GOVERNMENT OF INDIA
MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP
DIRECTORATE GENERAL OF TRAINING
COMPETENCY BASED CURRICULUM
MECHANIC MACHINE TOOL MAINTENANCE
(Duration: Two Years)
Revised in July 2022
CRAFTSMEN TRAINING SCHEME (CTS)
NSQF LEVEL- 4
SECTOR –CAPITAL GOODS AND MANUFACTURING
MECHANIC MACHINE TOOL
MAINTENANCE
(Engineering Trade)
(Revised in July 2022)
Version: 2.0
CRAFTSMEN TRAINING SCHEME (CTS)
NSQF LEVEL - 4
Developed By
Ministry of Skill Development and Entrepreneurship
Directorate General of Training
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE
EN-81, Sector-V, Salt Lake City,
Kolkata – 700 091
www.cstaricalcutta.gov.in
SNo.
Topics
Page No.
1.
Course Information
1
2.
Training System
2
3.
Job Role
6
4.
General Information
7
5.
Learning Outcome
9
6.
Assessment Criteria
11
7.
Trade Syllabus
18
Annexure I (List of Trade Tools & Equipment)
47
CONTENTS
1
Mechanic Machine Tool Maintenance
During the two-year duration, a candidate is trained on subjects Professional Skill,
Professional Knowledge and Employability Skills related to job role. In addition to this, a
candidate is entrusted to make/do project work and Extra Curricular Activities to build up
confidence. The practical skills are imparted in simple to complex manner & simultaneously
theory subject is taught in the same fashion to apply cognitive knowledge while executing task.
The content broadly covers maintenance of different machine tools and manufacturing
of components, for maintenance in conventional & CNC machines. The broad components
covered under Professional Skill subject are as below:-
FIRST YEAR: In this year, the contents cover from safety aspect related to trade, basic fitting
operation viz., marking, filling, sawing, chiseling, drilling tapping & grinding to an accuracy of
±0.25mm. Making different fits viz., sliding, T-fit & square fit with an accuracy ±0.2mm &
angular tolerance of 1. Also shaping and milling operation of different job and produce
components by different operations.
The practical training starts with maintaining the components of power transmission
elements. Followed by operation of lathe machine and making of different components. Next,
practical on machine foundation and geometrical tests with preventive maintenance of
machines viz., lathe, drilling, milling etc.
SECOND YEAR: In this year, welding and gas cutting of metals covered. Then practicals on total
hydraulic and pneumatic system with advanced electro and pneumatic circuit making done.
Followed by preventive and breakdown maintenance of milling and grinding machines.
The practical on electric, electronic and PLC system is covered. Then CNC operation
including setting operation and part programming in simulator done. In addition overhauling of
hydraulic press, pumps & compressor are covered. And finally fault finding & breakdown
maintenance of machines viz., shaper, grinding, milling machine.
2
Mechanic Machine Tool Maintenance
2.1 GENERAL
Directorate General of Training (DGT) under Ministry of Skill Development &
Entrepreneurship offers range of vocational training courses catering to the need of different
sectors of Labour market. The vocational training programmes are running under aegis of
Directorate General of Training (DGT). Craftsman Training Scheme (CTS) with variants and
Apprenticeship Training Scheme (ATS) are two pioneer programmes under DGTfor propagating
vocational training.
Mechanic Machine Tool Maintenance (MMTM) trade under CTS is one of the popular
courses delivered nationwide through a network of ITIs. The course is of two years duration. It
mainly consists of Domain area and Core area. The Domain area (Trade Theory & Practical)
imparts professional skills and knowledge, while Core area (Employability Skills) imparts
requisite core skill & knowledge and life skills. After passing out of the training programme, the
trainee is awarded National Trade Certificate (NTC) by DGTwhich is recognized worldwide.
Trainee broadly needs to demonstrate that they are able to:
Read & interpret technical parameters/documentation, plan and organize work
processes, identify necessary materials and tools;
Perform task with due consideration to safety rules, accident prevention regulations and
environmental protection stipulations;
Apply professional knowledge, core skills & employability skills while performing the job
and maintenance work.
Check the task/job for functioning, identify and rectify errors in task/job.
Document the technical parameters related to the task undertaken.
2.2 PROGRESSION PATHWAYS
Canjoin industry as Technician and will progress further as Senior Technician, Supervisor
and can rise up to the level of Manager.
Can become Entrepreneur in the related field.
Can appear in 10+2 examination through National Institute of Open Schooling (NIOS) for
acquiring higher secondary certificate and can go further for General/ Technical
education.
Can take admission in diploma course in notified branches of Engineering by lateral
entry.
2. TRAINING SYSTEM
3
Mechanic Machine Tool Maintenance
Can join Apprenticeship programme in different types of industries leading to National
Apprenticeship certificate (NAC).
Can join Crafts Instructor Training Scheme (CITS) in the trade for becoming instructor in
ITIs.
Can join Advanced Diploma (Vocational) courses under DGT as applicable.
2.3 COURSE STRUCTURE
Table below depicts the distribution of training hours across various course elements
during a period of two years: -
S No.
Course Element
Notional Training Hours
1
st
Year
2
nd
Year
1
Professional Skill (Trade Practical)
840
840
2
Professional Knowledge (Trade Theory)
240
300
3
Employability Skills
120
60
Total
1200
1200
Every year 150 hours of mandatory OJT (On the Job Training) at nearby industry,
wherever not available then group project is mandatory.
4
On the Job Training (OJT)/ Group Project
150
150
Trainees of one-year or two-year trade can also opt for optional courses of up to 240
hours in each year for 10th/ 12th class certificate along with ITI certification, or, add on short
term courses.
2.4 ASSESSMENT & CERTIFICATION
The trainee will be tested for his skill, knowledge and attitude during the period of course
through formative assessment and at the end of the training programme through summative
assessment as notified by the DGT from time to time.
a) The Continuous Assessment (Internal) during the period of training will be done by
Formative Assessment Method by testing for assessment criteria listed against learning
outcomes. The training institute has to maintain an individual trainee portfolio as detailed in
assessment guideline. The marks of internal assessment will be as per the formative assessment
template provided on www.bharatskills.gov.in.
4
Mechanic Machine Tool Maintenance
b) The final assessment will be in the form of summative assessment. The All India Trade Test
for awarding NTC will be conducted by Controller of examinations, DGTas per the guidelines.
The pattern and marking structure is being notified by DGT from time to time. The learning
outcome and assessment criteria will be the basis for setting question papers for final
assessment. The examiner during final examination will also check the individual trainee’s
profile as detailed in assessment guideline before giving marks for practical examination.
2.4.1 PASS REGULATION
For the purposes of determining the overall result, weightage of 100% is applied for six
months and one year duration courses and 50% weightage is applied to each examination for
two years courses. The minimum pass percent for Trade Practical and Formative assessment is
60% & for all other subjects is 33%.
2.4.2 ASSESSMENT GUIDELINE
Appropriate arrangements should be made to ensure that there will be no artificial
barriers to assessment. The nature of special needs should be taken into account while
undertaking assessment. Due consideration should be given while assessing for teamwork,
avoidance/reduction of scrap/wastage and disposal of scarp/wastage as per procedure,
behavioral attitude, sensitivity to environment and regularity in training. The sensitivity towards
OSHE and self-learning attitude are to be considered while assessing competency.
Assessment will be evidence based comprising some of the following:
Job carried out in labs/workshop
Record book/ daily diary
Answer sheet of assessment
Viva-voce
Progress chart
Attendance and punctuality
Assignment
Project work
Computer based multiple choice question examination
Practical Examination
Evidences and records of internal (Formative) assessments are to be preserved until
forthcoming examination for audit and verification by examination body. The following marking
pattern to be adopted for formative assessment:
5
Mechanic Machine Tool Maintenance
Performance Level
Evidence
(a) Marks in the range of 60 -75% to be allotted during assessment
For performance in this grade, the candidate
with occasional guidance and showing due
regard for safety procedures and practices, has
produced work which demonstrates
attainment of an acceptable standard of
craftsmanship.
Demonstration of good skill in the use
of hand tools, machine tools and
workshop equipment
60-70% accuracy achieved while
undertaking different work with those
demanded by the component/job/set
standards.
A fairly good level of neatness and
consistency in the finish
Occasional support in completing the
project/job.
(b)Marksin the range of above75% - 90% to be allotted during assessment
For this grade, the candidate, with little
guidance and showing due regard for safety
procedures and practices, has produced work
which demonstrates attainment of a
reasonable standard of craftsmanship.
Good skill levels in the use of hand
tools, machine tools and workshop
equipment
70-80% accuracy achieved while
undertaking different work with those
demanded by the component/job/set
standards.
A good level of neatness and
consistency in the finish
Little support in completing the
project/job
(c) Marksin the range of above 90% to be allotted during assessment
For performance in this grade, the candidate,
with minimal or no support in organization and
execution and with due regard for safety
procedures and practices, has produced work
which demonstrates attainment of a high
standard of craftsmanship.
High skill levels in the use of hand tools,
machine tools and workshop equipment
Above 80% accuracy achieved while
undertaking different work with those
demanded by the component/job/set
standards.
A high level of neatness and consistency
in the finish.
Minimal or no support in completing
the project.
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Mechanic Machine Tool Maintenance
Mechanic Machine Tool Maintenance installs, erects and changes layout of machines and
equipment in mills, factories, workshops etc. according to instructions or specifications. Studies
drawings and lay out sketches of machines or equipment to be erected. Calculates available
floor area in relation to dimension of machines, working space required etc. and marks areas on
floor for foundations of machines. Guides’ construction of foundations and setting of
foundation bolts and fixtures according to type of machines to be installed and allows
foundations to dry up and settle for required number of days. Places base or holding device of
machines through foundation bolts or on fixture one by one, using lifting equipment and aligns
and levels them with spirit level. Fastens or secures machines tightly to foundation bolts or
fixtures and rechecks alignment and leveling to ensure correctness. Makes adjustment if
necessary and gets grouting of foundations done. Allows grouting to dry up and adjust position
of different parts of machine for efficient operation. Gives necessary power supply to machine
or connects machine to line shaft. May run machine and observe performance. May assemble,
repair and overhaul machines. May specialize in erecting particular type of machine or
equipment such as printing machine, lathe, pneumatic hammer, grinder, pumps, etc.
Plan and organize assigned work and detect & resolve issues during execution.
Demonstrate possible solutions and agree tasks within the team. Communicate with required
clarity and understand technical English. Sensitive to environment, self-learning and
productivity.
May be designated as Mechanic Machine Tool Maintenance according to nature of work done
Reference NCO-2015:
a) 8211.1000 –Erector, Machine and Equipment
b) 8211.0100 –Assembler, Workshop Machine and Equipment
Reference NOS:
a) CSC/N0304
b) CSC/N0901
c) CSC/N0305
d) CSC/N9401
e) CSC/N9402
f) CSC/N9488
g) CSC/N9489
h) CSC/N9490
i) CSC/N9491
3. JOB ROLE
7
Mechanic Machine Tool Maintenance
Name of the Trade
MECHANIC MACHINE TOOL MAINTENANCE
Trade Code
DGT/1043
NCO - 2015
8211.1000, 8211.0100
NOS Covered
CSC/N0304, CSC/N0901, CSC/N0305, CSC/N 9401, CSC/N
9402, CSC/N 9488, CSC/N 9489, CSC/N 9490, CSC/N 9491
NSQF Level
Level – 4
Duration of Craftsmen
Training
Two years (2400 hours + 300 hours OJT/Group Project)
Entry Qualification
Passed 10th class examination with Science and Mathematics
or with vocational subject in same sector or its equivalent.
Minimum Age
14 years as on first day of academic session.
Eligibility for PwD
LD, CP, LC, DW, AA, BLIND, LV, DEAF, HH, AUTISM, ID, SLD
Unit Strength (No. Of
Student)
24 (There is no separate provision of supernumerary seats)
Space Norms
192 Sq.m
Power Norms
17 KW
Instructors Qualification for
1. Mechanic Machine Tool
Maintenance Trade
B.Voc/Degree in Mechanical Engineering from AICTE/UGC
recognized Engineering College/ university with one-year
experience in the relevant field.
OR
03 years Diploma in Mechanical Engineering from AICTE
recognized board of technical education or relevant
Advanced Diploma (Vocational) from DGT with two years’
experience in the relevant field.
OR
NTC/NAC passed in the Trade of "Mechanic Machine Tool
Maintenance" With three years' experience in the relevant
field.
Essential Qualification:
4. GENERAL INFORMATION
8
Mechanic Machine Tool Maintenance
Relevant Regular / RPL variants of National Craft Instructor
Certificate (NCIC) under DGT.
Note: Out of two Instructors required for the unit of 2(1+1),
one must have Degree/Diploma and other must have
NTC/NAC qualifications. However both of them must possess
NCIC in any of its variants.
2. Workshop Calculation &
Science
B.Voc/Degree in Engineering from AICTE/UGC recognized
Engineering College/ university with one-year experience in
the relevant field.
OR
03 years Diploma in Engineering from AICTE / recognized
board of technical education or relevant Advanced Diploma
(Vocational) from DGT with two years’ experience in the
relevant field.
OR
NTC/ NAC in any one of the engineering trades with three
years’ experience.
Essential Qualification:
Regular / RPL variants of National Craft Instructor Certificate
(NCIC) in relevant trade
OR
Regular / RPL variants NCIC in RoDA or any of its variants
under DGT
3. Engineering Drawing
B.Voc/Degree in Engineering from AICTE/UGC recognized
Engineering College/ university with one-year experience in
the relevant field.
OR
03 years Diploma in Engineering from AICTE / recognized
board of technical education or relevant Advanced Diploma
(Vocational) from DGT with two years’ experience in the
relevant field.
OR
NTC/ NAC in any one of the Mechanical group (Gr-I) trades
categorized under Engg. Drawing’/ D’man Mechanical /
D’man Civil’ with three years’ experience.
Essential Qualification:
Regular / RPL variants of National Craft Instructor Certificate
(NCIC) in relevant trade
OR
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Mechanic Machine Tool Maintenance
Regular / RPL variants of NCIC in RoDA / D’man (Mech /civil)
or any of its variants under DGT.
4. Employability Skill
MBA/ BBA / Any Graduate/ Diploma in any discipline with
Two years’ experience with short term ToT Course in
Employability Skills.
(Must have studied English/ Communication Skills and Basic
Computer at 12th / Diploma level and above)
OR
Existing Social Studies Instructors in ITIs with short term ToT
Course in Employability Skills.
5. Minimum Age for
Instructor
21 Years
List of Tools and Equipment
As per Annexure – I
10
Mechanic Machine Tool Maintenance
Learning outcomes are a reflection of total competencies of a trainee and assessment will be
carried out as per the assessment criteria.
5.1LEARNING OUTCOME
FIRST YEAR:
1. Plan and organize the work to make job as per specification applying different types of
basic fitting operation and Check for dimensional accuracyfollowing safety precautions.
[Basic fitting operation – marking, Hack-sawing, Chiseling, Filing, Drilling, Taping and
Grinding etc. Accuracy: ± 0.25mm] NOS:CSC/N0304
2. Make different fit of components for assembling as per required tolerance observing
principle of interchange ability and check for functionality. [Different Fit – Sliding,
Angular, Step fit, Required tolerance: ±0.20 mm, angular tolerance: 1 degree]
NOS:CSC/N0304
3. Set the different parameters to produce components involving basic operations on
different machine observing standard procedure and check for accuracy. [Different
machines – Shaper, Lathe & Milling, Different machining parameters – feed, speed &
depth of cut.] NOS:CSC/N0304
4. Prepare components for assembly by carrying out different Heat Treatment and
surface finishing operations. [Different Heat Treatment: - Hardening, Tempering case
hardening, different surface finish- scrapping, lapping] NOS:CSC/N0304
5. Make different fit of components for assembling as per required tolerance observing
principle of interchange ability and check for functionality. [Different Fit – square fits, T
fits, hexagonal fit, dovetail fit; surface accuracy: ±0.1 mm, angular tolerance: 30 min.]
NOS:CSC/N0304
6. Dismantle, Repair and Assemble of mechanical power transmission elements in
machine tools and check for functionality. NOS: CSC/N0901
7. Carryout preventive maintenance of lubrication & cooling system of different machines
as per manufactures guidelines. [Different machines- lathe, drilling, grinding]
NOS:CSC/N0901
8. Prepare machine foundation for erection, install different machines and carry out
geometrical tests. [Different machines – shaper, pedestal grinding] NOS:CSC/N0304
9. Conduct preventive maintenance, perform dismantling & assembly of different
components and test for accuracy to carryout advance lathe operation. [Different
components- head stock apron, saddle, tool post tail stock; Different advance lathe
operation – taper turning, thread cutting] NOS:CSC/N0901
5. LEARNING OUTCOME
11
Mechanic Machine Tool Maintenance
10. Demonstrate basic mathematical concept and principles to perform practical
operations. Understand and explain basic science in the field of study.
(NOS:CSC/N9402)
11. Read and apply engineering drawing for different application in the field of work.
(NOS:CSC/N9401)
SECOND YEAR:
12. Make / Produce different joints by setting up of gas and arc welding machines and
carry out the welding. NOS:CSC/N0304
13. Identify, dismantle, replace and assemble different pneumatics and hydraulics
components. [Different components – Compressor, Pressure Gauge, Filter Regulator
Lubricator, Valves and Actuators.] (NOS:CSC/N9488)
14. Construct circuit of pneumatics and hydraulics observing standard operating
procedure& safety aspect. (NOS:CSC/N9489)
15. Make pipe/tube fittings and valve connections for lubricants and coolants, test for
leakages. CSC/N0901
16. Conduct preventive maintenance, perform dismantling and assembly of different
components machine and test for accuracy of milling machine. NOS:CSC/N0901
17. Set the different grinding machine and produce component to appropriate accuracy.
[Different machine:- Surface & cylindrical grinding; appropriate accuracy ±0.02mm]
NOS:CSC/N0304
18. Conduct preventive maintenance, perform dismantling & assembly of different
components of grinding machine and test for accuracy. [Different components grinding
head, lead screw, table, hydraulic cylinders] NOS:CSC/N0901
19. Identify and explain basic functioning of different electrical equipment, sensors and
apply such knowledge in industrial application including basic maintenance work.
[Different electrical & electronics equipment- DC/ AC motors, passive & active electronic
components, resistor, capacitor, inductors, rectifier, diode transistor, SCRS & ICS;
Different sensors – proximity & ultrasonic] NOS:CSC/N0305
20. Programme PLC and interface with other devices to check its Applications.
(NOS:CSC/N9490)
21. Prepare part programme, test on simulation software and interpret different errors.
(NOS:CSC/N9491)
22. Troubleshoot & Overhaul of pumps, fans, blowers & compressors and perform
preventive maintenance. NOS:CSC/N0901
23. Identify fault carryout maintenance work and break down of different machineries/
equipment viz., shaper, surface grinding, drilling, lathe, milling, in the shop floor, using
appropriate tools & equipment to ensure its functionality. NOS:CSC/N0901
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Mechanic Machine Tool Maintenance
24. Demonstrate basic mathematical concept and principles to perform practical
operations. Understand and explain basic science in the field of study.
(NOS:CSC/N9402)
25. Read and apply engineering drawing for different application in the field of work.
(NOS:CSC/N9401)
13
Mechanic Machine Tool Maintenance
LEARNING OUTCOME
ASSESSMENT CRITERIA
FIRST YEAR
1. Plan and organize the work
to make job as per
specification applying
different types of basic
fitting operation and Check
for dimensional
accuracyfollowing safety
precautions. [Basic fitting
operation – marking, Hack-
sawing, Chiseling, Filing,
Drilling, Taping and
Grinding etc. Accuracy: ±
0.25mm] NOS:CSC/N0304
Plan & Identify tools, instruments and equipment for marking and
make this available for use in a timely manner.
Select raw material and visual inspect for defects.
Mark as per specification applying desired mathematical
calculation and observing standard procedure.
Measure all dimensions in accordance with standard specifications
and tolerances.
Identify Hand Tools for different fitting operations and make these
available for use in a timely manner.
Prepare the job for Hacksawing, chiselling, filing, drilling, tapping,
grinding.
Perform basic fitting operations viz., Hacksawing, filing, drilling,
tapping and grinding to close tolerance as per specification to
make the job.
Observe safety procedure during above operation as per standard
norms and company guidelines.
Check for dimensional accuracy as per standard procedure.
Avoid waste, ascertain unused materials and components for
disposal, store these in an environmentally appropriate manner
and prepare for disposal.
2. Make different fit of
components for assembling
as per required tolerance
observing principle of
interchange ability and
check for functionality.
[Different Fit – Sliding,
Angular, Step fit, Required
tolerance: ±0.20 mm,
angular tolerance: 1
degree] NOS:CSC/N0304
Recognize general concept of Limits, Fits and tolerance necessary
for fitting applications and functional application of these
parameters.
Ascertain and select tools and materials for the job and make this
available for use in a timely manner.
Set up workplace/ assembly location with due consideration to
operational stipulation
Plan work in compliance with standard safety norms and collecting
desired information.
Demonstrate possible solutions and agree tasks within the team.
Make components according to the specification for different fit
using a range of practical skills and ensuring interchange ability of
6. ASSESSMENT CRITERIA
14
Mechanic Machine Tool Maintenance
different parts.
Assemble components applying a range of skills to ensure proper
fit.
Check functionality of components.
3. Set the different
parameters to produce
components involving basic
operations on different
machine observing
standard procedure and
check for accuracy.
[Different machines –
Shaper, Lathe & Milling,
Different machining
parameters – feed, speed
& depth of cut.]
NOS:CSC/N0304
Ascertain basic working principles and safety aspect of lathe
machine.
Understand functional application of different levers, stoppers,
adjustment etc.
Identify different lubrication points and lubricants, their usage for
application in lathe machine as per machine manual.
Identify different work and tool holding devices and collect
information for functional application of each device.
Mount the work and tool holding devices with required alignment
and check for its functional usage to perform lathe operations.
Solve problem by applying basic methods, tools, materials and
information during setting.
Observe safety procedure during mounting as per standard norms.
Produce components observing standard procedure.
Check accuracy/ correctness of job using appropriate
equipment/gauge.
Avoid waste, ascertain unused materials and components for
disposal, store these in an environmentally appropriate manner
and prepare for disposal.
4. Prepare components for
assembly by carrying out
different Heat Treatment
and surface finishing
operations. [Different Heat
Treatment: - Hardening,
Tempering case hardening,
different surface finish-
scrapping, lapping]
NOS:CSC/N0304
Plan & identify tools & equipment required.
Carryout heat treatment by maintaining
Observe safety produce during the appropriate temperature and
observing standard procedure.
Perform surface finishing operation observing standard procedure.
Check the components for assembly.
5. Make different fit of
components for
Recognize general concept of Limits, Fits and tolerance necessary
for fitting applications and functional application of these
15
Mechanic Machine Tool Maintenance
assembling as per required
tolerance observing
principle of
interchangeability and
check for functionality.
[Different Fit – square fits,
T fits, hexagonal fit,
dovetail fit; surface
accuracy: ±0.1 mm, angular
tolerance: 30 min.]
NOS:CSC/N0304
parameters.
Ascertain and select tools and materials for the job and make this
available for use in a timely manner.
Set up workplace/ assembly location with due consideration to
operational stipulation
Plan work in compliance with standard safety norms and collecting
desired information.
Demonstrate possible solutions and agree tasks within the team.
Make components according to the specification for different fit
using a range of practical skills and ensuring interchangeability of
different parts.
Assemble components applying a range of skills to ensure proper
fit.
Check functionality of components.
6. Dismantle, Repair and
Assemble of mechanical
power transmission
elements in machine tools
and check for functionality.
NOS:CSC/N0901
Understand safety aspects while working with power transmission
system.
Explain the functions and constructional features of various
mechanical power transmission elements and drives.
Drain out lubrication oil from the power transmission system.
Select proper tools for the required task.
Dismantle the shaft, coupling, gears, belt, clutch, pulley, chain &
sprockets. keys, bearing from the power transmission system..
Clean and check for damage of all dismantled parts.
Repair / replace damaged parts..
Assemble the power transmission system in sequence.
Fill lubrication oil and check functionality.
7. Carryout preventive
maintenance of lubrication
& cooling system of
different machines as per
manufactures guidelines.
[Different machines- lathe,
drilling, grinding]
NOS:CSC/N0901
Collect relevant information from manufacturing guidelines to
carryout preventive maintenance.
Plan and select appropriate tools & raw materials to carryout
preventive maintenance.
Conduct preventive maintenance of lubrication and cooling system
as per standard guidelines.
Check the functionality of machines.
8. Prepare machine
Understand safety aspects related to the erection & installation of
16
Mechanic Machine Tool Maintenance
foundation for erection,
install different machines
and carry out geometrical
tests. [Different machines
– shaper, pedestal
grinding] NOS:CSC/N0304
heavy machines.
Plan and prepare machine foundation as per drawing.
Place the machine on the foundation for erection.
Provide electrical power connections as per the requirement
Level the machine and install all standard accessories and check
the functional requirement.
Conduct the geometrical test as per standards for installed
machine.
Carry out component trial machining test and check the
dimensional accuracy of the component.
9. Conduct preventive
maintenance, perform
dismantling & assembly of
different components of
lathe and check accuracy
by carrying out advance
lathe operation. [Different
components- head stock
apron, saddle, tool post,
tail stock; Different
advance lathe operation –
taper turning, thread
cutting]NOS: CSC/N0901
Collect relevant information to conduct preventive maintenance of
lathe.
Plan and identify different tools and materials required to carry out
preventive and dismantling assembling.
Perform dismantling and assembly of different components i.e.
head stock, tail stock etc as per stand procedure.
Observe safety procedure while carrying out above task.
Carryout advance lathe operation viz., taper turning, thread cutting
to check functionality and accuracy.
10. Demonstrate basic
mathematical concept and
principles to perform
practical operations.
Understand and explain
basic science in the field of
study.(NOS:CSC/N9402)
Solve different mathematical problems
Explain concept of basic science related to the field of study
11. Read and apply
engineering drawing for
different application in the
field of
work.(NOS:CSC/N9401)
Read & interpret the information on drawings and apply in
executing practical work.
Read &analyze the specification to ascertain the material
requirement, tools and assembly/maintenance parameters.
Encounter drawings with missing/unspecified key information and
17
Mechanic Machine Tool Maintenance
make own calculations to fill in missing dimension/parameters to
carry out the work.
SECOND YEAR
12. Make / Produce different
joints by setting up of gas
and arc welding machines
and carry out the welding.
NOS:CSC/N0304
Acquaint the safety practices related to welding.
Plan and prepare the gas & arc welding machines to perform
welding.
Understand to set up the welding machine parameters and
selection of electrode, welding torch adjustments according to the
task.
Operate the welding machine and perform different welding
joints, check visually for common welding defects.
Interpret the applications of different welding joints with respect
to machine tool maintenance.
13. Identify, dismantle, replace
and assemble different
pneumatics and hydraulics
components. [Different
components – Compressor,
Pressure Gauge, Filter
Regulator Lubricator,
Valves and Actuators.]
(NOS:CSC/N9488)
Select and ascertain tools for the job and make this available for
use in a timely manner.
Identify different pneumatics and hydraulics components.
Plan to dismantle and replace pneumatics & hydraulics circuit as
per drawing and collecting necessary information.
Perform dismantling and replacing of different components with
accuracy applying range of skills and standard operating
procedure.
Assemble different components.
Check functionality of the components.
14. Construct circuit of
pneumatics and hydraulics
observing standard
operating procedure&
safety aspect.
(NOS:CSC/N9489)
Select and ascertain tools for the job and make this available for
use in a timely manner.
Plan to construct pneumatics & hydraulics circuit as per drawing
and collecting necessary information.
Demonstrate possible solutions and agree tasks within the team
for constructing circuit.
Construct circuit of pneumatics and hydraulics observing standard
procedure.
Comply with safety rules when performing the above operations.
Check different parameters and functionality of the system.
15. Make pipe/tube fittings
and valve connections for
Acquaint the safety practices related to pipe fittings.
Plan and perform cutting, bending, threading, ferruling on tubes.
18
Mechanic Machine Tool Maintenance
lubricants and coolants,
test for leakages.
NOS:CSC/N0901
Dismantle and assemble of different valves and replace gaskets.
Prepare pipe/tube joints, connect valves and check for leakages.
Interpret the applications of different pipe/tube joints with respect
to machine tool maintenance.
16. Conduct preventive
maintenance, perform
dismantling and assembly
of different components
machine and test for
accuracy of milling
machine. NOS: CSC/N0901
Collect relevant information to conduct preventive maintenance of
milling.
Plan and identify different tools and materials required to carry
out preventive and dismantling assembling.
Perform dismantling and assembly of different components of
milling machine as per stand procedure.
Observe safety procedure while carrying out above task.
Test for accuracy of milling machine by conducting machining.
17. Set the different grinding
machine and produce
component to appropriate
accuracy. [Different
machine:-Surface &
cylindrical grinding;
appropriate accuracy
±0.02mm]NOS: CSC/N0304
Plan and identify tools and equipment to carrying grinding for
using the same timely manner.
Set the machine parameter and job observing safety.
Grind the components using appropriate machine and observing
standard procedure.
Check the components as per defined accuracy.
18. Conduct preventive
maintenance, perform
dismantling & assembly of
different components of
grinding machine and test
for accuracy. [Different
components grinding head,
lead screw, table, hydraulic
cylinders] NOS:CSC/N0901
Collect relevant information to conduct preventive maintenance of
grinding.
Plan and identify different tools and materials required to carry
out preventive and dismantling assembling.
Perform dismantling and assembly of different components of
grinding machine as per stand procedure.
Observe safety procedure while carrying out above task.
Test for accuracy of grinding machine by conducting machining.
19. Identify and explain basic
functioning of different
electrical equipment,
sensors and apply such
knowledge in industrial
Identify differnet electrical equipment viz.multi-meter,
transformer, relays, solenoids, motor & generator.
Identify different sensors viz, proximity &ultrasonic.
Examine functioning of different electrical equipment, sensors and
their utilization in industrial application.
19
Mechanic Machine Tool Maintenance
application including basic
maintenance work.
[Different electrical &
electronics equipment- DC/
AC motors, passive & active
electronic components,
resistor, capacitor,
inductors, rectifier, diode
transistor, SCRS & ICS;
Different sensors –
proximity & ultrasonic]
NOS:CSC/NO305
Observe safety precautions during examination of electrical
equipment and sensors.
20. Programme PLC and
interface with other
devices to check its
Applications.
(NOS:CSC/N9490)
Programme a PLC as per application requirement.
Interface PLC with other devices observing standard procedure and
safety.
Check the functionality of device as per programme.
21. Prepare part programme,
test on simulation software
and interpret different
errors. (NOS:CSC/N9491)
Plan and prepare part programme as per drawing.
Prepare tooling layout as required.
Demonstrate possible solution within the team.
Test the part programme using simulation.
Illustrate the safety/ precaution to be observed during machining.
Interpret different messages generate against different errors.
22. Troubleshoot& Overhaul of
pumps, fans, blowers &
compressors and perform
preventive maintenance.
NOS:CSC/N0901
Acquaint the safety practices related to the pumps, fans, blowers &
compressors.
Understand & identify the different types of pumps, fans, blowers
and compressors.
Plan and prepare trouble shoot chart for pumps, fans, blowers &
compressors and perform the task.
Carry out the preventive maintenance of pumps, fans, blowers and
compressors.
Interpret the industrial applications of pumps, fans, blowers and
compressors in different machine tools.
23. Identify fault carryout
Acquaint the safety practices related to the break down
20
Mechanic Machine Tool Maintenance
maintenance work and
break down of different
machineries/ equipments
viz., shaper, surface
grinding, drilling, lathe,
milling, in the shop floor,
using appropriate tools
&equipments to ensure its
functionality.NOS:
CSC/N0901
maintenance of machine tools.
Understand & identify various machine tools under break down.
Demonstrate the faults arised in the machine tools.
Conduct the break down maintenance of faulty machine.
Carry out the performance test.
24. Demonstrate basic
mathematical concept and
principles to perform
practical operations.
Understand and explain
basic science in the field of
study.(NOS:CSC/N9402)
Solve different mathematical problems
Explain concept of basic science related to the field of study
25. Read and apply
engineering drawing for
different application in the
field of
work.(NOS:CSC/N9401)
Read & interpret the information on drawings and apply in
executing practical work.
Read &analyze the specification to ascertain the material
requirement, tools and assembly/maintenance parameters.
Encounter drawings with missing/unspecified key information and
make own calculations to fill in missing dimension/parameters to
carry out the work.
21
Mechanic Machine Tool Maintenance
SYLLABUS FOR MECHANIC MACHINE TOOL MAINTENANCE TRADE
FIRST YEAR
Duration
Reference Learning
Outcome
Professional Skills
(Trade Practical)
With Indicative Hours
Professional Knowledge
(Trade Theory)
Professional
Skill 260Hrs;
Professional
Knowledge
50Hrs
Plan and organize
the work to make
job as per
specification
applying different
types of basic fitting
operation and Check
for dimensional
accuracy following
safety precautions.
[Basic fitting
operation –
marking, Hack-
sawing, Chiselling,
Filing, Drilling,
Taping and Grinding
etc. Accuracy: ±
0.25mm]
(Mapped NOS:
NOS:CSC/N0304)
1. Importance of trade
training, List of tools &
Machinery used in the
trade. (1 hr)
2. Safety attitude
development of the
trainee by educating them
to use Personal Protective
Equipment (PPE). (3 hrs)
3. First Aid Method and
basic training.(2 hrs)
4. Safe disposal of waste
materials like cotton
waste, metal chips/burrs
etc. (1 hrs)
5. Hazard identification and
avoidance. (2 hrs)
6. Safety signs for Danger,
Warning, caution &
personal safety
message.(1 hr)
7. Preventive measures for
electrical accidents &
steps to be taken in such
accidents.(2 hrs)
8. Use of Fire
extinguishers.(2 hrs)
All necessary guidance to be
provided to the new comers to
become familiar with the
working of Industrial Training
Institute system including
stores procedures.
Soft Skills, its importance and
Job area after completion of
training.
Importance of safety and
general precautions observed
in the in the industry/shop
floor.
Introduction of First aid.
Operation of electrical mains
and electrical safety.
Introduction of PPEs.
Response to emergencies e.g.;
power failure, fire, and system
failure.
Importance of housekeeping
& good shop floor practices.
Introduction to 5S concept &
its application.
Occupational Safety & Health:
Health, Safety and
Environment guidelines,
legislations & regulations as
applicable.
Basic understanding on Hot
7. TRADE SYLLABUS
22
Mechanic Machine Tool Maintenance
work, confined space work
and material handling
equipment. (04 hrs)
9. Study the drawing to plan
the job/ work.
Identification of tools
&equipments as per
desired specifications for
marking, filling & sawing.
(3 hrs)
10. Visual inspection of raw
material for rusting,
scaling, corrosion etc.(1
hr)
11. Familiarisation of bench
vice. (1 hr)
12. Filing- Flat and square
(Rough finish). (8 hrs)
13. Marking with scriber and
steel rule (2hrs)
14. Filing practice, surface
filing, marking of straight
and parallel lines with odd
leg callipers and steel rule.
(08 hrs)
Linear measurements- its
units, steel rule dividers,
callipers – types and uses,
Punch – types and uses. Uses
of different types of hammers.
Description, use and care of
marking off table. (04 hrs)
15. Filing Channel, Parallel. (4
hrs)
16. Filing- Flat and square
(Rough finish), (08 hrs)
17. Filing practice, surface
filing, marking of straight
and parallel lines with odd
leg callipers and steel rule.
(5 hrs)
18. Marking practice with
dividers, odd leg callipers
and steel rule (circles,
ARCs, parallel lines). (5
hrs)
Bench vice construction,
types, uses, care &
maintenance, vice clamps,
hacksaw frames and blades,
specification, description,
types and their uses, method
of using hacksaws.
Files- specifications,
description, materials, grades,
cuts, file elements, uses. Types
of files, care and maintenance
of files.
Measuring standards (English,
Metric Units), angular
23
Mechanic Machine Tool Maintenance
measurements. (04 hrs)
19. Marking off straight lines
and ARCs using scribing
block and dividers. (5 hrs)
20. Chipping flat surfaces
along a marked line. (05
hrs)
21. Marking, filing, filing
square and check using
tri-square.(05 hrs)
Marking off and layout tools,
dividers, scribing block, odd
leg callipers, punches-
description, classification,
material, care & maintenance.
Try square, ordinary depth
gauge, protractor- description,
uses and cares.
Callipers- types, material,
constructional details, uses,
care & maintenance of cold
chisels- materials, types,
cutting angles. (04hrs)
22. Marking according to
drawing for locating,
position of holes, scribing
lines on chalked surfaces
with marking tools. (5 hrs)
23. Finding centre of round
bar with the help of ‘V’
block and marking block.
(5 hrs)
24. Prepare mushroom head
and round bar and
bending metal plate by
hammering. (10hrs)
Marking media, Prussian blue,
red lead, chalk and their
special application,
description.
Surface plate and auxiliary
marking equipment, ‘V’ block,
angle plates, parallel block,
description, types, uses,
accuracy, care and
maintenance.
(04 hrs)
25. Chipping flat surfaces
along a marked line. (10
hrs)
26. Make a square from a
round job by chipping
upto 20mm length. (8hrs)
27. Slot, straight and angular
chipping (5hrs)
28. Mark off and drill through
holes. (5 hrs)
29. Drill and tap on M.S. flat.
(8 hrs)
Drill, Tap, Die-types &
application. Determination of
tap drill size.
Reamer- material, types (Hand
and machine reamer), parts
and their uses, determining
hole size for reaming, Reaming
procedure.
(7 hrs)
24
Mechanic Machine Tool Maintenance
30. Cutting external thread on
M.S. rod using Die.(5hrs)
31. Punch letter and number
(letter punch and number
punch) (5 hrs)
32. File steps and finish with
smooth file to accuracy of
± 0.25 mm.
(10 hrs)
33. File and saw on M.S.
Square and pipe. (15 hrs)
Micrometer- outside and
inside – principle,
constructional features, parts
graduation, leading, use and
care. Micrometer depth
gauge, parts, graduation,
leading, use and care. Digital
micrometer. (04 hrs)
34. File radius along a marked
line (Convex & concave) &
match. (15 hrs)
35. Chip sheet metal
(shearing). (5 hrs)
36. Chip step and file. (5 hrs)
Vernier calipers, principle,
construction, graduations,
reading, use and care. Vernier
bevel protractor, construction,
graduations, reading, use and
care, dial Vernier Calliper,
Digital verniercalliper. (04 hrs)
37. Truing of pedestal
grinding wheel. (10 hrs)
38. Grinding and re-
sharpening of hand tools.
(10 hrs)
39. Repair and maintenance
of hand tools. (10 hrs)
40. Dressing of grinding wheel
by diamond dresser tool.
(15hrs)
Pedestal grinder –
Introduction, care & use.
Procedure of wheel mounting
& wheel dressing. Related
hazards, risk and precautions.
(10 hrs)
41. Counter sinking, counter
boring and reaming with
an accuracy ± 0.04 mm.(5
hrs)
42. Drill blind holes with an
accuracy 0.04 mm.(2 hrs)
43. Form internal threads
with taps to standard size
(blind holes).(3 hrs)
Drilling machines-types &their
application, construction of
Pillar & Radial drilling
machine. Countersunk,
counter bore and spot facing-
tools and nomenclature.
Cutting Speed, feed, depth of
cut and Drilling time
calculations. (05hrs)
25
Mechanic Machine Tool Maintenance
44. Prepare studs and bolt to
standard size and watch
with nut. (15 hrs)
Professional
Skill 40Hrs;
Professional
Knowledge
08hrs
Make different fit of
components for
assembling as per
required tolerance
observing principle
of interchangeability
and check for
functionality.
[Different Fit –
Sliding, Angular,
Step fit, Required
tolerance: ±0.20
mm, angular
tolerance: 1 degree]
(Mapped NOS:
NOS:CSC/N0304)
45. File and make Step fit,
angular fit, with surface
accuracy of ±0.20 mm
(Bevel gauge accuracy 1
degree). (20hrs)
46. Make simple open and
sliding fits. (20hrs)
Interchangeability: Necessity
in Engg, field, Limit- Definition,
types, terminology of limits
and fits-basic size, actual size,
deviation, high and low limit,
zero line, tolerance zone,
allowances. Different standard
systems of fits and limits.
(British standard system & BIS
system)
(08 hrs)
Professional
Skill 90Hrs;
Professional
Knowledge
20Hrs
Set the different
parameters to
produce
components
involving basic
operations on
different machine
observing standard
procedure and
check for accuracy.
[Different machines
– Shaper, Lathe &
Milling, Different
machining
parameters – feed,
speed & depth of
cut.] (Mapped NOS:
NOS:CSC/N0304)
47. Perform the holding job
on shaper machine vice,
setting length of stroke,
setting of feed in a shaper
machine. (5 hrs)
48. Make a square block in
shaper machine. (10 hrs)
49. Perform preventive
maintenance of shaping
machine. (5hrs)
Shaper:
Introduction to Shaper
machine parts &
constructional details, its
function and operations.
Quick return mechanism of
shaper.
Calculation of cutting Speed,
feed & depth of cut. (04 hrs)
50. Grinding of R.H & L.H
tools, V tool, parting tool,
round nose tool & ‘V’
tools. (10 hrs)
51. Perform facing operation
to correct length. (5hrs)
52. Centre drilling & drilling
operations to required
size. (5hrs)
53. Perform parallel turning &
Grinding wheel: Abrasive,
grade structures, bond,
specification, use, mounting
and dressing. Selection of
grinding wheels. Bench grinder
parts and use.
Radius/fillet gauge, feeler
gauge, hole gauge, and their
uses, care and maintenance.
(08 hrs)
26
Mechanic Machine Tool Maintenance
step turning. (05hrs)
54. Perform drilling, boring,
undercut, parting,
grooving, chamfering
operation. (10hrs)
55. Demonstrate working
principle of milling
machine. (3hrs)
56. Set arbor and cutter on
arbor of milling machine.
(4hrs)
57. Sequence of milling six
faces of a solid block.
(08hrs)
58. Perform step milling and
slot milling with side &
face cutter. (10hrs)
59. Make ‘V’ block using
horizontal milling machine
(accuracy ±0.02mm)
(10hrs)
Milling:
Introduction to milling
machine, parts &
constructional details, types.
Safety precaution followed
during milling operation.
Milling machine attachments.
Different types of milling
cutters and its materials.
Nomenclature of milling
cutters.
Milling cutter holding devices,
work holding devices, Milling
machine operations, Up
milling and Down milling.
Calculation of cutting speed,
feed, machining time for
milling machine. Indexing
methods and its calculations.
(08 hrs)
Professional
Skill 65 Hrs;
Professional
Knowledge
15Hrs
Prepare
components for
assembly by carrying
out different Heat
Treatment and
surface finishing
operations.
[Different Heat
Treatment: -
Hardening,
Tempering case
hardening, different
surface finish-
scrapping, lapping]
60. Hardening and tempering
&Normalising. (10 hrs)
61. Case Hardening. (5 hrs)
62. Hardness Testing. ( 5 Hrs)
Heat Treatment:
Iron Carbon Equilibrium
Diagram, Time-Temperature-
Transformation Curve.
Annealing, Case Hardening,
Tempering, Normalizing and
Quenching (07 hrs)
63. Scraping practice on flat &
curved surface. (15hrs)
64. Make a plain flat surface
of by scraping the high
spots using Prussian blue.
(20 hrs)
65. Lapping the surface with
Classification, construction,
materials and functional detail
of Chisels & Hammers.
Chipping technique.
Related hazards, risk and
precautions while working.
Scrapers: Introduction, Its
27
Mechanic Machine Tool Maintenance
(Mapped NOS:
NOS:CSC/N0304)
lapping stone. (5 hrs)
66. Fixing hammer handle. (5
hrs)
types, material and use.
Types of nuts, bolts, studs,
locking devices for nut, wrench
and spanner, pliers, screw
drivers, Circlip, split pin,
washers, spring washer.
Concept of torque & torque
wrench.
Different types of rivets and
their applications.
Identification of different
fasteners & operating them by
using proper hand tool (08 hrs)
Professional
Skill 85Hrs;
Professional
Knowledge
15Hrs
Make different fit of
components for
assembling as per
required tolerance
observing principle
of interchange
ability and check for
functionality.
[Different Fit –
square fits, T fits,
hexagonal fit,
dovetail fit; surface
accuracy: ±0.1 mm,
angular tolerance:
30 min.] (Mapped
NOS: CSC/N0304)
67. Make Male & Female ‘T’
fitting with an accuracy
±0.15 mm and 30
minutes. (25hrs)
68. Make male female square
fit with accuracy ±0.1 mm.
(20hrs)
Surface finish - importance,
symbol, measuring
techniques.
Lapping & honing process.
Gauges: Classification and
uses of Sine bar, Slip gauge,
Limit gauge, Feeler gauge,
thread gauge, screw pitch
gauge, taper gauge. (6 hrs)
69. Make Male & Female
Hexagon fitting with
accuracy ±0.1 mm and 30
min. (20 hrs)
Tolerances &
interchangeability -Definition
and its necessity, basic size,
actual size, limits, deviation,
Tolerance, allowance,
clearance, interference, Fits-
definition, types, description
with sketches. Method of
expressing Tolerance as per
BIS, Hole and Shaft basis (BIS
standard).
Related calculation on Limit,
Fit and Tolerance. (03 hrs)
70. Make male & female
dovetail fitting scraping
the surface within an
accuracy ±0.1 & 30 min
Fasteners:
Introduction to fasteners,
screw threads, related
terminology and specification.
28
Mechanic Machine Tool Maintenance
angular (20hrs)
Keys- types & use, (parallel,
sunk, tangential, gib head,
woodruff, key ways.)
Related hazards, risk and
precautions, while working.
(06 hrs)
Professional
Skill 130Hrs;
Professional
Knowledge
20Hrs
Dismantle, Repair
and Assemble of
mechanical power
transmission
elements in machine
tools and check for
functionality.
(Mapped NOS:
NOS:CSC/N0901)
71. Identify different
components of power
transmission. (5 hrs)
72. Dismantle and assemble
different components of
power transmission. (10
hrs)
73. Safety precautions related
to power transmission. (5
hrs)
Maintenance Practice and
Mechanical Assembly
Introduction to various
maintenance practices such
as preventive maintenance,
predictive maintenance,
breakdown maintenance &
reconditioning.
Organization Structure for
maintenance, Roles and
responsibility, advantage and
disadvantage of TPM.
Transmission of Power
Elements of mechanical
power transmission, type of
spindles and shafts (Universal
spindle, Plain shaft, Hollow
shaft, crank shaft, cam shaft).
Positive and Non-positive
drive, Friction drive, Gear
drive, Belt drive, Chain drive
and Rope drive. (04 hrs)
74. Identify different types
clutches in machine tools
and their maintenance.
(05 hrs)
75. Making key and mounting
of coupling on the shaft
with key. (05 hrs)
76. Identification and
inspection of components
of different types of
brakes in machine tools.
Clutches
Function of Clutches, its types
and use in power
transmission system. Function
of mechanical &
electromagnetic system in
clutch mechanism.
Couplings:
Concept of coupling and its
type
viz. Rigid coupling- Muff
29
Mechanic Machine Tool Maintenance
(04hrs)
77. Fitting of hub and shaft
with key. (05 hrs)
78. Installation of belt in
transmission with
adjusting the tension. (05
hrs)
coupling, Flange coupling,
Flexible coupling, Pin-bush
coupling, Chain coupling,
Gear coupling, Spider
coupling, Tyre coupling, Grid
coupling, Oldham-coupling,
Fluid coupling, Universal
coupling and their specific
applications.
Brakes& Braking Mechanism:
Types & Functions. Inspection
of brakes for safe & effective
working.
Belts-
Belt types (Flat and V) and
specifications.
Pulleys used for belt drive.
Installation, Alignment of
belts.
Problems related to
belts(Creep and slip)
Belt maintenance.
Sheave alignment, Chain
drive- Roller chain, Silent
chain, alignment of sprockets,
and maintenance of chain
drive. (04 hrs)
79. Identification of various
types of bearings in
machine tools. (4 hrs)
80. Impression testing of split
bush bearing for proper
contact on journal &
housing. (4 hrs)
81. Preloading of Precision
angular contact bearing (4
hrs)
82. Dismantling, inspection
and mounting of ball
Bearing:
Description and function of
bearing, its types - Solid Bush,
Split Bush, Collar, Pivot and
Plummer Block Bearing.
Mounting of bearings,
measurement and
adjustment of clearances in
bearings.
Types of bearing fitting on
shaft and hubs.
Type of Roller contact
30
Mechanic Machine Tool Maintenance
bearing on shaft with
press & pullers. (10hrs)
83. Dismantling & assembly of
tail stock of a lathe.
(10hrs)
84. Demonstrate of different
types of knots and hitches
used in material handling.
(5 hrs)
85. Splicing of manila rope. (2
hrs)
86. Inspection of wire rope/
steel rope/belts. (2 hrs)
87. Lift an object by using
slings. (2 hrs)
bearings- Ball bearings- single
row & double row, Deep
groove ball bearing, Angular
contact, Self aligning and
Thrust bearing.
Roller bearing- Cylindrical,
Needle roller, Taper roller,
Spherical roller, self aligning
and Spherical roller thrust
bearing.
Use of ISO bearing
designation code to generate
market survey and purchase.
Checking and adjustment of
bearing clearance.
Methods of Mounting and
dismounting of roller contact
bearing, taper roller bearing
and angular contact ball
bearing. (Back-to-back, Face-
to-face, tandem)
Mounting-dismounting and
adjustment of
Taper bore bearings with
adopter and withdrawal
sleeve.
Handling and storage of
bearings.
Related hazards, risk and
precautions. Rigging
Knowledge of different tools &
tackles used in rigging.
Construction and capacity of
wire rope/steel rope/belts.
Application of knots and
hitches.
Care and maintenance of all
types of ropes. (6 hrs)
88. Identification different
Gear:
31
Mechanic Machine Tool Maintenance
types of gears and gear
bones used in machine
tools. (5 hrs)
89. Checking of gear elements
as PCD, gear tooth
thickness, clearance
concentricity. (08 hrs)
90. Checking of backlash and
root clearance by feeler
gauge, DTI & lead wire in
gear meshing. (07 hrs)
Type, description and
function of gears-
Spur, Helical, Spiral, Bevel,
Straight and Spiral bevel,
Worm gears, Rack and pinion.
Gear Terminology.
Gear train- simple,
compound, reverted and
epicyclic. (03 hrs)
91. Inspection & replacing the
lubricating oil of a given
gearbox.(5hrs)
92. Overhauling of gear box of
lathe & milling machine.
(08hrs)
93. Write a inspection report
for maintenance job.
(5hrs)
94. Prepare a action plan for
maintenance work. (5 hrs)
Types of Gear box
Gear meshing: Checking of
backlash and root clearances
with Feeler Gauge, Dial Test
Indicator and lead wire.
Impression testing of gear
mesh with Prussian blue.
Running maintenance
Related hazards, risk and
precautions. (03 hrs)
Professional
Skill 65 Hrs;
Professional
Knowledge
15Hrs
Carryout preventive
maintenance of
lubrication &cooling
system of different
machines as per
manufactures
guidelines.
[Different machines-
lathe, drilling,
grinding] (Mapped
NOS: CSC/N0901)
95. Identification of various
types of lubrication
system and their
components. (5hrs)
96. Cleaning of lubrication
lines and oil filters. (07
hrs)
97. Fittings of different types
of seals and oil rings.
(07rs)
98. Preparing and fitting of
gasket for different joint
surface. (08hrs)
99. Preventive maintenance
of lubrication system of
lathe, drilling and grinding
machines. (08hrs)
Lubrication and its
importance, lubricating
systems
Concept of lubrication
Types and properties of Oil
and Grease.
Methods of oil lubrication-
Once through and centralized
lubrication system. (05 hrs)
Methods of grease lubrication
system- grease guns,
centralized lubrication
system.
Warning & protective devices
used in centralized lubrication
system (Pressure switch,
temperature gauge, level
32
Mechanic Machine Tool Maintenance
100. Lubrication schedule-
daily, weekly, monthly
concept. (05 hrs)
indicator and relief valve.)
Lubrication fittings. Storage
and handling,
Contamination control,
Leakage prevention- Shaft
seals, sealing devices and “O”
rings. (05 hrs)
101. Identification of
components of coolant
system. (5hrs)
102. Preventive maintenance
of coolant system. (10hrs)
103. Breakdown maintenance
of coolant system. (10hrs)
Cutting Fluids and Coolants.
Essential parts of a basic
coolant system used in the
cutting of metals.
Various types of coolants, its
properties and uses
,coolantsystem type-soluble
oils-soaps, sudsparaffin,soda
water etc.
Effect of cutting fluids in
metal cutting.
Difference between coolant
and lubricants. (05 hrs)
Professional
Skill 85Hrs;
Professional
Knowledge
16Hrs
Prepare machine
foundation for
erection, install
different machines
and carry out
geometrical tests.
[Different machines
– shaper, pedestal
grinding] (Mapped
NOS: CSC/N0304)
104. Marking location, grouting
and installation of
foundation bolts. (10hrs)
105. Erection and installation
of a small machine like
shaper/ pedestal grinder
machine. (10hrs)
MACHINE FOUNDATION
Purpose & methods
employed for installation &
erection of precision &heavy
duty machines.
Location & excavation for
foundation. Different types
of foundations –structural,
reinforced, wooden, isolated
foundations. (04 hrs)
106. Levelling of small machine
like shaper. (10hrs)
107. Levelling of a lathe &
milling machines. (10hrs)
Foundation bolt: types (rag,
Lewis cotter bolt) description
of each erection tools, pulley
block, crow bar, spirit level,
Plumb bob, wire rope, manila
rope, wooden block.
The use of lifting appliances,
extractor presses and their
use. Practical method of
33
Mechanic Machine Tool Maintenance
obtaining mechanical
advantage. The slings and
handling of heavy machinery,
special precautions in the
removal and replacement of
heavy parts.
Energy usage in relevance for
Mechanical assembly. (04 hrs)
108. Alignment of shaft with
the help of feeler gauge &
dial test indicator & taper
gauges. (5hrs)
109. Alignment of pulley &
sprocket with straight
edge & thread. (5hrs)
110. Geometrical alignment
test of machine as per
test chart. (10hrs)
111. Dismantling, checking and
assembly of various parts
of drilling machine such as
Motor, spindle head, gear
box & arm. (10hrs)
112. Measure Current, Voltage
and Resistance using
Simple Ohm`s Law Circuit
And Familiarizing Multi-
meter. (3hrs)
113. Soldering Techniques.
(3hrs)
114. Step up and step down
transformers. (3hrs)
115. Working with Solenoids
and Relays. (3hrs)
116. Working of Motor&
Generators. (3hrs)
Maintenance
-Total productive maintenance
-Autonomous maintenance
-Routine maintenance
-Maintenance schedule
-Retrieval of data from
machine manuals
Geometrical tests and
inspection method with
instruments.
Preventive maintenance-
objective and function of
Preventive maintenance,
section inspection. Visual and
detailed, lubrication survey,
system of symbol and colour
coding. Revision, simple
estimation of materials, use of
handbooks and reference
table. Possible causes for
assembly failures and
remedies.
Hazardous waste
management.
Basic Electrical:
Study of basic Electricals-
Voltage –Current etc.
Working Of Solenoids,
Inductors, Motors, Generator
Based On Electromagnetic
Induction Principle. (08hrs)
34
Mechanic Machine Tool Maintenance
Professional
Skill 20Hrs;
Professional
Knowledge
05Hrs
Conduct preventive
maintenance,
perform dismantling
& assembly of
different
components and
test for accuracy to
carryout advance
lathe operation.
[Different
components- head
stock apron, saddle,
tool post tail stock;
Different advance
lathe operation –
taper turning,
thread cutting]
(Mapped NOS:
NOS:CSC/N0901)
117. Perform taper turning in
the lathe by different
methods. (04hrs)
118. Perform external thread
cutting operation on the
lathe machine. (04hrs)
119. Dismantling and assembly
of head stock apron,
saddle, tool post tail
stock, Removing Broken
Studs / Bolts of lathe
machine. (08hrs)
120. Accuracy checking of lathe
machine after assembly.
(2hrs)
121. Perform preventive
maintenance of lathe
machine. (2hrs)
Safely precautions to be
observed while working on a
lathe, Lathe specifications,
and constructional features.
Lathe main parts
descriptions- bed, head stock,
carriage, tail stock, feeding
and thread cutting
mechanisms. Holding of job
between centers, works with
catch plate, dog, simple
description of a facing and
roughing tool and their
applications.
(05 hrs)
ENGINEERING DRAWING: (40 Hrs.)
Professional
Knowledge
ED- 40 Hrs.
Read and apply
engineering drawing
for different
application in the
field of work.
(NOS:CSC/N9401)
Introduction to Engineering Drawing and Drawing Instruments –
Conventions
Sizes and layout of drawing sheets
Title Block, its position and content
Drawing Instrument
Lines-Types and applications in drawing Free hand drawing of-
Geometrical figures and blocks with dimension
Transferring measurement from the given object to the
freehand sketches.
Freehand drawing of hand tools and measuring tools.
Drawing of Geometrical figures:
Angle, Triangle, Circle, Rectangle, Square, Parallelogram.
Lettering & Numbering–Single Stroke.
Dimensioning
Types of arrow head
Leader line with text
Position of dimensioning (Unidirectional, Aligned)
35
Mechanic Machine Tool Maintenance
Symbolic representation–
Different symbols used in the related trades.
Concept and reading of Drawing in
Concept of axes plane and quadrant
Concept of Orthographic and Isometric projections
Method of first angle and third angle projections
(definition and difference)
Reading of Job drawing of related trades.
WORKSHOP CALCULATION & SCIENCE: (36 Hrs.)
WCS- 36 Hrs.
Demonstrate basic
mathematical
concept and
principles to
perform practical
operations.
Understand and
explain basic science
in the field of study.
(NOS:CSC/N9402)
Unit, Fractions
Classification of unit system
Fundamental and Derived units F.P.S, C.G.S, M.K.S and SI units
Measurement units and conversion
Factors, HCF, LCM and problems
Fractions - Addition, substraction, multiplication & division
Decimal fractions - Addition, subtraction, multilipication&
division
Solving problems by using calculator
Square root, Ratio and Proportions, Percentage
Square and suare root
Simple problems using calculator
Applications of pythagoras theorem and related problems
Ratio and proportion
Percentage
Precentage - Changing percentage to decimal and fraction
Material Science
Types metals, types of ferrous and non ferrous metals
Physical and mechanical properties of metals
Introduction of iron and cast iron
Difference between iron & steel, alloy steel
Properties and uses of insulating materials
Mass, Weight, Volume and Density
Mass, volume, density, weight and specific gravity Numerical
related to L,C, O sections
Speed and Velocity, Work, Power and Energy
Work, power, energy, HP, IHP, BHP and efficiency
Heat & Temperature and Pressure
Concept of heat and temperature, effects of heat, difference
36
Mechanic Machine Tool Maintenance
between heat and temperature, boiling point & melting point of
different metals and non-metals
Concept of pressure - Units of pressure
Basic Electricity
Introduction and uses of electricity
Electrical power, HP, energy and units of electrical energy
Mensuration
Area and perimeter of square, rectangle and parallelogram
Area and perimeter of Triangles
Area and perimeter of circle, semi-circle, circular ring, sector of
circle, hexagon and ellipse
Surface area and volume of solids - cube, cuboid, cylinder,
sphere and hollow cylinder
Finding the lateral surface area, total surface area and capacity
in litres of hexagonal, conical and cylindrical shaped vessels
Levers and Simple machines
Lever & Simple machines - Lever and its types
Trigonometry
Measurement of angles
Trigonometrical ratios
Trigonometrical tables
In-plant training/ Project work
Broad area:
a) Manufacturing of machine spares by conventional methods of manufacturing.
b) Changing of shearing pin of milling machine.
c) Setting up of Lathe machine.
37
Mechanic Machine Tool Maintenance
SYLLABUS FOR MECHANIC MACHINE TOOL MAINTENANCE TRADE
SECOND YEAR
Duration
Reference Learning
Outcome
Professional Skills
(Trade Practical)
With Indicative Hours
Professional Knowledge
(Trade Theory)
Professional
Skill 40 Hrs;
Professional
Knowledge
10 Hrs
Make / Produce
different joints by
setting up of gas and
arc welding machines
and carry out the
welding. (Mapped
NOS: CSC/N0304)
122. Setting up an Arc welding
machine. (5hrs)
123. Edge preparation of
material for Arc welding.
(5hrs)
124. Perform square lap joint,
butt joint, tee joint and
Pipe Joint in Arc welding.
(10hrs)
125. Making straight beads in
gas welding. (4hrs)
126. Perform square lap joint,
but joint & tee joint in
Gas welding. (08hrs)
127. Perform gas cutting of
MS plate. (08hrs)
Arc Welding:Introduction to
arc welding and its safety.
Welding types, Common
tools used in welding.
Basic Electricity as applied to
Welding
Arc Length & its effects
Arc Welding Machines: -
advantages & disadvantages
of AC & DC Arc Welding
Machine. Electrodes: - Sizes
& Coding.
Edge Preparation:
Nomenclature of butt & fillet
welding. Welding Symbols &
Weld defects.
Gas Welding:Introduction to
gas welding process, its
classifications, accessories
and its safety.
Gas Cutting: Principle of gas
cutting.
Systems of Oxy-Acetylene
Welding- Flashback &
backfire. Types of Oxy-
Acetylene flames: - Gases
used in welding & Gas flame
combination.
Safety in gas cutting process.
(10 hrs)
Professional
Skill 60Hrs;
Identify, dismantle,
replace and assemble
128. Demonstrate knowledge
of safety procedures in
Hydraulics & Pneumatics
Basic principles of Hydraulics
38
Mechanic Machine Tool Maintenance
Professional
Knowledge
18Hrs
different pneumatics
and hydraulics
components.
[Different
components –
Compressor, Pressure
Gauge, Filter
Regulator Lubricator,
Valves and
Actuators.]
(NOS:CSC/N9488)
hydraulic systems (Demo
by video).
(4 hrs)
129. Identify hydraulic
components – Pumps,
Reservoir, Fluids,
Pressure relief valve
(PRV), Filters, different
types of valves,
actuators, and hoses. (07
hrs)
130. Inspect fluid levels,
service reservoirs,
clean/replace filters.
(10hrs)
- Advantages & limitation of
hydraulic system, hydrostatic
transmission, Pascal’s law,
Brahma’s press, pressure
Temperature & flow, speed
of an actuator.
Control valves: Different type
of control valves used in
hydraulic System.
Function of pressure control
valve, directional control
valve, check valve, flow
control valve. (06 hrs)
131. Identify pneumatic
components –
Compressor, pressure
gauge, Filter-Regulator-
Lubricator (FRL) unit, and
Different types of valves
and actuators. (2 hrs)
132. Dismantle, replace, and
assemble FRL unit. (5 hrs)
133. Demonstrate knowledge
of safety procedures in
pneumatic systems and
personal Protective
Equipment (PPE). (2 hrs)
134. Identify the parts of a
pneumatic cylinder.(1 hr)
135. Dismantle and assemble
a pneumatic cylinder.(4
hrs)
136. Construct a circuit for the
direction & speed control
of a small-bore single-
acting (s/a) pneumatic
cylinder. (5 hrs)
Compressed air generation
and conditioning, Air
compressors, Pressure
regulation, Dryers, Air
receiver, Conductors and
fittings, FRL unit, Applications
of pneumatics, Hazards &
safety precautions in
pneumatic systems.
Pneumatic actuators:- Types,
Basic operation, Force, Stroke
length, Single-acting and
double-acting cylinders.
Pneumatic valves:-
Classification, Symbols of
pneumatic components, 3/2-
way valves (NO & NC types)
(manually-actuated &
pneumatically-actuated) &
5/2-way valves,
Check valves, Flow control
valves, One-way flow control
valve
39
Mechanic Machine Tool Maintenance
137. Construct a control
circuit for the control of a
double acting pneumatic
cylinder with momentary
input signals. (5 hrs)
138. Construct a circuit for the
direct & indirect control
of a double acting
pneumatic cylinder with
a single & double
solenoid valve. (08 hrs)
139. Dismantling &Assembling
of solenoid valves. (07
hrs)
Pneumatic valves: Roller
valve, Shuttle valve, Two-
pressure valve
Electro-pneumatics:
Introduction, 3/2-way single
solenoid valve, 5/2-way single
solenoid valve, 5/2-way
double solenoid valve,
Control components -
Pushbuttons (NO & NC type)
and Electromagnetic relay
unit, Logic controls (12 hrs)
Professional
Skill 110Hrs;
Professional
Knowledge
30Hrs
Construct circuit of
pneumatics and
hydraulics observing
standard operating
procedure& safety
aspect.
(NOS:CSC/N9489)
140. Inspect hose for twist,
kinks, and minimum bend
radius, Inspect hose/tube
fittings. (5 hrs)
141. Identify internal parts of
hydraulic cylinders,
pumps/motors. (10 hrs)
142. Construct a circuit for the
control of a single acting
hydraulic cylinder using a
3/2-way valve (Weight
loaded double acting
cylinder may be used as a
single acting cylinder),
4/2 & 4/3 way valves. (10
hrs)
143. Perform overhauling of
hydraulic pump. (10hrs)
144. Maintenance,
troubleshooting, and
safety aspects of
pneumatic and hydraulic
systems (The practical for
this component may
demonstrated by video).
- Symbols of hydraulic
components, Hydraulic oils
–function, properties, and
types, Contamination in
oils and its control
- Hydraulic Filters – types,
constructional features,
and their typical
installation locations,
cavitations, Hazards &
safety precautions in
hydraulic systems
- Hydraulic reservoir &
accessories, Pumps,
Classification – Gear/vane/
piston types, Pressure
relief valves – Direct acting
and pilot-operated types
- Pipes, tubing, Hoses and
fittings – Constructional
details, Minimum bend
radius, routing tips for
hoses
- Hydraulic cylinders –Types
- Hydraulic motors –Types
40
Mechanic Machine Tool Maintenance
(13 hrs)
- Hydraulic valves:
Classification, Directional
Control valves – 2/2- and
3/2-way valves
- Hydraulic valves: 4/2- and
4/3-way valves, Centre
positions of 4/3-way valves
- Hydraulic valves: Check
valves and Pilot-operated
check valves, Load holding
function
- Flow control valves: Types,
Speed control methods –
meter-in and meter-out
- Preventive maintenance &
troubleshooting of
pneumatic & hydraulic
systems, System
malfunctions due to
contamination, leakage,
friction, improper
mountings, cavitations,
and proper sampling of
hydraulic oils (13 hrs)
145. Construct Electro
Hydraulic circuit –Speed
and Pressure control of
double acting
cylinder.(10 hrs)
146. Perform overhauling of
pneumatic cylinders.
(12hrs)
147. Perform overhauling of
hydraulic actuators.
(10hrs)
148. Disassembly of power
pack, hydraulic pipes,
ferrules, hydraulic
cylinders, pistons etc.
Electro hydraulic circuit,
Electrical components
- Switches
- Solenoid
- Relay
Introduction to Pneumatic
actuators
Pneumatic Symbols
Pneumatic circuit
Electrical control components
- Switches
- Solenoid
- Relay
Study & working of a
hydraulic press along with its
41
Mechanic Machine Tool Maintenance
(10hrs)
149. Replacing &refitting of
hydraulic pipes, seals etc.
(10hrs)
150. Assemble the parts and
testing of the power
press after air bleeding.
(10hrs)
components. Breakdown &
preventive maintenance of a
hydraulic press. Safety in use
of and maintenance of
hydraulic presses.
Proximity Sensors
Classification And Operation-
Proximity Sensor-Types Of
Proximity Sensor And Their
Working-Industrial
Application
Sensors For Distance And
Displacement -LVDT-Linear
(17 hrs)
Professional
Skill 80Hrs;
Professional
Knowledge
20Hrs
Make pipe/tube
fittings and valve
connections for
lubricants and
coolants, test for
leakages. (Mapped
NOS: CSC/N0901)
151. Flaring of pipes and pipe
joints. (3 hrs)
152. Cutting & Threading of
pipe length.(3 hrs)
153. Fitting of pipes as per
sketch observing
conditions used for pipe
work. (09 hrs)
154. Bending of pipes- cold
and hot.(7 hrs)
155. Fit & assemble pipes,
valves and test for
leakage & functionality of
valves.(17 hrs)
156. Visual inspection for
visual defects e.g. dents,
surface finish.(3hrs)
Pipes and pipe fitting-
commonly used pipes. Pipe
schedule and standard sizes.
Pipe bending methods. Use of
bending fixture, pipe threads-
Std. Pipe threads Die and Tap,
pipe vices.
Standard pipefitting-
Methods of fitting or
replacing the above fitting,
repairs and erection on
rainwater drainage pipes and
house hold taps and pipe
work.
Inspection & Quality control
-Visual Inspection
- Basic 7 Quality tools (10
hrs)
157. Dismantle & assembly of
globe valve, gate valve,
butterfly, diaphragm,
direction control valve,
pressure relief, non
return& flow control
Pipe colour code.
Safety precautions to be
observed while working at
pipeline.
Constructional detail of
different type of valve & their
42
Mechanic Machine Tool Maintenance
valve. (30hrs)
158. Making & replacement of
gaskets, washer. (08hrs)
uses like: Gate, Globe,
butterfly, Diaphragm.
(10 hrs)
Professional
Skill 40Hrs;
Professional
Knowledge
10Hrs
Conduct preventive
maintenance,
perform dismantling
and assembly of
different components
machine and test for
accuracy of milling
machine. (Mapped
NOS: CSC/N0901)
159. Dismantle and assemble
of head stock, gear box
lead screw, table of
milling machine. (27hrs)
160. Check the accuracy of
milling machine of after
assembly. (08hrs)
161. Do the preventive
maintenance of milling
machine. (5hrs)
Breakdown maintenance and
preventive maintenance of a
milling machine. (10 hrs)
Professional
Skill 60Hrs;
Professional
Knowledge
18Hrs
Set the different
grinding machine and
produce component
to appropriate
accuracy. [Different
machine:- Surface &
cylindrical grinding;
appropriate accuracy
±0.02mm] (Mapped
NOS: CSC/N0304)
162. Demonstrate working of
grinding machine. (05
hrs)
163. Set the machine, stroke
length & do wheel
balancing. (10 hrs)
164. Perform grinding of
parallel and
perpendicular surfaces
(accuracy ±0.02mm). (15
hrs)
165. Perform grinding of
angular surfaces grinding
(accuracy ±0.02mm).
(10hrs)
166. Setting the cylindrical
grinding machine for
grinding internal and
external surfaces. (10hrs)
167. Setting the machine for
grinding taper holes.
(10hrs)
Grinding:
Grinding machine –
introduction, parts &
constructional details, types
– surface grinding and
cylindrical grinding
machines. Safety precaution
followed while working on
grinding machines. Grinding
wheels – abrasives, bond and
bonding process, grit, grade,
and structure of grinding
wheels and its marking
system.
Procedure for mounting of
grinding wheels, balancing of
grinding wheels, dressing
and truing of grinding
wheels, glazing and loading
in grinding wheel.
(18 hrs)
Professional
Skill 40Hrs;
Professional
Conduct preventive
maintenance,
perform dismantling
& assembly of
168. Dismantle and assembly
of grinding head, lead
screw, table, hydraulic
cylinders of grinding
Preventive and breakdown
maintenance of grinding
machine.
(10 hrs)
43
Mechanic Machine Tool Maintenance
Knowledge
10Hrs
different components
of grinding machine
and test for accuracy.
[Different
components grinding
head, lead screw,
table, hydraulic
cylinders] (Mapped
NOS: CSC/N0901)
machine. (20hrs)
169. Check the accuracy of
grinding machine after
assembly. (10hrs)
170. Do the preventive
maintenance of surface
grinder and cylindrical
grinding machine. (10hrs)
Professional
Skill 110Hrs;
Professional
Knowledge
30Hrs
Identify and explain
basic functioning of
different electrical
equipment, sensors
and apply such
knowledge in
industrial application
including basic
maintenance work.
[Different electrical &
electronics
equipment- DC/ AC
motors, passive &
active electronic
components, resistor,
capacitor, inductors,
rectifier, diode
transistor, SCRS &
ICS; Different sensors
– proximity &
ultrasonic] (Mapped
NOS: CSC/N0305)
171. Behaviour of Proximity
Sensors. (5hrs)
172. Behaviour of ultrasonic
sensors. (5hrs)
173. Logical Operation of
Sensors. (5hrs)
174. Limit & Level Control
using Sensors. (5hrs)
175. Interfacing of Sensors
with Electrical Actuators.
(5hrs)
176. Making simple wiring
circuits and
measurement of current
and voltage. (5hrs)
177. Testing of power supply
(AC & DC).(5 hrs)
178. Demonstration of use of
test lamp and megger. (5
hrs)
179. Connections of DC/AC
motors and its speed
control - demonstration
only. (5 hrs)
Switches, Fuse And Circuit
Breakers.
Introduction To Sensors--
Fundamental Of Sensor.
Potentiometer -Ultrasonic
And Optical Sensors-
Industrial Application.
Basic principles of DC
generators and motors,
Alternators and AC motors
and transformers. Various
types of switches, circuit
breakers, fuses, lamps,
proximity switches, relays
and contactor in electrical
circuits.
Passive circuit elements –
resistors, capacitors and
inductors. Its identification
and testing. Colour code.
(12 hrs)
180. Identification of passive
& active electronic
components. (8hrs)
181. Use of oscilloscope.
(05hrs)
182. Demonstrate of logic
BASIC ELECTRONICS
Introduction to electronics
and its industrial applications.
Introduction to digital
electronics – numbers system
and logic gates.
44
Mechanic Machine Tool Maintenance
gate operations. (5hrs)
183. Testing and
measurement of
resistors, capacitors,
inductors using
multimeter. (8hrs)
184. Perform soldering and
de-soldering of
components on printed
circuit board. (PCB).
(10hrs)
185. Study of rectifiers and
testing with multimeter.
(5hrs)
186. Preparing and checking
of rectifier circuits. (6hrs)
187. Demonstrate of solid
state devices –diode
transistors. (5hrs)
188. SCRS & ICS –identification
&testing. (5hrs)
189. Assembly of simple
battery eliminator circuit
using bright rectifier &
fitter capacitor. (8hrs)
Study of electronic circuit –
macro level with block
diagram. (18 hrs)
Professional
Skill 40Hrs;
Professional
Knowledge
10Hrs
Programme PLC and
interface with other
devices to check its
Applications.
(NOS:CSC/N9490)
192. Ascertain various
modules, controls, and
indicators of given PLC. (6
hrs)
193. Program and configure
the PLC to perform a
simple start/stop routine.
(6 hrs)
194. Program the PLC using
Timer and Counter
instructions. (10 hrs)
195. Program the PLC to
perform Move,
Arithmetic, and Logical
PLC:
Overview of different control
systems. Introduction about
PLC. Block diagram of PLC.
Different types of PLC, PLC
Architectures (Fixed and
Modular). Selection of PLC.
Advantages of PLC.
Applications of PLC. Various
types of modules used in PLC.
Familiarization of AND, OR
and NOT logics with
examples. Registers Basics.
Timer Functions. Counter
45
Mechanic Machine Tool Maintenance
operations. (3 hrs)
196. Program the PLC for
performing comparator
operations. (3 hrs)
197. Practice on PLC wiring. (9
hrs)
198. Program PLC for
controlling analog
parameter(s). (3 hrs)
Functions. Introduction and
importance of Sequential
Control Systems.
Communication protocols
used in PLC: RS-232, RS-485,
Ethernet, Profibus.
Different programming
languages of PLC: LDR,
STL,FBD, CSF.
Basic ladder programming of
PLC. Configuration of PLC and
its modules.
Wiring of PLC. (10 hrs)
Professional
Skill 60Hrs;
Professional
Knowledge
18Hrs
Prepare part
programme, test on
simulation software
and interpret
different errors.
(NOS:CSC/N9491)
199. Knowledge rules of
personal and CNC
machine safety, safe
handling of tools, safety
switches and material
handling equipment
using CNC
didactic/simulation
software and equipment.
(5hrs)
200. Identify CNC lathe
machine elements and
their functions. (5hrs)
201. Understand the working
of parts of CNC lathe,
using CNC didactic/
simulation software.
(05hrs)
202. Identify common tool
holder and insert shapes
by ISO nomenclature.
(5hrs)
203. Select cutting parameters
from tool manufacturer’s
catalogue. (2hrs)
204. Write CNC programs for
Concept of Co-ordinate
geometry, concept of
machine coordinate axis, axes
convention on CNC lathes,
work zero, machine zero.
Converting part diameters
and lengths into co-ordinate
system points. Absolute and
incremental programming.
Programming – sequence,
formats, different codes and
words.
ISO G codes and M codes for
CNC turning.
Describe CNC interpolation,
open and close loop control
systems. Co-ordinate systems
and Points.
Cutting tool materials,
application of various
materials.
46
Mechanic Machine Tool Maintenance
simple tool motions and
parts using linear and
circular interpolation;
check on program
verification/ simulation
software. (04hrs)
205. Write CNC part programs
using canned cycles for
stock removal, grooving,
threading operations,
with drilling and finish
turning. Use TNRC
commands for finish
turning. Check simulation
on program verification/
simulation software. (06
hrs)
206. Avoiding collisions
caused by program
errors. Knowing causes
and effects of collisions
due to program errors, by
making deliberate
program errors and
simulation on program
verification/ simulation
software. (6hrs)
207. Simple turning & Facing
(step turning) without
using canned cycles, on
CNC simulator. (06 hrs)
208. Program checking in dry
run, single block modes,
on CNC simulator (2hrs)
209. Absolute and incremental
programmingassignment
s and simulation. (6hrs)
210. Checking finish size by
over sizing through tool
Cutting tool geometry for
internal and external turning,
grooving, threading, face
grooving, drilling. Insert
holding methods for each.
Writing part programs as per
drawing & checking using
CNC program verification/
simulation software. Process
planning, work holding, tool
and cutting parameters
selection according to the
part geometry and
dimensions.
Collisions due to program
errors, effects of collisions.
Costs associated with
collisions – tool breakage,
machine damage, injuries.
Find out alarm codes and
meaning of those codes.
Program execution in
different modes like MDI,
single block and auto.
Process planning &
sequencing, tool layout &
selection and cutting
parameters selection.
Work and tool offsets.
Inputs value to the offset/
geometry page into machine.
First part checking: Program
47
Mechanic Machine Tool Maintenance
offsets, on CNC
simulator. (2hrs)
211. Recovering from axes
over travel, on CNC
simulator. (1 hr)
212. Interpret different
messages generated
against different errors.
(05hrs)
checking in single block and
dry run modes – necessity
and method.
(18 hrs)
Professional
Skill 90Hrs;
Professional
Knowledge
20Hrs
Troubleshoot &
Overhaul of pumps,
fans, blowers &
compressors and
perform preventive
maintenance.
(Mapped NOS:
CSC/N0901)
213. Demonstrate various
types of machine related
centrifugal pump and
their parts. (8hrs)
214. Overhauling of pumps
with fitting of gland
packing. (15hrs)
215. Priming of pump. (4hrs)
216. Testing of pump. (2hrs)
217. Perform preventive and
schedule maintenance.
(4hrs)
218. Trouble shooting in pump
operation. (12hrs)
Centrifugal Pump, Fan,
Blower and Compressor:-
Pump
Function of pump.
Types and working principle
of centrifugal pump (machine
related).
Constructional detail of pump
Starting and stopping
Pump performance and
characteristics.
Capitation & aeration
Preventive & schedule
maintenance of pumps.
Gland packing changing
procedure.
Concept of Mechanical seal
Trouble shooting in pump.
(10 hrs)
219. Identification of various
types of fans, blowers
and their parts. (5hrs)
220. Dismantle, inspect,
repair/ replace work out
part and assemble the
same. (10hrs)
221. Demonstrate
compressors and their
parts. (8 hrs)
222. Cleaning and changing of
Fan & Blowers:
Types and working principle
Constructional detail of Fans
& Blowers.
Starting and stopping of Fans
and Blowers
Different parts of Fans &
Blowers
Concept of surge.
Preventive & scheduled
maintenance.
48
Mechanic Machine Tool Maintenance
filters of compressors. (8
hrs)
223. Perform schedule and
preventive maintenance
of blower & compressor.
(6hrs)
224. Change compression ring
& oil rings in a
reciprocator compressor.
(8 hrs)
Compressors:
Compression theory, Types of
compressors
Constructional detail of
compressors, working
mechanism
Different parts and their
function.
Loading unloading system
Concept of air dryer.
Preventive & schedule
maintenance.
(10 hrs)
Professional
Skill 110Hrs;
Professional
Knowledge
30Hrs
Identify fault carryout
maintenance work
and break down of
different
machineries/
equipments viz.,
shaper, surface
grinding, drilling,
lathe, milling, in the
shop floor, using
appropriate tools
&equipments to
ensure its
functionality.
(Mapped NOS:
CSC/N0901)
225. Demonstrate mechanical
& hydraulic jack, rope
puller, chain puller, chain
block, and winch. (8 hrs)
226. Inspection of tools and
tackles of material
handling equipments. (6
hrs)
227. Shift a small machine
from layout to loading
centre/ different work
place. (10 hrs)
Different type of jacks, chain
block and pull lift.
Knowledge of different types
of scaffolding.
Material movement by using
different rigging tools and
techniques.
Safety appliances &
precautions in rigging.
Maintenance of tools and
tackles.
(09 hrs)
228. Practice various belt &
chain joining methods.
(20 hrs)
229. Demonstrate belt
conveyor system,
vibratory screen &
feeder. (Video demo)(6
hrs)
Bulk Material Handling
(Conveyor belt, Vibratory
screen, Feeders)
Principle & mode of material
handling.
Various components used in
belt conveyor system & their
functions.
(Pulleys, idlers, scrapers,
skirts, belt, take up unit
system and safety devices).
Vibratory screen- working
mechanism.
Feeders- types, working
49
Mechanic Machine Tool Maintenance
mechanism.
Maintenance practice-Pulley
lagging, belt sway control belt
joining methods.
(06 hrs)
230. Trouble shooting on
machine tools such as
drill, shaper, lathe &
power saw machine. (15
hrs)
231. Perform overhauling of
feed units of lathe milling
& grinding. (15hrs)
232. Geometrical testing of
machine tools. (10hrs)
Breakdown Maintenance,
Preventive Maintenance,
Predictive Maintenance &
Concepts of TPM,
OEE.(without calculations)
Difference between
breakdown and preventive
maintenance – Its importance
in productivity, types.
Normal procedure followed
for maintenance of machine
tools on the shop floor.
Accuracy testing of machine
tools.
Various maintenance
practices.
Concepts & Measurement of
machine performance: MTBF,
MTTR. (without calculations)
(09 hrs)
233. Preparation of check list
for inspection of different
machine tools. (5hrs)
234. Temperature
measurement of machine
tools. (5hrs)
235. Vibration measurement
of machine tools. (5hrs)
236. Fault finding practice on
machine tools. (05 hrs)
Inspection & Condition
Monitoring.
Maintenance strategy –
Reactive, Preventive,
Predictive and proactive.
Corrective Maintenance &
Plan Maintenance. Condition
Base Maintenance (CBM),
Reliability Centered
Maintenance (RCM),
Importance of inspection.
Type / methods of equipment
inspection.
Commonly used gadgets for
50
Mechanic Machine Tool Maintenance
inspection.
Concept of inspection check-
list.
Importance of condition
monitoring and Various
techniques used for condition
monitoring. (vibration,
temperature, sound and
lubricant condition)
Concept of Industry 4.0 and
Digital Manufacturing. (09
hrs)
ENGINEERING DRAWING: (40 Hrs.)
Professional
Knowledge
ED- 40 Hrs.
Read and apply
engineering drawing
for different
application in the
field of work.
(NOS:CSC/N9401)
Reading of drawing of nuts, bolt, screw thread, different
types of locking devices e.g., Double nut, Castle nut, Pin, etc.
Reading of foundation drawing
Reading of Rivets and riveted joints, welded joints
Reading of drawing of pipes and pipe joints
Reading of Job Drawing, Sectional View & Assembly view
WORKSHOP CALCULATION & SCIENCE: (36 Hrs.)
WCS- 36 Hrs.
Demonstrate basic
mathematical
concept and
principles to perform
practical operations.
Understand and
explain basic science
in the field of study.
(NOS:CSC/N9402)
Friction
Friction - Advantages and disadvantages, Laws of friction, co-
efficient of friction, angle of friction, simple problems related to
friction
Friction - Lubrication
Friction - Co- efficient of friction, application and effects of
friction in workshop practice
Centre of Gravity
Centre of gravity - Centre of gravity and its practical application
Area of cut out regular surfaces and area of irregular surfaces
Area of cut out regular surfaces - circle, segment and sector of
circle
Related problems of area of cut out regular surfaces - circle,
segment and sector of circle
Area of irregular surfaces and application related to shop
problems
Elasticity
Elasticity - Elastic, plastic materials, stress, strain and their units
and young’s modulus
51
Mechanic Machine Tool Maintenance
Elasticity - Ultimate stress and working stress
Heat Treatment
Heat treatment and advantages
Heat treatment - Different heat treatment process – Hardening,
tempering, annealing, normalising and case hardening
Estimation and Costing
Estimation and costing - Simple estimation of the requirement
of material etc., as applicable to the trade
Estimation and costing - Problems on estimation and costing
In-plant training/ Project work
Broad area:
a) Visit to CNC manufacturing industry /nearby industry involving CNC operation for production
purpose(mandatory)
b) Recondition electrical panel and motor of lathe/ milling and test functionality.
c) Reconditioning of a lathe/ milling with testing report.
52
Mechanic Machine Tool Maintenance
SYLLABUS FOR CORE SKILLS
1. Employability Skills (Common for all CTS trades) (120 hrs. + 60 hrs)
Learning outcomes, assessment criteria, syllabus and Tool List of Core Skills subjects
which is common for a group of trades, provided separately in www.bharatskills.gov.in/
www.dgt.gov.in
53
Mechanic Machine Tool Maintenance
List of Tools & Equipment
Mechanic Machine Tool Maintenance(For batch of 24 candidates)
S No.
Name of the Tool & Equipment
Specification
Quantity
A. TRAINEES TOOL KIT
1.
Steel Rule
15 cm both side Graduated in
Metric & English.
24+1 nos.
2.
Center punch
100 mm
24+1 nos
3.
File flat 2
nd
cut
250 mm
24+1 nos
4.
File flat bastard
350 mm
24+1 nos
5.
File flat smooth
200 mm
24+1 nos
6.
Hermaphrodite Caliper
150 mm
5 nos.
7.
Try Square
150 mm
5 nos.
8.
Hack Saw frame adjustable
250-300 mm with blades.
5 nos.
9.
Hammer ball peen
400 gm with handle.
5 nos.
10.
Cold Chisel
20 x200 mm
5 nos.
11.
Cross Chisel
10x150 mm
5 nos.
12.
Half Round Chisel
10x150 mm
5 nos.
13.
Diamond point Chisel
10x150 mm
5 nos.
14.
File Half round
2
nd
cut 250 mm
5 nos.
15.
File triangular smooth
200 mm
5 nos.
16.
File round smooth
200 mm
5 nos.
17.
File square smooth
200 mm
5 nos.
18.
Round nose pliers
200 mm
5 nos.
19.
Combination pliers
200 mm
5 nos.
20.
Scraper A
250 mm (Bearing)
5 nos.
21.
Scraper B
250 mm (Triangular)
5 nos.
22.
Scraper D
250 mm (Half Round)
5 nos.
23.
Spindle blade screw driver
100 mm
5 nos.
24.
Allen keys
2 to 16 mm (Hexagonal)
5 nos.
25.
Card file
5 nos.
26.
Screw driver set
5 nos.
B. INSTRUMENTS AND GENERAL SHOP OUTFIT
27.
Tap and die set
M6, M8, M10, M12, M16, M20&
M25 with necessary tap wrench
and die holder.
1 each
ANNEXURE-I
54
Mechanic Machine Tool Maintenance
28.
Spanner socket
set of 25 pieces (10 to 25, 27, 30,
32, mm = 18 pcs and assorted = 7
nos.)
1no.
29.
Hammer soft
(faced 30 mm dia.) plastic tipped.
As required
30.
Pipe wrench
450
As required
31.
Chain pipe wrench
650
As required
32.
Telescopic gauges
13 mm to 300 mm.
As required
33.
Tap Extractor
1 no.
34.
Linear Actuator (Differential and non-
differential)
1 each
35.
Cut section model of Pneumatic vales
1 no.
36.
Vibrometer
As required
37.
Flow Detector
1 no.
38.
Magnetic crack detector
1 no.
39.
Engineers Stethoscope
As required
40.
Stud Extractor
1 no.
41.
Tool picker
collate type
As required
42.
Tool picker
magnetic type
As required
43.
Magnifying Glass
75 mm
1 no.
44.
Pin spanner set
1set
45.
Hand keyway breacher
As required
46.
C.I. Surface plate
400 x 400 mm with stand and cover
As required
47.
Bearing and gear tester
As required
48.
Master test bars (Different sizes)
1 no.
49.
Spirit Level
150 mm, accuracy 0.02 mm / 1000
mm
2 nos.
50.
3 Cells Torch
2 nos,
51.
Gasket Hollow punches
5, 6, 8, 10, 12, 19, 25 mm dia.
1 each
52.
Bar type Torque Wrench
1 no
53.
Cam lock type Screw Driver
1 no
54.
Flaring tools
2 no
55.
Tube Expander
up to 62 mm
2 set
56.
Circlip Pliers (inside, outside and
straight)
1 each
57.
Hammer (Ball peen, cross peen,
straight peen)
500 grms.
3 sets
58.
Viscometer
1 no.
59.
Vernier height gauge
300 mm
1 no.
60.
Maintenance tool kit
trolley of 1200 x 800 x1200 mm (L x
W x H)
As required
61.
Steel lockers for 20 trainees
2 nos.
55
Mechanic Machine Tool Maintenance
62.
Steel cupboard
180 cm x 60 cm x 45 cm
6 nos.
63.
Workbench
240 cm x 120 cm x 75 cm (Each
bench fitted with 4 vices)
5 nos.
64.
Bench Vice
100 mm jaw
24 nos.
65.
Letter punch
5 mm set
1 set
66.
Number punch
5mm set
1 set
67.
Deep cutting hacksaw frame
300 mm
1 no.
68.
Bearing puller
1 no
69.
Bolts, nuts & studs & washer
M6-M20
4 sets
70.
Prussian Blue
2 boxes
71.
Adhesives
1) Lock tight
2) Araldite
2 each
72.
Circlip external & internal
bore size (20-40mm)
2 sets
73.
Gasket sheet material
As required
74.
Lubricants oil
servo grade
1 barrel
75.
Hydraulic fluid
1 barrel
C. PRECISION INSTRUMENTS
76.
Vernier Bevel protractor
with 150 mm blade
1 no.
77.
Vernier caliper
200 mm with Inside and depth
measurements
2 nos.
78.
Dial vernier caliper
200 mm, with 0.02 mm least count
1 no.
79.
Optical Bevel protractor
1 no.
80.
Outside micrometer
0 to 25mm
1 no.
81.
Outside micrometer
25 to 50 mm
1 no.
82.
Outside micrometer
50 to 75 mm
1 no.
83.
Combination set
300 mm blade centre head, square
head and protector head.
1 no.
84.
Sine bar 200 mm
1 no.
85.
Slip Gauge Box (workshop grade) - 87
pieces per set
1 no.
86.
Inside micrometer
50 mm to 200mm, 0.01 mm least
count with six extension rod.
1 no.
87.
Dial test indicator –stand )
Plunger type-Range 0-10 mm ,
Graduation 0.01 mm & 0.001mm
Reading 0-10 with revolution
counter ( complete with clamping
devices and magnetic Range 0-10
mm , Graduation 0.01 mm & 0.001
mm. Reading 0-10 with revolution
counter ( complete with clamping
1 set
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Mechanic Machine Tool Maintenance
devices and magnetic stand )
88.
Dial test indicator – Puppitast type-
1 set
89.
Feeler gauge
1 no.
90.
Radius gauge
1 to 25 mm radius
1 no.
91.
Screw pitch gauge for metric, standard
& fine pitches.
BSP & BSW pitches ( 0.25 to 6 mm)
1 no.
92.
Center gauge
55º x 47½º
1 no.
93.
Center gauge
60º
1 no.
94.
Plug gauge
Morse taper No.1, 2, 3, 4,
1 set
95.
Ring gauge
Morse taper No.1, 2, 3, 4,
1 set
96.
Ring gauge
Ø20mm (Go and No Go )
1 no.
97.
Limit plug gauges
Ø20mm
1 no.
98.
Wire gauges
1 no.
99.
Bore gauge
dial indicator (1 mm range, 0-0.01
mm graduation)-Range of bore
gauge 18-150 mm)
1 no.
100.
Straight edge
Min 500mm- Max 1000mm
1 each
101.
Bearing fitting tool
1 set
102.
Multimeter
2 Nos.
103.
Tong tester
1 No.
104.
Megger
1 No.
105.
Wire stripper cum cutter
1 No.
106.
Crimping Tool
1 No.
D. LATHE TOOL
107.
Reduction sleeve and extension
socket.
As required
108.
Centre drills
3, 4 and 5 mm (Consumable)
2 nos. each
109.
Revolving centre with arbor
As required
110.
Knurling tool with holder (straight,
cross, diamond )
1 each
111.
Dog carrier
As required
112.
Oil can pressure feed
As required
113.
Tool holder (straight) to suit
6 & 8 mm sq. bit size
As required
114.
H.S.S. tool bits
6 mm, 8 mm sq. x100 mm length
(consumable)
As required
115.
Carbide tip mechanically fastened tool
set
1 set
E. MILLING MACHINE TOOLS
116.
Cylindrical milling cutter
Ø 63 x 70 x Ø 27 mm
1 no.
117.
Side and face cutter
Ø 80 x 10 X Ø 27 mm
1 no
57
Mechanic Machine Tool Maintenance
118.
Slitting Saw cutter
Ø 100 x 6 X Ø 27 mm
1 no.
119.
Slitting Saw cutter
Ø 75 x 3 X Ø 27 mm
1 no.
120.
‘T’ slot cutter with parallel shank-
Ø 17.5 x 8 mm width x dia. of
shank 8 mm
1 no.
121.
Woodruff key seating cutters
A 13.5x3, A16x4
1 each
122.
Parallel shank
end mill Ø 5 mm, Ø 6 mm, Ø 8mm,
Ø 10 mm and Ø 12 mm
1 each
123.
Scribing block universal
300mm
As required
124.
V-Block
Approx 65x65x80 mm with
clamping capacity of 50 mm with
clamps
1 set each
125.
D.E spanners
3-4 , 6-8, 10-12, 13-14, 15-16, 18-
19, 20-22, 24-26 ( 8 spanners)
1 set
126.
Angle plate-adjustable
250x250x300 mm
1 no.
127.
Twist Drill
Parallel Shank Ø 4 mm to Ø 12 mm
in steps of 0.5 mm
1 each
128.
Grinding wheel dresser
(diamond dresser) with holder 1.5
carat diamond
2 nos.
129.
C – clamp
50 mm & 75 mm
1 each
130.
Hand reamer
6 to 16 mm in steps of 1 mm
1 each
131.
Machine reamer
6 to 16 in steps of 1 mm
1 each
F. GENERAL MACHINERY
132.
Lathe all gear head type
Centre height of 150 mm, Gap bed,
between centers 1000 mm (with 3
jaw and 4 jaw chuck, coolant
equipments)
2 nos.
133.
Universal Milling machine
1no
134.
Surface grinding machine
wheel dia 180 mm (or near)
reciprocating table, longitudinal
table traverse 200mm (or near) full
motorized supplied with magnetic
chuck 250 X120mm and necessary
accessories.
1no
135.
Drilling machine
Pillar type 20mm capacity
1no
136.
Double ended Pedestal Grinder
178 mm wheels(one fine and one
rough)- motorized with twist drill
grinding attachment
1no
137.
Flexible Hand Grinder
100 mm dia – light duty
1no
138.
Portable Drilling machine
6 mm capacity.
1no
139.
Shaping Machine
450 mm stroke (motorized) with all
attachments
1no
140.
Pipe bending machine
Manual/ Hydraulic
1no
58
Mechanic Machine Tool Maintenance
141.
Hydraulic trainer with necessary
elements for different machine circuit
with all types of transparent valves and
pressure gauge, reservoir etc.
1 set
142.
Pneumatic trainer with necessary
elements for demonstration different
machine circuit with all types of valves,
pressure gauge and compressor etc.
1 set
143.
Universal Cylindrical grinder
External & Internal
1 No.
144.
Muffle Furnace (Electric)
Capacity 20kgs.
1 no.
145.
Multimedia based simulator for CNC
technology and interactive CNC part
programming software for turning &
milling with virtual machine operation
and simulation using popular operation
control system such as Fanuc, Siemens,
etc. (Web-based or licensed based) (12
trainees + 1faculty)
With help of this software the trainees
should be able to Write, Edit, Verify &
Simulate
Software
10
146.
Desktop Computers
CPU: 32/64 Bit i3/i5/i7 or latest
processor, Speed: 3 GHz or Higher.
RAM:-4 GB DDR-III or Higher, Wi-Fi
Enabled. Network Card: Integrated
Gigabit Ethernet, with USB Mouse,
USB Keyboard and Monitor (Min. 17
Inch) Licensed Operating System
and Antivirus compatible with trade
related software
10
G. OLD MACHINES FOR JOB WORK (REPAIR & RECONDITIONING)
147.
Old Centre lathe
1no
148.
Old Milling Machine (Universal)
1no
149.
Old Grinding Machine (Universal)
1no
150.
Old Shaping Machine
1no
151.
Old Gear Box (any type)
1no
152.
Revolving Centre
1no
153.
Old hydraulic power pack with hydraulic
cylinder
1 no
154.
Old Centrifugal Pump
1 no
155.
Old Gear pump
1 no.
59
Mechanic Machine Tool Maintenance
156.
Old Vane pump fixed and variable
delivery
1each
157.
Old Piston pump ( Radial& Axial)
1each
158.
Old Reciprocating Compressor
1 no.
H. WELDING WORK
(i) GAS WELDING
159.
Oxy-acetylene welding Cylinder Trolley
1 no.
160.
Welding hose P.V.C. flexible
Internal dia. 6 mm (Blue and red)
5m
161.
Hose coupling Nipples
2 nos.
162.
Hose Protractor
2 nos.
163.
Double stage Pressure regulator for
Oxygen and Acetylene
1no. each
164.
High Pressure blow pipe with tips
1 no.
165.
Gas cutting torch with cutting tips
1 no
166.
Welding gloves pair (Leather)
1 pair
167.
Goggles
(4A) for Gas. Welding
4 nos.
168.
Spark lighter
2 nos.
169.
Spindle key
1 no.
170.
Gas Welding table with fire bricks.
1 no.
(ii) ARC WELDING
171.
Welding Machine DC or AC,
(Single phase / 3 phase), 150 – 300
Amps capacity with all accessories
1 no.
172.
Arc welding electrode
Ø4 mild steel
3 boxes
173.
Brass brazing rod
Ø3
3 boxes
174.
Gas welding flux (Borax)
As required
175.
Gas cylinder (Acetylene & Oxygen)
2 pair
(iii) ERECTION TOOLS
176.
Foundation bolts (different types)
1each.
177.
Plumb bob
1 no.
178.
Square Box Wrenches
1 no
179.
Square T Wrenches
1 no
180.
Engineers square
700 mm
1 no
181.
Threaded Fastener B Type
1 no
182.
Threaded Fastener C Type
1 no
183.
Threaded Fastener F Type
1 no
184.
Hoisting Equipment: chain pulley, steel
slings, rope, belt, tackles
1 set
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Mechanic Machine Tool Maintenance
185.
Slings
2 Nos.
186.
Hydraulic trolley
1 No.
187.
Screw jack
2 Nos.
188.
Hydraulic jack
2 Nos.
NOTE:
a) No additional items are required to be provided to the batch working in the second and third
shift except the items under trainee’s toolkit.
b) For units less than 8(4+4), the ITI can enter into MoU with Facilitator who will provide the
CNC Training to Trainees admitted and undergoing training in above Trade. The Facilitator
should be Government ITI, Engineering/ Polytechnic College, Recognized Training Institute,
Industry, Private ITI (Facilitators are arranged in descending preference order). The Facilitator
should have training infrastructure for providing CNC training. The facilities of CNC should be
made available to ITI trainees at the time of examination. This clause should be part of MoU to
be signed. The training provider must be within the range of 15 Km or within city whichever is
less.
c) Infrastructure of Electrician trade may be utilized for imparting training on basic electrical and
electronics components.
d) Infrastructure of computer lab of the institute to be utilized for imparting practical training on
CNC simulation.
e) Internet facility is desired to be provided in the class room.
61
Mechanic Machine Tool Maintenance
ABBREVIATIONS:
CTS
Craftsmen Training Scheme
ATS
Apprenticeship Training Scheme
CITS
Craft Instructor Training Scheme
DGT
Directorate General of Training
MSDE
Ministry of Skill Development and Entrepreneurship
NTC
National Trade Certificate
NAC
National Apprenticeship Certificate
NCIC
National Craft Instructor Certificate
LD
Locomotor Disability
CP
Cerebral Palsy
MD
Multiple Disabilities
LV
Low Vision
HH
Hard of Hearing
ID
Intellectual Disabilities
LC
Leprosy Cured
SLD
Specific Learning Disabilities
DW
Dwarfism
MI
Mental Illness
AA
Acid Attack
PwD
Person with disabilities
62
Mechanic Machine Tool Maintenance