Work applies to engine components to be rebuilt, which may include those of light vehicles, heavy vehicles, agricultural and plant equipment, recreational vehicles and motorcycles.

Work is carried out according to award provisions.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare to undertake metal building procedures

1.1. Workplace instructions are used to determine job requirements, including method, process and equipment

1.2. Information is sourced, procedures and methods are analysed, and appropriate tooling options are selected for rebuilding engine components

1.3. Tools and measuring equipment are checked and prepared for operation

1.4. Safe operating procedures and workplace health and safety (WHS) and environmental requirements are observed throughout the work

1.5. Engine component is prepared for metal application

2. Apply metal to engine components

2.1. Correct information is accessed and interpreted from manufacturer and component supplier specifications

2.2. Metal application process is used to rebuild damaged engine components

2.3. Rebuild method is completed in readiness for further repair without causing damage to components or system

3. Perform necessary machining to rebuild component

3.1. Machining is carried out according to workplace procedures and without causing damage to component or system

3.2. Component is checked and measured with instruments to ensure compliance with specifications

3.3. Machining operations are completed to specifications

4. Finalise rebuild process

4.1. Surfaces of component are finished to manufacturer and component supplier specifications and allowable tolerances

4.2. Finishing work is completed without causing damage to the component

4.3. Surfaces are protected with a rust prevention solution

4.4. Components are prepared for further process or storage

4.5. Workplace documentation is processed according to workplace procedures

Required skills

technical skills to:

identify and rectify weld defects

identify worn and damaged cutting and grinding tools

mount and position cutting and grinding tools

set machining parameters to achieve job requirements and maximise tool life

measure to specified tolerances and dimensions

communication skills to:

follow oral instructions

report deviations from specifications

interact with customers and team members with regard to workplace instructions

literacy skills to:

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

identify and analyse technical information

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

problem-solving skills to:

locate, interpret and apply workplace policies and procedures, including manufacturer and component procedures

identify and avoid planning and scheduling problems

prevent time and material wastage

organise work and plan processes

planning and organising skills to:

make good use of time and resources

set priorities

monitor own performance

self-management skills to:

manage risks and hazards associated with machinery for applying metal, cutting and grinding

optimise workflow and productivity

Required knowledge

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

personal protective equipment (PPE) for using welding equipment and machines to rebuild engine components

hazards associated with welding equipment

procedures for identifying existing heat treatment processes, including nitriding, tufftriding, and induction hardening

engine and engine component structures

specific welding procedures, including:

manual metal arc welding (MMAW)

gas metal arc welding (GMAW)

gas tungsten arc welding (GTAW)

flux core

metal spraying

submerged arc

procedures for hard chrome application

repair operations for components, including:

crankshaft journals, camshaft journals and lobes, seal areas, crankshaft nose and keyway, and pulley retaining thread damage

crankshaft radius treatment, including:

shot peening

radius rolling

deep fillet radius rolling

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 applying metal appropriate to the circumstances

complete preparatory activity in a systematic manner

rebuild a range of engine components 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 should be made available for the assessment of this unit:

appropriate worksite

crankshafts, camshafts, engine cylinder head assemblies, and engine block assemblies

material relevant to rebuilding engine components

equipment and hand and power tools appropriate to rebuilding engine components

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.

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.

Information may include:

Australian standards

engineer’s design specifications and instructions

instructions issued by authorised workplace or external persons

workplace specifications and requirements

regulatory and legislative requirements relating to the automotive industry, including Australian Design Rules

safe work procedures relating to the operation of machinery associated with rebuilding engine components

verbal, written and graphical instructions, signage, work schedules, plans, specifications, work bulletins, memos, material safety data sheets (MSDS), diagrams or sketches.

Appropriate tooling options may include:

grades of tool tips necessary to produce required finish

MMAW, GMAW, GTAW, flux core and metal spraying

types and grades of grinding stones

types of facing tools.

Tools and measuring equipment may include:

clamps

dial indicators

hand and power tools

inside and outside micrometers

lifting equipment

welding equipment, such as:

roll welders

short arc welding equipment

gas metal arc welders

gas tungsten arc welders

metal spraying equipment

hard chroming equipment.

WHS requirements may include:

individual state or territory regulatory requirements

operational risk assessment and treatments associated with:

electrical safety

machinery movement and operation

manual and mechanical lifting and shifting

toxic substances

working in proximity to others and site visitors

PPE required by legislation, regulations, codes of practice and workplace policies and procedures.

Environmental requirements include:

clean-up management

dust and noise minimisation

waste management.

Preparing the engine component may include:

cleaning the component using appropriate cleaning methods

fitting and clamping the component.

Engine components may include:

alloy and cast iron cylinder heads

camshaft lobes and journals

crankshaft and camshaft bearing faces

crankshaft journals and thrust surfaces

piston and connecting rod assemblies.

Rebuild methods will include:

building up lobes/journals by welding, metal spraying and hard chroming

repairing cast iron cylinder heads

repairing cracks in alloy cylinder heads.

Mechanical Miscellaneous

Sector

Technical - Manufacture

This unit contains employability skills.