4 Select proper lubracant for bearings

10. UNDERSTAND THE PISTON AND CYLINDER ARRANGEMENT. 10.1 Describe the piston.

10.2 State different type of liners

10.3 Define blow-by oil

10.4 Explain different types of pistons.

10.5 Discuss the characteristics

10.6 Discuss expansion of piston due to heat.

10.7 Describe piston and connecting rod attachments

11. UNDERSTAND THE ENGINE VALVE ASSEMBLY AND WORKING. 11.1 Describe valve.

11.2 Explain cam action.

11.3 Explain rocker arm.

11.4 Describe the valve seat and value lifter.

11.5 Describe the cam shaft.

11.6 Explain the speed of cam shaft and its tunning marks.

11.7 Define valve timing.

11.8 Explain valve timing diagram.

11.9 Discuss tappet clearance.

11.10 State purpose of tappet clearance

11.11 Discuss over lap.

11.13 Explain the valve assembly.

12. UNDERSTAND THE WORKING OF DIFFERENT ENGINE SYSTEM. 12.1 Explain the intake system.

12.2 Explain the exhaust system.

12.3 Explain lubrication system.

12.4 Explain ignition system.

12.5 Explain injection system.

12.6 Explain cooling system.

13. UNDERSTAND THE INTAKE SYSTEM OF THE I/C ENGINE. 13.1 Enlist the parts of intake system.

13.2 Explain the intake system.

13.3 State the effect of volume.

13.4 Describe air clearner, carburetor, inlet monifold and piston displacement

14. UNDERSTAND THE LUBRICATION SYSTEM. 14.1 State the types of lubrication.

14.2 Enlist the components of lubrication system.

14.3 Explain the types of oil pump.

14.4 Explain relief valve.

14.5 Describe all types of oil filters

14.6 Discuss oil pressure in the system.

14.7 Discuss the purpose & function of oil changing.

34

15. UNDERSTAND THE COOLING SYSTEM. 15.1 Enlist the cooling system parts/units.

15.2 Describe types of cooling system.

15.3 Describe radiator pressure cap, thermostat.

15.4 Explain antifreeze, process and its purpose.

15.5 Explain the cooling system.

16. UNDERSTAND THE WORKING OF PETROL AND DIESEL ENGINES. 16.1 Explain petrol engine with respect to its construction, fuel system, working.

16.2 Explain diesel engine with respect ot its construction fuel system, working.

16.3 Compare petrol and diesel engines

16.4 Describe construction of petrol engine.

16.5 Explain the working of diesel engine.

16.6 Describe the construction of diesel engine.

16.7 Discuss 4-stroke cycle.

16.8 Discuss 2-stroke cycle.

16.9 Compare 4-stroke and 2-stroke engines.

35

AD-123 INTERNAL COMBUSTION ENGINE.

LIST OF PRACTICALS 1. Identify the vehicle main units

2. Enlist the vehicle main units.

3. Identify the basic engine parts.

5. Identify the parts of crank shaft.

6. Identify the parts of cam shaft.

7. Assemble the cam shaft and crankshaft on engine block

8. Measure the piston size with micro meters position pin size

9. Measure the crank pin size, journal size.

10. Measure the dia of cylinder.

11. Lapping the valves.

12. Checking the valve seat.

13. Assemble the valves on cylinder head.

14. Assemble and disassemble the manifolds.

15. Assemble the oil pan to the engine with gasket.

16. Assemble air cleaner to engine

17. Check the engine oil

18. Identify the engine bearing.

19. Identify the engine liners.

20. Identify the intake and exhaust system parts.

21. Identify the lubrication and ignition system

22. Identify the parts of cooling system.

36

MT-143 BASIC ENGINEERING DRAWING AND CAD-I

TOTAL CONTACT HOURS:

Theory: 32 hours T P C


Pre-requisite: None

AIM:- At the end of this course the students will be able to understand the fundamentals of

engineering drawing used in the various fields of industry especially in the Mechanical

Technology. The student will be familiarized with the use of conventional drawing instruments

as well as the modern technology used for this subject. The CAD portion of the subject will

provide the student the knowledge & use of computer in the subject of Engineering Drawing.

COURSE CONTENTS:

1. USES AND APPLICATIONS OF TECHNICAL DRAWING 1 hours 1.1 Technical drawing and the technician.

1.2 Use of technical drawing.

1.3 Common drawing forms.

1.4 Application of drawing forms.

1.5 Practices and conventions.

2. DRAWING TOOLS AND ACCESSORIES. 2 hours 2.1 Drawing pencil

2.2 Drawing papers specifications

2.3 Drawing Instruments

2.4 Use and care of drawing instruments and material.

3. ALPHABET OF LINES USED IN DRAWING 2 hours 3.1 Importance the alphabet of lines.

3.2 Common alphabet of lines.

3.3 Uses and correct line weightage of the line.

3.4 Application of line.

4. LETTERING. 2 hours 4.1 Importance of good lettering.

4.2 Single stroke gothic.

4.3 Letter strokes.

4.4 Letter guide lines.

4.5 Vertical single stroke gothic

4.6 Inclined single stroke gothic

4.7 Composition of lettering

5. DRAWING LINES TECHNOLOGY. 2 hours 5.1 Introduction to sketching techniques

5.2 Sketching lines

5.3 Sketching circles and arcs

5.4 Sketching ellipse.

5.5 Sketching views of objects

6. GEOMETRICAL CONSTRUCTIONS. 2 hours 6.1 Introduction to geometry

6.2 Definition of terms

37

6.3 Different conventional shapes, surfaces and objects

6.4 Basic geometrical construction

6.5 Construction of ellipse, parabola

6.6 Involute, cycloids

7. INTRODUCTION TO MULTI-VIEW PROJECTIONS 3 hours 7.1 Definition and concept of multi-view drawings

7.2 Proceptual vies of plan of projections

7.3 Orthographic projections

7.4 1st angle and 3rd angle projections

7.5 Principal views

7.6 Arrangement of views

7.7 Multi-view drawings

8. INTRODUCTION TO PICTORIAL DRAWINGS. 2 hours 8.1 Uses of pictorial views

8.2 Three types of pictorial views

8.3 Isometric sketching of rectangular block

8.4 Isometric sketching of Arcs and circles

8.5 Oblique sketching of rectangular block

8.6 One point perspective sketching of a rectangular block.

8.7 Two point perspective sketching of a rectangular block.

8.8 Preparation of pictorial drawings of simple objects.

9. BASIC DIMENSIONING. 2 hours 9.1 Definition of dimensioning.

9.2 Types of dimensioning.

9.3 Elements of dimensioning.

9.4 System of measurements.

9.5 Dimensioning multi-view drawings.

9.6 Dimensioning pictorial views.

9.7 Dimensioning rules and practices.

9.8 Notes and specifications

10. SECTIONING AND SECTIONAL VIEWS. 2 hours 10.1 Definition and purpose.

10.2 Cutting planes position and cutting plane lines

10.3 Types of sectional views.

10.4 Conventional section lines of different materials.

10.5 Practice sectioned views.

11. MULTI-VIEW DRAWING OF MACHINE ELEMENTS 2 hours 11.1 Terminology and drawing of rivets and riveted joints

11.2 Terminology and drawing of screw threads.

11.3 Terminology and drawing of keys and cotters.

11.4 Description and drawing of simple bearings

11.5 Description and drawing of simple couplings

38

PART-B : CAD-I

12. CAD FUNDAMENTALS 2 hours

12.1 CAD & its importance.

12.2 Purpose.

12.3 Advantages.

13. CAD SOFTWARE 2 hours

13.1 CAD Abbreviations.

13.2 CAD Help.

13.3 Co-ordinate system.

14. BORDER TEMPLATE 2 hours

14.1 Drawing area.

12.2 SNAP & GRID.

12.3 Pedit & Qsave.

15. TITLE BLOCK 2 hours

15.1 Change Command.

15.2 Layer creation.

15.3 Zooming.

15.4 Type faces of CAD.

15.5 Plotting

15. LINES & CIRCLES 2 hours

16.1 Dedit

15.2 Analyzed line drawing.

15.3 U & Redo command.

15.4 Drawing a circle.

BOOK RECOMMENDED:

1. Engineering Drawing by French Wirk

2. ABC’s of Auto CAD Release-12 by Alan R Miller.

39

MT-143 BASIC ENGINEERING DRAWING & CAD-I


SECTION-I ENGINEERING DRAWING

1. USES AND APPLICATIONS OF TECHNICAL DRAWING.

1.1 Know the uses of Technical Drawing

1.1.1 Describe the importance of Technical Drawing from the point of view of a

Technician.

1.1.2 Explain the main uses of Technical Drawing from the point of view of

Technician.

1.2 Recognizes the different application of Technical drawing

1.2.1 Identify commonly used drawing forms.

1.2.2 Illustrate the different drawing forms.

1.2.3 Differentiate different drawing forms.

1.2.4 Develop Technical vocabulary.

2. KNOW THE COMMON DRAWING TOOLS AND ACCESSORIES. 2.1 Identify the uses of different pencils for Technical Drawing.

2.2 Identify different paper sizes for drawing.

2.3 Identify different types of papers suitable for drawing.

2.4 Identify different types of erasers and their uses.

2.5 Maintain a well sharpened pencil for drawing.

2.6 Describe the drawing instruments.

2.7 State the use of drawing instruments.

3. UNDERSTAND THE IMPORTANCE OF ALPHABET, CORRECT WEIGHTAGE

AND APPLICATION OF LINES USED IN TECHNICAL DRAWING. 3.1 Knows the importance of lines.

3.2 Knows the Alphabet the lines.

3.3 Identify the lines characteristics of each alphabet of lines.

3.4 Draw horizontal, vertical and inclined lines

3.5 Draw lines with correct weightages

4. APPLIES THE GOOD LETTERING AN A DRAWING. 4.1 Know the importance of lettering in a technical engineering drawing.

4.2 Identify the letter style used in Technical drawing.

4.3 State letter strokes and guide lines.

4.4 Perform letter stroke in single stroke gothic.

4.5 Print vertical single stroke letters and numbers.

4.6 Print inclined single stroke letters and numbers.

4.7 Observe stability and pleasing appearance of letters in printing

5. UNDERSTAND SELECTING OF CIRCLES, ARCS, AND VIEWS OF OBJECTS. 5.1 Draw circular arc using circular line method.

5.2 Draw a circular arc using square method.

5.3 Draw an ellipse using rectangular method.

5.4 Draw views of simple objects.

40

6. APPLY DRAWING SKILL WITH THE AID OF DRAWING INSTRUMENTS IN

GEOMETRICAL CONSTRUCTION. 6.1 Define common terms used in geometrical construction.

6.2 Explain different geometrical shapes, surfaces of objects.

6.3 Draw basic geometrical construction.

6.4 Draw involute, cycloid, spiral, tangent to circler and are

7. UNDERSTAND THE MULTI VIEW PROJECTIONS SPECIFIC OBJECTIVE 7.1 Define the concept of multi-view drawings.

7.2 Knows principal planes of projections.

7.3 Knows the orthographic method of projection.

7.4 Explain the 1st and 3rd angle projections.

7.5 State six principal views.

7.6 Practice multi view projections.

8. APPLY THE USE, TYPES AND METHODS OF PICTORIAL VIEWS. 8.1 Knows the use of pictorial views.

8.2 Knows the pre-requisites of pictorial drawing.

8.3 State three types of pictorial drawings.

8.4 Draw isometric view of rectangular Blocks, Ares, circles.

8.5 Draw oblique sketches of rectangular blocks.

8.6 Draw one-point perspective view of a Rectangular block.

8.7 Draw Two point perspective view of a rectangular block.

8.8 Prepare /draw pictorial drawings of simple objects.

9. APPLY GOOD DIMENSIONING ON MULTI VIEWS AND PICTORIALS. 9.1 Define dimensioning.

9.2 Identify the types of dimensioning.

9.3 Enlist the elements of dimensioning.

9.4 Identify the system of measurements.

9.5 Indicate complete dimensions on multi view drawings.

9.6 Indicate complete dimensions pictorial drawings.

9.7 Follow the general rules for dimensioning.

9.8 Indicate notes and specification or multiview drawings.

10. APPLY THE SECTIONING METHODS OF MATERIAL AND DRAW SECTIONAL

VIEWS. 10.1 Define sectioning and state its purpose.

10.2 Describe cutting planes and lines.

10.3 State types of sectional views.

10.4 Explain conventional section lines of different materials.

10.5 Practice sectioning.

11. APPLY DRAWING METHODS TO DRAW MULTI VIEWS OF MACHINE

ELEMENTS. 11.1 Define multiviews of vee-block.

11.2 Draw multiviewa of Gland

11.3 Draw keys & cotters.

11.4 Draw Multi views of simple bearing.

41

SECTION-II COMPUTER AIDED DESIGN

12. UNDERSTAND CAD FUNDAMENTALS

12.1 Define CAD.

12.2 Describes importance of CAD.

12.3 States purpose of CAD.

12.4 Explain advantages of CAD.

12.5 Establish importance of CAD usage in industry.

13. UNDERSTAND CAD SOFTWARE

13.1 Describe computer system requirements for CAD (e.g. Auto CAD release 12 or latest).

13.2 State procedure of giving command to CAD.

13.3 State CAD (e.g. autocad rel. 12 or latest) abbreviations.

13.4 State use of function keys.

13.5 Describe procedure of giving command with a mouse.

13.6 Explain procedure of getting general help for a specific command.

13.7 Explain drawing cursor and coordinate read out.

13.8 Explain Cartesian notion.

13.9 Explain polar notation.

14. UNDERSTAND BORDER TEMPLATE OF DRAWING

14.1 Describe setting up of drawing area.

14.2 Describe setting of displayed digits.

14.3 Explain changing the drawing limits.

14.4 Explain use of grid system (auto rel-12 or latest).

14.5 Explain adjustment of drawing scale.

14.6 Explain procedure of drawing line with line command.

14.7 Explain P-edit command for widening boarder.

14.8 Explain procedure of saving boarder template.

15. UNDERSTAND ADDING A TITLE BLOCK TO THE BORDER DRAWING

15.1 Describe checking the drawing time.

15.2 Explain change command.

15.3 Explain creation of layer for title block.

15.4 Explain procedure of creating a title block.

15.5 Explain Zoom command.

15.6 Explain importance of saving a drawing.

15.7 Explain use of CAD (Autocad R-12 or latest).

15.8 Explain filling in the title block by writing drawing title name etc.

15.9 Explain procedure of plotting drawing on a plotter or printer.

15.10 Explain Qsave command.

16. UNDERSTAND DRAWING LINES AND CIRCLES

16.1 State beginning of a new drawing.

16.2 Explain Dedit command (autocad R-12 or latest)

16.3 Describe viewing the entire drawing.

16.4 Explain drawing of angled line.

16.5 Explain U-command.

16.6 Explain Redo command.

16.7 Explain drawing a circle with circle command.

16.8 Explain automatic work saving procedure.

42

MT-143 BASIC ENGINEERING DRAWING & CAD-I

LIST OF PRACTICALS 192 Hours

A. BASIC ENGINEERING DRAWING 1. Lettering 5 mm height

2. Lettering 3 mm height

3. Use Tee Square and Set Squares for drawing horizontal, vertical and inclined lines.

4. Use of Tee square and for drawing centres, crossing of lines.

5. Use compass, circles, half circles, radius.

6. Draw round corners, figure inside and outside circle.

7. Plane geometry angles and triangles.

8. Plane Geometry quadrilateral, square, rhombus, rentable and parallelogram

9. Plane Geometry parallel-lines, perpendicular, bisect line and angle.

10. Plane geometry equal division of line and some radio with the help of compass and set square.

11. Plane geometry inscribe and circumscribe square, triangle and hexagon.

12. Plane geometry of construct polygon, five, six, seven and eight sides.

13. Plane geometry inscribe pentagon in a circle and pentagon by general and different methods.

14. Plane geometry of tangent circle inside and outside.

15. Plane geometry of construction of ellipse with two methods.

16. Plane geometry of construction of ellipse with next two methods.

17. Plane geometry of construction of parabola curve 4 methods.

16. Plane geometry of construction of hyperbola curve.

17. Plane geometry of spiral curve.

18. Plane geometry of helix curve.

19. Plane geometry of Spiral curve.

20. Plane geometry of helix curve.

21. Plane geometry of construction of involute curve of square rectangle hexagon and circle.

22. Different types of drawing lines.

23. Orthographic projection 1 and 3rd angle L block.

24. Orthographic projection 1 and 3rd angle Step block.

25. Orthographic projection 1 and 3rd angle Vee block.

26. Orthographic projection 1 and 3rd angle Given Block.

27. Orthographic projection 1 and 3rd angle Additional block.

28. Orthographic projection and Isometric Drawing Given Block.

29. Orthographic projection and Isometric Drawing Given Block next.

30. Orthographic projection and Isometric Drawing Given Block next.

31. Different types of sectioning.

32. Different section lines for different material.

33. Orthographic projection of Vee block sectional views.

34. Orthographic projection Gland sectional views.

35. Orthographic projection Open bearing sectional views.

36. Concept for different types of Drawings.

37. Isometric and oblige drawings of cube with one hole.

38. Isometric and oblige drawings of another given block.

39. Missing lines and portions on given views.

40. Missing lines and portions on given views next.



43. Isometric scale and development of cube.

44. Development of prism.

45. Development of cylinder.

46. Development of Cone.

43

47. Development of Pyramid.

48. Thread profile of square and vee threads.

49. Different types of threads.

50. Sketch of hexagonal nut and bolt.

51. Rivet heads.

52. Single riveted lap joint.

53. Single riveted but joint.

B. COMPUTER AIDED DESIGN (Auto cad Rel-12 or latest)

1. Practice loading CAD software into computer memory.

2. Practice un loading CAD software safely and cone to Dos prompt.

3. Practice CAD abbreviations, auto CAD release 12 of latest (e.g. A for Arc, C for circle, E for

Erase etc).

4. Practice function keys for short cuts.

5. Practice to draw two points using Cartesian Notation on graph paper.

6. Practice to draw straight line using polar coordinates on graph paper.

7. Set-up drawing area using CAD software.

8. Practice for Turning GRID ON and Off and SNAP ON and OFF.

9. Draw a lien with line command.

10. Widen Border lines with pedit.

11. Save Border Template (QSAVE).

12. Create layers and move border to it’s own layer.

13. Create a layer for Title Block

14. Create Title Block

15. Practice for Zoom command

16. Practice for CAD Type faces (Auto CAD Rel-12 or latest).

17. Practice for filling Title Block

18. Practice for plotting the drawing on plotter b r printer

19. Begin a New drawing

20. Practice with Dedit command to make changes in the drawing

21. Draw an Angled line

22. Practice with U Command and Redo command

23. Draw a circle with circle command

44

MT-164 WORKSHOP PRACTICE-I

(PART-A) MACHINE SHOP AND SAFETY PRACTICES & PROCEDURES

Total contact hours: Theory: 32 hours T P C


Pre-requisite: None

I. MACHINE SHOP.

AIM:- 1. Know different basic machines like drill machine, grinder, lathe, and shaper

2. Understand methods of producing simple jobs on lathe and shaper.

II. SAFETY PRACTICES & PROCEDURES

AIM:- 1. Describe the importance of safety.

2. State safety rules.

3. Explain safety procedures in work shop.

4. Explain safety procedures in Industries.

5. Identify hazards in shop/industries.

6. State cost of accidents.

7. State the rules in maintaining cleanliness and order lines of working area.

I. MACHINE SHOP.

COURSE CONTENTS:

1. LATHE CONSTRUCTION 2 hours 1.1 Parts of lathe

1.2 Description of each part

1.3 Types of lathe

1.4 Description of each type

1.5 Size of lathe

1.6 Accessories, attachments, work holding devices with uses

2. LATHE CUTTING TOOLS 1 hours 2.1 Types of lathe cutting tools

2.2 Description of each and their angles

3. CUTTING SPEED, FEED, AND CUT 2 hours 3.1 Speed and feed

3.2 Method of speed and feed calculation

3.3 Relationship between speed and feed

3.4 Depth of cut

4. LATHE OPERATION AND DRILLING 4 hours 4.1 Methods of centering the job

4.2 Importance of centering job

4.3 Method of turning a job

45

4.4 Shoulder turning/ step turning

4.5 Taper Turning

4.6 Principle of taper turning

4.7 Formulae for taper turning angle

4.8 Methods of taper turning

4.9 Definition of knurling

4.10 Purpose of knurling

4.11 Knurling Methods

4.12 Definition of thread

4.13 Pitch and lead

4.14 Thread cutting calculation

4.15 Thread cutting calculation based on system

4.16 Thread cutting operation

4.17 Definition of facing

4.18 Facing operation

4.19 Method of drilling on lathe machine

4.20 Methods of boring, reaming and types of reamers

5. DRILL PRESS/DRILLING. 2 hours 5.1 Types of drill machines

5.2 Description of each type

5.3 Parts of a drill machine

5.4 Drilling operation

5.5 Parts of a drill

5.6 Explanation of each parts

6. TOOL GRINDER. 1 hour 6.1 Parts of grinder

6.2 Grinding operation

7. SHAPER WORK. 2 hours 7.1 Parts of a shaper

7.2 Forward/backward stroke of a shaper

7.3 Shaper stroke adjustment

7.4 Types of shaper tools

7.5 Explanation of each part

7.6 Adjustment of shaper speed and feed

7.7 Different clamping devices for job and tool

II. SAFETY PRACTICES & PROCEDURES.

COURSE CONTENTS:

1. INTRODUCTION AND IMPORTANCE OF SAFETY. 2 hours 1.1 Introduction

1.2 Importance institute shops

1.3 Importance in Industry

1.4 Accident cost

46

2. ACCIDENTS IN CHEMICAL INDUSTRY 1 hours 2.1 Accidents in petroleum industry

2.2 Accidents in paint shop/industry

2.3 Explosive vapors and gases

2.4 Accident in fertilizers and others chemical industry.

3. ACCIDENTS IN MECHANICAL INDUSTRY. 2 hours 3.1 Material handling and transportation.

3.2 Accidents due to hand tools.

3.3 Accidents in machines shop.

3.4 Accidents in Metal work shop.

3.5 Accidents in wood working shop.

3.6 Accident in Foundry, welding, and forging shop.

3.7 Preventive measures

4. ACCIDENTS IN FLOW PRODUCTION INDUSTRY. 2 hours 4.1 Accidents in Textile mills.

4.2 Accidents in paper mills.

4.3 Accidents in Food industry.

5. ACCIDENTS IN OTHER INDUSTRIES. 2 hours 5.1 Accidents in mines.

5.2 Accidents in leather industries.

5.3 Accidents in power plant.

5.4 Accidents in printing industry.

6. ENVIRONMENTAL EFFECT ON ACCIDENTS. 1 hours 6.1 Industrial ventilation.

6.2 Exhaust systems.

6.3 Industrial noise.

6.4 Illumination for safety and comfort.

6.5 Industrial hygiene and plant sanitation.

7. PERSONNEL PROTECTIVE EQUIPMENTS. 1 hours 7.1 For face and hand protection.

7.2 For body protection.

7.3 For chemical gases protection.

8. SAFETY ON PLANT. 1 hours 8.1 Plant lay out for safety.

8.2 House keeping for safety.

8.3 Lay out for safety.

9. FIRE ACCIDENTS. 2 hours 9.1 Fire hazard.

9.2 Causes.

9.3 Fire fighting equipments.

9.4 Plant lay out for fire safety.

47

10. ANALYZING CAUSES OF ACCIDENTS. 2 hours 10.1 Accident prevention fundamentals.

10.2 Plan inspections.

10.3 Safety inventory.

10.4 Accidents investigation.

10.5 Records and reports.

11. FIRST AID. 1 hours 11.1 Importance.

11.2 Procedure.

11.3 Extended medical services.

12. PROMOTING SAFETY. 1 hours 12.1 Employees training.

12.2 Displays.

12.3 Guidance.

13. SAFETY LAWS. 1 hours 13.1 Pakistan factory act (laws concerning to safety).

13.2 Workman compensation act.

13.3 Industrial insurance.

48


(PART-A) MACHINE SHOP AND SAFETY PRACTICES & PROCEDURES

INSTRUCTIONAL OBJECTIVES:


I. MACHINE SHOP

1. KNOW FUNCTION OF LATHE PARTS. 1.1 List the parts of lathe

1.2 Describe each part

1.3 List types of lathe

1.4 Describe each type

1.5 Describe size of lathe

1.6 Describe accessories, attachments, work holding devices with uses

2. UNDERSTAND LATHE CUTTING TOOLS. 2.1 List types of lathe cutting tools

2.2 Explain each type of lathe cutting tool and their angles

2.3 Describe cutting tools angles

3. KNOW CUTTING SPEED, FEED, AND CUT. 3.1 Define speed and feed

3.2 Describe method of speed and feed calculation

3.3 Describe relationship between speed and feed

3.4 Describe depth of cut

4. UNDERSTAND LATHE OPERATION AND DRILLING. 4.1 List methods of centering the job

4.2 Explain importance of centering job

4.3 Explain method of turning a job

4.4 Explain shoulder turning/ step turning

4.5 Explain taper turning

4.6 State principle of taper turning

4.7 The use of formulae for taper turning angle

4.8 Explain methods of taper turning

4.9 Define knurling

4.10 Describe purpose of knurling

4.11 Describe method knurling

4.12 Define thread

4.13 Describe pitch and lead

4.14 Calculate the pitch and TPI of threads

4.15 Explain thread cutting calculation based on system

4.16 Explain thread cutting operation

4.17 Define facing

4.18 Describe facing operation

4.19 Describe method of drilling on lathe machine

4.20 Describe methods of boring, reaming and types of reamers

5. UNDERSTAND DRILL MACHINES. 5.1 List types of drill machines

5.2 Describe each type

49

5.3 List parts of a drill machine

5.4 Explain drilling operation

5.5 List parts of a drill

5.6 Explain each part

6. UNDERSTAND TOOL GRINDER. 6.1 List parts of grinder

6.2 Explain grinding operation

7. UNDERSTAND SHAPER MACHINE. 7.1 List parts of a shaper

7.2 Explain forward/backward stroke of a shaper

7.3 Explain shaper stroke adjustment

7.4 List types of shaper tools

7.5 Explain each type

7.6 Explain adjustment of shaper speed and feed

7.7 List different clamping devices for job and tool

II. SAFETY PRACTICES & PROCEDURES.

1. KNOW IMPORTANCE OF SAFETY PRACTICES AND ITS NECESSITY IN THE

INDUSTRY. 1.1 Describe safety

1.2 Describe the importance of safety practices in Institute work shop and industry

1.3 Define accident cost

1.4 Describe the factors related to accident cost

2. KNOW CAUSES AND PREVENTIONS OF ACCIDENT IN CHEMICAL BASED

INDUSTRY. 2.1 Describe the type of accidents in petroleum fertilizer, paint and chemical based

industry

2.2 State the methods of prevention, for chemical based industry

2.3 Describe effects of chemical explosive, gases and vapors

2.4 List preventive measures for chemical explosive gases and vapors

3. KNOW CAUSES AND PREVENTION OF ACCIDENTS IN MECHANICAL

INDUSTRY 3.1 List the possible accidents in material handling and transportation

3.2 Describe the method of prevention of accident in Mechanical handling and

transportation

3.3 State the types of possible accident in Machine Shop, Metal Work, Wood Working

Shop,Foundry,Welding and Forging Shop

3.4 List methods of preventing accident in Mechanical industry

4. KNOW CAUSES AND METHODS OF PREVENTION OF ACCIDENT IN FLOW

PRODUCTION INDUSTRY. 4.1 State the types of accident in flow production industry

4.2 List the accident in textile mills, paper and board mills and food industry

4.3 Describe the methods of prevention of accidents in flow production industry

50

5. KNOW CAUSES AND METHOD OF PREVENTION OF ACCIDENT IN DIFFERENT

INDUSTRIES. 5.1 State the types of accidents in leather industry, printing works, mines and power plants

5.2 Describe the method of prevention of accidents in leather industry, printing works,

mines and power plants

6. UNDERSTAND THE ENVIRONMENTAL EFFECT ON ACCIDENTS. 6.1 State environmental effects on human beings and surroundings

6.2 Explain importance and purpose of industrial ventilation

6.3 Describe exhaust system in industry

6.4 Explain the effect of noise on accidents

6.5 Explain the effect of illumination on safety and comfort

6.6 Explain the plant hygiene for safety and comfort

6.7 Explain the effect of plant sanitation for prevention of accidents

7. KNOW THE PRINCIPLE METHOD AND IMPORTANCE OF PERSONAL

PROTECTIVE DEVICE. 7.1 Define protective devices

7.2 List personal protective devices

7.3 State Importance of personal protective devices

7.4 Describe protective devices for protecting hands and faces

7.5 Describe protective devices for protecting human body

7.6 Describe protective devices for protection from chemical gases

8. KNOW THE BASIC CONCEPT OF SAFETY ON PLANT. 8.1 State the safety aspect for plant layout

8.2 Describe the house keeping procedure for safety on a plant

9.3 State the procedure to lay out machines and equipment considering safety aspect

9. UNDERSTAND THE CAUSES AND PREVENTION OF FIRE ACCIDENTS. 9.1 Define fire hazard

9.2 List the causes of accidents due to fire

9.3 Describe fire fighting equipment

9.4 Explain the procedure effective for lay out of plant for the purpose of safety

10. UNDERSTAND THE PROCEDURE OF ANALYZING THE CAUSES OF

ACCIDENTS. 10.1 Identify the general causes of accident

10.2 Explain the step by step procedure to analys the accident

10.3 Record accident inventory.

10.4 Prepare accident reports

10.5 Describe plan inspections

10.6 Use the accident data for analyzing the causes of accidents

11. KNOW THE METHOD OF PROVIDING FIRST AID. 11.1 State the importance of safety

11.2 Explain the methods of providing first aid

11.3 Identify the step by step procedure of providing medical services

12. KNOW THE METHODS AND PROCEDURES FOR PROMOTING SAFETY. 12.1 List methods of promoting safety concepts

12.2 Describe method to promote safety concept by display

12.3 State the importance of guidance for safety promotion

13. UNDERSTAND LAWS REGARDING SAFETY. 13.1 Explain clauses of Pakistan factory act related to safety.

13.2 Explain workman compensation act.

13.3 Explain industrial Insurance

51


(PART-B) METAL SHOP, WELDING PRACTICE AND FOUNDRY



Pre-requisite: None

AIM:- 1. Explain the shop setting of Metal work, wood work, welding and foundry.

2. State shop rules and regulations of individual shops

3. Explain the use of tools involved in these shops.

4. Identify the main parts of each tool and machine of all these shops.

5. Exercise proper care and maintenance of each tool and machine of Metal work, welding

and Foundry.

6. Prepare jobs/projects in all the aforesaid shops.

COURSE CONTENTS.

1. METAL WORK TOOLS AND MACHINES. 14 hours 1.1 Hand Tools

1.2 Measuring tools

1.3 Layout tools.

1.4 Cutting tools

1.5 Chisels

1.6 Files

1.7 Hacksaw

1.8 Drill

1.9 Miscellaneous tools

1.10 Drilling Machine.

1.11 Power Hacksaw

1.12 Bending Machine

1.13 Rolling Machine

1.14 Shearing machine.

2. WELDING, HAND TOOLS AND MACHINES. 6 hours 2.1 Gas welding Tools.

2.2 Welding processes.

2.3 Welding tests and equipment

2.4 Welding materials and electrodes

3. HAND FORGING OPERATIONS. 6 hours 3.1 Drawing

3.2 Swaging

3.3 Up-setting

3.4 Punching

3.5 Cutting.

3.6 Forge welding

52

4. FOUNDRY SHOP TOOLS AND MACHINES 6 hours 4.1 Hand Moulding Tools.

4.2 Moulding boxes.

4.3 Pit furnace.

4.4 Core baking furnace.

4.5 Grinding and brushing machines.

BOOK RECOMMENDED:

Chapman Vol-I - Workshop Technology

53


(PART-B) METAL SHOP, WELDING PRACTICE AND FOUNDRY

INSTRUCTIONAL OBJECTIVES: On the completion of this course, the student will be able to

1. UNDERSTAND KINDS OF TOOLS AND MACHINES 1.1 Describe Hand Tools like:

a. Measuring tools

b. Layout tools.

c. Cutting tools

d. Chisels

e. Files

f. Hacksaw

g. Drill

i. Miscellaneous tools

1.2 Explain Drilling Machine.

1.3 Explain Power Hacksaw

1.4 Explain Bending Machine

1.5 Explain Rolling Machine

1.6 Explain Shearing machine.

2. UNDERSTAND WELDING SHOP TOOLS AND MACHINES. 2.1 Describe hand lay out tools

2.2 Describe Gas welding Tools.

2.3 Describe Welding processes Gas, Electric, TIG,MIG.

2.4 State welding principles

2.5 Explain Welding tests and equipment

2.6 State Welding materials and electrodes

3. UNDERSTAND FORGING OPERATIONS. 3.1 Explain Drawing, Swaging Upsetting, Punching Cutting and Forge Welding

3.2 Describe the forging tools

3.3 State Up-setting

3.4 Describe Punching

3.5 State Cutting.

3.6 Explain Forge welding

4. KNOW KINDS OF FOUNDRY SHOP TOOLS AND MACHINES. 4.1 Describe Hand Moulding Tools.,

4.2 Describe Moulding boxes, moulding sands and moulding methods.

4.3 Describe Pit furnace and types of cores.

4.4 Describe Core baking furnace.

4.5 Describe grinding and brushing machines.

54


LIST OF PRACTICALS

A) MACHINE SHOP

1. Practice of facing

2. Practice of plain turning

3. Practice of Drilling & Boring

4. Practice of Threading (External)

5. Practice of Taper Turning

B) METAL SHOP 1. Practice of hacksaw cutting

2. Practice of filing

3. Practice of drilling on flat piece

4. Practice of threading on flat piece

C) WELDING 1. Practice of making Butt Joint

2. Practice of making Lap Joint

3. Practice of making Tee Joint

D) FORGING 1. Practice of Drawing

2. Practice of Swaging

55

AD-113 AUTOMOTIVE ELECTRICS AND ELECTRONICS



Pre-requisite: Applied Physics

AIM:- The student will be able to:

1. Know the basic principles of electricity and electronics

2. Recognize the different electrical units of an automobile

3. Repair and maintain the electrical and electronics units fitted on an automobile

4. Service, repair and maintain all types of batteries

5. Trace and rectify faults in electrical system of an automobile

6. Understand wiring diagrams of various makes of automobiles

7. Understand electronics devices, transistors, rectifiers, amplifiers, S.C.R; S.C.O; sensors

and microprocessors.

COURSE CONTENTS:

1. BASIC PRINCIPLES OF ELECTRICITY AND ELECTRONICS 2 hours 1.1 Electron Theory

(i) Electrons, free electrons

(ii) Protons

(iii) Neutrons

1.2 Electricity

(i) Static Electricity

(ii) Current, Electricity A.C. and D.C

1.3 Ohm's Law

(i) Application in series and parallel circuits

(ii) Problem solving

(iii) Series and parallel circuits and application

(iv) E.M.F and V.D

(v) Electrical quantities, definition of voltage, current, resistance, capacitance and

inductance and their units

2. CONDUCTOR, INSULATOR, SEMI-CONDUCTORS ELECTROMAGNETISM

AND COLOR CODE 3 hours 2.1 Conductors, insulators and semi-conductors

2.2 Materials for semiconductors, their properties and doping

3. MEASURING INSTRUMENTS AND ELECTROMAGNETISM 3 hours 3.1 Working principle of voltmeter, ohm meter, ampere meter and multimeter

3.2 Electromagnetism and relays

4. STORAGE BATTERY 3 hours 4.1 Battery Construction

4.2 Cell, types of battery-alkaline, dry charge battery

4.3 Cell arrangement

4.4 Chemical activity

4.5 Plates:- positive, negative separator

4.6 Capacity of cell and battery

4.7 Battery rating

4.8 Effect of temperature on specific gravity

56

4.9 (a) Battery Testing

(b) Light load, high discharge test with cell discharge, cadmium test

4.10 Inspection and servicing of batteries

4.11 Preparation of electrolyte

4.12 Storage of batteries for long time

5. BATTERY TROUBLES 3 hours 5.1 Self discharge

5.2 Sulphation

5.3 Internal short circuiting

5.4 Deterioration of plates

5.5 Pluck off and cracking of containers

5.6 Corrosion of battery terminals and clamps

5.7 Loss of water

5.8 Cell, gravity variation

5.9 Discoloring of electrolyte

5.10 Method of battery charging

(a) Constant current

(b) Constant potential

(c) Quick charging

6. IGNITION SYSTEM 4 hours 6.1 Types of ignition systems

6.2 Function of ignition system

7. MAGNETO IGNITION SYSTEM 3 hours 7.1 Components, principle and working.

8. BATTERY IGNITION SYSTEM 2 hours 8.1 Components

8.2 Ignition coil construction

8.3 Contact breaker

8.4 Distributor construction

8.5 Condenser

8.6 Ballast resistor

8.7 Condenser function

8.8 Spark plug, dwell angle

8.9 Spark plug advance mechanism, centrifugal vacuum, trouble shooting

9. ELECTRONIC IGNITION SYSTEM 3 hours 9.1 Introduction, working, advantages

9.2 Types of electronic ignition system High Energy Ignition (HEI) Hall effect ignition,

method of spark control

9.3 Computer controlled Ignition

10. GENERATORS 3 hours 10.1 Working principle

10.2 Construction

11. ALTERNATOR 3 hours 11.1 Working principle, Construction, star and delta connections, comparison of both

11.2 Advantages over D.C generator

57

12. CUT OUT RELAY 3 hours 12.1 Working

12.2 Construction

13. REGULATOR 3 hours 13.1 Working voltage and current

13.2 Construction and circuit, trouble shooting of charging systems

14. STARTING MOTOR 3 hours 14.1 Working principle

14.2 Construction, cranking motor drive mechanism types

14.3 Bendix drive, Lucas drive

14.4 Solenoid switch and its working

15. HEAD, TAIL, PARKING AND OTHER LIGHTS 3hours 15.1 Head light circuit

15.2 Head light efficiency adjustment

15.3 Aiming of head light, fault finding

15.4 Flasher and indicators, tail, parking and other lights

15.5 Complete wiring diagram of a vehicle

15.6 Horn circuits

16.3 Service and fault finding

16. ELECTRIC WIND SHIELD WIPERS AND GAUGES 3 hours 16.1 Wind shield wiper

16.2 Wipers Circuit fault finding

16.3 Fuel, temperature and pressure gauges

17. RECTIFIERS 2 hours 17.1 Half wave rectifier using semiconductors.

17.2 Full wave rectifier using semiconductors.

17.3 Power supply filters.

18. TRANSISTORS. 2 hours 18.1 Transistors, NPN and PNP, their working principles.

18.2 Transistor oscillators and their applications.

19. THYRISTORS. 2 hours 19.1 S.C.R. working and application.

19.2 DIAC & TRIAC working and application.

20. C.R.O. 2 hours 20.1 Study of C.R.O and its controls with application in Auto.

20.2 Stroboscope and its use in engine testing.

58

21. GATES AND INTEGRATED CIRCUITS/SENSORS. 3 hours 21.1 Transistor switch, logic gates, AND, OR, NOT.

21.2 Application of gates.

21.3 Integrated circuits, units and their types, analogue, digital.

21.4 Major I.C. pin diagram used in Auto.

22. SENSORS. 2 hours 22.1 Definition of sensor and types.

22.2 Application of electronic principles to operate sensors by

following effects.

a. Heat.

b. Pressure, pneumatic, liquid and mechanical.

c. Magnetic.

d. Chemical.

e. Light.

f. Sound.

23. MICROPROCESSORS AND MICROCOMPUTERS. 4 hours 23.1 Electronic symbols used in Auto.

23.2 Definition of microprocessor.

23.3 Types of MPU used in Auto.

23.4 Interface/relation of sensor with microprocessor.

23.5 Soft ware used for microprocessor to process input data.

23.6 Relation of microprocessor to microcomputer in response to sensor to control the

vehicles and engine performance.

23.7 Signal responses, lamp, audio, digital on a monitor and graphically.

23.8 International symbols for graphical display on dashboard through computer for various

indications and responses.

23.9 Electronic Control Assemblies (ECA) and Electronic Control Modules (ECM)

centralized performance to other systems of an engine.

BOOK RECOMMENDED:

1. Frank C, Derato - Automotive Electrical and Electronic Systems.

59




1. UNDERSTAND THE PRINCIPLES OF ELECTRICITY AND ELECTRONICS. 1.1 Explain atom and electronic theory, neutrons, protons, electrons and current.

1.2 Explain Electricity, D.C and A.C; voltage, E.M.F & V.D and resistance

1.3 Enlist all electrical symbols used in vehicle electrical circuits.

1.4 Explain volt, ampere, ohm, Ohm's law, capacitance, inductance and color code

1.5 Solve problems on Ohm's law, parallel and series circuits

2. UNDERSTAND MAGNETISM, MAGNETIC DEVICES, CONDUCTORS,

NSULATOR, SEMICONDUCTORS AND THEIR MATERIALS. 2.1 Define magnetism and permanent magnet.

2.2 Define electromagnetism.

2.3 Define flux ductance permeability permeance and magnetiomotiace force

2.5 Define Ohm`s law for magnetism.

2.6 Explain doping

2.7 Explain conductors, insulators and semiconductors

2.8 Differentiate between P-type, N-type materials

3. UNDERSTAND THE WORKING AND USE OF MEASURING ELECTRICAL

INSTRUMENT. 3.1 Explain the working of moving coil type instruments.

3.2 Explain the moving iron magnet type instruments.

3.3 Identify the different types of electrical meter used i.e voltmeter, ampere-meter, Ohm.

3.4 Explain the use of different meters.

4. UNDERSTAND THE STORAGE BATTERY ITS WORKING AND TESTING. 4.1 Define cell, battery, alkaline battery, dry charge battery

4.2 Describe construction of lead acid battery.

4.3 Explain chemical activity of battery.

4.4 Explain capacity and battery rating.

4.5 Explain effect of temperature on electrolyte.

4.6 State testing procedure of battery.

4.7 Discuss the servicing procedure of lead acid battery.

4.8 Explain the procedure of preparation of electrolyte.

4.9 State the method of storage of batteries

5. UNDERSTAND THE TROUBLES RELATED TO THE BATTERY. 5.1 Define self discharging.

5.2 Define sulphation.

5.3 Explain the internal short circuit.

5.4 Identify the problem of battery related to.

a. Deterioration of plates.

b. Pluck off.

c. Cracking of container.

d. Corrosion of battery terminals and clamps.

5.5 Discuss the cases of loss of water, discoloring of electrolyte & specific

gravity variation.

5.6 Explain the charging system of battery.

5.7 Explain the methods of battery charging.

60

6. UNDERSTAND THE IGNITION SYSTEMS AND THE FAULT TRACING

PROCEDURE FOR IGNITION SYSTEMS. 6.1 Explain the function of ignition system.

6.2 Enlist the types of ignition systems.

6.3 State working of (Mech. distributor type of ignition system).

6.4 Explain the working principle and construction of ignition coil.

6.5 Describe the ignition Distribution.

6.6 Explain the Dwell angle.

6.7 Explain the advance mechanism and types.

6.8 Explain the working principle and construction of different types of spark plug.

6.9 Discuss the trouble shooting procedure for ignition system.

6.10 Discuss the service procedure for ignition systems.

7. UNDERSTAND MAGNETO IGNITION SYSTEM. 7.1 Enlist the components

7.2 State the principle of the system

7.3 Explain the working of the system

8. UNDERSTAND BATTERY IGNITION SYSTEM. 8.1 Enlist the ocmponents

8.2 Explai the construciton of the system

8.3 Describe contact breaker, condension

8.4 Explain the construction of distribution

8.5 Explain spart plug advance mechanism

9. UNDERSTAND THE ELECTRONIC IGNITION SYSTEM. 9.1 State the advantages of electronic ignition system.

9.2 Name the types of electronic ignition system.

9.3 Describe the working of each type of electronic ignition system.

9.4 Identify different components of electronic ignition system.

9.5 Explain High Energy Ignition (HEI).

9.6 Describe Hall effect ignition and sensor.

9.7 Explain method of spark control.

9.8 Explain ignition timing.

10. UNDERSTAND COMPUTER CONTROLLED AND DISTRIBUTOR LESS

IGNITION. 10.1 Define computer controlled ignition system.

10.2 Explain distributor less ignition system.

10.3 Explain the function of magnetic sensor in ignition system.

11. UNDERSTAND GENERATORS. 11.1 State the working principle of DC Generator

11.2 Explain the construction and working of Dc generator

12. UNDERSTAND CUT OUT RELAY. 12.1 State the working principle of cut out relay

12.2 Explain the construction of C.O. Relay

13. UNDERSTAND ALTERNATOR. 13.1 Explain the working of alternator.

13.2 Describe construction of alternator.

13.3 Explain the service procedure of alternator.

13.4 Discuss advantages over D.C generator.

14. UNDERSTAND THE CONTROL OF CHARGING SYSTEMS A.C. & D.C. 14.1 State the principle of current and voltage regulators

14.2 Explain the construction current and voltage regulator.

14.3 Draw charging circuits A.C. & D.C.

14.4 Explain the method of trouble shooting and rectification of faults in current and voltage

regulators

61

14.5 Discuss trouble shooting of charging system A.C & D.C

15. UNDERSTAND THE STARTING SYSTEM. 15.1 Describe the construction and working.

15.2 Explain the starting motor driving mechanism and types of starting motors.Bendix drive

Lucas drive.

15.3 Discuss the controlling switch for starting motors i.e solenoid switch and

other switch.

15.4 Draw the starting circuit.

15.5 Identify the faults of starting system.

16. UNDERSTAND THE FAULTS OF ELECTRICAL SYSTEM. 16.1 Draw head light circuits.

16.2 Explain the head lights efficiency and adjustment.

16.3 Explain aiming of head light.

16.4 Describe horn circuit.

16.5 Explain construction working and service of horn.

16.6 Explain the method of fault finding and adjustment of horns.

17 UNDERSTAND WORKING & CIRCUIT OF WIND SHIELD WIPERS. 17.1 Explain the working of wipers motor.

17.2 Identify the fault of wiper system.

17.3 Draw the circuit of wind-shield wipers

18. UNDERSTAND THE CIRCUIT OF DIFFERENT TYPES OF LIGHT SYSTEMS. 18.1 Draw directional signal circuit

18.2 Identify the faults of directional signal circuit.

18.3 Explain the head light, tail and brake light.

18.4 Identify the faults of room light.

18.5 Draw the electrical wiring diagram of a car/vehicle using symbol and color

codes.

19. UNDERSTAND THE CIRCUITS AND WORKING OF DIFFERENT GAUGES. 19.1 Describe the Fuel gauge.

19.2 Draw the circuit diagram of fuel gauge.

19.3 Describe the temperature gauge.

19.4 Draw the circuit of temperatures gauge.

19.5 Discuss oil pressure gauge.

19.6 Draw the circuit of oil pressure gauge.

19.7 Identify the different gauges used in a car/vehicle.

20. UNDERSTAND USE OF RECTIFIERS IN CHANGING A.C TO D.C IN

CHARGING SYSTEM. 20.1 Describe half ware rectifier.

20.2 Describe full ware rectifier.

20.3 Explain working of power supply and power filters.

21. UNDERSTAND TRANSISTORS AND THEIR APPLICATIONS. 21.1 Describe working of PNP and NPN transistors.

21.2 Describes transistor oscillators and their uses.

22. UNDERSTAND THYRISTORS AND THEIR APPLICATIONS. 22.1 Explain working and uses of S.C.R..

22.2 States working and applications of DIAC and TRIAC.

23. UNDERSTAND USE OF C.R.O IN ENGINE TESTING. 23.1 Explain C.R.O and controls with applications in Auto.

23.2 State the use of stroboscope and its working.

24. UNDERSTAND GATES, INTEGRATED CIRCUITS. 24.1 Explain transistor switch, logic gates like AND, OR, NOT.

24.2 States application of gates.

24.3 Differentiate transistor, printed circuits and integrated circuits.

62

24.4 Describes coomon integrated circuits, their types, analogue and digital.

24.5 Prepares I.C. pin diagrams used in Auto.

25. UNDERSTAND SENSORS AND THEIR APPLICATION IN AUTO. 25.1 Define a sensor and its importance in Auto.

25.2 Explain application of electronic principles to operate sensors by following

effects.

a. Heat.

b. Pressure, pneumatic, liquid and Mechanical.

c. Magnetic.

d. Chemical.

e. Light.

f. Sound.

25.3 Differentiate different sensors like

a. Voltage generating sensors.

b. Zirconium dioxide sensors.

c. Piezoelectric sensors.

d. Magnetic sensors.

25.4 Explain forms used in sensing and signal storing systems like;

a. Programmable Read Only Memory (PROM).

b. Keep alive memory.

c. Electronically Erasable PROMS.

d. Memory.

e. Input device.

f. Output device.

26. UNDERSTAND A MICROPROCESSORS AND MICROCOMPUTERS. 26.1 Enlist and illustrate electronic symbols used in Auto.

26.2 Define a microprocessor.

26.3 Explain types of MPU used in Auto.

26.4 Interrelates a sensor and microprocessors.

26.5 Explain software used for microprocessor to process input data.

26.6 Describes relation of microprocessor to microcomputer in response to

sensor to control the vehicle and engine performance.

26.7 Define single responses e.g lamp, audio, digital on a monitor and

graphically.

26.8 Illustrates international symbols for graphical display on dashboard monitor

through computer for various responses.

26.9 Explain Electronic Control Assemblies (ECA) and Electronic Control

Modules (ECM) their centralized performance to other systems of an engine

and vehicle systems.

26.10 Draw a figure to give inter-relation of ECM or ECA to other sensing units of

engine/vehicle.

63


LIST OF PRACTICALS.

1. Identify the electrical units of a vehicle

2. Identify the location of different electrical units

3. Measure voltage of a battery

4. Measure current of a circuit

5. Verify Ohm's law

6. Make series and parallel circuits on bench board

7. Disassemble old unserviceable battery

8. Identify the battery parts

9. Prepare electrolyte and check specific gravity

10. Use the battery charging equipment

11. Identify the methods of battery testing

12. Service a battery

13. Identify trouble in a the problems of battery

14. Identify the units of ignition system and race the circuit

15. Identify the problems in ignition system

16. Identify the units of electronic ignition system

17. Identify the units of charging system of vehicle and trace its circuit

18. Identify the problems of charging system

19. Identify the units of starting circuit and trace its circuit

20. Identify the problems in starting system

21. Disassemble and assemble generator D.C

22. Disassemble and assemble Alternator A.C

23. Trace wiring circuit of a car

24. Adjust the head light (aiming of head lights)

25. Identify the different sensors used in vehicle

26. Make the different vehicle circuits on a board

27. Prepare full wave rectifier

28. Construct D.C supply circuit

29. Construct an amplifier circuit

64

OHSE-101 OCCUPATIONAL HEALTH, SAFETY AND ENVIRONMENT

Total contact hours T P C

Theory 32 Hours. 1 0 1

Practical 0 Hours

Prerequisite - None

Course Objectives

At the end of the course the students are expected to be able to:-

* Understand the issue affecting occupational health and safety.

* Apply concepts of environmental protection.

* Practice safety measure in laboratory and workplaces.

* Integrate health and safety consciousness in daily life.

Course Contents

1. Promoting Health and Safety 3 Hours

1.1 The Occupational Health and Safety (OH&S) program.

1.2 The costs of occupational injuries.

1.3 The essential components of a health and safety policy.

1.4 Recommended guidelines regarding rules and regulations on OH&S.

1.5 The benefits of rules and regulations on OH&S.

1.6 The value of a safety committee in promoting health and safety and

how it can be involved.

1.7 The importance of health and safety training.

1.8 Justification of suggestion regarding OH&S programs.

1.9 Main components of a suggestion program.

1.10 The aim of a visual awareness program.

1.11 Precautions to be taken with regard to signs and posters on OH&S.

1.12 Typical characteristics of an incentive program.

1.13 Precautions to be taken with regard to incentive programs.

1.14 The basic concepts to risk management.

1.15 Hazards that might cause harm to those working in an area.

2. Safety Hazards 4 Hours

2.1 Mechanical Hazards and Safeguarding

2.2 Falling, Impact Acceleration, ands Lifting Hazards.

2.3 Electrical Hazards

2.4 Confined Spaces

3. Fire Hazards 2 Hours

3.1 Sources of fire hazards.

3.2 The three elements to start and sustain fire.

3.3 The fire triangle.

3.4 Different classes of fire.

3.5 Common hazardous products of combustion.

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3.6 Methods of reducing fire hazards

3.7 Use of fire extinguisher.

3.8 Emergency procedures and means of escape.

3.9 Components of a fire extinguisher system

4. Chemical Hazards 4 Hours

4.1 Occupations diseases and illnesses

4.2 Agents which can cause disease and illness

4.3 Chemical, physical, biological and ergonomic stressors

4.4 Three routes of entry of chemicals into the body

4.5 Locations in the body of the effects of inhaled substances.

4.6 Absorption and excretion from the gastrointestinal (G) system.

4.7 Penetration of substances through the skin

4.8 Substance that can harm various target organs and systems.

4.9 Chemicals as acids/bases, oxidizing/reducing, inorganic/organic, metals/non

metals, aliphatic/aromatic, hydrocarbons/substituted hydrocarbons.

4.10 Acute and chronic effects.

4.11 Toxic and hazardous substances

4.12 Simple and chemical asphyxiation

4.13 Anesthetics and narcotics.

4.14 Local and systemic effects of poisons

4.15 Reproductive toxin

4.16 Chemical carcinogen

4.17 Concepts of exposure, does and thresholds dose

4.18 Exposure limit

4.19 Three different Threshold Limit Values (TLVs)

4.20 Medical monitoring of exposure be chemical hazard

5. Physicals Hazards 4 Hours

5.1 Noise

5.2 Vibration

5.3 Heart Stress

5.4 Radiation

5.5 Lasers

5.6 Lighting

6. Biological Hazards 2 Hours

6.1 Nature of a biological agent

6.2 Transmission of infectious agents

6.3 Diseases caused by bacteria, viruses, fungi, parasites, and plants.

6.4 Risk from exposure to each type of biological agent.

6.5 Ways to reduce the hazards due to biological agents at source.

6.6 Ways to reduce biological hazards along the path.

7. Ergonomics 2 Hours

7.1 Define the term Ergonomics

7.2 Musculoskeletal injuries (MSIs)

7.3 Alternative names for musculoskeletal injuries.

7.4 Three demands of the job itself that can cause MSIs

7.5 Significance of body posture while doing the job.

66

7.6 Force required to do the job.

7.7 Hazard associated with the repetitive nature of the work.

7.8 Five components of the workplace that can contribute to MSIs

7.9 Significance of the design and flexibility of a workstation.

7.10 The design of equipment and tools.

7.11 Aspects of manual materials handing required to do the job.

7.12 The significance of environmental factors in the workplace

7.13 The organization of work as a factor leading to MSIs.

7.14 Factors that should be considered for good workstations.

7.15 Ways of improving the working environment.

8. Exposure Controls 2 Hours

8.1 Strategies to control exposure at the source of the hazard.

8.2 The meaning of “engineering” controls.

8.3 The meaning of “administrative” controls, and controls using “work

practices”.

8.4 Controls “at the worker”.

8.5 Examples of engineering controls.

8.6 Examples of controls using administrative and work practices.

8.7 Control procedures at the worker himself.

9. Personal Protective Equipment 2 Hours

9.1 Head protectors

9.2 Types pf protection for the feet.

9.3 Protection for hands and arms

9.4 Protection of the eyes and face in various applications

9.5 Types of hearing protection

9.6 How to put on a hearing protector?

9.7 Limitations and applications of hearing protectors.

9.8 Outline the requirements for respiratory protection.

9.9 Air purifying and air supplying respirators.

9.10 Applications of both types of respirators.

9.11 Self Contained Breathing Apparatus (SCBA)

9.12 Applications of SCBA

9.13 Open circuit and closed circuit SCBA

9.14 Demand mode and pressure-demand mode of operation of SCBA.

9.15 Limitations of different types of respirators.

9.16 Appreciate the Importance of a good fit of a face-piece.

9.17 Appreciate the importance of through of a respirator.

9.18 How to put on a respirator?

9.19 Positive and negative pressure tests of a respirator.

10. Ventilation Basics 2 Hours

10.1 Technique of dilution ventilation

10.2 The limitations of dilution ventilation of chemical contaminants.

10.3 Limited applications of dilution ventilation.

10.4. Dilution ventilation may be used to control flammable/combustible vapours

below their lower.

10.5 Flammable limits as well as for control of toxic levels.

10.6 The meaning of “air changes per hour”.

10.7 Good and bad fan locations.

10.8 The technique of local exhaust ventilation.

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10.9 The necessary components of a local exhaust ventilation system.

10.10 Enclosing receiving, and capture hoods.

10.11 The benefits of flanging a hood.

11. Accident Prevention 4 Hours

11.1 The essential features of a site survey for OH&S.

11.2 Basic floor plan of a work area.

11.3 Survey table identifying hazards in a work area.

11.4 Show activities with potential hazards on the floor plan.

11.5 Complete part of a survey table evaluating the hazards.

11.6 Assess the adequacy of existing controls and show on a floor plan.

11.7 Complete the remainder of the survey table relating to control actions.

11.8 Use the survey table to carry out an OH&S survey in a selected workplace.

11.9 Rate hazards in a workplace following an accepted rating system.

11.10 Activities in the preparation stage of a workplace inspection.

11.11 Activities in the inspection stage of a workplace inspection.

11.12 Activities in the review and reporting stage of a workplace inspection.

11.13 The follow-up to a workplace inspection.

11.14 Checklist to carry out an inspection of a selected workplace.

11.15 Stages of an accident investigation and analysis.

11.16 Steps involved in finding causes of an accident.

11.17 Applications of permit systems.

11.18 Follow a checklist for completing permit to work.

11.19 The importance of good housekeeping in a workplace.

11.20 Factors contributing to good housekeeping.

11.21 The essential sections of a Material Safety Data Sheet.

11.22 Safe handling and storage of chemicals.

12. First Aid 01 Hour

12.1 ABCs of First Aid.

12.2 First Aid Training Program.

12.3 Contents of a Typical First Aid kit.

12.4 MSDS

Total Hours: 32

References

* Chemical Hazards of the Workplace, 4Ed, Proctor and Huges, Hathaway, Proctor,

Huges (Van Nostran Reinhold).

* Sax’s Dangerous Properties of Industrial Materials, 9Ed, Lewis (Van Nostrand

Reinhold).

* The occupational Environment-Its Evaluation and control, Editor Dinardi (AIHA Press).

* Basic Industrial Hygiene-A Training Manual, Brief (AIHA).

* Encyclopedia of Occupational Health and Safety, 4Ed, (ILO).

* Handbook of Industrial Solvents, Latest Edition, (Alliance of American Insurers).

* Fundamentals of Occupational Safety and Health, Kohn, Friend, Winterberger.

68

OHSE-101 OCCUPATIONAL HEALTH, SAFETY AND ENVIRONMENT


1. Promoting Health and Safety

1.1 Out line the reasons for an Occupational Health and Safety (OH&S) program.

1.2 Outline the costs of occupational injuries.

1.3 Illustrate the essential components of a health and safety policy.

1.4 Describe recommended guidelines regarding rules and regulations on OH&S.

1.5 Realize the benefits of rules and regulations on OH&S.

1.6 Understand why workers must be involved in all aspects, such as development,

implementation.

1.7 Assessment of a health and safety program.

1.8 Appreciate the value of a safety committee in promoting health and safety and how

it can be involved.

1.9 Explain the importance of health and safety training.

1.10 Justify suggestion programs regarding OH&S.

1.11 List main components of a suggestion program.

1.12 Describe the aim of a visual awareness program.

1.13 Describe precautions to be taken with regard to signs and posters on OH&S.

1.14 State typical characteristics of an incentive program.

1.15 Explain two precautions to be taken with regard to incentive programs.

1.16 Describe the basic concepts to risk management.

1.17 Identify hazards that might cause harm to those working in an area.

1.18 Identify those who might be harmed.

1.19 Decide whether risks are adequately controlled.

1.20 Suggest whether further action is necessary to control the risk.

1.21 Cary out a risk assessment of a hazard in a selected work area.

2. Safety Hazards

2.1 Mechanical Hazards and Safeguarding.

2.2 Identify mechanical hazards of power-driven tools and machines.

2.3 Describe different types of injuries that can be caused by these tools and machines.

2.4 State the requirements for safeguards.

2.5 Describe types of machine safeguards.

2.6 Explain what a lock out/tag out system is.

2.7 Discuss general precautions that should be taken.

2.8 Discuss training in proper use of tools and machines.

2.9 Discuss emergency procedures.

2.10 Explain why loose clothing and jewelry must not be worn around machinery.

2.11 Outline the necessity for machinery and safeguard maintenance of falling, impact

acceleration, and lifting hazards.

2.12 List causes of falls and categories them.

2.13 Describe walking and sliping accidents.

2.14 Outline key elements of slip and fall prevention programs.

2.15 Discuss recommended procedures for ladder safety.

2.16 Describe impact and acceleration hazards.

2.17 Discuss briefly protection of head, eyes and face, and feet.

2.18 Identify lifting hazards and their relation to back injuries.

69

2.19 Demonstrate recommended lifting procedures.

2.20 Discuss materials handling, both manual and mechanical.

2.21 Discuss office safety with regard to filing cabinets, office equipment, floors, stairs,

office.

3. Electrical Hazards

3.1 Explain basic electrical terminology and concepts.

3.2 Describe electrical hazard from bare wires carrying current.

3.3 Describe as an electrical hazard, working with unsafe electrical equipment.

3.4 Describe the danger of working with electrical equipment in the presence of

moisture.

3.5 Discuss dangers of working on live electrical equipment.

3.6 Describe hazards associated with arcs and sparks.

3.7 Discuss hazards of static electricity and lightning.

3.8 Describe the effects of electricity on humans.

3.9 Describe some methods of reducing electrical hazards.

3.10 Outline steps to be taken to assist a victim of electric shock.

4. Confined Spaces

4.1 List the characteristics of a confined space.

4.2 Distinguish the hazards involved in entering and working in a confined space due to

oxygen deficiency, flammable and/or toxic atmospheres.

4.3 Describe the testing of atmospheres in a confined space if equipment is available,

demonstrate testing in a confined space.

4.4 Explain why confined spaces need to be ventilated.

4.5 Describe how confined spaces can be isolated.

4.6 State the justification for requiring respirators to be worn in some confined spaces.

4.7 List the duties of standby person.

4.8 Discuss general/physical hazards in a confined space, such as temperature extremes,

engulfment hazards, noise and vibration, slippery surfaces, and lighting.

5. Fire Hazards

5.1 List sources of fire hazards and their properties with particular attention to solid

fuels, flammable/combustible liquids and gases.

5.2 List the three elements to start and sustain fire.

5.3 Draw the fire triangle.

5.4 Explain the different classes of fire.

5.5 State common hazardous products of combustion.

5.6 Describe methods of reducing fire hazards; no open flames near fuels, no smoking,

no electrical sparks, antistatic tools, proper storage of gas cylinders, proper storage of

flammable liquids, bonding and grounding during liquid transfer, fire extinguisher

and classes and preventing office fires.

5.7 Describe emergency procedures and means of escape; type of emergency, procedures

to be followed, coordination of activities, assignments and responsibilities during

emergency and scheduled drills.

5.8 Outline the components of a fire extinguishing system that uses smoke detectors, fire

detectors, etc. and carbon dioxide, dry chemicals, etc.

6. Chemical Hazards

6.1 Give examples of a variety of occupational diseases and illnesses.

6.2 Define, with some of their properties, agents which can cause disease and illness.

6.3 Distinguish between chemical, physical, biological, and ergonomic stressors.

70

6.4 Explain the three routes of entry of chemicals into the body.

6.5 Describe possible locations in the body of the effects of inhaled substances.

6.6 Explain absorption and excretion from the gastrointestinal (G) system.

6.7 Discuss penetration of substances through the skin.

6.8 Give examples of substances that can harm various target organs and system.

6.9 Classify chemicals as acids/bases, oxidizing/reducing, inorganic/organic, metals/

non-metals, apliphatic/aromatic, hydrocarbons/substituted hydrocarbons.

6.10 Give examples of each class of chemicals.

6.11 Distinguish between acute and chronic effects.

6.12 Distinguish between toxic and hazardous substances.

6.13 Distinguish between simple and chemical asphyxiation.

6.14 Distinguish between anesthetics and narcotics.

6.15 Distinguish between local and systemic effects of poisons.

6.16 explain what a reproductive toxin is.

6.17 Give examples of reproductive toxins.

6.18 Explain what a chemical carcinogen is.

6.19 Give examples of chemical carcinogens.

6.20 explain the concepts of exposure dose and threshold dose.

6.21 Explain permissible exposure limit.

6.22 Define the three different Threshold Limit Values (TLVs).

6.23 Briefly outline medical monitoring of exposure to chemical hazards.

7. Physical Hazards

7.1 Noise

7.1.1 List the auditory and extra-auditory effects of exposure to loud noise.

7.1.2 State the limits of frequencies of sound that we can hear.

7.1.3 Explain sound pressure level in dB.

7.1.4 Apply the 6 dB decrease with doubling of distance rule.

7.1.5 Determine the Total Hour sound pressure level of the noise sources running

simultaneously.

7.1.6 Describe the response of the ear to different frequencies.

7.1.7 Explain weighting networks.

7.1.8 Distinguish sound level, dB, from sound pressure level, dB.

7.1.9 Relate sound levels to loudness and hearing damage.

7.1.10 Describe typical methods of controlling exposure to noise at source, along the

path, and at the receiver.

7.1.11 Briefly outline noise control by anti-noise generation.

7.1.12 Discuss the essential elements of a hearing conservation program vibration.

7.1.13 Describe the effects of whole body vibration.

7.1.14 Distinguish hand/arm vibration effects from whole body effects.

7.1.15 Explain typical methods of control of vibrations at source, along the path and

at the receiver.

7.2 Heat Stress

7.2.1 Explain thermo-regulation of body temperature by convection, conduction

radiation, metabolic heat.

7.2.2 Production and evaporation of sweat.

7.2.3 Describe illnesses that can be causes by neat stress.

7.2.4 Discuss control of heat exposure through humidity control and air

conditioning.

7.2.5 Discuss the importance of providing potable drinking water and

acclimatization to working in hot conditions.

71

7.2.6 Understand the significance of seeking shade, erecting barriers, and building

enclosures to protect against heat.

7.2.7 Understand by work/rest regimes and changing hours of working are used in

some hot jobs to reduce heat stress.

7.2.8 Recognize the importance of wearing insulated and reflective clothing, and

protective eyewear against heat stress.

7.3 Radiation

7.3.1 Contrast ionizing radiation with non-ionizing radiation.

7.3.2 Distinguish between different types of ionizing radiation.

7.3.3 Explain half-life of a radioisotope.

7.3.4 Describe the effects of ionizing radiation on humans.

7.3.5 Outline control of radiation from external sources by distance, time and

shielding.

7.3.6 Outline control of radiation by using enclosures and interlocks.

7.3.7 Outline control of internal sources by containment and cleanliness.

7.3.8 Distinguish between non-ionizing radiation UV, IR, microwaves, RF, and

visible.

7.3.9 List recognized regions of the UV spectrum.

7.3.10 Give some sources of UV radiation.

7.3.11 Outline the effects on humans of exposure to UV.

7.3.12 Illustrate typical control methods for UV including clothing, distance,

barriers, sunscreens and sunblocks, and eyewear.

7.3.13 List recognize regions of the IR spectrum.

7.3.14 State some sources of IR radiation.

7.3.15 Outline the effects on humans of exposure to IR radiation.

7.3.16 Illustrate typical control methods for IR including clothing, distance, barriers,

and eyewear.

7.3.17 State the frequency ranges for microwave and radio frequency radiation.

7.3.18 Give some typical sauces of these radiation.

7.3.19 Outline the effects on humans of exposure to these radiation.

7.3.20 Illustrate typical control methods for microwaves and RF including distance,

shielding, enclosures and interlocks.

7.4 Lasers

7.4.1 Explain the meaning of the acronym “laser”.

7.4.2 Distinguish coherent light from non-coherent light.

7.4.3 List some different types of lasers and their applications.

7.4.4 Describe typical effects of lasers on humans, esp, eyes and skin.

7.4.5 Distinguish the four classes of lasers and their effects.

7.4.6 Outline exposure control for lasers through eyewear, barriers, enclosures and

interlocks.

7.5 Lighting

7.5.1 Summarize the benefits of good lighting.

7.5.2 Relate the frequencies of visible light to colours.

7.5.3 Describe the three aspects of the lighting triangle.

7.5.4 Discuss briefly the interaction between light source, task and observer.

7.5.5 Outline properties of each of the three aspects.

7.5.6 Define illuminance, luminance, and reflectance.

7.5.7 State the units of illuminance, luminance, and reflectance.

7.5.8 Select typical recommended levels of illuminance for various jobs from

tables.

7.5.9 List six common problems of lighting and their effects.

72

8. Biological Hazards

8.1 Define the nature of biological agent.

8.2 Describe tow routes of transmission of infectious agents.

8.3 Give examples of diseases caused by bacteria, viruses, fungi, parasites, and plants.

8.4 Give examples of workers at risk from exposure to each type of biological agent.

8.5 Outline ways to reduce the hazards due to biological agents at source.

8.6 Describe ways to reduce biological hazards along the path.

8.7 Discuss ways to reduce hazards from biological agents at the worker.

9. Ergonomics

9.1 Define the term Ergonomics.

9.2 Describe musculoskeletal injuries (MSIs) to various part of the body.

9.3 State alternative names for musculoskeletal injuries.

9.4 Recognize three demands of the job itself that can cause MSIs.

9.5 Discuss the significance of body posture while doing the job.

9.6 Discuss the force required to do the job.

9.7 Describe the hazard associated with the repetitive nature of the work.

9.8 Recognize five components of the workplace that can contribute to MSIs.

9.9 Explain the significance of the design and flexibility of a workstation.

9.10 Discuss the design of equipment and tools.

9.11 Discuss aspects of manual materials handling required to do the job.

9.12. Explain the significance of environmental factors in the workplace.

9.13 Describe how the organization of work can be a factor leading to MSIs.

9.14 Summarize factors that should be considered for good workstations, and apply

them to a VDU workstation.

10. Exposure Controls

10.1 Outline strategies to control exposure at the source of the hazard, along the

path from the hazard to the worker affected, and at the worker himself/herself.

10.2 Explain in the meaning of “engineering” controls.

10.3 Explain the meaning of “administrative” controls and controls using “ work

practices”

10.4 Explain controls “at the worker”

10.5 Describe and give examples of engineering controls.

10.6 Describe and give examples of controls using administrative and work practices.

10.7 Describe with examples control procedures at the worker himself/herself.

11. Personal Protective Equipment

11.1 Describe head protectors

11.2 Describe various types of protection for the feet

11.3 Describe protection for hands and arms

11.4 Describe protection of the eyes and dace in various applications]

11.5 Describe different types of hearing protection

11.6 Demonstrate how to put on a hearing protector

11.7 Discuss limitations and applications of hearing protectors.

11.8 Outline the requirements for respiratory protection

11.9 Distinguish between air purifying and air supplying respirators

11.10. Discuss applications of both types

11.11. Describe Self Contained Breathing Apparatus (SCBA)

11.12. Discuss applications of SCBA

73

11.13 Distinguish between open circuit and closed circuit SCBA

11.14 Distinguish between demand mode and pressure –demand mode of operation of

SCBA.

11.15 Discuss limitations of different types of respirators.

11.16 Appreciate the importance of a good fit of a face-piece.

11.17 Appreciate the importance of through of a respirator.

11.18 Demonstrate how to put on a respirator.

11.19 Demonstrate positive and negative pressure tests of a respirator.

12. Ventilation Basics

12.1 Describe the technique of dilution ventilation.

12.2 State the limitations of dilution ventilation of chemical contaminants.

12.3 Recognize that dilution ventilation has limited applications.

12.4 Understand that dilution ventilation may be used to control flammable/combustible

vapours below their lower flammable limits as well as for control of toxic levels.

12.5 Understand the meaning of “air changes per hour”.

12.6 Recognize good and bad fan locations.

12.7 Describe the technique of local exhaust ventilation.

12.8 Draw the necessary components of local exhaust ventilation system.

12.9 Describe, with examples, enclosing, receiving, and capture hoods.

12.10 State the benefits of flanging a hood.

12.11 Define the following terms; capture velocity, face velocity, slot velocity, plenum

velocity, and minimum duct velocity.

12.12 State the equation relating airflow, velocity, and area and use it is calculations.

12.13 Draw well-designed ductwork including branches.

12.14 Know the difference between an axial flow fan and a centrifugal fan.

12.15 Know that centrifugal fans are usually used in local exhaust ventilation systems.

13. Accident Prevention

13.1 Describe the essential features of a site survey for OH&S.

13.2 Prepare a basic floor plan of a work area.

13.3 Complete part of a survey table identifying hazards in a work area.

13.4 Show activities with potential hazards on the floor plan.

13.5 Complete part of a survey table evaluating the hazards.

13.6 Assess the adequacy of existing controls and show on a floor plan.

13.7 Complete the remainder of the survey table relating to control actions.

13.8 Use the survey table to carry out an OH&S survey in a selected workplace.

13.9 Rate hazards in a workplace following an accepted rating system.

13.10 Describe activities in the preparation stage of a workplace inspection.

13.11 Describe activities in the inspection stage of a workplace inspection.

13.12 Describe activities in the review and reporting stage of a workplace inspection.

13.13 Describe the follow-up to a workplace inspection.

13.14 Use a checklist to carry out an inspection of a selected workplace.

13.15 Outline stages of an accident investigation and analysis.

13.16 Discuss steps involved in finding causes of an accident.

13.17 Outline applications of permit systems.

13.18 Follow a checklist for completing a permit to work.

13.19 Explain the importance of good house-keeping in a workplace.

13.20 List factors contributing to good house-keeping.

13.21 Outline the essential sections of a Material Safety Data Sheet.

13.22 Discuss safe handling and storage of chemicals

74

14. First Aid

14.1 State the ABCs of First Aid.

14.2 List the essential activities of a basic First Aid training program.

14.2.1 Apply CPR.

14.2.2 Stopping bleeding.

14.2.3 Handling broken bones.

14.2.4 Treating burns.

14.2.5 Stopping choking.

14.2.6 Managing electric shock.

14.2.7 Handling an unconscious victim.

14.2.8 Treating eye injuries.

14.3 List the contents of a typical First Aid Kit.

14.4 Recognize an MSDS as a source of information about First Aid.

82

Ch-213 APPLIED CHEMISTRY

Total Contact Hours T P C Theory 64 Hours 2 3 3

Practical 96 Hours

AIM:- After studying this course a student will be able to:

1. Understand significance and role of chemistry in the development of modern

technology.

2. Become acquainted with the basic principles of chemistry as applied in the study of

relevant technology.

3. Know scientific methods for production, properties and use of materials of industrial &

technological significance.

4. Gain skill for the efficient conduct of practical in a chemistry lab.

1. INTRODUCTION. 4 Hours 1.1 Scope and significance of the subject.

1.2 Orientation with reference to this technology.

1.3 Terms used & units of measurements in the study of chemistry.

2. FUNDAMENTAL CONCEPTS OF CHEMISTRY. 4 Hours 2.1 Symbols, Valency, Radicals, formulas.

2.2 Chemical Reactions & their types.

2.3 Balancing of equations by ionic method.

3. ATOMIC STRUCTURE. 4 Hours 3.1 Sub-atomic particles.

3.2 Architecture of atoms of elements, Atomic No. and Atomic weight.

3.3 Periodic classification of elements, periodic law.

4. CHEMICAL BOND. 4 Hours 4.1 Nature of Chemical Bond.

4.2 Electrovalent bond with examples.

4.3 Covalent Bond (Polar and Non-polar) sigma & Pi Bonds. with examples.

4.4 Co-ordinate Bond with examples.

5. GASES AND LIQUIDS. 4 Hours 5.1 The liquid and gaseous state.

5.2 The Liquids and their general properties (Density, viscosity, surface tension,

capillary action etc).

5.3 Gases and their general properties.

5.4 Gas laws (Boyle's law, Charle's law & Graham's law of diffusion).

5.5 Problems involving gas laws.

6. WATER. 4 Hours 6.1 Chemical nature and properties.

6.2 Impurities.

6.3 Hardness of water (types, causes & removal)

6.4 Scales of measuring hardness (Degrees Clark, French, PPM, Mg-per liter).

6.5 Boiler feed water, scales and treatment.

83

7. ACIDS, BASES AND SALTS. 4 Hours 7.1 Definitions with examples.

7.2 Properties, their strength, Basicity & Acidity.

7.3 Salts and their classification with examples.

7.4 pH- Valve & Scale.

8. OXIDATION & REDUCTION. 4 Hours 8.1 The process, definition & scope with examples.

8.2 Oxidizing and Reducing agents.

8.3 Oxides and their classification.

9. NUCLEAR CHEMISTRY. 4 Hours 9.1 Introduction.

9.2 Radioactivity (alpha, beta & gamma rays).

9.3 Half life process.

9.4 Nuclear reaction & transformation of elements.

9.5 Isotopes and their uses.

10. ALLOYS. 4 Hours 10.1 Introduction with need.

10.2 Preparation and properties.

10.3 Some important alloys and their composition.

10.4 Uses.

11. FUELS. 4 Hours 11.1 Introduction with their significance.

11.2 Solid fuels.

11.3 Liquid Fuels.

11.4 Gaseous Fuels.

12. CORROSION. 4 Hours 12.1 Introduction, causes and types.

12.2 Rusting of iron.

12.3 Corrosion control.

13. METALLURGY. 4 Hours 13.1 General processes/operation of metallurgy.

13.2 Chemistry of Iron, copper and Aluminum with their Ores.

13.3 Ores, extraction and metallurgy of iron.

13.4 Cast iron, Wrought iron and steel.

14. THERMO-CHEMISTRY. 4 Hours 14.1 Introduction with its significance in modern technology.

14.2 Thermo-chemical units and reactions.

14.3 Heat of reaction and heat of combustion.

14.4 Hess's Law.

14.5 The process of combustion.

14.6 Calorific value.

14.7 Numerical problems pertaining to combustion.

84

15. LUBRICANTS. 4 Hours 15.1 Introduction.

15.2 Classification.

15.3 Properties of lubricants.

15.4 Selection of lubricants.

16. POLLUTION. 4 Hours 16.1 The problem and its dangers

16.2 Causes of pollution.

16.3 Air pollution and its control.

BOOKS RECOMMENDED

1. Text Book of Intermediate Chemistry (I&II)

2. Ilmi Applied science by Sh. Ata Mohammad.

3. Applied chemistry for engineers by Eric S. Gyngell.

4. Engineering Chemistry by M.A. Usmani.

85

Ch-213 APPLIED CHEMISTRY.


1. UNDERSTAND THE SCOPE, SIGNIFICANCE AND ROLE OF THE SUBJECT. 1.1 Define chemistry and its terms.

1.2 Define the units of measurements in the study of chemistry.

1.3 Explain the importance of chemistry in various fields of specialization.

1.4 Explain the role of chemistry in the concerned technology.

2. UNDERSTAND LANGUAGE OF CHEMISTRY AND CHEMICAL REACTIONS. 2.1 Define symbol, valency, radical, formula with examples of each.

2.2 Write chemical formula of common compounds.

2.3 Define chemical reaction and equation.

2.4 Describe types of chemical reactions with examples.

2.5 Explain the ionic method of balancing the equation.

3. UNDERSTAND THE STRUCTURE OF ATOMS. 3.1 Define atom.

3.2 Describe the fundamental sub atomic particles

3.3 Distinguish between atomic no. and mass no; and between isotopes and isobars.

3.4 Explain the arrangements of electrons in different shells and sub energy levels.

3.5 Explain the grouping and placing of elements in the periodic table.

3.6 State the periodic law of elements.

4. UNDERSTAND THE NATURE OF CHEMICAL BONDS. 4.1 Define chemical bond.

4.2 Describe the nature of chemical bond.

4.3 Differentiate between electrovalent and covalent bonding.

4.4 Explain the formation of polar and non polar, sigma and pi-bond with examples.

4.5 Describe the nature of coordinate bond with examples.

5. GASES AND LIQUIDS. 5.1 Understand the gaseous and liquid states of matter.

5.1.1 Describe the liquid and gaseous states of matter.

5.1.2 Describe the general properties of liquid.

5.1.3 Describe the general properties of gases.

5.2 Understand gas equation.

5.2.1 State Boyle's law, Charle's law, Graham's law of diffusion, Dalton's law of

partial pressure.

5.2.2 State the mathematical form of these laws.

5.2.3 Derive gas equation.

5.2.4 Solve problems using gas law and gas equation.

6. UNDERSTAND THE CHEMICAL NATURE OF WATER. 6.1 Describe the chemical nature of water with its formula.

6.2 Describe the general impurities present in water.

6.3 Explain the causes and methods to remove hardness of water.

6.4 Express hardness in different units like mg/liter. p.p.m, degrees Clark and degrees

French.

6.5 Describe the formation and nature of scales in boiler feed water.

6.6 Explain the method for the treatment of scales.

6.7 Explain the sewage treatment and desalination of sea water.

86

7. UNDERSTAND THE NATURE OF ACIDS, BASES AND SALTS. 7.1 Define acids, bases and salts with examples.

7.2 Describe general properties of acids and bases.

7.3 Differentiate between acidity and basicity and use the related terms.

7.4 Define salts, give their classification with examples.

7.5 Explain p-H value of solution and pH scale.

8. UNDERSTAND THE PROCESS OF OXIDATION AND REDUCTION. 8.1 Define oxidation.

8.2 Explain the oxidation process with examples.

8.3 Define reduction.

8.4 Explain reduction process with examples.

8.5 Define oxidizing and reducing agents with examples.

8.6 Define oxides.

8.7 Classify the oxides with examples.

9. UNDERSTAND THE FUNDAMENTALS OF NUCLEAR CHEMISTRY. 9.1 Define nuclear chemistry and radio activity.

9.2 Differentiate between Alpha , Beta and Gamma particles.

9.3 Explain half life process.

9.4 Explain nuclear reactions resulting in transformation of elements with examples.

9.5 State the uses of isotopes.

10. UNDERSTAND THE NATURE OF ALLOYS USED IN THE RELEVANT

TECHNOLOGY. 10.1 Define alloy.

10.2 Describe different methods for the preparation of alloys.

10.3 State important properties of alloys.

10.4 Explain composition, properties and uses of different alloys.

11. UNDERSTAND THE NATURE AND USES OF SOLID, LIQUID AND GASEOUS

FUELS. 11.1 Define fuel and give their significance in technological advancements.

11.2 Distinguish among solid, liquid and gaseous fuels.

11.3 Explain calorific value.

11.4 Describe coal with its utilization.

11.5 Describe petroleum and its utilization.

11.6 Describe various gaseous fuels.

11.7 Enlist nuclear and special fuels.

12. UNDERSTAND THE PROCESS OF CORROSION. 12.1 Define corrosion.

12.2 Describe different types of corrosion.

12.3 State the causes of corrosion.

12.4 Explain the process of rusting of iron.

12.5 Describe methods to prevent/control corrosion.

87

13. UNDERSTAND THE PROCESS INVOLVED IN THE EXTRACTION OF METALS

LIKE IRON, COPPER AND ALUMINUM. 13.1 Define metallurgy

13.2 Explain concentration, roasting, calcination and reduction.

13.3 Describe physical & chemical properties of iron, copper and aluminum.

13.4 Enlist relevant ores of iron, copper and aluminium with their formulae.

13.5 Explain the method of extraction and metallurgy in a blast furnace of relevant ores of

iron.

13.4 Outline important properties of cast iron, wrought iron and steel.

14. UNDERSTAND THERMO CHEMISTRY. 14.1 Define Thermo chemistry and state Thermo chemical units.

14.2 Explain heat of formation, combustion and neutralization.

14.3 Explain Hess's law.

14.4 Explain the process of combustion.

14.5 Solve numerical problems relating to quantities of air & other gases in combustion.

15. UNDERSTAND THE CHEMISTRY OF LUBRICANTS. 15.1 Define a lubricant

15.2 Explain the uses of lubricants.

15.3 Describe classification of lubricants with examples.

15.3 State the properties of oils, greases and solid lubricants.

15.4 Explain the method of selecting lubricant for particular purpose/job.

16. UNDERSTAND THE NATURE OF POLLUTION. 16.1 Define pollution (air, water, soil).

16.2 State the causes of environmental pollution.

16.3 Enlist air pollutant gases.

16.4 Explain the methods used to control air pollution.

88

Ch-213 APPLIED CHEMISTRY

LIST OF PRACTICALS

1. To introduce the common apparatus,glassware and chemical reagents used in the chemistry lab.

2. To purify a chemical substance by crystallization.

3. To separate a mixture of sand and salt.

4. To find the melting point of substance.

5. To find the pH of a solution with pH paper.

6. To separate a mixture of inks by chromatography.

7. To determine the co-efficient of viscosity of benzene with the help of Ostwald vasomotor.

8. To find the surface tension of a liquid with a stalagmometer.

9. To perform electrolysis of water to produce Hydrogen and Oxygen.

10. To determine the chemical equivalent of copper by electrolysis of Cu SO.

11. To get introduction with the scheme of analysis of salts for basic radicals.

12. To analyse 1st group radicals (Ag+ - Pb++ - Hg+).

13. To make practice for detection 1st group radicals.

14. To get introduction with the scheme of II group radicals.

15. To detect and confirm II-A radicals (hg++, Pb++++, Cu+, Cd++, Bi+++).

16. To detect and confirm II-B radicals (Sn+++, Sb+++, As+++).

17. To get introduction with the scheme of III group radicals (Fe+++ - Al+++, Cr+++)

18. To detect and confirm Fe+++, Al+++ and Cr+++.

19. To get introduction with he scheme of IV group radicals.

20. To detect and confirm An++ and Mn++ radicals of IV group.

21. To detect and conform Co++ and Ni++ radicals of IV group.

22. To get introduction with the Acid Radical Scheme.

23. To detect dilute acid group.-

24. To detect and confirm CO"3 and HCO'3 radicals.

25. To get introduction with the methods/apparatus of conducting volumetric estimations.

26. To prepare standard solution of a substance.

27. To find the strength of a given alkali solution.

28. To estimate HCO'3 contents in water.

29. To find out the %age composition of a mixture solution of KNO3 and KOH volumetrically.

30. To find the amount of chloride ions (Cl') in water volumetrically.

89

Math-212 APPLIED MATHEMATICS-II

Total Contact Hours T P C Theory 64 hours 2 0 2

Pre-requisite:- Must have completed Mathematics I.

AIM:- After completing the course the students will be able to:

1. Solve problems of Calculus and Analytic Geometry.

2. Develop mathematical skill, attitudes and logical perception in the use of mathematical

instruments.

3. Apply principles of Differential Calculus to work out rate measures, velocity,

acceleration, maxima & minima values

4. Use Principles of Integral Calculus to compute areas and volumes.

5. Acquire proficiency in solving technological problems with mathematical clarity and

insight.

COURSE CONTENTS

1. FUNCTIONS & LIMITS. 4 Hours 1.1 Constant & Variable Quantities

1.2 Functions & their classification

1.3 The concept of Limit

1.4 Limit of a Function

1.5 Fundamental Theorems on Limit

1.6 Some important Limits

1.7 Problems

2. DIFFERENTIATION 4 Hours 2.1 Increments

2.2 Differential Coefficient or Derivative

2.3 Differentiation ab-initio or by first Principle

2.4 Geometrical Interpretation of Differential Coefficient

2.5 Differential Coefficient of Xn, (ax + b)n

2.6 Three important rules

2.7 Problems

3. DIFFERENTIATION OF ALGEBRAIC FUNCTIONS 4 Hours 3.1 Explicit Functions

3.2 Implicit Functions

3.3 Parametric forms

3.4 Problems

4. DIFFERENTIATION OF TRIGONOMETRIC FUNCTIONS 4 Hours 4.1 Differential Coefficient of Sin x, Cos x, Tan x from first principle.

4.2 Differential Coefficient of Cosec x, Sec x, Cot x

4.3 Differentiation of inverse Trigonometric functions.

4.4 Problems.

5. DIFFERENTIATION OF LOGARITHMIC & EXPONENTIAL FUNCTIONS 4 Hours 5.1 Differentiation of ln x

5.2 Differentiation of Log ax

5.3 Differentiation of ax

5.4 Differentiation of ex

5.5 Problems

90

6. RATE OF CHANGE OF VARIABLE. 4 Hours 6.1 Increasing and decreasing functions

6.2 Maxima and Minima values

6.3 Criteria for maximum & minimum values

6.4 Methods of finding maxima & minima

6.5 Problems

7. INTEGRATION 8 Hours 7.1 Concept

7.2 Fundamental Formulas

7.3 Important Rules

7.4 Problems

8. METHODS OF INTEGRATION 6 Hours 8.1 Integration by substitution

8.2 Integration by parts

8.3 Problems

9. DEFINITE INTEGRALS 6 Hours 9.1 Properties

9.2 Application to area

9.3 Problems

10. PLANE ANALYTIC GEOMETRY & STRAIGHT LINE 6 Hours 10.1 Coordinate System

10.2 Distance Formula

10.3 The Ratio Formulas

10.4 Inclination and slope of a line

10.5 The slope Formula

10.6 Problems

11. EQUATIONS OF THE STRAIGHT LINE 6 Hours 11.1 Some important Forms

11.2 General Form

11.3 Angle Formula

11.4 Parallelism & Perpendicularity

11.5 Problems

12. THE EQUATIONS OF THE CIRCLE 8 Hours 12.1 Standard form of Equation

12.2 Central form of Equation

12.3 General form of Equation

12.4 Radius & Coordinates of the centre

12.5 Problems

REFERENCE BOOKS

1. Thomas Finny - Calculus and Analytic Geometry

2. Ghulam Yasin Minhas - Technical Mathematics Vol - II, Ilmi Kitab Khana, Lahore.

3. Prof. Riaz Ali Khan - Polytechnic Mathematic Series Vol I & II, Majeed Sons, Faisalabad

4. Prof. Sana Ullah Bhatti - Calculus and Analytic Geometry, Punjab Text Book Board, Lahore.

91

Math-212 APPLIED MATHEMATICS-II


1. USE THE CONCEPT OF FUNCTIONS AND THEIR LIMITS IN SOLVING SIMPLE

PROBLEMS. 1.1 Define a function.

1.2 List all types of functions.

1.3 Explain the concept of limit and limit of a function.

1.4 Explain fundamental theorems on limits.

1.5 Derive some important limits.

1.6 Solve simple problems on limits.

2. UNDERSTAND THE CONCEPT OF DIFFERENTIAL COEFFICIENT. 2.1 Derive mathematical expression for a differential

coefficient.

2.2 Explain geometrical interpretation of differential

coefficient.

2.3 Differentiate a constant, a constant associated with a

variable and the sum of finite number of functions.

2.4 Solve related problems.

3. USE RULES OF DIFFERENTIATION TO SOLVE PROBLEMS OF ALGEBRAIC

FUNCTIONS.

3.1 Differentiate ab-initio xn and (ax+b)n.

3.2 Derive product, quotient and chain rules.

3.3 Find derivatives of implicit functions & explicit functions

3.4 Differentiate parametric forms, functions w.r.t another function and by rationalization.


4. USE RULES OF DIFFERENTIATION TO SOLVE PROBLEMS INVOLVING

TRIGONOMETRIC FUNCTIONS. 4.1 Differentiate from first principle sin x, Cos x, tan x.

4.2 Derive formulas for derivation of Sec x, Cosec x, Cot x.

4.3 Find differential coefficients of inverse trigonometric functions.

5. USE RULES OF DIFFERENTIATION TO LOGARITHMIC AND EXPONENTIAL

FUNCTIONS.

5.1 Derive formulas for differential coefficient of logarithmic and exponential functions.


6. UNDERSTAND RATE OF CHANGE OF ONE VARIABLE WITH RESPECT TO

ANOTHER. 6.1 Write expression for velocity, acceleration and slope of a line.

6.2 Define an increasing and a decreasing function, maxima and minima values, point of

inflexion.

6.3 Explain criteria for maxima and minima values of a function.

6.4 Solve problems involving rate of change of variables.

92

7. APPLY CONCEPT OF INTEGRATION IN SOLVING TECHNOLOGICAL

PROBLEMS.

7.1 Explain the concept of integration.

7.2 Write basic theorems of integration.

7.3 List some important rules of integration.

7.4 Derive fundamental formulas of integration.

7.5 Solve problems based on these formulas/rules.

8. UNDERSTAND DIFFERENT METHODS OF INTEGRATION. 8.1 List standard formulas.

8.2 Integrate a function by substitution method.

8.3 Find integrals by the method of integration by parts.

8.4 Solve problems using these methods.

9. UNDERSTAND THE METHODS OF SOLVING DEFINITE INTEGRALS. 9.1 Define definite integral.

9.2 List properties of definite integrals using definite integrals.

9.3 Find areas under the curves.

9.4 Solve problems of definite integrals.

10. UNDERSTAND THE CONCEPT OF PLANE ANALYTIC GEOMETRY. 10.1 Explain the rectangular coordinate system.

10.2 Locate points in different quadrants.

10.3 Derive distance formula.

10.4 Prove section formulas.

10.5 Derive Slope formula.

10.6 Solve problem using the above formulas.

11. USE EQUATIONS OF STRAIGHT LINE IN SOLVING PROBLEMS. 11.1 Define a straight line.

11.2 State general form of equation of a straight line.

11.3 Derive slope intercept and intercept forms of equations of a straight line.

11.4 Derive expression for angle between two straight lines.

11.5 Derive conditions of perpendicularity and parallelism of two straight lines.

11.6 Solve problems involving these equations/formulas.

12. SOLVE TECHNOLOGICAL PROBLEMS USING EQUATION OF CIRCLE.

12.1 Define a circle.

12.2 Describe standard, central and general forms of the equation of a circle.

12.3 Convert general form to the central form of equation of a circle.

12.4 Deduce formulas for the radius and the coordinates of the center of a circle from the

general form.

12.5 Derive equation of the circle passing through three given points.

12.6 Solve problems involving these equations.

93

Phy-212 APPLIED MECHANICS

Total Contact Hours T P C

Theory 32 Hours 1 3 2

Practical 96 Hours

AIM:- 1. Apply the concepts of Applied Physics to understand Mechanics

2. Apply laws and principles of Mechanics in solving technological problems

3. Use the knowledge of App. Mechanics in learning advance technical courses.

4. Demonstrate efficient skill of practical work in Mechanics Lab.

COURSE CONTENTS

1. MEASUREMENTS 2 Hrs 1.1 Review: Dimensional formula of Equations of Motion

1.2 Review: Systems of measurement, S.I. Units, conversion

1.3 Significant Figures

1.4 Degree of accuracy

2. EQUILIBRIUM OF CON-CURRENT FORCES 3 Hrs 2.1 Concurrent forces

2.2 Addition and Resolution of Vectors

2.3 Toggle Joint, Hanging Chains

2.4 Roof Trusses, Cranes.

2.5 Framed structures

3. MOMENTS AND COUPLES: 2 Hrs 3.1 Principle of Moments - Review

3.2 Levers

3.3 Safety valve

3.4 Steel yard

3.5 Parallel forces, couple

3.6 Torque

4. EQUILIBRIUM OF NON CONCURRENT FORCES: 3 Hrs 4.1 Non-concurrent forces

4.2 Free body diagram

4.3 Varignon's theorem

4.4 Conditions of total Equilibibrium.

4.5 Ladders

5. MOMENT OF INERTIA: 3 Hrs 5.1 Review: Rotational Inertia

5.2 Moment of Inertia, Theorems

5.3 Moment of Inertia of symmetrical bodies

5.4 M.I. of Fly wheel with applications

5.5 Energy stored by Fly wheel

6. FRICTION: 2 Hrs 6.1 Review: Laws of friction

6.2 Motion of body along an inclined plane (up & down)

6.3 Rolling friction & Ball Bearings

6.4 Fluid Friction, Stokes' Law

94

7. WORK, ENERGY AND POWER 3 Hrs 7.1 Work-Energy relationship

7.2 Work done by variable force.

7.3 Power

7.4 I.H.P, B.H.P and Efficiency

7.5 Dynamometer.

8. TRANSMISSION OF POWER: 3 Hrs 8.1 Belts, Ropes.

8.2 Chains.

8.3 Gears.

8.4 Clutches, functions and types with application

9. MACHINES: 3 Hrs 9.1 Efficiency of machines

9.2 Inclined plane - Review

9.3 Reversibility of machines

9.4 Single purchase crab

9.5 Double purchase crab.

9.6 Worm and worm wheel.

9.7 Differential Screw Jack.

9.8 Differential Pulley, Wheel and Axle

10. VIBRATORY MOTION: 2 Hrs 10.1 S.H.M. - Review

10.2 Pendulums

10.3 Speed Governors.

10.4 Helical spring.

10.5 Cams

10.6 Quick return motion

11. ELASTICITY: 3 Hrs 11.1 Three Modulii of Elasticity

11.2 Loaded Beams, Types of Beam & Loads

11.3 Bending Stress

11.4 S.F & B.M diagram

11.5 Torsion and Torsional Stresses

12. SIMPLE MECHANISM: 1 Hr 12.1 Introduction

12.2 Kinematic link or Element

12.3 Kinematic pair and types.

12.4 Kinematic chains and types.

13. VELOCITY IN MECHANISM: 2 Hrs 13.1 Introduction.

13.2 Instantaneous centre.

13.3 Instantaneous velocity.

13.4 Velocity of a link by instantaneous centre method.

13.5 Relative velocity of two bodies in the straight line

13.6 Velocity of a link by relative velocity method.

REFERENCE BOOK

Applied Mechanics Author Prof Zahoor Ahmed (Ayesha Academy)

95

Phy 212 APPLIED MECHANICS


1. USE THE CONCEPTS OF MEASUREMENT IN PRACTICAL

SITUATIONS/PROBLEMS 1.1 Explain Dimensional formula

1.2 Explain systems of measurement

1.3 Use concept of significant figures and degree of accuracy to solve problems

2. USE THE CONCEPT OF ADDITION AND RESOLUTION OF VECTORS TO

PROBLEMS ON EQUILIBRIUM INVOLVING CONCURRENT FORCES 2.1 Describe concurrent forces

2.2 Explain resolution of vectors

2.3 Use the analytical method of addition of vectors for solving problems.

2.4 Use the graphical method of addition of vectors for solving problems.

2.5 Solve problems on forces with emphasis on roof trusses, cranes simple frames and

framed structures.

3. USE THE PRINCIPLE OF MOMENTS AND CONCEPT OF COUPLE TO SOLVE

PROBLEMS. 3.1 Describe the principle of moments.

3.2 Use the principle of moments to solve problems on compound levers, safety valve,

steel-yard.

3.3 Describe couple and torque.

3.4 Use the concept to solve problems on torque.

4. USE THE LAWS OF TOTAL EQUILIBRIUM OF FORCES TO SOLVE PROBLEMS

INVOLVING FORCES IN EQUILIBRIUM. 4.1 Distinguish between concurrent and non-concurrent forces.

4.2 Prepare a free body diagram of an object or a structure.

4.3 Explain Varignon's theorem.

4.4 Explain the second condition of equilibrium.

4.5 Use laws of total equilibrium to solve problems on forces involving framed structure

and ladders.

5. USE CONCEPTS OF MOMENT OF INERTIA TO PRACTICAL SITUATIONS AND

PROBLEMS. 5.1 Explain moment of inertia.

5.2 Explain the theorems of Parallel and perpendicular Axis.

5.3 Describe the M.I. of regular bodies

5.4 Explain M.I. of Fly wheel

5.5 Explain Energy stored by Fly Wheel

5.6 Use these concepts to solve simple problems.

6. UNDERSTAND THE CONCEPTS AND LAWS OF SOLID AND FLUID FRICTION. 6.1 Define Coefficient of friction between a body placed on an inclined plane and the

surface.

6.2 Explain motion of a body placed on an inclined plane

6.3 Calculate the force needed to move a body up and down an inclined plane.

6.4 Explain rolling friction and use of ball bearings.

6.5 Describe fluid friction and Stoke's law.

96

7. UNDERSTAND WORK, ENERGY AND POWER. 7.1 Derive work-energy relationship

7.2 Use formulae for work done by a variable force to solve problems.

7.3 Explain Power, I.H.P, B.H.P and efficiency.

7.4 Describe dynamometers.

7.5 Use the concepts to solve problems on power and work-energy

8. UNDERSTAND TRANSMISSION OF POWER THROUGH ROPES AND BELTS. 8.1 Describe the need for transmission of power.

8.2 Describe methods of transmission of power.

8.3 Describe transmission of power through ropes and belts.

8.4 Write formula for power transmitted through ropes and belts.

8.5 Describe transmission of power through friction gears and write formula.

8.6 Describe transmission of power through chains and toothed wheels/gears.

8.7 Use the formulae to solve/problems on transmission of power.

8.8 Describe types and function of clutches with applications

9. USE THE CONCEPTS OF MACHINES TO PRACTICAL SITUATIONS. 9.1 Explain theoretical, actual mechanical advantage and efficiency of simple machines.

9.2 Use the concept to calculate efficiency of an inclined plane.

9.3 Describe reversibility of machines.

9.4 Calculate the efficiency of:

i. Single purchase crab.

ii. Double purchase crab.

iii. Worm and worm wheel.

iv. Differential screw jack, Diff. Pulley, Wheel and Axle.

9.5 Use the formulae to solve the problems involving efficiency, M.A of the above

machines.

10. USE THE CONCEPTS OF VIBRATORY MOTION TO PRACTICAL SITUATIONS. 10.1 Define vibratory motion giving examples.

10.2 Describe circular motion and its projection on diameter of the circular path.

10.3 Relate rotatory motion to simple vibratory motion.

10.4 State examples of conversion of rotatory motion to vibratory motion and vice versa.

10.5 Describe speed governors, cams quick return motion.

10.6 Derive formulae for position, velocity and acceleration of a body executing S.H.M.

10.7 Use the concept of S.H.M to helical springs.

10.8 Use the concept S.H.M to solve problems on pendulum.

11. UNDERSTAND BENDING MOMENTS AND SHEARING FORCES. 11.1 Define three types of stresses and modulii of elasticity.

11.2 Describe types of beams and loads.

11.3 Explain shearing force and bending moment.

11.4 Use these concepts to calculate S.F and B.M in a given practical situation for point

loads, uniformly distributed loads.

11.5 Prepare S.F and B.M diagram for loaded cantilever and simply supported beams.

11.6 Describe torsion and torsional stresses giving formula

97

12. UNDERSTAND SIMPLE MECHANISMS. 12.1 Define simple mechanisms.

12.2 Define kinematics.

12.3 Explain kinematic link or element.

12.4 Explain kinematic chains.

12.5 Distinguish between types of kinematic chains.

13. UNDERSTAND THE METHOD OF FINDING VELOCITY IN MECHANISMS. 13.1 Explains relative velocity.

13.2 Explain instantaneous center.

13.3 Explain instantaneous velocity.

13.4 Explain the method of finding velocity of a link by:

i. Relative velocity method.

ii. Instantaneous center method.

98

Phy-212 APPLIED MECHANICS

LIST OF EXPERIMENTS

1. Find the weight of the given body using Law of Polygon of forces.

2. Find unknown forces in a given set of concurrent forces in equilibrium using Grave-sands

apparatus

3. Set a jib crane and analyse forces in its members

4. Set a Derrick Crane and analyse forces in its members

5. Study forces shared by each member of a Toggle Joint

6. Set a Roof Truss and find forces in its members

7. Verify Principle of Moments in a compound lever

8. Calibrate a steelyard

9. Find the Reactions at the ends of a loaded beam

10. Use Reaction of Beams apparatus to study resultant of Parallel forces

11. Find the Moment of Inertia of a Flywheel

12. Find the angle of reaction for a wooden block placed on an inclined plane

13. Find the B.H.P. of a motor

14. Study the transmission of Power through friction gears

15. Study the transmission of power through belts

16. Study the transmission of Power through toothed wheels

17. Study the function of clutches

18. Find M.A. and Efficiency of wom and worm wheel

19. Find M.A. and efficiency of differential wheel and axle

20. Find the efficiency of a screw

21. Find the efficiency of a differential pulley

22. Study conversion of rotatory motion to S.H.M. using S.H.M. Model/Apparatus

23. Study conversation of rotatory motion to vibratory motion of the piston in a cylinder

24. Study the reciprocating motion

25. Study the working of cams

26. Study the quick return motion

27. Compare the Elastic constants of the given wires

28. Verify Hooke's Law using Helical Spring

29. Find the coefficient of Rigidity of a wire using Maxewell's needle

30. Find the coefficient of Rigidity of a round bar using torsion apparatus

31. Find the coefficient of Rigidity of a rectangular bar using Deflection of Beam Apparatus

32. Determine S.F. and B.M. in a loaded canti-lever (Point Loads)

33. Determine S.F. and B.M. in a simply supported Beam (Point Loads)

34. Determine S.F. and B.M. in a simply supported Beam (Point loads and uniformly distributed

load)

35. Determine S.F. and B.M. in a simply supported Beam (Point loads and uniformly distributed)

36. Study working and function of link mechanism of different types

BOOKS RECOMMENDED 1. Applied Mechanics by R.S. Khurmi

2. Applied Mechanics by A.P.S Sahihney & Prakash D. Manikpyny.

3. Applied Mechanics by Inchley and Morley

4. Theories of Machines by R.S. Khurmi and J.K. Gupta.

5. Applied Mechanics by Junarker.

6. Engineering Science Vol-I by Brown and Bryant

7. Practical Physics by Mehboob Ilahi Malik & Ikram-ul-Haq

8. Experimental Physics Note Book by M. Aslam Khan & M. Akram Sandhu

9. Experimental Mechanics (Urdu Process) by M. Akram Sandhu

99

AD-212 APPLIED THERMODYNAMICS


1 3 2 Theory: 32 hours

Practical: 96 hours

Pre-requisite: Mathematics-I and Applied Physics

AIM:- After studying this course a student will be able to:-

1. Understand the fundamental laws of gases and thermodynamics

2. Apply the laws of various methods of heating and expansion of gases

3. Apply these laws to the cycles of operations of I.C.Engines.

4. Understand the fundamental of rotary and reciprocating air compressors

5. Calculate the power and torque of I.C.Engines

COURSE CONTENTS:

1. FUNDAMENTALS OF THERMODYNAMICS 4 hours

1.1 Temperature

1.2 S.I.Units of temperature

1.3 Pressure

1.4 S.I.Units of pressure

1.5 Types of pressure

1.6 Work

1.7 S.I.Units of work

1.8 Power

1.9 S.I.Units of power

1.10 Energy

1.11 S.I.Units of energy

1.12 Forms of energy

1.13 Heat

1.14 S.I.Units of heat

1.15 gas

1.16 Perfect Gas

1.17 Vapour

1.18 Specific heat of gases

1.19 Specific heat of gas at constant volume

1.20 Specific heat of gas at constant pressure

1.21 ratio of specific heats

1.22 Internal energy of a gas

1.23 Law of conservation of energy

1.24 Application of law of conservation of energy

2. THE HEATING AND EXPANSION OF GASES 8 hours 2.1 Heating of gas at constant volume

2.2 Heating of gas at constant pressure

2.3 Formula of work done at constant pressure

2.4 PV-diagram

2.5 Work done during expansion

2.6 Thermodynamics processes

2.7 List of thermodynamics processes

2.8 Volume ratio

2.9 Expression of volume ratio

2.10 Constant volume process

2.11 PV-diagram for constant volume process

2.12 Work done during constant volume process

2.13 Constant pressure process

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2.14 PV-diagram of constant pressure process

2.15 Work done during constant pressure process

2.16 Constant temperature or Isothermal process

2.17 PV-diagram for constant temperature process

2.18 Work done during constant temperature process

2.19 Hyperbolic process

2.20 PV-diagram for hyperbolic process

2.21 Work done during hyperbolic process

2.22 Adiabatic process

2.23 PV-diagram for adiabatic process

2.24 Work done during adiabatic process

2.25 Polytropic process

2.26 PV-diagram for polytropic process

2.27 Work done during polytropic process

2.28 Free Expansion

2.29 Work done during free expansion

2.30 Throttling process

2.31 Work done during throttling process

2.32 Value of expansion index "n"

3. LAWS OF PERFECT GASES 4 hours 3.1 Boyle's law

3.2 Mathematical expression for Boyle's law

3.3 Charles' Law

3.4 Mathematical expression for Charles' law

3.5 General gas equation

3.6 Characteristics of gas equation

3.7 Relationship of density of a gas with temperature

3.8 Zeroth law of thermodynamics

3.9 First law of thermodynamics

3.10 Second law of thermodynamics

3.11 Clausius' statement

3.12 Relationship between specific heats of gas and the gas constant

3.13 Equation of adiabatic process

3.14 Relationship between absolute temperature and volumes in adiabatic process

3.15 Relationship between absolute temperature and pressures in adiabatic process

4. AIR CYCLES 6 hours 4.1 Cycle of operation

4.2 Work done during cycle

4.3 Thermal efficiency of a cycle

4.4 Air standard efficiency of a cycle

4.5 Reversible and irreversible cycle

4.6 Carnot cycle

4.7 PV-diagram of Carnot cycle

4.8 Operations of Carnot cycle

4.9 Formula for thermal efficiency of Carnot cycle

4.10 Otto cycle

4.11 PV-diagram of Otto cycle

4.12 Operations of Otto cycle

4.13 Formula for air standard efficiency of Otto cycle

4.14 Diesel cycle

4.15 PV-diagram of Diesel cycle

4.16 Operations of Diesel cycle

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4.17 Formula for air standard efficiency of Diesel cycle

4.18 Dual cycle combustion

4.19 PV-diagram of Dual combustion cycle

4.20 Operations of Dual combustion cycle

4.21 Formula for air standard efficiency of Dual combustion cycle

5. AIR COMPRESSORS 6 hours 5.1 Working principle of air compressors

5.2 Classification of air compressors

5.3 Uses of compressed air

5.4 Effect of type of compression

5.5 Methods of approximating isothermal compression

5.6 Inter-cooling

5.7 Types of inter-cooling

5.8 Construction of intercooler

5.9 Work done by single stage reciprocating air compressor

5.10 Work done by two stage reciprocating air compressor

5.11 Power required to drive reciprocating air compressor

5.12 Clearance volume

5.13 PV-diagram of reciprocating air compressor showing clearance volume

5.14 Effect of clearance volume

5.15 Work done by reciprocating air compressor considering clearance volume

5.16 Special features of rotary air compressors

5.17 Types of rotary air compressors

5.18 Work done by single stage rotary air compressor

5.19 Work done by multi stage rotary air compressors

5.20 Comparison of reciprocating and rotary air compressors

6. PERFORMANCE OF I.C. ENGINES 4 hours

6.1 Torque

6.2 S.I. Units of torque

6.3 Mean effective pressure

6.4 Formula for mean effective pressure

6.5 Indicated horse power

6.6 Formula for indicated horse power

6.7 Brake horse power

6.8 Formula for brake horse power

6.9 Measurement of brake horse power

6.10 Friction horse power

6.11 Mathematical expression of friction horse power

6.12 Engine rating

6.13 RCA Rating

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6.14 SAE Rating

6.15 DIN Rating

6.16 Engine efficiency

6.17 Mechanical efficiency

6 18 Thermal efficiency

6.19 Relative efficiency

6.20 Volumetric efficiency

6.21 Scavenging efficiency

6.22 Heat balance sheet

BOOKS RECOMMENDED:

1. Mechanical Technology (Thermal Engineering)

By: R.S Khurmi

2. Heat Applied to Heat Engines

By: Metcalfe

3. Engineering Thermodynamics

By: Rayner Joel

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On the completion of this course, the student will be able to:-

1. UNDERSTAND FUNDAMENTALS OF THERMODYNAMICS. 1.1 Define of temperature.

1.2 State the S.I units of temperature.

1.3 Define pressure.

1.4 State the units of pressure in S.I system.

1.5 Describe the different types of pressures.

1.6 Define work.

1.7 State the units of work in S.I system.

1.8 Define power.

1.9 State the units of power in S.I system.

1.10 Define energy.

1.11 Describe the forms of energy.

1.12 State the units of energy in S.I system.

1.13 Define heat.

1.14 State the units of heat in S.I system.

1.15 Describe the term "gas".

1.16 Define perfect gas.

1.17 Describe the term vapour.

1.18 Define specific heat.

1.19 Define specific heat at constant volume.

1.20 Specific heat at constant pressure.

1.21 Write the ratio of specific heats.

1.22 Explain the internal energy of a gas.

1.23 State the law of conservation of energy.

1.24 State the application of law of conservation of energy.

2. UNDERSTAND THE HEATING AND EXPANSION OF GASES. 2.1 Explain the heating of a gas at constant volume. and constant pressure.

2.2 Develop a formula for work done in expanding a gas at constant pressure.

2.3 Define PV-diagram.

2.4 Show that the work done by a gas during expansion is the area under the expansion line

of PV-diagram.

2.5 Develop a general formula for work done during any type of expansion.

2.6 Define thermodynamic process.

2.7 List the important thermodynamic process.

2.8 Definehe volume ratio.

2.9 Write the mathematical expression of volume ratio.

2.10 Describe the constant volume process.

2.11 Draw PV-diagram for constant volume process.

2.12 Prove that work done during constant volume is zero.

2.13 State the constant pressure process.

2.14 Draw PV-diagram for constant pressure process.

2.15 Develop a formula for work done during constant pressure process.

2.16 Describe constant temperature (Isothermal) process.

2.17 Draw PV-diagram for constant temperature process.

2.18 Develop a formula for work done during constant temperature process.

2.19 Describe the hyperbolic process.

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2.20 Draw PV-diagram for hyperbolic process.

2.21 Develop formula for work done during hyperbolic process.

2.22 Discuss the adiabatic process.

2.23 Draw PV-diagram for adiabatic process.

2.24 Develop a formula for work done during adiabatic process.

2.25 Describe polytropic process.

2.26 Draw PV-diagram for polytropic process.

2.27 Develop formula for work done during polytropic process.

2.28 Describe free expansion process.

2.29 Prove that work done during free expansion process is zero.

2.30 Describe throttling process.

2.31 Prove that work done during throttling process is zero.

2.32 Determine the value of index "n".

3. UNDERSTAND LAWS OF PERFECT GASES. 3.1 State Boyle's law.

3.2 Write the mathematical expression for Boyle's law.

3.3 State Charles' law.

3.4 Write the mathematical expression for Charles' law.

3.5 Explain general gas equation.

3.6 Explain characteristic gas equation.

3.7 Write the relationship of density of a gas with temperature.

3.8 State zeroth law of thermodynamics.

3.9 State the first law of thermodynamics.

3.10 State second law of thermodynamics.

3.11 Explain the Clausius' statement.

3.12 Deduce a relationship between the specific heats of a gas and the gas constant.

3.13 Deduce the equation for adiabatic process.

3.14 Deduce the relationship between absolute temperatures and volumes in adiabatic

process.

3.15 Deduce the relationship between absolute temperature and pressures in adiabatic.

4. UNDERSTAND AIR CYCLES. 4.1 Define cycle.

4.2 Describe the work done during cycle.

4.3 Write the expression for thermal efficiency of a cycle.

4.4 Describe the air standard efficiency of a cycle.

4.5 Explain the reversible cycle and irreversible cycle.

4.6 Describe the Carnot cycle.

4.7 Draw PV-diagram of Carnot cycle.

4.8 Identify the operation of Carnot cycle.

4.9 Develop a formula for thermal efficiency of Carnot cycle.

4.10 Describe the Otto cycle.

4.11 Draw PV-diagram of Otto cycle.

4.12 Identify the operation of Otto cycle.

4.13 Develop a formula for air standard efficiency of Otto cycle.

4.14 Describe the diesel cycle.

4.15 Draw PV-diagram of Diesel cycle.

4.16 Identify the operations of Diesel cycle.

4.17 Develop a formula for air standard efficiency of Diesel cycle.

4.18 Describe the dual composition cycle.

4.19 Draw PV-diagram of dual composition cycle.

4.20 Identify the operations of dual consumption cycle.

4.21 Develop a formula for air standard efficiency of dual combustion cycle.

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5. UNDERSTAND AIR COMPRESSORS. 5.1 Describe the working principle of reciprocating air compressors.

5.2 Recognize the classification of compressors.

5.3 Identify the uses of compressed air.

5.4 Explain the effect of type of compression.

5.5 Discuss the methods of approximating isothermal compression.

5.6 Define intercooling.

5.7 Describe the types of intercooling.

5.8 Discuss the construction of intercooler.

5.9 Develop formulae for work done by single stage reciprocating air compressor.

5.10 Develop a formula for work done by two stage reciprocating air compressor.

5.11 Derive formulae for power required to drive one reciprocating air compressors.

5.12 Define clearance volume.

5.13 Draw pV-diagram of reciprocating air compressor showing clearance volume.

5.14 Describe the effect of clearance volume.

5.15 Develop a formula for work done by reciprocating air compressor considering

clearance volume.

5.16 Write the special features of rotary air compressors.

5.17 Explain the different types of rotary compressors.

5.18 Write the formulae for work done by single stage rotary compressors.

5.19 Explain the formula for work done in multistage rotary compressors.

5.20 Compare the reciprocating and rotary air compressors.

6. UNDERSTAND PERFORMANCE OF I.C. ENGINES. 6.1 Describe the term torque.

6.2 Write S.,I Units of torque.

6.3 Define mean effective pressure.

6.4 Write the formula for mean effective pressure.

6.5 State the definition of indicated horse power.

6.6 Develop formula for indicated horse power.

6.7 Define brake horse power.

6.8 Develop formula for brake horse power.

6.9 Explain the measurement of brake horse power.

6.10 Explain friction horse power.

6.11 Write mathematical expression for friction horse power.

6.12 Describe engine rating.

6.13 Explain RCA, SAE, DIN Rating of engines

6.14 Define engine efficiency.

6.15 Describe mechanical efficiency.

6.16 Explain thermal efficiency.

6.17 Discuss relative efficiency.

6.18 Explain volumetric efficiency.

6.19 Discuss scavenging efficiency.

6.20 Prepare heat balance sheet of air engine.

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LIST OF PRACTICALS

1. Solve problems based on fundamentals of thermodynamics

2. Solve problems Based on heating and expansion of gases

3. Solve problems based on laws of perfect gases

4. Solve problems based on air cycles

5. Solve problems based on air compressors

6. Solve problems based on performance of I. C. Engines

107

AD-234 WORKSHOP PRACTICE-II

TOTAL CONTACT HOURS:

Theory: 64 hours T P C


Pre-requisite: I.C. Engines and Workshop Practice-I

AIM:- 1. Understand the use of different tools and instruments for testing engines

2. Show skill in locating the faults of the engines

3. Show skill in using lubrication equipment

4. Understand periodic classes of lubrication

COURSE CONTENTS:

1. AUTOMATIC SPECIAL TOOLS. 4 hours

1.1 Pullers and their types

1.2 Oil seal extractor and installer

1.3 Flaring tool

1.4 Special wrench

1.5 Strap wrench

1.6 Torque wrench

2. AUTO WORKSHOP EQUIPMENT. 5 hours

2.1 Types of conveyors and their use

2.2 Jack stand creeper type

2.3 Chain pulley block

2.4 Engine repair stand and repair trolleys

2.5 Importance of compressed air and use of pneumatic wrenches

2.6 Ramp and its importance

2.7 Alignment gauge and platform

2.8 Computer and equipment for wheel alignment

3. ENGINE TESTING EQUIPMENT. 4 hours

3.1 Tachometers type and use

3.2 Types of vacuum and pressure gauges

3.3 Types of timing guns

3.4 Use of timing gun

4. IMPORTANCE OF LUBRICATION. 4 hours

4.1 Parts of engine where lubrication is necessary and selection of lubricant

4.2 Parts of vehicles where lubrication is necessary and selection of lubricant

for these points

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5. GAS ANALYZER. 4 hours

5.1 Use of gas analyzer

5.2 Tests using gas analyzer to calculate constituents of exhaust from

petrol and diesel engine

6. VACUUM GAUGE/PRESSURE GAUGE. 4 hours

6.1 Engine vacuum tests

6.2 Leakage test like cylinder head, valve seats, intake and early ignition

7. ENGINE ANALYZER. 4 hours

7.1 Types of engine analyzers, computerized handy and portable

7.2 Ignition patterns of S.I engine on oscilloscope

7.3 Fault diagnose from ignition patterns

8. TEST BEDS. 4 hours

8.1 Importance of test beds for engines

8.2 Types of the beds

8.3 Parameters which can be found by test beds

9. ENGINE PERFORMANCE TESTING. 4 hours

9.1 Fuel consumption

9.2 Air used

9.3 Types of dynamometers

9.4 Electrical dynamometers

9.5 Fluid dynamometer

10. TURBO SYSTEM. 5 hours

10.1 Turbo charging

10.2 Turbo boosting

10.3 Increase of efficiency by turbo system

11. ENGINE PARTS REPAIR & MAINTENANCE. 4 hours

11.1 Crank shaft grinding

11.2 Valve grinding

11.3 Cylinder boring and sizing

11.4 Cylinder honing

11.5 Valve lapping

11.6 Valve refacing

12. SEALS AND GASKETS. 4 hours

12.1 Importance of seals

12.2 Types of seals and material used

12.3 Importance of gaskets

12.4 Types of gaskets and materials used

109

13. BEARINGS. 4 hours

13.1 Types of bearings and their uses

13.2 Types of Antifriction bearings

13.3 Use of antifriction bearings in vehicle with special reference

14. QUALITY AND ITS MEASURES. 5 hours

14.1 Characteristics of quality in materials, performance and reliability

14.2 Quality in design, conformance, performance and service

14.3 Quality assurance in the sense of reliability, value usability process,

service and in quality feed back

14.4 Management of quality

15. QUALITY CONTROL METHODS. 5 hours

15.1 Training procedure to workers for quality control

15.2 Control charts like P-charts, X and R-charts

15.3 Quality circles and their systematic application

15.4 parameter of quality circle like brain storming, data collection and analyses,

Pare to analyses, cause and effect analyses

15.5 Relay task problem sheet

15.6 Just in Time (JIT) and its necessity

15.7 I.S.O 9000 and its importance

BOOKS RECOMMENDED:

1. Modern Automotive Mechanics

By: James E. Duffy

2. Engineering Metrology

By: Jain R.K.

3. Inspection and Gauging

By: Kennedy and Andrew

4. ISO 9000 Modules

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1. UNDERSTAND USE OF AUTO WORKSHOP TOOLS.

1.1 Explain the types of soft hammers and their uses.

1.2 Identify different spanners and wrenches.

1.3 Explain use of socket, box and torque wrenches.

1.4 Explain use of general purpose and special purpose extractors.

2. UNDERSTAND THE IMPORTANCE AND USE OF WORKSHOP HANDLING

AND LIFTING EQUIPMENT AND WHEEL ALIGNMENT EQUIPMENT.

2.1 Select jacks for proper use.

2.2 Describe the use of different cranes used in Auto Shop.

2.3 Explain different cranes used in Auto Shop like cantilever type, four post type and

hydraulic.

2.4 Select engine repair stand and service trolley.

2.5 Explain the use of compressed air.

2.6 Define a service station ramp.

2.7 Describe wheel alignment gauge.

2.8 Explain wheel alignment computerized equipment.

2.9 Explain conveyers, chain Pulley Block with their uses

3. UNDERSTAND ENGINE TESTING EQUIPMENT FOR DIAGNOSING ENGINE

FAULTS.

3.1 Compare different tachometers.

3.2 Describe vacuum and pressure gauge.

3.3 Define a timing gun.

3.4 Demonstrate timing setting with timing gun.

4. UNDERSTAND USE OF LUBRICATION IN VEHICLES.

4.2 Identify the lubrication points/parts of engine and chassis.

4.3 Select proper lubricants for different points of engine and chassis.

4.4 Compare different lubrication schedules.

5. USE GAS ANALYZER FOR EXHAUST ANALYSIS.

5.1 Explain the types and uses of gas analyzer.

5.2 Compute the results of analysis of exhaust in petrol and diesel engine.

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6. UNDERSTANDING VACUUM/PRESSURE AND ITS TESTING.

6.1 Define engine vacuum/pressure.

6.2 Explain the use of different vacuum and pressure gauges.

6.3 Compute the results of vacuum pressure testing of engine parts like cylinder head, valve

seats, intake and early ignition.

7. UNDERSTAND THE USE OF ENGINE ANALYZER.

7.1 Explain various types of analyzer handy, portable type and computerized.

7.2 Demonstrates ignition patterns formation on screen of analyzer.

7.3 DiAgnoce the fault in engine performance and suggest remedies.

8. UNDERSTAND USE OF TEST BEDS TO TEST DIFFERENT PARAMETERS OF

ENGINE PERFORMANCE.

8.1 Explain an engine test bed and its types.

8.2 Operate test beds for petrol and diesel engines.

8.3 Select parameters to be tested.

9. UNDERSTAND THE RESULTS OF ENGINE TESTING TO PREPARE THE

PERFORMANCE SHEET.

9.1 Compute the results of engine testing for specific fuel consumption, quantity of air used

in combustion, heat losses in convection, radiation and exhaust.

9.1.2 Compute data for brake power and thermal efficiency.

10. UNDERSTAND USE OF TURBO SYSTEMS IN ENGINES.

10.1 Define turbo charging and turbo boosting.

10.2 Explain the working of turbo systems.

10.3 Explain the enhancement of engine efficiency by using turbo systems.

11. UNDERSTAND MACHINING/RE-FINISHING OF ENGINE PARTS WITH USE

OF MACHINES.

11.1 Explain grinding of crank shaft and valves on machines.

11.2 Explain engine cylinder boring/sizing, sleeving brake drum turning.

11.3 Explain cylinder honing, valve lapping and valve refacing.

12. KNOW THE USE OF SEALS AND GAS KETS.

12.1 State the use of seals and gaskets.

12.2 Classify seals and gaskets.

12.3 Identify the material used in seals and gaskets.

13. UNDERSTAND THE USE OF BEARING IN POWER TRANSMISSION.

13.1 Explain the importance of bearings.

13.2 Explain the types of bearings.

13.3 Differentiate between bush and antifriction bearings.

112

14. UNDERSTAND QUALITY AND ITS MEASURES.

14.1 Enlist characteristics of quality in materials, performance and reliability

14.2 Explain quality in design, conformance, performance and service

14.3 Explain quality assurance in the sense of reliability, value usability process, service and

in quality feed back

14.4 Manage quality assurance

15. UNDERSTAND QUALITY CONTROL METHODS.

15.1 Organise training procedure to workers for quality control

15.2 Apply control charts like P-charts, X and R-charts

15.3 Evolve quality circles and their systematic application

15.4 Ensure use of parameter of quality circle like brain storming, data collection and

analyses, Pare to analyses, cause and effect analyses

15.5 Apply relay task problem sheet

15.6 Discuss Just in Time (JIT) and its necessity

15.7 Discuss ISO 9000 and its importance

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LIST OF PRACTICALS

1. Identification of jacks, cantilever crane for their particular use and capacity in lifting.

2. Identification of four post crane and hydraulic lift for its particular use and capacity and

difference in repair/service of vehicles.

3. Service of a hydraulic jack.

4. Alignment of a vehicle for caster, camber and toe-in angles.

5. Use of tachometer both mechanical and electronic to find the crank shaft speed of engine.

6. Use of vacuum gauge to find inlet manifold and cylinders vacuum and leakage in

gaskets/valves.

7. Use of pressure gauge in calculating pressure in cylinders during working strokes of engine.

8. Servicing of a vehicle by charging/cleaning, setting spark plug, C.B. point, charging engine oil

after washing/flushing, changing/toping gear oils.

9. Positive practice to judge the viscosity/quality of lubricants for engine and gear boxes.

10. Lubrication of all ball joints and other part of a car and bus chassis.

11. Testing/Analyzing exhaust of petrol engine by gas analyzer and rectification of faults.

12. Testing/analyzing exhaust of diesel engine by analyzer and rectification of faults.

13. Use of engine analyzer to check and rectify faults in ignition system of S.I. engine.

14. Test of petrol engine to determine, specific fuel consumption, air used heat balance sheet.

15. Test of diesel engine to determine specific fuel consumption air used, heat losses brake power

and preparing heat balance sheet.

16. Differentiation dynamometer like mech hydraulic and electrical in their performance to wards

calculating brake power in S.I. units.

17. Changing gasket of an engine.

18. Changing crank shaft oil seal.

19. Changing ball bearing of axle.

20. Changing universal joints bearing.

21. Prepare P, X and R charts for quality control.

22. Work practice on quality circles in group by taking examples.

114

AD-243 PROBLEMS IN INTERNAL COMBUSTION ENGINES

T P C

Total Contact Hours 2 3 3

Theory: 64 hours

Practical: 96 hours

Pre-requisite:- I.C. Engine

AIM:- After studying this course, a student will be able to:-

1. Understand power and implications in its transfer

2. Understand causes of I.C. engine problems and suggest their remedies

3. Recognize the engine problem by hearing engine noise

4. Understand combustion problem and suggest remedies

COURSE CONTENTS:

1. ENGINE PROBLEM SYMPTOMS 3 hours

1.1 Coolant in oil

1.2 Oil in coolant

1.3 Oil deposits on spark plug

1.4 Oil leaks

1.5 Blow by

1.6 Coolant leaks

1.7 Vacuum leaks

1.8 Exhaust smoke, blue, white and black

2. FACTORS INFLUENCING POWER 3 hours

2.1 Tuning of manifolds

2.2 Exhaust system

2.3 Supercharging

2.4 Scavenging

2.5 Fuel quality

2.6 Venturi size

3. CYLINDER PROBLEMS 3 hours

3.1 Heat stress

3.2 Wear

3.3 Distortion

3.4 scuffing

3.5 scoring

4. CRANKSHAFT BALANCE 3 hours

4.1 Numbers and arrangement of cylinder

4.2 Reciprocating masses

4.3 Torsional vibration

4.4 Static and dynamic balance

5. LUBRICATION PROBLEMS 3 hours

5.1 Under lubrication

5.2 Over lubrication

5.3 Lubrication service

5.4 Lubrication rating

5.5 Contamination

5.6 Sludge

5.7 Oil change

115

6. COOLING SYSTEM PROBLEMS 3 hours

6.1 Over heating

6.2 Fan belt tension

6.3 Slow engine warm up

6.4 Amount of coolant

6.5 Size of water pump

6.6 Fan capacity

6.7 Air distribution

6.8 Heat transfer

6.9 Dirt , scale, oil, and cavitations

7. PROBLEMS OF PISTON PINS 3 hours

7.1 Expansion

7.2 Contraction

7.3 Floating

7.4 Knock

8. CONNECTING ROD PROBLEMS 3 hours

8.1 Bend

8.2 Twist

8.3 Alignment

9. PISTON PROBLEMS 2 hours

9.1 Temperature

9.2 Scuffing

9.3 Ring land damage

9.4 Bosses damage

10. PISTON RING PROBLEM 3 hours

10.1 Scuffing

10.2 Sticking

10.3 Breakage

10.4 Expansion

10.5 Blow by

10.6 Rapid wear

10.7 Clearance

11. CYLINDER HEAD PROBLEMS 3 hours

11.1 Leakage

11.2 Crack

11.3 Carbon deposit

11.4 War page

12. ENGINE BEARING PROBLEMS 2 hours

12.1 Lack of oil supply

12.2 Fatigued bearing

12.3 Poor seating

12.4 Tapered journal

12.5 Contamination lubricant

13. VALVE PROBLEMS 3 hours

13.1 Burning

13.2 Wear

13.3 Breakage

13.4 Bending

116

14. ENGINE NOISE ANALYSIS 3 hours

14.1 Hisses

14.2 Knocks

14.3 Rattles

14.4 Pupping

15. COMBUSTION CHAMBER FOR S.I. ENGINE 2 hours

15.1 Types and their Characteristics

15.2 Wedge and hemispheric

15.3 Type of abnormal combustion

15.4 Detonation

15.5 Pre-ignition

15.6 After ignition dieseling

16. EFFECTS OF DETONATION ON ENGINE PERFORMANCE 3 hours

16.1 Factor effecting detonation

16.2 Turbulence

16.3 Squish

16.4 Quench

16.5 Types of combustion chamber

16.6 Fuels

16.7 Compression ratio

16.8 Engine operating condition i.e. humidity, high altitude

16.9 Higher air temperature

16.10 Lean air fuel mixture

16.11 Carbon deposits

16.12 Excessive spark advance

17. COMBUSTION CHAMBERS FOR C.I. ENGINES 3 hours

17.1 Types and their characteristics

17.2 Direct

17.3 Pre-combustion chambers

17.4 Turbulence

17.5 Swirl

17.6 Energy cell formation

17.7 Comparison between direct and pre-combustion chambers

18. PHASES OF COMBUSTION 3 hours

18.1 Delay period/ignition lag

18.2 Rapid/uncontrolled combustion

18.3 Controlled combustion

18.4 After burning

19. FACTORS EFFECTING KNOCKING 3 hours

19.1 Self ignition temperature

19.2 Delay period

19.3 Inlet air temperature and pressure

19.4 Engine speed

19.5 Compression ratio

19.6 Temperature of combustion chamber walls

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20. EXHAUST SYSTEM PROBLEM 2 hours

20.1 Effects of firing orders

20.2 Manifold design

20.3 Back pressure

20.4 Waste heat recovery

21. CAMSHAFT AND DRIVE SYSTEM PROBLEMS 3 hours

21.1 Effects of various cam designs on volumetric efficiency and power out put

21.2 Problems of timing gear/chain belts

21.3 Valve timing diagram

22. ENGINE MECHANICAL PROBLEMS CAUSED 3 hours

22.1 High mileage

22.2 Engine over heating

22.3 Lack of periodic maintenance

23. GASKET PROBLEMS 2 hours

23.1 Blown

23.2 Leakage due to surface war page

23.3 Intake manifold vacuum leak

23.4 Exhaust manifold leak

23.5 Broken

BOOKS RECOMMENDED

1. W.H.Crouse - Automotive Engines Design

2. M.L.Marther R.P.Sharma - I.C.Engines

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Upon completion of this course, the students will be able to:-

1. UNDERSTAND THE ENGINE PROBLEMS SYMPTOMS AND LEAKAGES.

1.1 Identify the engine troubles

1.2 Identify the engine oil leakage

1.3 Identify the coolant leakage

1.4 Identify the intake leakage

1.5 Compare the exhaust smokes

1.6 Explain methods to check engine leakage.

2. UNDERSTAND THE POWER FACTORS OF ENGINE.

2.1 Explain Intake system of engine.

2.2 Compare shape of the supercharging system with other systems.

2.3 Explain scavenging.

2.4 Explain the exhaust system.

2.5 Explain the effect of size of venturi on engine power.

3. UNDERSTAND PROBLEMS RELATING TO THE ENGINE CYLINDER.

3.1 Explain the effects of heat stress on cylinder wear.

3.2 Discuss distortion.

3.3 Discuss scuffing.

3.4 Discuss scoring.

3.5 Identify the cylinder damages.

4. UNDERSTAND THE FACTORS THAT EFFECT CRANKSHAFT PERFORMANCE

4.1 Describe the crankshaft.

4.2 Explain shape of crankshaft with respect to numbers of cylinder.

4.2 Discuss the static and dynamic balance.

4.3 Identify the factors that affect crankshaft damage

5. UNDERSTAND THE LUBRICATION SYSTEM PROBLEMS.

5.1 Explain under and over lubrication.

5.2 Explain the lubrication problems.

5.3 Explain lubrication rating.

5.4 Explain effect of contamination and sludge formation.

5.5 Explain the oil changing of engine.

5.6 Identify the problems and remedies of engine lubrication system.

6. UNDERSTAND COOLING SYSTEM PROBLEMS.

6.1 Explain over heating of engine.

6.2 Explain the effect of amount of coolant, water pump size and air distribution

cooling system.

6.3 Explain effect of Dirt, Scale, oil and cavitations on heat transfer.

6.4 Identify the cooling system problems and their remedies.

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7. UNDERSTAND THE IMPORTANCE OF PISTON PIN FITTING AND

PROBLEMS RELATED PISTON PIN

7.1 Discuss expansion and contraction of piston pin.

7.2 Discuss floating and knocking of piston pin.

7.3 Identify the problem of piston pin and their remedies.

8. UNDERSTAND THE CONNECTING ROD.

8.1 Discuss the problem related to connecting rod.

8.2 Explain the bending, twisting and Alignment of connecting rod.

8.3 Identify the problems relative to connecting rod.

9. UNDERSTAND THE PISTON PROBLEMS.

9.1 Explain temperature scuffing effect on piston working.

9.2 Explain ring land and Bosses damages.

9.3 Identify the piston problems.

10. UNDERSTAND THE PROBLEMS RELATED TO PISTON RINGS.

10.1 Explain scuffing, sticking, breaking of piston ring.

10.2 Explain expansion blow by rapid wear and clearance.

10.3 Identify the piston ring problems.

11. UNDERSTAND THE CYLINDER HEAD PROBLEMS.

11.1 Explain cylinder head leakage and cracking.

11.2 Explain war page and carbon deposit.

11.3 Identify the cylinder head problems.

12. UNDERSTAND THE ENGINE BEARING PROBLEMS.

12.1 State problems related to engine bearing and lubricant.

12.2 State problems of engine bearing related to mechanical reasons.

12.3 Identify the problems of engine bearing.

13. UNDERSTAND THE ENGINE VALVES PROBLEMS.

13.1 State valve burning, breakage and bending stem.

13.2 Identify valves problems.

14. UNDERSTAND ENGINE NOISE ANALYSIS.

14.1 State engine noises.

14.2 Explain Hisses, Knocks, Rattles, Pupping.

14.3 Differentiate different engine problems from noises.

15. UNDERSTAND THE COMBUSTION CHAMBER AND COMBUSTION.

15.1 Discuss the types of combustion problems.

15.2 Suggest remedies to combustion problems.

15.3 Identify the combustion problems.

15.4 Explain the types of combustion chambers.

16. UNDERSTAND THE FACTORS THAT EFFECTING THE DETONATION.

16.1 Discuss the effect of turbulence, Squish and Quench on detonation.

16.2 Discus the detonation due to types of combustion chambers, fuel, mixture

compression ratio.

16.3 Discuss carbon deposit, operating condition, spark advance effected on

detonation.

16.4 Identify causes of detonation.

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17. UNDERSTAND THE PROBLEM RELATED TO COMBUSTION CHAMBERS.

17.1 Explain types of combustion chamber for I.C Engines.

17.2 Explain the characteristic of combustion chamber.

17.3 Compare direct and pre-combustion chambers.

18. UNDERSTAND PHASES OF COMBUSTION.

18.1 Explain delay period.

18.2 Explain un-controlled combustion.

18.3 Explain controlled combustion.

18.4 Explain after burning of diesel.

19. UNDERSTAND DIESEL KNOCKING.

19.1 Identify the reasons of self ignition.

19.2 Explain effect of delay period.

19.3 Explain the effect of engine speed.

19.4 Explain effects of compression ratio.

19.5 Explain effects of cylinder walls.

20. UNDERSTAND THE PROBLEMS OF EXHAUST SYSTEM.

20.1 Explain importance of firing order.

20.2 Explain effects of manifold shape.

20.3 Explain effects of back pressure.

20.4 Explain waste heat recovery.

21. UNDERSTAND PROBLEM OF CAMSHAFT AND ITS DRIVE SYSTEM.

21.1 Explain various shapes of cams.

21.2 State procedure of valve timing setting.

21.3 Explain valve timing diagram.

22. UNDERSTAND MECHANICAL PROBLEMS OF I.C.ENGINES.

22.1 State effects of High Mileage.

22.2 Explain effects of over heating on basic engine parts.

22.3 Explain effects of insufficient lubrication.

23. UNDERSTAND HEAD GASKET PROBLEMS

23.1 Identify reasons and effects of blown gasket.

23.2 Explain surface war-page.

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LIST OF PRACTICALS

1. Identify various engine leakages by inspection.

2. Diagnose fault after study of colour of engine exhaust.

3. Verify the factors influencing power out put of the petrol engine.

4. Find taper-ness and ovality of engine cylinder.

5. Identify the scuffing and scoring

6. Estimate intensity of crankshaft/engine vibration by use of knock sensor

7. Judge the contamination of engine oil.

8. Change engine oil of an engine.

9. Locate the engine fault overheating and rectify it.

10. Compare the quantity of coolant of an engine with the quantity required.

11. Identify different types of blowers of air cooling system

12. Perform the straight and reverse flushing of engine cooling system

13. Identify methods of piston pin assembly.

14. Find out connecting rod problems bend and twist.

15. Identify the piston damages and wear.

16. Locate the problem of blow by of an engine practice.

17. Locate the cylinder head cracks by different methods.

18. Locate cylinder head war-page.

19. Dismantle the engine and identify engine bearing failure.

20. Decarbonize the cylinder head.

21. Measure bend of crank shaft.

22. Verify the bent stem of engine valves

23. Identify different types of combustion chambers of a petrol engine.

24. Enlist factors effecting detonation

25. Verify compression ratio of a petrol engine

26. Measure ignition spark advance.

27. Identify various types of combustion chambers of a diesel engine.

28. Measure engine speed by using tachometer.

29. Practice to verify effects of wrong firing order

30. Measure cam lift of cams on a camshaft.

31. Verify valve timing diagram of petrol engine.

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CMT-213 FUEL SYSTEM Total Contact Hours Theory 64 Hours T P C Practical 96 Hours 2 3 3 AIM:- After studying this course a student will be able to:-

a. Understand and diagnose problems of fuel system of construction machinery. b. Handling, servicing, disassembling, rectifying and assembling of fuel line and

components. c. Undertake phasing and calibration of inline Bosch Pump, PT pump and DPA

pump.

Pre-requisite: IC Engine.

COURSE CONTENT: 1. INTRODUCTION TO FUEL SYSTEM 12 Hours

1.1 Basic Definitions. 1.2 Function and purpose of fuel system. 1.3 Types of fuel system. 1.4 Fuel System of SI and CI Engines. 1.5 Combustion chamber design. 1.6 Valve and Ignition timing. 1.7 Mechanical and Electrical fuel pumps. 1.8 Difference between Petrol and Diesel Engines.

2. INLINE BOSCH PUMP 24 Hours 2.1 Structure, function and construction of inline pumps. 2.2 Operation of Bosch Pump. 2.3 Plungers.

2.3.1 Operation. 2.3.2 Metering Action of Plungers. 2.3.3 Types of plungers.

2.4 Delivery Valve Construction and operation. 2.5 PE (S)-PD type Injection Pump. 2.6 Pump Installation on engine. 2.7 Pump Assembly number Identification. 2.8 Governors.

2.8.1 Types of Governor. 2.8.2 Construction and working of Governor Bosch pump. 2.8.3 Governor action at starting, idling, max speed control and engine stopping. 2.8.4 Effect of Torque spring and angliech spring. 2.8.5 Governor Assembly Number Identification. 2.8.6 Reading Governor Performance curve.

2.9 Speed Droop Adjustment. 2.10 Feed Pump structure, function and working.

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2.11 Automatic Timing Advancer. 2.12 Injection nozzles, nomenclature, structure, function and types.

2.13 Types of Injectors 3. PRESSURE TIME (PT) PUMP 20 Hours 3.1 Fuel System in Cummins engine. 3.2 Main Features of Cummins Engine. 3.3 Construction of PT pump. 3.4 PTG Governor.

3.4.1 Construction and Working principle. 3.4.2 Effects of torque spring and weight assist spring. 3.4.3 Idling speed stabilization.

3.5 Throttle of PT pump. 3.6 MVS Governor. 3.7 Shutdown Valve. 3.8 Integral Type PT (type G) fuel pump cooling features. 3.9 Aneroid Control Valve structure and function. 3.10 AFC unit structure and function. 3.11 Fuel flow of PTG-VS fuel pump with AFC 3.12 PT Injectors

3.12.1 Principal of Pressure time metering 3.12.2 Metering action by injectors 3.12.3 Metering orifice 3.12.4 Fuel flow through injectors and care 3.12.5 Types of Injectors.

4. DPA PUMP (Distribution Pump Assembly) 8 Hours 4.1 Structure, Construction, function and working of DPA Pump

4.2 Governor DPA pump 4.2.1 DPA Mechanical Governor 4.2.2 DPA Hydraulic Governor

BOOKS RECOMMENDED 1. Diesel Mechanics by Schulz 2. Shop Manual of 6-D-125 series engine. 3. Unit Instruction Manual of PT Pump 4. Unit Instruction Manual of Inline Pump 5. Shop Manual of NT-855 series engine

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CMT -213 FUEL SYSTEM INSTRUCTIONAL OBJECTIVES: On the completion of Course the student will be able to 1. UNDERSTAND INTRODUCTION OF FUEL SYSTEM 1.1 Basic Definitions. 1.2 Function and Purpose of fuel System. 1.3 Types of fuel System. 1.4 Fuel System of SI and CI Engines. 1.5 Combustion chamber Design.

1.6 Valve and Ignition timing. 1.7 Mechanical and Electrical fuel pumps. 1.8 Difference between Petrol and Diesel Engines. 2. UNDERSTAND THE STRUCTURE, FUNCTION, WORKING AND TYPES OF INLINE BOSCH PUMP

2.1 Structure, function and Construction of inline pumps. 2.2 Operation of Bosch Pump. 2.3 Plungers.

2.3.1 Operation. 2.3.2 Metering Action of Plungers. 2.3.3 Types of plungers.

2.4 Delivery Valve Construction and operation. 2.5 PE (S)-PD type Injection Pump.

2.6 Pump Installation on engine. 2.7 Pump Assembly number Identification.

2.8 Governors. 2.8.1 Types of Governor. 2.8.2 Construction and working of Governor Bosch pump. 2.8.3 Governor action at starting, idling, max speed control and engine

stopping. 2.8.4 Effect of Torque spring and angliech spring. 2.8.5 Governor Assembly Number Identification. 2.8.6 Reading Governor Performance curve.

2.9 Speed Droop Adjustment. 2.10 Feed Pump structure, function and working. 2.11 Automatic Timing Advancer. 2.12 Injection nozzles, nomenclature, structure, function and types. 3. UNDERSTAND THE STRUCTURE, FUNCTION AND WORKING OF PRESSURE TIME (PT) PUMP

3.1 Fuel System in Cummins engine. 3.2 Main Features Cummins Engine. 3.3 Construction of PT pump. 3.4 PTG Governor.

3.4.1 Construction and Working principle. 3.4.2 Effects of torque spring and weight assist spring. 3.4.3 Idling speed stabilization.

3.5 Throttle of PT pump. 3.6 MVS Governor. 3.7 Shutdown Valve.

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3.8 Integral Type PT (type G) fuel pump. 3.9 Aneroid Control Valve structure and function. 3.10 AFC unit structure and function. 3.11 Fuel flow of PTG-VS fuel pump with AFC

4. UNDERSTAND THE STRUCTURE, FUNCTION AND WORKING OF DPA PUMP

4.1 Structure, Construction, function and working of DPA Pump 4.2 Governor DPA pump

4.2.1 DPA Mechanical Governor 4.2.2 DPA Hydraulic Governor

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CMT -213 FUEL SYSTEM LIST OF PRACTICALS 1. Practical Demonstration on different types of fuel system 2. Practical Demonstration of Ignition sequence of 4 cylinder and 6 cylinder engines on cutaway/working model 3. Fuel circuit line tracing 4. Tracing of Fuel Circuit line based on Inline Bosch pump 5. To familiarize with different components of Bosch pump / inline pump. 6. Practical study of plunger, plunger barrel of different types. 7. Practical study on working of plunger, turning mechanism and variation of effective

stroke 8. Practical study on operation of delivery valve 9. Disassembling and assembling of Bosch pump 10. Practical study on structure, working and operation of delivery valve 11. Phasing and calibration of Bosch pump 12. Disassembling and Assembling of Governor. 13. Structure, working and adjustment of governor 14. To familiarize the students with each component of PT pump 15. Testing of PTG Governor 16. Disassembling / assembling of PT pumps and injectors 17. Phasing and Calibration of PT pump 18. Practical study on structure and working of PT injectors 19. Movie on Injectors 20. Practical on Structure and function of DPA pump 21. Checking and adjusting of AFC on test bench

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CMT-224 OPERATION OF CONSTRUCTION MACHINERY


Theory - 64 2 6 4 Practical - 192

Pre Requisite:- None

AIM:- After studying this course a student will be able to:-

1 Acquire sufficient skill on highway/off highway construction Machines to

operate the machines safely for various civil Engineering works.

2. Understand rules regarding inspection and maintenance of construction

Machines.

3. Utilize effectively different techniques of earth moving by different types of

construction machines.

4. Understand different components and controls of construction machine.

COURSE CONTENTS

1. INTRODUCTION TO CONSTRUCTION MACHINERY 4 Hours

1.1 History and recent development of Construction Machinery.

1.2 Advantages and disadvantages of Construction Machinery.

1.3 Uses of Construction Machinery.

2. SAFETY PRECAUTION IN OPERATION OF CONSTRUCTION MACHINERY

2.1 General

2.2 Checks before starting

2.3 Checks on engine starting

2.4 Checks after engine start, prior to machine operation.

2.5 Checks prior to traveling.

2.6 Checks during operation.

2.7 Check after operation and before stopping the engine.

2.8 Checks on parking.

2.9 Causes of accidents.

6 Hours

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3. INTRODUCTION TO MAINTENANCE OF CONSTRUCTION MACHINERY 3.1 Definition

3.2 Types of maintenance

3.3 Significance of maintenance

3.4 Fluids and Lubricants

3.5 Good operator skills and qualities

4. BULLDOZER 7 Hours

4.1 Introduction to major components of bulldozer and their function.

4.2 Study of names, location and function of machine components of

Bulldozer as regards, Engine, Clutch, transmission, steering clutch,

steering brake, final drive, sprocket and track.

4.3 Trouble shooting.

5. MOTOR GRADER 7 Hours

5.1 Introduction to major components of Motor Grader. Study of major

controls in case of Motor Grader. Study of earth moving techniques by

Motor Grader.

5.2 Study of names, location and function of various components of motor

grader to include, engine, clutch, torque converter, transmission, final

drive, wheels and tires, steering and brake systems.


6. WHEEL LOADER/DOZER SHOVEL 8 Hours

6.1 Introduction to major components of wheel loader and dozer shovel. Study

of major controls in case of wheel loader and dozer shovel. Study of earth

moving techniques by wheel loader and dozer shovel.

6.2 Study of name, location and function of machine components of wheel

loader/dozer shovel as regards engine, clutch/torque converter,

transmission, steering system, final drive, sprocket, track and differential,

wheels, tires and brake system.


3 Hours

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7. EXCAVATOR AND DUMP TRUCK 6 Hours

7.1 Study of major controls/components of Excavator including engine, damper,

pump, travel motor, final drive, under carriage, swing motor.

7.2 Study of components of Dump Truck including engine, clutch, transmission,

differential, wheel and tires, hydraulic system, brake system and steering

system.

7.3 Study of earth moving techniques for Excavator and Dump Truck.

8. SCRAPER AND ROAD STABILIZER 5 Hours

8.1 Introduction to major components of motor scraper and road stabilizer

and their function. Study of major controls in case of motor scraper

and road stabilizer.

8.2 Study of earth moving techniques for motor scraper and road stabilizer.

9. ROAD ROLLER 4 Hours

9.1 Introduction to types of road roller to include pneumatic tired rollers,

vibratory roller etc Study of major components/controls in case of road

rollers. Study of operation techniques by road roller.

10. Introduction to truck crane, study of major components/controls 4 Hours

and moving techniques by above machinery.

11. Introduction to Asphalt Finishers and Asphalt Distributor. Study 3 Hours

of major components and Asphalt laying/distributing techniques

by above machines.

12. FUEL AND LUBRICANTS 2 Hours

12.1 Different types of fuels.

12.2 Fuel used in construction machinery (Diesel).

12.3 Lubricating oils for engine, transmission and hydraulic system of

construction machinery.

12.4 Grease used in under carriage of dozer.

13. Introduction to off road tires, their types and method of 2 Hours

identification by code numbers.

14. Soils, types, characteristics and field identification of soils, study 3 Hours

of types of rocks.

RECOMMENDED BOOKS

1. Text Book of Operation of Construction Machinery by JICA.

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On completion of this course, the student will be able to:-

1. KNOW THE HISTORY, DEVELOPMENT AND USED OF CONSTRUCTION MACHINERY

1.1 State history and recent development of Construction Machinery.

1.2 Describe advantages and disadvantages of Construction Machinery.

1.3 Know uses of Construction Machinery.

2. KNOW SAFETY PRECAUTION IN OPERATION OF CONSTRUCTION MACHINERY

2.1 Know general safety precaution.

2.2 Know checks before starting

2.3 Know checks on engine starting

2.4 Know checks after engine start, prior to machine operation.

2.5 Know checks prior to traveling.

2.6 Know checks during operation.

2.7 Know check after operation and before stopping the engine.

2.8 Know checks on parking.

2.9 Know causes of accidents.

3. KNOW THE BASICS OF MAINTENANCE OF CONSTRUCTION MACHINERY 3.1 Define maintenance.

3.2 Know types of maintenance

3.3 Know significance of maintenance

3.4 Know the fluids and Lubricants

3.5 Know good operator skills and qualities

4. KNOW STRUCTURE AND FUNCTION OF BULLDOZER 4.1 Know major components of bulldozer and their function.

4.2 Know names, location and function of machine components of

Bulldozer as regards, Engine, Clutch, transmission, steering clutch,

steering brake, final drive, sprocket and track.

4.3 Understand trouble shooting of bulldozer.

5. KNOW STRUCTURE AND FUNCTION OF MOTOR GRADER

5.1 Know the major components, major controls and earth moving techniques by

Motor Grader.

5.2 Know names, location and function of various components of motor

grader to include, engine, clutch, torque converter, transmission, final

drive, wheels and tires, steering and brake systems.

5.3 Understand the trouble shooting of motor grader.

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6. KNOW STRUCTURE AND FUNCTION OF WHEEL LOADER/DOZER SHOVEL

6.1 Know the major components, major controls and earth moving techniques by

wheel loader and dozer shovel.

6.2 Know name, location and function of machine components of wheel

loader/dozer shovel as regards engine, clutch/torque converter,

transmission, steering system, final drive, sprocket, track and differential,

wheels, tires and brake system.

6.3 Understand the trouble shooting of wheel loader/dozer shovel.

7. KNOW STRUCTURE AND FUNCTION OF EXCAVATOR AND DUMP TRUCK

7.1 Know the major controls/components of Excavator including engine, damper,

pump, travel motor, final drive, under carriage, swing motor.

7.2 Know the components of Dump Truck including engine, clutch, transmission,

differential, wheel and tires, hydraulic system, brake system and steering

system.

7.3 Know the earth moving techniques by Excavator and Dump Truck.

8. KNOW STRUCTURE AND FUNCTION OF SCRAPER AND ROAD STABILIZER

8.1 Know the major components, controls in case of motor scraper and road

stabilizer.

8.2 Know the earth moving techniques by motor scraper and road stabilizer.

9. KNOW STRUCTURE AND FUNCTION OF ROAD ROLLER

9.1 Know the types of road roller to include pneumatic tired rollers, vibratory

roller etc Study of major components/controls in case of road rollers.

Understand the operation techniques by road roller.

10. Know the truck crane, its major components/controls and moving techniques.

11. Know the Asphalt Finishers and Asphalt Distributor, their major components and

Asphalt laying/distributing techniques.

12. KNOW FUEL AND LUBRICANTS

12.1 Know different types of fuels. 12.2 Know fuel used in construction machinery (Diesel). 12.3 Know lubricating oils for engine, transmission and hydraulic system of

construction machinery. 12.4 Know grease used in under carriage of dozer.

13. Know the off road tires, their types and method of identification by code numbers.

14. Know the soils, types, characteristics and field identification of soils and types of

rocks.

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LIST OF PRACTICALS

1. Operating practice of following construction machines:-

a. Tractor

b. Bulldozer

c. Dozer Shovel

d. Loader

e. Motor Grader

f. Excavator

g. Road Roller

h. Crane

j. Scraper

k. Dump Truck

l. Asphalt Finisher

m. Asphalt Distributor

2. Visualize the movie on safety during operation of construction machinery. 3. Visualize the movies on Operation of Construction Machinery. 4. Visits to any on going project in surrounding area of Construction Technology

Training Institute.

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MGM-321 BUSINESS COMMUNICATION

Total contact hours T P C

Theory 32 Hours. 1 0 1

Prerequisites: The students shall already be familiar with the language concerned.

AIM:- The course has been designed to enable the students to:

1. Develop communication skills.

2. Understand basic principles of good and effective business writing in commercial and

industrial fields.

3. Develop knowledge and skill to write technical report with confidence and accuracy.

COURSE CONTENTS

1. COMMUNICATION PROCESS. 6 Hours 1.1 Purposes of communication

1.2 Communication process

1.3 Distortions in communication

1.4 Consolidation of communique

1.5 Communication flow

1.6 Communication for self development

2. ORAL COMMUNICATION SKILLS. 6 Hours 2.1 Significance of speaking.

2.2 Verbal and non-verbal messages.

2.3 Strategic steps of speaking.

2.4 Characteristics of effective oral messages.

2.5 Communication Trafficking.

2.6 Oral presentation.

3. QUESTIONING SKILLS. 3 Hours 3.1 Nature of question.

3.2 Types of questions.

3.3 Characteristics of a good question.

3.4 Questioning strategy

4. LISTENING SKILLS. 5 Hours 4.1 Principles of active listening.

4.2 Skills of active listening.

4.3 Barriers to listening.

4.4 Reasons of poor listening.

4.5 Giving Feedback.

5. INTERVIEWING SKILLS. 3 Hours 5.1 Significance of interviews.

5.2 Characteristics of interviews.

5.3 Activities in an interviewing situation

5.4 Types of interviews.

5.5 Interviewing strategy.

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6. REPORT WRITING. 3 Hours 6.1 Goals of report writing

6.2 Report format.

6.3 Types of reports.

6.4 Report writing strategy.

7. READING COMPREHENSION. 2 Hours 7.1 Reading problems.

7.2 Four Reading skills.

8. GROUP COMMUNICATION. 4 Hours 8.1 Purposes of conducting meetings.

8.2 Planning a meeting.

8.3 Types of meetings.

8.4 Selection f a group for meeting.

8.5 Group leadership skills.

8.6 Running a successful meeting.

8.7 Active participation techniques.

RECOMMENDED BOOKS 1. Sh. Ata-ur-Rehman Effective Business Communication & Report Writing.

2. Ulman J.N. Could JR. Technical Reporting.

142

MGM-321 BUSINESS COMMUNICATION


1. UNDERSTAND THE COMMUNICATION PROCESS.

1.1 State the benefits of two way communication.

1.2 Describe a model of communication process.

1.3 Explain the major communication methods used in organization.

1.4 Identify the barriers to communication and methods of overcoming these barriers.

1.5 Identify misconceptions about communication.

2. UNDERSTAND THE PROCESS OF ORAL.

2.1 Identify speaking situations with other people.

2.2 Identify the strategy steps of speaking.

2.3 Identify the characteristics of effective speaking.

2.4 State the principles of one-way communication.

2.5 State the principles of two-way communication.

2.6 Identify the elements of oral presentation skills.

2.7 Determine the impact of non-verbal communication on oral communication.

3. DETERMINE THE USES OF QUESTIONING SKILLS TO GATHER AND CLARIFY

INFORMATION IN THE ORAL COMMUNICATION PROCESS. 3.1 Identify different types of questions.

3.2 Determine the purpose of each type of question and its application.

3.3 Identify the hazards to be avoided when asking questions.

3.4 Demonstrate questioning skills.

4. DEMONSTRATE THE USE OF ACTIVE LISTENING SKILL IN THE ORAL

COMMUNICATION PROCESS. 4.1 State the principles of active listening.

4.2 Identify skills of active listening.

4.3 Identify barriers to active listening.

4.4 State the benefits of active listening.

4.5 Demonstrate listening skills.

4.6 Explain the importance of giving and receiving feed back.

5. DETERMINE THE APPROPRIATE INTERVIEW TYPE FOR THE SPECIFIC

WORK-RELATED SITUATION AND CONDUCT A WORK-RELATED

INTERVIEW.

5.1 State the significance of interviews.

5.2 State the characteristics of interviews.

5.3 Explain the activities in an interviewing situation.

5.4 Describe the types of interviews.

5.5 Explain the interviewing strategy.

5.6 Prepare instrument for a structured interview.

6. PREPARE A REPORT OUT-LINE, BASED ON SUBJECT MATTER AND

AUDIENCE. 6.1 Identify the different types of reports.

6.2 Determine when to use an informal or formal report presentation.

6.3 Identify the stages of planning a report.

6.4 Identify the parts of a report and choose the parts appropriate for each type of report.

6.5 Draft a report outline.

143

7. DEMONSTRATE READING COMPREHENSION. 7.1 Identify major reading problems.

7.2 Identify basic reading skills.

7.3 State methods of previewing written material.

7.4 Identify methods of concentration when reading.

7.5 Demonstrate reading comprehension.

8. UNDERSTAND THE PRINCIPLES OF GROUP COMMUNICATIONS. 8.1 State the purpose and characteristics of major types of meeting.

8.2 Explain responsibilities of a meeting/committee.

8.3 Identify problems likely to be faced at meeting and means to overcome these problems.

8.4 Distinguish between content and process at meetings.

8.5 Explain the key characteristics of a good group facilitator.

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CMT-315 TRANSMISSION OF CONSTRUCTION MACHINERY T P C Total Content Hours 3 6 5 Theory : 96 Hours Practical : 192 Hours

Pre-requisite:- IC Engine and Workshop Practice - I. AIM:- After studying this course a student will be able to :-

1 Understand the working of mechanical transmission system.

2. Understand the working of clutch.

3. Repair and maintain clutch and mechanical transmission.

4. Understand the fluid coupling and torque converter.

5. Understand the working of hydramatic transmission.

6. Develop skill in servicing and repair of torque converter and hydramatic

transmission.

7. Understand gear ratio and working of epicyclic gear train.

COURSE CONTENT

PART- A MECHANICAL TRANSMISSION

1. INTRODUCTION TO TRANSMISSION 08 Hours

1.1 Power train of wheeled vehicles.

1.2 Power train of tracked vehicles.

1.3 Introduction to gears.

1.4 Transmission, Types of Transmission.

1.5 Fundamentals of direct and indirect transmission.

1.6 Springs, Types of springs, material stiffness of different springs.

2. CLUTCH, ITS FUNCTION AND TYPES 16 Hours

2.1 Clutch and types of clutch, structure and function of dry type clutch (single

disc) and its theoretical capacity, trouble shooting of clutch.

2.2. Structure and function of wet type multi disc and automatic centrifugal weight

type clutches.

2.3 Structure and function of multi disc clutch used in bulldozer. Study of

hydraulic circuit of multi disc clutch.

2.4 Study of gear pump and hydraulic circuit used in multi disc clutch of

bulldozer.

2.5 Rebuilding clutch disc and pressure plate.

2.6 Study of hydraulic booster used in multi disc clutch of bulldozer.

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2.7 Study of over centre system of multi disc clutch of bulldozer.

2.8 Structure and Function of inertia brake band.

2.9 Study of testing and adjustment procedure of multi disc clutch.

2.10 Troubles and remedial measures of multi disc clutch.

3. TYPES OF GEARS 06 Hours

Spur, Helical, Bevel, Hypoid etc, types of gear meshes (slide and

constant), gear train (simple & compound). Material, pressure angles,

and nomenclature of gears.

4. TYPES OF MECHANICAL TRANSMISSION 12 Hours

4.1 Study of selective sliding type of transmission used in bulldozer.

4.2 Study of speed selection criteria of selective sliding type of transmission.

4.3 Study of interlock mechanism of selective sliding type of transmission.

4.4 Troubleshooting of selective sliding type transmission.

4.5 Structure and function of constant mesh type transmission.

4.6 Structure and function of synchro mesh type transmission.

4.7 Types of synchonizing units.

4.8 Structure and function of dump truck transmission based on constant

mesh/synchro mesh.

4.9 Study of different components used in dump truck transmission.

4.10 Study of quadrant box of dump truck transmission.

4.11 Study of hydraulic booster of dump truck transmission.

5. OVER DRIVE AND WHEELING DEVICES 06 Hours

5.1 Study of overdrive system of dump truck.

5.2 Testing of dump truck transmission.

5.3 Troubles of dump truck transmission, their causes and remedial measures.

146

PART- B HYDRAMATIC TRANSMISSION

1. HYDRAULIC PRINCIPLE 02 Hours

Study of basic principle of fluid dynamics i.e. force, density and angle

of incident of oil.

2. PROPERTIES OF FLUIDS 02 Hours

2.1 Pascal’s law and its application.

2.2 Fluid friction, lubrication properties.

3. FLUID COUPLING 06 Hours

3.1 Structure of fluid coupling components and study of hydraulic circuit of

fluid coupling, working principle of fluid coupling, axial flow and radial flow.

3.2. Study of different efficiency graphs to manipulate the performance of

fluid coupling. Disadvantages of fluid coupling on heavy machines.

4. TORQUE CONVERTER 12 Hours

4.1 Structure and function of torque converter.

4.2 Types of torque converters.

4.3 Study of performance characteristics of torque converter.

4.4 Comparison between torque converter and fluid coupling.

4.5 Study of hydraulic circuit of torque converter used in different Construction

Machines.

4.6 Study of pump, regulating valve and relief valve used in torque converter.

4.7 Structure and function of scavenging pump, oil cooler and solenoid valve

used in hydraulic circuit of torque converter.

4.8 Inspection, testing and trouble shooting of torque converter.

4.9 Study of torque converter stall test/leakage test and troubleshooting of

over heating problems.

5. PLANETARY GEAR TRANSMISSION 10 Hours

5.1 Structure and function of planetary gear transmission.

5.2 Study of laws of gearing and study of different vector diagrams used in

speed selection of planetary gear transmission of bulldozer.

5.3. Study of gear ratio of planetary transmission.

5.4 Study of planetary gear transmission of a bulldozer.

5.5 Study of hydraulic circuit of planetary gear transmission of bulldozer.

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6. HYDRAMATIC TRANSMISSION 08 Hours

6.1 Introduction to Hydramatic Transmission of fast moving vehicles.

6.2 Study of power train of wheel loader.

6.3 Study of hydro-shift transmission of wheel loader.

6.4 Study of power circuit of hydro shift transmission for different speeds.

6.5 Structure and function of transmission control valve assembly of

hydroshift transmission of wheel loader.

7. TRANSMISSION CONTROL VALVE ASSEMBLY 08 Hours

7.1 Study of transmission control valve assembly of bulldozer

including modulating, quick return, reducing, direction, speed

and safety valves in it.

7.2. Structure and function of different clutch packs of hydramatic transmission.

7.3 Speed range selection

7.4 Tractive effort.

RECOMMENDED BOOKS

1. Text book of Mechanic – II Chassis Course (CMTI)

2. Shop Manual of D-65,D-85 and D-155

3. Shop Manual of Dump Truck

4. Shop Manual of Wheel Loader

5. Fluid Mechanics by R.S Khurmi

148

CMT-315 TRANSMISSION OF CONSTRUCTION MACHINERY

INSTRUCTIONAL OBJECTIVE

PART- A MECHANICAL TRANSMISSION

After completing this course, the student will be able to:-

1. UNDERSTAND TRANSMISSION

1.1 Explain power train of wheeled vehicles.

1.2 Explain power train of tracked vehicles.

1.3 Define terms related to gears.

1.4 Explain transmission and types of transmission.

1.5 Understand structure and function of direct and indirect transmission.

1.6 Know springs, Types of springs, material stiffness of different springs.

2. UNDERSTAND CLUTCH, ITS FUNCTION AND TYPES

2.1 Describe clutch and types of clutch, structure and function of dry type clutch

(single disc) and its theoretical capacity, trouble shooting of clutch.

2.2. Understand structure and function of wet type multi disc and automatic

centrifugal weight type clutches.

2.3 Understand structure and function of multi disc clutch used in bulldozer.

Study of hydraulic circuit of multi disc clutch.

2.4 Understand gear pump and hydraulic circuit used in multi disc clutch of

bulldozer.

2.5 Understand rebuilding of clutch disc and pressure plate.

2.6 Understand hydraulic booster used in multi disc clutch of bulldozer.

2.7 Understand over centre system of multi disc clutch of bulldozer.

2.8 Understand structure and function of inertia brake band.

2.9 Understand testing and adjustment procedure of multi disc clutch.

2.10 Know troubles and remedial measures of multi disc clutch.

3. DESCRIBE TYPES OF GEARS

Spur, Helical, Bevel, Hypoid etc, types of gear meshes (slide and

constant), gear train (simple & compound). Material, pressure angles,

and nomenclature of gears.

149

4. UNDERSTAND WORKING OF DIFFERENT TYPES OF MECHANICAL TRANSMISSION

4.1 Understand selective sliding type of transmission used in bulldozer.

4.2 Understand speed selection criteria of selective sliding type of transmission.

4.3 Understand interlock mechanism of selective sliding type of transmission.

4.4 Understand troubleshooting and remedial measures of selective sliding type

transmission.

4.5 Understand structure and function of constant mesh type transmission.

4.6 Understand structure and function of synchro mesh type transmission.

4.7 Know types of synchonizing units.

4.8 Understand structure and function of dump truck transmission based on

constant mesh/synchro mesh.

4.9 Know the different components used in dump truck transmission.

4.10 Understand quadrant box of dump truck transmission.

4.11 Understand hydraulic booster of dump truck transmission.

5. UNDERSTAND OVER DRIVE AND WHEELING DEVICES

5.1 Understand overdrive system of dump truck.

5.2 Understand testing of dump truck transmission.

5.3 Know the troubles of dump truck transmission, their causes and remedial

measures.

150

PART- B HYDRAMATIC TRANSMISSION


1. STATE HYDRAULIC PRINCIPLE

Study of basic principle of fluid dynamics i.e. forces, density and angle of

incident of oil.

2. DESCRIBE PROPERTIES OF FLUIDS

2.1 State Pascal’s law and its application.

2.2 Define fluid friction, lubrication properties.

3. UNDERSTAND WORKING OF FLUID COUPLING

3.1 Understand structure of fluid coupling components and study of hydraulic

circuit of fluid coupling. Working principal of fluid coupling, axial flow, radial

flow.

3.2. Draw and explain different efficiency graphs to manipulate the performance

of fluid coupling. State the disadvantages of fluid coupling on heavy

machines.

4. UNDERSTAND WORKING OF TORQUE CONVERTER

4.1 Understand structure and function of torque converter.

4.2 Know the types of torque converters.

4.3 Draw and explain performance characteristics of torque converter.

4.4 Compare torque converter with fluid coupling.

4.5 Draw and explain hydraulic circuit of torque converter used in different

Construction Machines.

4.6 Understand working of pump, regulating valve and relief valve used in torque

converter.

4.7 Understand structure and function of scavenging pump, oil cooler and

solenoid valve used in hydraulic circuit of torque converter.

4.8 Understand inspection, testing and trouble shooting of torque converter.

4.9 Perform torque converter stall test/leakage test and troubleshoot over

heating problems.

151

5. UNDERSTAND THE PLANETARY GEAR TRANSMISSION

5.1 Understand structure and function of planetary gear transmission.

5.2 State laws of gearing and study of different vector diagrams used in speed

selection of planetary gear transmission of bulldozer.

5.3. Define gear ratio of planetary transmission.

5.4 Understand structure and function of planetary gear transmission of a

bulldozer.

5.5 Draw and explain hydraulic circuit of planetary gear transmission of

bulldozer.

6. UNDERSTAND STRUCTURE AND FUNCTION OF HYDRAMATIC TRANSMISSION

6.1 Understand hydramatic Transmission of fast moving vehicles.

6.2 Describe power train of wheel loader.

6.3 Understand hydro-shift transmission of wheel loader.

6.4 Understand power circuit of hydro shift transmission for different speeds.

6.5 Understand structure and function of transmission control valve assembly of

hydro shift transmission of wheel loader.

7. UNDERSTAND WORKING OF TRANSMISSION CONTROL VALVE ASSEMBLY

7.1 Understand function of transmission control valve assembly of bulldozer

including modulating, quick return, reducing, direction, speed

and safety valves in it.

7.2. Understand structure and function of different clutch packs of Hydramatic

transmission.

7.3 Understand speed range selection

7.4 Define tractive effort.

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CMT-315 TRANSMISSION OF CONSTRUCTION MACHINERY

LIST OF PRACTICALS

PART –A, MECHANICAL TRANSMISSION

1. Brief demonstration of all components used in the power train of track and wheeled

vehicles including fly wheel, multi disc clutch, torque convertor, all types of

transmission, steering and brake system, final drive, under carriage and

differentials.

2. Demonstration/study of single disc clutch, pressure plate housing, release bearing

and its other mechanical linkages.

3. Adjustment procedures and demonstration on various vehicles for single disc clutch.

4. Demonstration and study of hydraulic circuit of multi disc clutch of a bulldozer.

5. Demonstration of dismounting of multi disc clutch assembly from bulldozer.

6. Disassembling of multi disc clutch (bulldozer).

7. To familiarize the students with different components of multi disc clutch

(disassembled).

8. Assembling of multi disc clutch.

9. Demonstration of mounting of multi disc clutch on bull dozer.

10. Demonstration on different types of transmission used in construction machinery.

11. Demonstration on selective sliding type transmission used in bulldozer.

12. Demonstration of dismounting of selective sliding type transmission from bulldozer.

13. Disassembling of selective sliding type transmission. 14. Study of different components of selective sliding type of transmission.

15. Assembling of selective sliding type of transmission.

16. Demonstration of mounting of selective sliding type transmission on bulldozer.

17. Disassembling of synchromesh transmission of Dump Truck.

18. Study of components of dump truck transmission.

20. Assembling of dump truck transmission.

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PART – B, HYDRAMATIC TRANSMISSION

1. Demonstration on different parts of fluid coupling.

2. Demonstration and study on cutaway model of fluid coupling/torque converter.

3. Demonstration on different components used in a torque converter.

4. Disassembling of torque converter of bulldozer.

5. Component study of disassembled torque converter of bulldozer.

6. Assembling of torque converter of bulldozer.

7. Demonstration and practice of torque converter stall test on bulldozer.

8. Demonstration and practice of torque converter leakage test on bulldozer.

9. Study of planetary gear transmission on cutaway model of bulldozer.

10. Disassembling of planetary gear transmission of bulldozer.

11. Components study and power circuit of planetary gear transmission of bulldozer.

12. Study of lubrication circuit of planetary gear transmission.

13. Study of control valves used in planetary gear transmission.

14. Assembling of planetary gear transmission.

15. Disassembling of planetary gear transmission of various types of bulldozers.

16. Components study of planetary gear transmission of various types of bulldozers.

17. Assembling of planetary gear transmission of various types of bulldozers.

18. Disassembling of Hydroshift Transmission of wheel loader.

19. Study of different components of Hydroshift Transmission of Wheel Loader.

20. Circuit tracing of control valve Assembly of Hydroshift Transmission of wheel loader.

21. Assembling of Hydroshift Transmission of Wheel Loader.

154

CMT-323 STEERING AND BRAKE SYSTEM OF CONSTRUCTION MACHINERY


Theory - 64 2 3 3

Practical - 96 Pre-Requisite:- Workshop Practice – I and Operation of Construction Machinery.

AIM:- After studying this course a student will be able to :-

1. Understand the structure and function of steering and brake system of bulldozer.

2. Test and adjust the steering and brake system of bulldozer.

3. Understand the structure and function of steering system of wheeled vehicles.

4. Understand the structure and function of steering system of motor grader.

5. Understand the structure and function of steering system of wheel loader.

6. Understand various types of automotive brakes.

7. Understand the hydro-vacuum brake system motor grader.

8. Understand the hydraulic brake system of wheel loader.

9. Understand the air brake system of dump truck.

COURSE CONTENTS

1. STEERING AND BRAKE SYSTEM OF BULLDOZER 14 Hours

1.1 Classification of steering clutches used in bulldozers.

1.2 Structure and function of steering clutch CL-I type used in Bulldozer

D 85-12.

1.3 Structure and function of steering clutch CL-III type used in Bulldozer

D-65.

1.4 Comparison of steering systems of dozer and dozer shovel.

1.5 Study of steering control valve assembly of bulldozer.

1.6 Study of modulating valve used in steering control valve of bulldozer.

1.7 Study of steering pump used in bulldozer.

1.8 Study of different steering circuits of dozers.

1.9 Study of different brake circuits of dozers.

1.10 Study of brake system of dozer.

155

1.11 Testing and adjusting of steering and brake system of bulldozer.

1.12 Introduction to hydrostatic steering system.

2. STEERING SYSTEM OF WHEELED VEHICLES 10 Hours

2.1 Purpose of steering system of wheeled vehicles.

2.2 Components of steering system of wheeled vehicles.

2.2.1 Steering wheel 2.2.2 Steering shaft 2.2.3 Steering column 2.2.4 Steering gear box 2.2.5 Pitman arm 2.2.6 Relay rod 2.2.7 Idler arm 2.2.8 Tie rod 2.2.9 Steering arm. 2.3 Re-circulating-ball type steering gear. 2.4 Rack - and pinion steering gear. 2.5 Wheel – Alignment angles. 2.5.1 Suspension height 2.5.2 Camber 2.5.3 Steering axis inclination 2.5.4 Caster 2.5.5 Toe and turning radius 3. STEERING SYSTEM OF MOTOR GRADER 6 Hours

3.1 Structure and function of orbit roll type steering valve used in motor grader. 3.2 Flow of oil through orbit roll control valve during neutral, right turning

and left turning of motor grader. 3.3 Structure and function of flow control valve of motor grader. 3.4 Front end geometry of motor grader, its inspection, testing and adjustment. 3.5 Functions of front axle of motor grader. 4. STEERING SYSTEM OF WHEEL LOADER 6 Hours 4.1 Hydraulic circuit of steering system of wheel loader during neutral

position, right turning and left turning. 4.2 Operation of demand spool 4.3 Operation of steering relief valve. 4.4 Operation of safety valve with suction valve. 4.5 Operation of two way restrictor valve.

156

5. BRAKE SYSTEM OF AUTOMOTIVES 6 Hours

5.1 Classification of brakes. 5.2 Structure and function of drum brakes. 5.3 Construction of master cylinder and wheel cylinders. 5.4 Structure and function of different types of disc brakes. 5.5 Purpose and operation of Anti Lock Barking System (ABS). 6. BRAKE SYSTEM OF MOTOR GRADER 10 Hours 6.1 Brake piping diagram and operation of hydro master. 6.2 Disc type air brake system of motor grader and its circuit diagram.

6.3 Operation of brake valve, relay valve, air governor, pressure switch, automatic drain valve and air drier.

7. BRAKE SYSTEM OF WHEEL LOADER 4 Hours

7.1 Structure and operation of power master cylinder 7.2 Braking operation 8. BRAKE SYSTEM OF DUMP TRUCK 8 Hours

8.1 Air charging circuit of Dump Truck. 8.2 Front brake circuit of Dump Truck. 8.3 Rear brake circuit of Dump Truck. 8.4 Parking brake circuit of Dump Truck. REFERENCE BOOKS

1 Shop Manuals of Bulldozers

2. Unit Instruction Manuals of dump truck brake

3. Shop Manual of wheel loader

4. Shop Manual of motor grader

5. Automotive Mechanics by William H. Crouse.

6. Text book of Mechanic – II Chassis Course (CMTI)

157



After completing this course the student will be able to:-

1. UNDERSTAND STEERING AND BRAKE SYSTEM OF BULLDOZER

1.1 Classify of steering clutches.

1.2 Understand structure and function of steering clutch CL-I type used in

Bulldozer D 85-12.

1.3 Understand structure and function of steering clutch CL-III type used in

Bulldozer D-65.

1.4 Compare the steering systems of dozer and dozer shovel.

1.5 Understand steering control valve assembly of bulldozer.

1.6 Understand modulating valve used in steering control valve.

1.7 Understand the working of the steering pump.

1.8 Understand different steering circuits of dozers.

1.9 Understand different brake circuits of dozers.

1.10 Understand brake system of dozer.

1.11 Test and adjust steering and brake system.

1.12 Understand operation of hydrostatic steering system.

2. UNDERSTAND THE STEERING SYSTEM OF WHEELED VEHICLES

2.1 State the purpose of steering system of wheeled vehicles.

2.2 Understand structure and function of components of steering system.

2.2.1 Steering wheel

2.2.2 Steering shaft

2.2.3 Steering column

2.2.4 Steering gear box

2.2.5 Pitman arm

2.2.6 Relay rod

2.2.7 Idler arm

2.2.8 Tie rod

2.2.9 Steering arm.

158

2.3 Understand the structure and function of re-circulating-ball type

steering gear.

2.4 Understand the structure and function of rack - and pinion steering gear.

2.5 Define and explain Wheel – Alignment angles.

2.5.1 Suspension height

2.5.2 Camber

2.5.3 Steering axis inclination

2.5.4 Caster

2.5.5 Toe and turning radius

3. UNDERSTAND STEERING SYSTEM OF MOTOR GRADER {{

3.1 Understand structure and function of orbit roll type steering valve used in

motor grader.

3.2 Explain flow of oil through orbit roll control valve during neutral, right

turning and left turning of motor grader.

3.3 Understand structure and function of flow control valve of motor grader.

3.4 Define and explain front end geometry of motor grader, its inspection,

testing and adjustment.

3.5 Explain functions of front axle of motor grader.

4. UNDERSTAND STEERING SYSTEM OF WHEEL LOADER

4.1 Explain hydraulic circuit of steering system of wheel loader during neutral

position, right turning and left turning.

4.2 Describe operation of demand spool

4.3 Describe operation of steering relief valve.

4.4 Describe operation of safety valve with suction valve.

4.5 Describe operation of two way restrictor valve.

159

5. UNDERSTAND BRAKE SYSTEM OF AUTOMOTIVES 5.1 Classify the brakes. 5.2 Understand structure and function of drum brakes. 5.3 Understand structure and function of different types of disc brake 5.4 Understand construction of master cylinder and wheel cylinders 5.5 Understand purpose and operation of Anti Lock Barking System (ABS) 6. UNDERSTAND BRAKE SYSTEM OF MOTOR GRADER 6.1 Understand brake piping diagram and operation of hydro master 6.2 Understand disc type air brake system of motor grader and its circuit 6.3 Understand operation of brake valve, relay valve, air governor, pressure

switch, a automatic drain valve and air driver. 7. UNDERSTAND BRAKE SYSTEM OF WHEEL LOADER 7.1 Understand structure and operation of power master cylinder 7.2 Understand braking operation of Wheel Loader 8. UNDERSTAND BRAKE SYSTEM OF DUMP TRUCK 8.1 Understand air charging circuit of Dump Truck. 8.2 Understand front brake circuit of Dump Truck. 8.3 Understand rear brake circuit of Dump Truck. 8.4 Understand parking brake circuit of Dump Truck.

160


LIST OF PRACTICALS

1. Demonstration on layout of steering system of bulldozer on the machine.

2. Demonstration on cutaway model of steering clutch of CL-I type.

3. Demonstration on cutaway model of steering clutch of CL-III type.

4. Disassembling of steering clutch.

5. Assembling of steering clutch,

6. Study of hydraulic circuit board of steering system in the shop.

7. Disassembling of steering control valve assembly of bulldozer.

8. Assembling of steering control valve assembly of dozer.

9. Disassembling of steering pump of bulldozer.

10. Assembling of steering pump of bulldozer.

11 Testing and adjusting of steering and brake system of dozer according to shop

manual.

12. Demonstration on steering linkages of wheeled vehicles.

13 Demonstration on steering gear cutaway models

14. Demonstration on cutaway model of orbit roll type valve of motor grader.

15. Demonstration of steering system of wheel loader on the machine

16. Testing and adjusting of TOE of motor grader.

17. Demonstration on cutaway model of steering control valve of wheel loader.

18. Demonstration on cutaway model of hydro master used in motor grader brake.

19. Demonstration on air brake system board.

20. Demonstration on drum type brake model.

21. Demonstration on disc type brake model.

161

CMT-333 FINAL DRIVE, UNDER CARRIAGE AND POWER LINE



Practical 96 Hours

Pre-requisite: Workshop Practice – I and II.


1. Understand the final drive system of tracked and wheeled vehicles.

2. Define and explain different terms related to undercarriage.

3. Measure different components of undercarriage and utilize these

measurements to find out remaining life of undercarriage.

4. Know different techniques to prolong the undercarriage life from view

points of operational control and service/maintenance.

5. Rebuild the under carriage parts.

6. Understand the structure and function of OR tires.

COURSE CONTENTS

1. FINAL DRIVE SYSTEM OF TRACKED VEHICLES 8 Hours

1.1 Power line of bulldozer

1.2 Structure and function of Final Drive System of Bulldozer

1.3 Study of disassembling procedure of final drive system of bulldozer.

1.4 Study of assembling procedure of Final Drive System of Bulldozer.

2 FINAL DRIVE SYSTEM OF WHEELED VEHICLES 10 Hours

2.1 Power line of wheeled vehicles to include universal joint, slip joint,

propeller shaft, Differential, Axle types – plain, semi - floating,

three quarter floating and full floating axles.

2.2 Structure and function of differential used in wheeled vehicles.

2.3 Structure and function of inter axle differential assembly of dump Truck.

2.4 Testing and adjustment of inter-axle differential assembly of dump Truck.

162

3. UNDERCARRIAGE OF TRACKED VEHICLES 14 Hours

3.1 Introduction to undercarriage group of tracked vehicles,

its importance and function.

3.2 Structure and function of sprocket, Idler wheel, track roller, carrier roller,

track shoes, track links and floating seals.

3.3 Structure and function of recoil spring, equalizer bar and frame.

3.4 Introduction to measuring tools used for undercarriage components.

3.5 Measurement procedures for diameter of carrier roller and track roller, link

height, link pitch, idler wheel’s diameter, idler’s tread width and roller’s

flange.

3.6 Study the techniques to prolong the life of undercarriage parts from

operational point of view.

3.7 Study the techniques to prolong the life of undercarriage components

from service and maintenance point of view.

3.8 Adjustment procedures of track chain tension.

4. TROUBLES OF UNDERCARRIAGE PARTS AND THEIR REMEDIAL ACTIONS 12 Hours

4.1 Fundamentals of sprocket.

4.2 Causes and remedies of sprocket wear on forward and reverse drive

side when tracks are installed in normal manner and adverse manner.

4.3 Causes and remedies of wear of link, pin boss side faces, link mating

faces.

4.4 Causes and remedies of wear of pin and bushings, cracks in bushings.

4.5 Causes and remedies of wear of roller tread and roller flanges.

4.6 Causes and remedies of wear of grouser and plates of track shoes.

5. REBUILDING OF UNDERCARRIAGE PARTS BY WELDING 10 Hours

5.1 Rebuilding of track and carrier rollers.

5.2 Rebuilding of Idler.

5.3 Rebuilding of sprocket.

5.4 Rebuilding of track link.

5.5 Rebuilding of track shoe grouser.

5.6 Turning of link pins and bushings.

163

6. OFF ROAD TIRES 10 Hours

6.1 Nomenclature of OR tires.

6.2 Different parts of OR tires.

6.3 Different types of tread of OR tires and their application on

construction Machines.

6.4 Selection of appropriate tire according to load and road conditions.

6.5 Traction and flotation properties of OR tires and Ballast tires.

6.6 Importance of Ton Kilometer Per Hour (TKPH) value of a tire.

6.7 Correct way to use tires.

6.8 Comparison between tube type and tube less type tires.

REFERENCE BOOKS

1. Shop manuals of bulldozers by Komatsu

2. Unit Instruction Manuals of undercarriage by JICA

3. Structure of Tires by JICA.

4. Automotive Mechanics by William H. Crouse.

5. Text Book of Mechanic – II Chassis Course (CMTI)

164



On completion of this course, the student will be able to:-

1. UNDERSTAND FINAL DRIVE SYSTEM OF TRACKED VEHICLES

1.1 Define and draw Power line of bulldozer

1.2 Describe the structure and function of Final Drive System of Bulldozer

1.3 Understand disassembling procedure of final drive system of bulldozer.

1.4 Understand assembling procedure of Final Drive System of Bulldozer.

2 UNDERSTAND FINAL DRIVE SYSTEM OF WHEELED VEHICLES

2.1 Describe the power line of wheeled vehicles to include universal joint, slip

joint, propeller shaft, Differential, Axle types – plain, semi - floating, three

quarter floating and full floating axles.

2.2 Understand structure and function of differential used in wheeled vehicles.

2.3 Understand structure and function of inter axle differential assembly of dump

Truck.

2.4 Understand testing and adjustment of inter-axle differential assembly of

dump Truck.

3. UNDERSTAND UNDERCARRIAGE OF TRACKED VEHICLES

3.1 Describe undercarriage group of tracked vehicles, its importance and

function.

3.2 Understand structure and function of sprocket, Idler wheel, track roller,

carrier roller, track shoes, track links and floating seals.

3.3 Understand structure and function of recoil spring, equalizer bar and frame.

3.4 Recognize measuring tools used for undercarriage components.

3.5 Measure the diameter of carrier roller and track roller, link height, link pitch,

idler wheel’s diameter, idler’s tread width and roller’s flange.

3.6 Describe the techniques to prolong the life of undercarriage parts from

operational point of view.

3.7 Describe the techniques to prolong the life of undercarriage components

from service and maintenance point of view.

3.8 Understand adjustment procedures of track chain tension.

165

4. UNDERSTAND TROUBLESHOOTING OF UNDERCARRIAGE PARTS

4.1 Describe fundamentals of sprocket.

4.2 Describe causes and remedies of sprocket wear on forward and reverse drive

side when tracks are installed in normal manner and adverse manner.

4.3 Describe causes and remedies of wear of link, pin boss side face, link mating

faces.

4.4 Describe causes and remedies of wear of pin and bushings, cracks in

bushings.

4.5 Describe causes and remedies of wear of roller tread and roller flanges.

4.6 Describe causes and remedies of wear of grouser and plates of track shoes.

5. UNDERSTAND REBUILDING OF UNDERCARRIAGE PARTS BY WELDING

5.1 Understand rebuilding of track and carrier rollers.

5.2 Understand rebuilding of Idler.

5.3 Understand rebuilding of sprocket.

5.4 Understand rebuilding of track link.

5.5 Understand rebuilding of track shoe grouser.

5.6 Understand turning of link pins and bushings.

6. KNOW THE STRUCTURE AND FUNCTIONS OFF ROAD TIRES

6.1 Describe nomenclature of OR tires.

6.2 Describe different parts of OR tires.

6.3 Describe different types of tread of OR tires and their application.

6.4 Explain selection of appropriate tire according to load and road conditions.

6.5 Define traction and flotation properties of OR tires and Ballast tires.

6.6 Know importance of Ton Kilometer per hour (TKPH) value of a tire.

6.7 Understand correct way to use tires.

6.8 Compare tube type tires with tube less type tires.

166


LIST OF PRACTICAL

1. Demonstration of power line of bulldozer on the machine

2. Disassembling of Final Drive of Bulldozer.

3. Assembling of Final Drive of Bulldozer.

4. Demonstration on track group of dozer.

5. Demonstration on recoil spring in chassis shop.

6. Introduction to measurement tools for undercarriage parts.

7. Measurement of track roller

8. Measurement of carrier roller

9. Measurement of idler wheel

10. Measurement of link pitch of track chain of dozer.

11. Measurement of pin and bushing.

12. Demonstration on differential model of a wheeled vehicle.

13. Study of cutaway model of differential assembly.

14. Disassembling of inter-axle differential assembly of dump truck.

15. Assembling of inter-axle differential assembly of dump truck.

16. Demonstration on track link rebuilding machine.

17. Disassembling of track chain with the help of hydraulic press.

18. Assembling of track chain with the help of hydraulic press.

19. Adjustment of track tension of track chain of a bulldozer.

20. Observation of OR tires on different wheeled vehicles like dump track, wheel

loader and motor grader.

167

CMT-343 HYDRAULIC SYSTEM OF CONSTRUCTION MACHINERY



Practical 64 Hours

Pre-requisite: Applied Physics and Applied Mechanics


1. Define the basic terms and principles of hydraulics.

2. Recognized different hydraulic symbols.

3. Understand and draw hydraulic circuits.

4. Understand the structure and function of different components of

hydraulic system of bulldozer.

5. Test and adjust the hydraulic system of bulldozer.

6. Trouble shoot the hydraulic system of bulldozer.

COURSE CONTENTS

1. BASIC HYDRAULICS 10 Hours

1.1 Hydraulics

1.2 Pascal’s, law and hydraulic press.

1.3 Pressure 1.3.1 Atmospheric pressure 1.3.2 Gauge pressure 1.3.3 Vacuum pressure 1.3.4 Absolute pressure 1.3.5 Units of pressure in different measuring systems and their

conversion.

1.4 Flow and Flow Rate. 1.4.1 Flow Rate and its units in different systems and their conversion 1.4.2 Two methods of flow rate measurement (weight and Volume) 1.4.3 Types of flow meters.

1.5 Definitions of Entrained Air, Dissolved Air, Aeration, Set/Rated pressure, cracking pressure, surge pressure and fluid power.

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2. HYDRAULIC SYSTEM OF BULLDOZER 10 Hours

2.1 Definition of hydraulic system of bulldozer.

2.2 Parallel and series hydraulic systems.

2.3 Open centre and close centre hydraulic systems

2.4 Introduction to different components like hydraulic tank, hydraulic pump,

control valves, hydraulic cylinder, pipes/hoses, filter, cooler, and their

combination.

2.5 Symbols used for different components of hydraulic system

2.6 Study of hydraulic circuit of bulldozers in raise, lower, hold and float

positions of blade.

3. HYDRAULIC PUMP 12 Hours

3.1 Principle of hydraulic pumps of dozer

3.2 Nomenclature of Komatsu hydraulic pumps used in dozer.

3.3 Structure and function of FAL, GAL and PAL type pumps.

3.4 Design aspects of PAL type gear pump to include relief recess,

floating bush, side and radial clearances, pressure balancing groove.

3.5 Study of different graphs governing the discharge rate (capacity) of

pump at different discharge pressures, clearances, and viscosities of oil.

3.6 Eradication of problems of hydraulic pump like damages due to dirty

and foamy oil, and cavitations due to aeration.

4. CONTROL VALVES 12 Hours

4.1 Types of valves - pressure control, direction control and flow control

valves.

4.2 Structure and function of poppet, spool and pilot operated type main

relief Valves and their comparison.

4.3 Testing and adjusting of set pressure of main relief valve.

4.4 Safety valve or line relief valve.

4.5 Structure and function of check valve and suction valve.

4.6 Pressure compensated flow control valve.

4.7 Different positions of direction control spool type valve like Raise,

lower, hold and float.

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4.8 Smooth movement of spool type valve due to annular grooves, notches.

4.9 Function of detent and detent spring

4.10 Study of single spool, double spool and triple spool control valve

assemblies used in different dozers along with their hydraulic circuits.

5. HYDRAULIC CYLINDER 10 Hours

5.1 Types of hydraulic cylinder.

5.2 Structure and function of different components like piston, piston valve,

cylinder, cylinder head.

5.3 Structure and function of piston rings, wear ring, U Packing,

V - Packing and dust seal.

5.4 Structure and function of quick drop valve used in hydraulic cylinder.

5.5 Creeping rate/hydraulic drift test of work equipment of bulldozer.

5.6 Speed test of blade of bulldozer .

5.7 Machine lifting test of bulldozer

6. TROUBLE SHOOTING OF HYDRAULIC SYSTEM 6 Hours

6.1 Causes and remedies of lack of blade lifting force.

6.2 Causes and remedies of low lifting speed of blade.

6.3 Causes and remedies of blade not lifting.

6.4 Causes and remedies of larger hydraulic drift of lift cylinder.

6.5 Causes and remedies of pump failure.

6.6 Causes and remedies of relief valve failures

6.7 Causes and remedies of hydraulic cylinder failure.

7. HYDRAULIC OIL 4 Hours

7.1 Different grades of oils.

7.2 Viscosity and viscosity Index of oils.

7.3 Causes of deterioration of oil and preventive suggestions.

RECOMMENDED BOOKS.

1. Text book of hydraulic by Hitachi heavy industries ltd.

2. Shop manuals of D-85, D-65 and D-155 Komatsu bulldozer.

3. Advanced vehicle technology by Hemnz Hessel.

4. Text Book of Mechanic – II Chassis Course (CMTI)

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CMT-343 HYDRAULIC SYSTEM OF CONSTRUCTION MACHINERY


After completing this course the student will be able to:-

1. UNDERSTAND BASIC HYDRAULICS

1.1 Define hydraulics

1.2 State pascal’s, law and hydraulic press.

1.3 Define pressure 1.3.1 Atmospheric pressure 1.3.2 Gauge pressure 1.3.3 Vacuum pressure 1.3.4 Absolute pressure 1.3.5 Units of pressure in different measuring systems and their

conversion.

1.4 Define and explain Flow and Flow Rate:- 1.4.1 Flow Rate and its units in different systems and their

conversion 1.4.2 Two methods of flow rate measurement (weight and Volume) 1.4.3 Types of flow meters.

1.5 Define and explain Entrained Air, Dissolved Air, Aeration, Set/Rated

pressure, cracking pressure, surge pressure fluid power.

2. UNDERSTAND HYDRAULIC SYSTEM OF BULLDOZER

2.1 Define the hydraulic system of bulldozer.

2.2 Define Parallel and series hydraulic systems.

2.3 Define Open centre and close centre hydraulic systems

2.4 Know different components like hydraulic tank, hydraulic pump, control

valves, hydraulic cylinder, pipes/hoses, filter, cooler, and their combination.

2.5 Recognize symbols used for different components of hydraulic system

2.6 Understand and draw hydraulic circuit of bulldozers in raise, lower, hold and

float positions of blade.

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3. UNDERSTAND THE WORKING OF HYDRAULIC PUMP

3.1 State principle of hydraulic pump of dozer

3.2 Explain nomenclature of Komatsu hydraulic pumps of dozer.

3.3 Understand structure and function of FAL, GAL and PAL type pumps.

3.4 Explain design aspects of PAL types gear pump to include relief recess,

floating bush, side and radial clearances, pressure balancing groove.

3.5 Draw and explain different graphs governing the discharge rate (capacity)

of pump at different discharge pressures, clearances, and viscosities of oil.

3.6 Eradicate the problems of hydraulic pump like damages due to dirty

and foamy oil, and cavitations due to aeration.

4. UNDERSTAND STRUCTURE AND FUNCTION OF CONTROL VALVES

4.1 Describe Types of valves - pressure control, direction control and flow

control valves.

4.2 Understand Structure and function of poppet, spool and pilot operated

type main relief Valves and their comparison.

4.3 Test and adjust the set pressure of main relief valve.

4.4 Understand safety valve or line relief valve.

4.5 Understand structure and function of check valve and suction valve.

4.6 Understand pressure compensated flow control valve.

4.7 Understand different positions of direction control spool type valve like

Raise, lower, hold and float.

4.8 Know the smooth movement of spool type valve due to annular grooves,

notches.

4.9 Know the function of detent and detent spring.

4.10 Understand the working of single spool, double spool and triple spool control

valve assemblies used in different dozers along with their hydraulic circuits.

5. UNDERSTAND STRUCTURE AND FUNCTION OF HYDRAULIC CYLINDER

5.1 Describe types of hydraulic cylinder.

5.2 Understand structure and function of different components like piston,

piston valve, cylinder, cylinder head.

5.3 Understand structure and function of piston rings, wear ring, U Packing,

V - Packing and dust seal.

5.4 Understand structure and function of quick drop valve used in hydraulic

cylinder.

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5.5 Understand creeping rate/hydraulic drift test of work equipment.

5.6 Perform speed test of blade of bulldozer.

5.7 Perform machine lifting test of bulldozer

6. UNDERSTAND HYDRAULIC SYSTEM TROUBLE SHOOTING

6.1 Know the causes and remedies of lack of blade lifting force.

6.2 Know the causes and remedies of low lifting speed of blade.

6.3 Know the causes and remedies of blade do not lift

6.4 Know the causes and remedies of larger hydraulic drift of lift cylinder.

6.5 Know the causes and remedies of pump failure..

6.6 Know the causes and remedies of relief valve failures

6.7 Know the causes and remedies of hydraulic cylinder failure.

7. KNOW THE PROPERTIES OF HYDRAULIC OIL

7.1 Classify different grades of oils.

7.2 Define viscosity and viscosity Index of oils.

7.3 Know causes of deterioration of oil and preventive suggestions.

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CMT-343 HYDRAULIC SYSTEM OF CONSTRUCTION MACHINERY LIST OF PRACTICALS 1. Study of hydraulic circuit of hydraulic system of bulldozer on board in

workshop to recognize different hydraulic symbols

2. Demonstration of piping of hydraulic system of bulldozer on the machine.

3. Introduction to hydraulic components used in hydraulic system of bulldozer

4. Demonstration on cutaway model of PAL type hydraulic pump.

5. Disassembling of PAL type hydraulic pump.

6. Assembling of PAL type hydraulic pump.

7. Flow rate measurement of hydraulic pump by flow meter.

8. Discharge pressure measurement of hydraulic pump by pressure gauges.

9. Demonstration on cutaway model of hydraulic Tank of D-85 dozer.

10. Disassembling of hydraulic tank of D-85 dozer.

11. Assembling of hydraulic tank of D-85 dozer.

12. Demonstration on cutaway model of hydraulic Tank of D-155 dozer.

13. Disassembling of hydraulic tank of D-155 dozer

14. Assembling of hydraulic tank of D-155 dozer.

15. Testing and adjusting of set pressure of main relief valve.

16. Demonstration on cutaway model of hydraulic cylinder.

17. Demonstration on hydraulic service stand to install new packings of hydraulic

cylinder.

18. Speed test of raising and lowering of blade of bulldozer.

19. Hydraulic drift test of blade of bulldozer.

20. Machine lifting test of bulldozer.

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CMT-353 HYDRAULIC EXCAVATOR

Total Contact Hours T P C Theory 64 Hours 2 3 3 Practical 96 Hours AIM:- After studying this course a student will be able to:

a. Understand the structure and function of different components used in various systems of Hydraulic Excavator.

b. Understand Hydraulic Circuit of different systems of Hydraulic Excavator. c. Test and adjust different systems of Hydraulic Excavator.

COURSE CONTENTS 1. INTRODUCTION TO HYDRAULIC EXCAVATORS 4 Hours

1.1 Over all structure of Hydraulic Excavator. 1.2 Nomenclature of Komatsu Excavators 1.3 Attachments of Hydraulic Excavators.

2. POWER TRAIN OF HYDRAULIC EXCAVATOR PC200-3 12 Hours

2.1 Hydraulic circuit of power train of PC200-3. 2.2 Travel and brake system of Hydraulic Excavator PC200-3. 2.2.1 Outline.

2.2.2 Hydraulic circuit of Travel Control of PC200-3. 2.2.3 Structure and function of Centre Swivel joint of PC200-3.

2.2.4 Structure and operation of Travel Motor of PC200-3. 2.2.5 Structure and operation of Parking Brake of PC200-3. 2.2.6 Structure and operation of travel brake valve of PC200-3

including counter balance valve and safety valve 2.2.7 Structure and operation of Final Drive system of PC200-3.

2.3 Swing System of Hydraulic Excavator PC200-3. 2.3.1 Outline.

2.3.2 Hydraulic circuits of swing system. 2.3.3 Structure and operation of Swing Priority Valve. 2.3.4 Structure and operation of Swing Motor, swing brake

and safety valve. 2.3.5 Structure, function and operation of swing machinery. 2.3.6 Structure and operation of Swing Circle.

3. HYDRAULIC SYSTEM OF HYDRAULIC EXCAVATOR PC200-3 20 Hours

3.1 Hydraulic piping of PC200-3. 3.2 Structure and operation of swash plate type pump used in PC200-3.

3.3 Structure and function of servo valve unit. 3.4 Operation of servo valve to increase the delivery amount of pump.

3.5 Operation of servo valve to decrease the delivery amount of pump. 3.6 Function of charging pump along with relief valve function.

3.7 Specifications of hydraulic tank used in PC200-3 3.8 Function and operation of PPC (Proportional pressure control) valve. 3.9 Hydraulic circuit for operation of arm control lever in ARM IN position.

3.10 Hydraulic circuit for operation of arm control lever in ARM OUT position.

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3.11 Function and operation of arm throttle valve. 3.12 Hydraulic circuit for operation of bucket control lever in

BUCKET CURL position. 3.13 Hydraulic circuit for operation of bucket control lever in

BUCKET DUMP position. 3.14 Hydraulic circuit for operation of boom control lever in

BOOM RAISE position. 3.15 Hydraulic circuit for operation of boom control lever in

BOOM LOWER position.

4. OPEN CENTRE LOAD SENSING SYSTEM (OLSS) OF PC 200-3 8 Hours 4.1 Introduction to OLSS of PC200-3. 4.2 Functions of OLSS.

4.3 Basic circuit of OLSS. 4.4 Structure, function and operation of Torque Variable Control (TVC) Valve. 4.5 Structure, function and operation of Cut - off (CO) Valve. 4.6 Structure, function and operation of Flow Control / Negative Control

(NC) Valve. 4.7 Hydraulic control valve (4 spools and 5 spools). 4.8 Structure and function of main relief valve. 4.9 Structure and function of safety section valve. 4.10 Structure and function of accumulator.

5. HYDRAULIC SYSTEM OF HYDRAULIC EXCAVATOR PC150-1 14 Hours 5.1 Structure and function of bent axis type Piston Pump used in PC150-1.

5.2 Comparison between PC Control Mechanism and Constant Delivery System. 5.3 Comparison between Interconnected dual pump PC Control

Mechanism and an Individual PC Control Mechanism. 5.4 Structure and function of PC Regulator Valve. 5.5 Structure and function of Side Branch Hose. 5.6 Hydraulic control valve assembly (4 spools and 3 spools) 5.7 Structure, function and operation of Main Relief Valve. 5.8 Operation of Safety Valve (Differential type). 5.9 Operation of Safety Valve (Poppet valve). 5.10 Structure, function and operation of Safety Valve (with Suction Valve).

5.11 Principle of operation of leveling system. 5.12 Function and operation of slow return valve (variable throttle type). 5.13 Operating principle, construction and function of Swing Motor (PC150-1).

5.14 Operation of parking brake in swing system. 5.15 Function and operation of swing brake valve including counter balance

valve and safety valve. 5.16 Structure and function of Travel Motor (PC150-1) with built-in brake valve.

5.17 Function and operation of parking brake in travel system. 5.17 Function and operation of reduction gear.

6. TESTING AND ADJUSTING OF HYDRAULIC EXCAVATOR 6 Hours 6.1 Measuring Work Equipment speed.

6.2 Measuring Time Lag of Work Equipment. 6.3 Measuring Hydraulic Drift of Work Equipment. 6.4 Measuring deviation in travel.

6.5 Measuring travel speed. 6.6 Testing Swing Performance.

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BOOKS RECOMMENDED

1. Shop Manual Komatsu PC 200-3. 2. Shop Manual Komatsu PC 150-3. 3. Unit Instruction Manual of Hydraulic Excavator.

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CMT 363 HYDRAULIC EXCAVATOR

INSTRUCTIONAL OBJECTIVES: On the completion of Course the student will be able to

1. UNDERSTAND THE BASICS OF HYDRAULIC EXCAVATORS 1.1 Understand the overall structure of Hydraulic Excavator. 1.2 Understand the nomenclature of Komatsu Excavator. 1.3 Know the attachments of Hydraulic Excavator.

2. UNDERSTAND THE POWER TRAIN 2.1 Understand the circuit of power train of Hydraulic Excavator PC200-3.

2.2 Understand Travel and Brake System of Hydraulic Excavator PC200-3. 2.2.1 Outline

2.2.2 Understand hydraulic circuit of Travel Control of PC200-3. 2.2.3 Understand structure and function of Centre Swivel joint of PC200-3.

2.2.4 Understand structure and operation of Travel Motor of PC200-3. 2.2.5 Understand structure and operation of Parking Brake of PC200-3. 2.2.6 Understand structure and operation of travel brake valve of PC200-3

including counter balance valve and safety valve 2.2.7 Understand structure and operation of Final Drive system of PC200-3.

2.3 Understand the swing system of Hydraulic Excavator PC200-3. 2.3.1 Outline 2.3.2 Understand hydraulic circuit of swing system 2.3.3 Understand structure and operation of Swing Priority Valve. 2.3.4 Understand structure and operation of Swing Motor, swing brake

and safety valve. 2.3.5 Understand structure, function and operation of swing machinery. 2.3.6 Understand structure and operation of Swing Circle.

3. UNDERSTAND THE HYDRAULIC SYSTEMS OF HYDRAULIC EXCAVATOR PC200-3 3.1 Explain the Hydraulic Piping of PC 200-3. 3.2 Understand structure and operation of swash plate type pump PC200-3. 3.3 Understand structure and function of servo valve unit. 3.4 Understand operation of servo valve to increase the delivery of pump.

3.5 Understand Operation of servo valve to decrease the delivery of pump. 3.6 Understand function of charging pump along with relief valve function.

3.7 Understand specifications of hydraulic tank used in PC200-3 3.8 Understand function & operation of PPC (Proportional pressure control) valve. 3.9 Understand hydraulic circuit for operation of arm control lever in ARM IN position.

3.10 Understand hydraulic circuit for operation of arm control lever in ARM OUT position.

3.11 Understand function and operation of arm throttle valve. 3.12 Understand hydraulic circuit for operation of bucket control lever in

BUCKET CURL position. 3.13 Understand hydraulic circuit for operation of bucket control lever in

BUCKET DUMP position. 3.14 Understand hydraulic circuit for operation of boom control lever in

BOOM RAISE position. 3.15 Understand hydraulic circuit for operation of boom control lever in

BOOM LOWER position.

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4. UNDERSTAND THE OPEN CENTRE LOAD SENSING SYSTEM (OLSS) OF PC 200-3 4.1 Outline the OLSS of PC200-3. 4.2 Understand functions of OLSS.

4.3 Understand basic circuit of OLSS. 4.4 Understand structure, function and operation of Torque Variable Control

(TVC) Valve. 4.5 Understand structure, function and operation of Cut - off (CO) Valve. 4.6 Understand structure, function and operation of Flow Control / Negative

Control (NC) Valve. 4.7 Understand hydraulic control valve (4 spools and 5 spools). 4.8 Understand structure and function of main relief valve. 4.9 Understand structure and function of safety section valve. 4.10 Understand structure and function of accumulator.

5. UNDERSTAND HYDRAULIC SYSTEM OF HYDRAULIC EXCAVATOR PC150-1 5.1 Understand structure and function of bent axis type Piston Pump used in PC150-

5.2 Compare PC Control Mechanism with Constant Delivery System. 5.3 Compare Interconnected dual pump PC Control mechanism with an

Individual PC Control Mechanism. 5.4 Understand structure and function of PC Regulator Valve. 5.5 Understand structure and function of Side Branch Hose. 5.6 Understand hydraulic control valve assembly (4 spools and 3 spools) 5.7 Understand structure, function and operation of Main Relief Valve. 5.8 Understand operation of Safety Valve (Differential type). 5.9 Understand operation of Safety Valve (Poppet valve). 5.10 Understand structure, function & operation of Safety Valve with Suction

Valve. 5.11 Understand principle of operation of leveling system.

5.12 Understand function and operation of slow return valve (variable throttle type).

5.13 Understand operating principle, construction and function of Swing Motor (PC150-1).

5.14 Understand operation of parking brake in swing system. 5.15 Understand function and operation of swing brake valve including

counter balance valve and safety valve. 5.16 Understand structure and function of Travel Motor (PC150-1) with built-in brake valve.

5.17 Understand function and operation of parking brake in travel system. 5.17 Understand function and operation of reduction gear.

6. UNDERSTAND TESTING AND ADJUSTING OF HYDRAULIC EXCAVATOR 6.1 Measure work Equipment speed.

6.2 Measure time Lag of Work Equipment. 6.3 Measure hydraulic Drift of Work Equipment. 6.4 Measure deviation in travel.

6.5 Measure travel speed. 6.6 Test Swing Performance.

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CMT-363 HYDRAULIC EXCAVATOR LIST OF PRACTICALS 1. Visualize the film on Hydraulic Excavator. 2. Demonstration of Hydraulic Excavator and study of its component. 3. Practical on PC200-3 component identification. 4. Assembling and disassembling of travel motor. 5. Assembling and disassembling of swing motor. 6. Assembling and disassembling of piston pump of PC150-1 7. Assembling and Disassembling of Piston pump of PC200-3. 8. Visualize the film on Assembling and Disassembling of PC200-3. 9. Study of disassembled servo regulator valve and tracing of oil path. 10. Study of OLSS and tracing its oil path 11. Tracing of different hydraulic circuits. 12. PPC valve identification and its adjustment. 13. Testing and adjustment of travel of control valve. 14. Testing operating force of control lever. 15. Measuring Hydraulic oil temperature. 16. Air Bleeding of different hydraulic circuits. 17. Testing pressure of control circuit. 18. Testing and adjusting main relief valve. 19. Measuring work equipment speed. 20. Measuring time lag of work equipment. 21. Measuring Hydraulic drift of Work equipment. 22. Measuring deviation in travel. 23. Measuring travel speed. 24. Testing Swing Performance. 25. Demonstration of mechatronics simulator PC-200-6

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CMT-363 PLANNING AND MANAGEMENT OF CONSTRUCTION MACHINERY Total Contact Hours

Theory - 64 T P C Practical - 96 2 3 3

Pre-Requisite:- Operation of Construction Machinery (CMT-224).

AIMS:- After studying this course a student will be able to:-

1. Plan the employment of construction machinery on a project.

2. Manage and supervise the operation of construction machinery.

3. Calculate the productivities and depreciation of construction machinery

4. Supervise the maintenance of construction machinery.

5. Manage the workshop for construction machinery.

COURSE CONTENTS

1. PLANNING AND MANAGEMENT 18 Hours

1.1 Definition of planning and management. Explain its nature and scope.

1.2 Essential qualities for effective planning and management.

1.3 Principles of equipment management

1.4 Logistics planning and maintaining the log book of machine

1.5 Project Network Analysis (CPM).

1.6 Activity-On-Arrow Diagramming.

1.7 Activity-On-Node Diagramming.

1.8 Common errors in Network Diagramming.

1.9 The time grid diagram method.

2. FACTORS AFFECTING THE SELECTION OF CONSTRUCTION EQUIPMENT 18 Hours

2.1 Introduction to standard and special equipments.

2.2 Replacement of parts.

2.3 Time Value of Money, Discounted Present Worth Analysis, Rate of Return Analysis.

2.4 The cost of owning and operating the construction equipment.

2.5 Investment cost of construction equipment.

2.6 Depreciation of construction machinery (Different methods).

2.7 Main factors in selection of machine for a specific project.

2.8 Economic life of construction equipment.

2.9 Productivity of different construction machines, “Bulldozer, Dozer Shovel,

Wheel Loader, Hydraulic Excavator, Motor Grader and Compactor etc”.

2.10 Sources of construction machinery.

2.11 Tender procedures to buy new parts and machines.

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3. MANAGEMENT OF MAINTENANCE FOR CONSTRUCTION MACHINERY 18 Hours

3.1 Classification of maintenance system of Construction machinery.

3.2 Study of various maintenance systems related to Construction machinery

to include Routine services, Periodical services and Rebuilding.

3.3 Principles for maintenance of construction machinery and safety procedures.

3.4 Procedure of maintenance services.

3.5 Arrangement of machines and element classes for maintenance.

3.6 Study of periodical autonomous inspection system.

3.7 Study of procedure for lubrication control to include selection of lubrication oil,

planning for lubrication control, properties of lubricants,

lubrication record cards, storage of lubricants.

3.8 Requisitioning of spares, writing of specifications of machines and their

attachment and record keeping.

3.9 Parking of machines and storing of equipment and spares.

3.10 Organization and management of repair workshop of Construction Machinery.

3.11 Control of the tools and parts.

4. ENGINEERING FUNDAMENTS OF MOVING THE EARTH 10 Hours

4.1 Rolling resistance.

4.2 Effect of grade on tractive effort.

4.3 Coefficient of traction.

4.4 Effects of altitude on the performance of IC Engines.

4.5 Effects of temperature on the performance of IC Engines.

4.6 Combined effect of pressure and temperature on the performance

of IC Engines.

4.7 Draw bar pull.

4.8 Planning & selection of equipment for site clearance.

RECOMMENDED BOOKS

1. Text Book of Operation of Construction Machinery by JICA 2. Construction Planning, Equipment and Methods by Robert L. Peurifoy and William

B Ledbetter 3. Services and Rebuilding, Equipment and Tools for Earth Moving Machinery and

Automobile by Tel Maruma.

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CMT-363 PLANNING AND MANAGEMENT OF CONSTRUCTION MACHINERY

INSTRUCTIONAL OBJECTIVE


1. UNDERSTAND PLANNING AND MANAGEMENT

1.1 Define planning and management. Explain its nature and scope.

1.2 Know the essential qualities for effective planning and management.

1.3 State the principles of equipment management

1.4 Know the logistics planning and maintaining the log book of machines.

1.5 Understand the Project Network Analysis (CPM).

1.6 Draw the Activity-On-Arrow Diagram.

1.7 Draw the Activity-On-Node Diagram.

1.8 Recognize the common errors in Network Diagramming.

1.9 Draw the time grid diagram method.

2. KNOW FACTORS AFFECTING THE SELECTION OF CONSTRUCTION EQUIPMENT

2.1 Know the difference between standard and special equipments.

2.2 Understand the replacement of parts.

2.3 Know the Time Value of Money, Discounted Present Worth Analysis and Rate of Return Analysis.

2.4 Calculate the cost of owning and operating the construction equipment.

2.5 Calculate the investment cost of construction equipment.

2.6 Calculate the depreciation of construction machinery (Different methods).

2.7 Know the main factors in selection of machine for a specific project.

2.8 Understand the economic life of construction equipment.

2.9 Calculate the productivity of different construction machines, “Bulldozer,

Dozer Shovel, Wheel Loader, Hydraulic Excavator, Motor Grader and

Compactor etc”.

2.10 Know the sources of construction machinery.

2.11 Prepare tender procedures to buy new parts and machines.

3. UNDERSTAND MANAGEMENT OF MAINTENANCE FOR CONSTRUCTION MACHINERY

3.1 Classify the maintenance system of Construction machinery.

3.2 Understand various maintenance system related to Construction machinery

to include Routine services, Periodical services and Rebuilding.

3.3 Know the principles for maintenance of construction machinery and safety

procedures.

3.4 Know the procedure of maintenance services.

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3.5 Arrange the machines and element classes for maintenance.

3.6 Understand the periodical autonomous inspection system.

3.7 Understand the procedure for lubrication control to include selection of lubrication

oil, planning for lubrication control, properties of lubricants, lubrication record

cards, storage of lubricants.

3.8 Understand the requisitioning of spares and keeping records, writing of

specifications of machines and their attachment

3.9 Know the parking of machines and storing of equipment and spares.

3.10 Organize and manage of repair workshop of Construction Machinery.

3.11 Control the tools and parts.

4. KNOW THE ENGINEERING FUNDAMENTS OF MOVING THE EARTH

4.1 Know the rolling resistance.

4.2 Understand the effect of grade on tractive effort.

4.3 Define the coefficient of traction.

4.4 Know the effects of altitude on the performance of IC Engines.

4.5 Know the effects of temperature on the performance of IC Engines.

4.6 Know the combined effect of pressure and temperature on the performance

of IC Engines.

4.7 Define the draw bar pull.

4.8 Describe the procedures for site clearance.

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CMT-363 PLANNING AND MANAGEMENT OF CONSTRUCTION MACHINERY

LIST OF PRACTICAL 1 Preparation of CPM diagram.

2. Solve problems based on depreciation of construction machinery.

3. Solve problems based on calculating the cost of owning and operating various

construction equipment.

4. Solve problems based on productivity of following construction machines:-

a. Bulldozer.

b. Motor Grader.

c. Wheel Loader / Dozer Shovel.

d. Road Roller/Compactor.

e. Excavator.

5 Solve problems based on the effect of grade on tractive effort of vehicles.

6. Solve problems regarding selection of machines for a particular job of earth moving.

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CMT-372 PROJECT


Theory - 0 0 6 2

Practical - 192 Hours

AIM:- Course is intended to able the students to:-

1. Collect information and data about the assigned project.

2. Select from the information gathered, material useful for one’s own project.

3. Arrange the selected data in logical order.

4. Design the project according to the courses studies in three years.

5. Prepare full scale working drawing of the project.

6. Make the project in an economical way.

7. Write and submit a project report containing essential details of the project.

1. SAMPLE LIST OF DESIGN PROJECTS

1. Construction of an electronic hydraulic system board, transmission control

valve assembly of a wheel loader.

2. Overhauling/reconditioning of a PT pump

3. Overhauling/reconditioning of Bosch pump.

4. Rebuilding of an undersize crankshaft

5. Trouble analysis of cooling system when the engine gets overheated and

rectifying faults by flushing the system and changing the defective parts if

required.

REFERENCE BOOKS

a. Intermediate Engineering Drawing by A.C Parkinson

b. Workshop Technology part II by W.A.J Chapman

c. Modern workshop Technology by Baker.

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CURRICULUM FOR

DIPLOMA OF ASSOCIATE ENGINEER (DAE) IN Mechanical Technology with Specialization in

Construction Machinery

REVISED SEPTEMBER 2007

Mechanical Tech with sp in construction Machinery.pdf

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