SUBJECT

MAINTENANCE LAB-I

SEMESTER :

VI

COURSE

MACHINE TOOL MAINTENANCE AND REPAIRS

EXPERIMENT
NUMBER

NAME OF EXPERIMENTS

1.

Bearings-inspection, Removal and Assembly

2.

Installation of Couplings and Shaftings and Alignment

3.

Friction Clutches

4.

Belt and Chain Drives

5.

Removal and Replacement of Oil Seals 0 Rings, Piston

Rings

6.

Removal and Replacement of Mechanical Springs

7.

Cams and Crank Mechanism

8.

Cutting, Flaring, Swaging & Binding of Copper Tubing

9.

Pipe Cutting, threading and use of PVC Pipes

10.

Practice in Sheet Metal Work Funnel

11.

Practice in Sheet Metal Work Tray

12.

Dismantling and Assembling of Bench and Pipe Vice

13.

Dismantling and Assembling of Three Jaw Chuck

14.

Dismantling and Assembling of Four Jaw Chuck

15.

Hydraulic Systems: Servicing, Diagonis, Location,

Rectification
********

DIPLOMA IN MACHINE MAINTENANCE LAB-I

REMARKS

EX.NO.1.

BEARING INSPECTION, REMOVAL AND ASSEMBLY

AIM:
To dismantle and assemble the given bearing assembly.
TOOLS AND EQUIPMENTS REQUIRED:
Cleaning brush, centre punch, chisel, hammer, screw driver, allen key set, double end
and rings spanner set, cutting plier, box spanner set, inside and outside circlip player nose
player, bearing puller.
PROCEDURE:
DISMANTLING:
The given bearing unit is assembled in a crank case of an I.C. engine.
dismantling procedure for the bearing unit is as follows:

The

First drain out the lubricating oil from the sump. Dismantle fuel tank, crank pulleys,
fuel filter, fuel pipe line, silencer, fuel injector pump, rocker arm and valve assembly and
cylinder head by unscrewing the respective in both and studs. Nuts. In the process of engine
disassembly do not separate the matching parts. For this purpose matching parts are marked.
New remove the piston assembly, timing gear, cam shaft and connect rod assembly.
Then remove the driven gear, driving gear from the crank shaft. Remove the counter weight
from the crank shaft by unscrewing the nuts.
Take out the crank shaft by hammering it with a wooden block and mallet. While
dismantling crank shaft apply uniform force by hammering on crank shaft end. The uniform
force is achieved by rotating the crank shaft. After removing the crank shaft separate the
bearings from the crank case body. Bearings are removed by bearing puller.
After the bearing unit is completely dismantled keep the bolts, washers and other
fasteners away in a special case, temporarily assemble the fasteners back into their holes.
CLEANING AND INSPECTION:
Clean all the parts of engine and bearing with spindle oil or cleaning agents. Washed
parts are dried in the air or wiped dry with clean rags.
Inspect the washed and dried parts, group them and store separately. Then inspect
each part externally and then check for its shape and size.

-2-

ASSEMBLY:
The procedure for assembling the bearing unit is as follows. Before assemble the
bearing unit all the parts are thoroughly cleaned. First assemble the bearings in the crank
case body.
In the process of assembling, use a place of steel pipe instead of a copper drift pin.
The internal diameter of pipe as shown in figure should slightly exceed the diameter of the
crank shaft end and the thickness of the pipe wall should be slightly less than that of bearing
bore of crank case.
The pipe ends are machined so that they are strictly perpendicular to its axis. The
pipe is struck with hammer and the bearings are fitted in housing. Now assemble the crank
shaft and other units in the reverse order of dismantling.
PRECAUTIONS:
1. No burrs, dents, scratches or screws are permitted.
2. Do not use lead or babbit hammers.
3. During the dismantling note the thickness of packing paper and replace the
new same size of thickness packing during the cylinder head assembly.
4. After assembling the bearings and crank shaft in the crank case, rotate the
crank shaft so that it should rotate freely, smoothly without noticeably
play.
5. Before placing the crank shaft in position, check the counter sinking of the
holes which deliver the oil to the bearings.
TESTING:
1. Check the lubricating oil pump whether it is properly functioned or not.
2. Rotate the crank shaft so that it should rotate freely, smoothly without
noticeable play.

-3-

EX. NO.2

INSTALLATION
ALIGNMENT

OF

COUPLINGS

AND

SHAFTINGS

AND

AIM:
1. To install the given flange coupling halves on the shaft.
2. To couple and align the given electro motor and centrifugal pump.
TOOLS AND EQUIPMENT REQUIRED:
Dial indicator with magnetic base, screw driver, spanner set, trusquare, spirit level,
hammer, steel rule and straight edge.
INSTALLATION:
The procedure for the installing the flange couplings on their shafts as follows:
Prior to assembling a key joint of shaft and coupling, examine closely the parts to be
joined. Remove nicks, burrs, scoring and other kind of damage. Eliminate any other
discovered defect. Clean keyway of shaft and coupling. Then prepare a new key after
measuring the dimensions of key way.
PREPARATION OF KEY:
Measure the dimension of the key way. Make a key way in mild steel material as per
dimensions required. The key should be fitted with an interference into key way of the shaft
and with a clearance into the key way of the part mounted on the shaft. The key must have
the clearance in height in the key way of the shaft mounted part. The height of the key
should not be larger than prescribed. Then assemble the joint in the following sequence.
Fit the key to the key way of the shaft and that of the hole in the flange coupling.
Then drive the key into the shaft key way by light blows of a copper mallet and check for the
side clearance between matching surfaces of the slot and the key, using a feeler gauge. Now
drive the flange on the shaft and check and radial clearance. Now second coupling halve is
assembled in the same way.
Finally check the perpendicularity between the shaft and fact of each flange coupling
by means of dial indicator.
ALIGNMENT OF COUPLINGS:
In a perfect alignment of flange coupling there is no movement sliding or flexing in
a coupling. Space the driving and driven coupling halves properly so that the ends of the
shafts are in the proper relation. Then provide a normal gap between coupling halves as per
the catalogue. This clearance is checked with the help of feeler gauge at several points of the
circumstance. A uniform clearance is obtained by turning the shafts.
-4-

During the alignment we have to eliminate the following misalignments:

(i)

Angular misalignment

(ii)

Parallel misalignment

ELIMINATING ANGULAR MISALIGNMENT:

To eliminate the angular misalignment, align the coupling as follows:
Square the driving and driven coupling halves one with the other by using straight
edge and scale method or using dial indicator method.
To check angular misalignment, the indicator is attached rigidly to one hub member
and the stem is placed against the face of the opposite hub member. See the figure.
The connected shafts are then rotated together several revolutions to allow them to
take up their normal axial positions. Rotation is then continued in the same direction until the
indicator needle registers a maximum reading. The indicator dial is then set to zero, and
rotation again continued for a one half a turn. At this point the indicator reading will show
the total angular displacement in a distance equal to the diameter of the circle which the
indicator has described.
CORRECTING PARALLEL MISALIGNMENT:
To correct parallel misalignment the indicator stem must be moved to such a position
that it should contact a radial surface usually the outside diameter of the flanged hub.
Again the equipment is rotated until a maximum reading is obtained and the dial set to
zero. Continued rotation for one half turn will show the position and amount of parallel
misalignment.

-5-

EX. NO.3

FRICTION CLUTCHES MULTIPLE DISC FRICTION CLUTCH

AIM:
1. To study the function of given multiple disc friction clutch mechanism and
2. To dismantle and assemble the given multiple disc friction clutch assembly.
TOOLS AND EQUIPMENT REQUIRED:
Cleaning brush, centre punch, chisel, hammer, screw driver, allen key set, double end
and ring spanner set, cutting plier, nose plier, Box spanner set, inside and outside circlip
player plier and bearing puller.
FUNCTION OF GIVEN CLUTCH ASSEMBLY:
The clutch is assembled in the two wheeler enquire gear box. This enquire gives the
rotary power to chain sprocket called driving sprocket. The drive from the driving sprocket is
transmitted to the driven sprocket through double row roller chain. The driven sprocket
wheel is act as a driving hub for clutch assembly.
The driving hub transmits the power to the driven hub through the multiple disc of
driving and driven plates with the spring force. The driven and driving disc plates are shown
in figure.
The driving plates are always rotate with the driving hub and also driven plates are
always rotate with driven hub.
When the driving sprocket wheel rotate, the driving sprocket wheel or driving hub for
clutch also rotated. Due tot the frictional for driven hub also rotated. Here the clutch is used
for only disengaging the power for changing the speeds.
PROCEDURE:
The dismantling procedure for the multiple friction clutch assembly is as follows:
First drain out the lubricating oil from the . Disconnect the clutch cable, brake
cable changing cable to the gear box. Remove the by unscrewing nuts. Remove the chain
and driving sprocket wheel by releasing mechanism.
Clutch ring for holding clutch assembly. and driving disc plates, springs, hub for the
clutch and bush
CLEANING AND INSPECTION:
Clean all the parts of engine with spindle oil or cleaning agents. Washed parts are
dried in the air or wiped dry with clean rags.
-6-

Inspect the washed and dried parts, group them and store separately. Then inspect
each part externally and then check for its shape and size.
ASSEMBLY:
The procedure for assembling the clutch mechanism is as follows. Before the
assembling the clutch mechanism, all the parts are thoroughly element and lubricated.
Assemble the driven hub and bush bearings. Then assemble driving hub. Insert the spring
holding hub and springs and then assemble driving and driven disc alternatively. The clutch
assembly is compressed and hooked in position with hook rings. Then assemble the chain
and adjust in tension with tensioning mechanism. New oil seal is made and assemble in its
position. Then assemble the gear box cover. New lubricating oil is poured in the gear box to
a required level.
PRECAUTIONS:
1. No burrs, dents, scratches or scores are permitted.
2. Do not use lead or babbit hammers.
3. After assembling the clutch mechanism rotate the chain, so that it should rotate
with clutch without any obstruction in its transmission.
TEST:
1. Check the conclusion of oil.
2. Operate the clutch handle so that it should function properly.

-7-

EX. NO.4

BELT AND CHAIN DRIVES

AIM:
1. To align the given pulley and assemble the J belts.
2. To fasten the given flat bolt end by hooks fastener and
3. To dismantle and assemble given chain drive assembly.
TOOLS AND EQUIPMENT REQUIRED:
Steel rule, straight edge, try square, screw driver, spanners set, cutting plier, nose
plier, hammer, bearing puller and spirit level.
PROCEDURE:
1. Alignment of pulleys and shafting. An easy way to do this is shown in fig.
2. Align each shafts with a mechanists level applied directly to the shafts.
3. Determine if the shafts are parallel by placing a string between the shafts and
checking it with a large square.
4. Check alignment of pulley using a string along their edges. If the pulleys are
same width, the string should touch lightly at four points. A, B, C and D. If
pulleys are of different widths, the distance from the string to pulley at A and B
should be the same. If possible give a pulley s half turn and recheck. When the
pulleys are installed one above the other, a string with bob can be used to check
alignment.
FASTENING OF FLAT BEIT:
The given flat belt is cut to the required size, measure width of the flat belt. Cut the
two pieces of hook from the stock to a required size (equal to width of flat belt). Fire the
each hooks to the end of flat belts. Now insert the raw hide or fibre pin after bringing their
hook end.
Check for its correct meshing of loops before firing the belt hook.
DISMANTLING PROCEDURE FOR CHAIN DRIVE ASSEMBLY:
The dismantling procedure for chain drive assembly is as follows:
Function of drive:
The chain drive mechanism is assembled in the two wheels.

-8-

The engine given the rotary power to chain sprocket called driving sprocket. The
drive from the driving sprocket is transmitted to the drives sprocket through the double row
roller chain. The driven sprocket wheel is attached with driving hub of the clutch assembly.
First drain out the lubricating oil from the gear box. disconnect the clutch cable,
brake cable and gear changing cable to the gear box. Remove the gear box cover by
unscrewing nuts. Adjust or release the chain tensioning mechanism.
Now remove the chain from the driven and driving sprocket wheel.
CLEANING AND INSPECTION:
Clean all the parts of chains drive mechanism with spindle oil or cleaning agents.
Washed parts are drived in the air or wiped dry with clean rags.
Inspect the washed and dried parts, group them and store separately. Then inspect
each part externally and then check for its shape and size.
ASSEMBLY:
The procedure for assembling the chain drive mechanism is as follows. Before
assemble the chain drive mechanism, all the parts are thoroughly cleaned and lubricated.
Wrap the chain around the driven and then driving sprocket. Adjust the chain
tensioning mechanism to bring it fairly tight condition with a small amount of slack. The
assemble the gear box cover and pour the new lubricating oil into the gear box.
PRECAUTIONS:
1. No burrs, dents, scratches or scores are permitted.
2. Do not use lead or babbit hammers.
3. After assembling the chain drive mechanism check for its tension. Do not install
the chain with too tight or too loose.
TEST:
1. Rotate the chain so that it should rotate with sprocket without any jumping.
2. While under operating condition, there is no sound or it given noiseless, smooth
chain drive.

-9-

EX. NO.5

REMOVAL AND REPLACEMENT OF OIL SEALS 0 RINGS,

PISTON RINGS

AIM:
To dismantle and assemble the given cylinder assembly of I.C. engine.
TOOLS REQUIRED:
Cleaning brush, centre punch, hammer, chisel, screw driver, spanner set (both double
end and ring) cutting plier, nose plier, allen key set, box spanner set, inside and outside circlip
player.
PROCEDURE:
DISMANTLING:
The dismantling procedure for the cylinder assembly is as follows:
Drain out the fuel in the fuel tank. Then remove fuel tank by unscrewing the nuts.
Remove the silencer, fuel injector pump, cylinder head cover. Rocker arm and valve
assembly and cylinder head by unscrewing the nuts in both and studs.
During dismantling cylinder head measure the thickness of packing. Now remove the
crank case cover. Dismantle the connecting rod unit from the crank shaft by unscrewing nuts
in bolts.
Take out the piston assembly by hammering it with a wooden block and mallet.
While removing piston from the cylinder apply uniform force on the top of the piston. By
using circlip player, remove the circlips the piston hole and then remove the gudgeon pin and
oil rings in the pistons.
CLEANING AND INSPECTION:
Clean all parts of piston assembly with a spindle oil or cleaning agents. Washed parts
are dried in the air or wiped dry with clean rags.
Inspect the washed and dried parts, group them and store separately. Then inspect
each part externally and then check for it shape and size.
ASSEMBLY:
The procedure for assembling the cylinder unit is as follows:
Before assemble the piston assembly all the parts are thoroughly cleaned and
lubricated. First assemble piston and connect rod by inserting gudgeon pin inside the piston
hole. Then lock the circlips in its position. Then insert piston and connect rod inside
-10-

cylinder and connect the connect rod and crank shaft. Then assemble cylinder head, valve
assembly and cylinder head cover. Then assemble all other external accessories.
PRECAUTIONS:
1. No burrs, dents, scratches or scores are permitted inside the cylinder bore and in
bearings.
2. Do not use lead or babbit hammer during the piston and bearing assembly.
3. During the dismantling note the thickness of packing during the cylinder head
assembly.
4. After assembling the split bearings and connect rod in the crank shaft, rotate the
crank shaft so that connect rod should reciprocate freely, smoothy without
noticeable play.
5. Before placing split bearings in connect rod, check the counter sinking of the
holes which deliver the oil to the bearings.
TESTING:
1. Check the lubricating oil pump whether it is properly functioned or not.
2. Rotate the crank shaft so that it should rotate freely, smoothy without noticeable
play.
**********

-11-

EX. NO.6

REMOVAL AND REPLACEMENT OF MECHANICAL SPRINGS

AIM:
To dismantle and assemble the spring assembly given in the cylinder head of I.C.
engine.
TOOLS REQUIRED:
Chisel, cleaning brush, spanners, screw drivers, circlip players, hammer, allen key set,
box spanner set and cutting plier, etc.
PROCEDURE:
The procedure for dismantling the given spring assembly is as follows. Drain out the
line and fuel tank by unscrewing the nuts. Remove the silencer, fuel injecting nozzle, cooling
water inlet and outlet pipes and cylinder head cover by unscrewing nuts in bolts and studs.
During the dismantling the cylinder head, note the thickness of packing paper. Then
remove the packing paper. During the process of dismantling cylinder head assembly check
spring tension in the valve spring assembly. Remove the spring hooking pins and washer in
the valve spring assembly after compressing the spring alone.
After the valve spring unit is completely dismantled keep the bolts, washers, and other
fasteners away in a special core or temporarily assemble to the fasteners back into their holes.
CLEANING AND INSPECTION:
Clean all parts of valve spring assembly with a spindle oil or cleaning agents. Washed
parts are dried in the air or wiped dry with clean rags.
Inspect the washed and dried parts, group them and store separately. Then inspect
each part externally and then check for its shape and size.
ASSEMBLY:
The procedure for assembling valve spring assembly is as follows:
Before assembling the spring assembly all the parts are thoroughly cleaned and
lubricated. Assembly valve and then spring in its position. Then compress the spring and
locked in its position with split pins. Then assemble all other parts. New packing paper is
cut and pasted on the cylinder. Then assemble cylinder head.
PRECAUTIONS:
1. No burrs, dents, scratches or scores are permitted.
2. Do not use lead or babbit hammer.
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3. During dismantling, note the thickness of packing paper and replace the new same

size of thickness paper (packing) during cylinder head assembly.

4. Adjust the clearance between push rod and rocker arm with the feeler gauge given
in the catalogue.
5. Check up the spring tension on the valve.
TEST:
Rotate the crank shaft and observe the movement of the pushrod and rocker arm.
During the rotation of crank shaft the spring is compressed and released to original position.
*********

-13-

EX.NO.7.

CAMS AND CRANK MECHANISM

AIM:
To dismantle and assemble the given cams and crank mechanism in the I.C. engine.
TOOLS AND EQUIPMENTS REQUIRED:
Cleaning brush, centre punch, chisel, hammer, screw driver, allen key set, double end
and rings spanner set, cutting plier, nose plier, box spanner set, inside and outside circlip
plier, bearing puller.
PROCEDURE:
DISMANTLING:
The given cam and crank mechanism is assembled in a crank case of an I.C. engine.
The dismantling procedure for the cam and crank mechanism unit is as follows:
First drain out the lubricating oil from the sump. Dismantle fuel tank, crank pulley,
fuel filter, fuel pipe line, silencer, fuel injector pump, rocker arm and valve assembly and
cylinder head by unscrewing the respective nuts in both and studs. In the process of engine
disassembly do not separate the matching parts. For this purpose matching parts are marked.
New remove the crank case cover. Unscrew the nuts in the connecting rod and crank
shaft assembly. Then take out connecting rod and piston assembly. Now remove the counter
weight from the crank shaft by unscrewing the nuts.
Now take out the crank shaft by hammering it with a wooden block and mallet.
While dismantling crank shaft apply uniform force by hammering on crank shaft end. The
uniform force is achieved by rotating the crank shaft.
After the cam and crank mechanism is completely dismantled keep the bolts, washers
and other fasteners away in a special case or temporarily assemble the fasteners back into
their holes.
CLEANING AND INSPECTION:
Clean all the parts of engine and bearing with spindle oil or cleaning agents. Washed
parts are dried in the air or wiped dry with clean rags.
Inspect the washed and dried parts, group them and store separately. Then inspect
each part externally and then check for its shape and size.

-14-

ASSEMBLY:
The procedure for assembling the cam and crank mechanism is as follows.
Before assembling the crank shaft unit, all parts are thoroughly cleaned and
lubricated. First assemble crank shaft in the bearings by hammering it with a wooden block
and mallet. During this process rotate the crank shaft for proper sliding and seating. Then
assemble all the parts of the engine.
PRECAUTIONS:
1. No burrs, dents, scratches or scores are permitted.
2. Do not use lead or babbit hammers.
3. During the dismantling, note the thickness of packing paper and replace
the new same size of thickness packing during the cylinder head assembly.
4. After assembling the bearings and crank shaft in the crank case, rotate the
crank shaft so that it should rotate freely, smoothly without noticeably
play.
5. Before placing the crank shaft in position, check the counter sinking of the
holes which deliver the oil to the bearings.
TESTING:
1. Check the lubricating oil pump whether it is properly functioned or not
after assembling.
2. Rotate the crank shaft so that it should rotate freely, smoothly without
noticeable play.
*******

-15-

EX.NO.8.

CUTTING, FLARING, SWAGING & BINDING OF COPPER TUBING

AIM:
To become familiar with the operations like cutting of copper tube, flaring, swaging
and bending of copper tube.
TOOLS AND EQUIPMENTS REQUIRED:
Cutting tool, steel rule, flaring tool, benders, swaging tools, hammer, vice and flaring
block.
PROCEDURE:
i)

Mark the copper tubing to the required length.

ii)

Place the tubing against the rollers of the cutter.

iii)

Tighten the thumb screw until the cutting wheel just touches the copper
tubing.

iv)

Hold the tube in the left hand and revolve the cutter around the rubbing, so
that the cutting wheel makes uniform cut around the pipe.

v)

Turn the thumb screw to apply minimum pressure and again revolve the
cutting tool and repeat the above procedure until the tubing is completely cut
off.

vi)

Ream the edge of the tube. Hold the opening of the tube when reaming, so
that the metal will not fall into the tube.

PRECAUTION:
Do not apply too much pressure while cutting, which may lead to pinch off the tube.
FLARING OF COPPER TUBING:
i)

ii)
iii)
iv)
v)

Loosen the wing nut of the flaring block and insert he tubing into proper
diameter hole. Extend the tube to 3 mm to 5 mm from the block, and tighten
the wind nuts evenly in such a way that there is no slipping.
Attach the yoke over the block such that the cone at the centre of the tube.
Place a drop of oil on the cone and with a slow turning effect, screw the cone
firmly into the end of tubing.
When the flare is completed, unscrew the cone and remove the tubing from the
block.
Check the flare for defects. If defects are found cut off the flared edge and
repeat the above procedure until a perfect flare is
-16-

SWAGING OF COPPER TUBING:

Swage is to shape the copper tubing so that two pipes may be joined. This is done
with a punch type or screw type swaging. The tubing is clamped in a flaring block and the
larger diameter end of the swaging tool is hammered into the tubing.
BENDING OF COPPER TUBING USING WHEEL TYPE BENDERS:
a) Mark the place at which bending to be done.
b) Insert the tube into the bender wheel through the clamp in such a way that the bent
mark on the tube coincides with the zero mark on the wheel.
c) Holding tightly the bender by holding the central rod by left hand, with right hand
the tube is bend slowly by moving the other lever with constant pressure.
d) The minimum safe bending radius is usually the ten times of the dia of the tubing.
PRECAUTIONS:
Always bend the tube slowly.
***********