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The Register of Regulated Qualifications

View Unit : Maintaining Mechanical Equipment within an Engineered System

Unit Reference Number
Qualification Framework
Maintaining Mechanical Equipment within an Engineered System
Unit Level
Level 3
Unit Sub Level
Guided Learning Hours
Unit Credit Value
Date of Withdrawal
4.1 Engineering
Unit Grading Structure
Assessment Guidance

This unit must be assessed in a work environment and must be assessed in accordance with the ‘Common Requirements for National Vocational Qualifications (NVQ) in the QCF’ which can be downloaded from Semta’s website: http://www.semta.org.uk/training_providers__awarding/national_occupational_standard/qca_assessment_requirements.aspx

Additional assessment requirements have been published by Semta. These additional assessment requirements are set down in Semta’s Engineering Maintenance Level 3 unit assessment strategy which can be downloaded from Semta’s website: http://www.semta.org.uk/training_providers__awarding/national_occupational_standard/qca_assessment_requirements.aspx

Learning Outcomes and Assessment Criteria
Learning Outcome - The learner will:Assessment Criterion - The learner can:

1a. Maintain mechanical equipment within an engineered system


Work safely at all times, complying with health and safety and other relevant regulations and guidelines


Carry out all of the following during the maintenance activity as applicable to the equipment being maintained:

• plan and communicate the maintenance activities to cause minimal disruption to normal working

• obtain and use the correct issue of company and/or manufacturers’ drawings and maintenance documentation

• adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work

• ensure the safe isolation of equipment (such as mechanical, electricity, gas, air or fluids)

• provide and maintain safe access and working arrangements for the maintenance area

• carry out the maintenance activities using appropriate techniques and procedures

• reconnect and return the system to service on completion of the maintenance activities

• dispose of waste items in a safe and environmentally acceptable manner, ...


... and leave the work area in a safe condition


Carry out maintenance activities on three of the following types of mechanical equipment:

• gearboxes

• machine tools

• lifting and handling equipment

• workholding arrangements

• processing plant

• pumps

• compressors

• transfer equipment

• mechanical structures

• conveyors/elevators

• other specific equipment

• process control valves

• engines


Follow the relevant maintenance schedules to carry out the required work


Ensure that the maintenance activities comply with one of the following:

• organisational guidelines and codes of practice

• equipment manufacturer’s operation range

• BS7671/IEE wiring regulations

• BS, ISO and/or BSEN standards


Carry out the maintenance activities within the limits of their personal authority


Carry out the maintenance activities in the specified sequence and in an agreed timescale


1b. Maintain mechanical equipment within an engineered system (continued)


Use appropriate dismantling and re-assembly techniques to deal with two of the following:

Fluid power components:

• releasing stored pressure

• disconnecting/removing hoses and pipes

• chocking/supporting cylinders/rams/components

• removing and replacing units/components (such as pumps, valves, actuators)

Electrical components:

• isolating the power supply

• disconnecting and reconnecting wires/cables

• removing and replacing major electrical components (such as motors, switch/control gear)

• removing/replacing minor electrical components (such as relays, sensing devices, limit switches)

• removing and replacing wiring enclosures (such as conduit, trunking and traywork)

Process controller components:

• de-activating and resetting program controller

• re-loading programs and making minor amendments

• removing and ...


... replacing input/output interfacing

• disconnecting/reconnecting wires/cables

• removing and replacing program logic peripherals


Carry out all of the following maintenance techniques, as applicable to the equipment being maintained:

• draining and removing fluids

• dismantling equipment to unit/sub-assembly level

• dismantling units to component level

• proofmarking/labelling of components

• setting, aligning and adjusting replaced components

• replacing all ‘lifed’ items (such as seals, bearings, gaskets)

• tightening fastenings to the required torque

• making ‘off-load’ checks before powering up

• replenishing oils and greases

• functionally testing the complete system

• replacing damaged/defective components

• checking components for serviceability


Replace/refit a range of mechanical components, to include seven of the following:

• shafts

• couplings

• gears

• clutches

• valves and seats

• brakes

• bearing and seals

• fitting keys

• cams and followers

• springs

• chains and sprockets

• pulleys and belts

• slides

• levers and links

• locking and retaining devices (such as circlips, pins)


Report any instances where the maintenance activities cannot be fully met or where there are identified defects outside the planned schedule


Complete relevant maintenance records accurately, to include one of the following, and pass them on to the appropriate person:

• job cards

• permits to work/formal risk assessment and/or sign on/off procedures

• maintenance log or report

• company-specific documentation


Dispose of waste materials in accordance with safe working practices and approved procedures


2a. Know how to maintain mechanical equipment within an engineered system


Describe the health and safety requirements of the area in which the maintenance activity is to take place, and the responsibility these requirements place on the learner


Describe the isolation and lock-off procedure or permit-to-work procedure that applies to the system


Describe the specific health and safety precautions to be applied during the maintenance activity, and their effects on others


Explain how to recognise and deal with victims of electric shock (to include methods of safely removing the victim from the power source, isolating the power source, and methods of first aid resuscitation)


Describe the importance of wearing protective clothing and other appropriate safety equipment during the maintenance activities


Describe the hazards associated with carrying out maintenance activities on an integrated system (such as handling fluids, stored pressure/force, electrical supplies, process controller interface, using damaged or badly maintained tools and equipment, not following laid-down maintenance procedures), and how to minimise these and reduce any risks


Explain how to obtain and interpret drawings, charts, specifications, manufacturers’ manuals, history/maintenance reports and other documents needed for the maintenance activities


Describe the basic principles of how the system functions, its operation sequence, the working purpose of individual units/components, and how they interact


Describe the procedure for obtaining replacement parts, materials and other consumables necessary for the maintenance


Describe the company policy on repair/replacement of components during the maintenance activities


Describe the sequence to be adopted for dismantling and reassembling the equipment, to both sub-assembly and individual component level


Describe the methods of removing components that have interference fits (expansion, contraction or pressure)


2b. Know how to maintain mechanical equipment within an engineered system (continued)


Describe the techniques used to dismantle/assemble integrated equipment (such as release of pressures/force, proof marking to aid assembly, plugging exposed pipe/component openings, dealing with soldered joints, screwed, clamped and crimped connections)


Describe the methods of attaching identification marks/labels to removed components or cables, to assist with re-assembly


Describe the methods of checking that components are fit for purpose, and the need to replace ‘lifed’ items (such as seals, gaskets and bearings)


Explain how to make adjustments to components/assemblies, to ensure they function correctly


Explain how to check that tools and equipment are free from damage or defects, are in a safe and usable condition, and are configured correctly for the intended purpose


Describe the importance of making ‘off-load’ checks before proving the equipment with the electrical supply on


Describe the generation of maintenance documentation and/or reports on completion of the maintenance activity


Describe the equipment operating and control procedures to be applied during the maintenance activity


Explain how to use lifting and handling equipment safely and correctly in the maintenance activity


Describe the problems that can occur during the maintenance activity, and how they can be overcome


Describe the organisational procedure to be adopted for the safe disposal of waste of all types of material


Describe the extent of their authority and to whom they should report if they have a problem that they cannot resolve

Equivalent Units
There are no equivalences to display.