Service and repair electrical systems on land-based equipment

This standard covers the service and repair of electrical systems on land-based equipment. It covers the electrical principles, components and systems found in land-based equipment. It also includes some aspects of mains electricity but due to current regulations an approved electrician should be involved when working with mains electricity.

The standard includes both AC, (e.g. single, 3phase, voltage and colour coding - 415, 240, 110) and DC (e.g. starting circuits, ignition systems, charging/batteries, lighting/instrumentation and ancillary systems) systems and 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 repair is safe, prepared and isolated from power sources, where required
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 diagnostic information to identify defects and faults  
8. determine the requirements for service and repair
9. identify and establish the availability of replacement components required for the activity
10. identify, remove and replace components on electrical systems on land-based equipment
11. where required, dismantle, service/repair and reinstate electrical components and circuits in line with the manufacturer’s specifications and standards
12. confirm and rectify faults in electrical systems and components
13. use test equipment to accurately measure and interpret
14. maintain optimal integrity of electrical systems
15. verify the correct operation of safety devices  
16. carry out the service and repair of electrical systems, in accordance with instructions and specifications 
17. remove and replace worn and damaged components in accordance with instructions and specifications
18. use suitable testing methods to assess the performance of the reassembled system on completion of the activity, and confirm that it performs to the operating specifications prior to returning the equipment to the customer
19. 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 
20. complete records as required by the relevant legislation, warranty requirements and company procedures

1. how to identify hazards and assess risks when preparing to service and repair 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. how land-based equipment should be prepared for service and repair
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 different methods that can be used for the assessment of defects and faults with electrical systems on land-based equipment and for the identification of the root cause  
9. the typical defects and faults that occur with electrical systems on land-based equipment 
10. the factors that determine whether it is worthwhile carrying out the service and repair, such as cost, estimated working life or urgent need for the equipment
11. the components required for the service and repair and the company procedures for obtaining replacements 
12. the principles, construction and function of electrical circuits and their   component types
13. Ohm’s law and its application
14. the principles and effects of electromagnetism
15. the types of circuit protection and control
16. the different types of batteries and their specifications
17. how to safely charge and maintain different battery types
18. the risks posed to electrical systems and components by other activities or incidents
19. how to prevent and rectify corrosion on electrical systems
20. how to establish open circuit, short circuit, high resistance joints and dry joints
21. the methods of switching electrical circuits
22. how to route and secure cables and electrical harnesses
23. how to test, repair and verify electrical systems on land-based equipment using suitable techniques and tools in accordance with the manufacturer’s guidelines
24. the methods of testing electrical systems on completion of the activity to confirm that they perform to the operating specifications prior to returning the equipment to the customer
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 information that needs to be recorded, the company procedure for maintaining records and the requirements of data protection legislation

Circuit protection and control  e.g. battery isolation fuses, thermal switches, over-under voltage switching, battery isolation, relays, RCCD (Residual Current Circuit Device), earth bonding, double insulation

Common voltages : 6, 10, 12, 18, 24, 110, 240, 415 

Electrical circuits and their component types  e.g.

• starter circuits

• ignition circuits

• charging circuits

• lighting circuits

• instrumentation

• spark ignition

• ancillary circuits

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

Integrity of electrical systems  e.g. wiring harnesses, connections, earth, electrical consumers (batteries)

Methods of diagnosis:

• visual inspections

• functional and operational tests

• diagnostic equipment

• remote electronic control and monitoring systems

• reviewing technical data

Risks posed to electrical systems and components by other activities/incidents - e.g. welding, short circuit, battery open circuit, overcharging, reverse polarity

Safety devices  e.g. circuit protection, fuses, safety switches

Stored energy:

• springs

• belt tension

• hydraulic pressure

• electrical discharge

• accumulator discharge

Test equipment to measure and interpret  e.g. voltage, current flow, earth continuity, resistance

Types of battery  e.g. lead acid, gel, and maintenance free 

Verify conformity  e.g. flash test, visual inspection