Required skills

technical skills to

sharpen and shape cutting tools

identify worn and damaged cutting tools

mount and position cutting tools

set machining parameters to achieve job requirements and maximise tool life

use appropriate and sufficient clampingmounting of the work piece

use coolant and lubricant correctly

check for conformance to specifications

measure to specified tolerances and dimensions

communication skills to

follow oral instructions

report deviations from specifications

interact with customers and team members

literacy skills to

read and interpret routine job instructions specifications drawings and standard operating procedures

understand quality procedures

numeracy skills to use mathematical ideas and techniques to

calculate time

assess tolerances

apply accurate measurements

calculate material requirements

establish quality checks

problemsolving skills to

identify and avoid planning and scheduling problems

prevent time and material wastage

organise work and plan processes

selfmanagement skills to

select and use appropriate equipment materials processes and procedures

follow workplace documentation such as codes of practice and operating procedures

technology skills to use communication devices and computerised equipment to

search and gather supporting material

take locate download and view digital images

Required knowledge

WHS regulations and requirements equipment material and personal safety requirements including

correct personal protective equipment PPE for handling engine blocks using lineboring and honing machines and using chemical cleaning and lubricating agents

hazards associated with rotating lineboring and honing tools

types characteristics and limitations of lineboring and honing machines including

types and grades of boring tools

types and grades of honing stones

tool sharpening and dressing methods including

maintaining sharpness of tools throughout boring operations

dressing procedures of stones

line boring methods and procedures including

setting engine block or cylinder head into line boring machine and aligning to the centre line of the boring bar

setting the line boring tool to the correct diameter and locking the boring tool

welding and relocating main bearing caps

machining top and bottom of bearing caps

preparing line borer to accept engine block or cylinder head

machining parting faces of the cylinder head camshaft bearing

line boring cylinder head camshaft tunnels

line boring damaged tunnels to oversize to accept sleeving operation

machining parting faces of the cylinder block

line boring cylinder block tunnels to accept oversized back bearings

line boring tunnels to leave a honing allowance

line boring rear main bearing areas and thrustbearing diameters to original size

machining and squaring thrust faces in engine blocks

line boring semifinished camshaft bearings

linehoning methods and procedures including

procedures for setting the diameter of the honing stone

rotational and oscillating speeds of honing bar

connecting rod repair methods and procedures including

removing rod eye bush and measuring rod eye bore

checking alignment of connecting rod and straightening the connecting rod

boring rod eye for oversized bush

removing cap bolts and nuts and machining parting faces on connecting rod and bigend cap

resizing bigend for standard and oversize back bearings

fitting new littleend bushes and pin boring littleends

types and application of cleaning and lubricating agents

Australian standards relevant to engine reconditioning

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria required skills and knowledge range statement and the Assessment Guidelines for the Training Package

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The evidence required to demonstrate competency in this unit must be relevant to workplace operations and satisfy all of the requirements of the performance criteria and required skills and knowledge

A person who demonstrates competency in this unit must be able to

observe safety procedures and requirements

select methods and techniques for repairing bearing tunnels and connecting rods appropriate to the circumstances

complete preparatory activity in a systematic manner

line bore and hone a range of multicylinder engines according to workplace manufacturer and component supplier requirements

repair a range of connecting rods according to workplace manufacturer and component supplier requirements

complete work without damage to tools and equipment or injury to persons

Context of and specific resources for assessment

Competency is to be assessed in the workplace or a simulated workplace environment that accurately reflects performance in a real workplace setting Performance is demonstrated consistently over a period of time and in a suitable range of contexts

Assessment is to occur

using standard workplace practices and procedures

following safety requirements

applying environmental constraints

Assessment is to comply with relevant

regulatory requirements

Australian standards

industry codes of practice

The following resources must be made available for the assessment of this unit

appropriate worksite

multicylinder engine blocks and cylinder heads appropriate to the workplace including inline multicylinder engine blocks veeconfiguration multicylinder engine blocks and overhead camshaft cylinder heads

fixed and portable hand and power tools and equipment appropriate to line boring and honing engine blocks and cylinder heads

specifications and work instructions

Method of assessment

Assessment must satisfy the endorsed Assessment Guidelines of this Training Package

Assessment methods must confirm consistency and accuracy of performance over time and in a range of workplace relevant contexts together with application of required skills and knowledge

Assessment methods must be by direct observation of tasks and include questioning on required skills and knowledge to ensure its correct interpretation and application

Assessment must confirm that competency is able not only to be satisfied under the particular circumstance but is able to be transferred to other circumstances

Competence in this unit may be assessed in conjunction with other units which together form part of a holistic work role

Where applicable reasonable adjustment must be made to work environments and training situations to accommodate ethnicity age gender demographics and disability

Assessment processes and techniques must be culturally sensitive and appropriate to the language and literacy capacity of the candidate and the work being performed

Workplace instructions may include:

Information may include:

Appropriate tooling options may include:

Tooling and measuring equipment may include:

WHS requirements may include:

Environmental requirements include:

Measured and calibrationmay include:

Engine block or cylinder head is prepared may include:

Line-boring machine is prepared must include:

Set and locked will include:

Speeds and feed rates will include:

Honing allowances will include: