Assessment 2 Direct Observation Practical Demonstration of Tasks AURETR112

Student Book
Direct Observation
AURETR112 Test and repair basic electrical circuits
Assessment 2 – Direct Observation

Student Name Gurvinder Singh Student ID Number 0000013845
Unit Start Date 02/08/2021 Unit End Date 07/08/2021
Assessment Due Date 16/08/2021 Date Submitted 12/08/2021
This cover sheet is to be completed by the student and assessor and used as a record to determine student
competency in this assessment task
The assessment process and tasks were fully explained. √ Yes / No
I am aware of which evidence will be collected and how. √ Yes / No
I am aware of my right to appeal an assessment decision. √ Yes / No
I am aware that I can locate the AIBT’s Complaints and Appeals Policy and Procedure on their √ Yes / No
website at https://aibtglobal.edu.au/
I have discussed any additional educational support or reasonable adjustments I require in order to
undertake this assessment with the Student Support Services Officer and Trainer / Assessor, (if √ Yes / No
applicable). e.g. Student Handbook and Access and Equity Policy https://aibtglobal.edu.au/
I have access to all required resources? √ Yes / No
Cheating & Plagiarism Declaration
Student Declaration: In accordance with the AIBT’s Academic Misconduct Policy, I hereby acknowledge by
signing this declaration that I have not cheated or plagiarised any work regarding the assessment tasks undertaken
in this unit of competency except where the work has been correctly acknowledged.
NOTE: Student must sign this prior to submitting their assessments to the assessor
Date 12 / _082 /
Signature Gurvinder Singh : 20 21
Satisfactory or Not Yet Satisfactory

Assessment Results
(Please circle the assessment result for this task)
Feedback to Student - Please provide general feedback on the Student’s performance
Student Declaration: - I verify that the work completed

Assessor Declaration: - I verify that I have adequately
is my own and that I was adequately informed of the
explained and negotiated the assessment tasks with the
assessment process prior to commencing this
student prior to commencing assessment.
assessment task.
Student Signature: Gurvinder Singh Assessor Signature
Date: 12/08/2021 Date
Assessment 2 - Direct Observation – Version: 2.0 Created: May 2021

Practical Demonstration of Tasks –
AURETR112 Page 2 of 53
Context and Conditions of Assessment
This assessment will ensure that the elements, performance criteria, performance evidence and knowledge
evidence required and conditions are adhered to demonstrate competency in this unit assessment task.
• Read the assessment carefully before commencing.
• This is an open book assessment and will be conducted at your designated campus / workshop /
specialised lab.
• Your Assessor will use the assessment criteria in this document and will provide feedback / comment.
• You must answer all the questions in the assessment tasks in your own words and own handwriting.
• Your Trainer / Assessor will inform you of the due date for this assessment task.
• Your Assessor will grade as either S – Satisfactory or NS – Not Satisfactory for the assessment. In all cases
your Assessor will provide you with feedback.
• Only when all assessment tasks have been graded as S – Satisfactory you will be deemed C – Competent in the
final result of the unit of competency; if you do not satisfactorily complete all the assessment tasks you will be
deemed NYC – Not Yet Competent.
Re-Assessment Conditions
• If the evidence is graded as NS – Not Satisfactory you will be required to re-submit the evidence. In this
case, you will be provided with clear and constructive feedback based on the assessment decision so that
they can improve your skills / knowledge prior to reassessment.
• Where a ‘NS – Not Satisfactory’ judgement is made, you will be given guidance on steps to take to improve
your performance and provided the opportunity to resubmit evidence to demonstrate competence. The
assessor will determine and discuss the reasons for NS – Not satisfactory on any of the criteria and will
assess you through a different method of assessment e.g. verbal/oral questioning, problem solving
exercises.
• You will be notified between 10-30 working days of undertaking an assessment of their result in achieving
competency
o If a student does not complete the assessment, they should notify their trainer as to why they did
not complete the assessment and if due to illness, a medical certificate must be produced.
o In the above scenario, student will be given an opportunity for reassessment within 5 working days
with no reassessment fee charged.
o Students who are deemed to be Not Yet Competent (NYC) will be provided with information
identifying the areas in which they failed to achieve competency. Students will then have
the opportunity to repeat the assessment task within 5 working days of notification with no
reassessment fee charged.
o If a student is deemed NYC in the reassessment or if the student did not approach the AIBT’s
within five working days with a valid reason for not availing themselves of the reassessment
opportunity, then those students will be given a final chance to re-sit the assessment and will be
charged a reassessment fee as per AIBT rule.
o After this no further reassessment attempt will be provided to the student and the student will be
required to repeat the whole unit with full fee for the unit. The student will be made aware of the
impact of repeating the unit may have on their student visa.
o If a student is found to be cheating or plagiarising their assessment, a reassessment fee will be
charged for reassessing the assessment within 5 working days.
o If the student is found to be plagiarising or cheating again after conclusion of the Intervention
meeting with the Course Co-ordinator, the matter will be referred to the Academic
Management Committee which may result in the suspension or cancellation of their enrolment
o AIBT’s has intervention strategies, including student support services available to enable students to
complete qualification in the expected time frame. Students at risk of not completing within this
time frame are identified as early as possible and an intervention strategy is put in place.
The RTO will ensure access to:
• automotive workplace or simulated workplace

• workplace instructions

• manufacturer electrical system specifications

• vehicle or machinery with faults in the basic electrical circuits specified in the performance evidence
• electrical test equipment to test basic electrical circuits and components
• consumable materials relevant to repairing basic electrical circuits and components, including connectors,
terminals, wire, electrical tape and heat shrink sleeving
• electrical repair tools, equipment and materials relating to basic electrical circuits and components
Evidence to be submitted by the student: -
• Participation in demonstration of skills as required in the assessment task.

• Completion of Practical Activities for the tasks 1 to 3 (7 Job Cards)
Assessment Decision Making Rules
Your assessor will assess the evidence submitted for the following elements, performance criteria, performance
evidence and knowledge evidence to confirm that the student evidence submitted demonstrates validity, sufficiency,
authenticity and confirms current skills and knowledge relevant to the unit of competency.
Your assessor will be looking for the following in this assessment task: -
• Prepare to test basic electrical circuit
• Test circuit
• Repair and check circuit
• Complete work processes
• test a basic electrical circuit, including:
– one short circuit across an electrical resistive load
– one open circuit before or after an electrical resistive load
– one high resistance circuit before or after an electrical resistive load
– current flow and voltage drop across an electrical resistive load
• test for continuity in a basic wiring harness and visually check terminals in the wiring harness for moisture
ingress and corrosion
• carry out four different circuit repairs that include:
– crimping various terminal sizes
– soldering wire gauges to terminals
– applying heat shrink insulation to crimped or soldered joints
– replacing male and female terminals in a connector housing
• performing terminal retention checks to replaced terminals.

Assessment 2 – Direct Observation
Practical Demonstration of Tasks
Task 1: Test a basic electrical circuit

Upon completion of this task, you should be able to demonstrate how to test a basic electrical circuit such as a light
bulb circuit.
Student instructions:
You MUST test a basic electrical circuit, including the following four (4) on the vehicle you have been given by your
Trainer/Assessor:
• one (1) short circuit across an electrical resistive load.

• one (1) open circuit before or after an electrical resistive load such as a light bulb circuit.
• one (1) high resistance circuit before or after an electrical resistive load such as a light bulb circuit.
• current flow and voltage drop across an electrical resistive load such as a light bulb circuit.
You MUST complete the following four (4) Job Cards
Tools and Materials

• Digital Multimeter
• Test light suitable for testing circuits
• Test probes suitable for testing circuits
• Fused test lead
• Vehicles
• Wiring diagram for vehicle
• Basic hand tools
• Compass or Gauss gauge
Protective Clothing:
• PPE
• Safety goggles or glasses with side shields
• Steel-toed shoes
• Vehicle protection
Trainer / Assessor Notes:

1. The student MUST test a basic electrical circuit, including the following four (4):
• one short circuit across an electrical resistive load such as a light bulb circuit
• one open circuit before or after an electrical resistive load such as a light bulb circuit
• one high resistance circuit before or after an electrical resistive load such as a light bulb circuit
• current flow and voltage drop across an electrical resistive load such as a light bulb circuit
2. Assessors MUST verify performance evidence through questioning on skills and knowledge to ensure correct
interpretation and application.
3. The student MUST complete the following Job Cards
4. Observe the student performing each step in the practical observation checklist

WARNING!
The Assessment will be STOPPED IMMEDIATELY if you are attempting to carry out any step in an unsafe or
dangerous way.

Job Card 1: Testing for a short to ground

Job Details:
Upon completion of this job card, you will have demonstrated the ability to test a circuit and locate the short to ground.
Tool and Materials:

• A Vehicle
• Test light
• Workshop manual (WSM)
• Basic hand tools
• Compass or Gauss gauge
• PPE
Procedure:
WARNING!
dangerous way.
1. Obtain tools and equipment from your trainer

2. Ask the trainer to direct you to a work area.
3. Answer the questions between the Job Card
4. You must demonstrate the ability to test a circuit and locate the short to ground by following the procedure
in Job Card.
5. Complete post service testing to confirm repair
6. Clean-up the work area. Tools and equipment are stowed in their appropriate area and finalise the Job
Card documentation by filling in the “Rectification” section with the work you have carried out, and the parts
used on the job card.

Job Card 1
Customer Details
Customer: John Smith Contact Details: (H) 03 9 123 4567 (M) 0401 234 567
Address: 101010 Melbourne Street City Melbourne State: Victoria Post code: 3000
:
Vehicle Details (Must fill in the vehicle details) If simulated environment used, please tick ☐
Make: TOYOTA Model: CAMRY Colour: GREY License No: 5844327

VIN No: 1234567890QW Odometer Reading: 55000
Engine No: 123456QWE Engine Type: PETROL Trans Type: AUTO
Customer Concern
1. One short circuit across an electrical resistive load
Declaration By The Customer
Please execute at my cost and as soon as you conveniently can repair the listed items above, and also any work considered essential. The vehicle, its
accessories and contents are at my risk entirely whether theft or loss thereof or damaged thereto arises from any want of care on the part of yourself or
your contractors or servants or from any cause whatsoever. Any claims for faulty workmanship is to be raised within seven (7) working days after the
vehicle is returned to me. I agree such claim is limited solely to the rectification free of cost of the faulty work. No claim for loss consequential or otherwise
being admissible.
X J Smith / / 20
Signature of Owner Date (Fill in the date)

Tech Tip:
Before using a test light, it is good practice to check the tester’s lamp. To do this, simply connect the test
light across the battery. The light should come on.
WARNING!
Fuses and other protection devices normally do not wear out. They go bad because something went
wrong. Never replace a fuse or fusible link, or reset a circuit breaker, without finding out why they
went bad.
1. Which circuit does the short to ground affect? Trainer to Pick
Brake light
2. Are there any other related symptoms? □ Yes □

No If yes, describe the symptom(s) by filling in the “Fault” section of the Job Card.
WARNING!
When testing for a short, always use a fuse. Never bypass the fuse with a wire. The fuse should be rated
at no more than 50% higher capacity than specifications. This offers circuit protection and provides
enough amperage for testing. After the problem is found and corrected, be sure to install a fuse with the
specified rating.
3. Pull the fuse or circuit protection for the affected circuit from the fuse box.
4. With ignition switch in the RUN position, connect the test light across the fuse terminals in the fuse box.
Does the test light illuminate? □ Yes □
No
What does this test indicate? Fill in the “Cause” section of the Job Card.
5. With the test light connected across fuse terminals of the fuse box, disconnect components and connectors in
the affected circuit that are identified in the wiring diagram.
WARNING!
When working with connectors, never pull on the wires to separate the connectors. This can create an
intermittent contact and an intermittent problem that can be very difficult to find later. Always use the
special tools designed for separating connectors to prevent this problem.
6. Did the test light go out when a component was disconnected? □ Yes □
No What can be concluded thus far? Fill in the “Cause” section of the Job Card.

7. Connect the test circuit breaker across the fuse terminals of the fuse box and use the Compass or Gauss
gauge to find the location of the short to ground.
The needle of a compass or gauss gauge will fluctuate over the portion of the circuit that
has current flowing through it. Once the short to ground has been passed, the needle
will stop fluctuating.
8. Describe the location of the short to ground. Fill in the “Cause” section of the Job Card.
9. Repair the short to ground fault. Fill in the “Rectification” section of the Job Card.
10. Post-repair testing is carried out to confirm correct operation of the circuit.
11. Finalise Job Card documentation by filling in the Customers Fault, the Cause of the Fault, the Rectification to
repair the vehicle and the Parts used on the back of the Job Card

Fault: Record of Conversation with Customer:

One short circuit across an electrical resistance load Date:11/08/2021
Time:9 am
Service Advisor: Gurvinder Singh
Conversation:
Short circuit across resistance load
Cause:
Dry joint in the earth wire for the right hand side tail light
Rectification: Parts Used

Cleaning the contact of the wire 2 brake light bulbs
Recommendations: Sublet Repairs Order No

Check at next service
QT
Fluids Tyre Report Tech # Job # Time Clock Record
Y
Gear Oil L/H/F R/H/F ON 9 Am

Auto Oil mm mm OFF 11 AM
Engine Oil L/H/R R/H/R ON
Diff Oil mm mm OFF
Coolant Brake Report ON
P/S Oil L/H/F R/H/F OFF
Brake Fluid mm mm ON
Other L/H/R R/H/R OFF

mm mm
ON

OFF
Assessment 2 - Direct Observation –

Job Card 2: Testing for an open circuit with a test light

Job Details:
Upon completion of this job card, you will have demonstrated the ability to test for an open circuit with a test light.
Tool and Materials:

• A vehicle
• Test light suitable for testing circuits
• PPE
Procedure:
WARNING!
dangerous way.

3. Ask your trainer to direct you to a work area.
4. You must demonstrate the ability to test for an open circuit with a test light by following the procedure in Job
Card.

Job Card 2
Customer Details
:

Engine No: 1223456QW Engine Type: PETROLA Trans Type: AUTO
Customer Concern
2. One open circuit before or after an electrical resistive
being admissible.
X J Smith / / 20

Tech Tip:
Before using a test light, it is good practice to check the tester’s lamp. To do this, simply connect the test
light across the battery. The light should come on.
WARNING!
Fuses and other protection devices normally do not wear out. They go bad because something went
wrong. Never replace a fuse or fusible link, or reset a circuit breaker, without finding out why they
went bad.
1. Which circuit does the short to ground affect? Trainer to Pick
Brake light
2. Determine if the circuit to be tested is a power supply circuit or a ground circuit.

Power circuit □ Ground circuit √
3. If the circuit to be tested is a power supply circuit, connect the clip end of the test light to a ground on the
vehicle.
Ground point: Metal parts of the vehicle
4. Turn the ignition key to the ON position.
5. With the test light end, use the probe to check the wire in the circuit at each connector in the specific circuit. If
the test light comes on, there is continuity between the power supply and the point where you are testing.
Circuit tested: YES
The test light will illuminate if there is continuity between the power supply and the bulb.
WARNING!

6. If the circuit to be tested is a ground circuit, connect the clip end of the test light to a power supply, such as the
battery.
7. With the test light end, use the probe to check the wire in the circuit at each connector in the specific circuit. If
the test light comes on, there is continuity between the ground and the point where you are testing.
Circuit tested: yes
8. Describe the location of the open. Fill in the “Cause” section of the Job Card.
9. Repair the open circuit fault. Fill in the “Rectification” section of the Job Card.
repair the vehicle and the Parts used on the back of the Job Card.
12.


One open circuit before or after an electrical resistive Date:12/08/2021
Time:9 AM
Conversation:
Open circuit before or after an electrical

resistive
Cause:
Dry joint in the eye level connector

Clean the dry joint and connect it properly

QT
Y
Gear Oil L/H/F R/H/F ON 9 AM

Diff Oil mm mm OFF
mm mm
ON
OFF

Job Card 3: Test for high resistance in a headlight circuit

Job Details:
Upon completion of this job card, you will have demonstrated the ability to test for high resistance in a headlight circuit.
Tool and Materials:

• A vehicle
• Multimeter suitable for measuring ohms
• PPE
Procedure:
WARNING!
dangerous way.

4. You must demonstrate the ability to test for high resistance in a headlight circuit by following the procedure
in Job Card.

Job Card 3
Customer Details
:

Engine No: 123456QW Engine Type: PETROL Trans Type: AUTO
Customer Concern
3. One high resistance circuit before or after an electrical resistive load (Checking a Headlight switch).
being admissible.
X J Smith / / 20

WARNING!
To avoid possible damage to the meter or to the equipment under test, disconnect the circuit power and
discharge all high-voltage capacitors before measuring resistance.
1 Put the headlight switch in all possible positions and observe which lights are controlled by each position. List
each position and the controlled lights below. Fill in the “Fault” section of the Job Card.
2 Locate the headlight switch in the wiring diagram and print out or draw the switch with each possible
connection and possible position. Label the lights controlled by each position of the switch. Highlight the path
of each position from the power source to ground. Highlight different circuitry with different colours.
3 Remove the fuse to the headlights or disconnect the battery’s negative cable. Remove the headlight switch
according to the procedures outlined in the service information.
WARNING!
4 Identify the various terminals of the switch and list the different terminals that should have continuity in the
various switch positions. Fill in the “Fault” section of the Job Card.
5 Connect the ohmmeter across these terminals, one switch position at a time, and record your readings. Fill in
the “Fault” section of the Job Card.
WARNING!
Many DMMs with auto range display the measurement with a decimal point. Make sure you observe the
decimal and the range being used by the meter. A reading of .972 K ohm equals 972 ohms. If you ignore
the decimal point you will interpret the reading as 972,000 ohms.
6 Based on the test, what are your conclusions about the switch? Are they within manufactures specifications?
Fill in the “Cause” section of the Job Card.
7 Reinstall the switch and connect the negative battery cable or reinstall the fuse. Then check the operation of
the headlights.
8 Repair the high resistance fault. Fill in the “Rectification” section of the Job Card.
9 Post-repair testing is carried out to confirm correct operation of the headlight circuit.
10 Finalise Job Card documentation by filling in the Customers Fault, the Cause of the Fault, the Rectification to


One high resistance circuit before or after an electrical resistive load Date:12/08/2021
Time:9 Am
Conversation:
Checking a headlight switch
Cause:
Headlight relay has bad contact

Replace bad relay Headlight relay

QT
Y
Gear Oil L/H/F R/H/F ON 9 am

Auto Oil mm mm OFF 11:30 AM
Diff Oil mm mm OFF

mm mm
ON

OFF
End of Practical Task

Job Card 4: Test for current flow and voltage drop on the starting system
circuit
Job Details:
Upon completion of this job card, you will have demonstrated the ability to test for current flow and voltage drop on the
starting system circuit.
Tool and Materials:

• A vehicle
• Multimeter suitable for measuring volts
• Green highlighter
• Yellow highlighter
• Orange highlighter
• PPE
Procedure:
WARNING!
dangerous way.

4. You must demonstrate the ability to test for current flow and voltage drop on the starting system circuit by
following the procedure in Job Card.

Job Card 4
Customer Details
:

Customer Concern
4. Current flow and voltage drop across an electrical resistive load
being admissible.
X J Smith / / 20

WARNING!
1 Using the WSM, retrieve the wiring diagram for the starting system of the assigned vehicle and print it off.
A. Highlight the positive side of the system in yellow.

B. Highlight the negative side of the system in green.
C. Identify the control circuit with orange.
D. Attach to Job Card
2 Using the WSM, disable the ignition or fuel injection systems to prevent the engine from starting.
WARNING!
3 Connect the voltmeter across the battery’s negative cable. Crank the engine with the starter and observe the
readings on the voltmeter. Record your reading by filling in the “Fault” section of the Job Card.
4 What does this indicate? Fill in the “Fault” section of the Job Card.
5 Connect the voltmeter across the battery’s positive cable (from battery to starter motor). Crank the engine with
the starter and observe the readings on the meter. Record your reading by filling in the “Fault” section of the
Job Card.
6 This test measured the voltage drop across everything in the positive side of the circuit. What is included in
this circuit? Record your reading by filling in the “Cause” section of the Job Card.
7 What do the test results suggest? What are your recommendations? Fill in the “Recommendations” section of
the Job Card.
8 Reconnect the ignition or fuel injection systems to allow the engine to start.
9 Post-repair testing is carried out to confirm correct operation of the circuit.
10 Finalise Job Card documentation by filling in the Customers Fault, the Cause of the Fault, the Rectification to


Current flow and voltage drop across an electrical resistive load Date:12/08/2021
Time:9 AM
Conversation:
Current flow and voltage drop across

an electrical resistive load
Cause:
Relay is overheated due to overheating of solenoid

Replace the relay Relay

Clock
Fluids QTY Tyre Report Tech # Job # Time
Record
Gear Oil L/H/F R/H/F ON 9 Am

Diff Oil mm mm OFF
mm mm
ON
OFF

Task 2: Test for continuity in a basic wiring harness and visually check
terminals in the wiring harness for moisture ingress and corrosion
Upon completion of this task, you should be able to demonstrate how to test for continuity in a basic wiring harness
and visually check terminals in the wiring harness for moisture ingress and corrosion.
You MUST test for continuity in a basic wiring harness and visually check terminals in the wiring harness for moisture
ingress and corrosion on the vehicle you have been given by your Trainer/Assessor.
You MUST complete the following Job Card
Tools and Materials

• Inspection light
• Hand tools
• Multimeter suitable for measuring continuity
• Vehicle to test for moisture ingress and corrosion
• Workshop manuals (WSM)
• PPE

1. The student MUST test for continuity in a basic wiring harness and visually check terminals in the wiring
harness for moisture ingress and corrosion.
WARNING!
dangerous way.

Job Card 5: Test for continuity and visually check terminals in the wiring
harness for moisture ingress and corrosion in the exterior lighting circuit
Job Details:
Upon completion of this job card, you will have demonstrated the ability to test continuity in a basic wiring harness and
visually check terminals in the wiring harness for moisture ingress and corrosion in the Exterior Lighting circuit.
Tool and Materials:

• Inspection light
• Hand tools
• Multimeter suitable for measuring continuity
• Vehicle to test for moisture ingress and corrosion
• Workshop manuals (WSM)
• PPE
Procedure:
WARNING!
dangerous way.

4. You must demonstrate the ability to test continuity in a basic wiring harness and visually check terminals in
the wiring harness for moisture ingress and corrosion in the Exterior Lighting circuit by following the
procedure in Job Card.

Job Card 5
Customer Details
:
Make: TOYOTA Model CAMRY Colour: GREY License No: 5844326

:
Customer Concern
1. Test for continuity in a basic wiring harness and visually check terminals in the wiring harness for moisture
ingress and corrosion
being admissible.

X J Smith / / 20
1. Record the concern the customer would have with the exterior lighting system on the front of the Job Card.
2. Confirm the customer’s concern by performing a check of the exterior lighting system and record your results
by filling in the “Fault” section of the Job Card.
3. Determine if there are any other symptoms that may be related to the customer’s concern by testing the
operation of other systems. Fill in the “Fault” section of the Job Card.
4. Analyse the symptoms and reference the wiring diagram to determine the most likely location of the fault.
Record the component(s) and it’s (their) location(s) by filling in the “Fault” section of the Job Card.
WARNING!
5. Using the information in step 4, check all the connectors and terminals for moisture ingress and/or corrosion.
Record your results by filling in the “Fault” section of the Job Card
WARNING!
6. Based on your diagnostic checks, what is the cause of the problem? Record your results by filling in the
“Cause” section of the Job Card
7. Repair the fault. Fill in the “Rectification” section of the Job Card.
8. Post-repair testing is carried out to confirm correct operation of the exterior light circuit.


Test for continuity in a basic wiring harness and visually check terminals in the
Date:12/08/2021
wiring harness for moisture ingress and corrosion
Time:9 AM
Conversation:
Test for continuity in a basic wiring

harness and visually check terminals in
a wiring ingress and corrosion
Cause:
No continuity when testing parking light bulb

Replace the bulb Parking bulb

Check at next service x x
QT
Y

Diff Oil mm mm OFF

mm mm
Brake Fluid ON


mm mm ON
OFF
Instructions:
Ensure that the following actions / tasks / checks in your work area have been performed:
a. Tools & equipment used are in working order and have been put away ready for use next time. Where
necessary, tag any tools / equipment which had faulted during use and inform the Assessor about it.
b. Waste materials is to be disposed of via the appropriate recycling methods or place in general waste.
c. Ensure that any reusable materials are stored away appropriately and ready for reuse at another time.
d. Make sure the work area is cleaned and tidy. All equipment is put away and report on any issues / faults
with equipment when problems are noticed.
Job Card 5: AURETR012 Test and repair basic electrical circuits
Student’s Name (Must fill in) Student’s Signature (Must fill in) Date of Assessment (Must fill in)
Gurvinder Singh Gurvinder Singh 12/08/2021
Location of Assessment (Must fill in)
Moonah

Task 3: Carry out four different circuit repairs

Upon completion of this task, you should be able to demonstrate how to carry out four different circuit repairs.
You MUST carry out four different circuit repairs on the vehicle you have been given by your Trainer/Assessor that
include:
• crimping various terminal sizes

• soldering wire gauges to terminals
• applying heat shrink insulation to crimped or soldered joints
• replacing male and female terminals in a connector housing.
And then,
• performing terminal retention checks to replaced terminals
You MUST complete the following two (2) Job Cards
Tools and Materials
• Crimping tool
• Crimping terminals of various sizes
• Soldering iron
• Solder
• Heat shrink
• Terminal removing tools
• Hand tools
• Vehicles to carry out electrical repairs
• Workshop manuals
• PPE
1. The student MUST carry out four different circuit repairs that include:
- crimping various terminal sizes
- soldering wire gauges to terminals
- applying heat shrink insulation to crimped or soldered joints
- replacing male and female terminals in a connector housing.
- performing terminal retention checks to replaced terminals

WARNING!
dangerous way.

Job Card 6: Repair electrical circuits by soldering and crimping

Job Details:
Upon completion of this task, you should be able to demonstrate how to carry out soldering wire gauges to terminals
repairs.
Tools and Materials

• Soldering iron
• Solder
• Electrical terminals of various sizes
• Heat shrink
• Hand tools
• PPE
Procedure:
WARNING!
dangerous way.

4. You must demonstrate the ability to carry out soldering wire gauges to terminals repairs by following the
procedure in Job Card.

Job Card 6
Customer Details
:

:
Customer Concern
1. Carry out three (3) different circuit repairs that include:

- crimping various terminal sizes
And:
- performing terminal retention checks to replaced terminal
being admissible.
X J Smith / / 20

WARNING!
Always follow the manufacturer’s wiring and terminal repair procedures. On some components and
circuits, manufacturers recommend complete wiring harness replacement rather than making repairs to
the wiring. For most vehicles, SRS air bag harness components, including wiring, insulation, and
connectors, should not be repaired. Any SRS harness damage requires replacement of the related
harness.
WARNING!
Disconnect the fuse that powers the circuit being repaired. Note: If the circuit is not protected by a fuse,
disconnect the ground lead of the battery.
1. Using the correct size stripper, remove about 12 mm of the insulation from the wire. Be careful not to nick or
cut any of the wires.
2. Select the proper size electrical terminal to be fitted.
3. Place the correct length and size of heat shrink tube over the wire. Slide the tube far enough away so the
wires are not exposed to the heat of the soldering iron.
4. Insert the end into the electrical terminal and hold in place with thumb and forefinger. While the wire end is
centre in the electrical terminal, crimp it into place.
5. Heat the electrical terminal with the soldering iron while applying solder to the opening in the front of the
electrical terminal. Apply only enough solder to make a good connection. The solder should travel through the
wire.
WARNING!
Never use acid core solder. It creates corrosion and can damage electronic components.
6. Perform a wire retention check by gently push back and forth on the wire to confirm that the wire and terminal
is correctly in place.
7. After the solder cools, slide the heat shrink tube over the electrical terminal and heat the tube with the hot air
gun until it shrinks around the electrical terminal. Do not overheat the tube.
8. Repeat steps 1 to 7 on various size wires and electrical terminals two (2) more times


Date:12/08/2021
Time:9 AM
Conversation:
- applying heat shrink insulation
to crimped or soldered joints
Cause:
Broken wires in lighting system

Splice, solder and insulate the broken wire Soldering core
Insulating tape
Heat shrink

Check at next service x x
QT
Y

Auto Oil mm mm OFF 11 am
Diff Oil mm mm OFF


mm mm ON
OFF
Instructions:
Moonah

Job Card 7: Repair electrical circuits by replacing male and female terminals
in a connector housing
Job Details:
Upon completion of this task, you should be able to demonstrate how to carry out replacing male and female terminals
in a connector housing repairs.
Tools and Materials

• Wiring harness
• Special electrical tool for replacing male and female terminals in a connector housing
• Hand tools
• PPE
Procedure:
WARNING!
dangerous way.

4. You must demonstrate the ability to carry out replacing male and female terminals in a connector housing
repairs by following the procedure in Job Card.

Job Card 7
Customer Details
:

:
Customer Concern
2. Carry out a male and female terminal circuit repairs that include:
- replacing male and female terminals in a connector housing.
And:
- performing terminal retention checks to replaced terminal
being admissible.
X J Smith / / 20

WARNING!
Always follow the manufacturer’s wiring and terminal repair procedures. On some components and
circuits, manufacturers recommend complete wiring harness replacement rather than making repairs to
the wiring. For most vehicles, SRS air bag harness components, including wiring, insulation, and
connectors, should not be repaired. Any SRS harness damage requires replacement of the related
harness.
WARNING!
Disconnect the fuse that powers the circuit being repaired. Note: If the circuit is not protected by a fuse,
disconnect the ground lead of the battery.
WARNING!
dangerous way.
WARNING!
1. Use the special electrical tool, to depress the locking tang of the connector housing.
2. Pull the lead back far enough to release the locking tang from the connector housing.
3. Remove the pick, then pull the wire completely out of the connector housing.
4. Use the pick to bend the lock tang back into its original shape.
5. Do this for all the wires in the connector housing.
6. Replace the connector housing.
7. Insert the wire into the back of the connector. A noticeable “catch” should be felt when the wire is
halfway through the connector.
8. Perform a terminal retention check by gently push back and forth on the wire to confirm that the terminal is
locked in place.
9. Repeat steps 1 to 6 on various connectors two (2) more times


Performing terminal retention checks to replaced terminal Date:12/08/2021
Time: 9 AM
Conversation:
performing terminal retention checks to

replaced terminal
Cause:
Vibration

Check the continuity of the connector
Re-tension connector wires

QT
Y

Diff Oil mm mm OFF
mm mm
ON
OFF
Instructions:
Moonah

Assessment 2 – Direct Observation – Assessor Checklist

Observation Checklist (Assessor / Trainer only):
Assessment methods must be by direct observation of tasks and include verbal questioning on required skills
and knowledge to ensure correct interpretation and application.
Satisfactory = S
Observable skills/tasks Not Satisfactory = NS
Safety
1. Safely used appropriate safety equipment S | NS
2. Completed work safely, efficiently and within acceptable timeframes S | NS
3. Observed all safety, PPE, environmental and workplace policies throughout the work
S | NS
including correct manual handling techniques
4. Safely use relevant tooling and equipment to the level required by industry S | NS
Setup / preparation
5. Accessed a range of information sources, seeks assistance and used a range of

S | NS
strategies for learning and self-improvement
6. Select appropriate safety equipment, materials, processes and procedures S | NS
7. Attended at times required and was prepared for work S | NS
Generic skills
8. Followed task and job instructions and specifications including correct tool and
S | NS
equipment identification and testing in a safe and efficient manner
9. Collect, organise and understand technical information relating to recognising and

S | NS
reporting unsafe situations
10. Use manufacturer’s workshop manual/publication/database to access, interpret and

S | NS
apply information, safely makes adjustments where necessary
11. Communicated respectfully and inclusively with teachers and others S | NS
12. Adapted to changes in workshop environment S | NS
13. Solved problems using analytical skills and sought assistance as required S | NS
14. Worked consistently on tasks and managed time efficiently and effectively S | NS
15. Worked well in a team environment and resolved conflict and differences S | NS

16. Displayed appropriate numeracy skills for the task at hand S | NS
Specific task skills
18. Job Card 1 Testing for a short to ground S | NS
19. Job Card 2 Testing for an open circuit with a test light S | NS
20. Job Card 3 Test for high resistance in a headlight circuit S | NS
21. Job Card 4 Test for current flow and voltage drop on the starting system circuit S | NS
22. Job Card 5 Test for continuity and visually check terminals in the wiring harness for
S | NS
moisture ingress and corrosion in the exterior lighting circuit
23. Job Card 6 Repair electrical circuits by soldering and crimping S | NS
24. Job Card 7 Repair electrical circuits by replacing male and female terminals in a
S | NS
connector housing.
Clean up/ reporting
25. Completed documentation (e.g. job card) to workplace standard S | NS
26. Checked and stowed tools and equipment correctly; identified and reported any
S | NS
broken or faulty items for repair or replacement
27. Kept work area clean ensuring all waste is scrapped and/or recycled S | NS

Verbal Questioning – In Relation to Practical Tasks
Q1. Rings, necklaces, bracelets and watches should not be worn while working around electrical systems. Why?
Students response:
The metals in most jewellery conducts electricity very well and can easily cause a short,
through you if it
touches a bare wire.
Q2. Why should you NEVER use a test-light to diagnose components and wires in computer systems?
Students response:
The current draw of these test-lights may damage the computer system components.
Q3. What can Digital Multimeter measure?
Students response:
Most multimeters measure direct current (dc) and alternating current (ac) amperes,
volts, ohms, measure
diode continuity, frequency, temperature, engine speed, and dwell, and/or duty cycle.
Q4. How is digital multimeter connected when measuring resistance
Students response:
A digital multimeter is connected to a circuit in series.


Q5. What faults should you visually inspect for on wiring and connectors?
Students response:
Wires: Loose or corroded terminals, frayed, broken or oil soaked wires.
Connectors: Nearly all connectors have pushdown release-type locks. Make sure these
are not damaged.
Many connectors have covers over them to protect them from dirt and moisture. Make
sure these are properly installed to provide for that protection.
Q6. There are three major factors that determine the proper size of wire to be used. What are they?
Students response:
1. The wire must have a large enough diameter, for the length required, to carry
the necessary current for
the load components in the circuit to operate properly.
2. The wire must be able to withstand the anticipated vibration.

3. The wire must be able to withstand the anticipated amount of heat exposure
Q7. What is the procedure for soldiering electrical wire together?
Students response:
Join the two cables and place the tip of the soldering iron underneath the wire which
becomes hot enough
to melt the resin-core solder on the top of the of the wire.

Q8. Why is heat shrink used?
Students response:
Heat shrink tube provides additional protection. Heat shrink tube is plastic tubing that
shrinks in diameter
when exposed to heat.


Assessment 2 Direct Observation Practical Demonstration of Tasks AURETR112

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Student Book

Assessment 2 – Direct Observation

Unit Start Date 02/08/2021 Unit End Date 07/08/2021

Assessment Due Date 16/08/2021 Date Submitted 12/08/2021

The assessment process and tasks were fully explained. √ Yes / No

I am aware of which evidence will be collected and how. √ Yes / No

I am aware of my right to appeal an assessment decision. √ Yes / No

I have access to all required resources? √ Yes / No

Cheating & Plagiarism Declaration

Satisfactory or Not Yet Satisfactory

Feedback to Student - Please provide general feedback on the Student’s performance

Student Declaration: - I verify that the work completed

Student Signature: Gurvinder Singh Assessor Signature

Date: 12/08/2021 Date

Assessment 2 - Direct Observation – Version: 2.0 Created: May 2021

Context and Conditions of Assessment

The RTO will ensure access to:

• automotive workplace or simulated workplace

Assessment 2 - Direct Observation – Version: 2.0 Created: May 2021

• manufacturer electrical system specifications

Evidence to be submitted by the student: -

• Participation in demonstration of skills as required in the assessment task.

Assessment Decision Making Rules

Assessment 2 - Direct Observation – Version: 2.0 Created: May 2021

Assessment 2 – Direct Observation

Practical Demonstration of Tasks

Task 1: Test a basic electrical circuit

• one (1) short circuit across an electrical resistive load.

You MUST complete the following four (4) Job Cards

Tools and Materials

Trainer / Assessor Notes:

3. The student MUST complete the following Job Cards

Assessment 2 - Direct Observation – Version: 2.0 Created: May 2021

Assessment 2 - Direct Observation – Version: 2.0 Created: May 2021

Job Card 1: Testing for a short to ground

Tool and Materials:

1. Obtain tools and equipment from your trainer

Assessment 2 - Direct Observation – Version: 2.0 Created: May 2021

Make: TOYOTA Model: CAMRY Colour: GREY License No: 5844327

1. One short circuit across an electrical resistive load

Declaration By The Customer

Assessment 2 - Direct Observation – Version: 2.0 Created: May 2021

1. Which circuit does the short to ground affect? Trainer to Pick

2. Are there any other related symptoms? □ Yes □

Assessment 2 - Direct Observation – Version: 2.0 Created: May 2021

Assessment 2 - Direct Observation – Version: 2.0 Created: May 2021

Fault: Record of Conversation with Customer:

Service Advisor: Gurvinder Singh

Short circuit across resistance load

Rectification: Parts Used

Recommendations: Sublet Repairs Order No

Gear Oil L/H/F R/H/F ON 9 Am

Diff Oil mm mm OFF

Coolant Brake Report ON

P/S Oil L/H/F R/H/F OFF

Other L/H/R R/H/R OFF

Assessment 2 - Direct Observation – Version: 2.0 Created: May 2021

Assessment 2 - Direct Observation –

Job Card 2: Testing for an open circuit with a test light

Tool and Materials:

1. Obtain tools and equipment from your trainer

Assessment 2 - Direct Observation – Version: 2.0 Created: May 2021

Make: TOYOTA Model: CAMRY Colour: GREY License No: 5844326