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.
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.