Maintain, diagnose and rectify complex cycle gear systems

P3.1 cycle technical data

P3.2 maintenance and repair procedures

P3.3 legal requirements 

P4 identify components relevant to cycle complex gear systems

P5 prepare, check and use all the tools and equipment required following manufacturer’s instructions

P6 carry out all cycle complex gear system maintenance, diagnosis and rectification activities following: 

P6.1 manufacturer’s instructions

P6.2 industry recognised methods

P6.3 your workplace procedures

P6.4 health, safety and environmental requirements

P7 work in a way which minimises the risk of:

P7.1 damage to the cycle, its systems and components

P7.2 damage to your working environment

P7.3 injury to self and others

P8 use suitable testing methods to accurately evaluate the performance of the reassembled system 

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

P10 promptly report any problems or issues relating to the cycle’s condition or conformity  to the relevant person(s) 

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

P12 complete all complex cycle gear system maintenance and repair activities within the agreed timescale

P13 promptly report any anticipated delays in completion to the relevant persons(s)

K3.1 recording maintenance and repair information

K3.2 the referral of problems

K3.3 reporting delays to the completion of work

K4 how to work safely avoiding damage to other cycle systems, components and units and injury to self and others

K5 the importance of documenting cycle complex gear system maintenance and repair information

K6 the importance of working to agreed timescales and keeping others informed of progress

K7 the relationship between time and cost

K8 the importance of promptly reporting anticipated delays to the relevant person(s)

Use of technical information

K9 how to find, interpret and use sources of current technical information applicable to cycle complex gear system maintenance, diagnosis and rectification

K10 the importance of using the appropriate sources of technical information

Tools and equipment

K11 how to select, prepare, check and use all the maintenance, diagnosis and rectification tools and equipment required

Cycle internal hub system maintenance and repair

K12 what is meant by a cycle internal hub system

K13 the basic principles of epicyclic gearing

K14 how to identify the components in a cycle internal hub system

K15 the purpose and operation of each component of a cycle internal hub system

K16 the advantages and disadvantages of an internal hub system compared to a derailleur system

K17 how to check a cycle internal hub system for correct operation

K18 how to clean and adjust a cycle internal hub system

K19 how to remove and strip an internal hub and check it for serviceability

K20 how to identify and rectify faults presented on a cycle internal hub system *

K21 how to refit or replace cycle *internal hub system components

K22 how to lubricate and adjust internal hub system components

Electrical and electronic principles

K23 electrical and electronic principles, including Ohms Law, voltage, power, current (AC/DC) resistance, magnetism, electromagnetism, electromagnetic induction, EMC, digital and fibre optics principles

K24 types of circuit protection and why they are necessary

K25 how electrical and electronic systems operate, including electrical component function, electrical inputs, outputs, voltages, oscilloscope patterns and digital principles

K26 the interaction between electrical, electronic and mechanical components within electronic gear change systems

K27 electrical symbols, units and terms

K28 electrical safety procedures

K29 the hazards associated with working on or near high voltage electrical systems and components

Electronic gear change system diagnosis and rectification

K30 the main components of a cycle electronic gear change system

K31 the advantages and disadvantages of a cycle electronic gear change system compared with a conventional cable operated system

K32 the compatibility issues associated with electronic gear change systems

K33 the process for correctly diagnosing faults on a cycle electronic gear change system

K34 the process for correctly calibrating the cycle electronic gear change system following the diagnostic or rectification activity

K35 the procedure for checking the battery charge state on a cycle electronic gear change system

K36 the correct procedure for inspecting the operation and condition of a cycle electronic gear change system

Quality check

K37 the quality check process and how to report any faults highlighted during the quality check

K38 how to assess the condition of complex cycle gear systems following maintenance, diagnosis and rectification activity, ensuring the cycle is returned to the customer in a roadworthy condition prior to returning the cycle to the customer.

1.1 hand tools
1.2 electrical tools
1.3 diagnostic equipment
1.4 measuring equipment
1.5 bench mounted equipment
1.6 cleaning and degreasing equipment
1.7 lubricants

2. Internal hub system components are:

2.1 planet wheel
2.2 sun wheel
2.3 hub shell
2.4 planet wheel carrier
2.5 annular gear
2.6 sprocket
2.7 free wheel device
2.8 control mechanism

3. E*lectronic gear change components* are:

3.1 batteries
3.2 wiring loom
3.3 electronic shifter
3.4 electronic derailleur

4. Adjustments include:

4.1 system calibration
4.2 custom system set up