Restoring lifting platforms to service by replacing or repairing components
Overview
This standard identifies the competences you need to restore powered lifting platforms to usable condition by repairing or replacing components, in accordance with approved procedures. You will be required to restore a range of lifting platforms, such as traction, hydraulic, and direct drive, to operational condition by repairing or replacing assemblies/sub-assemblies and components. You will also be required to select the appropriate equipment to use, based on the nature of the repair, and the operations to be carried out.
Your responsibilities will require you to comply with organisational policy and procedures for the repair/replacement activities undertaken, and to report any problems with these activities, or with the tools, equipment or materials used, that you cannot personally resolve or that are outside your permitted authority, to the relevant people. You will be expected to work to instructions, either alone or in conjunction with others, taking personal responsibility for your own actions, and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will be sufficient to provide a sound basis for your work, and will provide an informed approach to applying component repair/replacement procedures to lifting platforms. You will have an understanding of the function and operating conditions of the various components, in sufficient depth to determine if a suitable repair can be made, and to ensure that any repairs or replacements carried out are safe and practical in operation.
You will understand the safety precautions required when carrying out the repair/replacement activity, especially those for isolating the equipment. You will also understand your responsibilities for safety, and the importance of taking the necessary safeguards to protect yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant specifications for the component to be repaired
- prepare the component for repair
- carry out the repairs within agreed timescale using approved materials and components and methods and procedures
- ensure that the repaired component meets the specified operating conditions
- produce accurate and complete records of all repair work carried out
Knowledge and Understanding
You need to know and understand:
- the health and safety requirements of the area in which the repair or replacement activity is to take place, and the responsibility these requirements place on you
- the isolation and lock-off procedure or permit-to-work procedure that applies
- the specific health and safety precautions to be applied during the repair/replacement procedure, and their effects on others
- the importance of wearing protective clothing and other appropriate safety equipment (PPE) during repair/replacement activities
- the hazards associated with carrying out repairs on lifting platforms (such as handling oils, greases, stored pressure/force, misuse of tools, using damaged or badly maintained tools and equipment, not following laid-down servicing procedures), and how to minimise them
- where to obtain, and how to interpret job instructions and other relevant documents used in the repair/replacement activities (such as drawings, specifications, manufacturers' manuals, maintenance schedules)
- the methods, techniques and company procedures to be followed for repairing/replacing components for lifting platforms
- the inspection and safety checks to be applied, and the importance of following them exactly during replacement/repair operation
- the methods and techniques used to dismantle/assemble lifting platform equipment (such as release of pressures/force, proof marking, extraction, pressing, alignment)
- methods of checking that components are fit for purpose, how to identify defects and wear characteristics, and the need to replace `lifed' items such as seals and gaskets
- the basic principles of how the lifting platform functions, its operating sequence, the working purpose of individual units/components and how they interact
- the uses of mechanical and electrical measuring devices
- how to make adjustments to components/assemblies to ensure that they function correctly (such as setting working clearance, setting travel, running and sliding conditions)
- the importance of making checks before running the lifting platform under power
- how to check that tools and equipment are free from damage or defects, and are in a safe and usable condition
- the importance of preparing documentation and/or reports following the replacement/repairing activity, and how to generate them
- the equipment operating and control procedures to be applied during the repair/replacement activity
- how to use lifting and handling equipment in the repair/replacement process
- the problems that can occur when carrying out repairs to lifting platforms, and what to do if they occur
- the organisational procedure(s) to be adopted for the safe disposal of waste of all types of materials
- the extent of your own authority and to whom you should report if you have a problem that you cannot resolve
Scope/range
Scope Performance
Carry out all of the following during the repair/replacement activity:
- undertake the activities in a way that causes minimal disruption to the customer
- adhere to procedures or systems in place for risk assessment, COSHH, personal protective equipment and other relevant safety regulations
- ensure the safe isolation of equipment (such as mechanical, electrical, air or fluids)
- provide safe access and working arrangements for the maintenance area
- carry out the repair/replacement activities, using appropriate techniques and procedures
- reinstate and return the lifting platform to service on completion of the repair/replacement activities
- ensure that any potential defects are identified and reported for further action
- record the repair/replacement, using appropriate methods or documentation
- dispose of waste items in a safe and environmentally acceptable manner
- leave the work area in a safe and tidy condition
Replace or repair four of the following lifting platform components:
- hydraulic pump unit
- rope/pulley system
- electrical motor
- door gates (such as manual or automatic)
- lift controller equipment
- hydraulic components (such as valves, hoses and connections)
Plus eight more from the following:
7. electrical wiring and cables
8. chassis
9. solenoids
10. panels
11. safety devices (such as switches, interlocks, fuses)
12. aperture
13. fire/smoke seals
14. pulleys and drums
15. bridging steps
16. brakes
17. overspeed governors
18. ramps
19. sling drive
20. seats
21. ropes
22. trim
23. guide shoes/rollers
24. guides and fixings
25. residual current devices
26. safety gear
27. printed circuit boards (PCBs)
28. controls (landing call stations)
29. push buttons/indicators
30. interlocks/key switches
Carry out all of the following replacement or repair activities:
- dismantling equipment to the appropriate level
- removing excess dirt and grime
- fitting, aligning and adjusting repaired or replaced units/components
- tightening fastenings to the required torque
- ensuring that working clearances are met
- applying lubrication
- ensuring that components are clear of obstruction, and are guarded, where appropriate
- making sensory checks (sight, sound, smell, touch)
- checking that all safety devices are operative
- functionally testing the completed system
Carry out repair or replacement of lifting platform components, in accordance with all of the following standards, as appropriate to the equipment being repaired:
- organisational guidelines and codes of practice
- equipment manufacturer's operation range
- customer requirements
- BS, ISO and/or BSEN standards
Complete one of the following servicing records, and pass it to the appropriate person
- job card
- company report
service log or report