Assessment Requirements for AURTTM007 Carry out crankshaft grinding

Release: 1

Assessment Requirements for AURTTM007 Carry out crankshaft grinding

Modification History

Release	Comment
Release 1	New unit of competency.

Performance Evidence

Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:

grind one crankshaft of an in-line petrol engine with at least four cylinders.

Knowledge Evidence

Individuals must be able to demonstrate knowledge of:

work health and safety (WHS) and occupational health and safety (OHS) requirements relating to grinding crankshafts, including procedures for:

selecting and using personal protective equipment (PPE) for using grinding machines and chemical cleaning and lubricating agents

identifying hazards associated with rotating grinding machines

manual handling techniques relating to grinding crankshafts

types, characteristics and limitations of crankshaft grinding machines, including:

hand-held machines for oil hole dressing

types and grades of grinding wheels, including grit grades

dismantling procedures for crankshafts, including:

numbering and removing counterweights

drive gears

oil seal sleeves and dowels

cleaning and inspection procedures, including:

chemically cleaning crankshafts, including methods of avoiding damage to nitride and Tufftride crankshafts

identifying crankshaft material

identifying heat treatment process, including nitriding, Tufftriding and induction hardening

identifying radius treatment, including deep fillet rolling, radius rolling and shot peening

checking alignment of crankshaft in V blocks

measuring journals against specifications and identifying damaged journals

testing procedures for crankshaft, including:

crack testing coil shot and end shot

testing hardness of journals

procedures for preparing crankshaft grinding wheel, including:

wheel preparation, including selecting wheel to suit radius and journal width of crankshaft

dressing procedures for wheel, including:

types of diamonds for front and radius dressing

procedures for dressing wheel to suit crankshaft radius

procedures for dressing front of wheel

procedures for big end grinding, including:

setting crankshaft rotation speed according to crankshaft material and big end diameter

setting crankshaft grinder wheel head position

setting chuck offsets for big end bearings and adjusting counterweights to suit

fitting crankshaft in correct direction of rotation and ensuring that critical surfaces are not damaged by the chuck

measuring journal diameters during grinding with constant measuring gauge

procedures for adjusting crankshaft grinder to suit main bearing journal grinding, including:

removing crankshaft from grinder

fitting crankshaft in correct direction of rotation

setting datum in relation to rear flange and nose for main bearing grinding

procedures for main bearing journal grinding, including:

setting crankshaft rotation speed according to crankshaft material and journal size

setting crankshaft grinder wheel head position

measuring journal diameters during grinding with constant measuring gauge

procedures for finishing journal grinding, including:

chamfering and dressing oil holes

linishing journals according to grade of belt, required finish, and rotational direction

setting up and facing flange ends and seal areas

final grinding inspections of crankshaft, including:

journal surface finish

taper, ovality, barrelling, and hourglass

grinding chatter

burning of radius and journals

methods of correcting faults

procedures for removing crankshaft from grinder and checking crankshaft for straightness in V blocks using dial indicator

requirements of Australian standards relating to engine reconditioning, including:

AS 4182 Automotive repairs – Code of practice for reconditioning reciprocating spark ignition engines

AS 4427 Automotive repairs – Code of practice for reconditioning reciprocating compression ignition engines

post-grinding operations, including rust protection of machined surfaces.

Assessment Conditions

Assessors must satisfy NVR/AQTF assessor requirements.

Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.

Assessment must include direct observation of tasks.

Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the crankshaft grinding that they have carried out, e.g. repair orders.

Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.

The following resources must be made available:

automotive repair workplace or simulated workplace

workplace instructions

manufacturer crankshaft specifications

AS 4182 Automotive repairs – Code of practice for reconditioning reciprocating spark ignition engines

AS 4427 Automotive repairs – Code of practice for reconditioning reciprocating compression ignition engines

crankshaft from an in-line petrol engine with at least four cylinders requiring grinding

engine crankshaft grinding machine

precision measuring equipment, including:

dial indicators

inside and outside metric and imperial micrometers.

Links

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=b4278d82-d487-4070-a8c4-78045ec695b1