1. Plan for inspection, testing and/or maintenance tasks

1.1 Access, interpret and apply compliance and other documentation relevant to the inspection, testing and maintenance of the ancillary systems of diesel engine systems

1.2 Obtain, interpret and clarify work requirements for the satisfactory completionoftasks

1.3 Resolvecoordinationrequirements with others at the site prior to commencing and during work activities

2. Prepare for inspection, testing and/or maintenance tasks

2.1 Inspect and prepare work area in coordination with others

2.2 Identify and obtain items and tools required for the safe, effective and efficient completion of the tasks

2.3 Identify and arrange support required for completion of tasks

2.4 Select and use personal protection equipment appropriate to the task

2.5 Carry out required equipment pre-start procedures

2.6 Carry out required isolation and lock-out of all equipment necessary for the safe execution of tasks

2.7 Recognise and respond to hazardous and emergency situations

3. Carry out inspection of diesel engines and their ancillary systems

3.1 Inspect diesel engine systems and their ancillary systems

3.2 Report outcomes of inspection to appropriate person

4. Carry out testing of diesel engines and their ancillary systems

4.1 Select and operate testing equipment and methods

4.2 Carry out safe effective and efficient testing and fault finding of diesel engine systems

4.3 Carry out testing and fault finding of ancillary systems on diesel engine systems

4.4 Diagnose and record existing or identified faults

5. Carry out routine maintenance of diesel engines and their ancillary systems

5.1 Select and use maintenance items, tools and equipment

5.2 Rectify diagnosed and identified faults

5.3 Carry out routine maintenance of diesel engine systems and their ancillary systems in accordance with the work requirements

5.4 Carry out maintenance of diesel engine ancillary systems in accordance with the work requirements

6. Carry out the overhaul of diesel engines and their ancillary systems

6.1 Select and use overhaul items, tools and equipment

6.2 Carry out overhaul of diesel engine systems in accordance with the work requirements and Australian Standards

6.3 Carry out overhaul of ancillary systems on diesel engine systems in accordance with work requirements and Australian Standards

7. Complete post-work activity requirements

7.1 Tidy up work area

7.2 Dispose of used oil, lubricant and other waste

7.3 Return and secure all tools and re-usable items

7.4 Report outcomes of inspection, testing, maintenance and overhaul tasks to appropriate person

7.5 Complete and maintain inspection, testing and maintenance records

Required skills

Specific skills are required to achieve the performance criteria in this unit, particularly for the application in the various circumstances in which this unit may be applied.

This includes the ability to carry out the following to inspect, test and maintain diesel engine systems and their ancillary systems:

apply legislative, organisation and site requirements and procedures

apply site risk, statutory compliance, health, safety, environmental, quality and communication requirements and procedures

apply site and manufacturer’s requirements and procedures

apply surface and underground worksite hazard identification and risk management requirements and procedures

apply task hazard identification and risk management requirements and procedures

apply technical literacy

interpret and apply technical and scientific/industry terminology

communicate with those providing support

apply work area and equipment inspection procedures

apply work area safeguarding options and requirements

apply isolation and lock-out requirements and procedures

apply hazard and emergency procedures

apply site service and maintenance reporting requirements and procedures

work wearing appropriate personal protective equipment

apply mechanical trade/engineering skills and experience

use tools for inspection, testing and maintenance

Required knowledge

Specific knowledge is required to achieve the Performance Criteria of this unit, particularly its application in a variety of circumstances in which the unit may be used.

This includes knowledge of the following, to inspect, test and maintain diesel engine systems and their ancillary systems:

site risk, statutory compliance, health, safety, environmental, quality and communication requirements and procedures

limitations on allowable maintenance including work in hazardous environments

limitations on allowable modifications and the required controls and procedures

site and manufacturer’s requirements and procedures

the relative characteristics, performance and suitability for the underground use of common diesel engine types including;

two stroke or four stroke,

directly injected or indirectly injected (pre-combustion),

naturally aspirated or charge boosted (turbocharged or super-charged) intake systems

basic type of mechanical fuel delivery systems including;

distributor type pumps (VE)

jerk type pumps

pressure/time type pumps (PT)

hydraulic injectors (internal pintle)

basic type of electrical/electronic fuel delivery and engine management systems including;

unit injectors [HEUI (hydraulic electric unit injectors), MEUI (mechanical electric unit injectors and piezo]

the effect of increased injection pressure on performance and emissions

the controls, sensors and management systems integrated into ECMs

characteristics of materials used in the diesel engine system,

items required to be used in performance of inspection, testing and maintenance tasks

tools required for the performance of inspection, testing and maintenance tasks

provisions of AS/NZS3584.1, 2 and 3 relating to fasteners and joints

recognise the requirements and performance of various types of fasteners, including bolts, studs, threads and washers

site inspection, testing and maintenance support requirements and availability

site work area inspection requirements

site work area safeguarding options and requirements

site isolation and lock-out requirements and procedures

site hazard and emergency procedures

site inspection, testing and maintenance reporting requirements and procedures

site inspection, testing and maintenance record procedures

site requirements and procedures for working in isolation

site requirements for the use of personal protective equipment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

The evidence required to demonstrate competency in this unit must be relevant to worksite operations and satisfy all of the requirements of the performance criteria, required skills and knowledge and the range statement of this unit and include evidence of the following:

Knowledge of the requirements, procedures and instructions for the inspection, testing and maintenance of diesel engine systems and their ancillary systems

Implementation of requirements, procedures and techniques for the safe, effective and efficient completion of the inspection, testing and maintenance of diesel engine systems and their ancillary systems

Working with others to undertake and complete the inspection, testing and maintenance of diesel engine systems and their ancillary systems that meets all of the required outcomes.

Consistent timely completion of the inspection, testing and maintenance of diesel engine systems and their ancillary systems that safely, effectively and efficiently meets the required outcomes.

Context of and specific resources for assessment

This unit must be assessed in the context of the work environment. Where personal safety or environmental damage are limiting factors, assessment may occur in a simulated environment provided it is realistic and sufficiently rigorous to cover all aspects of workplace performance, including task skills, task management skills, contingency management skills and job role environment skills.

The assessment environment should not disadvantage the participant. For example, language, literacy and numeracy demands of assessment should not be greater than those required on the job.

Customisation of assessment and delivery environment to sensitively accommodate cultural diversity.

Aboriginal people and other people from a non English speaking background may have second language issues.

Assessment of this competency requires typical resources normally used in a resources and infrastructure sector environment. Selection and use of resources for particular worksites may differ due to the site circumstances.

Where applicable, physical resources should include equipment modified for people with disabilities.

Access must be provided to appropriate learning and/or assessment support when required.

Method of assessment

This unit may be assessed in a holistic way with other units of competency. The assessment strategy for this unit must verify required knowledge and skill and practical application using more than one of the following assessment methods:

written and/or oral assessment of the candidate’s required knowledge

observed, documented and/or first hand testimonial evidence of the candidate’s:

implementation of appropriate requirement, procedures and techniques for the safe, effective and efficient achievement of required outcomes

consistently achieving the required outcomes

first hand testimonial evidence of the candidate:

working with others to undertake and complete the inspection, testing and maintenance of diesel engine systems and their ancillary systems

Guidance information for assessment

Consult the SkillsDMC User Guide for further information on assessment including access and equity issues.

Compliance documentation and other documentation may include

certification documentation

approval documentation

legislative, organisation and site requirements and procedures

manufacturer’s specifications and guidelines

Australian Standards, including: AS/NZS3584 and AS 4291

codes of practice

Employment and Workplace Relations legislation

Equal Employment Opportunity and Disability Discrimination legislation

Inspection may include:

checking the marking of parts/components

checking that the diesel engine system and engine compartment is free of loose materials, including coal dust

checking that there are no diesel fuel leaks or leaks of any other flammable liquids

checking that the engine oil level is correct

checking that guards are in place and secure. (e.g. radiator and pulley guards)

checking that the V belts are in place and undamaged

checking that the V belts are correctly tensioned

confirming that the vee belts are fire-resistant and anti-static (FRAS)

check that the vee-belt pulleys are lubricated (if required)

confirming that the engine mountings are secure

inspecting the throttle linkages to ensure that they are in good condition and fully operative

inspecting the fuel injector lines (including common rail, high pressure, lines) to ensure that they are in good condition, properly restrained, protected from abrasion and not showing any signs of wear cracks or leaks

inspecting (visual) that the compressor delivery line is in a good condition, if a flexible hose is used, confirm that it is PTFE/steel wire braid hose

removing hoses from air compressor and inspecting ports, fittings and hoses and ensuring that there is no significant build-up of carbon

checking that the engine sump is secure and undamaged and there is no evidence of oil leaks

checking that the engine crankcase breather is clean and not blocked

confirming that the starter motor is securely mounted

Testing may include:

conduct surface temperature test and confirm that the location and temperature are within a reasonable tolerance of the information provided on the drawings

Maintenance is:

the combination of actions carried out to retain a diesel engine system in, or to restore it to, conditions in which it is able to meet the requirements of the relevant specification and perform its required function

Maintenance may include:

service

adjust

replace

repair

overhaul

modify

Diesel engine ancillary equipment may include:

air compressors

Diesel engine systems are:

diesel engines for underground coal mines and their:

inlet systems

exhaust systems

cooling systems

starting systems

shut-down and protection systems

electrical or electronic devices

Work requirements may come from briefings, handovers, and work orders and may include:

nature and scope of tasks

procedures to be applied

quality standards to be applied

available resources

achievement targets

operational conditions

site layout

out-of-bounds areas

designated safe areas

explosion-risk zones

hazardous areas

other hazards and potential hazards

obtaining permits required

worksite inspection requirements

lighting conditions

plant or equipment defects

coordination requirements or issues

Others may include:

other maintenance personnel

support providers

contractors

under-ground production personnel

mobile or fixed plant operators

Inspect and prepare work area may include:

determining if the proposed work area is a designated safe area

identification of explosion-risk zones

identification of hazardous areas

identification of hazards, including:

workshop work area hazard

underground work area hazards, and

work activity hazards

fire

explosion

emissions

selection and implementation of control measures for the hazards identified

safeguarding site and non-site personnel by:

erection of barricades and posting of signs

selection of appropriate equipment to ensure personnel safety and protection

Items may include:

authorised replacement parts

fasteners as specified in manufacturer’s drawings, which may include:

tensile strength

head and nut configuration

thread form and engagement

corrosion resistance (materials)

coatings (materials and application)

tolerances for fits and threads

tolerances for mating surfaces

dimensions of clearance holes

fixing torques

lubricants and anti-seize compounds used

packing materials

Tools may include:

hand tools

power tools

special tools

testing equipment

Support may include:

other site personnel

contractors

cranes

other lifting equipment

Personal protection equipment may include:

hard hats

eye protection

hearing protection

breathing apparatus

gas/fume masks

prescribed footwear

Pre-start procedures include checking:

cleanliness, particularly coal dust

diesel and other flammable liquid leaks

coolant leaks in radiator or radiator hoses

coolant level

that guards are in place and secure

engine oil level is correct

Hazardous and emergency situations may include:

working alone

personal injury

fire

explosions

emissions

electrical

noise

dust

noxious gases

environmental

chemical

Diagnose faults may include:

root cause analysis

troubleshooting techniques

Routine maintenance is to include:

servicing, including:

cleaning

checking and filling lubricants, fuel and water

draining the fuel/water separator

draining all air receivers and water separators

emptying filters fitted to the pneumatic system

filling the pneumatic system lubricator

adjusting

changing (replacing), including

fuel filters

engine-oil and filter

pneumatic air filters

Overhaul may include:

removal

dismantling

cleaning

inspecting

replacing, eg:

gaskets

fasteners

testing, including:

flatness

measuring dimensions

hydrostatic

reassembly

reinstallation

Records may include:

inspection and test results

defect identified

defect rectification carried out

item consumed

hazard/risk management reports