Overhaul light electric vehicle e-system units and components
URN: IMICY15
Business Sectors (Suites): Maintenance and Repair - Cycle
Developed by: IMI
Approved on:
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 instructionsP5.2 your workplace proceduresP5.3 health and safety requirementsP6 work in a way which minimises the risk of:P6.1 damage to other vehicle systems, units and componentsP6.2 contact with leakage, hazardous substances and high voltage systemsP6.3 damage to your working environmentP6.4 injury to yourself and othersP7 ensure your assessment of the dismantled unit accurately identifies its condition and suitability for overhaulP8 promptly inform the relevant person(s) where an overhaul is uneconomic or unsatisfactory to performP9 use testing methods which comply with the manufacturer’s requirementsP10 correctly adjust the mechanical unit’s components correctly to ensure that they operate to meet the light electric vehicle e-system operating requirements, when necessaryP11 ensure the overhauled units and assemblies conform to the light electric vehicle operating specification and any legal requirementsP12 ensure your overhaul records are accurate, complete and promptly passed to the relevant person(s) in the format requiredP13 complete all overhauling activities within the agreed timescaleP14 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 activitiesK3.2 the referral of problemsK3.3 reporting delays to the completion of workK4 the importance of documenting repair informationK5 the importance of working to agreed timescales and keeping others informed of progressK6 the cost-benefit relationship between the reconditioning, repair and replacement of componentsK7 the importance of promptly reporting any anticipated delays to the relevant person(s)
EquipmentK8 how to prepare and assess the accuracy and operation of all the overhauling and testing tools and equipment requiredK9 how to use all the overhauling and testing tools and equipment required
E-system unit overhauling activitiesK10 how to find, interpret and use sources of information on e-system overhauling procedures and statutory requirementsK11 how e-system units and assemblies are constructed and their operationK12 how e-system units and assemblies are dismantled and reassembledK13 the types and possible causes of faults in e-system units and assemblie*s* and how to identify themK14 light electric vehicle e-system operating specification for limits, fits and tolerances and where this information can be sourcedK15 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 assembliesK17 how to carry out overhauling activities for the type(s) of light electric vehicle e-system unit on which you workK18 the relationship between test methodology and the faults rectified – the use of appropriate testing methodsK19 how to test and evaluate the performance of overhauled units against the operating specificationK20 how to interpret test results and make recommendationsK21 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 equipment4.4. 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
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;