Remove and replace lift truck driveline units and components

P2.1 lift truck technical data

P2.2 removal and replacement procedures

P2.3 legal requirements

P3 prepare, set up, 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 industry recognised repair methods

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 damage to your working environment

P5.6 instability when working on the lift truck

P6 ensure replaced driveline 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 assembled system

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

P10 ensure the reassembled transmission system performs to the lift truck operating specification and meets any legal requirements prior to return to the customer

P11 ensure your records are accurate, complete and promptly passed to the relevant person(s) in authority in the format required

P12 complete all removal and replacement activities within the agreed timescale

P13 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 transmission and driveline 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 transmission and driveline 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

Transmission and driveline system operation and construction

K17 how transmission and driveline systems and their related units and components are constructed, removed and replaced for the classification of lift truck worked upon

K18 how transmission and driveline systems and their related units and components operate for the classification of lift truck worked upon

K19 transmission schematic symbols and diagrams

Equipment

K20 how to prepare, inspect and use all the removal and replacement equipment required

Transmission and driveline system unit and component removal and replacement

K21 how to remove and replace transmission and driveline system mechanical, electrical and hydraulic units and components for the classification of lift truck worked upon

K22 how to select and use gaskets, sealants, seals, fittings and fasteners

K23 how to test and evaluate the performance of replacement transmission and driveline system 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 transmission system units and components replaced – the use of appropriate test methods

K25 the relationship between testing methods and the driveline system units and components replaced

K26 when replacement units and components must meet the original equipment specification (OES) for warranty or other requirements

K27 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

2. Testing methods include:

2.1. sensory

2.2. functional

2.3. measurement

3. Units and components include:

3.1. mechanical

3.2. electrical

3.3. hydraulic

4. Transmission and driveline systems include: 

4.1. powershift units

4.2. hubs and bearings

4.3. driveline shafts

4.4. torque converters

4.5. control valves

4.6. final drive units

4.7. motor control units

4.8. hydrostatic

4.9. generator