Competency in Removing and Replacing Lift Truck Mechanical Handling, Chassis Units and Components
This element assesses the learner's competence in safely removing and replacing lift truck mechanical handling and chassis units and components, such as masts, carriages, fork arms, and attachments. It covers working safely, interpreting technical information, selecting and using appropriate tools and equipment, executing the task to industry standards, and accurately recording work and recommendations. Mastery ensures operational reliability and compliance with health and safety regulations.
Assessment criteria
Topic Overview
The IMI Level 2 Diploma in Lift Truck Maintenance and Repair Competence is a vocational qualification designed for individuals working in the lift truck industry. It covers the skills and knowledge required to maintain, service, and repair counterbalance lift trucks, reach trucks, and other industrial vehicles. This diploma is essential for technicians who want to demonstrate their competence in a workshop environment, focusing on both routine maintenance and fault diagnosis.
This qualification is part of the Institute of the Motor Industry (IMI) suite of occupational standards, ensuring that learners meet industry-recognised benchmarks. It covers key areas such as engine systems, hydraulic systems, electrical systems, transmission, and steering. By completing this diploma, you will be able to carry out inspections, identify faults, and perform repairs safely and efficiently, which is critical for workplace safety and operational reliability.
In the wider context of Motor Vehicle & Transport, this diploma prepares you for a specialised career in materials handling equipment. Lift trucks are essential in logistics, warehousing, and manufacturing, so skilled technicians are in high demand. The qualification also provides a foundation for further study, such as the IMI Level 3 Diploma in Lift Truck Maintenance and Repair, or progression into supervisory roles.
Key Concepts
Core ideas you must understand for this topic
- →Health and safety regulations: Understanding LOLER (Lifting Operations and Lifting Equipment Regulations) and PUWER (Provision and Use of Work Equipment Regulations) is critical for safe maintenance and repair of lift trucks.
- →Engine systems: Knowledge of diesel, LPG, and electric powertrains, including fuel systems, cooling systems, and exhaust after-treatment (e.g., DPF regeneration).
- →Hydraulic systems: Understanding hydraulic pumps, control valves, cylinders, and hoses, including pressure testing and fluid contamination prevention.
- →Electrical systems: Diagnosing faults in starter motors, alternators, batteries, and electronic control units (ECUs), including CAN bus systems.
- →Braking and steering systems: Maintenance of hydraulic brakes, parking brakes, and power steering, including adjustment and bleeding procedures.
Learning Objectives
What you need to know and understand
- Be able to work safely when carrying outremoval and replacement activities, Be able to use relevant information to carry out the task, Be able to use appropriate tools and equipment, Be able to carry out removal and replacement of lift truck chassis units and components., Be able to record information and make suitable recommendations
Assessment Criteria
Key criteria assessors look for in your portfolio
- Award credit for demonstrating correct selection and consistent use of personal protective equipment (PPE) throughout the task, including safety footwear, gloves, and eye protection.
- Award credit for safely isolating the lift truck's energy sources (hydraulic, electrical) and verifying zero energy state before starting disassembly.
- Award credit for accurately referencing and applying manufacturer technical data, workshop manuals, or procedures to determine correct removal and replacement sequences.
- Award credit for proper use of lifting and support equipment to secure the lift truck and heavy components, preventing uncontrolled movement.
- Award credit for careful disconnection, labelling, and secure storage of removed components and fasteners to avoid damage or loss.
- Award credit for precise reassembly with correct alignment, torque settings, and functional checks, as per specifications.
- Award credit for completing a clear and legible job record, including part numbers, serial numbers, any findings, and a recommended course of action for further work.
Assessment Guidance
Guidance for achieving higher grades
- 💡Always start by reviewing the risk assessment and method statement, and ensure you have the correct personal protective equipment before touching any component.
- 💡Take photos or use masking tape to label every hose, wire, and part during disassembly – this saves time and prevents mistakes during reassembly.
- 💡Use manufacturer-specific tools where specified and double-check torque wrench calibration before critical tightening sequences.
- 💡When recording recommendations, be specific: note the component name, location, observed condition, and refer to the relevant service bulletin or standard if applicable.
- 💡When answering questions on fault diagnosis, always follow a logical process: identify symptoms, gather data (e.g., error codes, visual inspection), isolate the fault, and then propose a repair. This structured approach gains marks.
- 💡For practical assessments, pay close attention to torque settings and tightening sequences, especially for wheel nuts and cylinder head bolts. Examiners check for correct use of torque wrenches.
- 💡Know your safety procedures inside out. In exams, always mention isolating the battery, chocking wheels, and using correct PPE (e.g., gloves, safety glasses) before starting any task.
Common Mistakes
Common errors to avoid in your coursework
- Proceeding with removal without fully isolating or safely supporting the lift truck, leading to instability or crush hazards.
- Forgetting to relieve residual hydraulic pressure before disconnecting hoses, causing fluid injection injury or spillage.
- Misreading torque values or using uncalibrated tools, resulting in over-tightened fasteners that may fail or under-tightened joints that come loose.
- Not labelling or photographing complex assemblies prior to removal, leading to incorrect reconnection or misalignment.
- Making vague recommendations on the job card, such as 'check later', instead of specifying exact components and referencing manufacturer guidance.
- Misconception: Lift truck maintenance is the same as car maintenance. Correction: Lift trucks operate under different loads and environments, requiring specific knowledge of hydraulic systems, mast assemblies, and counterbalance stability.
- Misconception: You can skip safety checks if you're experienced. Correction: LOLER requires thorough examinations at specified intervals; skipping checks can lead to serious accidents and legal penalties.
- Misconception: All lift trucks use the same hydraulic fluid. Correction: Different manufacturers specify different grades (e.g., ISO 32, 46, or 68); using the wrong fluid can damage seals and reduce performance.
Frequently Asked Questions
Common questions students ask about this topic
Pass / Merit / Distinction Evidence Checklist
How your portfolio evidence is graded for THE INSTITUTE OF THE MOTOR INDUSTRY Competency in Removing and Replacing Lift Truck Mechanical Handling, Chassis Units and Components
Every vocational unit is marked against named criteria rather than an exam percentage. Your tutor's brief lists the exact codes for this unit — here is what each band is asking you to do.
Demonstrate baseline knowledge, accurate terminology, and core practical application.
Provide detailed analysis, structured explanations, and clear workplace reasoning.
Deliver thorough evaluation, original problem solving, and fully justified recommendations.
Before You Start
Prior knowledge that will help with this topic
- •Basic understanding of mechanical principles (e.g., levers, gears, hydraulics).
- •Familiarity with workshop tools and equipment (e.g., multimeters, hydraulic jacks, diagnostic scanners).
- •Completion of a Level 1 qualification in motor vehicle studies or equivalent experience in a workshop environment.
Coursework AI Review
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Key Terminology
Essential terms to know
- Be able to work safely when carrying outremoval and replacement activities, Be able to use relevant information to carry out the task, Be able to use appropriate tools and equipment, Be able to carry out removal and replacement of lift truck chassis units and components., Be able to record information and make suitable recommendations
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