Syllabus for Pump Operator
(Total Marks – 100)
Module 1 Workshop Safety &Basic Workshop Practice (8 marks)
Workshop Safety
Occupational health and safety safety practice personal safety and general precautions observed in the shop types of fires fire extinguishers types of fire extinguishers elementary first aid handling of fuel spillage safe handling and periodic testing of lifting equipments energy conservation process
Basic Workshop Practice
Drilling machines portable type drilling Machines cutting speed and RPM work holding devices drill holding devices drill bits hand taps and wrenches tap drill size die and die stock reamers hole size for reaming lapping rivets types and uses riveted joints brazing soldering principles of arc welding –arc welding machines oxyacetylene gas welding air impact wrench air ratchet wrenches –flaring flare fittings and testing the jointsgrinding machines –types of grinding machines uses of hoists,jacks and standsbearings and types.
Module 2 Workshop Tools and Equipments, Engineering Measurement (8 marks )
Workshop Tools and Equipments
Files classification of files Scrapers surface plates measuring tape engineer’s steel rule try square hacksaw blades and frames types of calipersdividers surface gauges scriber hand tools chisel angles of chisels hammers wooden mallet screwdrivers allen keys bench vice types of vices –C clamps and toolmaker’s clamps spanners and their uses pliers straight & bent snips puller anvil jacks and types.
Engineering Measurement
Outside micrometer depth micrometer vernier calipers universal vernier caliper and its application telescope gauge dial bore gauge dial test indicators straight edges feeler gauge & uses screw pitch gaugewire gaugesvacuum gaugepressure gauge.
Module 3 Basic Electrical ( 12 marks)
Conductorsinsulators semiconductors EMFpotential differencecurrent and resistance ohm’s law close circuitopen circuit short circuit AC and DC meters connection of an ammeter in circuit use of an ammeterconnection of a voltmeter use of a voltmeter connection of an ohmmeter use of an ohmmeter electric series circuits & parallel circuitstypes of resistors, construction and power rating tolerance in resistorsresistor colour code resistance symbols used in wiring diagram multimeters and digital multimeter application of multimeterelectric soldering ironnecessity of earthing system and equipment earthing need of a fuse in the circuit construction of a fuse types of fuses working of fuses circuit breakerscapacitor function of capacitor units of capacitance parallel and serial connection of capacitors–transformer AC motors DC motors –AC generators DC generatorsstarters and types.
Module 4 Basic Electronics,Battery(8 marks)
Basic electronics
semiconductors P and N materials property of a PN junction classifications of diodes uses of transistors classifications of transistors thyristor and characteristics of SCR working of SCR thermistor and its usage relay classification of relaysfunction of current sensing relay and voltage sensing relay solenoid and its application construction and symbol of UJT application of UJT bi polar transistors and field effect transistors JFET construction and working MOSFET’s operation principle and types.
Battery
classification of cellsconstruction of a lead acid batterychemical action during discharging and charging testing of a lead adid battery battery rating –different battery charging methods maintenance free battery thermo couple thermo electric energy piezo electric energy.
Module 5 Hydraulics and Pneumatics(10 marks)
Hydraulics
Pascal’s law concept of force multiplication Hydraulic oils functions of hydraulic fluids viscosity hydraulic systems reservoir external gear pump internal gear pump pumps and types working of hydraulic pump different types of hydraulic actuators single acting hydraulic cylinders –double acting hydraulic cylinders double rod end hydraulic cylinders2/2way directional control (DC) hydraulic valve 3/2 directional control (DC) hydraulic valve4/2 directional control (DC) hydraulic valve symbol and working of hydraulic DC valves symbol and working of nonreturn valve symbol and working of an adjustable type throttle valve.
Pneumatics
Pneumatic System Boyle’s law reciprocating piston compressor FRL or air service unit pneumatic actuators valves in fluid power system symbols for dc valves working of pneumatic cylinders.
Module 6–I C Engines, Engine components (16 marks)
Engines
Internal and external combustion engine classification of I.C. engines basic technical terms used in relation to engines two stroke engine four stroke engine differentiate between a four stroke and a two stroke engine OTTO cycle diesel cycle diesel engine spark ignition engineDirect and indirect fuel injection systems starting and stopping methods of engine petrol engine basics scavenging.
Engine components
Construction of cylinder head cylinder head design types of cylinder heads cylinder head gasket gasket materials cylinder block construction of cylinder block crankcase cylinder liner types of cylinder liners material of cylinder liners function of the valve constructional features of valves different types of valves and their material types of valve operating mechanism parts of the valve mechanism valve seats function of valve rotation size of intake and exhaust valve valve trains valve timing variable valve timing function of the camshaft construction and material of the camshaft different types of camshaft drive mechanisms piston constructional features of a piston different types of pistons different types of piston rings –construction of piston rings material of piston rings function of connecting rod various types of piston pins locking method and material of the piston pin function of the crankshaft –construction of crankshaft material of crankshaft crankshaft balancing function of firing order function of flywheel construction of flywheel functions of a vibration damper timing gear drive timing chain drive.
Module 7 Cooling and Lubrication System ( 10marks)
Engine cooling system
Necessity of the cooling system different types of cooling systems forced type of cooling system function of the water pump radiator temperature indicator pressure cap need and function of the thermostat valve vapour recovery system different types of thermostat valves constructional features of a radiator temperature indicator thermo switch coolant properties engine coolant change intervalanti Freeze mixtures.
Engine Lubrication system
Need of lubricating an engine different types of engine lubricating systems components of the pressure lubrication system functions of lubrication system function of pressure relief valve types of the pressure relief valve different types of crankcase ventilation positive crankcase ventilation oil level indicator oil pressure indicator oil pressure indicating light oil pumps gear type oil pump rotor type oil pump vane type oil pump plunger type oil pump properties of lubricating oils SAE oil grades.
Module 8 Intake &Exhaust Systems, Fuel System ( 10 marks)
Intake and exhaust systems
Intake system Exhaust system construction and operation of an air compressor construction and operation of an exhauster construction and operation of a super charger construction and operation of turbo charger types of air cleaners function of an air cleaner inlet manifold exhaust manifold – purpose of mufflers tail pip constructional features of the mufflers different types of mufflers as turbines sources of emission different type of emission emission control methods used in vehicles.
Fuel systems
specification and characteristics of fuel different types of fuel system petrol engine fuel system and components Diesel Engine fuel systems function of the fuel tank part of fuel tank function of fuel pipes need of a fuel filter types of fuel filter systems need for bleeding the fuel system function of water separators function of a feed pump construction of a feed pump working of a feed pump function of F.I.P constructional features of F.I.P need of calibration types of fuel injection system need of a governor types of governors constructional features of governors injectors different types of injectors glow
plugs
Module 9 Transmission & Control systems ( 10 marks)
Transmission system
principle of clutch need for a clutch different types of clutch function of the clutch various types of clutch actuation systems multiplate clutches dry clutches wet clutches –semicentrifugal clutch fully centrifugal clutch fluid couplingvarious types of gear shift mechanismreasons for the gear slipneed of a gearbox various resistances in vehicles motiongear ratios different types of gearboxes sliding mesh gearbox constant mesh gearbox reasons for gear noise synchromesh gearbox different types of synchromesh gearboxes function of a synchromesh unit power flow in different gear positions layout of drive lines front wheel drive rear wheel drive.transaxle function function of the propeller shaft Hotchkiss drive torque tube drive universal joint different types of universal joints slip joint various types of axle housings types of rear axles function of the differential transfer case automatic transmission
Control systems
functions of the steering system steering linkages steering columnsteering gear boxes wheel alignment suspension systems shock absorber types of shock absorbers tyres various types of brake systems mechanical brakes hydraulic brake master cylinder powerassisted hydraulic brakes vacuumassisted hydraulic brake drum brake disk brake wheel cylinder characteristics of brake fluid air brake system fail safe brake.
Module 10. Electrical& Electronics systems, Accessories ( 8 marks)
Electrical & Electronics systems
Electrical circuits in automobiles ignition circuit ignition coils sparkplugs need of a distributor constructional features of the distributor types of advance mechanism principle of electronic ignition system ECM pulse generator hall effect sensor electronic spark advance distributor less ignition systemMPFI state the main components of MPFI working principle MPFIengine management system sensor used in EFIprinciple of alternator functions of the various parts of an alternator working of an alternator starting system principle of starting motor construction of starting motor operation of bendix drive operation of over running clutch drive sliding armature drive.
Electrical Accessories
Various gauges in a vehicle fuel gauge oil pressure gauge different type of meters and their uses warning lights lighting circuitair conditioning system working of an airconditioner horn circuit types of horn wiper wiring circuit and operation power windowair bag & seat beltGPS.
NOTE: – It may be noted that apart from the topics detailed above, questions from other topics prescribed for the educational qualification of the post may also appear in the question paper. There is no undertaking that all the topics above may be covered in the question paper.
