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Elements and Performance Criteria

1. Prepare to dismantle air conditioning compressor
   • Job requirements are determined from workplace instructions
   • Australian automotive code of practice: Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners is sourced and interpreted
   • Dismantling information is sourced and interpreted
   • Dismantling options are analysed and those most appropriate to the circumstances are selected
   • Hazards associated with the work are identified and risks are managed
   • Dismantling tools and equipment are selected and checked for serviceability
2. Dismantle and evaluate compressor and components
   • Compressor is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements,and without causing unnecessary damage to components or systems
   • Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
   • Components are measured and compared with manufacturer specifications and serviceability is determined
   • Component repair method is determined
   • Unserviceable parts are identified and replacement parts sourced
3. Carry out overhaul
   • Overhaul information is sourced and interpreted
   • Overhaul options are analysed and those most appropriate to the circumstances are selected
   • Overhaul tools and equipment are selected and checked for serviceability
   • Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, safety and environmental requirements, and Australian automotive code of practice
4. Assemble compressor and components
   • Compressor is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
   • Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
   • Assembly of compressor is completed within workplace timeframes and without causing damage to other components or systems
   • Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
5. Complete work processes
   • Final inspection is made to ensure work is to workplace expectations and compressor 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, and any faulty electrical equipment is identified, tagged and isolated according to workplace procedures
   • Workplace documentation is processed according to workplace procedures
6. Prepare to dismantle air conditioning compressor
   • Job requirements are determined from workplace instructions
   • Australian automotive code of practice: Control of refrigerant gases during manufacture, installation, servicing or de-commissioning of motor vehicle air conditioners is sourced and interpreted
   • Dismantling information is sourced and interpreted
   • Dismantling options are analysed and those most appropriate to the circumstances are selected
   • Hazards associated with the work are identified and risks are managed
   • Dismantling tools and equipment are selected and checked for serviceability
7. Dismantle and evaluate compressor and components
   • Compressor is dismantled in a logical sequence according to manufacturer and workplace procedures, and safety and environmental requirements,and without causing unnecessary damage to components or systems
   • Components are cleaned for evaluation according to workplace procedures and safety and environmental requirements
   • Components are measured and compared with manufacturer specifications and serviceability is determined
   • Component repair method is determined
   • Unserviceable parts are identified and replacement parts sourced
8. Carry out overhaul
   • Overhaul information is sourced and interpreted
   • Overhaul options are analysed and those most appropriate to the circumstances are selected
   • Overhaul tools and equipment are selected and checked for serviceability
   • Components are machined, repaired and replaced as required, and adjustments are carried out according to manufacturer specifications, workplace procedures, safety and environmental requirements, and Australian automotive code of practice
9. Assemble compressor and components
   • Compressor is assembled according to manufacturer specifications, workplace procedures, and safety and environmental requirements
   • Tolerances and clearances are measured against manufacturer specifications and necessary adjustments are made
   • Assembly of compressor is completed within workplace timeframes and without causing damage to other components or systems
   • Post-assembly testing is carried out according to workplace procedures and safety and environmental requirements, and any problems detected as having been introduced during the assembly process are rectified
10. Complete work processes
    • Final inspection is made to ensure work is to workplace expectations and compressor 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, and any faulty electrical equipment is identified, tagged and isolated according to workplace procedures
    • Workplace documentation is processed according to workplace procedures

Range Statement

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.

Safety and environmental requirements must include:

work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for: working with refrigerants at boiling point given risk of frostbite working with system lubricants, including carcinogenic oils handling flammable refrigerants using personal protective equipment (PPE) identifying fire safety equipment environmental requirements, including procedures for preventing loss of refrigerant to the atmosphere.

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Performance Evidence

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:

overhaul the air conditioning compressors of two different vehicles or machinery, including:

piston, scroll and rotary vane compressors

electric compressors

variable displacement compressors

clutchless compressors

recover and evacuate refrigerants according to required code of practice and regulations, and recharge the system with the appropriate manufacturer refrigerant and oil type.

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Knowledge Evidence

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to overhauling air conditioning and heating, ventilation and air conditioning (HVAC) system components, including procedures for:

working with refrigerants at boiling point given risk of frostbite

working with system lubricants, including carcinogenic oils

handling flammable refrigerants

using personal protective equipment (PPE)

identifying and using fire safety equipment

environmental requirements, including procedures for preventing loss of refrigerant to the atmosphere

techniques for reading and interpreting technical information, including:

refrigerant saturation temperatures in relation to ambient temperatures and changing levels of humidity

graphic symbols and diagrams

principal types of vehicle air conditioning and HVAC systems, including:

piston, scroll and rotary vane compressors

electric compressors

variable displacement compressors

clutchless compressors

principal refrigerant types and their respective operating pressures and lubricating oils, including:

R12

R134a

R1234yf

air conditioning and HVAC system component overhaul procedures, including:

methods for cleaning and preparing air conditioning and HVAC system compressor for overhaul

air conditioning and HVAC system compressor dismantling procedures

air conditioning and HVAC system compressor inspection, measuring and evaluation procedures, including methods for measuring and calculating tolerances and clearances

air conditioning and HVAC compressor repair and adjustment procedures, including:

piston, scroll and rotary vane compressors

electric compressors

variable displacement compressors

clutchless compressors

procedures for tolerance measuring and calculating and adjusting components

post-overhaul bench testing procedures, including:

use of manifold gauges and surface probe thermocouples for complete system analysis

analysis of system operation while using gauges, temperature probes, electrical test equipment, scan tools, oscilloscopes and other industry-relevant test equipment

post-overhaul testing of air conditioning and HVAC systems in vehicle or machinery, including:

diagnostic procedures for air conditioning and HVAC systems, including:

accessing and interpreting diagnostic trouble codes (DTCs)

diagnostic flow charts

visual, aural and functional assessments

ambient temperature

centre vent temperature

condenser and suction line temperature

manifold gauge pressure readings

refrigerant leaks.

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