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Wiring Harness Inspection

10 points

Overview

This assignment guides students in visually inspecting a wiring harness to identify common defects such as damaged wires, poor connectors, or insulation issues. Students will document their findings with a photo and a brief report, developing essential skills in harness condition assessment for safety and reliability.

Resources

FAA AC 43.13-1B - Chapter 11, Sections 8-12

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Assignment

Document Preparation

Copy this document to your own Coda E-portfolio page using the “Copy doc” button in the top right.

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Be sure to add it to the AT 209 section.

If you wish, you can hide this worksheet after completion by selecting “Hide page” from the page’s menu bar.

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Photograph Wiring Harness

Identify a wiring harness from an approved piece of equipment, such as a vehicle, plane, or training/simulator station.

Take a well-lit photo of the wiring harness.

Be sure to capture all ends of the wiring harness (it may run point to point or it may include several breakouts).

Upload your photo(s) to the

Photos⁠

section below.

Report of Findings

Conduct a brief visual inspection of the harness, focusing on the following:

Condition of the wires (check for cuts, cracks, abrasions, fraying, or exposed conductors)

Integrity of insulation and coverings (look for missing tape, damaged conduit, or heat damage).

Condition of connectors (check for corrosion, broken clips, loose or bent pins).

Signs of overheating (burn marks, melted insulation).

Routing and securing (whether the harness is adequately supported, tied down, and clear of moving parts or sharp edges).

Write a short

Inspection Report⁠

(½ to 1 page maximum) that includes:

The photo of the harness.

A summary of your observations. Be sure that your observations use language represented in

FAA AC 43.13-1B - Chapter 11, Sections 8-12⁠

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Any defects or concerns you noticed.

A recommendation (e.g., “harness is acceptable for use,” “minor repair needed,” or “should be replaced”).

Photos

Figure 1.

Figure 1.

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Figure 2.

Figure 2.

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Figure 3.

Figure 3.

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Figure 4.

Figure 4.

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Figure 5.

Figure 5.

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Figure 6.

Figure 6.

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Figure 7.

Figure 7.

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Figure 8.

Figure 8.

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Figure 9.

Figure 9.

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Inspection Report

Visual Inspection

Condition of wires

There were no cuts, cracks, abrasion, fraying, or exposed conductors.

Integrity of insulation and coverings

I did not see any missing tape, damaged conduit, or heat damage.

Condition of connectors

There were no signs of corrosion, broken clips, loose or bent pins.

Signs of overheating

There were no burn marks or melted insulation.

Routing and securing

The wiring harness was adequately supported, tied down, and clear of moving parts or sharp edges.

Upon inspecting the wiring harness in Professor Barnes’ lab, I observed that the wires and cables in bundles are properly supported and bound so that there is no interference with other wires, cables, and equipment. The wires and cables are not tied or fastened together in conduit or insulating tubing and are not using tape, tie straps, or cords for primary support.

Wire bundles are fastened and secured together, traveling in the same direction, and there are no sharp bends in the wire; and there is sufficient slack so that bundles and individual wires are not under any tension or chafe.

Bundle breakout point is supported with a string tie, has a minimum bend radius of 3 times the harness diameter, located behind the component, and the service loop routing directly from the breakout point to the component. All metal stand-offs are used to maintain clearance between wires and structure. The minimum radius of bends in wire bundles is greater than 10 times the outside diameter of the largest wire or cable.

All junctions and buses are not considered exposed, and they are mechanically and electrically secured and not subject to strain or used as a support for insulating materials. Power feeder wires are routed so that they can be easily inspected or replaced. There is no lacing, tying, or insulation tape used. The only defect found is that no drain hole is present in the lowest portion of the tubing. The harness needs minor repairs.