Application
This unit describes the performance outcomes required to diagnose and repair faults in the hydraulic braking systems of forklift machinery. It involves preparing for the task, selecting the correct diagnostic procedure, carrying out the diagnosis and the repair, performing post-repair testing, and completing workplace processes and documentation.
It applies to those working in the automotive service and repair industry.
No licensing, legislative, regulatory or certification requirements apply to this unit at the time of publication.
Elements and Performance Criteria
Elements Elements describe the essential outcomes. | Performance Criteria Performance criteria describe the performance needed to demonstrate achievement of the element. Where bold and italicised text is used, further information is detailed in the range of conditions section. |
1. Prepare to diagnose and repair forklift braking system | 1.1 Job requirements are determined from workplace instructions 1.2 Diagnostic information is sourced and interpreted 1.3 Diagnostic options are analysed and those most appropriate to the circumstances are selected 1.4 Hazards associated with the work are identified and risks are managed 1.5 Diagnostic tools and equipment are selected and checked for serviceability |
2. Diagnose braking system | 2.1 Diagnostic tests are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements 2.2 Faults are identified from diagnostic test results and causes of faults are determined 2.3 Diagnosis findings, including recommendations for necessary repairs or adjustments, are reported according to workplace procedures |
3. Repair braking system | 3.1 Repair information is sourced and interpreted 3.2 Repair options are analysed and those most appropriate to the circumstances are selected 3.3 Repair tools, equipment and materials are selected and checked 3.4 Repairs and component replacements and adjustments are carried out according to manufacturer specifications, workplace procedures, and safety and environmental requirements, and without causing damage to components or systems 3.5 Post-repair testing is carried out according to workplace procedures to confirm fault rectification, and any further problems detected as having been introduced during the repair process are rectified |
4. Complete work processes | 4.1 Final inspection is made to ensure work is to workplace expectations and forklift is presented ready for use 4.2 Work area is cleaned, waste and non-recyclable materials are disposed of, and recyclable material is collected 4.3 Tools and equipment are checked and stored according to workplace procedures 4.4 Workplace documentation is processed according to workplace procedures |
Evidence of Performance
Before competency can be determined, individuals must demonstrate they can perform the following according to the standards defined in this unit’s elements, performance criteria, range of conditions and foundation skills:
diagnose and repair a fault in two of the following types of forklift hydraulic braking systems:
drum brake system
dry disc brake system
wet multi-plate disc brake system.
Evidence of Knowledge
Individuals must be able to demonstrate knowledge of:
work health and safety (WHS) and occupational health and safety (OHS) requirements relating to diagnosing and repairing forklift braking systems, including procedures for working with:
working with brake dust and hydraulic oil hazards
using lifting, jacking and supporting equipment
environmental requirements, including procedures for trapping, storing and disposing of hydraulic fluids and brake dust released from braking systems
operating principles of forklift hydraulic braking systems and associated components, including:
levers
friction
hydraulics, including the relationship between force, pressure and area
application, purpose and operation of forklift hydraulic braking systems and components, including:
power assisted systems, including:
drum brake systems
dry disc brake systems
wet multi-plate disc systems
parking brake systems
master cylinders
braking system valves and switches
brake boosting systems
full hydraulic systems, including:
wet multi-plate disc systems
parking brake systems
braking system valves and switches
oil pump and cooler
diagnostic testing procedures for forklift hydraulic braking systems, including:
brake pedal checks
brake booster operational tests
master cylinder operational tests
brake or hydraulic fluid tests
parking brake operational tests
drum, dry disc and wet multi-plate disc brake operational tests
brake drum, shoe, disc and pad measurement and evaluation
repair procedures for forklift hydraulic braking systems, including procedures for removing, repairing, replacing and adjusting:
hydraulic system components
braking system components
post-repair testing procedures for forklift braking systems.
Assessment Conditions
Assessors must satisfy NVR/AQTF assessor requirements.
Competency is to be assessed in the workplace or a simulated environment that accurately reflects performance in a real workplace setting.
Assessment must include direct observation of tasks.
Where assessment of competency includes third-party evidence, individuals must provide evidence that links them to the forklift hydraulic braking systems that they have worked on, e.g. repair orders.
Assessors must verify performance evidence through questioning on skills and knowledge to ensure correct interpretation and application.
The following resources must be made available:
automotive repair workplace or simulated workplace
workplace instructions
manufacturer forklift hydraulic braking system specifications
operational forklifts with faults in two different braking systems
diagnostic equipment for forklift hydraulic braking systems
tools, equipment and materials appropriate for repairing and adjusting forklift hydraulic braking systems.
Foundation Skills
This section describes those language, literacy, numeracy and employment skills that are essential to performance and are not explicit in the performance criteria.
Skills | Description |
Learning skills to: | locate appropriate sources of information efficiently. |
Reading skills to: | interpret information from manufacturer and workshop literature when seeking braking system specifications and procedures. |
Writing skills to: | legibly and accurately fill out workplace documentation when reporting diagnostic findings, making repair recommendations, and recording parts and material used. |
Oral communication skills to: | clarify instructions report diagnostic findings and make repair recommendations. |
Numeracy skills to: | measure braking system components and use basic mathematical operations, including addition and subtraction, to calculate distances, tolerances and deviations from manufacturer specifications interpret braking system hydraulic pressure gauges. |
Planning and organising skills to: | plan own work requirements and prioritise actions to achieve required outcomes and ensure tasks are completed within workplace timeframes. |
Technology skills to: | operate diagnostic and testing equipment conduct performance testing of components, systems and equipment. |
Range Statement
This section specifies work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included. Bold italicised wording, if used in the performance criteria, is detailed below.
Safety and environmental requirements must include: | work health and safety (WHS) and occupational health and safety (OHS) requirements, including procedures for: working with brake dust and hydraulic oil hazards using lifting, jacking and supporting equipment environmental requirements, including procedures for trapping, storing and disposing of hydraulic fluids and brake dust released from braking systems. |
Sectors
Technical - Brakes
Competency Field
Mechanical - Lifting Equipment