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00 Index and foreword
Handling of electrical equipment
Handling of electrical equipment
To maintain the performance of the machine over a long period, and to prevent failures or troubles before
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they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics components
and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".
Precautions for handling electric equipment
Handling wiring harnesses and connectors
Wiring harnesses consist of wires connecting
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one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wires.
Compared with other electrical components fit-
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ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling the wiring harnesses.
Main failures occurring in wiring harness Defec-
tive contact of connectors (defective contact
between male and female connectors)
Problems with defective contact are likely to oc-
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cur because the male connector is not properly
inserted into the female connector,or because
one or both of connectors are deformed or the
position is not correctly aligned, or because
there is corrosion or oxidization of the contact
surfaces. The corroded or oxidized contact sur-
faces may become shiny again (and contact
may become normal) by connecting and discon-
necting the connectors approximately 10 times.
00-32
Defective crimping or soldering of connectors
The pins of the male and female connectors are
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attached to wires by crimping or soldering. If ex-
cessive force is applied to the wire, the joining
area may become loose, which may result in a
defective connection or breakage.
Disconnections in wiring
If the wiring harness is pulled to disconnect the
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connector, or the components are lifted with a
crane while the wiring harness is still connected,
or a heavy object hits the wiring harness, the
crimping of the connector may separate, or the
soldering may be damaged, or the wiring har-
ness may be broken.
(Rev. 2012/11)
WA200-7
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