Remove and replace lift truck electrical 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 electrical 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 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 electrical unit and component removal and replacement

K9 the importance of using the correct sources of technical information

K10 the purpose of and how to use identification codes

Electrical auxiliary system operation and construction

K11 how electrical auxiliary units and components are constructed, removed and replaced for the classification of lift truck worked upon

K12 how electrical auxiliary units and components operate for the classification of lift truck worked upon

Equipment

K13 how to prepare, test and use all the removal and replacement equipment required

Electrical and electronic principles

K14 lift truck earthing methods

K15 electrical and electronic principles associated with electrical systems, including types of sensors and actuators, their application and operation

K16 types of circuit protection and why these are necessary

K17 electrical safety procedures

K18 how warning and charging and starter circuits work

K19 electrical units, terms and schematics

K20 electronic control system principles

K21 battery principles and safety working practices

Electrical unit and component removal and replacement

K22 how to remove and replace electrical units and components for the lift truck worked upon

K23 how to test and evaluate the performance of replacement electrical units and components and the reassembled system against the lift truck operating specifications and any legal requirements

K24 the relationship between testing methods and the electrical units and components replaced – the use of appropriate test methods

K25 the manufacturer’s specification for the type and quality of electrical 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

1.1. hand tools

1.2. special workshop tools

1.3. general workshop equipment

1.4. electrical meters

1.5. electronic diagnostic tools

1.6. on board diagnostic tools

2. Testing methods include:

2.1. sensory

2.2. functional

2.3. measurements

3. Electrical units and components are for:

3.1. lighting systems

3.2. accelerator systems

3.3. electric warning devices

3.4. direction control devices

3.5. hydraulic systems

3.6. speed governing devices

3.7. starting and generator systems

3.8. charging systems

3.9. traction control systems

3.10. electric drive, hydraulic and steering motors

3.11. monitoring and instrumentation systems

3.12. traction battery systems