Assessor Resource

AURTTM007
Carry out crankshaft grinding

Assessment tool

Version 1.0
Issue Date: May 2024


This unit describes the performance outcomes required to carry out grinding operations on engine crankshafts to specific under sizes. It involves preparing for the task, determining crankshaft damage and required repair action, preparing and using grinding machines to grind crankshafts to specifications, tolerances and workplace requirements, and completing workplace processes and documentation.

It applies to those working in the automotive service and repair industry. The crankshafts include those in vehicles from all sectors of the industry.

No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)


Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

Elements

Elements describe the essential outcomes.

Performance Criteria

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section.

1. Prepare to grind crankshaft

1.1 Job requirements are determined from workplace instructions

1.2 Crankshaft is cleaned and inspected and condition reported

1.3 Information is sourced, procedures and methods are analysed, and appropriate crankshaft grinding machine and equipment are selected for the crankshaft

1.4 Hazards associated with the work are identified and risks are managed

1.5 Tools and measuring equipment are selected and checked for serviceability

1.6 Crankshaft grinding wheel is prepared according to machine manufacturer specifications and tolerances, and workplace procedures

1.7 Crankshaft is measured to determine under size and tolerances, including journal diameters and sizes of grind

1.8 Crankshaft is positioned in grinder in correct direction of rotation, and clamped according to manufacturer specifications and workplace procedures

2. Grind crankshaft big end bearing journals

2.1 Chuck offsets are set according to the stroke of crankshaft

2.2 Crankshaft grinder wheel head position is set according to machine manufacturer procedures

2.3 Constant measuring gauge and steady rest are positioned on big end journal taking into account position of oil hole

2.4 Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements, and following machinery safe operating procedures

2.5 Crankshaft is measured to ensure compliance with specifications and tolerances

2.6 Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures

3. Grind crankshaft main bearing journals

3.1 Crankshaft is removed from grinder

3.2 Chucks are centralised for main bearings and counterweights are adjusted

3.3 Crankshaft is refitted to grinder in correct direction of rotation, and is clamped according to manufacturer specifications and workplace procedures

3.4 Datum is set in relation to crankshaft rear flange and nose

3.5 Crankshaft grinder wheel head movement is set according to manufacturer procedures

3.6 Constant measuring gauge and steady rest are positioned on main bearing journal taking into account position of oil hole

3.7 Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements, and following machinery safe operating procedures

3.8 Crankshaft is inspected to ensure compliance with specifications and tolerances

3.9 Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures

4. Finish crankshaft grinding

4.1 Oil holes are chamfered and dressed

4.2 Journals are linished with correct grade of belt and in right direction of rotation and required finish

4.3 Flange ends and seal areas are faced

4.4 Crankshaft is examined and measured according to manufacturer specifications and tolerances, and workplace procedures

4.5 Crankshaft is cleaned according to workplace procedures

4.6 Bright surfaces are treated with rust prevention solution and crankshaft is prepared for further process or storage according to workplace procedures

5. Complete work processes

5.1 Final inspection is made to ensure finished work complies with workplace requirements and crankshaft is presented ready for use or storage

5.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

5.3 Tools and equipment are checked and stored according to workplace procedures

5.4 Workplace documentation is processed according to workplace procedures

Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:

grind one crankshaft of an in-line petrol engine with at least four cylinders.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to grinding crankshafts, including procedures for:

selecting and using personal protective equipment (PPE) for using grinding machines and chemical cleaning and lubricating agents

identifying hazards associated with rotating grinding machines

manual handling techniques relating to grinding crankshafts

types, characteristics and limitations of crankshaft grinding machines, including:

hand-held machines for oil hole dressing

types and grades of grinding wheels, including grit grades

dismantling procedures for crankshafts, including:

numbering and removing counterweights

drive gears

oil seal sleeves and dowels

cleaning and inspection procedures, including:

chemically cleaning crankshafts, including methods of avoiding damage to nitride and Tufftride crankshafts

identifying crankshaft material

identifying heat treatment process, including nitriding, Tufftriding and induction hardening

identifying radius treatment, including deep fillet rolling, radius rolling and shot peening

checking alignment of crankshaft in V blocks

measuring journals against specifications and identifying damaged journals

testing procedures for crankshaft, including:

crack testing coil shot and end shot

testing hardness of journals

procedures for preparing crankshaft grinding wheel, including:

wheel preparation, including selecting wheel to suit radius and journal width of crankshaft

dressing procedures for wheel, including:

types of diamonds for front and radius dressing

procedures for dressing wheel to suit crankshaft radius

procedures for dressing front of wheel

procedures for big end grinding, including:

setting crankshaft rotation speed according to crankshaft material and big end diameter

setting crankshaft grinder wheel head position

setting chuck offsets for big end bearings and adjusting counterweights to suit

fitting crankshaft in correct direction of rotation and ensuring that critical surfaces are not damaged by the chuck

measuring journal diameters during grinding with constant measuring gauge

procedures for adjusting crankshaft grinder to suit main bearing journal grinding, including:

removing crankshaft from grinder

fitting crankshaft in correct direction of rotation

setting datum in relation to rear flange and nose for main bearing grinding

procedures for main bearing journal grinding, including:

setting crankshaft rotation speed according to crankshaft material and journal size

setting crankshaft grinder wheel head position

measuring journal diameters during grinding with constant measuring gauge

procedures for finishing journal grinding, including:

chamfering and dressing oil holes

linishing journals according to grade of belt, required finish, and rotational direction

setting up and facing flange ends and seal areas

final grinding inspections of crankshaft, including:

journal surface finish

taper, ovality, barrelling, and hourglass

grinding chatter

burning of radius and journals

methods of correcting faults

procedures for removing crankshaft from grinder and checking crankshaft for straightness in V blocks using dial indicator

requirements of Australian standards relating to engine reconditioning, including:

AS 4182 Automotive repairs – Code of practice for reconditioning reciprocating spark ignition engines

AS 4427 Automotive repairs – Code of practice for reconditioning reciprocating compression ignition engines

post-grinding operations, including rust protection of machined surfaces.

Assessors must satisfy NVR/AQTF assessor requirements.

Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.

Assessment must include direct observation of tasks.

Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the crankshaft grinding that they have carried out, e.g. repair orders.

Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.

The following resources must be made available:

automotive repair workplace or simulated workplace

workplace instructions

manufacturer crankshaft specifications

AS 4182 Automotive repairs – Code of practice for reconditioning reciprocating spark ignition engines

AS 4427 Automotive repairs – Code of practice for reconditioning reciprocating compression ignition engines

crankshaft from an in-line petrol engine with at least four cylinders requiring grinding

engine crankshaft grinding machine

precision measuring equipment, including:

dial indicators

inside and outside metric and imperial micrometers.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)

Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

Elements

Elements describe the essential outcomes.

Performance Criteria

Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section.

1. Prepare to grind crankshaft

1.1 Job requirements are determined from workplace instructions

1.2 Crankshaft is cleaned and inspected and condition reported

1.3 Information is sourced, procedures and methods are analysed, and appropriate crankshaft grinding machine and equipment are selected for the crankshaft

1.4 Hazards associated with the work are identified and risks are managed

1.5 Tools and measuring equipment are selected and checked for serviceability

1.6 Crankshaft grinding wheel is prepared according to machine manufacturer specifications and tolerances, and workplace procedures

1.7 Crankshaft is measured to determine under size and tolerances, including journal diameters and sizes of grind

1.8 Crankshaft is positioned in grinder in correct direction of rotation, and clamped according to manufacturer specifications and workplace procedures

2. Grind crankshaft big end bearing journals

2.1 Chuck offsets are set according to the stroke of crankshaft

2.2 Crankshaft grinder wheel head position is set according to machine manufacturer procedures

2.3 Constant measuring gauge and steady rest are positioned on big end journal taking into account position of oil hole

2.4 Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements, and following machinery safe operating procedures

2.5 Crankshaft is measured to ensure compliance with specifications and tolerances

2.6 Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures

3. Grind crankshaft main bearing journals

3.1 Crankshaft is removed from grinder

3.2 Chucks are centralised for main bearings and counterweights are adjusted

3.3 Crankshaft is refitted to grinder in correct direction of rotation, and is clamped according to manufacturer specifications and workplace procedures

3.4 Datum is set in relation to crankshaft rear flange and nose

3.5 Crankshaft grinder wheel head movement is set according to manufacturer procedures

3.6 Constant measuring gauge and steady rest are positioned on main bearing journal taking into account position of oil hole

3.7 Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements, and following machinery safe operating procedures

3.8 Crankshaft is inspected to ensure compliance with specifications and tolerances

3.9 Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures

4. Finish crankshaft grinding

4.1 Oil holes are chamfered and dressed

4.2 Journals are linished with correct grade of belt and in right direction of rotation and required finish

4.3 Flange ends and seal areas are faced

4.4 Crankshaft is examined and measured according to manufacturer specifications and tolerances, and workplace procedures

4.5 Crankshaft is cleaned according to workplace procedures

4.6 Bright surfaces are treated with rust prevention solution and crankshaft is prepared for further process or storage according to workplace procedures

5. Complete work processes

5.1 Final inspection is made to ensure finished work complies with workplace requirements and crankshaft is presented ready for use or storage

5.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected

5.3 Tools and equipment are checked and stored according to workplace procedures

5.4 Workplace documentation is processed according to workplace procedures

This section specifies work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. Bold italicised wording, if used in the performance criteria, is detailed below.

Cleaning and inspecting crankshaft must include:

following procedures for chemically cleaning nitride and Tufftride crankshafts

inspecting crankshaft, including:

coil shot

end shot

hardness

alignment

bend

thread condition

key way condition

seal running surfaces condition

rear flange condition

nose gear condition.

Preparation must include:

selecting wheel to suit radius and journal width

procedures for dressing wheel.

Safety requirementsmust include:

work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for:

selecting and using personal protective equipment (PPE) for using grinding machines and chemical cleaning and lubricating agents

identifying hazards associated with rotating grinding machines

manual handling techniques relating to grinding crankshafts.

Examining and measuring crankshaft must include:

checking journals for:

acceptable surface finish

taper

ovality

barrelling

hourglass

grinding chatter and journal burning

checking crankshaft for straightness in V blocks using a dial indicator.

Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:

grind one crankshaft of an in-line petrol engine with at least four cylinders.

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to grinding crankshafts, including procedures for:

selecting and using personal protective equipment (PPE) for using grinding machines and chemical cleaning and lubricating agents

identifying hazards associated with rotating grinding machines

manual handling techniques relating to grinding crankshafts

types, characteristics and limitations of crankshaft grinding machines, including:

hand-held machines for oil hole dressing

types and grades of grinding wheels, including grit grades

dismantling procedures for crankshafts, including:

numbering and removing counterweights

drive gears

oil seal sleeves and dowels

cleaning and inspection procedures, including:

chemically cleaning crankshafts, including methods of avoiding damage to nitride and Tufftride crankshafts

identifying crankshaft material

identifying heat treatment process, including nitriding, Tufftriding and induction hardening

identifying radius treatment, including deep fillet rolling, radius rolling and shot peening

checking alignment of crankshaft in V blocks

measuring journals against specifications and identifying damaged journals

testing procedures for crankshaft, including:

crack testing coil shot and end shot

testing hardness of journals

procedures for preparing crankshaft grinding wheel, including:

wheel preparation, including selecting wheel to suit radius and journal width of crankshaft

dressing procedures for wheel, including:

types of diamonds for front and radius dressing

procedures for dressing wheel to suit crankshaft radius

procedures for dressing front of wheel

procedures for big end grinding, including:

setting crankshaft rotation speed according to crankshaft material and big end diameter

setting crankshaft grinder wheel head position

setting chuck offsets for big end bearings and adjusting counterweights to suit

fitting crankshaft in correct direction of rotation and ensuring that critical surfaces are not damaged by the chuck

measuring journal diameters during grinding with constant measuring gauge

procedures for adjusting crankshaft grinder to suit main bearing journal grinding, including:

removing crankshaft from grinder

fitting crankshaft in correct direction of rotation

setting datum in relation to rear flange and nose for main bearing grinding

procedures for main bearing journal grinding, including:

setting crankshaft rotation speed according to crankshaft material and journal size

setting crankshaft grinder wheel head position

measuring journal diameters during grinding with constant measuring gauge

procedures for finishing journal grinding, including:

chamfering and dressing oil holes

linishing journals according to grade of belt, required finish, and rotational direction

setting up and facing flange ends and seal areas

final grinding inspections of crankshaft, including:

journal surface finish

taper, ovality, barrelling, and hourglass

grinding chatter

burning of radius and journals

methods of correcting faults

procedures for removing crankshaft from grinder and checking crankshaft for straightness in V blocks using dial indicator

requirements of Australian standards relating to engine reconditioning, including:

AS 4182 Automotive repairs – Code of practice for reconditioning reciprocating spark ignition engines

AS 4427 Automotive repairs – Code of practice for reconditioning reciprocating compression ignition engines

post-grinding operations, including rust protection of machined surfaces.

Assessors must satisfy NVR/AQTF assessor requirements.

Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.

Assessment must include direct observation of tasks.

Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the crankshaft grinding that they have carried out, e.g. repair orders.

Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.

The following resources must be made available:

automotive repair workplace or simulated workplace

workplace instructions

manufacturer crankshaft specifications

AS 4182 Automotive repairs – Code of practice for reconditioning reciprocating spark ignition engines

AS 4427 Automotive repairs – Code of practice for reconditioning reciprocating compression ignition engines

crankshaft from an in-line petrol engine with at least four cylinders requiring grinding

engine crankshaft grinding machine

precision measuring equipment, including:

dial indicators

inside and outside metric and imperial micrometers.
Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Job requirements are determined from workplace instructions 
Crankshaft is cleaned and inspected and condition reported 
Information is sourced, procedures and methods are analysed, and appropriate crankshaft grinding machine and equipment are selected for the crankshaft 
Hazards associated with the work are identified and risks are managed 
Tools and measuring equipment are selected and checked for serviceability 
Crankshaft grinding wheel is prepared according to machine manufacturer specifications and tolerances, and workplace procedures 
Crankshaft is measured to determine under size and tolerances, including journal diameters and sizes of grind 
Crankshaft is positioned in grinder in correct direction of rotation, and clamped according to manufacturer specifications and workplace procedures 
Chuck offsets are set according to the stroke of crankshaft 
Crankshaft grinder wheel head position is set according to machine manufacturer procedures 
Constant measuring gauge and steady rest are positioned on big end journal taking into account position of oil hole 
Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements, and following machinery safe operating procedures 
Crankshaft is measured to ensure compliance with specifications and tolerances 
Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures 
Crankshaft is removed from grinder 
Chucks are centralised for main bearings and counterweights are adjusted 
Crankshaft is refitted to grinder in correct direction of rotation, and is clamped according to manufacturer specifications and workplace procedures 
Datum is set in relation to crankshaft rear flange and nose 
Crankshaft grinder wheel head movement is set according to manufacturer procedures 
Constant measuring gauge and steady rest are positioned on main bearing journal taking into account position of oil hole 
Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements, and following machinery safe operating procedures 
Crankshaft is inspected to ensure compliance with specifications and tolerances 
Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures 
Oil holes are chamfered and dressed 
Journals are linished with correct grade of belt and in right direction of rotation and required finish 
Flange ends and seal areas are faced 
Crankshaft is examined and measured according to manufacturer specifications and tolerances, and workplace procedures 
Crankshaft is cleaned according to workplace procedures 
Bright surfaces are treated with rust prevention solution and crankshaft is prepared for further process or storage according to workplace procedures 
Final inspection is made to ensure finished work complies with workplace requirements and crankshaft is presented ready for use or storage 
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 
Tools and equipment are checked and stored according to workplace procedures 
Workplace documentation is processed according to workplace procedures 
Job requirements are determined from workplace instructions 
Crankshaft is cleaned and inspected and condition reported 
Information is sourced, procedures and methods are analysed, and appropriate crankshaft grinding machine and equipment are selected for the crankshaft 
Hazards associated with the work are identified and risks are managed 
Tools and measuring equipment are selected and checked for serviceability 
Crankshaft grinding wheel is prepared according to machine manufacturer specifications and tolerances, and workplace procedures 
Crankshaft is measured to determine under size and tolerances, including journal diameters and sizes of grind 
Crankshaft is positioned in grinder in correct direction of rotation, and clamped according to manufacturer specifications and workplace procedures 
Chuck offsets are set according to the stroke of crankshaft 
Crankshaft grinder wheel head position is set according to machine manufacturer procedures 
Constant measuring gauge and steady rest are positioned on big end journal taking into account position of oil hole 
Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements, and following machinery safe operating procedures 
Crankshaft is measured to ensure compliance with specifications and tolerances 
Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures 
Crankshaft is removed from grinder 
Chucks are centralised for main bearings and counterweights are adjusted 
Crankshaft is refitted to grinder in correct direction of rotation, and is clamped according to manufacturer specifications and workplace procedures 
Datum is set in relation to crankshaft rear flange and nose 
Crankshaft grinder wheel head movement is set according to manufacturer procedures 
Constant measuring gauge and steady rest are positioned on main bearing journal taking into account position of oil hole 
Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements, and following machinery safe operating procedures 
Crankshaft is inspected to ensure compliance with specifications and tolerances 
Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures 
Oil holes are chamfered and dressed 
Journals are linished with correct grade of belt and in right direction of rotation and required finish 
Flange ends and seal areas are faced 
Crankshaft is examined and measured according to manufacturer specifications and tolerances, and workplace procedures 
Crankshaft is cleaned according to workplace procedures 
Bright surfaces are treated with rust prevention solution and crankshaft is prepared for further process or storage according to workplace procedures 
Final inspection is made to ensure finished work complies with workplace requirements and crankshaft is presented ready for use or storage 
Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 
Tools and equipment are checked and stored according to workplace procedures 
Workplace documentation is processed according to workplace procedures 

Forms

Assessment Cover Sheet

AURTTM007 - Carry out crankshaft grinding
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Assessment Record Sheet

AURTTM007 - Carry out crankshaft grinding

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Assessment task 1: [title] Result: Competent Not yet competent

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