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Evidence Guide: AURTTM3008 - Dismantle and evaluate engine blocks and sub-assemblies

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

AURTTM3008 - Dismantle and evaluate engine blocks and sub-assemblies

What evidence can you provide to prove your understanding of each of the following citeria?

Prepare to dismantle engine block and sub-assemblies

  1. Workplace instructions are used to determine job requirements, including method, process and equipment
  2. Information is accessed, procedures and methods are analysed, and appropriate tooling options are selected for dismantling engines and sub-assemblies
  3. Tools and measuring equipment are checked and prepared for operation
  4. Safe operating procedures and workplace health and safety (WHS) and environmental requirements are observed throughout the work
  5. Engine is set up for dismantling using appropriate lifting equipment and avoiding fluid spillage
  6. Engine block and sub-assemblies are cleaned in line with appropriate environmental constraints, and positions of auxiliary equipment are recorded
Workplace instructions are used to determine job requirements, including method, process and equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Information is accessed, procedures and methods are analysed, and appropriate tooling options are selected for dismantling engines and sub-assemblies

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Tools and measuring equipment are checked and prepared for operation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

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

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine is set up for dismantling using appropriate lifting equipment and avoiding fluid spillage

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block and sub-assemblies are cleaned in line with appropriate environmental constraints, and positions of auxiliary equipment are recorded

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Dismantle engine block and sub-assemblies

  1. Correct information is accessed and interpreted from manufacturer or component supplier specifications
  2. Covers and ancillary components are removed, cleaned and stored without causing damage to components or system according to workshop requirements
  3. Engine blocks and sub-assemblies are dismantled and laid out in a logical order using approved methods, tools and equipment and without causing damage to components or system
  4. Component parts are cleaned using appropriate cleaning agents for the type of material and kept in a logical order in preparation for evaluation
Correct information is accessed and interpreted from manufacturer or component supplier specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Covers and ancillary components are removed, cleaned and stored without causing damage to components or system according to workshop requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine blocks and sub-assemblies are dismantled and laid out in a logical order using approved methods, tools and equipment and without causing damage to components or system

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Component parts are cleaned using appropriate cleaning agents for the type of material and kept in a logical order in preparation for evaluation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine repair procedures

  1. Correct information is accessed and interpreted from manufacturer and component supplier specifications
  2. Engine block and sub-assembly components are inspected, measured and tested against manufacturer and component supplier specifications and tolerances
  3. Inspection, measurement and testing are completed without causing damage to components or system
  4. Engine block and sub-assembly components are evaluated against measurements, tests and inspections made
  5. Repair requirements are identified and reported according to workplace policy and procedures
  6. Workplace documentation is completed and dealt with in line with inspection, measurement and testing outcomes
Correct information is accessed and interpreted from manufacturer and component supplier specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block and sub-assembly components are inspected, measured and tested against manufacturer and component supplier specifications and tolerances

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Inspection, measurement and testing are completed without causing damage to components or system

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block and sub-assembly components are evaluated against measurements, tests and inspections made

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Repair requirements are identified and reported according to workplace policy and procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Workplace documentation is completed and dealt with in line with inspection, measurement and testing outcomes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Finalise dismantle and evaluation processes

  1. Work performed is documented
  2. Final inspection is made to ensure safety features are in place
  3. Engine block and sub-assemblies are prepared for storage according to workplace requirements
  4. Workplace documentation is processed according to workplace procedures
Work performed is documented

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Final inspection is made to ensure safety features are in place

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Engine block and sub-assemblies are prepared for storage according to workplace requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Workplace documentation is processed according to workplace procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

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 dismantling and evaluation methods and techniques appropriate to the circumstances

complete preparatory activity in a systematic manner

complete the dismantling and evaluation of a range of engine blocks and sub-assemblies

measure and check work against manufacturer and component supplier specifications

evaluate components according to workplace requirements and specifications

determine required repair procedures

complete the dismantling and evaluation of engine blocks and sub-assembly components within workplace timeframes

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 must be made available for the assessment of this unit:

appropriate worksite

multi-cylinder engine blocks appropriate to the workplace, including those with and without cylinder sleeves

equipment and hand, air and power tools appropriate to dismantling and evaluating engine blocks and sub-assembly 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.

Required Skills and Knowledge

Required skills

technical skills to:

dismantle engine blocks without causing damage to components

clean parts using appropriate solutions and procedures

identify components for re-use or replacement

check for abnormal wear and defects

check for conformance to specifications

measure to specified tolerances and dimensions

identify repair procedures

communication skills to:

follow oral instructions

work as part of a team

literacy skills to:

understand quality procedures

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

obtain and record measurements

document required repairs and parts

numeracy skills to use mathematical ideas and techniques to:

assess tolerances and clearances

apply accurate measurements

calculate component dimensions

problem-solving skills to:

prevent time and material wastage

plan and sequence operations

self-management skills to:

select and use appropriate equipment, materials, processes and procedures

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

technology skills to use communication devices and computerised equipment to:

search and gather supporting material

take, locate, download and view digital images

Required knowledge

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

personal protective equipment (PPE) for handling engine blocks and sub-assemblies and using chemical cleaning agents

correct operation of specialised equipment, such as pullers

manual-handling techniques, including:

using machinery for lifting engine blocks and engine components

using slings, chains and other lifting equipment according to safe work practices

dismantling methods and procedures, including:

reasons for selecting the chosen tools, techniques and equipment

hazards and fluid control measures associated with the removal of engines and engine components, including housekeeping

pre-evaluation checks to determine suitability of component to be re-used

reasons for checking endfloats before disassembly

cleaning solutions and cleaning procedures of components

use of pullers, presses and specialised tools, and the application of heat to dismantle components, such as gears, pulleys and dowels

procedures for recording the facing directions of pistons, connecting rods, main and big-end caps and positions of removable counterweights and counterweight shafts assemblies

precautions to be aware of when removing the connecting rod cap in relation to snap-broken rods

removing crankshaft and identifying main bearing caps that have lost register

removing dry and wet sleeves

dismantling pistons from connecting rods

removing camshaft bearings and balance/idler shaft bearings

removing welsh plugs and oil gallery plugs

removing diesel injection pumps

dismantling components that have seized, bent or broken, including seized stud and bolt removal

measuring, testing and evaluating procedures, including:

characteristics of surface finishes and wear patterns as applied to cylinder bores, crankshafts, pistons, gears, cam followers, camshafts, bearings and bushes, block facings, parting faces of connecting rod and main bearing caps

crack testing components

testing hardness of alloy cylinder blocks, pistons, crankshaft journals and camshaft followers

straightness of shafts

taper, ovality and wear of:

crankshaft and camshaft journals

main bearing and connecting rod tunnels

cylinder bores in conventional engine blocks and the parent bores of engine blocks with dry sleeves

camshaft lobe lift

main bearing tunnels for alignment

connecting rod alignment and little-end bore size

cylinder block flatness and deck height

piston ring land clearance, piston skirt wear and gudgeon pin to piston clearance

cylinder liner register in both the upper and lower parts of the cylinder block

oil pump for serviceability

idler gear hub to bearing clearance

Australian standards relating to engine reconditioning

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. 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 dismantling engine components

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

Tools and measuring equipment may include:

depth micrometers

dial bore gauges

dial indicators

inside and outside micrometers

pullers

other specialised tools.

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 are to include:

clean-up management

dust and noise minimisation

waste management.

Sub-assemblies include:

balance shafts

bearings

belts and pulleys

camshafts

chains

connecting rods

crankshafts

cylinder barrels

cylinder head assemblies

cylinder liners (wet and dry)

gears

idler shafts

oil pumps

pistons

rings.

Positions of auxiliary equipment may include:

clamps

missing parts

mounting brackets

position of sensors.