Carry out routine lift truck maintenance

This standard is about conducting routine maintenance, adjustment and replacement activities as part of the periodic servicing of fork lift trucks.

P5.1 the manufacturer’s approved examination methods

P5.2 your workplace procedures

P5.3 health and safety requirements

P6 ensure any problems that you notice whilst carrying out your servicing activity are promptly reported to the relevant person(s) in authority 

P7 carry out adjustments, replacements and replenishment of consumable materials following the manufacturer’s current specification and timescales for:

P7.1 the particular service interval

P7.2 working methods and procedures

P7.3 use of equipment

P7.4 tolerances relevant to the lift truck you are working on

P8 record work details accurately and where system adjustments cannot be made within the manufacturer’s specification report these deviations to the relevant person(s)

P9 carry out a risk assessment to avoid risk of damage to the lift truck, its systems, the surrounding environment and yourself

P10 use suitable testing methods to evaluate the performance of all replaced and adjusted components and systems accurately, prior to returning the lift truck to the customer

P11 promptly report any problems or issues relating to the lift truck’s condition or conformity to the relevant person(s) 

P12 ensure your maintenance records are accurate, complete and promptly passed to the relevant person(s) in the format required

P13 complete all lift truck maintenance activities within the agreed timescale

P14 promptly report any anticipated delays in completion to the relevant persons(s) in authority 

K4.1 recording maintenance work and any variations from the original specification

K4.2 the referral of problems

K4.3 reporting delays to the completion of work

K5 how to carry out a risk assessment

K6 the importance of documenting maintenance information

K7 how to complete a maintenance report

K8 the importance of working to agreed timescales and keeping others informed of progress

K9 the relationship between time and costs

K10 the importance of promptly reporting anticipated delays to the relevant person(s) in authority 

K11 the responsibilities towards environmental issues for:

K11.1 your organisation

K11.2 the customer workplace in which you are working

K11.3 yourself 

Use of technical information

K12 how to find, interpret and use sources of technical information for scheduled maintenance activities including manufacturers’ recommended timescales and on-board diagnostic displays

K13 the importance of using the correct sources of technical information *

K14 the purpose of and how to use identification codes

Lift truck system operation 

K15 how power source systems for lift trucks operate; including gas, diesel, electric and alternative fuels

K16 how transmission systems and components, for internal combustion and electric lift trucks function

K17 how the lifting systems, steering systems, braking systems operate

K18 the purpose, operating principles, location and limits of responsibility of power storage systems (including batteries), power generating systems,(including off vehicle charging systems) starting systems

K19 the operating specifications and tolerances for the type(s) of lift trucks that you are maintaining

Routine maintenance requirements

K20 how to conduct scheduled, routine *examination methods and assessments against specifications to identify damage, corrosion, inadequate fluid levels, leaks, wear and general condition and serviceability

K21 check and make adjustments to clearances, gaps, settings, alignment, pressures, tension, speeds and levels in accordance with the manufacturers’ service schedule

K22 how to replenish and replace routine service components and materials in accordance with the service schedule

K23 how to identify and report damage to the lift truck

K24 how to identify codes and grades of lubricants

K25 how to work safely avoiding damage to the lift truck and its systems

​1. Sources of technical information include:

1.1. lift truck technical data

1.2. schedules of inspection

1.3. regulations

2. Examination methods include:

2.1. sensory

2.2. functional

2.3. measurements

3. Assessments are for:

3.1. malfunction

3.2. damage

3.3. fluid levels

3.4. leaks

3.5. wear

3.6. condition and serviceability

3.7. conformity

3.8. necessity for adjustment(s)

3.9. battery (lead acid/traction)