Remove and replace lift truck mechanical handling and chassis units and components

P2.1 lift truck technical data

P2.2 removal and replacement procedures

P2.3 legal requirements

P3 prepare, inspect 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 mechanical handling and chassis 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 mechanical handling and chassis 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 mechanical handling and chassis systems

K9 the importance of using the correct sources of technical information 

K10 how to use parts lists and identification codes

Electrical and electronic principles

K11 lift truck earthing methods

K12 electrical and electronic principles associated with chassis and mechanical handling systems, including types of sensors and actuators, their application and operation

K13 types of circuit protection and why these are necessary

K14 electrical safety procedures

K15 electrical units, terms and schematics

K16 electronic control system principles

Hydraulics and Hydraulic Principles

K17 how hydraulic lift truck systems operate including rams, pumps, motors and valve blocks

K18 how to inspect hydraulic systems and components to ensure they fall within manufacturer’s specifications

K19 how to remove and replace hydraulic system components

K20 hydraulic schematics and symbols

K21 health and safety risks associated with hydraulic systems

Mechanical handling and chassis system operation and construction

K22 how mechanical handling and chassis systems are constructed, dismantled and reassembled for the classification of lift truck worked upon

K23 how mechanical handling and chassis systems operate for the classification of lift truck worked upon

Equipment

K24 how to prepare, inspect and use all the removal and replacement equipment required

K25 the regulations relating to lifting and slinging equipment

Mechanical handling and chassis system unit and component removal and replacement

K26 how to remove and replace mechanical handling and chassis system mechanical, electrical and hydraulic units and components for the classification of lift truck worked upon

K27 how to select and use gaskets, sealants, seals, fittings and fasteners

K28 how to test and evaluate the performance of replacement mechanical handling and chassis system units and components and the reassembled system against the lift truck operating specifications and any legal requirements

K29 how to select the appropriate test method for the unit/component being worked upon

K30 when replacement units and components must meet the original equipment specification (OES) for warranty or other requirements

K31 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 testing equipment

1.5. lifting and slinging 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

3.3. hydraulic

4. Mechanical handling and chassis systems include:

4.1. mast, carriage and attachment assemblies

4.2. hydraulic units and components

4.3. steering systems

4.4. braking systems