Overhaul light electric vehicle e-system units and components

URN: IMICY15
Business Sectors (Suites): Maintenance and Repair - Cycle
Developed by: IMI
Approved on: 30 Mar 2022

Overview

This standard is about the bench-based overhaul of light electric vehicle e- system units, involving dismantling, assessment, repair, replacement or adjustment of internal components together with re-assembly and testing. Units and components include motors, controllers, sensors and wiring.

For the purposes of this standard, a light electric vehicle is any small vehicle powered by an electric motor (e-system) with 1, 2, 3 or more wheels, for example electric bikes, electric scooters, quadrimobiles, etc.


Performance criteria

You must be able to:

P1 use suitable personal protective equipment throughout all overhauling activities
P2 use suitable sources of technical information to support your overhauling activities
P3 assess and prepare all the tools and equipment required, following manufacturer’s instructions, prior to use
P4 use the tools and equipment required correctly and safely throughout all overhauling activities
P5 carry out all overhauling activities following:

P5.1 manufacturer’s instructions
P5.2 your workplace procedures
P5.3 health and safety requirements
P6 work in a way which minimises the risk of:

P6.1 damage to other vehicle systems, units and components 
P6.2 contact with leakage, hazardous substances and high voltage systems
P6.3 damage to your working environment
P6.4 injury to yourself and others 
P7 ensure your assessment of the dismantled unit accurately identifies its condition and suitability for overhaul
P8 promptly inform the relevant person(s) where an overhaul is uneconomic or unsatisfactory to perform
P9 use testing methods which comply with the manufacturer’s requirements
P10 correctly adjust the mechanical unit’s components correctly to ensure that they operate to meet the light electric vehicle e-system operating requirements, when necessary
P11 ensure the overhauled units and assemblies conform to the light electric vehicle operating specification and any legal requirements
P12 ensure your overhaul records are accurate, complete and promptly passed to the relevant person(s) in the format required
P13 complete all overhauling activities within the agreed timescale
P14 promptly report any anticipated delays in completion to the relevant person(s)


Knowledge and Understanding

You need to know and understand:

Legislative and organisational requirements and procedures
K1 the legal requirements applicable to the light electric vehicle mechanical units and e-system assemblies overhauled (including road safety requirements)
K2 the health and safety legislation, environmental requirements and workplace procedures relevant to workshop practices and personal and light electric vehicle protection
K3 your workplace procedures for:

K3.1 recording overhauling activities
K3.2 the referral of problems
K3.3 reporting delays to the completion of work
K4 the importance of documenting repair information
K5 the importance of working to agreed timescales and keeping others informed of progress
K6 the cost-benefit relationship between the reconditioning, repair and replacement of components 
K7 the importance of promptly reporting any anticipated delays to the relevant person(s) 

Equipment
K8 how to prepare and assess the accuracy and operation of all the overhauling and testing tools and equipment required
K9 how to use all the overhauling and testing tools and equipment required

E-system unit overhauling activities
K10 how to find, interpret and use sources of information on e-system overhauling procedures and statutory requirements
K11 how e-system units and assemblies are constructed and their operation
K12 how e-system units and assemblies are dismantled and reassembled
K13 the types and possible causes of faults in e-system units and assemblie*s* and how to identify them
K14 light electric vehicle e-system operating specification for limits, fits and tolerances and where this information can be sourced
K15 how to assess the condition evident within e-system sub-assemblies and components

K16 the cost-benefit relationship between the reconditioning, repair and replacement of components within units and assemblies
K17 how to carry out overhauling activities for the type(s) of light electric vehicle e-system unit on which you work
K18 the relationship between test methodology and the faults rectified – the use of appropriate testing methods
K19 how to test and evaluate the performance of overhauled units against the operating specification
K20 how to interpret test results and make recommendations
K21 how to make suitable adjustments to light electric vehicle e-system units and assemblies


Scope/range

1. Overhauling activities are:

1.1. dismantling
1.2. assessment
1.3. repair
1.4. replacement
1.5. adjustment of internal components
1.6. reassembly
1.7. functional testing
1.8. software updates

2. Units and components are:

2.1. batteries

2.2. motors
2.3. controllers
2.4. sensors
2.5. actuators
2.6. electronic control unit (ECU)
2.7. wiring
2.8. chargers
2.9. displays

3. Testing methods are:

3.1. sensory
3.2. functional
3.3. measurement

4. Tools and equipment include:

4.1. hand tools
4.2. special workshop tools
4.3. general workshop equipment

4.4. electrical and electronic testing equipment


Scope Performance


Scope Knowledge


Values


Behaviours


Skills


Glossary

This section contains examples and explanations of some of the terms used but does not form part of the standard.

*
Agreed timescales
Examples include manufacturer’s recommended work times, job times set by your company or a job time agreed with a specific customer

Light electric vehicle
For the purposes of this standard, a light electric vehicle is any small vehicle powered by an electric motor (e-system) with 1, 2, 3 or more wheels, for example electric bikes, electric scooters, quadrimobiles, etc.

Sensory diagnostic methods*
These may include looking, listening, smelling and touching for heat




Links To Other NOS


External Links


Version Number

1

Indicative Review Date

30 Mar 2025

Validity

Current

Status

Original

Originating Organisation

IMI

Original URN

CY15

Relevant Occupations

E-bike Technician

SOC Code

5223

Keywords

Overhaul; e-system; units and components; batteries; motors; controllers; sensors; actuators; ECU; wiring; chargers; displays;