| 1 | 1a. Produce piston engine assemblies | 1.1 | Work safely at all times, complying with health and safety and other relevant regulations and guidelines |
| 1.2 | Carry out all of the following during the assembly activities: • obtain and use the appropriate documentation (such as job instructions, engine/sub-assembly drawings, quality control documentation, planning documentation) • adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work • follow safe practice/approved assembly techniques at all times • check that all cables, extension leads or air supply hoses are in a serviceable condition • check that all tools and measuring equipment are within current calibration/certification dates • use lifting and slinging equipment in accordance with health and safety guidelines and procedures • ensure that all components to be assembled are free from damage, foreign objects, dirt or other contamination before assembling them • return all ... |
| 1.3 | ... tools and equipment to the correct location on completion of the assembly activities • leave the work area and assembly in a safe and appropriate condition on completion of the activities |
| 1.4 | Follow the relevant instructions, assembly drawings and any other specifications |
| 1.5 | Ensure that the specified components are available and that they are in a usable condition |
| 1.6 | Use the appropriate methods and techniques to assemble the components in their correct positions |
| 1.7 | Use five of the following assembly methods and techniques: • assembly of components by pressure • assembly of components by expansion or contraction • aligning components • setting working clearances • torque setting of bolts, fasteners, clips, sub-assemblies • balancing of components • applying sealants/adhesives • drilling, reaming and riveting • electrical bonding of components • blue-bedding components • securing components using mechanical fasteners and threaded devices • applying bolt locking methods (such as split pins, wire locking, lock nuts, stiff nuts, swage nuts) |
| 2 | 1b. Produce piston engine assemblies (continued) | 2.1 | Produce the piston engine assembly by fitting twelve of the following: • cylinder block • cylinder heads • fly wheel • torque converters • piston assemblies • crank shafts • camshaft assemblies • timing mechanisms • valve mechanisms • oil pumps • bearings • seals and gaskets • pulleys and sprockets • belts and chains • levers and linkages • injector mechanisms • sensing devices • manifolds • sump pans • exhaust systems • pipes and unions • fuel pumps • other components |
| 2.2 | Secure the components using the specified connectors and securing devices |
| 2.3 | Check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification |
| 2.4 | Carry out all of the following checks for accuracy, using the correct inspection testing equipment: • dimensions • positional accuracy/timing • freedom of movement • operating/working clearance • bearing end float • orientation • alignment • completeness • freedom from damage or foreign objects |
| 2.5 | Produce piston engine assemblies which comply with one of the following quality and accuracy standards: • BS, ISO or BSEN standards and procedures • customer standards and requirements • company standards and procedures • specific system requirements |
| 2.6 | Deal promptly and effectively with problems within their control and report those that cannot be solved |
| 3 | 2a. Know how to produce piston engine assemblies | 3.1 | Describe the specific safety precautions to be taken while carrying out the piston engine/sub-unit assembly (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials) |
| 3.2 | Describe the health and safety requirements of the work area in which they are carrying out the assembly activities, and the responsibility these requirements place on them |
| 3.3 | Describe the COSHH Regulations with regard to the substances used in the assembly process |
| 3.4 | Describe the hazards associated with producing piston engine assemblies, and how to minimise them and reduce any risks |
| 3.5 | Describe the personal protective equipment and clothing to be worn during the assembly activities |
| 3.6 | Explain how to extract and use information from engineering drawings and related specifications (to include symbols and conventions to appropriate BS, ISO or BSEN standards) in relation to work undertaken |
| 3.7 | Explain how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing |
| 3.8 | Explain how to identify the components to be used (such as component identification systems, codes and component orientation indicators) |
| 3.9 | Describe the preparations to be undertaken on the components prior to fitting them into the assembly |
| 3.10 | Describe the assembly methods and procedures to be used, and the importance of adhering to these procedures |
| 3.11 | Explain how to complete basic fitting practices meeting company requirements (such as torque tightening, wire locking, fitting wire thread inserts, fitting O-ring seals, fitting lock nuts, blue-bedding and swage nuts) |
| 3.12 | Explain how the components are to be aligned and positioned prior to securing, and the tools and equipment that are used, including jigs and fixtures |
| 3.13 | Describe the various mechanical fasteners that will be used and their method of installation (such as bolts, nuts, rivets, threaded fasteners, special securing devices) |
| 3.14 | Describe the importance of using the specified mechanical fastening devices for the assembly, and why they must not use substitutes |
| 4 | 2b. Know how to produce piston engine assemblies (continued) | 4.1 | Describe the COSHH Regulations with regard to the substances used in the assembly process |
| 4.2 | Explain how to deal with components or fastening devices incorrectly assembled, damaged, or having other faults |
| 4.3 | Describe the application of sealants and adhesives within the assembly activities, and the precautions that must be taken when working with them |
| 4.4 | Describe the quality control procedures to be followed during the assembly operations |
| 4.5 | Explain how to conduct any necessary checks to ensure the accuracy and quality of the assemblies produced |
| 4.6 | Explain how to detect assembly defects (such as ineffective fasteners, foreign object damage), and what to do to rectify them |
| 4.7 | Explain how to move large components and assemblies; the methods and equipment used to transport, handle and lift the components into position; and how to check that the equipment is within its current certification dates. |
| 4.8 | Explain how to check that the tools and equipment to be used are correctly calibrated and are in a safe and serviceable condition |
| 4.9 | Describe the importance of ensuring that all tools are used correctly and within their permitted operating range |
| 4.10 | Describe the importance of ensuring that the completed assembly is free from dirt, swarf and foreign objects |
| 4.11 | Describe the importance of ensuring that all tools, equipment and components are accounted for and returned to their correct location on completion of the assembly activities |
| 4.12 | Describe the problems with the assembly operations, and the importance of informing appropriate people of non-conformances |
| 4.13 | Describe the extent of their own responsibility and to whom they should report if they have problems that they cannot resolve |
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