iti 15 April 2025
Mechanic Mining Machinery

ITI Mechanic Mining Machinery Trade Syllabus 

The ITI Mechanic Mining Machinery trade is a two-year vocational training program under the Craftsman Training Scheme (CTS), governed by the National Council for Vocational Training (NCVT). This course equips trainees with skills in installing, maintaining, troubleshooting, repairing, and overhauling machinery used in mining operations, including drilling rigs, conveyors, crushers, pumps, haulage systems, and ventilation equipment. The syllabus integrates theoretical knowledge, practical skills, and employability skills to prepare students for roles such as mining machinery technicians, maintenance mechanics, or service engineers in mining industries, or as self-employed service providers.

Course Overview

  • Duration: 2 years (4 semesters, each 6 months)
  • NSQF Level: Level 5
  • Eligibility: Minimum 10th grade pass with Science and Mathematics (or equivalent)
  • Objective: To train individuals in ensuring the efficient and safe operation of mining machinery through maintenance, repair, and system optimization.

Detailed Syllabus Breakdown

1. Trade Theory (Theoretical Knowledge)

Covers principles of mining machinery, maintenance techniques, and safety standards.

  • Semester 1
    • Introduction to Mining Machinery
      • Overview: types of mining (surface, underground), role of machinery (drills, loaders, crushers).
      • Industry scope: mining sectors (coal, metal, quarries), job roles, Industry 4.0 in mining.
      • Safety: PPE (helmets, gloves, boots), mine safety regulations, hazard identification.
    • Basic Mechanics
      • Concepts: force, torque, friction, levers, gears, bearings in mining equipment.
      • Components: shafts, couplings, chains, belts used in conveyors, haulage systems.
      • Materials: metals, alloys, wear-resistant coatings for mining conditions.
    • Electrical Fundamentals
      • Principles: voltage, current, resistance, AC/DC circuits, motors in mining machinery.
      • Components: starters, relays, circuit breakers, cables for rugged environments.
      • Safety: grounding, insulation, explosion-proof electrical systems (ATEX standards).
    • Hydraulic and Pneumatic Systems
      • Components: pumps, valves, cylinders, hoses in mining equipment (excavators, drills).
      • Operation: fluid power, pressure control, air compression in mining applications.
      • Maintenance: checking leaks, replacing seals, fluid quality management.
    • Tools and Measuring Instruments
      • Mechanical: spanners, torque wrenches, vernier calipers, micrometers for repairs.
      • Diagnostic: vibration analyzers, pressure gauges, alignment tools for machinery.
      • Precision: ensuring tolerances (±0.01 mm) in critical mining components.
    • Workshop Practices
      • Operations: drilling, grinding, welding, assembling mining machinery parts.
      • Techniques: fitting bearings, aligning shafts, balancing rotating equipment.
      • Documentation: maintenance logs, spare part lists, downtime reports.
  • Semester 2
    • Mining Machinery Types
      • Equipment: drilling rigs (rotary, percussive), loaders, dumpers, conveyor systems.
      • Operation: principles of cutting, hauling, crushing in surface/underground mines.
      • Maintenance: lubrication schedules, wear checks for drill bits, conveyor belts.
    • Engines and Power Systems
      • Types: diesel engines, electric motors in mining trucks, pumps, ventilation fans.
      • Components: fuel systems, cooling systems, exhausts, turbochargers.
      • Maintenance: overhauling engines, testing motor efficiency, replacing filters.
    • Lubrication Systems
      • Types: grease, oil-based systems for gears, bearings in crushers, conveyors.
      • Operation: centralized lubrication, automatic lubricators in mining setups.
      • Maintenance: checking viscosity, topping fluids, cleaning lubrication lines.
    • Preventive Maintenance
      • Schedules: daily, weekly checks for drills, haulage, ventilation systems.
      • Techniques: inspecting wear, tightening bolts, monitoring noise/vibration.
      • Records: logging maintenance, predicting failures, spare part inventory.
    • Troubleshooting Basics
      • Methods: fault diagnosis in hydraulic, electrical, mechanical systems.
      • Tools: multimeters, hydraulic testers, diagnostic software for mining equipment.
      • Solutions: replacing worn parts, adjusting alignments, recalibrating controls.
    • Mining Safety Standards
      • Regulations: DGMS (Directorate General of Mines Safety) guidelines, ISO 45001.
      • Practices: ventilation checks, dust suppression, emergency shutdown systems.
      • Compliance: maintaining equipment logs, safety audits, operator training.
  • Semester 3
    • Advanced Mining Machinery
      • Equipment: longwall systems, continuous miners, shuttle cars, roof bolters.
      • Operation: automation, remote control in underground mining systems.
      • Maintenance: servicing gearboxes, hydraulic arms, cutting heads.
    • Conveyor and Haulage Systems
      • Components: belts, rollers, pulleys, tensioners in material transport.
      • Operation: belt tracking, load distribution, speed control in mines.
      • Maintenance: splicing belts, aligning rollers, replacing idlers.
    • Ventilation and Pumping Systems
      • Systems: mine fans, ducting, water pumps for dewatering, slurry handling.
      • Operation: airflow control, pressure management, pump efficiency.
      • Maintenance: cleaning impellers, balancing fans, checking seals.
    • Welding and Fabrication
      • Techniques: arc, MIG welding for repairing buckets, chutes, drill frames.
      • Applications: rebuilding worn parts, fabricating mining fixtures.
      • Safety: handling welding gases, ensuring structural integrity.
    • Condition Monitoring
      • Techniques: vibration analysis, thermal imaging, oil analysis for machinery.
      • Tools: IoT sensors, predictive maintenance software, data loggers.
      • Analysis: trending wear, scheduling proactive repairs, reducing downtime.
    • Customer Interaction
      • Skills: explaining downtime, repair plans to mine supervisors, operators.
      • Coordination: sourcing spares from OEMs, managing service contracts.
      • Documentation: preparing service reports, warranty records, cost estimates.
  • Semester 4
    • Automation in Mining Machinery
      • Systems: PLCs, SCADA, IoT-enabled equipment for smart mining.
      • Maintenance: updating firmware, troubleshooting control circuits, sensors.
      • Integration: linking machinery with mine management systems.
    • Heavy Earth-Moving Machinery
      • Equipment: excavators, bulldozers, draglines in surface mining.
      • Maintenance: servicing hydraulic systems, tracks, counterweights.
      • Repairs: overhauling transmissions, replacing buckets, undercarriages.
    • Environmental Control Systems
      • Systems: dust collectors, gas monitors, cooling systems in mines.
      • Maintenance: calibrating sensors, cleaning filters, ensuring compliance.
      • Standards: adhering to pollution control, mine air quality norms.
    • Entrepreneurship and Management
      • Business: starting a mining machinery service, sourcing components.
      • Planning: budgeting repairs, managing maintenance contracts.
      • Marketing: promoting services, building mining industry networks.
    • Industry Trends
      • Innovations: autonomous haul trucks, AI diagnostics, green mining tech.
      • Standards: ISO 14001 for environment, DGMS for safety compliance.
      • Future: electric mining equipment, digital twins, predictive analytics.
    • Professional Ethics
      • Practices: transparency in repairs, quality assurance for safety.
      • Responsibilities: ensuring machinery uptime, operator safety.
      • Compliance: adhering to DGMS, environmental, and labor regulations.

2. Trade Practical (Hands-On Skills)

Focuses on practical tasks in mining machinery workshops and simulated mine setups.

  • Semester 1
    • Safety Practices
      • Using PPE: wearing helmets, gloves, dust masks in workshops.
      • Procedures: lockout-tagout, handling heavy equipment safely.
      • Drills: mine rescue, fire suppression, first aid for injuries.
    • Mechanical Operations
      • Performing: assembling gears, bearings, shafts in mock setups.
      • Measuring: checking tolerances with calipers, micrometers.
      • Maintaining: lubricating components, cleaning assemblies.
    • Electrical Circuit Work
      • Wiring: building basic motor control circuits in lab setups.
      • Testing: measuring voltage, current with multimeters.
      • Repairing: replacing fuses, starters, soldering connections.
    • Hydraulic/Pneumatic Practice
      • Assembling: setting up hydraulic cylinders, valves in mock systems.
      • Testing: checking pressure, flow in lab setups.
      • Repairing: replacing seals, topping fluids in workshops.
    • Workshop Tasks
      • Performing: drilling, grinding, fitting for mining fixtures.
      • Assembling: mounting pulleys, belts in mock conveyors.
      • Documenting: preparing part lists, maintenance schedules.
    • Project Work
      • Servicing a pump: dismantling, repairing, testing in labs.
      • Report: documenting faults, fixes, performance outcomes.
  • Semester 2
    • Mining Machinery Maintenance
      • Servicing: inspecting drill rigs, loaders in mock setups.
      • Repairing: replacing drill bits, tightening conveyor frames.
      • Testing: verifying equipment alignment, load capacity.
    • Engine Maintenance
      • Dismantling: overhauling diesel engines in lab setups.
      • Repairing: replacing fuel injectors, cooling fans in workshops.
      • Testing: ensuring engine RPM, torque meet specs.
    • Lubrication Practice
      • Applying: greasing bearings, oiling gears in mock crushers.
      • Testing: checking lubrication flow, viscosity in labs.
      • Maintaining: cleaning lube systems, replacing filters.
    • Preventive Maintenance
      • Performing: inspecting belts, motors in mock haulage systems.
      • Testing: checking vibration, noise levels in workshops.
      • Logging: preparing downtime reports, maintenance logs.
    • Troubleshooting Practice
      • Diagnosing: tracing faults in mock hydraulic, electrical systems.
      • Repairing: replacing worn sprockets, recalibrating controls.
      • Testing: ensuring error-free operation post-repair.
    • Project Work
      • Servicing a conveyor: repairing belts, testing load in labs.
      • Portfolio: presenting logs, photos, system performance.
  • Semester 3
    • Advanced Machinery Repair
      • Servicing: inspecting continuous miners, roof bolters in mock setups.
      • Repairing: replacing hydraulic arms, cutting heads in labs.
      • Testing: verifying automation, load capacity in workshops.
    • Conveyor System Maintenance
      • Servicing: aligning rollers, splicing belts in mock systems.
      • Repairing: replacing pulleys, tensioners in workshops.
      • Testing: ensuring belt tracking, speed control.
    • Ventilation/Pumping Practice
      • Servicing: cleaning mine fans, water pumps in lab setups.
      • Repairing: replacing impellers, seals in workshops.
      • Testing: verifying airflow, pump pressure in mock mines.
    • Welding Practice
      • Performing: welding buckets, chutes in lab setups.
      • Repairing: rebuilding worn crusher jaws, drill frames.
      • Testing: ensuring weld strength, structural integrity.
    • Condition Monitoring Practice
      • Monitoring: using vibration sensors, thermal cameras on mock equipment.
      • Analyzing: trending failure data, predicting faults in labs.
      • Reporting: preparing maintenance forecasts, logs.
    • Project Work
      • Servicing a drilling rig: repair, calibration, testing in labs.
      • Portfolio: presenting repair logs, test results, photos.
  • Semester 4
    • Automation System Maintenance
      • Servicing: inspecting PLCs, sensors in mock smart mining setups.
      • Repairing: updating firmware, fixing control circuits in labs.
      • Testing: ensuring IoT connectivity, automation accuracy.
    • Heavy Machinery Repair
      • Servicing: inspecting excavators, draglines in mock setups.
      • Repairing: replacing tracks, hydraulic rams in workshops.
      • Testing: verifying load capacity, system stability.
    • Environmental System Maintenance
      • Servicing: calibrating dust collectors, gas sensors in labs.
      • Repairing: replacing filters, cleaning ducts in mock setups.
      • Testing: ensuring air quality, compliance with norms.
    • Entrepreneurship Practice
      • Simulating: running a mock machinery service, sourcing spares.
      • Planning: budgeting mine contracts, managing inventory.
      • Marketing: creating mock service ads, client proposals.
    • Safety and Compliance
      • Inspecting: checking ventilation, grounding in mock setups.
      • Auditing: conducting mock DGMS, ISO safety audits.
      • Testing: ensuring equipment meets regulatory standards.
    • Project Work
      • Restoring a haulage system: repair, integration, testing.
      • Portfolio: presenting logs, photos, system efficiency data.

3. Workshop Calculation and Science

Supports mining machinery with relevant concepts.

  • Semester 1: Arithmetic (tolerances, power), physics (mechanics, electricity).
  • Semester 2: Algebra (hydraulic equations), thermodynamics (engine heat).
  • Semester 3: Geometry (gear ratios), fluid mechanics (pumps, airflow).
  • Semester 4: Statistics (failure analysis), applied physics (vibration, wear).

4. Engineering Drawing

Focuses on technical drafting for mining machinery.

  • Semester 1: Sketching mechanical parts, circuit diagrams, orthographic views.
  • Semester 2: Drawing hydraulic circuits, conveyor layouts, engine assemblies.
  • Semester 3: Designing ventilation systems, haulage schematics, gearboxes.
  • Semester 4: Creating blueprints for automated mining systems, heavy equipment.

5. Employability Skills

Enhances job readiness and soft skills.

  • Semester 1: Communication (reporting faults), time management, basic IT (diagnostics).
  • Semester 2: Teamwork (with mine crews), problem-solving (machinery faults).
  • Semester 3: Leadership (supervising repairs), negotiation (vendor deals), advanced IT (PLCs, IoT).
  • Semester 4: Entrepreneurship (service business), client management, trends (autonomous mining).

Assessment and Certification

  • Examinations: Semester-wise (theory + practical).
  • Certification: National Trade Certificate (NTC) from NCVT, recognized nationally.
  • Evaluation: Based on repair accuracy, system efficiency, safety compliance, and project work.

Career Opportunities

  • Employment: Mining machinery technician, maintenance mechanic, service engineer in coal, metal, or quarry mining industries.
  • Self-Employment: Starting a mining equipment maintenance or repair service.
  • Further Studies: Diploma in Mechanical Engineering, certifications in mining automation, or heavy equipment maintenance.

Note

  • This syllabus aligns with NCVT guidelines and may vary slightly by institution or state.
  • For the latest version, refer to the Directorate General of Training (DGT) or local ITI.

Trade Type

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