Remove and replace power source units and components

P2.1 lift truck technical data

P2.2 removal and replacement procedures

P2.3 legal requirements

P3 prepare, test and use all the equipment required following manufacturers’ instructions

P4 carry out all removal and replacement activities following:

P4.1 manufacturers’ instructions

P4.2 your workplace procedures

P4.3 health and safety requirements

P5 work in a way which minimises the risk of:

P5.1 damage to other lift truck systems

P5.2 damage to other lift truck components and units

P5.3 injury to yourself and others

P5.4 contact with hazardous substances.

P5.5 instability when working on the lift truck

P6 ensure replaced power source units and components conform to the lift truck operating specification and any legal requirements

P7 promptly record and report any additional faults you notice during the course of your work 

P8 use suitable testing methods to evaluate the performance of the reassembled system

P9 ensure the reassembled power source system performs to the lift truck operating specification and meets any legal requirements prior to return to the customer

P10 ensure your records are accurate, complete and promptly passed to the relevant person(s) in the format required

P11 complete all removal and replacement activities within the agreed timescale

P12 promptly report any expected delays in completion to the relevant person(s) in authority 

K3.1 recording removal and replacement information

K3.2 the referral of problems

K3.3 reporting delays to the completion of work

K4 the importance and purpose of recording removal and replacement activities

K5 the importance of working to agreed timescales and keeping others informed of progress

K6 the relationship between time and costs

K7 the importance of promptly reporting anticipated delays to the relevant person(s) in authority 

Use of technical information

K8 how to find, interpret and use sources of information applicable to unit and component removal and replacement within power source systems

K9 the importance of using the correct sources of technical information

K10 the purpose of and how to use identification codes

Electrical and electronic principles *

K11 lift truck earthing methods

K12 electrical and electronic principles associated with lift truck *power source systems, including types of sensors, actuators, their application and operation

K13 types of circuit protection and why these are necessary

K14 electrical safety procedures

K15 how warning, charging and starter circuits work

K16 electrical units, terms and schematics

K17 battery charging and voltage

K18 electronic control system principles

Power source system operation and construction

K19 how power source systems and their related units and components are constructed, dismantled and reassembled for the classification of lift truck worked upon

K20 how power sources and their related units and components operate for the classification of lift truck worked upon

Equipment

K21 how to prepare, test and use all the removal and replacement equipment required

Power source unit and component removal and replacement

K22 how to remove and replace power source system mechanical and electrical units and components for the classification of lift truck worked upon

K23 how to select and fit gaskets, sealants, fittings and fasteners

K24 how to test and evaluate the performance of replacement power source unit and components and the reassembled system against the lift truck operating specifications and any legal requirements - the use of appropriate test methods

K25 the manufacturer’s specification for the type and quality of power source units and components to be used

K26 how to work safely avoiding damage to other lift truck systems, components and units and contact with leakage and hazardous substances relating to yourself and the environment

​1. Equipment includes:

1.1. hand tools

1.2. special workshop tools and equipment

1.3. general workshop equipment

1.4. electrical testing equipment

2. Testing methods include:

2.1. sensory

2.2. functional

2.3. measurements

3. Units and components include:

3.1. mechanical

3.2. electrical

4. Power source systems and components include:

4.1. diesel and gas engine mechanical systems

4.2. cooling systems

4.3. air supply and exhaust systems

4.4. fuel and ignition systems

4.5. engine electrical systems

4.6. lubrication systems

4.7. electric motor systems

4.8. motor control systems

4.9. hybrid storage systems

4.10. starting systems (IC)

4.11. charging systems