Auter401 Vehicle Electrical Systems Installation and Maintenance PDF

Introduction ------------ The lighting system provides power to both exterior and interior lights. The vehicle has many different lighting and signaling systems, each with its own specific components and operating characteristics. The major light-related circuits and systems covered include: - E...

Introduction ------------ The lighting system provides power to both exterior and interior lights. The vehicle has many different lighting and signaling systems, each with its own specific components and operating characteristics. The major light-related circuits and systems covered include: - Exterior lighting - Headlights (halogen, HID, and LED) - Bulb trade numbers - Brake lights - Turn signals and flasher units - Courtesy lights - Rear view mirrors Module Code and Title: AUTER401 VEHICLE ELECTRICAL SYSTEMS INSTALLATION AND MAINTENANCE --------------------------------------------------------------------------------------- Learning outcome1: Describe Lightning and Signaling System ========================================================== STRUCTURE OF LEARNING OUTCOMES 1.1. Proper identification of lighting and signaling system =========================================================== Indicative content 1.1: Proper identification of lighting and signaling system ------------------------------------------------------------------------------ **Content 1: Essentials of lighting system** 1.1.1. Definition of lighting system ==================================== Lighting system is the system which is used for illuminating road to help the driver to see and to be seen in dark by converting electrical energy into light energy. 1.1.2. Definition of signaling system ===================================== Signaling system is the system which is used indicate driver's intention to the other road users. It enables the driver to warn other road users. 1.1.3. Purpose of lighting system ================================= - To illuminate the road. Eg. Main beam, dipped beam head light. - To make contours of vehicle visible in the darkness. Eg. Clearance lamps, parking lights - To make the driver aware of certain switch status of lighting system. Eg. Main beam, indicator lamps 1.1.4. Purpose of signaling system ================================== - To indicate intended manoeuvres to the other road users. Eg. Direction indicator lamps, break lights. - To warn other road users. Eg. Hazard warning system 1.1.5. Main components of lighting and signaling system ======================================================= - Battery - Switches - Fuses - Relays - Lamps - Flasher unit - Wires - Horn 1.1.6. Vehicle interior light ----------------------------- - Roof light - Door light - Luggage light - Groove box light 1.1.7. Vehicle exterior light ----------------------------- - Tail light - Reverse light - License plate light - Brake light - Direction indicator light - Hazard warning light Written assessment (answer by TRUE or FALSE) -------------------------------------------- 1. Lighting system is the system which is used indicate driver's intention to the other road users. It enables the driver to warn other road users. 2. Lighting system is the system which is used for illuminating road to help the driver to see and to be seen in dark by converting electrical energy into light energy. It produces current to interior and exterior lights 3. Functions of lighting system in motor vehicle is: a. To illuminate the road. b. To make contours of vehicle visible in the darkness. c. To indicate intended manoeuvres to the other road users d. To warn other road users. e. To make the driver aware of certain switch status of lighting system. **Answers:** 1. False 2. True a. True b. True c. False d. False e. True Learning outcome 1.2 Describe Lighting and signaling system components ---------------------------------------------------------------------- **Content 2 : Headlamp layout** 1.2.1. Headlamp layout ---------------------- **Dual-headlight system:** the dipped beam and main beam are beamed into a common reflector. The light is created by bulbs with two filaments, which use a common reflector. **Quad-headlight system:** one headlight pair is designed either for dipped beam and main beam or for dipped beam only. The second headlight pair is only designed for main beam.  **Six headlight system:** in addition to the quad-headlight system, another headlight pair may also be provided for front fog lamps or main beam headlights, depending on headlight layout. 1.2.2. Design of headlight -------------------------- There are four types of headlight design: - The halogen headlight - Paraboloid reflector headlight - Ellipsoid reflector headlight - Freeform headlight ### *[The design of halogen headlight]*  ### *[Paraboloid headlight]* ### *[Ellipsoidal headlight]*  ### *[Freeform reflector headlight]*  The reflectors of free form headlamps are designed by computers to tight tolerances. The surface of the reflector focuses and scatters the light beams. It is divided up into segments to illuminate different segments of the highway. For example: Zone I: illumination of the distant zone of the right-hand side of the road Zone II: illumination of the zone directly under the light-dark cut- off. Zone III: primary for the road illumination Zone IV: primary for illuminating the edge of the carriageway carriage way 1.2.3. Types of headlamps ------------------------- - Low beam headlamp - High beam headlamp - Auxiliary lamp - Fog lamp - Search lamp - Flush to pass lamp 1.2.4. Light source of headlight and lights ------------------------------------------- a. Metal filament lamp b. Halogen lamp c. Gas discharge lamp d. Neon-gas discharge lamp e. LED lights ### 1.2.4.1. Metal filament lamps The light source (filament, coil) is made of tungsten, which has a melting point of approximately 3,400 ^0^C. the coil itself can reach temperatures of up to 3,000 ^0^C. They come into two varieties: **Single wire lamp:** A lamp with one filament **Dual wires lamp:** A lamp with two filaments ### 1.2.4.1. Halogen lamps These are bulbs which contain a gas with halogen admixture (bromine, iodine). The operating behavior of halogen lamps differ from filament lamps in: - The higher temperature of the filament and glass bulb. - The higher interior pressure of the gas filling (up to approximately 40 bar)  The greater luminous efficiency due to the higher temperature of filament.  ### 1.2.4.2. Gas discharge lamp Between two electrode located in a small ball-shaped glass bulb, an arc is ignited in a xenon gas atmosphere by a high voltage pulse. The metal salts within the glass bulb evaporate and ionize the spark gap. In doing so, they emit light and prevent the electrode from wearing. #### Advantages of gas-discharge lamps by comparison with halogen lamps - Better road illumination - Lower current consumption - Light output independent of the vehicle power supply - Lower heat generation - Longer service life - The light color is almost of the daylight. #### Disadvantage of gas-discharge lamps by comparison with halogen lamps ### 1.2.4.3. Neon gas-discharge lamps These are gas-discharge lamps that achieve full brightness in approximately 0.2 microseconds. They are primary used in auxiliary brake lights. **1.2.4.4. Light emitting diodes (LED).** A certain number of diodes are interconnected with a physical unit according to the brightness required and the desired color. LED have a service life of approximately 10,000 hours. They are used in particular brake lights, as they achieve their maximum brightness in a significantly shorter time of approximately 2 microseconds than filament lamps or halogen lamps. 1.2.5. Fuse ----------- It is inevitable that during the life of a vehicle, an electrical circuit will fail. Each circuit is protected by a fuse, in case a failure results in a short circuit. A fuse contains a thin wire element that will burn out. The fuse 'blows' open circuit, when the specified current limit for the circuit is exceeded.  There are many different types of fuses on the market. Generally, a fuse is marked with the maximum amount of current (Amperes) that it will allow to flow in a circuit, without blowing.  1.2.6. Relay ------------ A relay is an electromagnetic operated switch that uses a small input current to switch high currents. ### Relay Terminal Identification - Terminals 86 and 85 are the primary side of the relay, which utilizes an electromagnet to close (connect) the secondary electrical circuit inside the relay. This electromagnet is activated by a simple power (+) and ground (-) much like a light bulb circuit. - Terminals 87 or 88 and 30 are the secondary side of the relay which acts as the \"switch\" that connects electrical current from one terminal to the other. - Terminal 87a or 88a is not widely used and does not need to be connected for the relay to operate. #### *[Operation]* A 12-volt supply must be connected to the switch. When the switch is closed, a magnetic field is created by the electromagnet, which attracts the armature to the coil. The contacts close. A high value current can then flow across the relay contacts. When the switch is opened, the magnetic field collapses and the return spring pulls the contacts apart. **There are three types of relay:** - Make relay - Break relay - Changeover relay ### 1.2.6.1. Make relay This closes the control circuit between the voltage source and consumer, i.e. the consumer is switched on. The control current through the electromagnetics (terminal connectors 85 and 86) causes the switch armature to be activated. This closes the switch contact. Thus, the working current Circuit (terminal connectors 88 and 88a) is connected. **Example of use**: main beam headlamps and auxiliary lamps, signal horn, fan motor, window regulator.  ### 1.2.6.2. Break relay This opens the control current circuit between the voltage source and consumer, i.e, the consumer is switched off. **Example of use:** breaking electric circuits of consumers during the start process. Ex. Main beam headlamps, rear window heating, radio, etc. ### 1.2.6.3. Changeover relay This is a combination of make relay and a break relay, i.e. it activates two control circuit at the same time. The relay switches the current path from one consumer to the other by changing the break contact of one circuit to the make contact of another circuit. Example of use: switching between two consumers (bulbs).  - What are the three layout possibilities of lighting system? - How the headlight can be designed? **Formative assessment** Written evidence ---------------- Complete the following table Types of lamp Advantages Disadvantages ------------------- ------------ --------------- Metal filament LED Halogen Neo gaz discharge **Answers:** +-----------------------+-----------------------+-----------------------+ | Types of lamp | | disadvantages | +=======================+=======================+=======================+ | Metal filament | - Cheap | - Extremely hot | | | | | | | - long service life | - large in scale | +-----------------------+-----------------------+-----------------------+ | LED | - Long service life | Many small LEDs | | | | required to create | | | - Reduced | the necessary light | | | electrical power | output. | +-----------------------+-----------------------+-----------------------+ | Halogen | - Halogen Lamps are | - Extremely hot | | | small, | | | | lightweight | - Not as efficient | | | | as HID lamps | | | - Low cost to | | | | produce | | +-----------------------+-----------------------+-----------------------+ Learning outcome 1.3 Describe lighting and signaling systems ------------------------------------------------------------ **Content 4:** **Wiring diagram of external light/lamp** 1.3.1. Wiring diagram of external light/lamp -------------------------------------------- ### 1.3.1.1. Wiring diagram of high and low beam head light ### 1.3.1.2. Wiring diagram of Parking and tail light When the headlamp switch is in the OFF position, all lamps are off.  When the switch is in the PARK position, the park and tail lamps are on. When the switch is in the HEAD position, the park and tail lamps are on. ### 1.3.1.3. Wiring diagram of fog light  **Fog lamps E17/E18**. There is a voltage at terminal 83 of fog lamp switch S23 if the light switch S18 is in position 1 or 2. With the fog lamp in position 1, the current flows from 83a via the control winding of fog lamp relay k5 to terminal 56a and E16 to earth 31, if the main beam is switched off. The relay operates and the fog lamps are supplied with power from terminal 30. If the main beam is switched on, terminal 56a is positive. Therefore, no more power is supplied between terminals 85 and 86 in the fog lamp relay and the magnetic field collapses. The switch in fog lamp relay opens and switches the fog light off. 1.3.1.4. Wiring diagram of Reverse light When backup gear is selected, the backup switch closes, switching on the backup lamps. The lamps illuminate the area behind the vehicle, warning others that the vehicle is moving backward. The backup switch is usually screwed into the gearbox selector housing. One side of the switch is connected to the backup lamps; the other side is connected to the ignition switch. Movement of the backup selector rod, pushes the plunger against the terminals of the switch, to complete the circuit.  ### 1.3.1.5. Wiring diagram of brake light Stop lamps warn others that the brake pedal has been pressed. Single or twin filament bulbs may be used. The twin filament bulb combines stop and tail lamps. The tail filament is usually rated at 5 watts. The stop filament is usually rated at 21 watts. The higher the wattage, the brighter the bulb. #### 1.3.1.5.1. Plunger Type Brake Switch The brake switch is mechanically linked to the brake pedal. One side of the switch is connected to the stop lamps; the other side is connected to the ignition switch. The switch is operated when the brake pedal is pressed downward. #### 1.3.1.5.2. Hydraulic Pressure Type Brake Switch Some types of older brake switches are operated by hydraulic pressure. The switch is screwed into an adapter, located in a hydraulic brake line. One side of the switch is connected to the stop lamps; the other side is connected to the ignition switch. A spring holds the contact away from the terminals, until the brake pedal is pressed.  ### 1.3.1.6. Wiring diagram of turn signal light Turn signal flashing operation: The flasher receives battery power via a fuse, the ignition switch and normally closed hazard warning switch contact. Hazard warning operation: flasher receives power directly from the battery, via a fuse and hazard warning switch contacts. #### Turn Signal Flasher - Bimetal Type  Flashers on early vehicles contained a bimetal strip and a heating element. When the turn signal switch is set to on, current flows through the heating element, heating up the bimetal strip. This causes the bimetal strip to bend and the contacts open, switching off the turn lamps. While the contacts are open, the heating element and the bimetal strip cool down. The bimetal-strip returns to its original position and the contacts close, switching on the turn lamps. The process repeats until the turn signal switch is set to off**.** #### Turn Signal Flasher - Electronic Type Flashers on modern vehicles are electronic. They can maintain a constant flashing rate, even if the supply voltage fluctuates. In addition, an electronic unit can provide a hazard warning signal for many hours of continuous use. Bulb failure can be detected and is signaled by doubling the flash rate. The main components of an electronic type flasher unit are: - Integrated circuit (IC) - an electronic chip that performs desired functions. - Relay - switches large currents from a small signal. - Capacitor - stores electrical charge. - Resistor - value determines charging and discharging rate of capacitor. #### The Integrated Circuit The oscillator produces a square wave that controls the relay. The on/off frequency of the square wave is determined by the charge/discharge rate of the capacitor (C) and the resistor (R). The on/off pulses from the oscillator operate the relay driver. The amplified signal from the relay driver switches the relay. The turn lamps correspondingly flash. The bulb failure detector monitors voltage drops. If a bulb fails, voltage change is sensed by the detector and it doubles the flash rate.  ### 1.3.1.7. Wiring diagram of horn circuit Closing the horn button energizes the relay coil. The relay contact closes and the horns are provided with battery voltage. The horn button wire is thin, because the relay coil requires a low current to operate. The wire from the relay contacts to the horns is thick, because the horns require a very high current to operate (typically 10 amps). Two horns (twin horns) are used to produce a greater and more pleasing sound. One produces a high tone and the other produces a low tone. #### *1.3.2. [Wiring diagram of internal light/lamp]* Two types of bulbs are usually used in interior lighting systems: - Single contact - Festoon. #### Single contact The single contact circuit contains a battery, a fuse, a bulb and a switch. When the switch is in the off (open) position, the lamp is off. When the switch is in the on (closed) position, the lamp is on.  #### Festoon The festoon bulb is generally used in courtesy lighting circuits. Its filament is a tungsten wire, held by two supports. The supports are fitted to the metal caps at each end. This type of bulb can be fitted either way round in its holder. Power rating of bulbs ranges from 3 to 15 watts.  #### Courtesy Lamp Courtesy lighting circuit contains a battery, a fuse, a bulb, a switch and door contacts. The switch is usually a slide type and has three positions. Generally, the number of door contacts equals the number of doors. #### Courtesy Lamp Operation When the slide switch is set to its middle (OFF) position, the courtesy lamp is switched off. When the slide switch is moved to the right (ON) position, the courtesy lamp is switched on, independent of door position.  When the slide switch is moved to the left (ON) position, the courtesy lamp is switched on, when a door contact is closed (door open). **Formative assessment** #### Written evidence Match the parts of sentences from column A and B to form logical statements. then write the answer in answer column **Answer** **Column A** **Column B** ------------ --------------------- -------------- **1** **2** **3** **4** **5** **6** **6.** Flasher unit **7** **8** **Answers:** **Answer** **Column A** **Column B** ------------ --------------------- -------------- **1 f** **2 h** **3 a** **4 g** **5 b** **6 c** **6)** Flasher unit **7 e** **8 d** Learning Unit 2: Repair lighting and signaling systems ------------------------------------------------------ **Content 6: Selection of tools, materials and equipments** LO2.1 Select tools, materials and equipment ------------------------------------------- ### Tools - Power tools - Measuring tools - Hand tools ### Materials +-----------------------------------+-----------------------------------+ | - Grease | - Wires | | | | | - Lubricants | - Fuse | | | | | - Brushes | - Connectors | | | | | - Lamps | - Relay | +-----------------------------------+-----------------------------------+ - Insulator taps **Equipment** - PPE - Diagnostic machine ### Formative assessment N. MOTORVEHICLE WORKSHOP Ltd is a company which deals with all vehicles related services in NYANZA and GASABO districts. Mr. Rolland is a tourist and while travelling from Kigali to NYUNGWE National Park by his TOYOTA LANDCRUISER V8, arrived at ISONGA, he noticed a bad smelling of something burnt followed by the trouble of lighting and signaling systems and then all lamps went off. He called the service Manager of the above mentioned GARAGE for help. As an auto electricity and electronics technician from the aforesaid company, you are requested to identify tools, equipment and materials to be used to correct problems with 20 minutes. **Score** -- ----------- -- **Yes** Learning outcome 2.2 Identify faults ------------------------------------ **Content 7: identify lighting and signaling faults** 2.2.1. Lighting and signaling systems possible faults ----------------------------------------------------- +-----------------------------------+-----------------------------------+ | - Open circuits | - Burnt wiring | | | | | - High resistance circuits | - Connector damaged | | | | | - Short circuits | - Terminal damaged | | | | | - Damaged insulation | - Water and moisture | +-----------------------------------+-----------------------------------+ **2.2.2. Diagnosis procedures** - Verify the fault. - Collect further information. - Evaluate the evidence. - Carry out further tests in a logical sequence. - Rectify the problem. - Check all systems and tight. ### Formative assessment Written evidence Complete the possible causes and correction for the light bulb which does not light up **Possible causes** **correction** --------------------- ---------------- **Answers:** **Possible causes** **correction** ----------------------------- --------------------------- Battery discharged Charge battery Open circuit Repair circuit Bulb burnout Replace light bulb Damaged fuse Replace fuse Incorrect wires connections Correct wires corrections Learning outcome 2.3 Repair of lighting and signaling circuit/wire ------------------------------------------------------------------ **Content 8: Repair lighting and signaling circuit/wire** 2.3.1. Repair open circuits --------------------------- An open electrical circuit means that there is a break in the continuity of the circuit. An open circuit is one that is discontinuous at a point preventing electricity from flowing through it. You can test for an open circuit by testing the continuity of the circuit using a multimeter. 2.3.2. Repair high resistance circuit/ wires -------------------------------------------- A circuit resistance test is used to locate faulty wiring, loose connections, partially burnt wire, corroded terminals, or other similar types of problems. ### Ground Circuit Resistance Test Ground circuit resistance test the voltmeter leads are placed across the negative battery terminal and wire. The voltmeter should NOT read over 0.1 volt per electrical connection. If the reading is higher, this indicates such problems as loose or faulty connections, burnt plug sockets, or other similar malfunctions. 2.3.3. Replace short circuits/wires ----------------------------------- Short circuits are usually caused by a breakdown in a wire\'s insulation or when another conductor is introduced and causes the electricity to flow in an unintended way. **Testing for continuity** - Turn the multimeter settings knob to \"continuity.\" - Place the negative multimeter probe, the black one, on one end of the wire you want to test for continuity. - Place the positive multimeter probe, the red one, on other end of the wire you want to test for continuity. - Look at the monitor on the multimeter. **Replace the short wire:** - Determine which appliance has a short in it. - Locate the wires in your device that are causing the short. Remove the wire by using a soldering gun to melt the solder holding the wire to the contact point and pulling the wire free. - Make a new wire to replace the damaged one. 2.3.4. Replace burnt wiring --------------------------- - Check the fuse. A blown fuse usually causes both lights to go out. - Look at the lamp wiring. These are the wires that lead to the lamp lights, located inside the lid of the trunk. - Check the light bulbs. If the fuse and wiring look right, the bulbs themselves might be the problem. - Replace the burnt wire or bulb. 2.3.5. Cleaning of headlights ----------------------------- Washing of the headlight lenses can be done by using a car soap and water and toothpaste. Use toothpaste to clean car headlights: - Rub toothpaste into the headlight cover using a toothbrush. - Keep rubbing until you feel and see the headlight getting cleaner. - Spray warm water onto the headlight and wipe away the toothpaste with a cloth. - For a deeper clean use, a rotary buffer to apply the toothpaste. ### Practical assessment NGADEO Ltd is a company which deals with all vehicles related services in Muhanga district. Mr. John is a town, he noticed a bad smelling of something burnt followed by the trouble of lighting and signaling systems and then all lamps went off. He called the service Manager of the above mentioned GARAGE for help. As an auto electricity and electronics technician from the aforesaid company, you are requested to test on system components within 30minutes to find the problems. ### Checklist -- -- -- -- -- -- Learning Unit 3: Perform basic maintenance lighting and signaling components ----------------------------------------------------------------------------  STRUCTURE OF LEARNING UNIT +-----------------------+-----------------------+-----------------------+ | **Duration: 45hrs** | | | +-----------------------+-----------------------+-----------------------+ | **Learning outcome** | | | | **3.1** Test lighting | | | | and signaling | | | | components | | | | | | | | **Learning outcome | | | | 3.1 Objectives :** | | | | | | | | By the end of the | | | | learning outcome, the | | | | trainees will be able | | | | to: | | | | | | | | 1. Demonstrate | | | | testing | | | | procedures | | | | | | | | 2. Perform component | | | | testing | | | +-----------------------+-----------------------+-----------------------+ | **Resources** | | | +-----------------------+-----------------------+-----------------------+ | **Equipment** | **Tools** | **Materials** | +-----------------------+-----------------------+-----------------------+ | Vehicle with lighting | Lamps | Whiteboard | | system | | | | | Internet | Marker pen | | Projector | | | | | Battery | Handout note | | Workshop | | | +-----------------------+-----------------------+-----------------------+ **Content 9: Testing lighting and signaling components** **LO3.1: Test lighting and signaling components** 3.1.1. Testing procedures of lighting and signaling components -------------------------------------------------------------- - Hand and eye checks (loose wires, loose switches and other obvious faults) -- all connections clean - Check battery must be 70% charged. - Check bulb(s) -- visual check or test with ohmmeter. - Fuse continuity -- (do not trust your eyes) voltage at both sides with a meter or a test lamp. - If used, does the relay click, this means the relay has operated, it is not necessarily making contact. - Supply to switch -- battery volts. - Supply from the switch -- battery volts. - Supplies to relay -- battery volts. - Feed out of the relay -- battery volts. - Voltage supply to the light -- within 0.5 V of the battery. - Earth circuit (continuity or voltage) -- 0 or 0V. 3.1.2. Test of flasher unit --------------------------- - To test the conventional type of flasher unit, use a circuit tester between the terminal marked B on the unit and the earth. Turn on the ignition. - If the supply side of the unit is working, the bulb should light. If it does not, look for a break in the wiring between the unit and the fuse box. - If the tester lights, test between the terminal marked L and the earth. The lamp should light; it may flash. - If it works, the fault is in the switch or the wiring; if not, the flasher unit is faulty. The electronic type cannot be checked with a circuit tester. It can be damaged by a short circuit. The only way to determine if an electronic type is faulty is by measuring input and output of voltage to the circuit. 3.1.3. Test of horn ------------------- - Remove the horn connector - Attach a jumper lead between the battery's positive post and the (+) terminal on the horn. - Connect the other jumper wire between the negative battery post and the (-) terminal on the horn. - The horn should now sound. If it does not, the horn is faulty and should be replaced. 3.1.4. Test of relays --------------------- - The test light is set up connect each end to terminals 86 and 85. - Start the vehicle and operate the accessory switch, the test light should illuminate, if not the switch or circuit ground has shorted. - Use the test light grounded to check for power, and then switch the test light lead to the power side of the battery to check for circuit ground. - Use a piece of wire automotive wire. Turn the ignition to the \"ON\" position and jump terminals 87 and 30 the relay is now jumped and the accessory should activate, if so the relay has failed. If no power is observed at either 87 or 30, the fusible link has shorted. - When replacing a relay be sure to match up the terminal location from the old relay to the new unit. ### Theoretical learning Activity ### Practical learning Activity - Group exercise on testing flasher unit - Individual exercise on testing horn - Group exercise on testing relays ### Points to Remember (Take home message) The system malfunction may cause a hazardous accident, make sure that the lighting system is well functioning. ### Practical assessment ATECAR Ltd is a company which deals with all vehicles related services in NYARUGENGE district. Mr. Paul while travelling from NYABUGOGO to KACYIRU by his TOYOTA HILUX, arrived at KINAMBA, he noticed that his signal horn does not sound. He called the service Manager of the above mentioned GARAGE for help. As an auto electricity and electronics technician from the aforesaid company, you are requested to solve those problems within 1 hour. **Score** -- ----------- -- **Yes** Learning outcome 3.2 Replace lighting and signaling components -------------------------------------------------------------- +-----------------------+-----------------------+-----------------------+ | **Learning outcome | | | | 3.2 objectives:** | | | | | | | | By the end of the | | | | learning outcome, the | | | | trainees will be able | | | | to: | | | | | | | | 1. Identify the | | | | components to be | | | | replaced | | | | | | | | 2. Demonstrate | | | | Headlight removal | | | | procedures | | | | | | | | 3.Demonstrate | | | | Headlight | | | | installation | | | | procedures | | | | | | | | 4\. Adjust headlight | | | | aiming | | | +=======================+=======================+=======================+ | **Resources** | | | +-----------------------+-----------------------+-----------------------+ | **Equipment** | **Tools** | **Materials** | +-----------------------+-----------------------+-----------------------+ | Vehicle with lighting | Tool kit | Whiteboard | | system Projector | | | | | | Marker pen | | Workshop | | | | | | Handout note | +-----------------------+-----------------------+-----------------------+ | **Advance | | | | preparation:** Put in | | | | place a vehicle with | | | | lighting system | | | +-----------------------+-----------------------+-----------------------+ **Content 10: Replace lighting and signaling components** 3.2.1. Components to be replaced -------------------------------- - Flasher unit - Horn - Relay - Bulbs/lamps - Fuses - Wires - Ignition switch - Hazard switch - Brake switch - Reverse switch 3.2.2. Headlight removal procedures ----------------------------------- - Disconnect cable from battery - Remove other obstacles - Remove the bolts and two screws - Disconnect sockets from headlight - Remove front bumper assembly - Remove head light assembly 3.2.3. Headlight installation procedures ---------------------------------------- - Install headlight assembly - Install front bumper assembly - Tighten with bolts and screws - Install removed obstacles - Connect headlight sockets - Connect battery cable 3.2.4. Adjust headlight aiming ------------------------------ Headlights must be kept in adjustment to obtain the safest and best light beams on the road ahead. Headlights that are properly adjusted cover the correct range and afford the driver the proper night time view. Headlights that are out of adjustment can cause other drivers discomfort and sometimes create hazardous conditions. **3.2.4.1. Conditions that should be fulfilled by the vehicle before adjustment:** - The vehicle must be on a level floor. - If the vehicle is coated with snow, ice, or mud, clean it, especially the underside. The additional weight can alter the riding height. - Try to make the adjustment with the fuel tank half full; this should be the only load present on the vehicle. - Worn or broken suspension components affect the setting, so check the springs or shock absorbers. - Inflate all tires to the recommended air pressure levels. - Make sure the wheel alignment and rear axle tracking path are correct before adjusting the headlights. - After placing the vehicle in position for the headlight test, push down on the front fender to settle the suspension. ### 3.2.4.2. Procedures of headlight aiming #### Using aiming board Alignment can be checked by projecting the upper beam of each light on a screen or chart at a distance of about 25 feet ahead of the headlight.  - The vehicle must be exactly perpendicular to the chart. - To mark the chart for reference, measure the distance between the centers of the headlights. Use this measurement to draw two vertical lines that correspond to the center of the headlights. - Then draw a vertical center-line halfway between the two vertical lines. - Measure the distance from the floor to the centers of the headlights. - Subtract 2 inches from this height and draw a horizontal line on the screen at this new height. - With the headlights on high beam, the hot spot of each projected beam should be centered on the point - of intersection of the vertical and horizontal lines on the chart. - If necessary, adjust the headlights vertically and laterally to obtain proper aim. - Demonstration on vehicle to verify headlight aiming and headlight functionalities - Demonstration on vehicle to verify full lighting system functionalities - Practical exercise on verification of headlight aiming and headlight functionalities Practical work #### Practical assessment AKAGERA MOTOR Ltd is a company which deals with all vehicles related services in KICUKIRO district. Mr. Fulgence is a business man and while travelling from Kicukiro to Nyabugogo by his TOYOTA LANDCRUISER V6, arrived at RWANDEX, he noticed a bad smelling of something burnt followed by the trouble of lighting and signaling systems and then all lamps went off. He called the service Manager of the above mentioned GARAGE for help. As an auto electricity and electronics technician from the aforesaid company, you are requested to solve those problems within 3hours. #### Assessment Criterion 1: Quality of Process **Score** -- ----------- -- **Yes** -- -- -- -- -- -- #### Assessment Criterion 2: Quality of product **Score** -- ----------- -- **Yes** #### Assessment Criterion 3: Relevance **Checklist** **Score** ----------------------------------------------- ----------- -------- **Yes** **No** **Indicator: Time is well respected** 3hours is respected **Indicator: Materials are efficiently used** No materials are wasted **Observation** **References:** 1. ERJAVEC, J. (2009). Automotive technology 5th edition. 2. Gscheilder R. (2006). *Modern Automotive Technology Fundamentals, Service, Diagnostics*; Verlag Europa-Lhermitte ; Germany. 3. 4. 5. James D, h. (2012). Automotive technology 4th edition. 6. James E, D. (2009). Modern Automotive technology. 7. JamesD, H. (2012). Modern Technology. 8. Rockwell, T. H., Safford, R. R. (1969): *An evaluation of rear-end signal system characteristics in night driving,* pp. 12--13, 17, 33, 41--42. 9. Tom D. (2004). *Automobile Electrical and Electronic Systems 3rd edition*, Elsevier Butterworth-Heinemann, Linacre House, Jordan Hill, Oxford.