Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

MEA394 Mapping and Delivery Guide
Repair and/or overhaul aircraft piston engine crankcase assembly components

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency MEA394 - Repair and/or overhaul aircraft piston engine crankcase assembly components
Description
Employability Skills
Learning Outcomes and Application This unit of competency requires application of hand skills, theory knowledge and maintenance publication procedures to repair and overhaul aircraft piston engine crankcase assembly components.Applications include components from fixed and rotary wing aircraft piston engines. Work can be performed individually or as a member of a team.The unit is part of the Mechanical Certificate IV (Component Workshop Maintenance Stream) training pathway. The unit is used in workplaces that operate under the airworthiness regulatory systems of the Australian Defence Force (ADF) and the Civil Aviation Safety Authority (CASA).
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

Competency should be assessed in the work environment, or simulated work environment, using tools and equipment specified in maintenance documentation. It is also expected that general purpose tools and test equipment found in most routine situations would be used where appropriate

Knowledge of crankcase assembly operation and the relationship of individual components will be necessary to supplement evidence of ability to troubleshoot component faults before undertaking any action. The work plan should take account of applicable safety and quality requirements in accordance with the industry and regulatory standards.

The following conditions of assessment represent the requirements of the Regulators (ADF and CASA) and maintenance stakeholders and must be rigorously observed.

A person cannot be assessed as competent until it can be demonstrated to the satisfaction of the workplace assessor that the relevant elements of the unit of competency and the performance criteria are being achieved under routine supervision on at least one (1) item from each of the following groups:

crankshaft, gears, con rods and counterweights

camshaft, hydraulic tappets/cam followers and gears

propeller shaft, reduction drive gear and quill shaft

component gear drives/trains

crankcase castings, bearings, component mounting pads and studs

oil system components

supercharger and turbocharger components (may be omitted where not applicable to the enterprise)

propeller governor (may be omitted where not applicable to the enterprise)

This shall be established via the records in the Log of Industrial Experience and Achievement or, where appropriate, an equivalent Industry Evidence Guide (for details refer to the Companion Volume Assessment Guidelines).

Assessors must satisfy the requirements of the National Vocational Education and Training Regulator (Australian Skills Quality Authority, or its successors).
Prerequisites/co-requisites
Competency Field Aviation maintenance
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Determine requirements
  • Component defect reports (removal tags) or customer order are correctly interpreted and matched by part and serial numbers
  • Crankcase assembly components are inspected and/or operated through prescribed test procedures to establish serviceability and confirm defects, if necessary, while observing relevant work health and safety (WHS) procedures, including the use of material safety data sheets (MSDS) and personal protective equipment (PPE)
  • Modification status is clearly established to assist in determining the overhaul requirements for the components
  • Extent of overhaul or repair is identified and documented in accordance with standard enterprise procedures
       
Element: Dismantle and inspect piston engine crankcase assembly components/parts
  • Crankcase assembly component parts are dismantled in accordance with maintenance manual and/or enterprise procedures while observing relevant WHS procedures, including the use of MSDS and PPE
  • Component parts are assessed for serviceability in accordance with the relevant maintenance documentation
  • Parts requiring specialist repair are tagged and repair instructions are specified in accordance with standard enterprise procedures
  • Parts requiring non-destructive testing (NDT) are prepared for testing in accordance with the relevant maintenance documentation
  • Parts lists are compiled and processed in accordance with standard enterprise procedures
       
Element: Repair and/or modify piston engine crankcase assembly components or parts
  • Component parts are repaired or replaced in accordance with the relevant maintenance documentation
  • Modification of components is undertaken where required by reference to relevant manufacturer's bulletins or procedures, regulatory requirements and/or customer requirements while observing relevant WHS procedures, including the use of MSDS and PPE
       
Element: Assemble, test and adjust piston engine crankcase assembly components
  • Crankcase assembly component parts are assembled within specified tolerances and in accordance with the appropriate maintenance documents while observing relevant WHS procedures, including the use of MSDS and PPE
  • Components are tested, adjusted or calibrated to operate within prescribed specifications
  • Crankcase assembly is prepared for engine reassembly
  • Where components are not to be assembled into an engine the finished components are tagged, sealed and packaged in accordance with standard enterprise procedures
  • Required maintenance documentation and modification records are completed and processed in accordance with standard enterprise procedures
       


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 describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1.

Determine requirements

1.1

Component defect reports (removal tags) or customer order are correctly interpreted and matched by part and serial numbers

1.2

Crankcase assembly components are inspected and/or operated through prescribed test procedures to establish serviceability and confirm defects, if necessary, while observing relevant work health and safety (WHS) procedures, including the use of material safety data sheets (MSDS) and personal protective equipment (PPE)

1.3

Modification status is clearly established to assist in determining the overhaul requirements for the components

1.4

Extent of overhaul or repair is identified and documented in accordance with standard enterprise procedures

2.

Dismantle and inspect piston engine crankcase assembly components/parts

2.1

Crankcase assembly component parts are dismantled in accordance with maintenance manual and/or enterprise procedures while observing relevant WHS procedures, including the use of MSDS and PPE

2.2

Component parts are assessed for serviceability in accordance with the relevant maintenance documentation

2.3

Parts requiring specialist repair are tagged and repair instructions are specified in accordance with standard enterprise procedures

2.4

Parts requiring non-destructive testing (NDT) are prepared for testing in accordance with the relevant maintenance documentation

2.5

Parts lists are compiled and processed in accordance with standard enterprise procedures

3.

Repair and/or modify piston engine crankcase assembly components or parts

3.1

Component parts are repaired or replaced in accordance with the relevant maintenance documentation

3.2

Modification of components is undertaken where required by reference to relevant manufacturer's bulletins or procedures, regulatory requirements and/or customer requirements while observing relevant WHS procedures, including the use of MSDS and PPE

4.

Assemble, test and adjust piston engine crankcase assembly components

4.1

Crankcase assembly component parts are assembled within specified tolerances and in accordance with the appropriate maintenance documents while observing relevant WHS procedures, including the use of MSDS and PPE

4.2

Components are tested, adjusted or calibrated to operate within prescribed specifications

4.3

Crankcase assembly is prepared for engine reassembly

4.4

Where components are not to be assembled into an engine the finished components are tagged, sealed and packaged in accordance with standard enterprise procedures

4.5

Required maintenance documentation and modification records are completed and processed in accordance with standard enterprise procedures

Evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria under the specified conditions of assessment, and must include:

applying relevant WHS procedures, including the use of MSDS and PPE

using relevant maintenance documentation, specifications and aircraft/component manuals to:

recognise state of serviceability and overhaul or repair requirements for piston engine crankcase assembly components as listed in the Range of Conditions

dismantle and inspect crankcase assembly component parts for serviceability and identify repair requirements as applicable

repair/replace/modify crankcase component parts

assemble, test for correct operation and adjust crankcase assembly components

correctly tagging, sealing and packaging completed components.

Evidence of transferability of skills and knowledge related to repair is essential. This shall be demonstrated through application across a number of different piston engine crankcase assembly components. Ability to assess component serviceability and interpret parts requirements will be necessary to supplement the required evidence. Capability to interpret inspection procedures and specifications (allowable limits) and apply them in practice is critical. The application of testing procedures should also clearly indicate knowledge of crankcase assembly operation.

Evidence required to demonstrate competency in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria and include knowledge of:

how to obtain relevant MSDS

the use of applicable items of PPE

WHS procedures

component inspection and wear measurement procedures

non-destructive testing methods and application

component repair and overhaul procedures and processes.

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, 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 describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1.

Determine requirements

1.1

Component defect reports (removal tags) or customer order are correctly interpreted and matched by part and serial numbers

1.2

Crankcase assembly components are inspected and/or operated through prescribed test procedures to establish serviceability and confirm defects, if necessary, while observing relevant work health and safety (WHS) procedures, including the use of material safety data sheets (MSDS) and personal protective equipment (PPE)

1.3

Modification status is clearly established to assist in determining the overhaul requirements for the components

1.4

Extent of overhaul or repair is identified and documented in accordance with standard enterprise procedures

2.

Dismantle and inspect piston engine crankcase assembly components/parts

2.1

Crankcase assembly component parts are dismantled in accordance with maintenance manual and/or enterprise procedures while observing relevant WHS procedures, including the use of MSDS and PPE

2.2

Component parts are assessed for serviceability in accordance with the relevant maintenance documentation

2.3

Parts requiring specialist repair are tagged and repair instructions are specified in accordance with standard enterprise procedures

2.4

Parts requiring non-destructive testing (NDT) are prepared for testing in accordance with the relevant maintenance documentation

2.5

Parts lists are compiled and processed in accordance with standard enterprise procedures

3.

Repair and/or modify piston engine crankcase assembly components or parts

3.1

Component parts are repaired or replaced in accordance with the relevant maintenance documentation

3.2

Modification of components is undertaken where required by reference to relevant manufacturer's bulletins or procedures, regulatory requirements and/or customer requirements while observing relevant WHS procedures, including the use of MSDS and PPE

4.

Assemble, test and adjust piston engine crankcase assembly components

4.1

Crankcase assembly component parts are assembled within specified tolerances and in accordance with the appropriate maintenance documents while observing relevant WHS procedures, including the use of MSDS and PPE

4.2

Components are tested, adjusted or calibrated to operate within prescribed specifications

4.3

Crankcase assembly is prepared for engine reassembly

4.4

Where components are not to be assembled into an engine the finished components are tagged, sealed and packaged in accordance with standard enterprise procedures

4.5

Required maintenance documentation and modification records are completed and processed in accordance with standard enterprise procedures

This field allows for different 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.

Piston engine crankcase assembly components include:

Crankshaft, gears, con rods and counterweights

Camshaft, hydraulic tappets/cam followers and gears

Propeller shaft, reduction drive gear and quill shaft

Component gear drives/trains

Crankcase castings, bearings, component mounting pads and studs

Oil system components

Supercharger and turbocharger components (where applicable to the enterprise)

Propeller governor (where applicable to the enterprise)

Testing and adjustment:

Complex testing and adjusting of components, where required, will be carried out under supervision at the appropriate level

Procedures and requirements include:

Industry standard procedures specified by manufacturers, regulatory authorities or the enterprise

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
Component defect reports (removal tags) or customer order are correctly interpreted and matched by part and serial numbers 
Crankcase assembly components are inspected and/or operated through prescribed test procedures to establish serviceability and confirm defects, if necessary, while observing relevant work health and safety (WHS) procedures, including the use of material safety data sheets (MSDS) and personal protective equipment (PPE) 
Modification status is clearly established to assist in determining the overhaul requirements for the components 
Extent of overhaul or repair is identified and documented in accordance with standard enterprise procedures 
Crankcase assembly component parts are dismantled in accordance with maintenance manual and/or enterprise procedures while observing relevant WHS procedures, including the use of MSDS and PPE 
Component parts are assessed for serviceability in accordance with the relevant maintenance documentation 
Parts requiring specialist repair are tagged and repair instructions are specified in accordance with standard enterprise procedures 
Parts requiring non-destructive testing (NDT) are prepared for testing in accordance with the relevant maintenance documentation 
Parts lists are compiled and processed in accordance with standard enterprise procedures 
Component parts are repaired or replaced in accordance with the relevant maintenance documentation 
Modification of components is undertaken where required by reference to relevant manufacturer's bulletins or procedures, regulatory requirements and/or customer requirements while observing relevant WHS procedures, including the use of MSDS and PPE 
Crankcase assembly component parts are assembled within specified tolerances and in accordance with the appropriate maintenance documents while observing relevant WHS procedures, including the use of MSDS and PPE 
Components are tested, adjusted or calibrated to operate within prescribed specifications 
Crankcase assembly is prepared for engine reassembly 
Where components are not to be assembled into an engine the finished components are tagged, sealed and packaged in accordance with standard enterprise procedures 
Required maintenance documentation and modification records are completed and processed in accordance with standard enterprise procedures 

Forms

Assessment Cover Sheet

MEA394 - Repair and/or overhaul aircraft piston engine crankcase assembly components
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:

Assessment Record Sheet

MEA394 - Repair and/or overhaul aircraft piston engine crankcase assembly components

Student name:

Student ID:

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

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: