Diagnose and rectify lift truck mechanical handling and chassis system faults

This standard is about diagnosing and rectifying faults occurring within lift truck mechanical handling, steering and braking systems.

P2.1 technical data

P2.2 diagnostic test procedures

P3 prepare, connect and test all the required equipment following manufacturers' instructions prior to use

P4 use diagnostic testing methods which are relevant to the symptoms presented

P5 collect diagnostic information in a systematic way relevant to the diagnostic testing methods used

P6 collect sufficient diagnostic information to enable an accurate diagnosis of chassis system faults

P7 accurately identify and record any system deviation from acceptable limits 

P8 ensure your assessment of dismantled sub-assemblies, components and units accurately identifies their condition and suitability for repair or replacement

P9 promptly inform the relevant person(s) where repairs are uneconomic or unsatisfactory to perform

P10 use the equipment required, correctly and safely throughout all rectification activities

P11 carry out all rectification activities following:

P11.1 manufacturers' instructions

P11.2 your workplace procedures

P11.3 health and safety requirements

P12 work in a way which minimises the risk of :

P12.1 damage to other lift truck systems

P12.2 damage to other components and units

P12.3 injury to yourself and others

P12.4 contact with hazardous substances.

P12.5 instability when working on a lift truck

P13 ensure all repaired and replaced  components and units conform to the lift truck operating specification and any legal requirements

P14 adjust components and units correctly to ensure that they operate to meet system requirements, when necessary

P15 promptly record and report any additional faults you notice during the course of work 

P16 use testing methods which are suitable for assessing the performance of the system rectified

P17 ensure the mechanical handling and chassis system rectified performs to the lift truck operating specification and any legal requirements prior to return to the customer

P18 ensure your records are accurate, complete and promptly passed to the relevant person(s) in the format required

P19 complete all system diagnostic activities within the agreed timescale

P20 promptly report any anticipated delays in completion to the relevant person(s)in authority 

K3.1 recording fault location and correction activities

K3.2 reporting the results of tests

K3.3 the referral of problems

K3.4 reporting delays to the completion of work

K4 the importance of working to recognised diagnostic and rectification procedures and processes and obtaining the correct information for diagnostic and rectification activities to proceed 

K5 the importance  and purpose of recording diagnostic and rectification activities

K6 the importance of working to agreed timescales and keeping others informed of progress

K7 the relationship between time, costs and profitability

K8 the importance of promptly reporting anticipated delays to the relevant person(s) in authority 

Electrical and electronic principles

K9 electrical and electronic principles associated with mechanical handling and lift truck chassis systems, including types of sensors and actuators, their application and operation

K10 how electrical and electronic mechanical handling and lift truck chassis systems operate, including electrical component function, motor controls, electrical inputs, outputs, voltages digital and fibre optics principles

K11 the interaction between electrical, electronic and mechanical components within mechanical handling and lift truck chassis systems

K12 how mechanical handling and lift truck chassis systems interlink and interact, including multiplexing

K13 electrical units, terms and schematics

K14 electrical safety procedures

Hydraulics and hydraulic principles

K15 how hydraulic lift truck systems operate including rams, pumps, motors and valve blocks

K16 how to inspect and test hydraulic systems and components

K17 how to remove, strip and re-seal hydraulic system components

Use of diagnostic and rectification equipment

K18 how to prepare and test the accuracy of diagnostic testing equipment *

K19 how to use diagnostic and rectification *equipment for mechanical handling and chassis mechanical, electrical, hydraulic and fluid systems, specialist repair tools and general workshop equipment

Mechanical handling and chassis faults, their diagnosis and correction

K20 how mechanical handling and chassis mechanical, electrical, electronic and hydraulic and fluid systems are constructed, dismantled, reassembled and operate

K21 the types and causes of mechanical handling and chassis mechanical, electrical, electronic and hydraulic and fluid system, component and unit faults and failures

K22 mechanical handling and chassis mechanical, electrical and hydraulic and fluid component and unit replacement procedures, the circumstances which will necessitate replacement and other possible courses of action

K23 how to find, interpret and use sources of information on chassis electrical operating specifications, diagnostic test procedures, repair procedures and legal requirements

K24 lift truck operating specifications for limits, fits, pressures and tolerances relating the mechanical handling and chassis mechanical, electrical, electronic and hydraulic and fluid systems for the lift truck(s) on which you work 

K25 how to select the most appropriate diagnostic testing method for the symptoms presented

K26 how to carry out systematic diagnostic testing of mechanical handling and chassis

K27 mechanical, electrical and electronic, hydraulic and fluid systems using a prescribed process or format

K28 how to assess the condition evident within mechanical handling and chassis mechanical, electrical, electronic, hydraulic and fluid components and units 

K29 how to interpret test results and lift truck data in order to identify the location and cause of lift truck system faults

K30 how to carry out rectification activities in order to correct faults in the mechanical handling and chassis mechanical, electrical, electronic and hydraulic and fluid systems

K31 the relationship between test methodology and the faults repaired – the use of appropriate testing methods

K32 how to make cost effective recommendations for rectification

1.1. mast and carriage assemblies

1.2. steering 

1.3. braking

1.4. hydraulic systems 

2. Diagnostic testing methods include:

2.1. measurement

2.2. functional testing

2.3. electrical and electronic systems testing

3. Equipment includes:

3.1. diagnostic and rectification equipment for mechanical handling and chassis mechanical systems 

3.2. diagnostic and rectification equipment for mechanical handling and chassis electrical systems

3.3. diagnostic and rectification equipment for mechanical handling and chassis hydraulic and fluid systems 

3.4. specialist repair tools

3.5. general workshop equipment

4. Faults can be:

4.1. mechanical

4.2. electrical and electronic

4.3. hydraulic and fluid