CITS Mechanic Diesel Trade Syllabus (English)

Overview

The CITS Mechanic Diesel trade is a one-year program designed to train instructors to teach the repair, maintenance, and diagnostics of diesel engines in ITIs. Divided into two semesters, the course covers Trade Technology (theory and practical), Training Methodology, Engineering Drawing, Workshop Calculation & Science, and Soft Skills. It aligns with NSQF Level 5 standards, emphasizing advanced diesel technology, emission control, and effective teaching methods. The syllabus adheres to the latest Directorate General of Training (DGT) guidelines for outcome-based learning.

Semester 1 Syllabus

Trade Technology - Theory

• Introduction to CITS and Mechanic Diesel Trade: Role of instructors, scope of the diesel mechanic industry, and trends (e.g., hybrid systems, low-emission engines).

• Safety and Standards:

  • Advanced workshop safety: Risk assessment, PPE usage, and handling fuels.

  • Compliance with IS, ISO, and BS-VI emission standards for diesel engines.

  • Safe handling of high-pressure fuel systems and chemicals.

• Diesel Engine Fundamentals:

  • Types: Four-stroke, two-stroke, and turbocharged engines.

  • Components: Crankshaft, camshaft, pistons, and fuel injection systems.

• Fuel Systems:

  • Fuel injection: Mechanical and common rail direct injection (CRDI).

  • Fuel pumps, injectors, and filtration systems.

• Cooling and Lubrication Systems:

  • Radiators, water pumps, and cooling circuits.

  • Types of lubricants and their applications in diesel engines.

• Electrical Systems:

  • Starting and charging systems: Batteries, alternators, and starters.

  • Basic wiring diagrams for diesel vehicles.

• Maintenance Basics:

  • Preventive maintenance: Schedules for engine components.

  • Troubleshooting common issues: Starting failures, power loss.

• Quality Control: Inspection of repaired engines for performance and compliance.

Trade Technology - Practical

• Implement safety protocols in a diesel workshop (e.g., PPE, fuel handling).

• Dismantle and assemble diesel engine components (e.g., pistons, injectors).

• Service and test fuel injection systems (mechanical and CRDI).

• Maintain cooling and lubrication systems (e.g., radiator flushing, oil changes).

• Diagnose and repair electrical systems (e.g., starters, alternators).

• Perform preventive maintenance on diesel engines.

• Troubleshoot engine faults using basic diagnostic tools (e.g., pressure gauges).

• Conduct quality checks on repaired engines for performance.

• Document maintenance and repair procedures.

Training Methodology

• Instructor Role: Lesson planning, teaching strategies, and student evaluation techniques.

• Communication Skills: Clear verbal and non-verbal communication for effective training.

• Classroom Management: Engaging diverse learners and ensuring discipline.

• Instructional Aids: Using projectors, digital tools, and e-learning platforms.

• Practical Training: Demonstrating repair tasks, guiding practice, and providing feedback.

Semester 2 Syllabus

Trade Technology - Theory

• Advanced Diesel Technology:

  • Electronic control units (ECUs) for diesel engines.

  • Turbochargers and intercoolers: Design and operation.

• Emission Control Systems:

  • Exhaust gas recirculation (EGR), diesel particulate filters (DPF), and selective catalytic reduction (SCR).

  • Compliance with BS-VI and Euro VI emission norms.

• Diagnostics and Repair:

  • Advanced diagnostics: Use of OBD-II scanners and software.

  • Overhauling diesel engines and fuel systems.

• Hybrid Diesel Systems:

  • Basics of diesel-electric hybrid engines.

  • Integration with battery management systems.

• Automation in Diesel Mechanics:

  • IoT for engine monitoring and telematics.

  • Automated diagnostic tools and smart sensors.

• Sustainable Practices:

  • Fuel-efficient engine tuning and emission reduction.

  • Recycling of engine components and fluids.

• Entrepreneurship:

  • Starting a diesel repair workshop: Business plans, budgeting, and marketing.

  • Client acquisition and service contracts.

• Industry 4.0 in Diesel Mechanics:

  • AI for predictive maintenance and fault prediction.

  • Cloud-based engine management systems.

• Legal and Ethical Issues: Emission regulations, labor laws, and ethical repair practices.

Trade Technology - Practical

• Diagnose and repair ECU-controlled diesel engines.

• Service and test emission control systems (e.g., EGR, DPF).

• Use OBD-II scanners for advanced engine diagnostics.

• Overhaul diesel engines and fuel injection systems.

• Tune engines for fuel efficiency and emission compliance.

• Integrate IoT-based monitoring for engine performance (if available).

• Perform maintenance on hybrid diesel systems (if available).

• Develop a business plan for a diesel repair workshop.

• Document compliance with emission and safety standards.

Training Methodology

• Advanced Teaching Techniques: Micro-teaching, flipped classrooms, and blended learning.

• Assessment and Evaluation: Designing tests, practical assessments, and grading systems.

• Digital Tools: Using Learning Management Systems (LMS), virtual labs, and e-learning modules.

• Mentoring: Supporting trainees in skill development and career planning.

• Project-Based Learning: Guiding trainees to complete repair projects (e.g., engine overhaul).

Additional Components

Workshop Calculation & Science

• Calculations: Compression ratios, fuel consumption, and torque calculations.

• Science: Thermodynamics, combustion chemistry, and fluid dynamics.

Engineering Drawing

• Drawing Basics: Detailed engine component drawings.

• Schematics: Fuel injection and electrical system diagrams.

Soft Skills & Employability Skills

• Communication: Client consultations, report writing, and technical presentations.

• Leadership: Managing repair teams and service workflows.

• Time Management: Meeting repair and maintenance deadlines.

Assessment

• Internal Assessment: Continuous evaluation through assignments, practicals, and tests.

• Final Examination: Theory and practical exams conducted by NCVT at year-end.

• Project Work: Complete a diesel engine repair project (e.g., restoring a diesel engine) and a teaching demonstration.