Service and repair transmission systems on land-based equipment

This standard covers the service and repair of transmission systems on land-based equipment. It includes the removal, dismantling, servicing, repairing, reassembly and reinstating of transmission systems and their component parts, along with the testing, diagnosis and repair practices required for both simple and complex transmissions (e.g. powershift, CVT including belt drive or hydrostatic).

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 using their initiative in a customer-facing role. It may include mentoring a junior colleague to assist in aspects of service and repair.

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. categorise faults and determine the requirements for service and repair
9. identify and establish the availability of replacement components required for the activity
10. interpret schematic drawings of transmissions and their components
11. remove and replace transmission systems and their related components on land-based equipment
12. dismantle, service/repair and reinstate transmission systems in line with the manufacturer’s specification and standards, where applicable
13. identify the components controlling the sequencing of speed, direction and range changes
14. carry out the service and repair of equipment, in accordance with instructions and specifications 
15. remove and replace worn and damaged components in accordance with instructions and specifications
16. confirm that equipment is correctly set or calibrated following service and repair
17. use suitable testing methods to assess the performance of the reassembled system on completion of the work and confirm that it performs to the operating specifications prior to returning the equipment to the customer
18. recycle or sustainably dispose of the different types of waste, including hazardous and non-hazardous, caused by the activity, in accordance with the relevant legal and environmental requirements and company policies 
19. 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 transmission systems on land-based equipment and for the identification of the root cause  
9. the typical defects and faults that occur with transmission 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. how to interpret schematic drawings of transmissions and their components
13. how to remove and replace transmission systems and their components on land-based equipment
14. how to establish the serviceability of transmission parts
15. how to dismantle, service/repair and reinstate transmission systems and their components in line with the manufacturer’s specifications and standards
16. the types, layout, construction and operating principles of transmission systems
17. the methods used to achieve different speed ranges and speeds in transmission systems and the relationship between speed and torque
18. the necessity of timing epicyclic components correctly
19. the procedures used to check phasing, alignment and balance of drive shafts
20. the types of safety and protection devices used to protect the integrity of transmission systems
21. the bearing specification, application and characteristics
22. the methods for setting or calibrating equipment following maintenance or repair 
23. the methods of testing equipment on completion of the activity to confirm that that it performs to the operating specifications prior to returning it to the customer
24. how to recycle or sustainably dispose of the different types of waste, including hazardous and non-hazardous, caused by the activity, in accordance with the relevant legal and environmental requirements and company policies 
25. the potential impact that the activity could have on the environment and the ways in which this can be controlled
26. the information that needs to be recorded, the company procedure for maintaining records and the requirements of data protection legislation

Work on two of the following types of transmission systems:

• powershift

• hydrostatic

• CVT systems (including belt drive)

• dual clutch/semi-automatic transmission

Identify and categorise at least two of the following types of faults on the transmissions worked on:

• mechanical

• hydraulic

• electrical/electronic

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

Stored energy:

• springs

• belt tension

• hydraulic pressure

• electrical discharge

• accumulator discharge