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Elements and Performance Criteria

1. Prepare to grind crankshaft
   • Job requirements are determined from workplace instructions
   • Crankshaft is cleaned and inspected and condition reported
   • Information is sourced, procedures and methods are analysed, and appropriate crankshaft grinding machine and equipment are selected for the crankshaft
   • Hazards associated with the work are identified and risks are managed
   • Tools and measuring equipment are selected and checked for serviceability
   • Crankshaft grinding wheel is prepared according to machine manufacturer specifications and tolerances, and workplace procedures
   • Crankshaft is measured to determine under size and tolerances, including journal diameters and sizes of grind
   • Crankshaft is positioned in grinder in correct direction of rotation, and clamped according to manufacturer specifications and workplace procedures
2. Grind crankshaft big end bearing journals
   • Chuck offsets are set according to the stroke of crankshaft
   • Crankshaft grinder wheel head position is set according to machine manufacturer procedures
   • Constant measuring gauge and steady rest are positioned on big end journal taking into account position of oil hole
   • Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements, and following machinery safe operating procedures
   • Crankshaft is measured to ensure compliance with specifications and tolerances
   • Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures
3. Grind crankshaft main bearing journals
   • Crankshaft is removed from grinder
   • Chucks are centralised for main bearings and counterweights are adjusted
   • Crankshaft is refitted to grinder in correct direction of rotation, and is clamped according to manufacturer specifications and workplace procedures
   • Datum is set in relation to crankshaft rear flange and nose
   • Crankshaft grinder wheel head movement is set according to manufacturer procedures
   • Constant measuring gauge and steady rest are positioned on main bearing journal taking into account position of oil hole
   • Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements, and following machinery safe operating procedures
   • Crankshaft is inspected to ensure compliance with specifications and tolerances
   • Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures
4. Finish crankshaft grinding
   • Oil holes are chamfered and dressed
   • Journals are linished with correct grade of belt and in right direction of rotation and required finish
   • Flange ends and seal areas are faced
   • Crankshaft is examined and measured according to manufacturer specifications and tolerances, and workplace procedures
   • Crankshaft is cleaned according to workplace procedures
   • Bright surfaces are treated with rust prevention solution and crankshaft is prepared for further process or storage according to workplace procedures
5. Complete work processes
   • Final inspection is made to ensure finished work complies with workplace requirements and crankshaft is presented ready for use or storage
   • Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
   • Tools and equipment are checked and stored according to workplace procedures
   • Workplace documentation is processed according to workplace procedures
6. Prepare to grind crankshaft
   • Job requirements are determined from workplace instructions
   • Crankshaft is cleaned and inspected and condition reported
   • Information is sourced, procedures and methods are analysed, and appropriate crankshaft grinding machine and equipment are selected for the crankshaft
   • Hazards associated with the work are identified and risks are managed
   • Tools and measuring equipment are selected and checked for serviceability
   • Crankshaft grinding wheel is prepared according to machine manufacturer specifications and tolerances, and workplace procedures
   • Crankshaft is measured to determine under size and tolerances, including journal diameters and sizes of grind
   • Crankshaft is positioned in grinder in correct direction of rotation, and clamped according to manufacturer specifications and workplace procedures
7. Grind crankshaft big end bearing journals
   • Chuck offsets are set according to the stroke of crankshaft
   • Crankshaft grinder wheel head position is set according to machine manufacturer procedures
   • Constant measuring gauge and steady rest are positioned on big end journal taking into account position of oil hole
   • Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements, and following machinery safe operating procedures
   • Crankshaft is measured to ensure compliance with specifications and tolerances
   • Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures
8. Grind crankshaft main bearing journals
   • Crankshaft is removed from grinder
   • Chucks are centralised for main bearings and counterweights are adjusted
   • Crankshaft is refitted to grinder in correct direction of rotation, and is clamped according to manufacturer specifications and workplace procedures
   • Datum is set in relation to crankshaft rear flange and nose
   • Crankshaft grinder wheel head movement is set according to manufacturer procedures
   • Constant measuring gauge and steady rest are positioned on main bearing journal taking into account position of oil hole
   • Crankshaft is ground at correct rotational speed for crankshaft material and diameter according to safety requirements, and following machinery safe operating procedures
   • Crankshaft is inspected to ensure compliance with specifications and tolerances
   • Grinding operations are completed to required specifications and tolerances according to safety requirements, and following machinery safe operating procedures
9. Finish crankshaft grinding
   • Oil holes are chamfered and dressed
   • Journals are linished with correct grade of belt and in right direction of rotation and required finish
   • Flange ends and seal areas are faced
   • Crankshaft is examined and measured according to manufacturer specifications and tolerances, and workplace procedures
   • Crankshaft is cleaned according to workplace procedures
   • Bright surfaces are treated with rust prevention solution and crankshaft is prepared for further process or storage according to workplace procedures
10. Complete work processes
    • Final inspection is made to ensure finished work complies with workplace requirements and crankshaft is presented ready for use or storage
    • Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected
    • Tools and equipment are checked and stored according to workplace procedures
    • Workplace documentation is processed according to workplace procedures

Range Statement

This section specifies work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. Bold italicised wording, if used in the performance criteria, is detailed below.

Cleaning and inspecting crankshaft must include:	following procedures for chemically cleaning nitride and Tufftride crankshafts inspecting crankshaft, including: coil shot end shot hardness alignment bend thread condition key way condition seal running surfaces condition rear flange condition nose gear condition.
Preparation must include:	selecting wheel to suit radius and journal width procedures for dressing wheel.
Safety requirementsmust include:	work health and safety (WHS) and occupational health and safety (OHS) requirements, 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.
Examining and measuring crankshaft must include:	checking journals for: acceptable surface finish taper ovality barrelling hourglass grinding chatter and journal burning checking crankshaft for straightness in V blocks using a dial indicator.

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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.

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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.

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