This unit of competency requires application of hand skills, the use of maintenance publications, and knowledge of piston engine and system theory to inspect, test and troubleshoot, remove and install normally aspirated piston engines and engine system components during the performance of scheduled or unscheduled maintenance. Maintenance may be performed individually or as part of a team.

Applications include normally aspirated piston engines of basic light fixed wing aircraft and basic rotary wing aircraft, and fixed pitch propellers.

The unit is part of the Mechanical Certificate IV (Aircraft Maintenance Stream) training pathway.

Where a Civil Aviation Safety Authority (CASA) licensing outcome is sought this unit forms part of the CASA requirement for the granting of the chosen maintenance certification licence under Civil Aviation Safety Regulation (CASR) Part 66, in accordance with the licensing provisions in the Companion Volume Implementation Guide.

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 and aircraft manuals

recognising external and internal signs of defects in piston engines, components and system components visual/physical inspection

assisting with testing of piston engine and engine system operation, be able to operate systems, monitor indications, record parameters and recognise correct function

compiling engine condition monitoring records

rigging and adjusting engine controls and systems

using fault diagnosis guides and equivalent data to accurately and efficiently troubleshoot the causes of unserviceabilities in piston engines and engine systems, clearly record details and identify the required rectification actions

correctly removing and installing piston engine, engine components and fixed pitch propellers, including spinners

inspecting propellers for security, damage and deterioration

blending out metal propeller nicks and dents that are within maintenance manual limits.

The underlying skills inherent in this unit should be transferable across a range of inspection, testing, troubleshooting and removal and installation tasks (including the timely involvement of supervisor or other trades) associated with engines, engine systems and fixed pitch propellers. It is essential that system testing procedures take into account all safety precautions associated with piston engine system operation, and that awareness be demonstrated of dual inspection requirements associated with work on engine controls.

This shall be demonstrated through application across a number of engine systems or types and propellers made from different materials. Ability to interpret inspection procedures and specifications (allowable limits) and apply them in practice is critical. The application of testing procedures and functional rigging checks should also indicate knowledge of system 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:

WHS procedures associated with engine and propeller maintenance, including lifting and handling of heavy objects

how to obtain MSDS

use of PPE

relevant maintenance manuals

relevant regulatory requirements and standard procedures

fault diagnosis techniques

piston engine and engine system layout and operation:

four stroke engine theory of operation and performance

cylinder configurations

construction (components and materials)

carburettors and air induction systems

fuel injection systems

fuels and their characteristics

ignition systems

lubricating systems and lubricants

cooling systems

exhaust systems

accessory drives and mounts

normally aspirated piston engine maintenance requirements and troubleshooting procedures

system component operation. including electrical and instrument system interfaces:

magnetos and ignition harnesses

spark plugs

fuel pumps

fuel filters

oil pumps

oil filters

oil tanks

vacuum pumps

generators

starter motors

oil pressure gauges (direct reading)

temperature gauges (direct reading)

tachometers

manifold pressure gauges

maintenance requirements and troubleshooting procedures

removal and installation procedures for piston engines and engine components:

removal procedures and handling

control linkages

electrical wiring

engine instrument connections

installation and rigging

ground running

system component removal, installation and system testing

propellers, materials and damage and deterioration criteria:

fixed pitch propeller types, terminology and theory:

tractor/pusher

matching to engine and aircraft

leading edge/trailing edge

blade stations

forces acting on a propeller

propeller balance

materials and construction methods:

metal propeller metals, construction and surface protection

wooden propeller materials, construction and surface protection

composite propeller materials, construction and surface protection

damage and deterioration

methods of blending out of minor damage to metal propellers

propeller removal and installation procedures.

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.

Engine system operation knowledge, the relationship of individual components and the links with other systems will be necessary to supplement evidence of ability to carry out rigging checks and troubleshoot the system within the limits of the aircraft/system fault-finding guide 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 and performance criteria of the unit of competency are being achieved under routine supervision on at least one (1) item from each of:

normally aspirated engine (all types), main components and accessories/drives

control system

starter system

fuel and air systems

exhaust system

oil system (if dry sump) (may be omitted where not applicable to the enterprise)

and on at least one (1) type of fixed pitch propeller.

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).

Where the unit is to be used for CASA licensing purposes the Assessor must also meet the criteria specified in the CASR Part 147 Manual of Standards.

Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.

Aviation maintenance