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
 CONTENTS

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

Mechanic Machine Tool Maintenance
1. COURSE INFORMATION

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.

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2. TRAINING SYSTEM

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.

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 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: -

Notional Training Hours

S No. Course Element
1st Year 2nd 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.

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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:

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Performance Level Evidence

(a) Marks in the range of 60 -75% to be allotted during assessment
For performance in this grade, the candidate  Demonstration of good skill in the use
with occasional guidance and showing due of hand tools, machine tools and
regard for safety procedures and practices, has workshop equipment
produced work which demonstrates  60-70% accuracy achieved while
attainment of an acceptable standard of undertaking different work with those
craftsmanship. 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  Good skill levels in the use of hand
guidance and showing due regard for safety tools, machine tools and workshop
procedures and practices, has produced work equipment
which demonstrates attainment of a  70-80% accuracy achieved while
reasonable standard of craftsmanship. 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,  High skill levels in the use of hand tools,
with minimal or no support in organization and machine tools and workshop equipment
execution and with due regard for safety  Above 80% accuracy achieved while
procedures and practices, has produced work undertaking different work with those
which demonstrates attainment of a high demanded by the component/job/set
standard of craftsmanship. standards.
 A high level of neatness and consistency
in the finish.
 Minimal or no support in completing
the project.

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3. JOB ROLE

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

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4. GENERAL INFORMATION

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
Two years (2400 hours + 300 hours OJT/Group Project)
Training
Passed 10th class examination with Science and Mathematics
Entry Qualification
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
24 (There is no separate provision of supernumerary seats)
Student)
Space Norms 192 Sq.m
Power Norms 17 KW
Instructors Qualification for
1. Mechanic Machine Tool B.Voc/Degree in Mechanical Engineering from AICTE/UGC
Maintenance Trade 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:

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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 & B.Voc/Degree in Engineering from AICTE/UGC recognized
Science 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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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 21 Years
Instructor
List of Tools and Equipment As per Annexure – I

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5. LEARNING OUTCOME
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

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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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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)

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6. ASSESSMENT CRITERIA

LEARNING OUTCOME ASSESSMENT CRITERIA

FIRST YEAR
1. Plan and organize the work Plan & Identify tools, instruments and equipment for marking and
to make job as per make this available for use in a timely manner.
specification applying Select raw material and visual inspect for defects.
different types of basic Mark as per specification applying desired mathematical
fitting operation and Check calculation and observing standard procedure.
for dimensional Measure all dimensions in accordance with standard specifications
accuracyfollowing safety and tolerances.
precautions. [Basic fitting Identify Hand Tools for different fitting operations and make these
operation – marking, Hack- available for use in a timely manner.
sawing, Chiseling, Filing, Prepare the job for Hacksawing, chiselling, filing, drilling, tapping,
Drilling, Taping and grinding.
Grinding etc. Accuracy: ± Perform basic fitting operations viz., Hacksawing, filing, drilling,
0.25mm] NOS:CSC/N0304 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 Recognize general concept of Limits, Fits and tolerance necessary
components for assembling for fitting applications and functional application of these
as per required tolerance parameters.
observing principle of Ascertain and select tools and materials for the job and make this
interchange ability and available for use in a timely manner.
check for functionality. Set up workplace/ assembly location with due consideration to
[Different Fit – Sliding, operational stipulation
Angular, Step fit, Required Plan work in compliance with standard safety norms and collecting
tolerance: ±0.20 mm, desired information.
angular tolerance: 1 Demonstrate possible solutions and agree tasks within the team.
degree] NOS:CSC/N0304 Make components according to the specification for different fit
using a range of practical skills and ensuring interchange ability of

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different parts.
Assemble components applying a range of skills to ensure proper
fit.
Check functionality of components.

3. Set the different Ascertain basic working principles and safety aspect of lathe
parameters to produce machine.
components involving basic Understand functional application of different levers, stoppers,
operations on different adjustment etc.
machine observing Identify different lubrication points and lubricants, their usage for
standard procedure and application in lathe machine as per machine manual.
check for accuracy. Identify different work and tool holding devices and collect
[Different machines – information for functional application of each device.
Shaper, Lathe & Milling, Mount the work and tool holding devices with required alignment
Different machining and check for its functional usage to perform lathe operations.
parameters – feed, speed Solve problem by applying basic methods, tools, materials and
& depth of cut.] information during setting.
NOS:CSC/N0304 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 Plan & identify tools & equipment required.
assembly by carrying out Carryout heat treatment by maintaining
different Heat Treatment Observe safety produce during the appropriate temperature and
and surface finishing observing standard procedure.
operations. [Different Heat Perform surface finishing operation observing standard procedure.
Treatment: - Hardening, Check the components for assembly.
Tempering case hardening,
different surface finish-
scrapping, lapping]
NOS:CSC/N0304

5. Make different fit of Recognize general concept of Limits, Fits and tolerance necessary
components for for fitting applications and functional application of these

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assembling as per required parameters.

tolerance observing Ascertain and select tools and materials for the job and make this
principle of available for use in a timely manner.
interchangeability and Set up workplace/ assembly location with due consideration to
check for functionality. operational stipulation
[Different Fit – square fits, Plan work in compliance with standard safety norms and collecting
T fits, hexagonal fit, desired information.
dovetail fit; surface Demonstrate possible solutions and agree tasks within the team.
accuracy: ±0.1 mm, angular Make components according to the specification for different fit
tolerance: 30 min.] using a range of practical skills and ensuring interchangeability of
NOS:CSC/N0304 different parts.
Assemble components applying a range of skills to ensure proper
fit.
Check functionality of components.

6. Dismantle, Repair and Understand safety aspects while working with power transmission
Assemble of mechanical system.
power transmission Explain the functions and constructional features of various
elements in machine tools mechanical power transmission elements and drives.
and check for functionality. Drain out lubrication oil from the power transmission system.
NOS:CSC/N0901 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 Collect relevant information from manufacturing guidelines to

maintenance of lubrication carryout preventive maintenance.
& cooling system of Plan and select appropriate tools & raw materials to carryout
different machines as per preventive maintenance.
manufactures guidelines. Conduct preventive maintenance of lubrication and cooling system
[Different machines- lathe, as per standard guidelines.
drilling, grinding] Check the functionality of machines.
NOS:CSC/N0901

8. Prepare machine Understand safety aspects related to the erection & installation of

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foundation for erection, heavy machines.

install different machines Plan and prepare machine foundation as per drawing.
and carry out geometrical Place the machine on the foundation for erection.
tests. [Different machines Provide electrical power connections as per the requirement
– shaper, pedestal Level the machine and install all standard accessories and check
grinding] NOS:CSC/N0304 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 Collect relevant information to conduct preventive maintenance of

maintenance, perform lathe.
dismantling & assembly of Plan and identify different tools and materials required to carry out
different components of preventive and dismantling assembling.
lathe and check accuracy Perform dismantling and assembly of different components i.e.
by carrying out advance head stock, tail stock etc as per stand procedure.
lathe operation. [Different Observe safety procedure while carrying out above task.
components- head stock Carryout advance lathe operation viz., taper turning, thread cutting
apron, saddle, tool post, to check functionality and accuracy.
tail stock; Different
advance lathe operation –
taper turning, thread
cutting]NOS: CSC/N0901

10. Demonstrate basic Solve different mathematical problems

mathematical concept and Explain concept of basic science related to the field of study
principles to perform
practical operations.
Understand and explain
basic science in the field of
study.(NOS:CSC/N9402)

11. Read and apply Read & interpret the information on drawings and apply in
engineering drawing for executing practical work.
different application in the Read &analyze the specification to ascertain the material
field of requirement, tools and assembly/maintenance parameters.
work.(NOS:CSC/N9401) Encounter drawings with missing/unspecified key information and

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make own calculations to fill in missing dimension/parameters to

carry out the work.
SECOND YEAR
12. Make / Produce different Acquaint the safety practices related to welding.
joints by setting up of gas Plan and prepare the gas & arc welding machines to perform
and arc welding machines welding.
and carry out the welding. Understand to set up the welding machine parameters and
NOS:CSC/N0304 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 Select and ascertain tools for the job and make this available for
and assemble different use in a timely manner.
pneumatics and hydraulics Identify different pneumatics and hydraulics components.
components. [Different Plan to dismantle and replace pneumatics & hydraulics circuit as
components – Compressor, per drawing and collecting necessary information.
Pressure Gauge, Filter Perform dismantling and replacing of different components with
Regulator Lubricator, accuracy applying range of skills and standard operating
Valves and Actuators.] procedure.
(NOS:CSC/N9488) Assemble different components.
Check functionality of the components.

14. Construct circuit of Select and ascertain tools for the job and make this available for
pneumatics and hydraulics use in a timely manner.
observing standard Plan to construct pneumatics & hydraulics circuit as per drawing
operating procedure& and collecting necessary information.
safety aspect. Demonstrate possible solutions and agree tasks within the team
(NOS:CSC/N9489) 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 Acquaint the safety practices related to pipe fittings.
and valve connections for Plan and perform cutting, bending, threading, ferruling on tubes.

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lubricants and coolants, Dismantle and assemble of different valves and replace gaskets.
test for leakages. Prepare pipe/tube joints, connect valves and check for leakages.
NOS:CSC/N0901 Interpret the applications of different pipe/tube joints with respect
to machine tool maintenance.

16. Conduct preventive Collect relevant information to conduct preventive maintenance of

maintenance, perform milling.
dismantling and assembly Plan and identify different tools and materials required to carry
of different components out preventive and dismantling assembling.
machine and test for Perform dismantling and assembly of different components of
accuracy of milling milling machine as per stand procedure.
machine. NOS: CSC/N0901 Observe safety procedure while carrying out above task.
Test for accuracy of milling machine by conducting machining.

17. Set the different grinding Plan and identify tools and equipment to carrying grinding for
machine and produce using the same timely manner.
component to appropriate Set the machine parameter and job observing safety.
accuracy. [Different Grind the components using appropriate machine and observing
machine:-Surface & standard procedure.
cylindrical grinding; Check the components as per defined accuracy.
appropriate accuracy
±0.02mm]NOS: CSC/N0304

18. Conduct preventive Collect relevant information to conduct preventive maintenance of

maintenance, perform grinding.
dismantling & assembly of Plan and identify different tools and materials required to carry
different components of out preventive and dismantling assembling.
grinding machine and test Perform dismantling and assembly of different components of
for accuracy. [Different grinding machine as per stand procedure.
components grinding head, Observe safety procedure while carrying out above task.
lead screw, table, hydraulic Test for accuracy of grinding machine by conducting machining.
cylinders] NOS:CSC/N0901

19. Identify and explain basic Identify differnet electrical equipment viz.multi-meter,
functioning of different transformer, relays, solenoids, motor & generator.
electrical equipment, Identify different sensors viz, proximity &ultrasonic.
sensors and apply such Examine functioning of different electrical equipment, sensors and
knowledge in industrial their utilization in industrial application.

18
Mechanic Machine Tool Maintenance

application including basic Observe safety precautions during examination of electrical

maintenance work. equipment and sensors.
[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

20. Programme PLC and Programme a PLC as per application requirement.

interface with other Interface PLC with other devices observing standard procedure and
devices to check its safety.
Applications. Check the functionality of device as per programme.
(NOS:CSC/N9490)

21. Prepare part programme, Plan and prepare part programme as per drawing.
test on simulation software Prepare tooling layout as required.
and interpret different Demonstrate possible solution within the team.
errors. (NOS:CSC/N9491) 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 Acquaint the safety practices related to the pumps, fans, blowers &
pumps, fans, blowers & compressors.
compressors and perform Understand & identify the different types of pumps, fans, blowers
preventive maintenance. and compressors.
NOS:CSC/N0901 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

19
Mechanic Machine Tool Maintenance

maintenance work and maintenance of machine tools.

break down of different Understand & identify various machine tools under break down.
machineries/ equipments Demonstrate the faults arised in the machine tools.
viz., shaper, surface Conduct the break down maintenance of faulty machine.
grinding, drilling, lathe, Carry out the performance test.
milling, in the shop floor,
using appropriate tools
&equipments to ensure its
functionality.NOS:
CSC/N0901

24. Demonstrate basic Solve different mathematical problems

mathematical concept and Explain concept of basic science related to the field of study
principles to perform
practical operations.
Understand and explain
basic science in the field of
study.(NOS:CSC/N9402)

25. Read and apply Read & interpret the information on drawings and apply in
engineering drawing for executing practical work.
different application in the Read &analyze the specification to ascertain the material
field of requirement, tools and assembly/maintenance parameters.
work.(NOS:CSC/N9401) Encounter drawings with missing/unspecified key information and
make own calculations to fill in missing dimension/parameters to
carry out the work.

20
Mechanic Machine Tool Maintenance
7. TRADE SYLLABUS

SYLLABUS FOR MECHANIC MACHINE TOOL MAINTENANCE TRADE

FIRST YEAR

Professional Skills
Reference Learning Professional Knowledge
Duration (Trade Practical)
Outcome (Trade Theory)
With Indicative Hours
Professional Plan and organize 1. Importance of trade All necessary guidance to be
Skill 260Hrs; the work to make training, List of tools & provided to the new comers to
job as per Machinery used in the become familiar with the
Professional
specification trade. (1 hr) working of Industrial Training
Knowledge
applying different 2. Safety attitude Institute system including
50Hrs
types of basic fitting development of the stores procedures.
operation and Check trainee by educating them Soft Skills, its importance and
for dimensional to use Personal Protective Job area after completion of
accuracy following Equipment (PPE). (3 hrs) training.
safety precautions. 3. First Aid Method and Importance of safety and
[Basic fitting basic training.(2 hrs) general precautions observed
operation – 4. Safe disposal of waste in the in the industry/shop
marking, Hack- materials like cotton floor.
sawing, Chiselling, waste, metal chips/burrs Introduction of First aid.
Filing, Drilling, etc. (1 hrs) Operation of electrical mains
Taping and Grinding 5. Hazard identification and and electrical safety.
etc. Accuracy: ± avoidance. (2 hrs) Introduction of PPEs.
0.25mm] 6. Safety signs for Danger, Response to emergencies e.g.;
(Mapped NOS: Warning, caution & power failure, fire, and system
NOS:CSC/N0304) personal safety failure.
message.(1 hr) Importance of housekeeping
7. Preventive measures for & good shop floor practices.
electrical accidents & Introduction to 5S concept &
steps to be taken in such its application.
accidents.(2 hrs) Occupational Safety & Health:
8. Use of Fire Health, Safety and
extinguishers.(2 hrs) Environment guidelines,
legislations & regulations as
applicable.
Basic understanding on Hot

21
Mechanic Machine Tool Maintenance

work, confined space work

and material handling
equipment. (04 hrs)
9. Study the drawing to plan Linear measurements- its
the job/ work. units, steel rule dividers,
Identification of tools callipers – types and uses,
&equipments as per Punch – types and uses. Uses
desired specifications for of different types of hammers.
marking, filling & sawing. Description, use and care of
(3 hrs) marking off table. (04 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)
15. Filing Channel, Parallel. (4 Bench vice construction,
hrs) types, uses, care &
16. Filing- Flat and square maintenance, vice clamps,
(Rough finish), (08 hrs) hacksaw frames and blades,
17. Filing practice, surface specification, description,
filing, marking of straight types and their uses, method
and parallel lines with odd of using hacksaws.
leg callipers and steel rule. Files- specifications,
(5 hrs) description, materials, grades,
18. Marking practice with cuts, file elements, uses. Types
dividers, odd leg callipers of files, care and maintenance
and steel rule (circles, of files.
ARCs, parallel lines). (5 Measuring standards (English,
hrs) Metric Units), angular

22
Mechanic Machine Tool Maintenance

measurements. (04 hrs)

19. Marking off straight lines Marking off and layout tools,
and ARCs using scribing dividers, scribing block, odd
block and dividers. (5 hrs) leg callipers, punches-
20. Chipping flat surfaces description, classification,
along a marked line. (05 material, care & maintenance.
hrs) Try square, ordinary depth
21. Marking, filing, filing gauge, protractor- description,
square and check using uses and cares.
tri-square.(05 hrs) Callipers- types, material,
constructional details, uses,
care & maintenance of cold
chisels- materials, types,
cutting angles. (04hrs)
22. Marking according to Marking media, Prussian blue,
drawing for locating, red lead, chalk and their
position of holes, scribing special application,
lines on chalked surfaces description.
with marking tools. (5 hrs) Surface plate and auxiliary
23. Finding centre of round marking equipment, ‘V’ block,
bar with the help of ‘V’ angle plates, parallel block,
block and marking block. description, types, uses,
(5 hrs) accuracy, care and
24. Prepare mushroom head maintenance.
and round bar and (04 hrs)
bending metal plate by
hammering. (10hrs)
25. Chipping flat surfaces Drill, Tap, Die-types &
along a marked line. (10 application. Determination of
hrs) tap drill size.
26. Make a square from a Reamer- material, types (Hand
round job by chipping and machine reamer), parts
upto 20mm length. (8hrs) and their uses, determining
27. Slot, straight and angular hole size for reaming, Reaming
chipping (5hrs) procedure.
28. Mark off and drill through (7 hrs)
holes. (5 hrs)
29. Drill and tap on M.S. flat.
(8 hrs)

23
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 Micrometer- outside and
smooth file to accuracy of inside – principle,
± 0.25 mm. constructional features, parts
(10 hrs) graduation, leading, use and
33. File and saw on M.S. care. Micrometer depth
Square and pipe. (15 hrs) gauge, parts, graduation,
leading, use and care. Digital
micrometer. (04 hrs)
34. File radius along a marked Vernier calipers, principle,
line (Convex & concave) & construction, graduations,
match. (15 hrs) reading, use and care. Vernier
35. Chip sheet metal bevel protractor, construction,
(shearing). (5 hrs) graduations, reading, use and
36. Chip step and file. (5 hrs) care, dial Vernier Calliper,
Digital verniercalliper. (04 hrs)
37. Truing of pedestal Pedestal grinder –
grinding wheel. (10 hrs) Introduction, care & use.
38. Grinding and re- Procedure of wheel mounting
sharpening of hand tools. & wheel dressing. Related
(10 hrs) hazards, risk and precautions.
39. Repair and maintenance (10 hrs)
of hand tools. (10 hrs)
40. Dressing of grinding wheel
by diamond dresser tool.
(15hrs)
41. Counter sinking, counter Drilling machines-types &their
boring and reaming with application, construction of
an accuracy ± 0.04 mm.(5 Pillar & Radial drilling
hrs) machine. Countersunk,
42. Drill blind holes with an counter bore and spot facing-
accuracy 0.04 mm.(2 hrs) tools and nomenclature.
43. Form internal threads Cutting Speed, feed, depth of
with taps to standard size cut and Drilling time
(blind holes).(3 hrs) calculations. (05hrs)

24
Mechanic Machine Tool Maintenance

44. Prepare studs and bolt to

standard size and watch
with nut. (15 hrs)
Professional Make different fit of 45. File and make Step fit, Interchangeability: Necessity
Skill 40Hrs; components for angular fit, with surface in Engg, field, Limit- Definition,
assembling as per accuracy of ±0.20 mm types, terminology of limits
Professional required tolerance (Bevel gauge accuracy 1 and fits-basic size, actual size,
Knowledge observing principle degree). (20hrs) deviation, high and low limit,
08hrs of interchangeability 46. Make simple open and zero line, tolerance zone,
and check for sliding fits. (20hrs) allowances. Different standard
functionality. systems of fits and limits.
[Different Fit – (British standard system & BIS
Sliding, Angular, system)
Step fit, Required (08 hrs)
tolerance: ±0.20
mm, angular
tolerance: 1 degree]
(Mapped NOS:
NOS:CSC/N0304)
Professional Set the different 47. Perform the holding job Shaper:
Skill 90Hrs; parameters to on shaper machine vice, Introduction to Shaper
produce setting length of stroke, machine parts &
Professional components setting of feed in a shaper constructional details, its
Knowledge involving basic machine. (5 hrs) function and operations.
20Hrs operations on 48. Make a square block in Quick return mechanism of
different machine shaper machine. (10 hrs) shaper.
observing standard 49. Perform preventive Calculation of cutting Speed,
procedure and maintenance of shaping feed & depth of cut. (04 hrs)
check for accuracy. machine. (5hrs)
[Different machines 50. Grinding of R.H & L.H Grinding wheel: Abrasive,
– Shaper, Lathe & tools, V tool, parting tool, grade structures, bond,
Milling, Different round nose tool & ‘V’ specification, use, mounting
machining tools. (10 hrs) and dressing. Selection of
parameters – feed, 51. Perform facing operation grinding wheels. Bench grinder
speed & depth of to correct length. (5hrs) parts and use.
cut.] (Mapped NOS: 52. Centre drilling & drilling Radius/fillet gauge, feeler
NOS:CSC/N0304) operations to required gauge, hole gauge, and their
size. (5hrs) uses, care and maintenance.
53. Perform parallel turning & (08 hrs)

25
Mechanic Machine Tool Maintenance

step turning. (05hrs)

54. Perform drilling, boring,
undercut, parting,
grooving, chamfering
operation. (10hrs)
55. Demonstrate working Milling:
principle of milling Introduction to milling
machine. (3hrs) machine, parts &
56. Set arbor and cutter on constructional details, types.
arbor of milling machine. Safety precaution followed
(4hrs) during milling operation.
57. Sequence of milling six Milling machine attachments.
faces of a solid block. Different types of milling
(08hrs) cutters and its materials.
58. Perform step milling and Nomenclature of milling
slot milling with side & cutters.
face cutter. (10hrs) Milling cutter holding devices,
59. Make ‘V’ block using work holding devices, Milling
horizontal milling machine machine operations, Up
(accuracy ±0.02mm) milling and Down milling.
(10hrs) Calculation of cutting speed,
feed, machining time for
milling machine. Indexing
methods and its calculations.
(08 hrs)
Professional Prepare 60. Hardening and tempering Heat Treatment:
Skill 65 Hrs; components for &Normalising. (10 hrs) Iron Carbon Equilibrium
assembly by carrying 61. Case Hardening. (5 hrs) Diagram, Time-Temperature-
Professional out different Heat 62. Hardness Testing. ( 5 Hrs) Transformation Curve.
Knowledge Treatment and Annealing, Case Hardening,
15Hrs surface finishing Tempering, Normalizing and
operations. Quenching (07 hrs)
[Different Heat 63. Scraping practice on flat & Classification, construction,
Treatment: - curved surface. (15hrs) materials and functional detail
Hardening, 64. Make a plain flat surface of Chisels & Hammers.
Tempering case of by scraping the high Chipping technique.
hardening, different spots using Prussian blue. Related hazards, risk and
surface finish- (20 hrs) precautions while working.
scrapping, lapping] 65. Lapping the surface with Scrapers: Introduction, Its

26
Mechanic Machine Tool Maintenance

(Mapped NOS: lapping stone. (5 hrs) types, material and use.

NOS:CSC/N0304) 66. Fixing hammer handle. (5 Types of nuts, bolts, studs,
hrs) 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 Make different fit of 67. Make Male & Female ‘T’ Surface finish - importance,
Skill 85Hrs; components for fitting with an accuracy symbol, measuring
assembling as per ±0.15 mm and 30 techniques.
Professional required tolerance minutes. (25hrs) Lapping & honing process.
Knowledge observing principle 68. Make male female square Gauges: Classification and
15Hrs of interchange fit with accuracy ±0.1 mm. uses of Sine bar, Slip gauge,
ability and check for (20hrs) Limit gauge, Feeler gauge,
functionality. thread gauge, screw pitch
[Different Fit – gauge, taper gauge. (6 hrs)
square fits, T fits, 69. Make Male & Female Tolerances &
hexagonal fit, Hexagon fitting with interchangeability -Definition
dovetail fit; surface accuracy ±0.1 mm and 30 and its necessity, basic size,
accuracy: ±0.1 mm, min. (20 hrs) actual size, limits, deviation,
angular tolerance: Tolerance, allowance,
30 min.] (Mapped clearance, interference, Fits-
NOS: CSC/N0304) 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 Fasteners:
dovetail fitting scraping Introduction to fasteners,
the surface within an screw threads, related
accuracy ±0.1 & 30 min terminology and specification.

27
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 Dismantle, Repair 71. Identify different Maintenance Practice and
Skill 130Hrs; and Assemble of components of power Mechanical Assembly
mechanical power transmission. (5 hrs) Introduction to various
Professional transmission 72. Dismantle and assemble maintenance practices such
Knowledge elements in machine different components of as preventive maintenance,
20Hrs tools and check for power transmission. (10 predictive maintenance,
functionality. hrs) breakdown maintenance &
(Mapped NOS: 73. Safety precautions related reconditioning.
NOS:CSC/N0901) to power transmission. (5 Organization Structure for
hrs) 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
clutches in machine tools Function of Clutches, its types
and their maintenance. and use in power
(05 hrs) transmission system. Function
75. Making key and mounting of mechanical &
of coupling on the shaft electromagnetic system in
with key. (05 hrs) clutch mechanism.
76. Identification and Couplings:
inspection of components Concept of coupling and its
of different types of type
brakes in machine tools. viz. Rigid coupling- Muff

28
Mechanic Machine Tool Maintenance

(04hrs) coupling, Flange coupling,

77. Fitting of hub and shaft Flexible coupling, Pin-bush
with key. (05 hrs) coupling, Chain coupling,
78. Installation of belt in Gear coupling, Spider
transmission with coupling, Tyre coupling, Grid
adjusting the tension. (05 coupling, Oldham-coupling,
hrs) 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 Bearing:
types of bearings in Description and function of
machine tools. (4 hrs) bearing, its types - Solid Bush,
80. Impression testing of split Split Bush, Collar, Pivot and
bush bearing for proper Plummer Block Bearing.
contact on journal & Mounting of bearings,
housing. (4 hrs) measurement and
81. Preloading of Precision adjustment of clearances in
angular contact bearing (4 bearings.
hrs) Types of bearing fitting on
82. Dismantling, inspection shaft and hubs.
and mounting of ball Type of Roller contact

29
Mechanic Machine Tool Maintenance

bearing on shaft with bearings- Ball bearings- single

press & pullers. (10hrs) row & double row, Deep
83. Dismantling & assembly of groove ball bearing, Angular
tail stock of a lathe. contact, Self aligning and
(10hrs) Thrust bearing.
84. Demonstrate of different Roller bearing- Cylindrical,
types of knots and hitches Needle roller, Taper roller,
used in material handling. Spherical roller, self aligning
(5 hrs) and Spherical roller thrust
85. Splicing of manila rope. (2 bearing.
hrs) Use of ISO bearing
86. Inspection of wire rope/ designation code to generate
steel rope/belts. (2 hrs) market survey and purchase.
87. Lift an object by using Checking and adjustment of
slings. (2 hrs) 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:

30
Mechanic Machine Tool Maintenance

types of gears and gear Type, description and

bones used in machine function of gears-
tools. (5 hrs) Spur, Helical, Spiral, Bevel,
89. Checking of gear elements Straight and Spiral bevel,
as PCD, gear tooth Worm gears, Rack and pinion.
thickness, clearance Gear Terminology.
concentricity. (08 hrs) Gear train- simple,
90. Checking of backlash and compound, reverted and
root clearance by feeler epicyclic. (03 hrs)
gauge, DTI & lead wire in
gear meshing. (07 hrs)
91. Inspection & replacing the
Types of Gear box
lubricating oil of a given
Gear meshing: Checking of
gearbox.(5hrs)
backlash and root clearances
92. Overhauling of gear box of
with Feeler Gauge, Dial Test
lathe & milling machine.
Indicator and lead wire.
(08hrs)
Impression testing of gear
93. Write a inspection report
mesh with Prussian blue.
for maintenance job.
Running maintenance
(5hrs)
Related hazards, risk and
94. Prepare a action plan for
precautions. (03 hrs)
maintenance work. (5 hrs)
Professional Carryout preventive 95. Identification of various Lubrication and its
Skill 65 Hrs; maintenance of types of lubrication importance, lubricating
lubrication &cooling system and their systems
Professional system of different components. (5hrs) Concept of lubrication
Knowledge machines as per 96. Cleaning of lubrication Types and properties of Oil
15Hrs manufactures lines and oil filters. (07 and Grease.
guidelines. hrs) Methods of oil lubrication-
[Different machines- 97. Fittings of different types Once through and centralized
lathe, drilling, of seals and oil rings. lubrication system. (05 hrs)
grinding] (Mapped (07rs) Methods of grease lubrication
NOS: CSC/N0901) 98. Preparing and fitting of system- grease guns,
gasket for different joint centralized lubrication
surface. (08hrs) system.
99. Preventive maintenance Warning & protective devices
of lubrication system of used in centralized lubrication
lathe, drilling and grinding system (Pressure switch,
machines. (08hrs) temperature gauge, level

31
Mechanic Machine Tool Maintenance

100. Lubrication schedule- indicator and relief valve.)

daily, weekly, monthly Lubrication fittings. Storage
concept. (05 hrs) and handling,
Contamination control,
Leakage prevention- Shaft
seals, sealing devices and “O”
rings. (05 hrs)
101. Identification of Cutting Fluids and Coolants.
components of coolant Essential parts of a basic
system. (5hrs) coolant system used in the
102. Preventive maintenance cutting of metals.
of coolant system. (10hrs) Various types of coolants, its
103. Breakdown maintenance properties and uses
of coolant system. (10hrs) ,coolantsystem type-soluble
oils-soaps, sudsparaffin,soda
water etc.
Effect of cutting fluids in
metal cutting.
Difference between coolant
and lubricants. (05 hrs)
Professional Prepare machine 104. Marking location, grouting MACHINE FOUNDATION
Skill 85Hrs; foundation for and installation of Purpose & methods
erection, install foundation bolts. (10hrs) employed for installation &
Professional different machines 105. Erection and installation erection of precision &heavy
Knowledge and carry out of a small machine like duty machines.
16Hrs geometrical tests. shaper/ pedestal grinder Location & excavation for
[Different machines machine. (10hrs) foundation. Different types
– shaper, pedestal of foundations –structural,
grinding] (Mapped reinforced, wooden, isolated
NOS: CSC/N0304) foundations. (04 hrs)
106. Levelling of small machine Foundation bolt: types (rag,
like shaper. (10hrs) Lewis cotter bolt) description
107. Levelling of a lathe & of each erection tools, pulley
milling machines. (10hrs) 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

32
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 Maintenance
the help of feeler gauge & -Total productive maintenance
dial test indicator & taper -Autonomous maintenance
gauges. (5hrs) -Routine maintenance
109. Alignment of pulley & -Maintenance schedule
sprocket with straight -Retrieval of data from
edge & thread. (5hrs) machine manuals
110. Geometrical alignment Geometrical tests and
test of machine as per inspection method with
test chart. (10hrs) instruments.
111. Dismantling, checking and Preventive maintenance-
assembly of various parts objective and function of
of drilling machine such as Preventive maintenance,
Motor, spindle head, gear section inspection. Visual and
box & arm. (10hrs) detailed, lubrication survey,
112. Measure Current, Voltage system of symbol and colour
and Resistance using coding. Revision, simple
Simple Ohm`s Law Circuit estimation of materials, use of
And Familiarizing Multi- handbooks and reference
meter. (3hrs) table. Possible causes for
113. Soldering Techniques. assembly failures and
(3hrs) remedies.
114. Step up and step down Hazardous waste
transformers. (3hrs) management.
115. Working with Solenoids Basic Electrical:
and Relays. (3hrs) Study of basic Electricals-
116. Working of Motor& Voltage –Current etc.
Generators. (3hrs) Working Of Solenoids,
Inductors, Motors, Generator
Based On Electromagnetic
Induction Principle. (08hrs)

33
Mechanic Machine Tool Maintenance

Professional Conduct preventive 117. Perform taper turning in Safely precautions to be

Skill 20Hrs; maintenance, the lathe by different observed while working on a
perform dismantling methods. (04hrs) lathe, Lathe specifications,
Professional & assembly of 118. Perform external thread and constructional features.
Knowledge different cutting operation on the Lathe main parts
05Hrs components and lathe machine. (04hrs) descriptions- bed, head stock,
test for accuracy to 119. Dismantling and assembly carriage, tail stock, feeding
carryout advance of head stock apron, and thread cutting
lathe operation. saddle, tool post tail mechanisms. Holding of job
[Different stock, Removing Broken between centers, works with
components- head Studs / Bolts of lathe catch plate, dog, simple
stock apron, saddle, machine. (08hrs) description of a facing and
tool post tail stock; 120. Accuracy checking of lathe roughing tool and their
Different advance machine after assembly. applications.
lathe operation – (2hrs) (05 hrs)
taper turning, 121. Perform preventive
thread cutting] maintenance of lathe
(Mapped NOS: machine. (2hrs)
NOS:CSC/N0901)
ENGINEERING DRAWING: (40 Hrs.)
Professional Read and apply Introduction to Engineering Drawing and Drawing Instruments –
Knowledge engineering drawing  Conventions
ED- 40 Hrs. for different  Sizes and layout of drawing sheets
application in the  Title Block, its position and content
field of work.
 Drawing Instrument
(NOS:CSC/N9401)
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)

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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 Unit, Fractions
mathematical Classification of unit system
concept and Fundamental and Derived units F.P.S, C.G.S, M.K.S and SI units
principles to Measurement units and conversion
perform practical Factors, HCF, LCM and problems
operations. Fractions - Addition, substraction, multiplication & division
Understand and Decimal fractions - Addition, subtraction, multilipication&
explain basic science division
in the field of study. Solving problems by using calculator
(NOS:CSC/N9402) 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

35
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.

36
Mechanic Machine Tool Maintenance

SYLLABUS FOR MECHANIC MACHINE TOOL MAINTENANCE TRADE

SECOND YEAR
Professional Skills
Reference Learning Professional Knowledge
Duration (Trade Practical)
Outcome (Trade Theory)
With Indicative Hours
Professional Make / Produce 122. Setting up an Arc welding Arc Welding:Introduction to
Skill 40 Hrs; different joints by machine. (5hrs) arc welding and its safety.
setting up of gas and 123. Edge preparation of Welding types, Common
Professional arc welding machines material for Arc welding. tools used in welding.
Knowledge and carry out the (5hrs) Basic Electricity as applied to
10 Hrs welding. (Mapped 124. Perform square lap joint, Welding
NOS: CSC/N0304) butt joint, tee joint and Arc Length & its effects
Pipe Joint in Arc welding. Arc Welding Machines: -
(10hrs) advantages & disadvantages
125. Making straight beads in of AC & DC Arc Welding
gas welding. (4hrs) Machine. Electrodes: - Sizes
126. Perform square lap joint, & Coding.
but joint & tee joint in Edge Preparation:
Gas welding. (08hrs) Nomenclature of butt & fillet
127. Perform gas cutting of welding. Welding Symbols &
MS plate. (08hrs) 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 Identify, dismantle, 128. Demonstrate knowledge Hydraulics & Pneumatics
Skill 60Hrs; replace and assemble of safety procedures in Basic principles of Hydraulics

37
Mechanic Machine Tool Maintenance

different pneumatics hydraulic systems (Demo - Advantages & limitation of

Professional and hydraulics by video). hydraulic system, hydrostatic
Knowledge components. (4 hrs) transmission, Pascal’s law,
18Hrs [Different 129. Identify hydraulic Brahma’s press, pressure
components – components – Pumps, Temperature & flow, speed
Compressor, Pressure Reservoir, Fluids, of an actuator.
Gauge, Filter Pressure relief valve Control valves: Different type
Regulator Lubricator, (PRV), Filters, different of control valves used in
Valves and types of valves, hydraulic System.
Actuators.] actuators, and hoses. (07 Function of pressure control
(NOS:CSC/N9488) hrs) valve, directional control
130. Inspect fluid levels, valve, check valve, flow
service reservoirs, control valve. (06 hrs)
clean/replace filters.
(10hrs)
131. Identify pneumatic Compressed air generation
components – and conditioning, Air
Compressor, pressure compressors, Pressure
gauge, Filter-Regulator- regulation, Dryers, Air
Lubricator (FRL) unit, and receiver, Conductors and
Different types of valves fittings, FRL unit, Applications
and actuators. (2 hrs) of pneumatics, Hazards &
132. Dismantle, replace, and safety precautions in
assemble FRL unit. (5 hrs) pneumatic systems.
133. Demonstrate knowledge
of safety procedures in Pneumatic actuators:- Types,
pneumatic systems and Basic operation, Force, Stroke
personal Protective length, Single-acting and
Equipment (PPE). (2 hrs) double-acting cylinders.
134. Identify the parts of a Pneumatic valves:-
pneumatic cylinder.(1 hr) Classification, Symbols of
135. Dismantle and assemble pneumatic components, 3/2-
a pneumatic cylinder.(4 way valves (NO & NC types)
hrs) (manually-actuated &
136. Construct a circuit for the pneumatically-actuated) &
direction & speed control 5/2-way valves,
of a small-bore single- Check valves, Flow control
acting (s/a) pneumatic valves, One-way flow control
cylinder. (5 hrs) valve

38
Mechanic Machine Tool Maintenance

137. Construct a control Pneumatic valves: Roller

circuit for the control of a valve, Shuttle valve, Two-
double acting pneumatic pressure valve
cylinder with momentary Electro-pneumatics:
input signals. (5 hrs) Introduction, 3/2-way single
138. Construct a circuit for the solenoid valve, 5/2-way single
direct & indirect control solenoid valve, 5/2-way
of a double acting double solenoid valve,
pneumatic cylinder with Control components -
a single & double Pushbuttons (NO & NC type)
solenoid valve. (08 hrs) and Electromagnetic relay
139. Dismantling &Assembling unit, Logic controls (12 hrs)
of solenoid valves. (07
hrs)
Professional Construct circuit of 140. Inspect hose for twist, - Symbols of hydraulic
Skill 110Hrs; pneumatics and kinks, and minimum bend components, Hydraulic oils
hydraulics observing radius, Inspect hose/tube –function, properties, and
Professional standard operating fittings. (5 hrs) types, Contamination in
Knowledge procedure& safety 141. Identify internal parts of oils and its control
30Hrs aspect. hydraulic cylinders, - Hydraulic Filters – types,
(NOS:CSC/N9489) pumps/motors. (10 hrs) constructional features,
142. Construct a circuit for the and their typical
control of a single acting installation locations,
hydraulic cylinder using a cavitations, Hazards &
3/2-way valve (Weight safety precautions in
loaded double acting hydraulic systems
cylinder may be used as a - Hydraulic reservoir &
single acting cylinder), accessories, Pumps,
4/2 & 4/3 way valves. (10 Classification – Gear/vane/
hrs) piston types, Pressure
143. Perform overhauling of relief valves – Direct acting
hydraulic pump. (10hrs) and pilot-operated types
144. Maintenance, - Pipes, tubing, Hoses and
troubleshooting, and fittings – Constructional
safety aspects of details, Minimum bend
pneumatic and hydraulic radius, routing tips for
systems (The practical for hoses
this component may - Hydraulic cylinders –Types
demonstrated by video). - Hydraulic motors –Types

39
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 Electro hydraulic circuit,
Hydraulic circuit –Speed Electrical components
and Pressure control of - Switches
double acting - Solenoid
cylinder.(10 hrs) - Relay
146. Perform overhauling of Introduction to Pneumatic
pneumatic cylinders. actuators
(12hrs) Pneumatic Symbols
147. Perform overhauling of Pneumatic circuit
hydraulic actuators. Electrical control components
(10hrs) - Switches
148. Disassembly of power - Solenoid
pack, hydraulic pipes, - Relay
ferrules, hydraulic Study & working of a
cylinders, pistons etc. hydraulic press along with its

40
Mechanic Machine Tool Maintenance

(10hrs) components. Breakdown &

149. Replacing &refitting of preventive maintenance of a
hydraulic pipes, seals etc. hydraulic press. Safety in use
(10hrs) of and maintenance of
150. Assemble the parts and hydraulic presses.
testing of the power Proximity Sensors
press after air bleeding. Classification And Operation-
(10hrs) Proximity Sensor-Types Of
Proximity Sensor And Their
Working-Industrial
Application
Sensors For Distance And
Displacement -LVDT-Linear
(17 hrs)
Professional Make pipe/tube 151. Flaring of pipes and pipe Pipes and pipe fitting-
Skill 80Hrs; fittings and valve joints. (3 hrs) commonly used pipes. Pipe
connections for 152. Cutting & Threading of schedule and standard sizes.
Professional lubricants and pipe length.(3 hrs) Pipe bending methods. Use of
Knowledge coolants, test for 153. Fitting of pipes as per bending fixture, pipe threads-
20Hrs leakages. (Mapped sketch observing Std. Pipe threads Die and Tap,
NOS: CSC/N0901) conditions used for pipe pipe vices.
work. (09 hrs)
154. Bending of pipes- cold Standard pipefitting-
and hot.(7 hrs) Methods of fitting or
155. Fit & assemble pipes, replacing the above fitting,
valves and test for repairs and erection on
leakage & functionality of rainwater drainage pipes and
valves.(17 hrs) house hold taps and pipe
156. Visual inspection for work.
visual defects e.g. dents, Inspection & Quality control
surface finish.(3hrs) -Visual Inspection
- Basic 7 Quality tools (10
hrs)
157. Dismantle & assembly of Pipe colour code.
globe valve, gate valve, Safety precautions to be
butterfly, diaphragm, observed while working at
direction control valve, pipeline.
pressure relief, non Constructional detail of
return& flow control different type of valve & their

41
Mechanic Machine Tool Maintenance

valve. (30hrs) uses like: Gate, Globe,

158. Making & replacement of butterfly, Diaphragm.
gaskets, washer. (08hrs) (10 hrs)
Professional Conduct preventive 159. Dismantle and assemble Breakdown maintenance and
Skill 40Hrs; maintenance, of head stock, gear box preventive maintenance of a
perform dismantling lead screw, table of milling machine. (10 hrs)
Professional and assembly of milling machine. (27hrs)
Knowledge different components 160. Check the accuracy of
10Hrs machine and test for milling machine of after
accuracy of milling assembly. (08hrs)
machine. (Mapped 161. Do the preventive
NOS: CSC/N0901) maintenance of milling
machine. (5hrs)
Professional Set the different 162. Demonstrate working of Grinding:
Skill 60Hrs; grinding machine and grinding machine. (05 Grinding machine –
produce component hrs) introduction, parts &
Professional to appropriate 163. Set the machine, stroke constructional details, types
Knowledge accuracy. [Different length & do wheel – surface grinding and
18Hrs machine:- Surface & balancing. (10 hrs) cylindrical grinding
cylindrical grinding; 164. Perform grinding of machines. Safety precaution
appropriate accuracy parallel and followed while working on
±0.02mm] (Mapped perpendicular surfaces grinding machines. Grinding
NOS: CSC/N0304) (accuracy ±0.02mm). (15 wheels – abrasives, bond and
hrs) bonding process, grit, grade,
165. Perform grinding of and structure of grinding
angular surfaces grinding wheels and its marking
(accuracy ±0.02mm). system.
(10hrs) Procedure for mounting of
166. Setting the cylindrical grinding wheels, balancing of
grinding machine for grinding wheels, dressing
grinding internal and and truing of grinding
external surfaces. (10hrs) wheels, glazing and loading
167. Setting the machine for in grinding wheel.
grinding taper holes. (18 hrs)
(10hrs)
Professional Conduct preventive 168. Dismantle and assembly Preventive and breakdown
Skill 40Hrs; maintenance, of grinding head, lead maintenance of grinding
perform dismantling screw, table, hydraulic machine.
Professional & assembly of cylinders of grinding (10 hrs)

42
Mechanic Machine Tool Maintenance

Knowledge different components machine. (20hrs)

10Hrs of grinding machine 169. Check the accuracy of
and test for accuracy. grinding machine after
[Different assembly. (10hrs)
components grinding 170. Do the preventive
head, lead screw, maintenance of surface
table, hydraulic grinder and cylindrical
cylinders] (Mapped grinding machine. (10hrs)
NOS: CSC/N0901)
Professional Identify and explain 171. Behaviour of Proximity Switches, Fuse And Circuit
Skill 110Hrs; basic functioning of Sensors. (5hrs) Breakers.
different electrical 172. Behaviour of ultrasonic Introduction To Sensors--
Professional equipment, sensors sensors. (5hrs) Fundamental Of Sensor.
Knowledge and apply such 173. Logical Operation of Potentiometer -Ultrasonic
30Hrs knowledge in Sensors. (5hrs) And Optical Sensors-
industrial application 174. Limit & Level Control Industrial Application.
including basic using Sensors. (5hrs) Basic principles of DC
maintenance work. 175. Interfacing of Sensors generators and motors,
[Different electrical & with Electrical Actuators. Alternators and AC motors
electronics (5hrs) and transformers. Various
equipment- DC/ AC 176. Making simple wiring types of switches, circuit
motors, passive & circuits and breakers, fuses, lamps,
active electronic measurement of current proximity switches, relays
components, resistor, and voltage. (5hrs) and contactor in electrical
capacitor, inductors, 177. Testing of power supply circuits.
rectifier, diode (AC & DC).(5 hrs) Passive circuit elements –
transistor, SCRS & 178. Demonstration of use of resistors, capacitors and
ICS; Different sensors test lamp and megger. (5 inductors. Its identification
– proximity & hrs) and testing. Colour code.
ultrasonic] (Mapped 179. Connections of DC/AC (12 hrs)
NOS: CSC/N0305) motors and its speed
control - demonstration
only. (5 hrs)
180. Identification of passive BASIC ELECTRONICS
& active electronic Introduction to electronics
components. (8hrs) and its industrial applications.
181. Use of oscilloscope. Introduction to digital
(05hrs) electronics – numbers system
182. Demonstrate of logic and logic gates.

43
Mechanic Machine Tool Maintenance

gate operations. (5hrs)

183. Testing and Study of electronic circuit –
measurement of macro level with block
resistors, capacitors, diagram. (18 hrs)
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)
Professional Programme PLC and 192. Ascertain various PLC:
Skill 40Hrs; interface with other modules, controls, and Overview of different control
devices to check its indicators of given PLC. (6 systems. Introduction about
Professional Applications. hrs) PLC. Block diagram of PLC.
Knowledge (NOS:CSC/N9490) 193. Program and configure Different types of PLC, PLC
10Hrs the PLC to perform a Architectures (Fixed and
simple start/stop routine. Modular). Selection of PLC.
(6 hrs) Advantages of PLC.
194. Program the PLC using Applications of PLC. Various
Timer and Counter types of modules used in PLC.
instructions. (10 hrs) Familiarization of AND, OR
195. Program the PLC to and NOT logics with
perform Move, examples. Registers Basics.
Arithmetic, and Logical Timer Functions. Counter

44
Mechanic Machine Tool Maintenance

operations. (3 hrs) Functions. Introduction and

196. Program the PLC for importance of Sequential
performing comparator Control Systems.
operations. (3 hrs) Communication protocols
197. Practice on PLC wiring. (9 used in PLC: RS-232, RS-485,
hrs) Ethernet, Profibus.
198. Program PLC for Different programming
controlling analog languages of PLC: LDR,
parameter(s). (3 hrs) STL,FBD, CSF.
Basic ladder programming of
PLC. Configuration of PLC and
its modules.
Wiring of PLC. (10 hrs)
Professional Prepare part 199. Knowledge rules of Concept of Co-ordinate
Skill 60Hrs; programme, test on personal and CNC geometry, concept of
simulation software machine safety, safe machine coordinate axis, axes
Professional and interpret handling of tools, safety convention on CNC lathes,
Knowledge different errors. switches and material work zero, machine zero.
18Hrs (NOS:CSC/N9491) handling equipment
using CNC Converting part diameters
didactic/simulation and lengths into co-ordinate
software and equipment. system points. Absolute and
(5hrs) incremental programming.
200. Identify CNC lathe
machine elements and Programming – sequence,
their functions. (5hrs) formats, different codes and
201. Understand the working words.
of parts of CNC lathe,
using CNC didactic/ ISO G codes and M codes for
simulation software. CNC turning.
(05hrs)
202. Identify common tool Describe CNC interpolation,
holder and insert shapes open and close loop control
by ISO nomenclature. systems. Co-ordinate systems
(5hrs) and Points.
203. Select cutting parameters Cutting tool materials,
from tool manufacturer’s application of various
catalogue. (2hrs) materials.
204. Write CNC programs for

45
Mechanic Machine Tool Maintenance

simple tool motions and Cutting tool geometry for

parts using linear and internal and external turning,
circular interpolation; grooving, threading, face
check on program grooving, drilling. Insert
verification/ simulation holding methods for each.
software. (04hrs)
205. Write CNC part programs Writing part programs as per
using canned cycles for drawing & checking using
stock removal, grooving, CNC program verification/
threading operations, simulation software. Process
with drilling and finish planning, work holding, tool
turning. Use TNRC and cutting parameters
commands for finish selection according to the
turning. Check simulation part geometry and
on program verification/ dimensions.
simulation software. (06
hrs) Collisions due to program
206. Avoiding collisions errors, effects of collisions.
caused by program Costs associated with
errors. Knowing causes collisions – tool breakage,
and effects of collisions machine damage, injuries.
due to program errors, by
making deliberate Find out alarm codes and
program errors and meaning of those codes.
simulation on program
verification/ simulation Program execution in
software. (6hrs) different modes like MDI,
207. Simple turning & Facing single block and auto.
(step turning) without
using canned cycles, on Process planning &
CNC simulator. (06 hrs) sequencing, tool layout &
208. Program checking in dry selection and cutting
run, single block modes, parameters selection.
on CNC simulator (2hrs)
209. Absolute and incremental Work and tool offsets.
programmingassignment Inputs value to the offset/
s and simulation. (6hrs) geometry page into machine.
210. Checking finish size by
over sizing through tool First part checking: Program

46
Mechanic Machine Tool Maintenance

offsets, on CNC checking in single block and

simulator. (2hrs) dry run modes – necessity
211. Recovering from axes and method.
over travel, on CNC (18 hrs)
simulator. (1 hr)
212. Interpret different
messages generated
against different errors.
(05hrs)
Professional Troubleshoot & 213. Demonstrate various Centrifugal Pump, Fan,
Skill 90Hrs; Overhaul of pumps, types of machine related Blower and Compressor:-
fans, blowers & centrifugal pump and Pump
Professional compressors and their parts. (8hrs) Function of pump.
Knowledge perform preventive 214. Overhauling of pumps Types and working principle
20Hrs maintenance. with fitting of gland of centrifugal pump (machine
(Mapped NOS: packing. (15hrs) related).
CSC/N0901) 215. Priming of pump. (4hrs) Constructional detail of pump
216. Testing of pump. (2hrs) Starting and stopping
217. Perform preventive and Pump performance and
schedule maintenance. characteristics.
(4hrs) Capitation & aeration
218. Trouble shooting in pump Preventive & schedule
operation. (12hrs) maintenance of pumps.
Gland packing changing
procedure.
Concept of Mechanical seal
Trouble shooting in pump.
(10 hrs)
219. Identification of various Fan & Blowers:
types of fans, blowers Types and working principle
and their parts. (5hrs) Constructional detail of Fans
220. Dismantle, inspect, & Blowers.
repair/ replace work out Starting and stopping of Fans
part and assemble the and Blowers
same. (10hrs) Different parts of Fans &
221. Demonstrate Blowers
compressors and their Concept of surge.
parts. (8 hrs) Preventive & scheduled
222. Cleaning and changing of maintenance.

47
Mechanic Machine Tool Maintenance

filters of compressors. (8 Compressors:

hrs) Compression theory, Types of
223. Perform schedule and compressors
preventive maintenance Constructional detail of
of blower & compressor. compressors, working
(6hrs) mechanism
224. Change compression ring Different parts and their
& oil rings in a function.
reciprocator compressor. Loading unloading system
(8 hrs) Concept of air dryer.
Preventive & schedule
maintenance.
(10 hrs)
Professional Identify fault carryout 225. Demonstrate mechanical Different type of jacks, chain
Skill 110Hrs; maintenance work & hydraulic jack, rope block and pull lift.
and break down of puller, chain puller, chain Knowledge of different types
Professional different block, and winch. (8 hrs) of scaffolding.
Knowledge machineries/ 226. Inspection of tools and Material movement by using
30Hrs equipments viz., tackles of material different rigging tools and
shaper, surface handling equipments. (6 techniques.
grinding, drilling, hrs) Safety appliances &
lathe, milling, in the 227. Shift a small machine precautions in rigging.
shop floor, using from layout to loading Maintenance of tools and
appropriate tools centre/ different work tackles.
&equipments to place. (10 hrs) (09 hrs)
ensure its 228. Practice various belt & Bulk Material Handling
functionality. chain joining methods. (Conveyor belt, Vibratory
(Mapped NOS: (20 hrs) screen, Feeders)
CSC/N0901) 229. Demonstrate belt Principle & mode of material
conveyor system, handling.
vibratory screen & Various components used in
feeder. (Video demo)(6 belt conveyor system & their
hrs) functions.
(Pulleys, idlers, scrapers,
skirts, belt, take up unit
system and safety devices).
Vibratory screen- working
mechanism.
Feeders- types, working

48
Mechanic Machine Tool Maintenance

mechanism.
Maintenance practice-Pulley
lagging, belt sway control belt
joining methods.
(06 hrs)
230. Trouble shooting on Breakdown Maintenance,
machine tools such as Preventive Maintenance,
drill, shaper, lathe & Predictive Maintenance &
power saw machine. (15 Concepts of TPM,
hrs) OEE.(without calculations)
231. Perform overhauling of Difference between
feed units of lathe milling breakdown and preventive
& grinding. (15hrs) maintenance – Its importance
232. Geometrical testing of in productivity, types.
machine tools. (10hrs) 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 Inspection & Condition
for inspection of different Monitoring.
machine tools. (5hrs) Maintenance strategy –
234. Temperature Reactive, Preventive,
measurement of machine Predictive and proactive.
tools. (5hrs) Corrective Maintenance &
235. Vibration measurement Plan Maintenance. Condition
of machine tools. (5hrs) Base Maintenance (CBM),
236. Fault finding practice on Reliability Centered
machine tools. (05 hrs) Maintenance (RCM),
Importance of inspection.
Type / methods of equipment
inspection.
Commonly used gadgets for

49
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 Read and apply  Reading of drawing of nuts, bolt, screw thread, different
Knowledge engineering drawing types of locking devices e.g., Double nut, Castle nut, Pin, etc.
ED- 40 Hrs. for different  Reading of foundation drawing
application in the  Reading of Rivets and riveted joints, welded joints
field of work.  Reading of drawing of pipes and pipe joints
(NOS:CSC/N9401)  Reading of Job Drawing, Sectional View & Assembly view
WORKSHOP CALCULATION & SCIENCE: (36 Hrs.)
WCS- 36 Hrs. Demonstrate basic Friction
mathematical Friction - Advantages and disadvantages, Laws of friction, co-
concept and efficient of friction, angle of friction, simple problems related to
principles to perform friction
practical operations. Friction - Lubrication
Understand and Friction - Co- efficient of friction, application and effects of
explain basic science friction in workshop practice
in the field of study. Centre of Gravity
(NOS:CSC/N9402) 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

50
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.

51
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

52
Mechanic Machine Tool Maintenance
ANNEXURE-I

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. 15 cm both side Graduated in 24+1 nos.
Steel Rule
Metric & English.
2. Center punch 100 mm 24+1 nos
3. File flat 2nd 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 2nd 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& 1 each
M25 with necessary tap wrench
and die holder.

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Mechanic Machine Tool Maintenance

28. Spanner socket set of 25 pieces (10 to 25, 27, 30, 1no.
32, mm = 18 pcs and assorted = 7
nos.)
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- 1 each
differential)
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 2 nos.
mm
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 1 each
straight)
57. Hammer (Ball peen, cross peen, 500 grms. 3 sets
straight peen)
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 As required
W x H)
61. Steel lockers for 20 trainees 2 nos.

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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 5 nos.
bench fitted with 4 vices)
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 each
2) Araldite
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 2 nos.

measurements
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 1 no.
head and protector head.
84. Sine bar 200 mm 1 no.
85. Slip Gauge Box (workshop grade) - 87 1 no.
pieces per set
86. Inside micrometer 50 mm to 200mm, 0.01 mm least 1 no.
count with six extension rod.
87. Dial test indicator –stand ) Plunger type-Range 0-10 mm , 1 set
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

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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 BSP & BSW pitches ( 0.25 to 6 mm) 1 no.
& fine pitches.
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 1 no.
mm graduation)-Range of bore
gauge 18-150 mm)
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 As required
socket.
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, 1 each
cross, diamond )
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 As required
(consumable)
115. Carbide tip mechanically fastened tool 1 set
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

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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 1 no.
shank 8 mm
121. Woodruff key seating cutters A 13.5x3, A16x4 1 each
122. Parallel shank end mill Ø 5 mm, Ø 6 mm, Ø 8mm, 1 each
Ø 10 mm and Ø 12 mm
123. Scribing block universal 300mm As required
124. V-Block Approx 65x65x80 mm with 1 set each
clamping capacity of 50 mm with
clamps
125. D.E spanners 3-4 , 6-8, 10-12, 13-14, 15-16, 18- 1 set
19, 20-22, 24-26 ( 8 spanners)
126. Angle plate-adjustable 250x250x300 mm 1 no.
127. Twist Drill Parallel Shank Ø 4 mm to Ø 12 mm 1 each
in steps of 0.5 mm
128. Grinding wheel dresser (diamond dresser) with holder 1.5 2 nos.
carat diamond
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, 2 nos.
between centers 1000 mm (with 3
jaw and 4 jaw chuck, coolant
equipments)
133. Universal Milling machine 1no
134. Surface grinding machine wheel dia 180 mm (or near) 1no
reciprocating table, longitudinal
table traverse 200mm (or near) full
motorized supplied with magnetic
chuck 250 X120mm and necessary
accessories.
135. Drilling machine Pillar type 20mm capacity 1no
136. Double ended Pedestal Grinder 178 mm wheels(one fine and one 1no
rough)- motorized with twist drill
grinding attachment
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 1no
attachments
140. Pipe bending machine Manual/ Hydraulic 1no

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Mechanic Machine Tool Maintenance

141. Hydraulic trainer with necessary 1 set

elements for different machine circuit
with all types of transparent valves and
pressure gauge, reservoir etc.
142. Pneumatic trainer with necessary 1 set
elements for demonstration different
machine circuit with all types of valves,
pressure gauge and compressor etc.
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, Software 10
etc. (Web-based or licensed based) (12
trainees + 1faculty)
With help of this software the trainees
should be able to Write, Edit, Verify &
Simulate
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, 10
USB Keyboard and Monitor (Min. 17
Inch) Licensed Operating System
and Antivirus compatible with trade
related software
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 1 no
cylinder
154. Old Centrifugal Pump 1 no
155. Old Gear pump 1 no.

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Mechanic Machine Tool Maintenance

156. Old Vane pump fixed and variable 1each

delivery
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 1no. each
Oxygen and Acetylene
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. (Single phase / 3 phase), 150 – 300 1 no.
Welding Machine DC or AC,
Amps capacity with all accessories
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 1 set
slings, rope, belt, tackles

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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.

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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

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Mechanic Machine Tool Maintenance

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