Wiring Inspection and Harness repair

Battery cable repair guidelines

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Potential places where battery cable can chafe

Ensure no contact between Ensure no contact

harnesses with door hinge

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How a battery connection should not be done
The battery is not properly secured. No fuse holders fitted to both the positive wires. The battery
ALWAYS use a battery hold down cable should have a 225A fuse and the micro wire a 5A fuse.
bracket to secure the battery. Also note that both battery cables and the micro wire is guided
through 1 hole. This is not correct

In the illustration we can see that none of the battery terminals is greased. ALWAYS grease the
battery terminals when servicing. This prevents corrosion that may lead to poor contact which in turn
will result in a Voltage drop. Following the arrow, we can also see the unprotected positive cables
resting against the battery box. Through time, the vibration will cause the cable to chaff through and
cause a short circuit. In the current state nothing will prevent the wire from burning in the event.
How a battery connection must look

Battery cables tied neatly to the battery box

by a solid cable tie that can hold the weight
of the cables.
Thin positive wire going to the unit is fitted
with an in-line fuse holder and a 5A fuse as
per the factory recommendations.
Cables not kinked and has a “natural bend”
This puts less stress on the cable.
Main fuse holder fitted correctly and fused
with a 225A fuse as per the factory
recommendations.
Approved battery hold down used to secure
battery in place.
How a battery connection must look

In this illustration we can see that both cables Ensure that the cabling leaving the
are routed through their own holes battery box is not touching the frame
(individually) This is correct. Also see that both or any protruding bolts which can
cables are properly sleeved and guided through cause chaffing.
the grommets as supplied with the installation
materials. Should no grommet be available
please request a grommet from your team -
leader / manager.
Potential places where battery cable can chafe

Improper use of
cable tie to
support fuel
line (crushed)

Chaffing of cable
against other cables
or fuels lines

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Termination

Do not cut ring terminals or spread fork terminals to fit

Use glue lined heat shrink tubing with uninsulated terminals

Pre-insulated terminals are not recommended for use outside a sealed box.
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 Cutting & Stripping
When doing any electrical work, make sure not to damage any
of the wires during stripping of the insulation.
Poor wire insulation stripping can lead to electrical arcing

Exemplary contactors

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Cutting & Stripping

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Cutting & Stripping

Wire insulation removal

All conductors should be

covered (no bare wire)
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Lugs

Wire Terminals – Lock nuts and lock washers should be

used

Lock washers and jam nut to prevent movement and loosening of the connection.
Max of 2 fork terminals or 3 ring terminals per nut.

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Lugs

Wire Terminals – Do not align the connection crimp over

each other

Wire Terminals - Not connected fully under connection

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Joining (splicing) of wires

Pre-insulated butt splices are not approved.

Especially on High Voltage/current and/or outside closed box
All non-insulated butt splices must be covered with heat shrink

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Splicing

20 mm (0,8in)
20mm(0,8in)

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Examples of wire routing

No contact between wire and any Poor routing

surface other than the intended
mounting point
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 Examples of wire routing

Check that all wiring is Movement between

adequately protected harness and pipe
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Examples of wire routing

Do not bundle positive

and negative battery
cables together. Route
Route wires away individually or separate
with plastic spacer in
from rotating objects
between the cables.
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Examples of wire routing

Route electrical wires, harnesses and positive battery cables away from high temperature
surfaces, flammable materials (fuel lines, press tite insulation, flammable plastic…etc.) as
much as possible, especially at locations with potential chaffing or moisture ingress induced
failures.

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Examples of wire routing

Separate high voltage and low voltage harness

High Voltage
High Voltage

Low Voltage Low Voltage

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Examples of wire routing

Wires and wire bundles should be supported so they

don’t “chafe” against other objects

No cable, wire or wire harness should come in

contact with anything other than its
intended mounting point.

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Examples of wire routing

Wire insulation
rated at 105°C

150°C

Loose wire can be pinched in door

Starter motors can become very
hot, cable is not to contact surface

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Examples of wire routing

Attach flag terminals pointing down to prevent

water entry

Water entry point - Even with waterproof seal not a good practice

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Examples of wire routing

Door

Door and battery cable

worn from movement and
contact
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Bending

Too sharp bending of the wire can result in

damaged insulation

Stressing insulation by bending can

result in exposed conductor or broken
stands
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Harness Clamping

Proper clamp should be sized for wire to prevent

crushing and rotation

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Harness Clamping

Check for indentation in wiring that indicates

damage to wiring due to too tight cable ties

Insulation
damage

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Harness Clamping

Improper cutting of ty-wraps can cause insulation

damage to other wires and injury to service people
due to sharp edges

Sharp
edge

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Harness Clamping

Sufficient slack must be provided in the wire to prevent any direct

stress on parts or wires as a result of flexing during maintenance or
operation.

Do not allow wire in excess of required slack.

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Harness Clamping

Unprotected edge Protected edge

Exposed wire No exposed

wire

No relative motion

Do not use sleeving that can pull apart and

expose wiring
Split sleeving instead of spiral binding.
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Harness Clamping

Secured with cable tie

Edge guard

Use edge clips or similar

fasteners to prevent
chaffing
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Protection of wiring

Insulation damage
Sharp edge of wire loom
damaged wire insulation

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Protection of wiring

For all wiring going through holes you must provide

complete edge protection

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Also remember to check the wiring at the evaporator/s
• Evaporators have wiring that need to be protected
• Ensure that the wiring is supported correctly (cable ties and the
necessary clamps) and not just hanging loose
• Also check that all grommets are in place where necessary.
• The rules and
guidelines also apply
for the evaporator
harness and wiring
• Remove the covers of
remote evaporators to
do a proper inspection

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Things to look out for
• Any possible places where wires can rub (chafe) against any
surface. Also limit movement of wires to prevent rubbing
(chaffing).
• Correct protection (fuses) for battery cables and other power
cables

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Things to look out for
• Make sure wires are protected (sleeving) against any possible
damage and that the protection is installed correctly as not to
damage to damage the wire (cut)
• Wires should only touch its mounting point and have no other
contact with any other surface (wire, bolt or surface)

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Things to look out for
• Check the routing of the wires to make sure that there is no
possible places where they can rub on any surface (other wires,
covers or any part of the frame)

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Things to look out for
• Check the routing of the wires to make sure that there is no
possible places where they are pinched between surfaces
• Make sure that there is enough slack in wires to prevent damage
due to chaffing and connections becoming loose.

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Commonality

Summary
No cable, wire or wire harness should
come in contact with anything other
than its
intended mounting point and should in
all cases be protected with adequate
insulation

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