AURETR010 - Acumen Institute of Further Education_ Australian National University _ Repair wiring harnesses and looms

AURETR010 - Acumen Institute of Further Education_ Australian National University _ Repair wiring harnesses and looms Repair wiring harnesses and looms viii Table of Contents 1 Introduction...... 1 2 Preparation and job requirements ......... 2 2.1 Work health safety (WHS) 2 2.2 Using safety data sheets (SDS) .. 3 2.3 Hazard identification and risk assessment.... 3 2.3.1 Identifying firefighting equipment .....5 2.3.2 Safely handling hazardous materials and toxic substances ....8 2.3.3 Safe operating procedures while handling soldering equipment.....9 2.3.4 Safety procedures while soldering electrical wiring and circuits .....10 2.4 Safety 11 2.4.1 Personal safety ...12 2.4.2 Tools and equipment safety ..12 2.4.3 Vehicle safety.....13 2.4.4 Work area safety14 2.5 Environmental requirements.... 14 2.6 Tools and equipment ..... 16 2.6.1 Multimeter 16 2.6.2 Continuity tester .16 2.6.3 Crimping tools.....16 2.6.4 Soldering equipment....17 2.6.5 Heat gun...18 2.6.6 Terminals and connectors......18 2.7 Service information ......... 21 2.7.1 Manufacturer specifications..21 2.7.2 Service manuals.21 3 Wiring systems 23 3.1 Overview..... 23 3.2 Types of wiring systems found in vehicles ... 24 3.2.1 Basic single wiring .........24 3.2.2 Complex multi-wiring with varying wire gauges.25 3.2.3 Controller area network databus (CAN-bus) wiring.....26 3.3 Electrical circuits ... 27 3.3.1 Conductor28 3.3.2 Conductor splices.........28 Repair wiring harnesses and looms ix 3.3.3 Insulators ...29 3.3.4 Circuit protection devices......29 3.3.5 Power source......32 3.4 Types of electrical circuits ........ 32 3.4.1 Series circuit.........32 3.4.2 Parallel circuits....34 3.5 Circuit diagrams ... 34 3.5.1 Component symbols....34 3.5.2 Wire colour ..........36 3.5.3 Wiring connector ..........37 4 Wiring harness and loom diagnosis ...... 39 4.1 Accessing electrical terminals. 39 4.2 Testing wiring harnesses and looms... 39 4.2.1 Electrical resistance......39 4.2.2 Voltage drop ......40 4.3 Visual and functional assessments .... 40 4.3.1 Component damage and wear .....42 4.3.2 Component corrosion..42 4.3.3 Water and moisture ingress....42 4.3.4 Damaged insulation.....42 4.3.5 Frayed wires ........43 4.3.6 Burnt wiring..........43 4.3.7 Terminal and connector damage ..43 4.3.8 Water and moisture ingress....43 4.4 Testing procedure of electrical circuits and components....... 43 5 Repair procedure .... 45 5.1 Removal procedures for wiring harnesses and looms ... 45 5.1.1 Accessing wiring and removing panels and covers.....45 5.1.2 Removing and replacing components.....45 5.1.3 Disconnecting terminals from connectors45 5.2 Repair procedures of wiring harnesses and looms, including: 47 5.2.1 Determining cable and terminal types and sizes..........47 5.2.2 Wire soldering procedures .....47 5.2.3 Terminal crimping process .....48 5.2.4 Replacing male and female terminals within a connector housing..........48 5.2.5 Protecting and routing harness and loom49 5.3 Post-repair testing procedures 49 Repair wiring harnesses and looms x 6 Post repair inspection and documentation... 50 6.1 Post repair inspection ..... 50 6.2 Workshop procedures .... 51 6.3 Workshop tools storage and cleaning ........ 52 6.4 Documentation .... 54 7 References ..... 57