Competency in Removing and Replacing Lift Truck Power Plants Units and Components
This topic covers the safe removal and replacement of lift truck power plant units and components. Learners must use relevant information, appropriate tools, and record findings to make suitable recommendations.
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 (forklift) maintenance and repair industry. It covers the essential skills and knowledge required to safely and effectively maintain, service, and repair counterbalance lift trucks, reach trucks, and other industrial vehicles. This diploma is part of the Institute of the Motor Industry (IMI) occupational qualifications framework and is recognised by employers across the UK logistics, warehousing, and manufacturing sectors.
The qualification focuses on practical competence in areas such as engine systems, hydraulic systems, electrical systems, transmission systems, and chassis components. Students learn to diagnose faults, perform routine maintenance, and carry out repairs in line with manufacturer specifications and health and safety regulations. The course also emphasises the importance of using diagnostic equipment, interpreting technical data, and maintaining accurate service records. By completing this diploma, students demonstrate they are job-ready for roles such as lift truck technician, service engineer, or maintenance fitter.
This diploma fits into the wider Motor Vehicle & Transport sector by addressing the specific needs of materials handling equipment. Unlike general motor vehicle maintenance, lift trucks operate in industrial environments with unique safety risks, such as working at height, handling heavy loads, and operating in confined spaces. The qualification ensures technicians understand load charts, stability triangles, and pre-use inspections, which are critical for preventing accidents. It also aligns with the Lifting Operations and Lifting Equipment Regulations (LOLER) and Provision and Use of Work Equipment Regulations (PUWER), making it essential for compliance in the workplace.
Key Concepts
Core ideas you must understand for this topic
- →Pre-use inspection and daily checks: Understanding the legal requirement to inspect lift trucks before use, including checking tyres, brakes, steering, lights, and hydraulic fluid levels. This ensures the vehicle is safe to operate and complies with PUWER.
- →Hydraulic system operation and maintenance: Knowledge of hydraulic pumps, valves, cylinders, and filters. Students must be able to identify common faults such as leaks, cavitation, or contamination, and perform tasks like bleeding air from the system.
- →Electrical fault diagnosis: Using multimeters and wiring diagrams to trace faults in starter circuits, alternators, batteries, and control systems. Understanding CAN bus systems and electronic control units (ECUs) is increasingly important.
- →Engine systems for LPG, diesel, and electric lift trucks: Differences between internal combustion and electric powertrains, including spark plugs, injectors, glow plugs, and battery maintenance. Electric lift trucks require knowledge of traction motors, controllers, and charging procedures.
- →Load handling and stability: Principles of the stability triangle, load centre distance, and capacity plate interpretation. Technicians must understand how modifications or repairs can affect the truck's safe working load (SWL).
Learning Objectives
What you need to know and understand
- Be able to work safely when carrying out removal 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 power plant units and components., Be able to record information and make suitable recommendations
Assessment Criteria
Key criteria assessors look for in your portfolio
- Follow health and safety procedures throughout the task.
- Use manufacturer's information to guide removal and replacement.
- Select and use correct tools and equipment.
- Carry out removal and replacement without causing damage.
- Record work accurately and provide recommendations.
Assessment Guidance
Guidance for achieving higher grades
- 💡Always state the safety precautions you would take.
- 💡Refer to specific tools and their purposes.
- 💡Explain how you would verify correct installation.
- 💡Always refer to the manufacturer's service manual during practical assessments. Examiners look for candidates who can locate torque settings, fluid specifications, and diagnostic procedures independently. Memorising generic values is not enough.
- 💡When diagnosing faults, use a systematic approach: gather information (customer complaint), perform visual inspection, use diagnostic tools, and then test components. Document each step clearly in your service report. This demonstrates competence and logical thinking.
- 💡Pay close attention to health and safety throughout the assessment. Isolate the truck (remove key, disconnect battery), use wheel chocks, and wear appropriate PPE. Examiners will fail candidates who skip safety steps, even if the repair is correct.
Common Mistakes
Common errors to avoid in your coursework
- Skipping safety checks before starting work.
- Using incorrect tools leading to component damage.
- Failing to refer to technical data or manuals.
- Misconception: 'Any motor vehicle mechanic can work on lift trucks.' Correction: Lift trucks have unique systems like mast assemblies, tilt cylinders, and side shifters. They also operate under different regulations (LOLER, PUWER). Specialised training is essential for safety and compliance.
- Misconception: 'Hydraulic oil never needs changing.' Correction: Hydraulic oil degrades over time due to heat, contamination, and moisture. Regular oil analysis and changes are critical to prevent pump failure and system damage. Always follow manufacturer service intervals.
- Misconception: 'Battery maintenance is just topping up with water.' Correction: For electric lift trucks, battery care includes equalisation charges, checking specific gravity, cleaning terminals, and ensuring proper ventilation during charging. Neglecting these can reduce battery life and create safety hazards.
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 Power Plants 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 motor vehicle principles: Familiarity with four-stroke engine cycles, electrical circuits (Ohm's law), and mechanical systems (gears, bearings, seals) is assumed.
- •Health and safety awareness: Knowledge of COSHH, risk assessments, and safe working practices in a workshop environment. This is often covered in a Level 1 qualification or workplace induction.
- •Manual handling and tool safety: Ability to safely use hand tools (spanners, sockets, torque wrenches) and power tools (impact guns, grinders). Experience with lifting equipment (engine hoists, jacks) is beneficial.
Coursework AI Review
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Key Terminology
Essential terms to know
- Be able to work safely when carrying out removal 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 power plant units and components., Be able to record information and make suitable recommendations
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