Assembling power plant units
Overview
This standard identifies the competences you need to assemble power plant units, in accordance with approved procedures. You will be required to assemble a range of different power plant components, including engine dress, fuel and ignition system units and, where appropriate, clutch and gearbox assemblies. You will also assemble associated components, pipe and cable connections, by using a variety of assembly methods and techniques. You will be expected to use a range of tools and specialist equipment associated with the assembly methods, and to check that the assembly has been completed to the level of accuracy and quality required by the specification.
Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken, and to report any problems with the process that you cannot resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying procedures appropriate to the assembly of power plant units. You will understand the assembly methods and techniques used, and their application, and will know about the tooling and ancillary equipment, power plant unit components and consumables, in adequate depth to provide a sound basis for carrying out the activities to the required specification.
You will understand the safety precautions required when carrying out the assembly activities. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- ensure that the specified components are available and that they are in a usable condition
- assemble the components in their correct positions, using appropriate methods and techniques
- secure the components using the specified connectors and securing devices
- check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- ensure that work records are completed, stored securely and available to others as per organisational requirements
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and activities and the responsibility they place on you
- the hazards associated with the activities, and how to minimise them and reduce any risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the procedures for obtaining the various types of drawings, job instructions and specifications that are used during the assembly of power plant units, and how to interpret them to correctly
- how to identify different power units, the components to be used and component identification systems (codes and component orientation indicators)
- the assembly methods and procedures to be used, and the importance of adhering to these procedures
- how the components are to be aligned and positioned, prior to securing and the tools and equipment that are used (including jigs and fixtures)
- the various mechanical fasteners that will be used, and their method of installation (threaded fasteners, set and self-tap screws, weld nuts and bolts, and fasteners)
- the application of sealants and adhesives within the assembly activities and the precautions to be taken when working with them
- the company coding procedure for component variants to meet customer requirements
- the operational function of the various power plant components
- the use of torque wrenches and the importance of ensuring fasteners are adjusted to the required settings
- how to apply correct lubricant/fluids to power plant units and the correct waste disposal of surplus fluids
- the consumables, tools and equipment to be used for the assembly of power plant units
- the importance of using the specified fasteners for the assembly and why you must not use substitutes
- how to deal with components or fastening devices that are incorrectly assembled, damaged, or have other faults
- the quality control procedures to be followed during the assembly operations
- how to conduct any necessary checks to ensure the accuracy and quality of the assembly produced
- how to recognise defects (incorrect assembly, ineffective fasteners, component damage)
- the importance of ensuring that the completed assembly is free from left-over items and foreign objects
- the methods and equipment used to transport, handle and lift the power plant units into position, and how to check that the equipment is within its current certification dates
- the preparations to be undertaken on the components and fixing points, prior to fitting the components into the power plant units
- how to check that the tools and equipment to be used are correctly calibrated and are in a safe, tested and serviceable condition
- the importance of ensuring that all tools are used correctly and within their permitted operating range
- the problems with the assembly operations and the importance of informing appropriate people of non-conformances
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the assembly activities:
- obtain and use the appropriate documentation (job instructions, assembly drawings, quality control documentation)
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- check that all cables, extension leads or air supply hoses are in a tested and serviceable condition
- check that all tools and equipment to be used are within current calibration/certification dates
- ensure that sub-assemblies and components used are free from damage, foreign objects, dirt or other contamination before assembling them
- use lifting and slinging equipment in accordance with health and safety guidelines and procedures
- use safe and approved techniques to assemble the sub-assemblies and components
- return all tools and equipment to the correct location on completion of the fitting activities
- leave the work area in a safe and appropriate condition on completion of the activities
Assemble one of the following complete power plant units:
- petrol engine
- diesel engine
- hybrid engine
Assemble components, using four of the following:
- bolts
- weld nuts/bolts
- cable fittings/connections
- drive/interference fits
- clip/spring fastenings
- pipe fittings/connectors
- set/self-tap screws
Assemble components using three of the following devices:
- jigs
- power drivers
- alignment devices
- fixtures
- torque drivers
- fluid filling devices
- balancing devices
- lifting devices
- measuring devices
Assemble the vehicle power plant unit, to include all of the following components:
- cylinder head assembly
- filter systems
- exhaust manifold systems
- piston assembly
- sensing devices
- cables and connections
- crankshaft assembly
- pipes and connections
- seals and gaskets
- fuel supply systems
- gear and belt drives
- vehicle mounting systems
- fuel ignition systems
Assemble ancillary components to the power plant unit, to include one of the following:
- all wheel drive units
- gearbox assembly
- turbo/supercharge system
- coolant system
- clutch assembly
Check that assemblies comply with all of the following quality and accuracy standards:
- the power plant unit assembly is complete
- all fastenings and connections are secure and, where appropriate, torque loaded to specifications
- correct alignment, seating, and clearance of components is achieved
- pipe joints are free from leaks
- the system is free from contaminants and complies to specification