Diagnose, repair and test the trailer and body lighting circuit

You are an auto electrical technical operator on the fit-out line.

Simulated workplaceIntermediate missionCAQA Nexus Automotive Manufacturing

What is going on

Two marker light faults have appeared in a week. Non-conformance NCR-26-090 records an intermittent side marker circuit on pantech WO-26-0415, traced to a chafed loom behind the rear pillar. NCR-26-094 is a warranty return on flat top trailer WO-26-0409, delivered last week, where the fault was a loose earth stud. The Body Build and Fit-out Manager wants the pantech circuit diagnosed and repaired, the whole lighting installation tested against the heavy vehicle lighting requirements, both non-conformance records updated and an opinion on whether the loom routing work instruction needs to change. The customer quality audit in October will look at repeat non-conformances.

Kylie Anstey, Body Build and Fit-out Manager
Subject: Marker light faults: fix WO-26-0415 and find out why it keeps happening

We now have two marker light faults, one on the pantech in fit-out and a warranty return on the flat top we delivered last week. Please diagnose and repair the intermittent circuit on WO-26-0415, test the whole lighting circuit against the heavy vehicle lighting requirements, and update both non-conformance records. Then look at the loom routing behind the rear pillar and tell me whether the work instruction needs to change. Use the multimeter from the calibrated set, not the one in the drawer.

Your brief

Diagnose and repair the intermittent circuit, install and test the lighting to the applicable heavy vehicle standards, record the results, update both non-conformances with root causes and recommend a change to the work instruction if the evidence supports it.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

Read NCR-26-090 and NCR-26-094 in the Non-Conformance Register and the wiring diagram supplied, and write a diagnostic plan for the intermittent side marker circuit.
Using the test readings supplied by your assessor, identify the fault location, describe the repair including loom protection and routing, and explain why the chafe occurred.
List the lighting, reflector and marking requirements that apply to this body from the Heavy Vehicle Standards and Compliance Policy and check the installed lamps against them.
Test every lighting circuit and record voltage drop, function and earth integrity on the work order, using the calibrated multimeter from the Plant and Equipment Register.
Update both non-conformance records with the root cause, the repair and the verification required, and propose a disposition for each.
Write a short recommendation to the manager on whether the loom routing work instruction needs to change, with the evidence from both faults.
Draft the changed step for the work instruction if you recommend a change, including the protection and securing method behind the rear pillar.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Diagnostic plan and fault finding record
Lighting compliance check against the policy
Circuit test record on the work order
Updated non-conformance records with root causes
Recommendation on the work instruction

Printing this is a record of what you explored. It is not a certificate or a qualification.