Syllabus of Motor Transport Inspector (Technical)
Detailed syllabus for the Post of Motor Transport Inspector (Technical)
I-Mechanical Engineering (Total: 45 Marks)
I : Industrial Management and Industrial Engineering 10 Marks
INDUSTRIAL MANAGEMENT
Principles of Management: Meaning of management – Taylor’s scientific management, Functions of management – Different types of ownership – organizational structure.
The Principles of a good Wage Payment System: Types of Wages – Nominal,
real, living, fair and minimum wages – Incentives.
Quality Planning and its developments: Definitions of quality – dimensions of quality – TQM concept
Project Management Techniques: Introduction to network analysis – Commonly used terms in CPM and PERT – CPM – operation, earliest finish time (EFT), latest finish time (LFT), critical path, even slack, or float, dummy activity – construction and numbering of network diagram – Fulkerson’s rule – Simple problems on CPM (by AOA method only) – PERT – Comparison between CPM and PERT – Calculation of expected time – Event, activity, successor event, predecessor event, earliest expected time, latest allowable time, slack.
Quantitative techniques in Management: Methods – Linear programming – formulation of LPP – transportation problem – North West corner rule, Vogel’s approximation method – Simple problems – Game theory – two-persons zero sum game – Maxi-min and mini-max principle – saddle point – simple problems.
Materials and Sales Management: Inventory management – definition and classification – purchase procedure – buying techniques – EOQ and ABC analysis. Stores management – introduction – store keeping functions – duties of store keeper – store layout – Centralized and decentralized store – store records – indent forms – bincard – store ledger. Sales – importance – functions of sales department – sales forecasting.
INDUSTRIAL ENGINEERING
Production Planning and Control: Concepts of industry – Meaning of the term production and productivity – Methods of increasing productivity – types of production – Job production batch production, mass production, continuous production – Explanation of production planning control – Benefits and functions of PPC – pre-planning activities – Forecasting, plant location, product planning, design and development, material selection, process planning, determination of men, machines, material and tool requirements – Process planning – Choice of machine in process planning – Break even analysis – Process sheet – Process planning procedure – Routing – Scheduling – Dispatching – value engineering – Plant location and layout – Factors to be considered in locating industrial plants – plant layout – Types of layouts – Compare the advantages and disadvantages of each type – Plant maintenance – Types of maintenance.
Method Study: Work study – Advantages and application of work study to increase productivity – Method study – Therbligs and their symbols – Process chart symbols – preparation of operation process chart, flow process chart, man-machine chart, right hand left hand chart, and SIMO chart – Flow diagram – Principles of motion economy – Rules concerning human body, work place layout and material handling, tools and equipment design – Objectives of work measurement – Procedure of stop watch time study – standard time calculation – Production study – work sampling – steps in work sampling.
Inspection and Quality Control: Concept of quality and quality control – product control – concepts of inspection- Types of inspection – first piece inspection. Working inspection, sample inspection, operation inspection, key operation inspection, floor or patrolling inspection, centralized inspection – Advantages and limitations.
Fundamental Statistical Concepts: Explain the term variability in measurements – Explain the terms variable, attribute, frequency, frequency distribution and frequency plot – Normal distribution curve – Tally sheet – Explanation of the terms mean, mode, median and standard deviation – Calculation of mean, mode, median and standard deviation – Statistical quality control – Types of control charts – X, R, P, 100P and C.
Project Analysis: Need and scope for project analysis – Explanation of the constituents elements of project analysis – Production cost – Market survey – Selling price – Capital investment – Return on investment – Elements of costing – Classification of costs – Depreciation – Types of depreciation – Obsolescence – Basic formula for calculation of machining times for the operation such as turning, drilling and shaping – simple problems.
II : Metallurgy and Machine Tools 7 Marks
MATERIAL SCIENCE
Metals and alloys: Structure of materials – structure of solids – Crystal structure – BCC, FCC and HCP – Ferrous and non ferrous – Cast iron – white malleable, grey and nodular cast iron – Manufacturing of Pig iron – Blast Furnace – Manufacturing of Cast iron – Cupola Furnace – Types of steel – Manufacturing of steel – Bessemer process, LD process, open hearth and Electric furnace – Steel alloys – Non ferrous metals and alloys – Aluminium, Copper and its alloys – Crucible furnace.
Heat Treatment Processes: Cooling curve for pure iron – iron carbon equilibrium diagram – TTT diagram – Micro constituents of steel – Heat treatment process, annealing, normalizing, hardening, tempering, mar tempering, austempering, case hardening (cyaniding, nitriding and carburising), age hardening – induction hardening – flame hardening – residual stress due to heat treatment.
Properties, testing and inspection of materials: Mechanical properties such as strength, hardness, toughness, brittleness, creep, fatigue, stiffness, ductility, malleability, elasticity and plasticity – Thermal properties such as specific heat, thermal conductivity, thermal resistance, and thermal diffusivity – Destructive testing – Tensile and compressive test – Hardness test – Impact test – Fatigue test – Creep test – Non-destructive testing – Radiographic – Ultrasonic testing – Inspection – spark test, magnetic particle, x-ray and dye penetration tests.
MANUFACTURING PROCESS
Measuring Instruments, gauges and comparators: Classification of measuring instruments – precision and non precision instruments – Direct reading and indirect measuring instruments – Vernier calliper, micrometer (inside, outside) – classifications of gauges – plug, ring, snap, screw pitch gauge, feeler gauge, standard wire gauge and indicating gauges – comparators – Mechanical comparators, Electrical comparators, optical comparators, pneumatic comparators. Welding, Soldering and Brazing: Arc welding – principle of arc welding – welding positions – Flat, horizontal, vertical and overhead welding – welded joints – Butt, lap, corner, tee, edge, V-joints, U-joint – selection of welding electrodes – Electrode coatings – Functions of electrode coating – Gas welding – type of flames – functions and operation of oxy-acetylene cylinders, pressure regulators, welding torch, nozzle – explanation of submerged arc welding, tungsten inert gas (TIG) welding, metal inert gas (MIG) welding, Atomic hydrogen welding and thermit welding – Defects in welding – causes and remedies of the defects such as porosity, poor penetration, warping, under cut, distortion crack, poor appearances – soldering – brazing.
Foundry: Tools – rammer, trowel, slick, lifter, strike off bar, bellow, sprue pin, mallet, gate cutter, swab, vent rod, draw spike, moulding box – composition of moulding sands – types of moulding sand – green sand, dry sand, parting sand, loom sand, facing sand and core sand – properties of moulding sand such as porosity, plasticity, adhesiveness, cohesiveness, refractoriness. Types of patterns – single piece pattern, split pattern, match plate pattern, gated pattern, loose piece pattern, sweep pattern, – Pattern allowances – shrinkage allowance, draft allowance, machining allowance, distortion or camber allowance, rapping allowance.
Bench work and fitting: Fitting operations like chipping, filing, scraping, grinding, sawing, marking, drilling, reaming, tapping, dieing – tools used in fitting – vice (bench vice, pipe vice, hand vice), files – various types of files – specification of files – chisels, hammers, hack saw, scrapers, punches, surface plate, surface gauge, Vblock, angle plate, try square, combination set, steel rule, callipers (outside and inside), divider, scriber, drills, reamer, tap and tap wrench, die and die stock, goggles.
MACHINE TOOLS
Metal Cutting: Orthogonal cutting and oblique cutting, chip formation, type of chips, cutting speed, feed and depth of cut – Tool life – Machinability. Lathe and Lathe Work: Type of lathe – Lathe parts, function of each part – Lathe accessories – Work holding and tool holding devices – Speed, feed and depth of cut – Operations – taper turning methods – Lathe specification.
Drilling Machines: Classification – Work holding devices – Types of drill bits – Tool holding devices – Operations.
Shaping Machines: General use of a shaper – Parts and their functions.
Slotting Machines: General use of a slotter – Slotter parts and their functions.
Planing Machines: General use of a planer – Planer parts and their functions.
Milling Machines: General use of milling machines – Parts of milling machines and their functions – types of milling machines – Cutter holding devices (a) arbours (b) Collets – Milling operations – plain milling, key and key ways, gang milling, Tslot milling – Milling methods (a) conventional milling (b) climb milling – Types of indexing.
Broaching Machines: General use of a broaching machines – Parts and their functions,
Gear Manufacture: Method of making gears – Gear hobbling.
Jigs and Fixtures: Definition of jigs and fixtures.
Grinding: Abrasives – natural, artificial – Bonding materials – vitrified, silicate, shellac, rubber – kinds of abrasives, grain size, grade and structure, kind of bond material, functions of the grinding wheels – Grinding machines – Cylindrical grinders – centre type and centre less type grinders.
Capstan and Turret Lathe: Construction and parts – tooling layout.
Automatic and Copying Machines: Automation – definition.
Flexible Manufacturing System: Flexible automation – flexible manufacturing cell – components of FMS.
Robots and Robotics: Basic elements of robots – types of joints – robotic arms – robotic hands.
Computer Numerical Control (CNC): Machine tools (brief description only)
III:Fluid Mechanics, Pneumatics and Hydraulic Machines 8 Marks
FLUID MECHANICS AND PNEUMATICS
Properties of Fluids: Density – specific weight – specific volume – specific gravity – problems – viscosity – kinematics viscosity – Newton’s law of viscosity – types of fluids – compressibility – surface tension – capillarity.
Fluid Pressure and its Measurement: Fluid pressure at a point – pressure head – problems – Pascal’s law – absolute, gauge, atmospheric and vacuum pressures – simple problems – measurement of fluid pressure – Piezometer tube – simple manometer – differential manometer – inverted differential manometer – Bourdon’s tube pressure gauge – total pressure.
Kinematics and Dynamics of Fluid Flow: Introduction – types of fluid flow – steady and unsteady flow – uniform and non-uniform flow – laminar and turbulent flow – compressible and incompressible flow – rotational and irrotational flow – rate of flow or discharge – equation of continuity of liquid flow – simple problems – energy of a liquid in motion – potential energy – kinetic energy – pressure energy – total energy – total head of liquid in motion – Bernoulli’s equation – practical applications of Bernoulli’s equation – venturimeter – Orifice meter – Pitot tube. Flow through Orifices, Notches,
Pipes and Nozzles: Orifices – types of orifices – Vena contracta – coefficient of contraction – coefficient of velocity – coefficient of discharge – Notches – types of notches – Flow through pipes – loss of head in pipes – major energy losses – -minor energy losses – loss of energy due to friction – Darcy’s formulae (No derivation) for loss of head in pipes – Chezy’s formula (No derivation) for loss of head in pipes – simple problems – loss of head due to sudden enlargement – loss of head due to sudden contraction (No derivation) – water hammer – nozzles.
Fluid Power: Introduction – Basic law – Applications of fluid power Hydraulic System: Basic elements of hydraulic system – oil reservoir pump unit – principles of working of positive displacement pump – classifications – Gear pumps, Screw pump, Vane pumps, Lobe pump, Simple piston pumps.
Hydraulic Control Elements and Components: Control valves – Functions – classifications – Describe the working of pressure control valves such as relief valves – Poppet valve – Direction control valves – check valves – Flow control valves – types – gate, globe, butterfly valves, non return valve.
Pneumatic System: Comparison of pneumatic system with hydraulic system – identification of standard pneumatic symbols – basic pneumatic system – air filter – pressure regulator – lubricator – mufflers. Pneumatic Control Elements and Components: Pneumatic control valves – Air cylinders.
HYDRAULIC MACHINES
Impact of Jets: Force exerted by the jet – stationary – vertical – inclined – curved plate (symmetrical and unsymmetrical) – force exerted by the jet on moving plates – simple problems.
Impulse Turbines: Development of water Turbines – classification – impulse Turbine – Pelton wheel components.
Reaction Turbines: Components – difference between impulse & reaction – classification of Reaction Turbines – Francis Turbine – Kaplan Turbine – Draft tubes – specific speed.
Centrifugal Pump: Types of casing – piping system of CP – work done, manometric head – efficiencies – discharge – power required to drive – multistage pumps – specific speed of CP – cavitation – priming.
Reciprocating Pump: Types – comparison of CP & RP – discharge – slip – air vessels, Hydraulic ram.
IV : Applied Mechanics, Strength of Materials and Design of Machine Elements 10 Marks
APPLIED MECHANICS, STRENGTH OF MATERIALS
Direct Stresses and Strains: Types of Stresses and strains – tensile and compressive – longitudinal and lateral strain – Poisson’s ratio – behaviour of mild steel under tension – stress strain diagram – limit of proportionality – elastic limit – yield point – ultimate stress – working stress – factor of safety – comparison of stress strain diagram of a mild steel and a brittle material – Hooks law and Young’s modulus – principle of superposition – stresses in varying section – stresses in composite section – simple problems.
Shear Stress and Shear Strain: Shear stress and strain – modulus of rigidity – volumetric strain, bulk modulus – simple problems.
Thermal Stress and Strain: Nature and magnitude of stresses due to change in temperature – total or partial prevention of expansion and contraction – temperature stress on composite bar – simple problems.
Truss Analysis: Types of frames – formula for finding the redundancy – free body diagram – equilibrium – forces in various members of stress due to loading – method of joints and method of sections.
Friction: Introduction – type of friction – static friction, dynamic friction, sliding friction, rolling friction, pivot friction, limiting friction, angle of friction, coefficient of friction, cone of friction – state laws of friction – static friction and kinetic friction.
Centre of Gravity of Sections: Centroids – centre of gravity – axis of symmetry and axis of reference – methods to find centre of gravity – simple geometric sections such as rectangle, triangle and circle.
Moment of Inertia of Sections: Moment of inertia – radius of gyration.
Riveted Joints: Types – lap joint – single riveted, double riveted (Chain and zigzag) – butt joint single cover single riveted, double cover single riveted – failure of riveted joints – failure of rivets – shearing and crushing – failure of plates – tearing across a row of rivets – tearing off plate at an edge – strength of rivet, plate and riveted joint – efficiency of a riveted joint – caulking and Fullering operations.
Welded Joints: Welding terms – leg of the weld, size of the fillet weld, throat thickness, effective length of the weld, side fillet weld and end fillet weld – strength of welded joints.
Thin Cylinders: Failures of thin cylinder – stresses in thin cylindrical shell – hoop stress – longitudinal stress.
Torsion of Circular Shafts: Torsion equation – strength equation for solid and hollow shaft (no proof) – power equation – polar moment of inertia.
Springs: Types of spring – leaf spring – helical springs.
Shear Force and Bending Moment: Types of beams – cantilever beam, simply supported beam, overhanging beam, built in beam or fixed beam and continuous beam – types of loading – concentrated or point load, uniformly distributed load and uniformly varying load – shear force and bending moment diagrams – cantilever beams – point load, uniformly distributed load and combination of point load and uniformly distributed load – simply supported beam – point load, uniformly distributed load and combination of point load and uniformly distributed load – maximum bending moment on the section. – deflection of beams.
Columns and Struts: Column, strut, buckling load, equivalent length, slenderness ratio – types of columns – short column, medium size column, long column.
MACHINE DRAWING AND DESIGN OF MACHINE ELEMENTS
Screw Threads: Thread terminology – Forms of screw threads (square thread, V thread) – Witworth thread – British Association thread – American standard thread – Acme thread – ISO metric thread – square thread – single start and multi start threads – right hand and left hand threads – conventional representation of threads. Bolted connection using standard proportions.
Welded joints and Piping Layout: Classification of welds – Elementary welding symbols – types of pipes – Methods of connecting pipes – pipe threads – representation of pipe threads – types of pipe joints – single and double line orthographic symbols for pipe fittings and valves (flanged, screwed and welded joints).
Limits, Fits and Tolerances: Definition of limits, fits and tolerances.
Surface Roughness: Surface roughness terminology – surface roughness values, Grades and symbols.
General Design Considerations: General procedure – Design stress and working stress – factor of safety – Kinematic link – pair – chain – four bar chain – examples and applications – mechanism – inversion.
Bolts, Nuts and Key: Designation of screw threads – stresses in screwed fastenings due to static loading – initial stresses – stresses due to external forces – bolts of uniform strength – types of keys – forces acting on a sunk key – strength of a sunk key – calculation of key size using empirical proportions.
Shafts: Torsional stresses and strains – strength of solid and hollow shaft – design of shaft considering strength and rigidity – comparisons – power transmitted by shaft – compare solid and hollow shaft in terms of their weight, strength and stiffness.
Couplings: Shaft couplings – requirement – types.
Bearings: Functions of bearings – classification of bearings – Radial bearings – thrust bearings – sliding contact bearings – rolling contact bearings.
Cams: Classification of followers and cams – motion of the followers – uniform velocity, simple harmonic motion – uniform acceleration and retardation – cam terminology – displacement diagrams.
Governors and Flywheels: Functions of the governors – types of governors – simple watt governor – porter governor – flywheels – comparison with governors – coefficient of fluctuation of speed – fluctuation of energy – maximum fluctuation of energy – coefficient of fluctuation of energy.
Belt Drives: Types of belts – flat belt, circular belt or rope, V-belt – types of flat belt drives – open and crossed belt drive – compound belt drive – stepped or cone pulley drive – velocity ratio – slip – creep.
Gears and Gear Trains: Functions of gears – friction wheels – advantages and disadvantages of a gear drive – spur gear nomenclature – simple gear drive – velocity ratio – gear trains – simple gear train – compound gear train.
V: Thermal Engineering 10 Marks
THERMAL ENGINEERING
Air Standard Cycles: Assumption, Air standard efficiency – explanation with diagrams and derivation of air standard efficiency of Carnot Cycle, Otto cycle, Diesel cycle, dual combustion cycle.
Fuels & Combustion: Classification of fuels – solid, liquid & gaseous – Merits & demerits of various types of fuels – requirements of a good fuel – Calorific Value – combustion of fuel.
Testing of I. C. Engines: Performance of I. C. Engines – testing – Indicated power, Brake power, Friction power – Mechanical efficiency – Indicated Thermal efficiency, Brake Thermal efficiency, Relative efficiency – Total fuel consumption & Specific Fuel Consumption – Morse test for determination of I. P. of multi-cylinder engine – Heat balance sheet – problems.
Heat Transfer: Heat Transfer – conduction, convection and radiation – Fourier’s law – Thermal conductivity – Conduction through plane wall and composite wall – Black body concept – Stefan-Boltzman law – Gray body concept – Newton Rikhman equation – free and forced convection.
Heat Exchangers: Heat exchangers – Classification – Recuperator type and regenerative type, parallel flow, counter flow type & cross flow – concept of overall heat transfer coefficient – LMTD.
Air Compressors: Construction and working of Air compressors – function of an air compressor – uses of compressed air – classification of the air compressors – working of reciprocating compressors (single stage and two stage), rotary compressors – fans and blowers, centrifugal compressors and axial flow compressors. Mechanical efficiency & volumetric efficiency.
Different Systems of I. C. Engines: Fuel systems – components – carburetion – functions of carburettor – working fuel systems of diesel engine – fuel filter – injector and injection nozzle – ignition system – cooling system – classification of cooling system – radiators – IC engine lubrication system – forced system – governing systems – quantity governing – quality governing – hit and miss governing.
Principles of Refrigeration: Definition of refrigeration, concept of C. O. P., unit of refrigeration – reversed Carnot cycle – COP, Application of refrigeration.
Vapour Compression Refrigeration Systems: Principles and working of a vapour compression system with the help of flow diagram. C.O.P. of vapour compression systems.
Refrigeration Equipments: Compressors – Condensers – Evaporators – Expansion Devices – capillary tube, Thermostatic expansion valve.
Refrigerants: Definition, primary and secondary refrigerants, desirable properties of refrigerants.
Psychrometry: Definition, Dry air, moist air, saturated, unsaturated and super saturated air, degree of saturation, dry bulb temperature, wet bulb temperature, dew point temperature.
Psychrometric Processes: Sensible heating, sensible cooling – humidifying, dehumidifying
Air Conditioning: Definition, factors affecting human comfort, effective temperature.
Air Conditioning Systems: Classification – industrial, comfort air conditioning, working of summer air conditioning, winter and year round air conditioning.
II- Automobile Engineering (Total: 45 Marks)
I: Automobile Power Plant 10 Marks
Constructional Details of I. C. Engines: Cylinder block – Single cylinder and multi-cylinder, materials, Water jackets – cooling fins, cylinder liners – wet type and dry type – materials. Cylinder head – Materials, method of fixing the cylinder block, cylinder head gasket, combustion chamber of petrol engines – expansion chambers Pistons – Trunk type pistons, composite pistons – piston materials expansion control in pistons – methods and types of piston, Piston rings – Materials, method of manufacture, types of rings – compression ring, oil ring and special purpose ring. Gudgeon pin – Types of fastening, material used Connecting rod – Function, materials used big end and small end bearings Crank shaft – different shapes, different crank shaft arrangements Main bearings, Fly wheel functions Types of valves – Poppet, reed valve and disc valve, sodium vapour cooled valves, hydraulic tappet and free valve rotators Classification of engine according to valve arrangement 1-Head, LHead, T-Head and F-Head engines – Valve operating mechanisms – side cam shaft and over head cam shaft – Inlet and exhaust valve materials, valve timing diagram Cam shaft – functions and drives, cam shaft bearings.
Fuel Systems in Engines Petrol: Different fuel feed systems, A. C. mechanical pump, S U Electrical pump, petrol Filters and air Cleaners, Carburettors, Simple carburettors – parts, principle of working, compensation, mixture strength requirement, modern carburettors, float system, idle and slow speed system, high speed system, Acceleration pump and choke system. Other commercial carburettors, Su, Solex and Solex – Mikuni carburettor. Exhaust system – Manifolds, silencer types, tail pipes etc.
Diesel: Various components in Diesel fuel system – types of fuel injection – air injection and mechanical injection, common rail and unit injection system. Types of combustion chamber in Diesel engines – open, turbulent and pre-combustion chamber etc. Fuel injection – single cylinder and multi cylinder. Distributor type pump, rotary type pumps, Fuel feed pump and hand priming, diesel fuel filters. Governors – purpose, types – mechanical, pneumatic and hydraulic governors, Fuel injectors – single hole, multi hole, pintle and pintox type.
Lubrication and cooling system: Lubrication system : Properties of lubricating oil, different ratings of lubricating oil, types of engine lubrication – wet and dry sump lubrication, splash and pressure feed systems. Oil pumps – gear type, Vane type, plunger type and lobe type, pressure relief valve, oil pressure indicator Oil coolers, oil filters, oil seals, Crank case ventilation – dilution Cooling system : – air and water cooling, thermo-siphon and pump circulation system over cooling, under cooling and optimum cooling – thermostat radiators – types, pressure cap, types of coolants, pump, antifreeze solution, cooling fan – types.
II: Autoelectrical systems and equipments 10 Marks
Battery: Introduction, Types of battery. Brief description of lead acid and alkaline cell, Constructional details of lead acid cell, nickel alkaline cell, Active materials of lead acid cell, Chemical action of lead acid cell, Rating of Battery, Capacity of Battery – ampere hour and watt hour, Efficiency Battery – ampere hour and watt hour, Effect of discharge rate on voltage and capacity, Effect of temperature on voltage and capacity, Battery charging, Constant voltage, Constant current. Defects – Effect of overheating, Effect of overcharging, dislocation of active material, sulphation, Internal short circuits, Corrosion / sulphation of terminals. Testing of battery – Polarity test, State of charge, Specific gravity test by hydrometer, high rate discharge test by cell tester, Cadmium test, Lamp test Care and maintenance of battery – Topping up of Battery & other maintenance schedule, Storage of lead acid battery (in dry & wet condition), Maintenance free battery.
Generator and Alternator: Constructional details of automobile dynamo – special features of automobile dynamo, constructional details of alternator – special features of automobile alternator, charging system – Introduction – necessity, Types of regulators – circuit diagram, Cut out, Voltage regulator, current regulator – 3 stage, Electronic voltage regulator in alternators, Starter motor & its drive mechanism, Introduction, Starting of I. C. Engine (Petrol & Diesel) – motor characteristics, Terms like Engine torque – motor torque – cranking speed – motor locked torque etc, starter switch, starter motor – constructional features – special features of automobile starters, Starter Motor Drives, Necessity, Types of starter motor drives – mechanisms of – Bendix drive (inboard & outboard), Over running Clutch, Axial starter (sliding armature), Pre-engaged type Spark Ignition System: Introduction, Types of ignition system – coil & magneto – study of coil ignition, Component study of ignition system – ignition coil, Contact breaker points, Cam angle, condenser, distributor, Spark plug – types, Spark plug specifications, Spark advance & retard mechanism (centrifugal & vacuum), Magneto ignition system – Low tension & high tension, Rotating armature & rotating magnet type, Polar inductor type C. D. ignition system, Electronic ignition systems, Magnetic
pickup type & hall effect sensor type, Transistorized ignition, computer controlled ignition, Distributor-less ignition system.
Lighting system & other electrical accessories: Head light – Reflectors, lenses, Bulbs (constructional features), Dazzle and its avoidance, Focusing of head lamps, Automatic dim & bright circuit, other lights – parking light, side lamp, tail lamp, roof lamp, fog lamp, brake light, dash board light, Types of bulbs – vacuum, gas filled, halogen. Introduction, Electrical fuel pump, electric horn, wind screen
wiper – types, constructional features, working, Traffic Indicator – Electrical & Electronic, gauges like, fuel level indicator, oil pressure gauge, temperature gauge, Electrically operated – power window, solenoid operated fuel cut off, wind shield washer, constructional features & working, electronically operated central locking system.
III: Automobile Chassis 8 Marks
Chassis: Introduction, constructional details, types of frame, frame for two wheeler, three wheelers and four wheeler, frame sections, bumpers, sub frames, materials used, testing of chassis – Front Axle – Introduction, types – dead & live axle, construction – material – cross section – checking the alignment of front axle, stub axle – different arrangements.
Suspension Systems: Types of front suspension for two, three and four wheeler, air suspension, hydro-elastic suspension, rear suspension system. Types – Introduction to springs and shock absorbing devices, Types leaf coil, springs & their arrangements, Helper spring, spring shackle – shackle pin, Telescopic type shock absorber, Hydraulic, gas filled type, twin tube type, Basic suspension movements – pitching, bouncing, rolling etc.
Steering System & Steering Geometry: Principles of steering, Ackerman, Davis fifth wheel, Steering gear box – types, worm & roller, worm & sector, Recirculating ball, Rack & pinion, Steering linkages – arrangement – components, Power steering – integral – linkage type, Collapsible type steering column, Wheel alignment – factors affecting wheel alignment.
Brake Systems: Principle of operation, weight transfer principle, types of brakes – mechanical, hydraulic, pneumatic, servo brake, Air brake – vacuum brake – fail safe brake – dual brake – antilock brake, Drum and disc brake system – Internal expanding and externally contracting – Layout of brake system, mechanical components, hydraulic – master cylinder, types – working principle – wheel cylinder – brake bleeding, brake shoe. Air brake – construction details – working – details components – servo brakes – working of servo brake – types, vacuum and air – disc brake – constructional details and working of engine exhaust brake – testing of brake
efficiency.
Transmission Systems: Various components in transmission required for a good transmission system, principle of friction clutches – constructional features and working of – single plate dry clutch – diaphragm clutch – cone clutch – centrifugal clutch – semi centrifugal clutch – vacuum clutch – hydraulic clutch – electromagnetic clutch – over running clutches – Multiplate clutch (dry & wet) Fluid fly wheel – clutch disc – constructional details and functions of each part, pressure plate – constructional details and functions of each part, Clutch operating mechanism.
Necessity and functions of gearbox: Gearbox constructional features & working of – Sliding mesh gearbox – Constant mesh gearbox – Synchromesh gearbox – progressive type gearbox – Epicyclic gearbox – Torque converter – Gear selector and shifting mechanism, two wheeler transmissions – Gear drive – chain drive – V matic transmission, CVT & ECVT – Automatic transmission in cars – Introduction of
Propeller shaft and universal joint – Torque tube drive – Hotchkiss drive – Variable velocity joints – constant velocity joints – Front wheel drive – differential mechanism – Locking differential – limited slip differential – Rear Axles – types
Wheels & Tyres: Wheels – wire – spoked wheel, disc wheel and alloy cast wheel, composite wheel – wheel specification – Tyres – Tyre specification – Tyre construction (cross sectional details.) – Tubeless tyre – Tyre treads patterns – Inflation pressure and its effects (both over & under inflation) – Factors affecting tyre performance.
IV : Fuels and Combustion and Applied Thermodynamics 7 Marks
Fossil and non Fossil Fuels: Properties of SI and CI engine fuels – Properties and performances – LPG, CNG, Alcohol – Hydrogen and Bio-diesel – Bi-fuel and Dual fuel systems – electric cars, hybrid vehicles – fuel cell
Combustion Phenomenon in SI Engines: Stages of combustion in SI engines – the effects of engine variables – ignition lag – flame propagation – abnormal combustion – detonation, pre-ignition & surface ignition.
Combustion Phenomenon in CI Engines: Stages of combustion in CI engines – various air fuel ratios – delay period and variables affecting the delay period – Diesel Knock and its control
Super Charging & Air Conditioning System: Super charging – Effects of super charging. Methods of supercharging and turbo charging. Lean burn engines – Automobile air conditioning system – working – components and their location, Refrigerants, their properties, refrigeration controls
APPLIED THERMODYNAMICS
Thermodynamic Processes: Revision of topics like, thermodynamic system, thermodynamic properties, boundary, state, process, internal energy, flow of work, enthalpy, and entropy, first and second law of thermodynamics. Specific heats at constant volume and at constant pressure. Establish the relation between specific heats and gas constant. Derivation of formulae for work, heat, change in internal energy, relation between pressure, volume and temperature during constant volume, constant pressure, constant temperature, adiabatic and polytropic processes – problems.
Air Standard Cycles: Reversible and irreversible cycle. Available work and energy of a cycle. Theoretical thermal efficiency and air standard efficiency. Pressure-volume diagram and temperature-entropy diagram. Derivation of formulae for air standard efficiency of Carnot cycle, Otto cycle, Diesel cycle – problems to find air standard efficiency.
Power Developed in I. C. Engines: Indicator diagram and measurement of mean effective pressure. Engine indicators. Indicated power, brake power, friction power, indicated thermal efficiency, brake thermal efficiency, volumetric efficiency, specific fuel consumption, Morse test and preparation of heat balance sheet. Air compressors – uses of compressed air, classification of air compressors – working of single stage and multistage air compressors. Intercooler.
V: Automobile Service & Maintenance and Transport Management 10 Marks
AUTOMOBILE SERVICE & MAINTENANCE
Introduction to Servicing and Maintenance of Automobiles: Various signs showing the necessity of overhauling engine decarburizing, vacuum test, compression test and cylinder leakage test. Causes of excessive lubricating oil consumption. Engine dismantling and assembling. Checking of engine components – causes of cylinder wear – cylinder rebooting and honing – linear replacement. Servicing of valves. Valve adjustment and defects of valves. Piston defects and reconditioning methods. Testing of connecting rods. Defects and reconditioning methods. Measurement of bearing clearance and adjustment of connecting rod bearings. Crank
shaft balancing and machining processes. Renewal of flywheel ring gear.
Servicing of Petrol Engine: Defects in coil ignition system like ‘No spark’, weak spark, Intermitted spark and spark at some wires. Testing of ignition system components. Setting of ignition timing. Checking of advancing units. Servicing of spark plug. Trouble shooting of fuel system. Testing of A. C. mechanical pump. Tuning of carburettor. Causes of excessive fuel consumption and defects of carburettor. Engine tuning procedure. Servicing of diesel engine – F. I. pump timing and bleeding of diesel fuel system. Testing of Nozzles. Phasing and calibration of F. I. pump. Defects of F. I. Pump and Nozzles. Troubles and diagnosis in MPFI and CRDI systems.
Servicing of Clutch Assembly: Fitting of clutch, clutch adjustments. Removal and refitting of trans-axle. Dismantling of propeller shaft and universal joint. Defects in propeller shaft. Servicing of differential and rear axle. Removal of axles in full floating, semi floating and three quarter floating types. Differential troubles and adjustments. Tube repair. Causes of tyre wear. Tyre rotation, retreading and balancing of wheels.
Servicing of Suspension System: Checking of wheel alignment. Adjustment of torsion bars. Care and maintenance of vibration dampers. Replacement of suspension rubber bushes. Play adjustment in steering gear boxes. Centralizing steering wheel.
Troubles in steering system. Brake shoe removal and re-lining. Brake bleeding and adjustment. Servicing of master cylinder and wheel cylinder checking of braking efficiency. Troubles in hydraulic and air brake systems. Periodic and break down maintenances. Maintenance schedule. Cleaning of vehicle in a service station. Equipment used in a service station.
Vehicle Body Engineering: Car body construction details, major body sections of a passenger car – front section, centre section, rear section, construction types – conventional body over frame, unitised frame and body construction. Fibre reinforced and Metal reinforced body structures. Classification of coach work, coach and bus body styles, typical layout of bus and coach body, typical layout of commercial vehicles, vehicle body materials – steel, light alloys, plastics, textiles, glass, wood, aluminium materials, adhesives and their properties, corrosion and their prevention. Hand tool study, power tool and equipment, shop safety, minor repairs – repairing plastics, hood, bumper, fender, lid, and trim service, door, roof, glass service, passenger compartment service Major body repair – frame repair, frame / body
damage measurement, frame re-alignment. Paint materials, paint characteristics, refinishing process – paint removal, preparing bare metal, prime coat selection, final sanding, masking, surface cleaning. Spray guns, equipment and material preparation, spray gun setup, spray booth.
TRANSPORT MANAGEMENT
Features of M. V. Act: Definition of terms – test for drivers and conductors – registration of vehicles – duties of drivers and conductors – traffic signs – mode of staffing in a depot – site selection and facilities in a depot – M. T. O. and functional wings – organization chart – type of co-ordination and co-coordinating factors.
Bus Operation: Factors governing bus schedule – making a bus schedule – operating characteristics – trip generation and trip distribution – Number of buses required for operation – preparation of time table for bus and crew – factors governing crew scheduling – making a crew scheduling. Intermediate public transport in Indian cities (IPT) / Para transit, Characteristics of IPT modes, Light rail transit (LRT/Tram), electric trolley bus (ETB), Magnetic levitation (MAGLEV) system, container freight station, Trailer, on flat car, Automatic Guided Vehicle (AGV). Fare collection – Route planning – Fare structure and table – trip sheet and way bill – ticket system – accident prevention – operational cost – fare methods – fare stage – organization of automotive business – marketing background – functions of marketing activities – workshop management – responsibilities of dealer – duties of workshop staff – warranty, Consignment shipment.
Importance of Roads: Traffic studies and high way planning – Road geometry – width of high way – gradient – cross section of road – super elevation and sight distance – road intersection – traffic lights – location of bus stop, bus bay, zebra crossing and parking positions – traffic census. Insurance surveying – companies – classification of policies – third party insurance – factors involved in assessing – MACT
III. DRIVING- 10 MARKS
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
