AURR401103A
Overhaul two and four cycle outboard engines

This unit of competency describes the skills and knowledge required to overhaul two and four cycle outboard engines and components.It requires the ability to interpret work requirements, logically dismantle the engine system, overhaul and reassemble the engine and finalise work processes.No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.

Application

This unit applies to individuals who undertake the overhauling of two and four cycle water cooled outboard engines with significant repair in a marine environment.


Elements and Performance Criteria

ELEMENT

PERFORMANCE CRITERIA

1. Prepare to carry out engine overhaul

1.1. Confirm nature and scope of work to be carried out

1.2. Locate occupational health and safety (OHS) and workplace environmental and sustainable procedures and practices, applicable to the work

1.3. Access and interpret overhaul method, workshop manuals and manufacturer information

1.4. Check and prepare tools, equipment and materials

1.5. Set up work area

2. Dismantle engine and components

2.1. Dismantle engine and components in a logical sequence without causing damage

2.2. Clean engine and arrange components ready for inspection

2.3. Measure and compare components against supplier specifications and tolerances

2.4. Decide serviceability and repair method of each component in accordance with OHS, environmental and industry regulations and guidelines, and enterprise procedures

2.5. Source replacement parts as required

2.6. Determine and arrange outsourcing of third-party repair

3. Overhaul and assemble engine and components

3.1. Perform overhaul operations in accordance with workplace procedures and manufacturer and component supplier specifications and tolerances

3.2. Re-assemble engine following manufacturer and component supplier procedures

3.3. Measure running clearances against component manufacturer and supplier specifications

3.4. Make the necessary adjustments

3.5. Apply appropriate lubricants to engine

3.6. Complete assembly of engine within established industry guidelines and timeframes and without causing damage to system or components

4. Undertake engine pre-start check

4.1. Mount engine securely in preparation for starting

4.2. Conduct pre-start checks, make required adjustments and re-test

4.3. Seal engine openings against ingress of foreign matter

4.4. Make final inspection to ensure protective features are in place and according to workplace requirements

4.5. Determine the need for water testing

5. Clean up work area and finalise work

5.1. Clean and store engine according to workplace requirements

5.2. Clean and inspect equipment and tooling according to workplace requirements

5.3. Tag unserviceable equipment and faults identified in accordance with workplace requirements

5.4. Finalise and process work completion documentation, update customer and warranty information and give to appropriate persons as required

5.5. Clean work area, dispose of waste and scrap, and store tools and equipment in accordance with workplace procedures

Required Skills

Required skills

Required skills include:

technical skills to the level required to use workplace technology related to the overhaul of two and four cycle engines and components, including use of specialist tooling, measuring equipment, use of communication devices and workplace technology to record results of repair work

communication skills to the level required to confirm work requirements and specifications, to communicate effectively regarding work requirements with supervisor, other workers and customers, to relate to people from a range of social, cultural and ethnic backgrounds and of varying physical and mental abilities, and to report work outcomes and problems

literacy skills to the level required to understand information related to work orders, including common industry terminology, plans and safety procedures, to interpret technical information and specifications and to prepare reports

numeracy skills to the level required to correctly calculate time, assess tolerances, apply accurate measurements, calculate material requirements and establish quality checks

problem-solving skills to the level required to identify technical and procedural problems to avoid planning and scheduling problems and time and material wastage

team skills to the level required to work effectively and cooperatively with others to optimise workflow and productivity

analytical skills to the level required to analyse technical information and issues related to the overhaul of two and four cycle engines and components

Required knowledge

Required knowledge includes:

operating principles, construction and types of two and four cycle engines and components

engine overhaul procedures and methodologies

component evaluation methods

dismantling, assembling and adjustment methods

measuring, testing and adjustment procedures

types of lubricants and application methods

manufacturer and component supplier specifications and tolerances, including workshop manuals and repair guides

applicable commonwealth, state or territory legislation, regulations, standards and codes of practice, including OHS, personal safety and environment, relevant to the overhaul of two and four cycle engines and components

organisational policies and procedures, including quality requirements, reporting and recording procedures, related to repairing engines and components,

OHS regulations and requirements, equipment, and material and personal safety requirements, related to the overhaul of two and four cycle engines and components

Evidence Required

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

Assessors must be satisfied that the candidate can competently and consistently:

observe safety procedures and requirements

communicate effectively with others involved in or affected by the work

select methods and techniques which are appropriate to overhauling marine engines and components

complete preparatory activity in a systematic manner

overhaul a range of two and four cycle outboard engines to industry and manufacturer specifications and within workplace timeframes

test prior to placing in service

complete workplace records as required by the workplace.

Context of, and specific resources for assessment

The application of competency is to be assessed in the workplace or a simulated environment that reflects as far as possible the actual working environment.

Assessment is to occur using standard and authorised work practices, safety requirements and environmental constraints.

Assessment is to comply with relevant regulatory requirements, including specified Australian standards.

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

The following resources should be made available:

appropriate worksite

range of two and four cycle outboard engines

work instructions

equipment, hand and power tooling appropriate to repairing marine engines

relevant information, including manufacturer specifications .

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 may be applied under project-related conditions (real or simulated) and require evidence of process.

Assessment must confirm a reasonable inference 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 functional units which together form part of the holistic work role.

Guidance information for assessment

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


Range Statement

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. 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.

Engines

Engines may include:

2-stroke spark ignition for marine craft

4-stroke compression ignition engines for marine craft

Overhaul

Overhaul may include:

complete dismantling of an assembly and component parts

measuring and evaluation of wear

the replacement, repair, rebuilding or reconditioning of parts comparable to original parts

re-assembly procedures

performance of functional testing

completion of records

Pre-start checking procedures

Pre-start checking procedures may include:

running to operating temperature

priming oil

checking engine fluid levels, including lubrication and coolant

checking fuel system for leaks

checking for abnormal noises

checking for pressures

checking gauges and warning devices for operation

Safe operating procedures

Safe operating procedures may include operational risk assessments associated with:

toxic substances

electrical safety

machinery movement and operation

manual and mechanical lifting and shifting

working in proximity to others

Environmental work practices

Environmental work practices may include:

use of renewable, recyclable, reusable and recoverable resources

minimisation and appropriate disposal of waste and packaging

prevention of contaminants and wastewater entering stormwater drains, waterways or marine environments

minimisation and containment of hazards to air quality

minimisation of noise generating activities

safe storage of parts and components containing environmentally hazardous material

provision of appropriate storage or recycling containers for solid and liquid waste

use of impervious paved area for surface cleaning, engine degreasing and preparation

use of an approved parts washer

use of drip trays under vehicles

cleaning hands over drains connected to an oil/water separator or liquid waste collection drums

minimisation of vehicle exhausts and emissions and provision of ventilated work areas

use of a ventilated, enclosed booth or chamber for spray painting and abrasive sanding

recovering chlorofluorocarbons (CFCs), hydrochlorofluorocarbons (HCFCs) and blends from air conditioning systems for recycling or approved disposal

prevention of tributyltin, arsenic, mercury and dichlorodiphenyltrichloroethane (DDT) entering the marine environment

Information/documents

Information/documents may include:

verbal, written and graphical instructions issued by authorised internal and external persons

parts listing prices and catalogues

inventory systems

material safety data sheets (MSDS)

diagrams or sketches

engineer's design specifications and instructions

manufacturer specifications

industry standards (e.g. American Boat and Yacht Council, National Marine, Manufacturer's Association and US Coast Guard)

Australian standards

workplace specifications and requirements

Legislative requirements

Legislative requirements are to be in accordance with applicable commonwealth, state or territory legislation, regulations, certification requirements and codes of practice, and may include:

Environment Protection Regulations related to diesel fuels

award and enterprise agreements

industrial relations

Australian standards

Australian Design Rules

confidentiality and privacy

OHS

the environment

equal opportunity

anti-discrimination

duty of care

OHS requirements

OHS requirements are to be in accordance with applicable commonwealth, state or territory legislation and regulations, and organisational safety policies and procedures, and may include:

personal protective equipment and clothing

safety equipment

first aid equipment

hazard and risk control

elimination of hazardous materials and substances

manual handling, including shifting, lifting and carrying of engine cradles, slings and shackles and the safety ratings against the load to be lifted

emergency procedures

Environmental requirements

Environmental requirements may include:

waste management

noise

dust

clean-up management

Organisational policies and procedures

Organisational policies and procedures may include:

quality policies and procedures, including Australian standards

OHS, sustainability, environment, equal opportunity and anti-discrimination

manufacturer specifications and industry codes of practice

safe work procedures

reporting and recording procedures


Sectors

Unit sector

Marine


Employability Skills

This unit contains employability skills.


Licensing Information

Refer to Unit Descriptor