Removing and refitting electrical/electronic equipment on motorsport vehicles
Overview
This standard identifies the competences you need to carry out the removal and refitting of motorsport electrical/electronic equipment and other components such as wiring looms, electronic control units (ECUs), electronic displays, master switches, system switches, lighting units and 'lifed' components, in accordance with approved procedures.
It covers a range of motorsport vehicles such as single seater, rallying, sports cars, karts, historic and other specific approved competition vehicles. The removal and refitting methods and techniques will include, dismantling the equipment to sub-assembly and component level, protecting exposed components, cables and looms, checking components for serviceability, and marking/labelling components.
On completion of the removal and refitting activities, you will be required to carry out a range of checks, tests and adjustments such as continuity checking systems for cable breaks, checking electrical looms for correct routeing and security for prevention of wear and chafing, checking data sensors for correct adjustment and operation, ensuring that correct specification bulbs/LEDs are fitted, ensuring that fire systems are armed, and checking that all breakers/fuses are intact. You will also be expected to check that the driver communication system is operating correctly, that electrical/electronic units are anti-vibration mounted, and that all electrical/electronic system components are free from foreign objects, dirt or other contamination, and meet the required specification.
Your responsibilities will require you to comply with organisational policy and procedures for the removal and refitting activities undertaken, and to report any problems with these activities that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You must ensure that all tools, equipment and materials used are correctly accounted for on completion of the activities, and that all necessary job/task documentation is completed accurately and legibly.
You will be expected to work as a member of a team, with minimal supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Where team working is involved, you must demonstrate a significant personal contribution during the team activities in order to satisfy the requirements of the standard, and competence in all the areas required by the standard must be demonstrated.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the appropriate removal and refitting techniques and procedures to motorsport electrical/electronic systems and components. You will understand the removal and refitting methods and procedures, and their application. You will know how the equipment functions, the common problems that can occur, the purpose of the individual components and associated defects, in adequate depth to provide a sound basis for carrying out the removal and refitting activities, correcting faults and ensuring that the equipment is replaced to the required standard. You will also have sufficient knowledge of these components to ensure that they are fit for purpose and meet the specifications, thus providing a sound basis for carrying out the removal and refitting activities.
You will understand the safety precautions required when working on motorsport vehicles, especially those for isolating the equipment. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect yourself and others in the workplace
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, vehicle manuals and publications to carry out the required work
- remove and re-fit the components in their correct positions using appropriate methods and techniques
- take suitable precautions to prevent damage to components and surrounding structure
- ensure that the removed components are clean and free from dirt, oil and debris and that they are in a usable condition prior to being re-fitted and tested
- replace and secure the components using the specified connectors and securing devices
- check that all operations have been completed and the finished assembly meets the required specification
- label and store components that require repair or overhaul deal promptly and effectively with problems within your control and report those that cannot be solved
ensure that work records are completed, stored securely and available to others, as per organisational requirements
leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the precautions to be taken to prevent electrostatic discharge (ESD) damage to circuits and sensitive components (use of earthed wrist straps)
- the procedures for obtaining the various types of manual/drawing, job instructions and specifications that are used during the removal and refitting of electrical/electronic equipment to motorsport vehicles, and how to interpret them correctly
- how to identify different types of electrical/electronic systems used on motorsport vehicles
- the removal and refitting methods and procedures used, and the importance of adhering to these
- how the components are to be aligned and positioned prior to securing, and the tools and equipment that are used
- the various mechanical fasteners and other components that are used (threaded fasteners, cable ties, p-clips, saddles and specialised fasteners)
- the application of adhesives, sealants and fluids within the removal and refitting activities, and the precautions that must be taken when working with them
- the operational function of the various electrical/electronic systems that are used
- the use of heat shrink guns/soldering irons and the importance of ensuring that they are used in a safe manner
- the preparations to be undertaken on the components, prior to fitting them onto the motorsport vehicle
- the consumables, tools and equipment used for removal and refitting of electrical /electronic systems to the vehicle
- the importance of using the specified fasteners for the installation, and why you must not use substitutes
- how to deal with components or fastening devices that are incorrectly fitted, damaged or that have other faults
- the quality control procedures to be followed during the removal and refitting operations
- the various tests, checks and adjustments to be made on completion of the removal and refitting activities
- how to recognise assembly defects (incorrect installation, ineffective fasteners, component damage)
- the importance of ensuring that the completed assembly is free from foreign objects, dirt or other contamination
- the importance of ensuring that all sealants and lubricants used are of the correct specification for the electrical /electronic system being rebuilt
- how to check that the tools and equipment to be used are correctly calibrated, and are in a safe, tested and serviceable condition
- the importance of ensuring that all tools are used correctly, checked and stored after use
- problems with the removal and refitting operations, and the importance of informing appropriate people of non- conformances
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the removal and refitting of motorsport vehicle electrical/electronic equipment:
- plan the removal and refitting activities prior to beginning the work
- obtain and use the appropriate documentation (such as job instructions, assembly drawings, manuals, quality control documentation)
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide safe access and working arrangements for the work area, and ensure that any appropriate environmental conditions can be met
- ensure that the work area is suitably prepared for the removal and refitting activities to take place
- obtain approval to carry out the removal and refitting activities
- position and secure the vehicle, using the correct equipment
- ensure that any required consumables are available
- leave the vehicle and work area in a safe condition, free from spillages and foreign object debris
- return all tools and equipment to the correct location on completion of the activities
Carry out the removal and refitting of electrical/electronic equipment on one of the following types of motorsport vehicle:
- single seater
- sports car
- rallying
- historic
- kart
- other specific approved competition vehicle
Remove and refit components in five of the following types of motorsport vehicle sub-systems:
- charging systems
- data acquisition system
- direct current power supply system
- auxiliary power supply system
- communication system
- lighting systems
- instrumentation, indication and warning systems
- electrical/electronic control system
- safety and emergency systems
Use appropriate methods and techniques to remove and refit electrical/electronic equipment, to include fifteen of the following:
- removing covers, cowlings, bodywork and hatches
- making mechanical connections
- making an initial judgment of the condition of the electrical/electronic systems (such as damage, missing components)
- making electrical connections
- replacing all 'lifed' items (such as cable ties, saddles, p-clips, shielding)
- dismantling the system to sub-assembly level
- replacing damaged/defective components
- dismantling the system to component level
- re-assembling components to sub-assembly level
- protecting exposed plugs, cables and looms
- routeing looms in correct positions
- marking/labelling components
- setting, aligning and adjusting replaced components
- checking components for serviceability
- checking circuits for continuity
- tightening loom fastenings to correct tension
- checking operation of dashboard/warning lights
Use five of the following during the removal and refitting activities:
- jigs
- specialist tools
- multimeters
- fixtures
- crimping tools
- test lights
- hand tools
- heat shrink guns
- soldering irons
Remove and refit twelve of the following motorsport vehicle electrical/electronic systems and components:
- wiring looms and connectors
- fire extinguisher trigger module
- motors
- electronic control units (ECUs)
- data control units
- microphone/headsets
- electronic displays
- sensors (data, pickup)
- radio aerials
- master switches
- pumps
- batteries
- system switches
- capacitors
- thermistors or thermocouples
- locking and retaining devices
- circuit boards
- starter motors
- overload protection devices
- electrical switches
- relay components
- transmitter beacons
- lighting components
- radio transmitter
- other specific motorsport related components
Carry out checks and adjustments on the refitted electrical/electronic equipment, to include six of the following:
- continuity checking of systems for cable breaks
- checking electrical looms for correct routeing and security for prevention of wear and chafing
- checking data sensors for correct adjustment and operation
- ensuring that correct specification bulbs/LEDs are fitted
- ensuring that fire systems are armed
- checking that all circuit breakers/fuses are intact
- aural checking of driver communication systems
- ensuring that electrical/electronic units are anti-vibration mounted
- ensuring that all electrical/ electronic system components are free from foreign objects, dirt or other contamination
- other specific tests
Check motorsport vehicle electrical/electronic components, comply with one of the following:
- race associations
- vehicle manufacturer's specification
- team/company standards and procedures
- specific vehicle requirements