Service and maintain engines on land-based equipment

This standard covers the service and maintenance of engines on land-based equipment. It includes the construction and operating principles of spark ignition and compression ignition engines and their configurations. It also includes the identification and function of components, the removal and replacement of engine assemblies and components and the dismantling and reassembly methods and techniques.

This standard covers engine systems and performance, incorporating the systems used to deliver the fuel (including carburettors and injection systems) and air supplied by inlet manifolds or pressure-charged intake systems, as well as air required in an engine combustion process, and the types, construction and function of the components.

When working with machinery or equipment you should be trained and hold current certification, where required, in accordance with the relevant legislation.

When working on high voltage (hazardous voltage/HaV) electric vehicles, de-energising must be done by a person who has been trained in accordance with the manufacturer’s procedures.

This standard is for those who work in land-based engineering under supervision.

1. be aware of hazards and assess the risks associated with the activity and the location where it is to be carried out
2. be aware of the potential environmental impact associated with the activity and the ways in which this can be controlled
3. select and wear suitable clothing and personal protective equipment (PPE)
4. select, prepare, use, maintain, and store the tools and equipment required to carry out the activity, in accordance with the relevant legal requirements, manufacturer's instructions and company practices
5. check that the land-based equipment requiring service and maintenance is safe, prepared and isolated from power sources, where required, before work commences
6. take the necessary precautions to prevent the escape of chemicals, gases and other substances and minimise dangers from contamination and hazards, where required
7. use a variety of methods to collect data to identify defects and faults  
8. confirm the requirements for service and maintenance
9. identify and establish the availability of serviceable items required for the activity
10. remove engine system components from land-based equipment in preparation for service and maintenance
11. replace worn and damaged components in accordance with instructions and specifications
12. set and adjust engine components to the manufacturer’s specifications and standards
13. replace or reinstate engine system components to manufacturer’s specifications and standards
14. identify mechanical and electronically controlled fuel-injection systems
15. use suitable testing methods to assess the performance of the reassembled system on completion of the activity, and confirm that it performs to operating specifications prior to returning the equipment to the customer
16. leave the workplace in a safe condition following completion of the activity
17. recycle or sustainably dispose of the different types of waste, hazardous and non-hazardous, caused by the activity, in accordance with instructions and the relevant legal and environmental requirements
18. complete records as required in accordance with company instructions

1. how to identify hazards and assess risks when preparing to service and maintain land-based equipment 
2. the type of clothing and personal protective equipment (PPE) suitable for the activity
3. the tools and equipment required to carry out the activity and how to select, prepare, use, maintain and store these safely and correctly, in accordance with the manufacturer's instructions and company practices
4. the relevant legal requirements for the preparation and use of work equipment
5. the methods of preparing land-based equipment for service and maintenance
6. the dangers created by stored energy and how to respond to these during the preparation stage 
7. the hazardous chemicals, gases and other substances that may be present and how they should be dealt with 
8. the types of fuel sources available, how to recognise them and how they affect the servicing and maintenance of engines
9. the methods that can be used for the identification of defects and faults with engines 
10. the typical defects and faults that occur with engines on land-based equipment 
11. the factors that determine whether it is worthwhile carrying out the service and maintenance
12. the serviceable items required to carry out the service and maintenance work and the company procedures for obtaining these
13. the types, construction and operating principles of different types of engines and fuel sources on land-based equipment
14. the types and function of engine system components
15. exhaust emissions, regulations and methods of control, including filters and fluids
16. the effects of moisture and contaminates in fuel and ignition systems
17. engine running-in procedures
18. engine starting and stopping procedures
19. how to remove and replace engine system components in preparation for service and maintenance
20. how to set and adjust engine system components to manufacturer’s specifications and standards, including how to time and balance engine components
21. how to identify and select the appropriate methods of sealing engine units and components after service and maintenance
22. the methods for setting or calibrating equipment and machinery following service and maintenance 
23. the methods of testing engine systems on completion of the activity to confirm that they perform to operating specification prior to returning to the customer
24. the importance of leaving the workplace in a safe condition following completion of the activity
25. how to recycle or sustainably dispose of the different types of waste, including hazardous and non-hazardous, caused by the activity, in accordance with instructions and the relevant legal and environmental requirements 
26. the potential impact that the activity could have on the environment and the ways in which this can be controlled
27. the records that need to be completed and the company procedure for these

Components e.g.

• carburetters

• spark plugs

• injection pumps

• fuel-delivery pumps

• injectors

• governors

• cold-start aids

• air-filtration systems

• exhaust systems

• turbo and superchargers

Dismantle and repair e.g.

· cylinder heads and valve train assemblies

· pistons, rings and liner assemblies

· engine component timing, e.g. camshaft, balancer

· crankshafts

· spark ignition systems

· fuel-supply pumps and delivery systems

· exhaust systems

Engines:  spark ignition and compression ignition engines and their configurations e.g.

· air cooled and water cooled

· wet and dry liners, monoblock

· naturally aspirated and pressure charged (to include turbo compounding and supercharging)

· balancers and vibration suppression

Filters and fluids:

• Diesel Oxidation Catalyst (DOC)

• Diesel Particulate Filter (DPF)

• Selective Catalytic Reduction (SCR)

• Diesel Exhaust Fluid (DEF)

Fuel sources  e.g.

• petrol

• diesel

• hybrid

• LPG

• methane

• hydrogen

Hazardous chemicals and substances could include:

• fuels

• oils

• fluids

• gases

• dust

• compressed air

Instructions and specifications:

• drawings/plans

• schedules

• method statements

• Standard Operating Procedures (SOPs)

• manufacturer’s instructions

• customer requirements

• verbal instructions

Methods of diagnosis:

• visual inspections

• functional and operational tests

• diagnostic equipment

• remote electronic control and monitoring systems

• reviewing technical data

Reassemble following repair e.g.

• gap piston rings

• engine components balance and alignment

• piston and liner clearances

• engine component timing

• tightening sequences

Stored energy:

• springs

• belt tension

• hydraulic pressure

• electrical discharge

• accumulator discharge