Work applies to the removal and installation of engine assemblies of heavy vehicles in the road transport, mining, construction, agricultural and marine environments.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare to remove heavy vehicle engine assemblies

1.1. Workplace instructions are used to determine job requirements relating to removing heavy vehicle engine assemblies

1.2. Workplace health and safety (WHS) requirements are observed and applied throughout the work

1.3. Procedures and information are sourced and interpreted

1.4. Removal options are analysed and those most appropriate to the circumstances are selected

1.5. Warnings in relation to working with lifting and jacking equipment are observed

2. Carry out the removal of heavy vehicle engine assemblies

2.1. Engine assembly is removed according to workplace procedures and manufacturer and component supplier specifications and without causing damage to components or systems

2.2. Observations are noted and documented during the removal of engine assembly

3. Install heavy vehicle engine assemblies

3.1. Installation options are analysed and those most appropriate to the circumstances are selected

3.2. Appropriate tools and equipment are selected and prepared

3.3. Engine assembly is installed according to workplace procedures and manufacturer and component supplier specifications and without causing damage to components or systems

4. Carry out post-installation tests and adjustments

4.1. Post-installation adjustments are carried out according to workplace procedures and manufacturer and component supplier specifications

4.2. Post-installation tests are carried out according to workplace procedures and manufacturer and component supplier specifications

5. Clean up work area and finalise work processes

5.1. Final inspection is made to ensure work is to workplace expectations and vehicle is presented ready for use

5.2. Tools and equipment are checked and stored according to workplace expectations

5.3. Workplace documentation is completed according to workplace procedures

Required skills

communication skills to:

clarify workplace instructions and determine job requirements

gain information from appropriate persons and assistance as required

learning skills to identify sources of information, assistance and expert knowledge

literacy skills to

read, interpret and follow information on written job instructions, specifications, standard operating procedures, charts, lists, drawings and other applicable reference documents

follow workplace documentation, such as codes of practice or operating procedures

document work performed during inspection and servicing operations

numeracy skills to:

assess tolerances and apply accurate measurements and adjustments

interpret gauges, instruments and measuring equipment

planning and organising skills to ensure tasks are completed within an acceptable timeframe

problem-solving skills to seek information and assistance as required to solve problems

self-management skills to:

select and use appropriate equipment, materials, processes and procedures

follow workplace documentation, such as codes of practice or operating procedures

teamwork skills to apply knowledge of own role to complete activities efficiently to support team activities and tasks

technical skills to use workplace tools and equipment relating to the removal and installation of heavy vehicle engine assemblies

technology skills to use technology to collect and provide information

Required knowledge

WHS regulations, requirements, equipment and material, and personal safety requirements

dangers of working with lifting and jacking equipment

methods of disconnecting related systems, including:

air conditioning system

cooling system

electrical systems

exhaust system

fuel system

power steering system

transmission systems, including:

automatic transmission

manual transmission

removal procedures for heavy vehicle engine assemblies, including:

correct use of lifting and supporting equipment

item tagging procedures

correct disposal methods of hazardous substances

installation procedures for heavy vehicle engine assemblies

post-installation testing and adjustment procedures for heavy vehicle engine assemblies, including:

pre-start procedures

operational testing and run-in procedures

The evidence guide provides advice on assessment and must be read in conjunction with the Performance Criteria, required Skills and Knowledge, the 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 appropriate to the circumstances

remove and install a range of heavy vehicle engine assemblies according to workplace, manufacturer and component supplier requirements

present heavy vehicle in a condition that complies with workplace requirements.

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.

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:

workplace location or simulated workplace

heavy vehicles and heavy vehicle engine assemblies

tools and equipment appropriate for the removal and installation of heavy vehicle engine assemblies

specifications and workplace 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 the 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 correct interpretation and application.

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 the needs of diverse clients.

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

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

Workplace instructions may include:

computer-generated instructions

verbal instructions

written instructions.

Job requirements may include:

removal and installation methods, processes and equipment.

Workplace health and safety (WHS) requirements:

are those prescribed under legislation, regulations, codes of practice, and workplace policies and procedures

may include:

protective clothing and equipment

use of tools and equipment

handling of material

use of fire-fighting equipment

first aid equipment

hazard control, including control of hazardous materials and toxic substances.

Procedures and information may include:

safe work procedures relating to the removal and installation of heavy vehicle engine assemblies

verbal, written and graphical instructions

signage

work schedules, plans and specifications

work bulletins or memos

material safety data sheets (MSDS)

diagrams or sketches

regulatory and legislative requirements relating to the automotive industry

Australian Design Rules

engineer's design specifications and instructions

organisation work specifications and requirements

instructions issued by authorised enterprise or external persons

Australian Standards

heavy vehicle service requirements and repair manuals.

Removal optionsmay include:

removal of the engine assembly alone or with the transmission assembly

removal with the engine attached to chassis.

Observations may include:

routing of system components

damaged or faulty components

components and parts required for engine installation.

Installation options may include:

installation of the engine assembly alone or with the transmission assembly

installation with the engine attached to chassis.

Post-installation adjustments may include:

throttle adjustments

coolant replacement

oil replacement

tappet adjustment

re-tensioning of cylinder head bolts.

Post-installation tests may include:

stationary and mobile engine performance tests

testing of associated systems, including:

air conditioning system

cooling system

power steering system

ancillary systems

transmission system.

Mechanical – Heavy Vehicle

Unit sector

Technical - Engines

This unit contains employability skills.