ITI/NCVT Mechanic Machine Tool Maintenance (AITT Theory) study plan

List the hazards and matching controls for lathe, drilling, grinding, welding and manual lifting tasks, naming the specific guard, PPE item or procedure that removes each risk.

Set up and use a bench vice, hacksaw, files, taps and dies on a scrap plate, then diagnose three typical failures (broken tap, stripped thread, crooked cut) back to the wrong tool or wrong technique.

Take ten repeat readings of one workpiece with a 0.02 mm vernier caliper, a 0.01 mm outside micrometer and a 0.01 mm dial indicator, and record the spread of each instrument.

Calculate least count and reading for vernier (0.02 mm), micrometer (0.01 mm) and dial gauge scales, and convert five readings between millimetre and inch to three decimal places.

Apply lockout/tagout, correct fire-extinguisher class selection and coolant/oil waste segregation to a written shop-floor scenario, stating the isolation point and disposal route for each.

Scrape a flat cast-iron surface using a surface plate and marking compound until a 25 mm square grid shows at least 8 bearing spots, counting spots with a template and recording the map.

Compute offset and angular misalignment from rim-and-face dial indicator readings on a shaft coupling, then calculate the shim thickness and foot correction needed at each support.

Select fits from a hole-basis chart (H7/k6, H7/p6, H7/g6) for a keyed joint, a press-fit bearing and a sliding guide, and state the assembly method: press, induction heat or freeze.

Drill, tap and hand-ream a scrap plate: choose the tap drill for M10 x 1.5 (8.5 mm), cut the thread, then remove a broken stud with an extractor without damaging the parent thread.

Check squareness, flatness and mating gap of an assembled bracket with a dial indicator, try square and feeler gauge, and record the deviation against a stated tolerance.

Identify spur, helical, bevel and worm gears from a sample set, and compute velocity ratio, module, pitch-circle diameter and centre distance for a two-stage reduction.

Calculate driven speed and belt length for a V-belt drive, then classify slip, overload and pulley misalignment from three described wear patterns.

Select a deep-groove ball bearing for a stated radial load and speed using L10 = (C/P)^3 x 10^6 revolutions, and convert the result into service hours.

Match bearing type to load direction (deep groove, angular contact, cylindrical roller, spherical roller, thrust) and specify the shaft and housing fits, internal clearance and mounting method for each.

Choose an ISO VG viscosity grade and NLGI grease class for given speed and temperature conditions, and explain boundary, mixed and hydrodynamic lubrication with one failure cause for each regime.

Level a machine bed with a precision spirit level in a defined sequence, correcting twist first and then bed straightness, recording readings at six stations along the guideways.

Differentiate installation levelling from geometric accuracy testing, and demonstrate checks for spindle runout, squareness of column to table and parallelism of guideways.

Measure spindle taper runout and face runout with a dial indicator on a test mandrel and compare the results with typical acceptance values such as 0.01 mm over 300 mm.

Diagnose how poor levelling, weak grouting and vibration transmission cause taper, chatter and premature guideway wear, and specify the corrective action for each symptom.

Plan an installation sequence covering foundation and base plate grouting, cure time, re-levelling after cure, alignment of driven equipment and handover documentation.

Compare preventive, predictive, corrective and reliability-centred maintenance strategies and choose a realistic inspection interval using MTBF and MTTR figures for a given machine.

Build a cause-and-effect matrix for three symptoms (high vibration, overheating, taper or oversize on a turned part) and list the checks that confirm or eliminate each suspected root cause.

Interpret vibration severity against ISO 20816 zones and identify unbalance, misalignment, looseness and bearing defect frequencies (BPFO, BPFI, FTF) from described spectral peaks.

Read an oil analysis report and an ISO 4406 cleanliness code, and explain what water content, viscosity change and ferrous wear debris indicate about a gearbox.

Carry out basic electrical checks with a multimeter on an isolated motor starter: continuity, insulation resistance, three-phase voltage and current balance, contactor coil resistance and proximity sensor output.

Trace a hydraulic circuit diagram and diagnose no pressure, slow or erratic movement, overheating and cylinder creep using pressure and flow test results.

Assemble and test a simple hydraulic circuit with relief valve, directional control valve, flow control and double-acting cylinder, then set the relief pressure and check for internal leakage.

Service a pneumatic FRL unit, 5/2 directional valve and cylinder, and identify moisture carry-over, oil contamination and seal failure from described symptoms.

Calculate cylinder force, oil flow and piston speed (F = p x A, Q = A x v), and size a cylinder and pump flow for a stated load and cycle time.

Apply a 5-why and fishbone analysis to one real breakdown and convert the outcome into corrective and preventive actions with an owner and a due date.

Specify material and heat treatment for a spindle, a gear, a guideway, a bearing housing and a chuck jaw, stating the treatment route and a typical hardness range for each.

Read tensile, hardness and torque data, and solve shaft torque and stress, taper angle, cutting speed and feed calculations, showing units at every step.

Read an assembly drawing to identify components, fits, datums and tolerance stack-up, and extract a bill of materials with part numbers and quantities.

Interpret flatness, parallelism, perpendicularity and runout symbols on a drawing and state the inspection instrument and method used to verify each one.

Convert drawing scale to actual dimensions, apply machining allowances, and interpret section and detail views to determine hidden features and assembly order.

Practise workplace scenarios on 5S, teamwork, conflict handling, communication and statutory worker welfare, and answer employability-style questions in writing.

Sit two full-length timed mock papers under exam conditions and log every incorrect answer with the reason it was wrong and the correct reference idea.

Re-work all items on the personal weak list drawn from earlier milestone scores until each is answered correctly without notes.

Compress the syllabus into a one-page formula and specification sheet covering fits, bearing life, hydraulics, levelling tolerances and heat-treatment hardness ranges.