Certificate Course in Heavy Vehicle Service Technology

Teacher

SUDEEP KUMAR SINGH

Category

Certificate Courses

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Description

 

The automotive industry and use of heavy vehicles in transport industry is on the rise since last two decades. So the employment opportunities in this segment is also on the rise.  But for getting an employment opportunity in this sector requires the skills, knowledge and practices of the trade. This necessitates the development of a course which can give proper guidance  and skills to explore the emerging opportunities.

Course Objectives

  • Would be able to understand each individual parts working mechanism
  • Able to find out the problems using fault diagnosis method or by scan tool
  • Would be able to guide the technicians for standard operating procedures to resolve fault
  • To empower the students through projects, internships leading to development of creativity, self-confidence and team spirit.
  • To create the ambience with scope for developing communication and life skills so as to meet the needs of the society in the globalized environment
  • Dismantles partially or completely defective unit or parts of vehicle such as engine, gear box, rear axle, front axle, steering assembly, radiator, etc. according to nature of repairs to be done, using hoist, jack, pullers, hand tools and other devices.

Learning Outcomes

  • It is applicable in both your personal and professional lives.
  • Can be self employed
  • Explain personnel finance, entrepreneurship and manage/organize related task in day to-day work for personal & societal growth.
  • Overhaul, service and testing Diesel Engine, its parts and check functionality.
  • Evaluate the information gathered from the customer report/job card /technician notes
  • warranty claim and maintenance details and take appropriate action to ensure maximum customer

Course Syllabus

Module I

Introduction to an Automobile

Introduction on BS engine & its categories of BS-I,BS-II,BS-III,Bs-IV & BS VI, What is BS-IV & BS-VI Technology ,What are the feature of a BS-IV & BS- VI engine, Engine number codification

Module 2

Hand and power tools

Learn how to use the Marking scheme, marking material-chalk, Prussian blue .Cleaning tools- Scraper, wire brush, Emery paper, steel rule, measuring tape, try square. Callipers-inside and outside. Dividers, surface gauges, scriber, Punches-prick punch, centre, punch, pin punch, hollow punch, number and letter punch. Chisel-flat, cross-cut. Hammer- ball pain, lump, mallet. Screw drivers-blade, Screwdriver, Phillips screw driver, Ratchet screwdriver. Allen key, bench vice & C -clamps, Spanners- ring spanner, open end spanner & the combination spanner, universal adjustable open end spanner. Sockets & accessories, - Pliers - Combination pliers, multi grip, long nose, flat nose, Nippers or pincer pliers, Side cutters, Circlip pliers, external circlips pliers. - Air impact wrench, air ratchet, wrenches- Torque wrenches, pipe wrenches, Pipe flaring & cutting tool, pullers-Gear and bearing.

Module 3

Systems of measurement

Description, Least Count calculation, care & use of -Micrometres, Micrometre adjustments,

Description, Least Count calculation, care & use of Vernier Calliper. Use of Telescope gauges, Dial bore gauges, Dial indicators, straightedge, Use of feeler gauge, thread pitch gauge, vacuum gauge, and tire pressure gauge

 

Module 4

Introduction to engine 

Description of internal & external combustion engines, Classification of IC engines, Principle & working of 2&4-stroke diesel engine (Compression ignition Engine (C.I)), Principle of Spark Ignition Engine(SI), differentiate between 2-stroke and 4 stroke, C.I engine and S.I Engine, Main Parts of IC Engine, Direct injection and indirect injection, Technical terms used in engine,

Engine specification., major  exterior components or parts  of the automobile(instrument on a dash board of a vehicle- Speedometer, Tachometer, Odometer and Fuel gauge, and Indicators such as gearshift position, Seat belt warning light, Parking-brake-engagement warning light and an)

Description and Constructional feature of Cylinder head, Importance of Cylinder head design Valves & Valve Actuating Mechanism (Description and Function of Engine Valves, different types, materials, - Type of valve operating mechanism, Importance of Valve seats, Valve seats inserts in cylinder heads, , -

Type of Diesel combustion chambers, - Effect on size of Intake & exhaust passages, Head gaskets. –

Importance of Turbulence Description & functions of different types of pistons, piston rings and piston pins and materials. Used recommended clearances for the rings and its necessity precautions while fitting rings, common troubles and remedy. Compression ratio.

Description function of connecting rod importance of big- end split obliquely Materials used for connecting rods big end & main bearings. Shells piston pins and locking methods of piston pins. Construction and working principle of crank shaft, Timing gear cooling system

 

Module 5

Cooling system

Components-(Radiator, Coolant hoses, - Water pump, Cooling system thermostat, Cooling fans- Temperature indicators, Radiator pressure cap, Recovery system, Thermo switch. Need for lubrication system,) Different components of lubrication system & it’s working principle

 

Module 6

Intake & exhaust systems

Description and function of Exhaust manifold, Exhaust pipe, Extractors, Mufflers Reactive, absorptive, Combination of Catalytic converters, Flexible connections, - (Description of Diesel, Exhaust systems.

Description & function of air compressor, exhauster, Super charger, Intercoolers, turbo charger, variable turbo charger mechanism. Intake system components-

Description and function of Air cleaners, Different type air cleaner, Description of Intake manifolds and material,

 

 

 

 

Module 7

Diesel Fuel Systems

- Description and function of Diesel fuel injection, fuel characteristics

- Electronic Diesel control systems, Common Rail Diesel Injection (CRDI) system,. Sensors, actuators and ECU (Electronic Control Unit) Reduction (SCR), EGR VS SCR

 

Module 8

BS VI Model

Describe briefly working model of BS VI engine & diagnostic scan tool

Session Plan

Session 1

Introduction on BS engine & its categories of BS-I,BS-II,BS-III,Bs-IV & BS VI, What is BS-IV & BS-VI Technology ,What are the feature of a BS-IV & BS- VI engine, Engine number codification

Video link: https://www.youtube.com/watch?v=c1HmOTrkcLs

Practice- overview Inspection of BS engine and there different parts

Session 2

Learn how to use the Marking scheme, marking material-chalk, Prussian blue .Cleaning tools- Scraper, wire brush, Emery paper, steel rule, measuring tape, try square. Callipers-inside and outside

Video link: https://www.youtube.com/watch?v=YKDVjytfOXg

Video link: https://www.youtube.com/watch?v=qP8KlUD_X7w&t=194s

Practice- Demonstration and Practice of major exterior components or parts of the automobile & Layout of an automobile

Session 3

Dividers, surface gauges, scriber, Punches-prick punch, centre, punch, pin punch, hollow punch, number and letter punch

Video link: https://www.youtube.com/watch?v=nNToptuOIG0&t=177s

Practice: Demonstration of Perform measuring camshaft journal dia., crank shaft journal dia. , piston diameter by the help of micro meter.

Session 4

Chisel-flat, cross-cut. Hammer- ball pain, lump, mallet. Screw drivers-blade, Screwdriver, Phillips screw driver, Ratchet screwdriver. Allen key

Video link: https://www.youtube.com/watch?v=v4na-nJxaeo

Practice: Demonstration and Hands on practice on Execute overhauling of injectors and testing of injector

Session 5

Bench vice & C -clamps, Spanners- ring spanner, open end spanner & the combination spanner, universal adjustable open end spanner. Sockets & accessories

Video link: https://www.youtube.com/watch?v=8epmBRmmZWU

Video link: https://www.youtube.com/watch?v=qKSaKvYyejQ

Practice: Demonstration and Practice of all electrical components like Headlamp, tail lamp, switches and indicators

Session 6

Pliers - Combination pliers, multi grip, long nose, flat nose, Nippers or pincer pliers, Side cutters, Circlip pliers, external circlips pliers

Video link: https://www.youtube.com/watch?v=9tWKM0Y82Q4

Practice: Perform to remove the wheel lug nuts and tyre with the help of hand tools and mount it.

Session 7

Air impact wrench, air ratchet, wrenches- Torque wrenches, pipe wrenches, Pipe flaring & cutting tool, pullers-Gear and bearing.

Video link: https://www.youtube.com/watch?v=F0oVxQoE79Y

Practice: perfome to check the air pressure inside the vehicle tyre maintained at the recommended

Session 8

Description, Least Count calculation, care & use of -Micrometres, Micrometre adjustments

Video link: https://www.youtube.com/watch?v=imEqHCW5--o

Practice: Take a observation general work shop hand tools & power tools.

Session 9

Description, Least Count calculation, care & use of Vernier Calliper.

Video link: https://www.youtube.com/watch?v=SX0K9MiwolM

Practice: To measure the free length of the valve spring

Session 10

Use of Telescope gauges, Dial bore gauges

Video link: https://www.youtube.com/watch?v=_JLhUYeMNbo&t=236s

https://www.youtube.com/watch?v=2JkHt2Wc0M0

Video link: Practice: To practise air bleeding of the fuel supply system

Assignment

To be given by the subject teacher based on the content covered.

Session 11

Dial indicators, straightedge, Use of feeler gauge, thread pitch gauge, vacuum gauge, and tire pressure gauge

Video link: https://www.youtube.com/watch?v=Ew7KmAMcyxA

Video link: https://www.youtube.com/watch?v=H_1ySs7liS4

Video link: https://www.youtube.com/watch?v=NEjeb4cklQM

Session 12

Description of internal & external combustion engines, Classification of IC engines, Principle & working of 2&4-stroke diesel engine (Compression ignition Engine (C.I)), Principle of Spark Ignition Engine (SI), differentiate between 2-stroke and 4 stroke.

Video link: https://www.youtube.com/watch?v=Z6YC3I54so4

Video link: https://www.youtube.com/watch?v=AgrI3hRQzOA&t=640s

Video link: https://www.youtube.com/watch?v=Pu7g3uIG6Zo

 

Practice: To practise servicing of fuel filter

Session 13

C.I engine and S.I Engine, Main Parts of IC Engine, Direct injection and indirect injection, Technical terms used in engine,

Video link: https://www.youtube.com/watch?v=4xNITPh7Dro&t=89s

Video link: https://www.youtube.com/watch?v=cI0vdx8qRaI

Practice: Adjust the tappet clearance of diesel engine before start

Session 14

Engine specification., major  exterior components or parts  of the automobile(instrument on a dash board of a vehicle- Speedometer, Tachometer, Odometer and Fuel gauge, and Indicators such as gearshift position, Seat belt warning light, Parking-brake-engagement warning light and an)

Video link: https://www.youtube.com/watch?v=ijX6YJ3zuQI

Video link: https://www.youtube.com/watch?v=2xNu6edWHnk

Video link: https://www.youtube.com/watch?v=3oG9dUWk45k

Practice: Measure the cylinder bore worn out by bore dial gauge

Session 15

Description and Constructional feature of Cylinder head, Importance of Cylinder head design

Video link: https://www.youtube.com/watch?v=26SVb0DCfpE&t=274s

Practice- Demonstration and Practice of Perform measuring practice to check the flatness of the cylinder head is warped or twisted with straightedge is used with a feeler gauge.

Session 16

Valves & Valve Actuating Mechanism (Description and Function of Engine Valves, different types, materials, - Type of valve operating mechanism, Importance of Valve seats, Valve seats inserts in cylinder heads

Video link: https://www.youtube.com/watch?v=UjlHm9Gp-98

Video link: https://www.youtube.com/watch?v=CC4doq880Hc

Video link: https://www.youtube.com/watch?v=8jTM5rPKI6M

Video link: https://www.youtube.com/watch?v=_N6yQyCXnVA

Practice: Disassembling and assembling of differential

Session 17

Type of Diesel combustion chambers, - Effect on size of Intake & exhaust passages, Head gaskets

 

Video link: https://www.youtube.com/watch?v=mvDkWnownI8

Video link: https://www.youtube.com/watch?v=Dv-mBXueRtY

Practice: Demonstration of Perform measuring practice on cylinder bore, Connecting rod bore, inside diameter (ID) of a camshaft bearing with Telescope gauges.

Session 18

Importance of Turbulence Description & functions of different types of pistons, piston rings and piston pins and materials. Used recommended clearances for the rings and its necessity precautions while fitting rings, common troubles and remedy. Compression ratio.

Video link: https://www.youtube.com/watch?v=WhvDBg1wj9c

Practice- Demonstration and Practice of Checking connecting rod for bend and twist. Assemble the piston and connecting rod assembly.

Session 19

Description function of connecting rod importance of big- end split obliquely Materials used for connecting rods big end & main bearings. Shells piston pins and locking methods of piston pins

Video link: https://www.youtube.com/watch?v=yyY82nLzHjk&t=19s

Practice: Remove the fly wheel & take observation and mount it.

Session 20

Construction and working principle of crank shaft, Timing gear cooling system

Video link: https://www.youtube.com/watch?v=HLvYTJVOWi4

Video link: https://www.youtube.com/watch?v=GhgHWCSU1o0

Video link: https://www.youtube.com/watch?v=dGkJ63NuyFs&t=661s

Practice: Perform measure wear on crankshaft end play, crank shaft run out with dial indicator.

Session 21

Components-(Radiator, Coolant hoses, - Water pump)

Video link: https://www.youtube.com/watch?v=1tckg-WYiKE

Video link: https://www.youtube.com/watch?v=euO2NKOR9ec

Video link: https://www.youtube.com/watch?v=BaEHVpKc-1Q

Practice: Disassembling and assembling of water pump and radiator.

Session 22

Cooling system thermostat, Cooling fans- Temperature indicators, Radiator pressure cap, Recovery system, Thermo switch. Need for lubrication system,)

Video link: https://www.youtube.com/watch?v=V7inC4lOpGs&t=91s

Video link: https://www.youtube.com/watch?v=S-xfcDkEcpE

Video link: https://www.youtube.com/watch?v=m5YXYWCrbV0

Practice: Disassembling and assemble cooling Cooling system thermostat, Cooling fans- Temperature indicators, Radiator pressure cap, Recovery system, Thermo switch

Session 23

Different components of lubrication system & its working principle

Video link: https://www.youtube.com/watch?v=Z01hX8lsCBo&t=147s

Session 24

Description and function of Exhaust manifold, Exhaust pipe, Extractors, Mufflers Reactive, absorptive & Exhaust systems.

Video link: https://www.youtube.com/watch?v=Dw3qTobtzFg

Video link: https://www.youtube.com/watch?v=VX5HcEMVJew

Video link: https://www.youtube.com/watch?v=W6dIsC_eGBI

Practice: To practise taking out dismantling cleaning checking and reassembling after checking the start motor.

Session 25

Description & function of air compressor

Video link: https://www.youtube.com/watch?v=bJluUxA7aaY

Practice: Demonstration and Practice of working and service procedure of ABS and identification of different parts of air brake system and its work principle.

Session 26

Super charger, Intercoolers, turbo charger, variable turbo charger mechanism. Intake system components

Video link: https://www.youtube.com/watch?v=ji3MpElXr4s&t=30s

Practice: To practice removing of battery, checking it for charge & dis charge & servicing & fitting after recharging

Session 27

Description and function of Air cleaners, Different type air cleaner, Description of Intake manifolds and material

Video link: https://www.youtube.com/watch?v=MgG21FfCplE&t=125s

Session 28

Combination of Catalytic converters, Flexible connections

Video link: https://www.youtube.com/watch?v=ZGvDGtfFtJU&t=354s

Practice: Testing of relay using multimeter

Session 29

Description and function of Diesel fuel injection, fuel characteristics

Video link: https://www.youtube.com/watch?v=OTqd3bjdqAE&t=146s

Practice: Disassembly oil pump & oil filter, oil cooler

Session 30

Electronic Diesel control systems, Common Rail Diesel Injection (CRDI) system,.

Video link: https://www.youtube.com/watch?v=dNq8gs2Y-Y8&t=104s

Practice: Checking & study the different type of electrical circuit of vehicle & practice the soldering of the electrical joint

Session 31

Selective Catalyst Reduction (SCR), EGR VS SCR

Video link: https://www.youtube.com/watch?v=90xNrMnMQkY

Video link: https://www.youtube.com/watch?v=AgJRIIMdIM0

Practice: Demonstration and Practice of EGR /SCR Valve Remove and installation for inspection.

Session 32

Describe briefly working model of BS VI engine

Video link: Video link: https://www.youtube.com/watch?v=GXQPsAW-iZA

Session 33

Describe briefly working model of BS VI engine

Video link: Video link: https://www.youtube.com/watch?v=GXQPsAW-iZA

Project List:

 

Two seated electric vehicle

Solar power electric vehicle (two seated vehicle)

Chasises design for an Electric vehicle

Design a battery operated go kart.

Disassembling and assembling a Vehicle engine

References:

Automobile Engineering K K Jain & R B Asthana

Automobile Engineering Vol-2 Dr. kirpal singh

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    SUDEEP KUMAR SINGH

    Assistant Professor in Mechanical Engg. Dept.
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    Sudeep currently working as Assistant Professor in Mechanical Engg. Dept, Centurion University of Technology and Management, bears a long experience of 12+ years in teaching and research. Prior to that he also has worked in manufacturing industry like Apollo Tyres Ltd(Vadodara Plant), Project Technologists Pvt. Ltd. and Vishav Components Sourcing India Pvt. Ltd. He has […]