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

communicate effectively with others involved in or affected by the work

select methods and techniques to balance engine components appropriate to the circumstances

complete preparatory activity in a systematic manner

balance a range of crankshafts and components according to workplace, manufacturer and component supplier requirements

balance components within workplace timeframes

present components to customer according to workplace requirements.

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.

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:

workplace location or simulated workplace

material relevant to balancing rotating and reciprocating engine components

equipment and hand and power tools appropriate to balancing rotating and reciprocating engine components

multi-cylinder engines appropriate to the workplace, including in-line multi-cylinder engine and vee-configuration multi-cylinder engine blocks

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

technical skills to:

identify worn and damaged machine mountings

mount and position components

set machining parameters to achieve job requirements and maximise tool life

set and measure components to specified tolerances and dimensions

use appropriate machines to correct imbalance of components

communication skills to:

follow oral instructions

report deviations from specifications

work as part of a team

literacy skills to:

read and interpret routine job instructions, specifications, drawings and standard operating procedures

record information for use in calculations

identify and analyse technical information

understand quality procedures

numeracy skills to use mathematical ideas and techniques to:

assess tolerances

apply accurate measurements

calculate balancing requirements

establish quality checks

problem-solving skills to:

locate, interpret and apply workplace policies and procedures, including manufacturer and component supplier procedures

identify and avoid planning and scheduling problems

prevent time and material wastage

organise work and plan processes

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

use interfaces to communicate with computerised controls

Required knowledge

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

operating principles of component balancing, including:

static and dynamic balance

inertia

internally and externally balanced engines

reciprocating mass

rotating mass

sources of torsional vibration

gas pressure

purpose of counterweights, torsional vibration dampeners and balance shafts in balancing

difference between in-line engine balance, flat-plane and vee-type engine balance

balancing procedures and techniques, including:

procedures for in-line engines, flat-plane crankshafts and vee-type engines

procedures for weight-matching the pistons and rod-ends

methods of calculating bob-weight values for vee-type engines, including:

rotating mass with oil allowance

reciprocating mass

effect of vee-angle on the total calculation

procedures for mounting bob-weights on crankshafts of vee-type engines

procedures for balancing internally balanced engines

procedures for balancing externally balanced engines

procedures for adding and removing metal to the crankshaft, including:

drilling to remove weight

welding to add weight

machining and adding heavy metal

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 balancing engine components

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

Appropriate tooling options may include:

comparator gauges and ring compressors

hand tooling

plasti-gauge

power tooling

torque wrenches.

Tools and measuring equipment may include:

balancing equipment

balancing weights

scales.

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

personal protective equipment (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.

Preparation for balancing includes:

thoroughly cleaning all components

checking all components to ensure there is no further machining required.

Engine components to be balanced include:

crankshafts

flywheels

piston and connecting rod assemblies.

Balancing procedures of rotating engine components include:

using different machines to determine positions where material is to be removed or added

different methods of removing or adding weight to engine components, such as drilling, welding, machining and adding metal slugs.

Balancing procedures of reciprocating engine components include:

using different scales and associated equipment to measure the weight of the piston and connecting rod assembly.

different methods of removing or adding weight to piston and connecting rod assembly, such as drilling, welding, machining and adding metal slugs.