THE 7 SINS OF WIRE HARNESS ASSEMBLY TRAINING CERTIFICATION TEST (DVD-60C)

Transcription

1 This test consists of twenty multiple-choice questions. All questions are from the video: The 7 Sins of Wire Harness Assembly (DVD-60C). Each question has only one most correct answer. Circle the letter corresponding to your selection for each test item. If you wish to change an answer, erase your choice completely. You should read through the questions and answer those you are sure of first. After your first pass through the test, then go back and answer the questions that you were not sure of. If two answers appear to be correct, pick the answer that seems to be the most correct response. When you are finished, check to make sure you have answered all of the questions. Turn in the test materials to the instructor. The passing grade for this test is 70% (14 correct answers or better). Good luck! 1

2 ANSWER SHEET Name: Date: Circle the letter corresponding to your answer for each test item. 1 A B C D 2 A B C D 3 A B C D 4 A B C D 5 A B C D 6 A B C D 7 A B C D 8 A B C D 9 A B C D 10 A B C D 11 A B C D 12 A B C D 13 A B C D 14 A B C D 15 A B C D 16 A B C D 17 A B C D 18 A B C D 19 A B C D 20 A B C D 2

3 1. Wire preparation involves a. selecting the right wire b. cutting the wire to the correct length c. stripping the wire if required 2. Having nicks or cuts on the conductor after wire stripping means a. the cutting blades are too sharp b. the cutting depth is too deep c. the cutting depth is not deep enough d. the wire is probably defective 3. Compressed insulation usually means a. the cutting blades are dull b. the cutting depth is too deep c. the rollers are too tight d. any of the above 4. During manual wire stripping, the biggest cause of wire damage occurs when a. an inappropriate tool is used b. there is an incorrect diameter setting c. a thermal stripper is improperly used d. using a tool with a dull blade 5. Proper wire harness layout is important because a. wires are not identified b. specific lengths of wire are needed to break out of the bundle in different locations c. some wires are stripped and some are not d. none of the above 6. A form board is a. the physical duplication of the assembly drawing b. used for complex wire harness assemblies c. also called a template 7. If you were to route a smaller AWG wire in place of the correct larger wire a. there may be damage to the wire, or possibly to parts of the system b. the system would operate normally since wires are basically interchangeable c. there would only be a problem if another wire was missing d. the system would operate normally as long as the wire length was correct 3

4 8. The most common error in wire harness assembly is a. improper wire stripping b. incorrect terminations c. incorrect labeling d. missing hardware 9. An example of a labeling problem is a. incorrect information b. illegible marking c. incorrect location 10. When a correctly marked label is attached to the wrong wire a. there will not be a place to connect it b. there will be incorrect terminations when the harness is connected to the chassis c. the assembly drawing will have to be changed to reflect the change d. the wire will be too small for the job 11. The mechanical compression of the metal terminal around the exposed wire is called the a. conductor crimp b. bellmouth c. insulation crimp d. conductor brush 12. The bellmouth is the a. mechanical compression of the metal terminal around the exposed wire b. strands of wire that extend past the conductor crimp c. mouth of insulation after the conductor crimp d. flare that is formed on the edge of the conductor crimp 13. The purpose of the insulation crimp is to provide a. mechanical compression for the crimp b. protection against nicking the wire strands c. wire support d. resistance during pull tests 14. If the wire strands are not fully enclosed in the conductor crimp section a. the mechanical strength of the crimp will be reduced b. the electrical current carrying ability will be reduced c. the loose strands may cause a short circuit 4

5 15. When selecting a soldering iron tip, always select a a. heat efficient conical tip b. medium size chisel tip c. a tip that has the greatest contact area without overhanging the joint d. a tip with plenty of oxidation 16. The reason for tinning the soldering iron tip is to a. transfer heat rapidly b. increase operator satisfaction by having a shiny tip c. avoid burning solder and creating a bad smell d. keep the solder flowing smoothly 17. An ideal, or target solder connection is where a. all of the metals are covered by solder b. the outline of the lead remains visible under the solder c. the solder fillet is concave, or curved inward 18. An example of incorrect hardware is having a. a solder bridge b. the wrong screw thread size c. an oversized bellmouth 19. The correct hardware for the wire harness is called out in the a. assembly documentation b. Standard Operating Procedure c. quality assurance guidelines d. IPC/WHMA-A The purpose of tying the wires is to a. make the wires neat and orderly b. maintain the form of the harness c. break out individual wires at their designated connection points d. both b and c 5