CURRI CULUM

FOR THE TRADE OF

M ECHANI C EARTH M OVI NG

M ACHI NERY

UNDER

APPRENTI CESHI P TRAI NI NG SCHEM E

GOVERNM ENT OF I NDI A

M I NI STRY OF SKI LL DEVELOPM ENT& ENTREPRENURESHI P
DI RECTORATE GENERAL OF TRAI NI NG

1
 CONTENTS

Sl. No. Topics Page No.

1 Acknowledgement 3
2 Background 4
1.1Apprenticeship Training under Apprentice Act 1961
1.2Changes in Industrial Scenario
1.3 Reformation

3 Rationale 5
4 Job roles: reference NCO 6
5 General Information 7
6 Course structure 8
7 Syllabus 9-27
7.1 Basic Training
7.1.1 Detail syllabus of Core Skill
A. Block-I (Engg. drawing& W/ Cal. & Sc.)
B. Block-II (Engg. drawing& W/ Cal. & Sc.)
7.1.2 Detail syllabus of Professional Skill & Professional
Knowledge
A. Block – I
B. Block – II
7.1.3 Employability Skill
[Link] Syllabus of Employability skill
A. Block – I
B. Block – II
7.2 Practical Training (On-Job Training)
7.2.1 Broad Skill Component to be covered during on-job
training.
A. Block – I
B. Block – II
Assessment Standard 27-30
8.1 AssessmentGuideline
8
8.2 Final assessment-All India trade Test (Summative
assessment)
9 Further Learning Pathways 31
10 Annexure-I – Tools & Equipment for Basic Training 32-36
11 Annexure-II – Tools & Equipment for On-Job Training 38
12 Annexure-III - Guidelines for Instructors & Paper setter 39

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 1. ACKNOWLEDGEM ENT
The DGT sincerely express appreciation for the contribution of the Industry, State Directorate,
Trade Experts and all others who contributed in revising the curriculum.

Special acknowledgement is expended by DGT to the following expert members who had
contributed immensely in this curriculum.

Coordinator for the course:Shri G. Venkatesh, ADT, ATI, Vidyanagar, Hyderabad

Sl. Name & Designation Organization Expert Group Designation

No. Sh./M r./M s.
1. Kumar Y Ankolekar BEML, KGF Complex Manager, Trg.
2. Patil Shankar Goud BEML, KGF Complex Sr. Supervisor
3. R. Chandresekar BEML, KGF Complex Supervisor
4. P. Babu Reddy BEML, KGF Complex Supervisor
5. E. Narayanan BEML, KGF Complex Supervisor
6. N Ramesh Kumar CTI, Chennai Trg. Officer

3
 2. BACKGROUND
1.1 Apprenticeship Training Scheme under Apprentice Act 1961
The Apprentices Act, 1961 was enacted with the objective of regulating the programme of
training of apprentices in the industry by utilizing the facilities available therein for
imparting on-the-job training. The Act makes it obligatory for employers in specified
industries to engage apprentices in designated trades to impart Apprenticeship Training on
the job in industry to school leavers and person having National Trade Certificate(ITI pass-
outs) issued by National Council for Vocational Training (NCVT) to develop skilled
manpower for the industry. There are four categories of apprentices namely; trade
apprentice, graduate, technician and technician (vocational) apprentices.
Qualifications and period of apprenticeship training of trade apprentices vary from trade to
trade. The apprenticeship training for trade apprentices consists of basic training followed
by practical training. At the end of the training, the apprentices are required to appear in a
trade test conducted by NCVT and those successful in the trade tests are awarded the
National Apprenticeship Certificate.

The period of apprenticeship training for graduate (engineers), technician (diploma holders
and technician (vocational) apprentices is one year. Certificates are awarded on completion
of training by the Department of Education, Ministry of Human Resource Development.

1.2 Changes in I ndustrial Scenario

Recently we have seen huge changes in the Indian industry. The Indian Industry registered
an impressive growth during the last decade and half. The number of industries in India have
increased manifold in the last fifteen years especially in services and manufacturing sectors.
It has been realized that India would become a prosperous and a modern state by raising
skill levels, including by engaging a larger proportion of apprentices, will be critical to
success; as will stronger collaboration between industry and the trainees to ensure the supply
of skilled workforce and drive development through employment. Various initiatives to
build up an adequate infrastructure for rapid industrialization and improve the industrial
scenario in India have been taken.

1.3 Reformation
The Apprentices Act, 1961 has been amended and brought into effect from 22nd December,
2014 to make it more responsive to industry and youth. Key amendments are as given
below:

• Prescription of number of apprentices to be engaged at establishment level instead of

trade-wise.
• Establishment can also engage apprentices in optional trades which are not designated,
with the discretion of entry level qualification and syllabus.
• Scope has been extended also to non-engineering occupations.
• Establishments have been permitted to outsource basic training in an institute of their
choice.
• The burden of compliance on industry has been reduced significantly.
4
 3. RATI ONALE
(Need for Apprenticeship in MECHANICEARTH MOVING MACHINERY trade)

The revised Apprenticeship Training Scheme (ATS) shall make the students more adapt to
industry requirement through latest theoretical & practical inputs as:

1. It offers a good synergy between BT (Theoretical Inputs) & PT (On the Job training) unlike
earlier scheme where students need to complete two year’ s classroom training before
undergoing PT (On The Job training).
2. It will enhance knowledge about scientific principles, familiarization with industrial culture, and
basics of Earth Moving Machinery and its need.
3. It will enhance the ability to work with help of hand tools, power tools and machines. At the
same time it creates the base for achieving hard skills.
4. It will enhance knowledge about different types of earth moving machinery, Diagnosis
techniques and various tools used in industries.
5. It will enhance the ability to work on conventional as well as latest earth moving machineryand
to service and trouble shoot machinery parts.
6. It will enhance knowledge about industrial terminology, industrial practices and revitalize
previous learning.
7. It will enhance the ability of problem solving related to Diesel Engines, Hydraulic equipment in
the earth movers.

5
 4. JOB ROLES: REFERENCE NCO

Brief description of Job roles:

On successful completion of the course the candidates can either get employed, or become a
self-employed Entrepreneur in any one of the following fields.

a) Wage Employment
1. Auto Diesel engine Mechanic
2. Diesel Engine Service Technician
3. Mechanic in earth moving Manufacturing Industry
4. Dealers service mechanic
5. Earth mover Operator
6. Spare Parts Sales Assistant / Manufacturers' Representative

b) Self Employment

1. Maintenance Mechanic
2. Diesel Fuel System Service Mechanic
3. Earth mover Operator

Reference NCO: 735.41

6
 5. GENERAL I NFORM ATI ON

1. Name of the Trade : M ECHANI C EARTH M OVI NG

M ACHI NERY
2. N.C.O. Code No. : 735.41

3. Duration of Apprenticeship Training (Basic Training + Practical Training): 2years

3.1 For Fresher :-

Duration of Basic Training: -
a) Block –I : 3 months
b) Block – II : 3 months
Total duration of Basic Training: 6 months
Duration of Practical Training (On -job Training): -
a) Block–I: 9 months
b) Block–II : 9 months
Total duration of Practical Training: 18 months
3.2 For I TI Passed :-
Duration of Basic Training: - NIL
Duration of Practical Training (On -job Training): 12 months
6. Entry Qualification : 10th Passed
7. Selection of Apprentices: The apprentices will be selected as per Apprentices
Act amended time to time.

8. Rebate to I TI Passed out Trainees :one year for the trade of M ECHANI C EARTH
M OVI NG M ACHI NERY

Note: Industry may impart training as per above time schedule for different block,
however this is not fixed. The industry may adjust the duration of training considering the
fact that all the components under the syllabus must be covered. However the flexibility
should be given keeping in view that no safety aspects is compromised.

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 6. COURSE STRUCTURE

Training duration details: -

Time 1-3 4-12 13-15 16-24

(in months)
Basic Training Block– I ----- Block – I I ------
Practical Training ---- Block – I ------ Block – I I
(On - job training)

Duration of Training in Months

Components
of Training
Duration of Training in M onths

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Basic
Training
Block - I
Practical
Training
Block - I
Basic
Training
Block - I I
Practical
Training
Block - I I

8
 7. SYLLABUS
7.1 BASI C TRAI NI NG
(BLOCK – I & I I )
DURATI ON: 06 MONTHS

GENERAL I NFORM ATI ON

1) Name of the Trade :M ECHANI C EARTH M OVI NG

M ACHI NERY
2) Hours of I nstruction : 1000 Hrs. (500 hrs. in each block)
3) Batch size : 16 Nos.
4) Power Norms : 4.8 KW for Workshop
5) Space Norms : 210Sq.m. (including Parking area)
6) Examination : The internal assessment will beheld on
completion of each Block.
7) I nstructor Qualification :

Degree/Diploma in Mechanical / Automobile Engg. from recognized

university/Board with one/two year post qualification experience respectively
in the relevant field.
OR
NTC/NAC in the trade of MechanicTractor / Mechanic Diesel engine with three
year post qualification experience in the relevant field.
Preference will be given to a candidate with Craft Instructor Certificate (CIC)

8) Tools, Equipment& M achinery required : - As per Annexure – I

9
 7.1.1 DETAI LSYLLABUS OF CORE SKI LL

A. Block– I
Basic Training
Topic a) Engineering Drawing Duration b) Workshop Science & Duration
No. (in hours) Calculation (in hours)
1 Engineering Drawing: I ntroduction and 30 Unit: Systems of unit- FPS, 20
its importance CGS, MKS/SI unit, unit of
- Viewing of engineering drawing sheets. length, Mass and time,
- Method of Folding of printed Drawing Conversion of units
Sheet as per BIS SP:46-2003
2 Drawing I nstruments : their uses Fractions: Fractions, Decimal
Drawing board, T-Square, Drafter (Drafting fraction, Addition, Subtraction,
M/c), Set Squares, Protractor, Drawing Multiplication and Division of
Fractions and Decimals,
Instrument Box (Compass, Dividers, Scale,
conversion of Fraction to Decimal
Diagonal Scales etc.), Pencils of different and vice versa. Simple problems
Grades, Drawing pins / Clips. using Calculator.
3 Lines : Properties of M aterial :
- Definition, types and applications in properties -Physical &
Drawing as per BIS SP:46-2003 Mechanical, Types –Ferrous &
- Classification of lines (Hidden, centre, Non-Ferrous, difference between
construction, Extension, Dimension, Ferrous and Non-Ferrous metals,
Section) introduction of Iron, Cast Iron,
- Drawing lines of given length (Straight, Wrought Iron, Steel, difference
curved) between Iron and Steel, Alloy
- Drawing of parallel lines, perpendicular steel, carbon steel, stainless steel,
line Non-Ferrous Alloys.
Methods of Division of line segment
4 Drawing of Geometrical Figures:Drawing Average :Problems of Average.
practice on: Ratio & Proportion : Simple
- Angle: Measurement and its types, calculation on related problems.
method of bisecting. M ass, Weight and Density:
- Triangle -different types Mass, Unit of Mass, Weight,
- Rectangle, Square, Rhombus, difference between mass and
Parallelogram.
weight, Density, unit of density.
- Circle and its elements.
5 Dimensioning:
- Definition, types and methods of
dimensioning (functional, non-
functional and auxiliary)
- Types of arrowhead
- Leader Line with text
6 Free hand drawing of
- Lines, polygons, ellipse, etc.
- geometrical figures and blocks with
dimension
- Transferring measurement from the given
object to the free hand sketches.
10
7 M ethod of presentation of Engineering Percentage: Introduction, Simple
Drawing calculation. Changing percentage
- Pictorial View to decimal and fraction and vice-
- Orthogonal View versa.
- Isometric view
8 Symbolic Representation (as per BI S - Forces definition.
SP:46-2003) of : - Definition and example of
- Fastener (Rivets, Bolts and Nuts) compressive, tensile, shear forces,
- Bars and profile sections axial and tangential forces.
- Weld, brazed and soldered joints. Stress, strain, ultimate strength,
- Electrical and electronics element factor of safety for MS.
- Piping joints and fittings Speed and Velocity: Rest and
motion, speed, velocity,
difference between speed and
velocity, acceleration, retardation.
9 Dimensioning practice: M ensuration: Area and
- Position of dimensioning perimeter of square, rectangle,
(unidirectional, aligned, oblique as per parallelogram, triangle, circle,
BIS SP:46-2003) semi circle.
- Symbols preceding the value of Volume of solids – cube, cuboids,
dimension and dimensional tolerance. cylinder and Sphere.
Surface area of solids – cube,
cuboids, cylinder and Sphere.
- Area of cut-out regular surfaces:
circle and segment and sector of
circle.

- Volume of cut-out solids:

hollow cylinders, frustum of
cone, block section.
- Volume of simple solid blocks.
10 Construction of Geometrical Drawing Algebra : Addition, Subtraction,
Figures: Multiplication, Division,
- Polygons and their values of included Algebraic formula, Linear
angles. equations (with two variables).
Conic Sections (Ellipse) - Circular Motion: Relation
between circular motion and
Linear motion, Centrifugal force,
Centripetal force.
11 Projections: Work, Power and Energy:
- Concept of axes plane and quadrant. work, unit of work, power, unit of
- Orthographic projections power, Horse power, mechanical
- Method of first angle and third angle efficiency, energy, use of energy,
projections (definition and difference) potential and kinetic energy,
- Symbol of 1st angle and 3rd angle examples of potential energy and
projection as per IS specification. kinetic energy.

Drawing of Orthographic projection from

isometric/3D view of blocks

11
 B. Block- I I
Basic Training
Topic a) Engineering Drawing Duration b) Workshop Science & Calculation Duration
No. (in hours) (in hours)

1 - Machined components; concept 30 Trigonometry: Trigonometric ratios, 20

of fillet & chamfer; surface finish Trigonometric tables.
symbols. - Finding the value of unknown sides
and angles of a triangle by
Trigonometrical method.
- Finding height and distance by
trigonometry.
Friction and its application in
Workshop practice.
2 - Screw thread, their standard Heat & Temperature: Heat and
forms as per BIS, external and temperature, their units, difference
internal thread, conventions on the between heat and temperature, boiling
features for drawing as per BIS. point, melting point, scale of
temperature, relation between different
scale of temperature, Thermometer,
pyrometer, transmission of heat,
conduction, convection, radiation.
3 - Reading & interpretation of Basic Electricity: Introduction, use of
assembly drawing and detailing. electricity, Types of current_ AC, DC,
their comparison, voltage, resistance,
their units. Conductor, insulator, Types
of connections – series, parallel, electric
power, Horse power, energy, unit of
electrical energy. Concept of earthing.
Heat treatment – Necessity, different
common types of Heat treatment.

Graph:
- Read images, graphs, diagrams
– bar chart, pie chart.
- Graphs: abscissa and ordinates, graphs
of straight line, related to two sets of
varying quantities.

4 - Reading of drawing. Simple Transmission of power: By belt,

exercises related to missing lines, pulleys & gear drive.
dimensions and views.
How to make queries.
5 - Simple exercises related to trade Concept of pressure – units of
related symbols. pressure, atmospheric pressure, gauge
- Solution of NCVT test papers. pressure – gauges used for measuring
pressure.
I ntroduction to pneumatics &
hydraulics systems.
Solution of NCVT test papers

12
7.1.2DETAI L SYLLABUS OF PROFESSI ONAL SKI LLS & PROFESSI ONAL
KNOWLEDGE
A. Block –I
Basic Training

Week PROFESSIONAL SKILL PROFESSIONAL KNOWLEDGE

no. (275 Hours) (120 Hour)

1 ADMISSION AND ORIENTATION OF Admission & introduction to the trade:

THE COURSE Introduction to the Course duration, course
content, study of the syllabus.
Admission formalities and orientation of
the course Occupational Safety & Health
Importance of Safety and general
GENERAL SHOP SAFETY
Precautions to be observed in the shop.
First aid and Fire safety, Use of fire Basic first aid, safety signs - for Danger,
extinguishers. Warning, caution & personal safety
message.
Identify fuels, oils and chemicals used in
Safe handling of Fuel Spillage, Fire
the engines and accessories-handling of
extinguishers used for different types of
shop safety equipment-handling of safety
fire. Safe disposal of toxic dust, safe
devices-first aid- practice on hazard waste
handling and Electrical safety tips.
disposal.

2 MEASURING SYSTEMS AND Measuring systems and types- description

MEASUREMENTS of steel rule- description of feeler gauge-
Practice on measuring on the given jobs- constructional details and working
measuring space with a feeler gauge- principle of precision measuring
measuring the given jobs with precision instruments like Vernier caliper,
measuring instruments- checking external micrometer, bore gauge and dial gauge-
and internal diameter and run outs- description of surface plate and V blocks-
measure straightness on the given job. importance of correct roundness-surface
finish and its importance.
3 BASIC HAND TOOLS Details of various types of marking and
Practice on marking and cutting of a given cutting tools- punch, scriber, hammer and
job- file the job to bring required size- mallets, hack saw frame and blade, chisels
practice on drilling, tapping and dying- etc. – marking media-description of work
reaming practice- repair damaged threads- holding devices like vices- details of
- sharpening the tools. various drill bits- description and types of
drilling machines- details of taps,dies and
reamers- details of screw extractors- details
of bench grinders- safety precautions to be
observed while working with hand
toolsand lifting& carrying components and
equipment.

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 4 FASTENERS AND BEARINGS Threads- thread categorization- types of
Practice on general cleaning, checking and threads- types of screwed joints- types of
on loosening and tightening of various nuts- property classes of bolts- screw
types of screwing joints using screwing locking arrangements- types and
tools. Removal of broken stud /bolt from description of screwing tools- description
blind hole. and types different types of bearings.
Remove and replace bearings from the
given jobs.
5 BASIC WELDING AND SHEET Basics of gas welding, constructional and
METAL working principle of gas and acetylene
welding equipment.
Practice on heating, cutting using welding
torch. Sheet metal operations - Shearing, bending,
Drawing, Squeezing. Sheet metal joints -
Practice on making Rectangular Tray. Pipe Hem & Seam Joints.
bending, Fitting nipples unions in pipes.
Soldering and Brazing of Pipes. Fastening Methods - Riveting, soldering,
Brazing. Fluxes used on common joints.
Sheet and wire-gauges. Different types of
pipe fittings.
6 BASIC HYDRAULICS AND Fundamentals of Hydraulics & Pneumatics.
PNEUMATICS
Symbols of various Hydraulics &
Construction of hydraulic circuits using all Pneumatic elements.
frequently used valves like check valves, Application of different types of hydraulic
flow control valve, pressure relief valve, components like actuators, directional
actuators, directional control valves, control valves, flow control valves,
hydraulic accumulator, etc. hydraulic accumulator, etc.
Description of air compressors, impact
Exercise on using impact wrenches wrenches. Description of Power tools and
equipment.
Safety precautions to be observed while
working with Hydraulic and pneumatics
equipment.
7 BASIC ELECTRICAL AND General principles of electrical
ELECTRONICS engineering- structure of atoms- voltage-
Identify and interpret electrical/electronic current- fuses- electrical conduction-
system concern. Practice on measuring current direction- types of current- voltage
circuit voltage, ampere and resistance. drop- resistance- PTC and NTC resistors-
Practice on measuring voltage drop. types of resistors- ohm’ s law- resistor
Practice on installing crimp connector and circuits- electro magnetism-
terminal end. Practice on soldering wires. electromagnetic induction- description of
Practice on testing fuses and relays- test multimeter- function and types of relays-
diodes semiconductors- N type and P type
semiconductors- description of diodes and
[Link] precautions to be
observed while working with electrical
equipments.
8 Demonstration of Garage, Service station Brief description and uses of Vehicle
equipment.- Vehicle hoists, Moving hoist, hoists, Moving hoist, Engine hoists,

14
 Jacks, Stands. Jacks,& Stands.

Demonstration of EMM specification EMM Industry in India – leading

Data. Identification of different major manufacturers.
assemblies of EMM and Cleaning of
EMMs, oil greasing and lubricating all Description of EMMs & their major
moving parts of EMM. Practice on starting assemblies, and their functions.
and stopping of EMM engine. Constructional differences between
different types of EMM and their
application.

Different type of EMM starting and

stopping method. Development in EMM
industry, trends, new products.
9 Identification of major components of Introduction to Engine:
diesel engine and its accessories. Description of internal & external
combustion engines, Classification of IC
engines, Principle & working of 2& 4-
Different types of Starting and Stopping
stroke diesel engine (Compression ignition
Method of Diesel Engine. Engine (C.I)) & spark ignitionengine(S.I) ,
differentiate between 2-stroke and 4 stroke,
C.I engine and S.I Engine, Direct injection
and Indirect injection, Technical terms
used in engine, Engine specification.
General Description of Motor Vehicles
10 COOLING AND LUBRICATING Engine operating temperature-
SYSTEM requirements of cooling system- types of
Drain, flush and refill cooling system- cooling system and its description-
remove and replace drive belt and hoses- description of pump circulating system
remove and replace coolant pump- remove components- radiator and its types- Oil
and replace radiator and fan assembly- test cooler description- expansion tank- details
thermostat. of radiator pressure cap- coolant pump-
construction and working- fan- rigid and
Drain engine oil- change oil filter- replace variable drive- electrically driven fans-
new engine oil- blotting paper test- remove viscous coupling- types of thermostat and
and replace oil pump- remove, clean and its description
replace oil cooler.
Functions of a lubricating system-
description of different types of lubricating
systems- forced feed and dry sump
lubrication- list out engine lubricating
components- description of different types
of oil pumps- gear, rotor and crescent oil
pumps- oil pressure limiting valves- types
of oil filtering systems and its description-
description of oil cooler- crank case
ventilation
11 BATTERY

15
 Remove and connect battery terminal from Purpose of battery- types- construction and
a battery- clean terminals- check voltage working principle of a lead acid battery-
of a battery- check cranking voltage- maintenance free batteries- battery ratings-
check charging voltage- top up distilled battery charging methods- trouble shooting
water up to the level- connecting two a battery.
batteries in series- charging a battery – test
battery- specific gravity test. Description of Lighting system in EMM,
LIGHTING SYSTEMS reading Instrument panel light.
Practice on tracing wiring circuit of
lighting system.
Identification of various lights installed in
vehicle.
12 STARTING SYSTEM Study about wiring diagram of a stating
Remove and replace starter- check starting system- Principle of starter- components of
system wiring harness- test ignition a starter- construction and working of
switch- remove and replace starter relay- starter- starter field coil design- solenoids-
dismantle and assemble starter. types and function.

CHARGING SYSTEM Study about wiring diagram of a charging

Check the operation of the charging system- construction and working principle
system- perform voltage drop tests- of alternator- description of voltage
remove and replace alternator- dismantle regulator operation.
and reassemble alternator.
13 Assessment / Exam -03 days

16
 B. Block –I I
Basic Training
Week PROFESSIONAL SKILL PROFESSIONAL KNOWLEDGE (120
no. (275 Hours) Hour)

1 INTAKE AND EXHAUST SYSTEMS Description of air induction system- description

Remove, clean and replace intake system- of intake and exhaust manifold- details of various
remove and replace exhaust manifold, types of mufflers- trouble shooting in intake and
silencer and exhaust pipe. exhaust systems.
2 CYLINDER HEAD ASSEMBLY Description of different types engine according to
Remove accessories fitted with the diesel valve arrangements- cylinder head design- details
engine- remove and dismantle cylinder of arrangement of valves in engines- valve timing
head- clean and lubricate cylinder head diagram of a diesel engines- details of
components viz. valve, valve guide, valve arrangement of camshaft in engines- multiple
seats, valve spring, timing belt, rocker arm valve technology- detailed description of valve
and cam shaft - reassemble and refit components- details of camshaft drives- valve
cylinder head components- set valve clearance- description of hydraulic valves-
timing- adjust valve clearance. description of variable engine timing technology.

3 CYLINDER BLOCK ASSEMBLY Functions of a cylinder- cylinder types and

Dismantle engine block components- description- types of cylinder liners- description
clean and lubricate components viz. of cylinder head gasket- functions of a piston-
Crank shaft, main and connecting rod types and material used for piston- connecting
bearings, piston, piston rings, connecting rod- functions- material and design of connecting
rods, fly wheel and vibration damper- rod- crank shaft- functions- material and design
tighten cylinder head bolts-reassemble of crank shaft- fly wheel- description of vibration
engine block assembly. damper.

4 DIESEL FUEL SYSTEM (INLINE AND

ROTARY PUMPS) Lay out of diesel fuel systems- description of fuel
Clean fuel tank- remove and replace fuel tank- details of low pressure pump- importance of
filters- check leaks in fuel system-remove clean fuel- types of fuel filters and its description-
and replace fuel hoses- removing and construction and working of different types of
refitting fuel injection pump and injectors-
fuel injection pumps- types and working of
setting injection timing- bleed fuel system
governor- description of injectors- different types
CRDI SYSTEM of nozzles.

Disconnect and connect fuel supply hoses- Common rail direct injection system – need,
relief fuel pressure- check fuel leakage-
advantages- layout of common rail direct
remove and install high pressure pipe line-
remove and install fuel injector- remove injection system- low pressure and high pressure
and replace high pressure fuel pump- flush circuits- components of CRDI system- working
fuel tank- remove, test and replace fuel principle of common rail direct injection system.
pump- replace fuel
5 ENGINE CONTROL SYSTEMS Description of electronic control system-
classification of sensors- description of various
Practice on tracing input sensor wiring and
17
 connectors-remove and replace sensors- types of sensors-Function and working principle
remove and replace ECU. of sensors. Description of OBD.

6& 7 Power Train Clutch:-types, construction and function. Clutch

mechanism and their uses.
Dismantle clutch assembly identify the
parts of clutch relining of clutch plate & Manual transmissions- Function, description,
assemble. types and their application.
Different types of gear box used in EMM.
Practice on coupling the clutch with
flywheel & join the engine with gear box. Gearbox layout. Components of EMM gear box.
Lubrication methods adopted in gear box.
Dismantle gear box of a EMM identify the
parts and assemble the gear box. Types of power take off (PTO) mechanism,
transfer case.
Dismantle transfer case of a EMM identify
the parts and assemble. Torque converter, its necessity, Power shift
transmission method, automatic transmission,
FINAL DRIVE & DRIVE SHAFTS
Description and function of fluid coupling torque
Dismantle & Assemble PTO Shaft. converters, elements of power shit transmission
planetary type transmission. Automatic
Dismantle, identify and assemble Transmission construction used for automatic
Differential assembly. shifting hydraulic system used in power shift

Differential carriers double reduction gearing,

differential lock, Bevel gear and pinion
adjustments, and function.
Types of front & rear axles in wheeled
equipment.

Need of 4 x 4 wheel drive / Front wheel drive,

universal joint and propeller shaft.

Common trouble and their remedies, care and

maintenance.
8 STEERING SYSTEMS Function and types of steering system.
Description, construction and function of
Trace the layout of different parts of mechanical steering system their movement and
Mechanical and Hydraulic steering adjustment. Description and mechanism of foot
system. Remove steering sub-assembly steerage pedal as incorporated in EMMs.
and assemble Description, working and principle of hydraulic
steering system. Different parts such as pump,
distributor valves, pipe line and hoses etc
Development of mechanical framing.
9 BRAKING SYSTEMS Braking fundamentals Principles of braking,
Cleaning of all components of Braking Drum & disc brakes, Lever/mechanical
system. advantage, Hydraulic pressure & force, Brake
Dismantle brake assembly components, fade.
identify parts and assemble.
18
 Practice on Adjusting brake pedal play. Description on Braking system components—
Bleeding hydraulic brakes & Disk brakes. Drum, Disc and Hydraulic - Power booster or
brake unit, Hydraulic valves. Applying brakes,
Brake force, Brake light switch.
10 UNDER CARRIAGE Constructional features, function and purpose of
Remove and refit Track chain assembly under carriage equipment- Rollers, chains,
sprockets, idlers etc.
Fitting wheels on EMMs. Tightening of
Main frame / Chassis of EMM
wheel in correct sequence. Checking &
adjusting tire pressure by use of air Description, construction and function of Wheel
Importance of in-Flatting tyres to correct
pressure. Repair and maintenance of tyres and
tubes.
11 Hydraulic System Description of Hydraulic pump and its
classifications, Different types of Hydraulic
pumps and its functions.
Trace Hydraulic circuits for different
Hydraulic Cylinder and their purpose. Hydraulic
components. Tank design and filters.

Check leakages in the Hydraulic circuits. Hydraulic control valves description and their
purpose, different types of valves and their
Maintenance practice of Hydraulic system functions.

Hoses, sealing and fitting procedures,

Hydraulic system used in earth moving

machinery.

Hydraulic system working procedure in EMM.

Hydraulic system controlling method operating of
hydraulic lever, Manual joy stick method.
12 Attachments Different types of attachments used in earth
moving equipment like towing, winch, ripper
Mounting and demounting of different single shank etc.
attachments.
Purpose, Operating method and operating
Cleaning and lubricating the mounting systems of different attachment.
attachments.

13 Revision
Assessment / Exam -03 days

19
 7.1.3 EM PLOYABI LI TY SKI LLS
GENERAL I NFORM ATI ON

1) Name of the subject : EM PLOYABI LI TY SKI LLS

2) Applicability : ATS- Mandatory for fresher only

3) Hours of I nstruction : 110 Hrs. (55 hrs. in each block)

4) Examination : The examination will be held at the end of

two years Training by NCVT.

5) I nstructor Qualification :

i)M BA/BBA with two years experience or graduate in sociology/social

welfare/Economics with two years experience and trained in Employability skill from
DGET I nstitute.
And
M ust have studied in English/Communication Skill and Basic Computer at 12th
/diploma level
OR
ii) Existing Social Study I nstructor duly trained in Employability Skill from DGET
I nstitute.

[Link] SYLLABUS OF EM PLOYABI LI TY SKI LLS

20
 A. Block – I
Basic Training

Topic Duration
No. Topic (in hours)

English Literacy

1 Pronunciation :
Accentuation (mode of pronunciation) on simple words, Diction (use of word and speech)
2 Functional Grammar
Transformation of sentences, Voice change, Change of tense, Spellings.
3 Reading
Reading and understanding simple sentences about self, work and environment
4 Writing
Construction of simple sentences Writing simple English 15
5 Speaking / Spoken English
Speaking with preparation on self, on family, on friends/ classmates, on know, picture reading
gain confidence through role-playing and discussions on current happening job description,
asking about someone's job habitual actions. Cardinal (fundamental) numbers ordinal
numbers. Taking messages, passing messages on and filling in message forms Greeting and
introductions office hospitality, Resumes or curriculum vita essential parts, letters of
application reference to previous communication.

I .T. Literacy

1 Basics of Computer
Introduction, Computer and its applications, Hardware and peripherals, Switching on-
Starting and shutting down of computer.

2 Computer Operating System

Basics of Operating System, WINDOWS, The user interface of Windows OS, Create, Copy,
Move and delete Files and Folders, Use of External memory like pen drive, CD, DVD etc,
Use of Common applications.

3 Word processing and Worksheet

Basic operating of Word Processing, Creating, opening and closing Documents, use of
shortcuts, Creating and Editing of Text, Formatting the Text, Insertion & creation of Tables.
Printing document. 15
Basics of Excel worksheet, understanding basic commands, creating simple worksheets,
understanding sample worksheets, use of simple formulas and functions, Printing of simple
excel sheets

4 Computer Networking and I NTERNET

Basic of computer Networks (using real life examples), Definitions of Local Area Network
(LAN), Wide Area Network (WAN), Internet, Concept of Internet (Network of Networks),
Meaning of World Wide Web (WWW), Web Browser, Web Site, Web page and Search
Engines. Accessing the Internet using Web Browser, Downloading and Printing Web Pages,
Opening an email account and use of email. Social media sites and its implication.
Information Security and antivirus tools, Do's and Don'ts in
Information Security, Awareness of IT - ACT, types of cyber crimes.

21
 Communication Skill

1 I ntroduction to Communication Skills

Communication and its importance
Principles of Effective communication
Types of communication - verbal, non verbal, written, email, talking on phone.
Non verbal communication -characteristics, components-Para-language
Body - language
Barriers to communication and dealing with barriers.
Handling nervousness/ discomfort.
Case study/Exercise
2 Listening Skills
Listening-hearing and listening, effective listening, barriers to effective listening
guidelines for effective listening.
Triple- A Listening - Attitude, Attention & Adjustment.
Active Listening Skills.
3 M otivational Training
Characteristics Essential to Achieving Success
The Power of Positive Attitude 25
Self awareness
Importance of Commitment
Ethics and Values
Ways to Motivate Oneself
Personal Goal setting and Employability Planning.
Case study/Exercise
4 Facing I nterviews
Manners, Etiquettes, Dress code for an interview
Do's & Don'ts for an interview
5 Behavioral Skills
Organizational Behavior
Problem Solving
Confidence Building
Attitude
Decision making
Case study/Exercise

22
 B. Block–I I
Basic Training

Topic Topic Duration

No. (in hours)

Entrepreneurship skill 10
1 Concept of Entrepreneurship
Entrepreneurship- Entrepreneurship - Enterprises:-Conceptual issue
Entrepreneurship vs. Management, Entrepreneurial motivation. Performance &
Record, Role & Function of entrepreneurs in relation to the enterprise & relation to
the economy, Source of business ideas, Entrepreneurial opportunities, The process of
setting up a business.
2 Project Preparation & M arketing analysis
Qualities of a good Entrepreneur, SWOT and Risk Analysis. Concept & application
of Product Life Cycle (PLC), Sales & distribution Management. Different Between
Small Scale & Large Scale Business, Market Survey, Method of marketing, Publicity
and advertisement, Marketing Mix.
3 I nstitutions Support
Preparation of Project. Role of Various Schemes and Institutes for self-employment
i.e. DIC, SIDA, SISI, NSIC, SIDO, Idea for financing/ non financing support
agencies to familiarizes with the Policies /Programmes& procedure & the available
scheme.
4 I nvestment Procurement
Project formation, Feasibility, Legal formalities i.e., Shop Act, Estimation & Costing,
Investment procedure - Loan procurement - Banking Processes.
Productivity 10
1 Productivity
Definition, Necessity, Meaning of GDP.
2 Affecting Factors
Skills, Working Aids, Automation, Environment, Motivation
How improves or slows down.
3 Comparison with developed countries
Comparative productivity in developed countries (viz. Germany, Japan and Australia)
in selected industries e.g. Manufacturing, Steel, Mining, Construction etc. Living
standards of those countries, wages.
4 Personal Finance M anagement
Banking processes, Handling ATM, KYC registration, safe cash handling, Personal
risk and Insurance.
Occupational Safety, Health & Environment Education 10
1 Safety & Health
Introduction to Occupational Safety and Health importance of safety and health at
workplace.
2 Occupational Hazards
Basic Hazards, Chemical Hazards, Vibro-acoustic Hazards, Mechanical Hazards,
Electrical Hazards, Thermal Hazards. Occupational health, Occupational hygienic,
Occupational Diseases/ Disorders & its prevention.
3 Accident & safety
Basic principles for protective equipment.
Accident Prevention techniques - control of accidents and safety measures.

23
4 First Aid
Care of injured & Sick at the workplaces, First-Aid & Transportation of sick person
5 Basic Provisions
Idea of basic provision legislation of India.
of safety, health, welfare under legislation of India.
6 Ecosystem
Introduction to Environment. Relationship between Society and Environment,
Ecosystem and Factors causing imbalance.
7 Pollution
Pollution and pollutants including liquid, gaseous, solid and hazardous waste.
8 Energy Conservation
Conservation of Energy, re-use and recycle.
9 Global warming
Global warming, climate change and Ozone layer depletion.
10 Ground Water
Hydrological cycle, ground and surface water, Conservation and Harvesting of water
11 Environment
Right attitude towards environment, Maintenance of in -house environment
Labour Welfare Legislation 5

1 Welfare Acts
Benefits guaranteed under various acts- Factories Act, Apprenticeship Act,
Employees State Insurance Act (ESI), Payment Wages Act, Employees Provident
Fund Act, The Workmen's compensation Act.
Quality Tools 5
1 Quality Consciousness :
Meaning of quality, Quality Characteristic
2 Quality Circles :
Definition, Advantage of small group activity, objectives of quality Circle, Roles and
function of Quality Circles in Organization, Operation of Quality circle. Approaches
to starting Quality Circles, Steps for continuation Quality Circles.
3 Quality M anagement System :
Idea of ISO 9000 and BIS systems and its importance in maintaining qualities.
4 House Keeping :
Purpose of Housekeeping, Practice of good Housekeeping.
5 Quality Tools
Basic quality tools with a few examples
Leadership and Team Building skills. 5
1 Leadership
Discipline and Morale
Team Work
Case Study/ Exercise
2 M eet the M entor 5
Role - play as a Supervisor
Organizing and Planning. 5
1 Time Management
Group Dynamics
Case Study/ Exercise

24
 7.2 PRACTI CAL TRAI NI NG (ON-JOB TRAI NI NG)
(BLOCK – I & I I )
DURATI ON: 18 MONTHS (9 months in each block)

GENERAL I NFORM ATI ON

1) Name of the Trade :M ECHANI C EARTH M OVI NG

M ACHI NERY
2) Duration of On-Job Training : As per Apprentices Act amended time to
time.
3) Batch size : 16 Nos.
4) Examination : i) The internal assessment will be held on
completion of each block
ii) NCVT exam will be conducted at the end of
2nd year.
5) I nstructor Qualification :

i) Degree/Diploma in Mechanical / Automobile Engg. from recognized

university/Board with one/two year post qualification experience in the relevant
field.
OR
NTC/NAC in the trade of Mechanic Tractor /Mechanic Diesel with three year post
qualificationexperience in the relevant field.
Preference will be given to a candidate with Craft Instructor Certificate (CIC)

6) Tools, Equipments& M achinery required : - As per Annexure – II

25
7.2.1 BROAD SKI LL COM PONENT TO BE COVERED DURI NG ON-
JOB TRAI NI NG

A. BLOCK – I (09 M onth)

1) MEASURING PRACTICE – taper measurement of the given job and flatness of the given job
2) Practice on Hacksawing and filing to given dimensions.
3) Practice on Marking and Drilling clear and Blind Holes
4) Construction of simple electrical circuits
5) Diagnose series, parallel, series parallel circuits using Ohm’ s law,
6) Check electrical circuit with a test lamp.
7) Use of service manual wiring diagram for troubleshooting.
8) Observe and report the reading of Tachometer, Odometer, temp and Fuel gauge under ideal and
on load condition.
9) Perform engine vacuum test, engine compression and engine oil pressure test, interpret and
conclude the results
10) SERVICE COOLING SYSTEM-
a. perform cooling system pressure tests, inspect and test radiator, pressure cap, coolant
recovery tank, and hoses; determine necessary action
b. inspect, replace and adjust drive belts, tensioners, and pulleys; check pulley and belt
alignment
c. inspect, test, and replace thermostat
d. inspect and test fan (electrical)
11) SERVICE LUBRICATING SYSTEM- change engine oil and filter, flush lubricating system,
Service oil pump
12) Perform a battery load test
13) Perform jump start an engine with jumper cables
14) Maintenance of Battery
15) Inspect, test and diagnose starting system
16) Inspect, test and diagnose charging system
17) Test alternator in an auto electrical test bench
18) Test starter in an auto electrical test bench
19) Diagnose instrument panel board warning light problems

26
B. BLOCK – I I (09 M onths)
1. Service and Inspect an Intake system
2. Service and Inspect an exhaust system
3. OVERHAULING OF CYLINDER HEAD ASSEMBLY

Dismantle engine head assembly, visual inspection of components for cracks, check gasket
surface areas for warpage and surface finish, inspect and measure valves, valve seats and valve
spring, replace valve seats and valves, valve lapping, replace valve guide, check valve stem- to-
guide clearance, reaming valve guide for correct clearance, inspect and measure rocker
assembly, determine necessary action, Inspect and measure cam shaft run out, journal and cam
lobe wear, Inspect valve lifters, Inspect and replace drive belt/chain, reassemble engine head
assembly

4. OVERHAULING OF CYLINDER BLOCK ASSEMBLY

Dismantle engine block assembly, Inspect engine block for visible cracks and surface warpage,
Inspect and measure cylinder walls/sleeves for damage, wear and ridges, Inspect and measure
crank shaft for journal wear, Inspect and measure main and connecting rod bearings for wear,
Determine piston to bore clearance, Inspect, measure and install piston rings, Service oil pump,
measure oil pump components, Reassemble engine block components, Adjust valve clearance

5. SERVICE FUEL FEED SYSTEM

Clean fuel tank, service low pressure pump, service fuel filter, phasing and calibration of fuel
injection pump, service and test injectors, Check low and high pressure fuel circuits using
gauges, Calibrating a CRDI pump

6. Overhauling of gear box.

7. Overhauling Transfer case and auxiliary gear box.
8. Overhauling of differential. Servicing of reduction gear, rear axle wheel hub.
9. Servicing of PTO (Power Take Off).
10. Checking/ Inspection of Steering mechanism and necessary repair.
11. Overhauling of steering gear box of EMM.
12. Checking of Power steering.
13. Steering fault finding and remedies
14. Overhauling brakes, Inspection of both shoe and lever.
15. Inspecting and setting parking brakes.
16. Inspecting and setting hydraulic main brake including replacement of washer and oil seals.
17. Under Carriage Track adjustment
18. Overhauling of Hydraulic Oil pump
19. Trouble shooting of Hydraulic circuits.
20. Servicing of Hydraulic valves
21. Servicing of Hydraulic cylinders
22. Exercise in driving a EMM with different work attachment.
23. Adjusting working attachment for correct functioning during field operation.
24. Periodic and Preventive Maintenance of EMM.

27
 8. ASSESSM ENT STANDARD
8.1 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 to be given while assessing for team work,
avoidance/reduction of scrape/wastage and disposal of scarp/wastage as per procedure,
behavioral attitude and regularity in training.

The following marking pattern to be adopted while assessing:

a)Weightage in the range of 60-75% to be allotted during assessment under following

performance level:

For this grade, the candidate with occasional guidance and showing due regard for safety
procedures and practices, has produced work which demonstrates attainment of an
acceptable standard of craftsmanship.

In this work there is evidence of:

• Good skill levels in the use of hand tools, machine tools and workshop equipment
• Many tolerances while undertaking different work are in line with those demanded
by the component/job.
• A fairly good level of neatness and consistency in the finish
• Occasional support in completing the project/job.

b)Weightage in the range of above75%- 90% to be allotted during assessment under

following performance level:

For this grade, the candidate, with little guidance and showing due regard for safety
procedures and practices, has produced work which demonstrates attainment of a
reasonable standard of craftsmanship.

In this work there is evidence of:

• Good skill levels in the use of hand tools, machine tools and workshop equipment
• The majority of tolerances while undertaking different work are in line with those
demanded by the component/job.
• A good level of neatness and consistency in the finish
• Little support in completing the project/job

28
c)Weightage in the range of above 90% to be allotted during assessment under following
performance level:

For performance in this grade, the candidate, with minimal or no support in organization
and execution and with due regard for safety procedures and practices, has produced
work which demonstrates attainment of a high standard of craftsmanship.

In this work there is evidence of:

• High skill levels in the use of hand tools, machine tools and workshop equipment
• Tolerances while undertaking different work being substantially in line with those
demanded by the component/job.
• A high level of neatness and consistency in the finish.
• Minimal or no support in completing the project

29
 8.2 FI NAL ASSESSM ENT- ALL I NDI A TRADE TEST (SUM M ATI VE
ASSESSM ENT FOR TWO YEARS TRADE)
SUBJECTS M arks I nternal Full Pass M arks Duration
assessment M arks of Exam.
based on
competency
Basic Training(Block-I) 250 250 150
Professional Skill 250 250 150 08 hrs.
Professional Knowledge 100 100 40 3 hrs.
Workshop Cal. & Sc. 50 50 20 3 hrs.
Engineering Drawing 50 50 20 4 hrs.
Employability Skill 50 50 20 3 hrs.
Basic Training (Block-II) 250 250 150
Grand Total 500 500 1000 550

30
 9. FURTHER LEARNI NG PATHWAYS

• On successful completion of the course trainees can opt for Diploma course
(L ateral entry).
• On successful completion of the course trainees can opt for CITS course.

Employment opportunities:

On successful completion of this course, the candidates shall be gainfully

employed in the following industries:

1. Production & Manufacturing industries of EMM

2. Mining Industries
3. Earth mover repair
4. Self employment

31
 ANNEXURE – I

TOOLS & EQUI PM ENT FOR BASI C TRAI NI NG

I NFRASTRUCTURE FOR PROFESSI ONAL SKI LL & PROFESSI ONAL

KNOWLEDGE

TRADE:M ECHANI C EARTH M OVI NG M ACHI NERY

LI ST OF TOOLS & EQUI PM ENTS FOR 16APPRENTI CES

A : TRAI NEES TOOL KI T:-

[Link]. Item with specification Qty (Nos.)

1. Allen Key set of 12 pieces (2mm to 14mm) (5+1)
2. Caliper inside 15 cm Spring 6
3. Calipers outside 15 cm spring 6
4. Center Punch 10 mm. Dia. x 100 mm. 6
5. Dividers 15 cm Spring 6
6. Electrician Screw Driver 250mm 6
7. Hammer ball peen 0.5 kg with handle 6
8. Hands file 20 cm. Second cut flat 6
9. Philips Screw Driver set of 5 pieces (100 mm to 300 mm) 6
10. Pliers combination 20 cm. 6
11. Screw driver 20cm.X 9mm. Blade 6
12. Screw driver 30 cm. X 9 mm. Blade 6
13. Scriber 15 cm 6
14. Spanner D.E. set of 12 pieces (6mm to 32mm) 6
15. Spanner, ring set of 12 metric sizes 6 to 32 mm. 6
16. Spanners socket with speed handle, T-bar, ratchet and 6
universal upto 60 mm set of 28 pieces with box
17. Steel rule 30 cm inch and metric 6
18. Steel tool box with lock and key (folding type) 6
400x200x150 mm
19. Wire cutter and stripper 6

32
B :TOOLS I NSTRUM ENTS AND GENERAL SHOP OUTFI TS
[Link]. I tem with specification Qty (Nos.)
1. Adjustable spanner (pipe wrench 350 mm) 2
2. Air blow gun with standard accessories 1
3. Air impact wrench with standard accessories 4
4. Air ratchet with standard accessories 4
5. Allen Key set of 12 pieces (2mm to 14mm) 4
6. Alternator assembly 2
7. Ammeter 300A/ 60A DC with external shunt 4
8. Auto Electrical test bench 1
9. Battery –charger 2
10. Belt Tensioner gauge 1
11. Caliper inside 15 cm Spring 4
12. Calipers outside 15 cm spring 4
13. Car Jet washer with standard accessories 1
14. Chisel 10 cm flat 4
15. Chisels cross cut 200 mm X 6mm 4
16. Circlip pliers Expanding and contracting type 15cm and 4
20cm each
17. Clamps C 100mm 2
18. Clamps C 150mm 2
19. Clamps C 200mm 2
20. Cleaning tray 45x30 cm. 4
21. Compression testing gauge suitable for diesel Engine 2
with standard accessories
22. Connecting rod alignment fixture 1
23. Cylinder bore gauge capacity 20 to 160 mm 4
24. Cylinder liner- Dry & wet liner, press fit & slidefit liner 1 each
25. DC Ohmmeter 0 to 300 Ohms, mid scales at 20 Ohms 2
26. Depth micrometer 0-25mm 4
27. Dial gauge type 1 Gr. A (complete with clamping devices 4
and with magnetic stand)
28. Different type of Engine Bearing model 1 set
29. Different type of piston model 1each
30. Dividers 15 cm Spring 4
31. Drift Punch Copper 15 Cm 4
32. Drill twist 1.5 mm to 15 mm (various sizes) by 0.5 mm 4
33. Electric Soldering Iron 230 V 60 watts 230 V 25 watts 2 each
34. Electric tester 4
35. Engineer’ s square 15 cm. Blade 4
36. Engineers stethoscope 1
37. Executive Auto Electrical tool kit 1
38. Feeler gauge 20 blades (metric) 4

33
39. File flat 20 cm bastard 4
40. File, half round 20 cm second cut 4
41. File, Square 20 cm second cut 4
42. File, Square 30 cm round 4
43. File, triangular 15 cm second cut 4
44. Files assorted sizes and types including safe edge file 2 set
45. Flat File 25 cm second cut 4
46. Flat File 35 cm bastard 4
47. Fuel feed pump for diesel 1
48. Fuel injection pump (Diesel) inline 1
49. Fuel injection pump dismantling tool kit /Universal Vice 1
50. Fuel injection pump, VE pump / Distributor fuel rotary 1 each
pump (DPC) pumps / along with special tools and
accessories.
51. Functional/experiment model of different type of sensors. 1 set
52. Gloves for Welding (Leather and Asbestos) 5 sets
53. Glow plug tester 2
54. Granite surface plate 1600 x 1000 with stand and cover 1
55. Growler 2
56. Hacksaw frame adjustable 20-30 cm 10
57. Hammer Ball Peen 0.75 Kg 4
58. Hammer Chipping 0.25 Kg 5
59. Hammer copper 1 Kg with handle 4
60. Hammer Mallet 4
61. Hammer Plastic 4
62. Hand operated crimping tool (i) for crimping up to 4mm 2
and (ii) for crimping up to 10mm
63. Hand reamers adjustable 10.5 to 11.25 mm, 11.25 to 1 sets
12.75 mm, 12.75 to 14.25 mm and 14.25 to 15.75 mm
64. Hand vice – 37 mm 2
65. Hollow Punch set of seven pieces 6mm to 15mm 2 sets each
66. Impact screw driver 2
67. Injector – Multi hole type, Pintle type 4 each
68. Injector cleaning unit 1
69. Injector tester (Hand tester) 1
70. Insulated Screw driver 20 cm x 9mm blade 4
71. Insulated Screw driver 30 cm x 9mm blade 4
72. Magnifying glass 75mm 2
73. Marking out table 90X60X90 cm. 1
74. Multimeter digital 5
75. Oil can 0.5/0.25 liter capacity 4
76. Oil pump for dismantling and assembling. 2
77. Outside micrometer 0 to 25 mm 4
78. Outside micrometer 25 to 50 mm 4
34
79. Outside micrometer 50 to 75 mm 1
80. Outside micrometer 75 to 100 mm ,100 to 125 mm, 125 1
to 150 mm
81. Philips Screw Driver set of 5 pieces (100 mm to 300 mm) 2
82. Piston ring compressor 2
83. Piston Ring expander and remover. 2
84. Piston Ring groove cleaner. 2
85. Pliers combination 20 cm. 2
86. Pliers flat nose 15 cm 2
87. Pliers round nose 15 cm 2
88. Pliers side cutting 15 cm 2
89. Portable electric drill Machine 1
90. Prick Punch 15 cm 4
91. Punch Letter 4mm (Number) 2 set
92. Radiator cut section-down flow 1
93. Radiator pressure cap 2
94. Scraper flat 25 cm 2
95. Scriber 15 cm 2
96. Scriber with scribing black universal 2
97. Spanner D.E. set of 12 pieces (6mm to 32mm) 4
98. Spanner, adjustable 15cm. 2
99. Spanner, ring set of 12 metric sizes 6 to 32 mm. 4
100. Spanners socket with speed handle, T-bar, ratchet and 2
universal upto 32 mm set of 28 pieces with box
101. Starter motor axial type, pre-engagement type & Co-axial 1each
type
102. Steel measuring tape 10 meter in a case 4
103. Steel rule 15 cm inch and metric 4
104. Steel rule 30 cm inch and metric 4
105. Straight edge gauge 2 ft. 2
106. Straight edge gauge 4 ft. 2
107. Stud extractor set of 3 2 sets
108. Stud remover with socket handle 1
109. Surface gauge with dial test indicator plunger type i.e. 4
0.01 mm
110. Tachometer (Counting type) 1
111. Taps and Dies complete sets BSF 1 set
112. Taps and wrenches - metric 2 sets
113. Telescope gauge 4
114. Thermostat 2
115. Thread pitch gauge metric, BSW 2
116. Torque wrenches 5-35 Nm, 12-68 Nm & 50-225 Nm 1 each
117. Turbocharger cut sectional view 1
118. Universal puller for removing pulleys, bearings 1
35
119. V’ Block 75 x 38 mm pair with Clamps 2
120. Vacuum gauge to read 0 to 760 mm of Hg. 2
121. Valve spring compressor universal. 1
122. vernier caliper 0-300 mm with least count 0.02mm 4
123. Vice grip pliers 2
124. Wire Gauge (metric) 2
125. Work bench 250 x 120 x 60 cm with 4 vices 12cm Jaw 4
126. 4 Point relays 2
127. 5 Point relays 2
128. Vacuum pump gauge 1
129. Glow plug wrench 1
130. Oil seal remover 1
131. Oil seal installer 1
132. Valve guide remover 1
133. Forceps 1
134. Fly wheel holder 1
135. Bearing puller 1
136. Bearing installer 1
137. Injection pump pulley remover 1
138. Cam shaft pulley holder 1
139. Cam shaft locking tool 1
140. Oil filter wrench socket 1
141. Oil pressure gauge 1
142. Radiator pressure tester 1
143. Fuel pressure gauge with adopters 1

C :GENERAL M ACHI NERY I NSTALLATI ONS:-

1 Diesel Engine – CRDI - 4 stroke for Dismantling and assembling 1
with swiveling stand
2 Diesel engine (Runningcondition) Stationary type. 1
3. Bench grinder 1
4. Drilling machine (general purpose) 1
5. Hand operated Hydraulic press 1
6. Multi Scan Tool with oscilloscope 1
7. Electro Hydraulic Trainee Kit 3

Note: I n case of basic training setup by the industry the tools, equipment and
machinery available in the industry may also be used for imparting basic training.

36
 I NFRASTRUCTURE FOR WORKSHOP CALCULATI ON & SCI ENCE AND
ENGI NEERI NG DRAWI NG

TRADE: M ECHANI C EARTH M OVI NG M ACHI NERY

LI ST OF TOOLS& EQUI PM ENTS FOR 16 APPRENTI CES

1) Space Norms : 45 Sq.m.(For Engineering Drawing)

2) I nfrastructure:
A : TRAI NEES TOOL KI T:-

Sl. Quantity
Name of the items
No. (indicative)
1. Draughtsman drawing instrument box 16
2. Set square celluloid 45⁰ (250 X 1.5 mm) 16
3. Set square celluloid 30⁰-60⁰ (250 X 1.5 mm) 16
4. Mini drafter 16
5. Drawing board (700mm x500 mm) IS: 1444 16

B : FURNI TURE REQUI RED

Sl. Quantity
Name of the items
No. (indicative)
1 Drawing Board 20
2 Models : Solid & cut section as required
3 Drawing Table for trainees as required
4 Stool for trainees as required
5 Cupboard (big) 01
6 White Board (size: 8ft. x 4ft.) 01
7 Trainer’ s Table 01
8 Trainer’ s Chair 01

37
 ANNEXURE – I I

TOOLS & EQUI PM ENT FOR ON-JOB TRAI NI NG

I NFRASTRUCTURE FOR PROFESSI ONAL SKI LLS &

PROFESSI ONAL KNOWLEDGE

TRADE: M ECHANI C EARTH M OVI NG M ACHI NERY

For Batch of 16 APPRENTI CES

Actual training will depend on the existing facilities available in the

establishments. However, the industry should ensure that the broad skills defined against
On-Job Training part are imparted. In case of any short fall the concern industry may
impart the training in cluster mode/ any other industry/ at ITI.

38
 ANNEXURE-I I I

GUI DELI NES FOR I NSTRUCTORS AND PAPER SETTERS

[Link] care to be taken for proper & inclusive delivery among the batch. Some of the
following some method of delivery may be adopted:

A) LECTURE
B) LESSON
C) DEMONSTRATION
D) PRACTICE
E) GROUP DISCUSSION
F) DISCUSSION WITH PEER GROUP
G) PROJECT WORK
H) INDUSTRIAL VISIT

2. Maximum utilization of latest form of training viz., audio visual aids, integration of
IT, etc. may be adopted.

3. The total hours to be devoted against each topic may be decided with due diligence to
safety & with prioritizing transfer of required skills.

39