TDS SD 5.5

NUMBER:
Truck Design Standards TDS-SD-5.5

TITLE: REVISION:
Routing & Clipping Standards 6

WRITTEN / REVIEWED BY APPROVED BY: REVISION DATE:
T. Firrone / R&C Task Force Truck Design Standards Team SEPTEMBER 2004
PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION

Change Notice: Added pictures, new sections and reworded
Table of Contents
Routing & Clipping Standards .................................................................................................................................................1
Table of Contents.......................................................................................................................................................................1
1.0 PURPOSE.......................................................................................................................................................................5
2.0 SCOPE ............................................................................................................................................................................5
3.0 REFERENCES ..............................................................................................................................................................5
4.0 DEFINITIONS ...............................................................................................................................................................5
5.0 RESPONSIBILITIES....................................................................................................................................................5
6.0 ACTIONS/REQUIREMENTS .....................................................................................................................................6
6.1 Electrical harness.......................................................................................................................................................6
6.1.1 Heat source distance table....................................................................................................................................6
6.1.2 Heat source distance table alternative ..................................................................................................................6
6.1.3 Sharp and abrading surfaces ................................................................................................................................9
6.1.4 Requires no tension between fixed points..........................................................................................................11
6.1.5 Moving parts:.....................................................................................................................................................13
6.1.6 Squeaks & rattles ...............................................................................................................................................15
6.1.7 Connectors and breakouts ..................................................................................................................................16
6.1.8 Shrink Wrap.......................................................................................................................................................17
6.1.9 Harnesses under the vehicle...............................................................................................................................17
6.1.10 Harness clipping ................................................................................................................................................18
6.1.11 Grommets & Harnesses .....................................................................................................................................20
6.1.12 Connections & fuel tank ....................................................................................................................................21
6.1.13 Wire Identification .............................................................................................................................................21
6.1.14 Drip point...........................................................................................................................................................21
6.1.15 Engine Compartment .........................................................................................................................................22
6.1.16 Congestion In Routing .......................................................................................................................................24
6.1.17 Clamps ...............................................................................................................................................................26
6.1.18 Convoluted tubing..............................................................................................................................................26
6.2 Battery Cables ..........................................................................................................................................................27
6.2.1 Battery cables & fuel .........................................................................................................................................27
6.2.2 Battery Cable Clipping ......................................................................................................................................28
6.2.3 Cables And Turns ..............................................................................................................................................28
6.2.4 Battery Cable Strap Lock...................................................................................................................................31
6.2.5 Battery Cables And Metal..................................................................................................................................31
6.2.6 Battery Cable Crossover ....................................................................................................................................32
6.2.7 Accessible battery ground..................................................................................................................................32
6.2.8 Grommet & battery cable...................................................................................................................................32
6.3 Brakes- Specific - Pipes and Hoses .........................................................................................................................32
6.3.1 Connection Fitting Strain Relief ........................................................................................................................32
6.3.2 1 Splice Per Repair - Truck................................................................................................................................33
6.3.3 School Bus Air Brake Splices............................................................................................................................33
6.3.4 Unique Air Brake System ..................................................................................................................................33
6.3.5 Dips In Air Compressor Hose/Pipe....................................................................................................................33
TDS-SD-5.5 Page 1 of 57 Printed: 09/30/04
This document is printed from the official electronic version and is considered a controlled copy for the date indicated in the footer. After
that date, the user must first check the index on the Intranet to verify that it is still the current, approved revision.
6.3.6 Clipping To Hydraulic Brake Pipes. ..................................................................................................................34
6.4 Fuel System – Specific – Pipes and Hoses ..............................................................................................................35
6.4.1 Fuel hose below tank .........................................................................................................................................35
6.4.2 Hose Loops/Bends .............................................................................................................................................36
6.4.3 Fuel Hose & Electrical Harness .........................................................................................................................36
6.5 Power Train / Steering – Specific – Pipes and Hoses ............................................................................................37
6.5.1 Reservoir and hose dips .....................................................................................................................................37
6.5.2 Reservoir and clipping .......................................................................................................................................38
6.6 Hoses, Tubing and Pipes – General Practice .........................................................................................................38
6.6.1 P-Clamps and hoses ...........................................................................................................................................38
6.6.2 Hose bend radii ..................................................................................................................................................41
6.6.3 Clipping to high pressure pipes..........................................................................................................................41
6.6.4 Clipping and Connections..................................................................................................................................41
6.6.5 Strap locks on hoses...........................................................................................................................................42
6.6.6 Formed hoses should be used wherever possible...............................................................................................42
6.6.7 Moving parts ......................................................................................................................................................43
6.6.8 Distance from heat source..................................................................................................................................44
6.6.9 Heat source table alternative ..............................................................................................................................44
6.6.10 Grommets and hoses ..........................................................................................................................................46
6.6.11 Sharp or abrading surfaces.................................................................................................................................48
6.6.12 Drip points .........................................................................................................................................................51
6.6.13 Sufficient hose length ........................................................................................................................................51
6.6.14 Squeaks & rattles ...............................................................................................................................................52
6.6.15 Hoses/Pipes under engine ..................................................................................................................................53
6.6.16 Hoses between side rails ....................................................................................................................................54
6.6.17 Clipping at connections......................................................................................................................................55
6.6.18 Clipping support ................................................................................................................................................56
7.0 RECORDS....................................................................................................................................................................57

TABLE of FIGURES
FIGURE 1 CORRECT. HARNESS IS 76 MM (3”) MINIMUM FROM CAC PIPE 7

FIGURE 2 INCORRECT. HARNESS MELTED BECAUSE IT WAS NOT MORE THAN 127 MM (5”) AWAY FROM
THE EXHAUST PIPE. 7
FIGURE 3 CORRECT. HARNESS IS GREATER THAN 76 MM (3”) FROM THE MUFFLER. 8
FIGURE 4 INCORRECT. HARNESS IS NOT A MINIMUM OF 12.5 MM (0.50”) FROM A DISCHARGE PIPE. 8
FIGURE 5 CORRECT. HEAT SHIELD HAS AIRFLOW ALL AROUND IT. 9
FIGURE 6 CORRECT. HARNESS IS A MINIMUM OF 12.5 MM (0.50”) FROM THE DISCHARGE HOSE. 9
FIGURE 7 CORRECT. HARNESS IS AWAY FROM SHARP AND ABRADING EDGES. 10
FIGURE 8 INCORRECT. HARNESS IS IN CONTACT WITH A SHARP OR ABRADING EDGE. 10
FIGURE 9 INCORRECT. BATTERY CABLE IS IN CONTACT WITH THE BOLT THREADS. 11
FIGURE 10 INCORRECT. THERE IS TOO MUCH SLACK ALONG THE HARNESS. 12
FIGURE 11 CORRECT. BUNDLES ARE MADE OF THE EXCESS LENGTH OF HARNESS AND CLIPPED ALONG
THE FRAME. 12
FIGURE 12 CORRECT. THE HARNESS HAS THE PROPER AMOUNT OF TENSION AND IS CLIPPED TO THE
CROSS MEMBER. 13
FIGURE 13 INCORRECT. HARNESS IS NOT A MINIMUM OF 25.4 MM (1”) AWAY FROM MOVING PARTS. 14
FIGURE 14 INCORRECT. HARNESS IS NOT A MINIMUM OF 25.4 MM (1”) AWAY FROM MOVING PARTS. 14
FIGURE 15 CORRECT. HOOD HARNESS IS CLIPPED SO IT WILL NOT RUB. 15
FIGURE 16 INCORRECT. HARNESS RUBS ON BUMPER. 15
FIGURE 17 CORRECT. THERE IS A MINIMUM OF 102 MM (4”) OF CLEARANCE. 16
FIGURE 18 CORRECT. THERE IS A MINIMUM OF 102 MM (4”) OF CLEARANCE. 17
FIGURE 19 CORRECT. CONNECTORS CAN BE EASILY MATED. 17
FIGURE 20 CORRECT. HARNESS IS INSIDE CONVOLUTED TUBING UNDER THE VEHICLE. 18
FIGURE 21 CORRECT. SUPPORT POINTS ARE LESS THAN 610MM (24”) APART. 19
FIGURE 22 INCORRECT. DISTANCE BETWEEN SUPPORTS IS GREATER THAN 610 MM (24”). 20
FIGURE 23 CORRECT. THE WIRES ARE PROTECTED BY A GROMMET WHILE PASSING THROUGH A METAL
HOLE. 20
FIGURE 24 INCORRECT. HARNESS IS IN CONTACT WITH FUEL LINES. 21
FIGURE 25 CORRECT. DRIP POINT IS BELOW THE CONNECTOR. 22
FIGURE 26 CORRECT. BRACKETS ARE UTILIZED TO KEEP HARNESSES AWAY FROM THE ENGINE. 23
FIGURE 27 CORRECT. BRACKETS HOLD THE HARNESS AWAY FROM THE ENGINE. 24
FIGURE 28 CORRECT. A CHANNEL IS PROVIDED FOR ROUTING. 25
FIGURE 29 CORRECT. A DUCTWORK IS PROVIDED FOR ROUTING. 25
FIGURE 30 CORRECT. HARNESS IS HELD WITH PLASTIC CLIPS. 26
FIGURE 31 CORRECT. CONVOLUTED TUBING IS USED WITH A CUSHIONED PAD ON THE RAIL FOR WEAR
RESISTANCE. 27
FIGURE 32 CORRECT. BATTERY CABLE SUPPORTS ARE LESS THAN 610MM (24”) APART. 28
FIGURE 33 INCORRECT. CABLES ARE NOT PROPERLY SEATED IN THE SADDLE. 29
FIGURE 34 CORRECT. BATTERY CABLE IS CAPTURED IN A NON-CONDUCTIVE SADDLE. BEND RADIUS
REMAINS CONSTANT DUE TO BRACKET AT THE BEGINNING OF THE BEND. 29
FIGURE 35 CORRECT. SWIVEL TIE STRAP HOLDING BATTERY CABLES IN PLACE. 30
FIGURE 36 CORRECT. CLOSE UP VIEW OF SWIVEL TIE STRAP HOLDING BATTERY CABLES IN PLACE. 30
FIGURE 37 CORRECT. SWIVEL TIE STRAP USED IN THE ABOVE TWO PICTURES. 31
FIGURE 38 CORRECT. STRAP LOCKS ARE 13MM (0.5”) WIDE. 31
FIGURE 39 CORRECT. HOSES HAVE A STRAIN RELIEF APPLIED WHEN RELATIVE MOTION IS PRESENT 33
FIGURE 40 INCORRECT. THERE ARE DIPS IN THE DISCHARGE HOSE. 34
FIGURE 41 CORRECT. THE DISCHARGE HOSE SLANTS DOWN WITHOUT ANY DIPS IN IT. 34
FIGURE 42 CORRECT. NOTHING ELSE IS CLIPPED TO THE HYDRAULIC LINES. 35
FIGURE 43 CORRECT. THERE ARE NO FUEL HOSES BELOW THE FUEL TANK. 36
FIGURE 44 INCORRECT. ELECTRIC WIRES ARE CLIPPED TO THE FUEL LINE. 37
FIGURE 45 CORRECT. FUEL TANK SENDER WIRE IS CLIPPED SEPARATE FROM THE FUEL LINE. 37
FIGURE 46 CORRECT. POWER STEERING HOSES ARE BELOW THE RESERVOIR. 38
FIGURE 47 CORRECT. SADDLE BRACKET IS USED. 39
FIGURE 48 CORRECT. BRACKET IS USED TO PROTECT THE TUBE GOING THROUGH A RAIL. 39
FIGURE 49 CORRECT. SAME BRACKET AS FIGURE 48; REAR VIEW. 40
FIGURE 50 INCORRECT. P-CLAMP DOES NOT RETAIN THE HOSE. 41
FIGURE 51 CORRECT. DUAL SWIVEL SADDLE AND STRAP USED WITH A SMALL DIAMETER SOFT 42
FIGURE 52 CORRECT. APPLICATION OF FORMED HOSE. 43
FIGURE 53 CORRECT. FUEL HOSE IS A MINIMUM OF 25.4 MM (1”) AWAY FROM MOVING COMPONENTS. 44
FIGURE 54 CORRECT. HOSES ARE GREATER THAN 12.5 MM (0.5”) FROM DISCHARGE PIPE/TUBE. 45
FIGURE 55 CORRECT. FUEL LINE IS A MINIMUM OF 76 MM (3”) AWAY FROM THE TAIL PIPE. 45
FIGURE 56 CORRECT. HOSES ARE A MINIMUM OF 12.5 MM (0.5”) FROM THE DISCHARGE PIPE. 45
FIGURE 57 CORRECT. HOSE IS GREATER THAN 101.6MM (4”) FROM SHIELDED EXHAUST PIPE. NOTE
THAT THE HEAT SHIELD HAS AIRFLOW AROUND IT. 46
FIGURE 58 INCORRECT. GROMMETS ARE SPLIT AND NOT PROPERLY SEATED. 47
FIGURE 59 CORRECT. GROMMET IS USED THROUGH A METAL SURFACE. 47
FIGURE 60 CORRECT. HOSES ARE IN A SADDLE TO AVOID ANY SHARP EDGES FROM THE FRAME RAIL. 48
FIGURE 61 CORRECT. HOSES ARE ROUTED AWAY FROM SHARP EDGES. 49
FIGURE 62 INCORRECT. FUEL LINE IS IN CONTACT WITH THE SHARP EDGE OF THE FRAME. 49
FIGURE 63 CORRECT. HOSES ARE INSIDE A PROTECTIVE CONDUIT. 50
FIGURE 64 INCORRECT. FUEL LINE IS PINCHED BETWEEN THE TRANSMISSION BELL HOUSING AND THE
CAB FLOOR CROSS MEMBER. P-CLAMP IS USED FOR CLIPPING. 50
FIGURE 65 CORRECT. DRIP POINT FROM HOSE IS NOT OVER A HEAT SOURCE. 51
FIGURE 66 CORRECT. HOSES HAVE SUFFICIENT SLACK WITHOUT BEING LOOSE. 52
FIGURE 67 CORRECT. STRAP SECURES HOSES SECURELY TO THE FRAME RAIL. 52
FIGURE 68 CORRECT. TUBING IS PROPERLY SECURED TO FRAME RAIL SUPPORTS. 53
FIGURE 69 INCORRECT. FUEL LINES ARE NOT PROPERLY SECURED TO THE FRAME. 53
FIGURE 70 CORRECT. THERE ARE NO HOSES OR PIPES LOWER THAN THE FRONT BUMPER. 54
FIGURE 71 CORRECT. HOSES GOING UNDER THE VEHICLE ARE INSIDE CONVOLUTED TUBING. 54
FIGURE 72 CORRECT. HOSES ARE BETWEEN THE FLANGES ON THE SIDE MEMBER. 55
FIGURE 73 CORRECT. STRAP LOCK IS A MINIMUM OF 100 MM (4”) AWAY FROM THE CONNECTION
FITTING. 55
FIGURE 74 CORRECT. STRAP LOCK IS A MINIMUM OF 100 MM (4”) AWAY FROM THE CONNECTION
FITTING. 56
FIGURE 75 INCORRECT. CLIP IS GREATER THAN 406 MM (16”) FROM THE CONNECTION/FITTING. 56
FIGURE 76 CORRECT. SUPPORT CLIPPING IS LESS THAN 610 MM (24”) BETWEEN SUPPORTS. 57

1.0 PURPOSE
Establish standards to route and clip all, hoses, pipes, electrical harnesses, electrical wiring and
battery cables.
2.0 SCOPE
Cover all design and manufacturing sites within International Truck Division.
3.0 REFERENCES
Concurrent Engineering Recommended Clipping Devices
Brake Systems Home Page
Serviceability Design Standards
4.0 DEFINITIONS
Should – Compliance to requirements with some latitude depending on circumstances.
Shall – Compliance to requirements without any latitude.
Steel Pipe – Pipes used for hydraulic brake system applications.
Nylon Hose – Hoses used for pneumatic brake system and fuel systems applications.
Rubber Hosing – Hoses used for power train, fuel systems and brake system applications.
Silicone Hosing – Hoses used for power train system applications.
Electrical Harness – Bundles of electrical wires with diameters of 1 gauge or smaller.
Battery Cables – Wires with diameters of 0 gauge or larger.
Electrical Wires – Wires with diameters of 1 gauge or smaller.
Traps – A condition where a pipe or hose is at a ninety-degree elbow at an air dryer inlet.
Dips – Condition where a pipe or hose from the air compressor to the air tank or air dryer fails to slope
continuously downhill from the air compressor without any droops, that exceeds 1/2 the pipe or hose
diameter.
Drip Point – The bottom of a dip in a hose, wire or pipe where a fluid would drip off.
Strap Locks – Clipping devices with UV resistance and high impact strength used with pipes, saddles,
hoses and harness bundles.
Small Diameter Hose – Hose with an outside diameter of 5/8 inch or less.
Large Diameter Hose – Hose with an outside diameter larger than 5/8 inch.
Heat Shield Minimum Distance – Any time a heat shield is used a minimum distance is required from
the heat source in both static and dynamic conditions that is defined by Design Engineering.
Hose Clamp Orientation - Unless orientation is specified on the design installation drawing with a
specific note about orientation of the fastener head, the orientation of the fastener head can be changed
to meet manufacturing process requirements.
Rubs – Rubbing is considered to have occurred if scuffing or material removal occurs and is visible to
the naked eye.
Congestion – Harnesses, wires, hose or tubing routed in an area that lacks sufficient volume.
5.0 RESPONSIBILITIES
Dimensional Management – Responsible for creating and maintaining routing and clipping
standards and all corresponding documentation dealing with the Route and Clip Design Standard.

Manufacturing/Plant Quality – Responsible for implementing routing and clipping design
standards in the assembly process.
Design – Responsible for implementing routing and clipping design standards into the designs.
6.0 ACTIONS/REQUIREMENTS
6.1 Electrical harness
6.1.1 Heat source distance table
Harnesses and cables are to be clipped such that the harness or cable is the following
minimum distance from the heat source:
Radiant Heat Source Type Unshielded Minimum Shielded Minimum

Distance Away Distance Away
Exhaust system from exhaust manifold 127mm 101.6mm
to the muffler inlet (including: flex 5 inches 4 inches
pipes, intermediate pipes, catalytic
converter, elbows, turbo exhaust pipes,
etc)
Exhaust system from the muffler inlet 76mm 51mm
to the end of the tail pipe; EGR valves, 3 inches 2 inches
EGR piping, hot CAC pipes
EGR cooler, air compressor discharge 12.5 mm 12.5 mm
pipe or air compressor discharge hose 0.5 inch 0.5 inch
6.1.2 Heat source distance table alternative

In lieu of the above table, an approved table may be used by engineering for clipping
distance away from a heat source. The table shall contain the UL or SAE continuous use
temperature of the material as well as a measured temperature matrix of the heat source
and proximity from the heat source. For shielded applications, the heat soak
temperatures of the shielded materials (harness or hose) shall be measured to determine
the continuous operating temperature the materials will be exposed to.
6.1.2.1 Philosophy:
Heat can degrade materials such that they lose their mechanical and electrical
properties. Materials too close to a heat source can also melt or ignite.

Figure 1 CORRECT. Harness is 76 mm (3”) minimum from CAC pipe
Figure 2 INCORRECT. Harness melted because it was not more than 127 mm (5”) away from
the exhaust pipe.

Figure 3 CORRECT. Harness is greater than 76 mm (3”) from the muffler.
Figure 4 INCORRECT. Harness is not a minimum of 12.5 mm (0.50”) from a discharge pipe.

Figure 5 CORRECT. Heat shield has airflow all around it.
Figure 6 CORRECT. Harness is a minimum of 12.5 mm (0.50”) from the discharge hose.
6.1.3 Sharp and abrading surfaces

Requires no contact with sharp or abrading surfaces or the surface must have a securely
fastened protective covering to avoid contact with the harness.
Sharp or abrading surfaces include: edges of screws, bolts, and edge of frame rails or
component edges. Transmission housings are an abrading surface.
6.1.3.1 Philosophy:
Insulation eroded or rubbed away can cause electrical shorts and possibly fires. The
rule of thumb should be “if it touches, it can rub, if it rubs it can short out.”
Additional brackets may be necessary.
Figure 7 CORRECT. Harness is away from sharp and abrading edges.
Figure 8 INCORRECT. Harness is in contact with a sharp or abrading edge.

Figure 9 INCORRECT. Battery cable is in contact with the bolt threads.
6.1.4 Requires no tension between fixed points.

Fixed points are clips, clamps, and fixed connectors on mounted electrical devices.
Consideration should be given to minimum tolerance conditions and prevention of flex
failure.
There should be sufficient slack to prevent terminals from becoming unseated due to
expected vehicle movement.
6.1.4.1 Philosophy:
Normal vehicle movement can strain and break wires resulting in an electrical failure,
if the wires are routed too tightly. Temperature changes result in expansion or
contraction (different materials have different expansion rates). Too much slack is
just as bad as not enough slack, for different reasons.

Figure 10 INCORRECT. There is too much slack along the harness.
Figure 11 CORRECT. Bundles are made of the excess length of harness and clipped along the
frame.

Figure 12 CORRECT. The harness has the proper amount of tension and is clipped to the cross
member.
6.1.5 Moving parts:

Requires all electrical harnesses and cables to be clear of all moving parts with a
minimum clearance of 25.4mm (1 inch). Examples:
• Belts, fans, and pulleys in the engine compartment
• Door window track mechanisms
• Ashtray and glove box doors
• Seat adjustment mechanisms
• Windshield wiper arms and motor
• Parking brake mechanisms Brake and clutch pedals
• Wheels
• Clutch
• Linkage Suspension Brackets Drive Shafts
6.1.5.1 Philosophy:
Moving parts can cut or wear through the wire insulation resulting in electrical failure
and/or shorts.

Figure 13 INCORRECT. Harness is not a minimum of 25.4 mm (1”) away from moving parts.
Figure 14 INCORRECT. Harness is not a minimum of 25.4 mm (1”) away from moving parts.

Figure 15 CORRECT. Hood harness is clipped so it will not rub.
Figure 16 INCORRECT. Harness rubs on bumper.
6.1.6 Squeaks & rattles

Requires all wiring, harnesses and cables to be secured tightly to prevent squeaks and
rattles.

6.1.6.1 Philosophy:
Squeaks and rattles can be an annoyance to the driver and result in customer
dissatisfaction.
6.1.7 Connectors and breakouts

Requires routing length between connectors to be long enough to make accessible a
proper connection. A minimum of 102 mm (4 inches) of length between harness breakout
and connector.
Requires all connections to be easily mated during vehicle assembly. Connection must
be easily accessible for maintenance and diagnostics and must not be a blind assembly.
6.1.7.1 Philosophy:
There should be sufficient length and space to make connections. Strap locks applied
after a connection is made, and less than 102mm (4 inches) to the connector, may
interfere with normal servicing or troubleshooting.
Figure 17 CORRECT. There is a minimum of 102 mm (4”) of clearance.

Figure 18 CORRECT. There is a minimum of 102 mm (4”) of clearance.
Figure 19 CORRECT. Connectors can be easily mated.
6.1.8 Shrink Wrap

Where shrink-wrap insulation is used with eyelet connectors, the shrink-wrap shall be
positioned on the eyelet such that when the nut is tightened down, the shrink-wrap is not
caught under the eyelet(s) or nut.
6.1.8.1 Philosophy
Shrink-wrap caught between eyelets or the eyelet and the nut will have a tendency to
relax allowing the nut to become loose.
6.1.9 Harnesses under the vehicle

Requires all wiring harnesses and cables on the underside of the vehicle engine and
underbody:

To have wiring in this area protected with braid, or covered from end of conduit or jacket
to connector to protect the harness or cable from exposure to the elements.
To have conduit not open to the entry of sand and grit with spot taping every 300 mm (12
inches) minimum. Where bends and turns occur, the distance between taping should be
reduced to 150mm (6 inches) minimum.
No harnesses shall be below the front bumper.
6.1.9.1 Philosophy:
Cables and harnesses on the underside of the vehicle need to be protected from the
elements and road grit. They should be routed and clipped such that consideration is
given to normal splash patterns, snowdrifts and other hazards the vehicle may
normally encounter.
Figure 20 CORRECT. Harness is inside convoluted tubing under the vehicle.
6.1.10 Harness clipping

Requires support on electrical harnesses and cables every 610 mm (24 inches) maximum
with UV resistant, high impact clipping devices. Examples: strap locks, button head strap
locks, and saddles. Harnesses shall not be routed in a manor that restricts access for the
customer to standard maintenance items, (I.E., engine oil dip stick or windshield washer
fluid reservoir, etc.). Harnesses routed through a restricted area (grommet, hole, etc.)
with other hoses or tubes, shall have sufficient area to allow the connector to pass through
the restricted area without removing the hoses or tubing. Harnesses passing along or near

a component (I.E., transmission) shall not be clipped to the components assembly or
mounting hardware. Fir trees are not to be used into the cab skin.
6.1.10.1 Philosophy:
Frequent support limits the amount of travel the harness can have while the
vehicle is in operation, and provides a neater appearance. This reduces the
possibility of the harness coming in contact with something it can rub against.
Due to specific conditions (including routing bends), some harnesses may require
a shorter distance between clipping devices. Clipping to component assembly
hardware (I.E., transmission bolts) may void the warrantee of the component as
well as present maintenance difficulties. Fir trees into the cab skin allow water
and air leaks into the cab. When using fir trees, consider vibration and side
loading as these may weaken or break the fir tree.
Figure 21 CORRECT. Support points are less than 610mm (24”) apart.

Figure 22 INCORRECT. Distance between supports is greater than 610 mm (24”).
6.1.11 Grommets & Harnesses

Requires that harnesses be protected when passing through holes in metal by a grommet
that is not cut or split, or the wiring shall be protected with a metal covering with no
sharp edges to contact the wire harness.
Cut or split grommets can come apart or separate from the hole in the metal, thus,
offering no wear protection to the harness/wires. Using a sealant to seal the
grommet in place (as well as the harness in the grommet) is recommended.
Figure 23 CORRECT. The wires are protected by a grommet while passing through a metal
hole.

6.1.12 Connections & fuel tank
Requires all electrical harnesses not to contact the fuel tanks or fuel hoses. A distance of
12.7mm (0.5 inch) minimum is to be maintained between the harness and a fuel delivery
component at the closest articulated position. Requires having no terminals or splices
located above a fuel tank without a metal barrier to prevent contact with the fuel tank –
except for the fuel sender wiring and terminals. The metal barrier cannot contact the
terminals or splices.
Protection against fuel fumes coming in contact with connections or damage to
the hose in the event of arcing.
Figure 24 INCORRECT. Harness is in contact with fuel lines.
6.1.13 Wire Identification

All wires shall be identified according to the engineering drawing specifications.
6.1.13.1 Philosophy
Without identification, it is very difficult to know what the wire is for.
6.1.14 Drip point
Requires that when electrical wires, cables and harnesses are routed downward to a
connector or terminal, a drip point must be provided for liquid to drip off the wire, cable
or harness prior to reaching the connector or terminal.
This helps keep the connectors dry. Wet, unsealed connectors can become corroded,
raising resistance, and possibly resulting in a sub-system failure.

Figure 25 CORRECT. Drip point is below the connector.
6.1.15 Engine Compartment

Engine compartment harnesses should be clipped to brackets keeping the harness away
from the engine metallic surfaces and heat sources.
Brackets will keep harnesses away from surfaces that could cause a short. The
height of the bracket may also be sufficient for the required unshielded distance
from heat sources. This gives a neater, uncluttered appearance to the area.

Figure 26 CORRECT. Brackets are utilized to keep harnesses away from the engine.

Figure 27 CORRECT. Brackets hold the harness away from the engine.
6.1.16 Congestion In Routing

Congestion should be avoided. Blind connections shall be avoided.
Congestion contributes to routing errors with other harnesses, hose or tubing as
pulling through a harness or hose may create a strain and/or dislodge other
harnesses or hoses from correct routing positions. A congested area also looks
sloppy. When a harness for more than one wheelbase is used, the longer
wheelbase harness excess should be stored in a junction box (or equivalent) for
neatness on the shorter wheelbase versions. Rail routing per “Figure 11
CORRECT. Bundles are made of the excess length of harness and clipped along
the frame.” is acceptable.

Figure 28 CORRECT. A channel is provided for routing.
Figure 29 CORRECT. A ductwork is provided for routing.

6.1.17 Clamps
P-Clamps should be avoided in favor of brackets and other retention devices. When P-
Clamps cannot be avoided, only cushioned P-Clamps shall be used (with convoluted
tubing, or equivalent). Plastic dipped P-Clamps are not to be used in electrical
applications.
Plastic dipped P-Clamps can cut into the wire insulation over time. Brackets with
strap locks, or plastic clips are the preferred clipping methods.
Figure 30 CORRECT. Harness is held with plastic clips.
6.1.18 Convoluted tubing

Tape (coroplast, etc.) on the harness is not acceptable for wear resistance protection.
Convoluted tubing (conduit) can be used in areas where clipping brackets or other fixed
clipping devices cannot be used. The convoluted tubing should be used as a protection
for the harness. Design alternatives should be considered before using convoluted tubing
as a wear resistance material.
The correct size of the convoluted tubing shall be used for the size of the harness.
While the best wear protection is to not subject the harness to a wear condition,
there are a small number of cases where that may not be possible. Should a
medium or high wear environment exist, a means of not exposing the harness to
the wear environment must be found. For low wear environments, and where
conventional clipping points cannot be used, a protective barrier between the
harness and the wear point(s) may be used. The preferred method is a barrier
surface on the wearing surface and convoluted tube (or a better substance) on the
harness.
Where the wrong size convoluted tubing for a harness is used, the harness will be
permitted to move around in the tubing. This movement can wear away the
harness/wire insulation resulting in electrical failure.
Figure 31 CORRECT. Convoluted tubing is used with a cushioned pad on the rail for wear
resistance.
6.2 Battery Cables

6.2.1 Battery cables & fuel
Requires all battery cables not to contact the fuel tanks or fuel hoses. A distance of
25.4mm (1 inch) minimum is to be maintained between the battery cables and a fuel
delivery component.
6.2.1.1 Philosophy:
The battery cables convey a lot of current. A safe distance away from fuel delivery
systems is only prudent.

6.2.2 Battery Cable Clipping
Requires support on battery cables every 610 mm (24 inches) maximum with UV
resistant, high impact non-conductive clipping devices. Examples: strap locks, and
saddles.
6.2.2.1 Philosophy:
Supports are necessary to keep the cables from coming into contact with a surface
that could cause shorting or arcing. There are places where the distance between
supports (I.E. bends, etc.) should be less than 610mm (24 inches).
Figure 32 CORRECT. Battery cable supports are less than 610mm (24”) apart.
6.2.3 Cables And Turns

When the cables are bent or make greater than 30° turns, supports shall be used to keep
the cable in the desired location.
6.2.3.1 Philosophy:
Cables that make turns will not always stay in place without additional support.

Figure 33 INCORRECT. Cables are not properly seated in the saddle.
Figure 34 CORRECT. Battery cable is captured in a non-conductive saddle. Bend radius

remains constant due to bracket at the beginning of the bend.

Figure 35 CORRECT. Swivel tie strap holding battery cables in place.
Figure 36 CORRECT. Close up view of swivel tie strap holding battery cables in place.

Figure 37 CORRECT. Swivel tie strap used in the above two pictures.
6.2.4 Battery Cable Strap Lock

Requires all strap locks to have a 13 mm (0.5 inches) minimum width with saddles when
utilized as a supporting clamp on battery cables.
6.2.4.1 Philosophy:
Smaller sizes will fail to adequately hold battery cables in place.
Figure 38 CORRECT. Strap locks are 13mm (0.5”) wide.
6.2.5 Battery Cables And Metal

Requires all positive battery cables to be a minimum of 13mm (0.5 inch), at its closest
articulated position (including engine torque movement [engine roll]), with conductive

materials including but not limited to: frame rails, battery boxes, metal extensions and
metal clamps. This distance is across open air and does not apply across insulators.
6.2.5.1 Philosophy:
Vibration and normal vehicle component movement may result in contact with the
battery cables. A short may result (arcing).
6.2.6 Battery Cable Crossover

When a battery cable crosses over an opposite polarity cable, a 13mm (0.5 inch)
minimum distance between the cables (including engine torque movement [engine roll])
shall be maintained between the cables, and clipped in a manor that will not allow the
cables to move closer to each other. Cables routed parallel to each other are acceptable,
provided they do not have motion that may cause them to rub. The positive cable shall be
incased in a protective barrier (convoluted tubing or equivalent) when close to a negative
cable.
6.2.6.1 Philosophy:
Cables that cross over and contact each other are subject to rubbing. The insulation will
eventually rub through and could short out. Parallel cables shall have sufficient clipping
to preclude the possibility of them rubbing against each other.
6.2.7 Accessible battery ground

Requires that battery ground and trailer return ground connections on a grounded system
shall be readily accessible.
6.2.7.1 Philosophy:
There may be a need by the customer to disconnect these cables in a hurry.
6.2.8 Grommet & battery cable

Requires that whenever the positive battery cable to the starting motor passes through a
metal opening, the cable shall be protected against grounding by an acid and waterproof
insulating grommet that is not cut or split. The grommet shall then be sealed in place.
The cable shall have support clipping within 203mm (8 inches) of the grommet.
6.2.8.1 Philosophy:
The cable must not be allowed, over time, to short out against the metal it is passing
through. The sealed grommet adds assurance that the grommet will not move around
in the hole and possibly become dislodged in the future (exposing the cable to the
metal). Grommets that have large diameter flanges work best. Support close to the
grommet protects the grommet from pulling out due to cable movement through the
grommet.
6.3 Brakes- Specific - Pipes and Hoses

See section 6.6 “Hoses, Tubing and Pipes – General Practice” for additional requirements.
6.3.1 Connection Fitting Strain Relief

Requires strain relief on connection fittings used with air hoses and harnesses that
experience relative motion.

6.3.1.1 Philosophy:
Relative motion, or oscillation can cause a connection to fail or come loose.
Figure 39 CORRECT. Hoses have a strain relief applied when relative motion is present
6.3.2 1 Splice Per Repair - Truck

Requires that for repairs (other than School Bus air brake systems) there will be no more
than (1) splice in either primary or secondary air brake systems.
6.3.2.1 Philosophy:
The more splices there are, the more opportunities there are for leaks and system
failure.
6.3.3 School Bus Air Brake Splices

Requires no splices be allowed on School Bus air brake systems.
6.3.3.1 Philosophy:
Safety issue. This includes repairs.
6.3.4 Unique Air Brake System

Requires that any new or unique air brake system route and clip application be reviewed
and approved by the Brake Systems Design Group and the Design Standards Team.
6.3.4.1 Philosophy:
Sometimes the best of intentions have flaws that the system designer cannot see.
Since brakes are a safety item, the more trained eyes looking at it the better.
6.3.5 Dips In Air Compressor Hose/Pipe

Requires no traps or dips in the air compressor discharge pipe or compressor discharge
hoses. If a dip is necessary, then the air compressor discharge hose should run vertically
straight upward from the air compressor discharge port to a height that will permit a
downhill slope to the air dryer. The compressor discharge tube shall be secured with a
fastener meeting CEMS Spec G-20, and TMS-6031 Type 1. Consult with TDTC Break
Engineering when using less than three clipping points on the discharge tube.
6.3.5.1 Philosophy:
This is to prevent filling the dipped area with fluid and preventing flow.
Figure 40 INCORRECT. There are dips in the discharge hose.
Figure 41 CORRECT. The discharge hose slants down without any dips in it.
6.3.6 Clipping To Hydraulic Brake Pipes.

Requires no clipping of other components to hydraulic brake pipes.
6.3.6.1 Philosophy:
The hydraulic lines will not be subjected to external stresses if no other hoses of
harnesses are clipped to them. This is not an FMVSS requirement, but is good
common sense to preserve the integrity of the hydraulic pipes.

Figure 42 CORRECT. Nothing else is clipped to the hydraulic lines.
6.4 Fuel System – Specific – Pipes and Hoses

See section 6.6 “Hoses, Tubing and Pipes – General Practice” for additional
requirements.
6.4.1 Fuel hose below tank

Requires protective housing for any portion of a fuel hose that extends more than
50mm (2 inches) below its fuel tank or its sump. All fuel lines extending below the
bottom of the fuel tank must be protected from impact damage.
6.4.1.1 Philosophy:
Federal requirement – FMVSS 393.95 section F. The fuel lines should not be
placed into a situation where damage to the fuel lines could result.

Figure 43 CORRECT. There are no fuel hoses below the fuel tank.
6.4.2 Hose Loops/Bends

Requires that all loops and bends (radii) in the hoses should be at a minimum
length to minimize the draw from the hose.
6.4.2.1 Philosophy:
The shorter the linear length of the fuel hose, the less distance the fuel will
travel. However, The bend radii shall be large enough to make sure
kinking or crimping does not occur (this may increase the length of the
hose).
6.4.3 Fuel Hose & Electrical Harness

Requires fuel hoses to be clipped separately from electrical harnesses or wiring.
6.4.3.1 Philosophy:
Safety issue. Should arcing occur, a fire may result.

Figure 44 INCORRECT. Electric wires are clipped to the fuel line.
Figure 45 CORRECT. Fuel tank sender wire is clipped separate from the fuel line.
6.5 Power Train / Steering – Specific – Pipes and Hoses

See section 6.6“Hoses, Tubing and Pipes – General Practice” for additional requirements.
6.5.1 Reservoir and hose dips

Requires that the pipes or hoses from the power steering reservoir to the pump do not
have any segments that are routed above the bottom of the reservoir.
6.5.1.1 Philosophy:
A gravity feed is necessary to the pump.

Figure 46 CORRECT. Power steering hoses are below the reservoir.
6.5.2 Reservoir and clipping

Requires that power steering hoses be clipped and supported a maximum distance of
610mm (24 inches) from the power steering reservoir.
6.5.2.1 Philosophy:
This is for hose stability from the reservoir.
6.6 Hoses, Tubing and Pipes – General Practice
6.6.1 P-Clamps and hoses

P-Clamps shall not be used with flexible hose. Cushioned P-Clamps are acceptable with
metal tubing providing kinking does not occur. Plastic dipped P-Clamps are acceptable
when clamped on metal connectors joining flexible hose.
6.6.1.1 Philosophy:
P-Clamps do compress the flexible hose restricting the flow through the hose if the P-
Clamp is too small. P-Clamps that are too large do not have any retention of the
hose. Uncushioned P-Clamps can kink/crimp metal tubing.

Figure 47 CORRECT. Saddle bracket is used.
Figure 48 CORRECT. Bracket is used to protect the tube going through a rail.

Figure 49 CORRECT. Same bracket as Figure 48; rear view.

Figure 50 INCORRECT. P-Clamp does not retain the hose.
6.6.2 Hose bend radii

Bend radii for hoses and flexible tubing shall be according to an engineering bend radius
chart. The chart shall include material, size and location on spool (outer middle core)
with and against coiling direction.
6.6.2.1 Philosophy:
Kinking is a function of location on the spool as well as the size. The SAE document
J844 is not acceptable for determining bend radii in assembly.
6.6.3 Clipping to high pressure pipes

Requires no clipping of other components to high-pressure steel pipes or reinforced
hoses.
6.6.3.1 Philosophy:
Should a high pressure pipe fail, system components clipped to the pipe could also
sustain damage and fail. Keeping other hoses and harnesses away from high pressure
pipes is prudent. Metal reinforced hoses can arc if they are close to a positive wire.
6.6.4 Clipping and Connections

Wherever possible, hoses and tubing should be connected with push-in connectors.
Hoses/pipes/tubing passing along or near a component (I.E., transmission) shall not be
clipped to the components assembly or mounting hardware.

6.6.4.1 Philosophy
Assembly consistency and maintenance are facilitated by not using connectors that
require tools to make the connection. Reliability of the connector shall be evaluated
when selecting type of connector (push-in or screw-in, etc.). Clipping to component
assembly hardware (I.E., transmission bolts) may void the warrantee of the
component as well as present maintenance difficulties.
6.6.5 Strap locks on hoses

Requires not using strap locks on large soft type hoses defined as OD larger than 5/8
inch. Examples: heater hoses and coolant hoses and air compressor fresh air intake hoses.
Strap locks can be used on small soft type hoses defined as OD 5/8 inch or smaller, with
a minimum strap width of 7.8mm (5/16 inch). Example: surge hoses, drop hoses and
transmission cooler hoses.
6.6.5.1 Philosophy:
This is to prevent the hose from being restricted in flow. Large hoses are more prone
to deform with the application of heat.
Figure 51 CORRECT. Dual swivel saddle and strap used with a small diameter soft
6.6.6 Formed hoses should be used wherever possible.

6.6.6.1 Philosophy:
Formed hoses are an asset in the assembly process. They are also far less likely to
kink.

Figure 52 CORRECT. Application of formed hose.
6.6.7 Moving parts

Requires all pipes and hoses to be clear of all moving components, with a minimum
clearance of 25.4 mm (1 inch) at its closest articulated position.
Examples:
• Belts, fans, and pulleys in the engine compartment
• Windshield wiper arms and motors
• Parking brake mechanisms
• Brake and clutch pedals
• Wheels
• Clutch Linkage
• Suspension Brackets and Springs
• Drive Shafts
6.6.7.1 Philosophy:
Moving parts can cut through the hose resulting in a system failure.

Figure 53 CORRECT. Fuel hose is a minimum of 25.4 mm (1”) away from moving
components.
6.6.8 Distance from heat source

Requires pipes and hoses to be clipped such that the following minimum distances from
the heat source are observed.
Radiant Heat Source Type Unshielded Shielded
Minimum Distance Minimum
Away Distance Away
Exhaust system from exhaust manifold 127mm 101.6mm
to the muffler inlet (including: flex 5 inches 4 inches
pipes, intermediate pipes, elbows, turbo
exhaust pipes, etc)
Exhaust system from the muffler inlet 76mm 51mm
to the end of the tail pipe; EGR valves, 3 inches 2 inches
EGR piping, hot CAC pipes
EGR cooler, air compressor discharge 12.5mm 12.5mm
pipe or air compressor hose 0.5 inch 0.5 inch
Exhaust system Air dryer ports Air dryer ports
153mm (6 inches) 127mm (5 inches)
6.6.9 Heat source table alternative

In lieu of the above table, an approved table may be used by engineering for clipping
distance away from a heat source. The table shall contain the UL or SAE continuous use
temperature of the material as well as a measured temperature matrix of the heat source
and proximity from the heat source. For shielded applications, the heat soak
temperatures of the shielded materials (harness or hose) shall be measured to determine
the continuous operating temperature the materials will be exposed to.
6.6.9.1 Philosophy:
Heat can degrade materials such that they lose their mechanical properties.

Figure 54 CORRECT. Hoses are greater than 12.5 mm (0.5”) from discharge pipe/tube.
Figure 55 CORRECT. Fuel line is a minimum of 76 mm (3”) away from the tail pipe.
Figure 56 CORRECT. Hoses are a minimum of 12.5 mm (0.5”) from the discharge pipe.

Figure 57 CORRECT. Hose is greater than 101.6mm (4”) from shielded exhaust pipe. Note
that the heat shield has airflow around it.
6.6.10 Grommets and hoses

Requires that hoses/pipes/tubing be protected when passing through holes in metal by a
grommet that is not cut or split.
Cut or split grommets can come apart or separate from the hole in the metal, thus,
offering no wear protection to the hose/pipe. Using a sealant to seal the grommet
in place (as well as the hose/pipe in the grommet) is recommended. If a metal
pipe is bracket clipped next to the hole, such that the pipe cannot contact the edge
of the hole (minimum 0.3 inches radially away), then a grommet for the pipe is
not needed.

Figure 58 INCORRECT. Grommets are split and not properly seated.
Figure 59 CORRECT. Grommet is used through a metal surface.

6.6.11 Sharp or abrading surfaces
Requires no contact with sharp or abrading surfaces or the surface must have a securely
fastened protective covering to avoid contact with the hose. Sharp or abrading surfaces
include: screws, bolts, and frame rail flange edges, component edges. Transmission
housings are abrading surfaces. Hoses that convey flammable fluid shall be a minimum
of 12.7mm (0.5 inch) away from abrading surfaces at the closest articulated position.
Hoses and metal pipes eroded or rubbed through can cause system failures. The
rule of thumb should be “if it touches, it can rub, if it rubs it can fail.”
Additional brackets may be necessary.
Figure 60 CORRECT. Hoses are in a saddle to avoid any sharp edges from the frame rail.

Figure 61 CORRECT. Hoses are routed away from sharp edges.
Figure 62 INCORRECT. Fuel line is in contact with the sharp edge of the frame.

Figure 63 CORRECT. Hoses are inside a protective conduit.
Figure 64 INCORRECT. Fuel line is pinched between the transmission bell housing and the cab
floor cross member. P-Clamp is used for clipping.
6.6.12 Drip points
Requires that any drip points in pipes or hoses that carry any flammable fluids such as
fuel, power steering fluid or hydraulic fluid not be located above any heat sources.
Centrifugal force and air velocity, causing the fluid to contact the heat source from
normal vehicle movement/operation shall be taken into consideration.
Fluid from a drip point may drip onto the heat source and ignite.
Figure 65 CORRECT. Drip point from hose is not over a heat source.
6.6.13 Sufficient hose length

Requires hoses to be long enough and flexible enough to accommodate normal movements of the
parts to which it is attached without incurring damage.
Hoses that are too restrictive, or lack sufficient flexibility due to the distance between the
connector and closest fixed clipping point, will tend to fail.

Figure 66 CORRECT. Hoses have sufficient slack without being loose.
6.6.14 Squeaks & rattles

Requires all hoses to be secured tightly to prevent squeaks and rattles.
Squeaks and rattles can be an annoyance to the driver and result in customer
dissatisfaction.
Figure 67 CORRECT. Strap secures hoses securely to the frame rail.

Figure 68 CORRECT. Tubing is properly secured to frame rail supports.
Figure 69 INCORRECT. Fuel lines are NOT properly secured to the frame.
6.6.15 Hoses/Pipes under engine

Requires that all hoses and pipes that pass beneath the engine be shielded from road
debris.
Hose protection under engine to have hoses and pipes protected with convoluted tubing
to protect the hose from exposure to the elements and road grit or road debris.
Hoses or pipes shall not be below the front bumper.
Hoses and pipes on the underside of the vehicle need to be protected from the elements
and road grit. They should be routed and clipped such that consideration is given to
normal splash patterns, snowdrifts and other hazards the vehicle may normally encounter.

Figure 70 CORRECT. There are no hoses or pipes lower than the front bumper.
Figure 71 CORRECT. Hoses going under the vehicle are inside convoluted tubing.
6.6.16 Hoses between side rails

Requires all hose routing to be located between the side member flanges unless routing is
required to external components or fitting connections.
The hoses are better protected when routed inside the rails.

Figure 72 CORRECT. Hoses are between the flanges on the side member.
6.6.17 Clipping at connections

Requires routing length between connectors to be long enough to make accessible a
proper connection. Strap locks used on nylon hoses that have been inserted into
connection fittings require not bending the hose more than 20 degrees as it exits the
connection fitting. The strap locks should be positioned no closer than 100mm (4 inches)
to the connection fitting. Requires clipping support for flexible hose within 406 mm (16
inches) from the connection, component, or fitting.
There should be sufficient length and space to make connections. Strap locks
applied closer than 100mm (4 inches) to a connection may interfere with normal
servicing or troubleshooting.
Figure 73 CORRECT. Strap lock is a minimum of 100 mm (4”) away from the connection
fitting.

Figure 74 CORRECT. Strap lock is a minimum of 100 mm (4”) away from the connection
fitting.
Figure 75 INCORRECT. Clip is greater than 406 mm (16”) from the connection/fitting.
6.6.18 Clipping support

Requires clipping support for all vehicle hoses, tubes and pipes to be clipped 610 mm (24
inches) maximum, including along the rails, with UV resistant, high impact clipping
devices unless otherwise approved. Examples: strap locks, button head strap locks, and
saddles. Where bends of more than 30° occur, clipping support at the bend shall occur.
Fir trees are not to be used into the cab skin.
Distance between supports for copper discharge pipes is to be a maximum of 406mm (16
inches). There should be at least two supports along the copper discharge tube.

Relative motion and oscillation could allow the hose to “swing” into contact with
a component that may result in a rub through. Depending on the circumstances,
clipping closer than 610mm (24 inches) could be necessary (bends in routing,
etc.). Judgment should be exercised. Copper discharge tubes can oscillate and
damage the connection fitting, if not properly supported. Fir trees into the cab
skin allow water and air leaks into the cab.
Figure 76 CORRECT. Support clipping is less than 610 mm (24”) between supports.
7.0 RECORDS


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Truck Design Standards TDS-SD-5.5

Routing & Clipping Standards 6

PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION

TDS-SD-5.5 Page 2 of 57 Printed: 09/30/04

FIGURE 1 CORRECT. HARNESS IS 76 MM (3”) MINIMUM FROM CAC PIPE 7

TDS-SD-5.5 Page 4 of 57 Printed: 09/30/04

TDS-SD-5.5 Page 5 of 57 Printed: 09/30/04

Radiant Heat Source Type Unshielded Minimum Shielded Minimum

6.1.2 Heat source distance table alternative

TDS-SD-5.5 Page 6 of 57 Printed: 09/30/04

TDS-SD-5.5 Page 7 of 57 Printed: 09/30/04

TDS-SD-5.5 Page 8 of 57 Printed: 09/30/04

6.1.3 Sharp and abrading surfaces

Figure 7 CORRECT. Harness is away from sharp and abrading edges.

Figure 8 INCORRECT. Harness is in contact with a sharp or abrading edge.

TDS-SD-5.5 Page 10 of 57 Printed: 09/30/04

6.1.4 Requires no tension between fixed points.

TDS-SD-5.5 Page 11 of 57 Printed: 09/30/04

TDS-SD-5.5 Page 12 of 57 Printed: 09/30/04

6.1.5 Moving parts:

TDS-SD-5.5 Page 13 of 57 Printed: 09/30/04

TDS-SD-5.5 Page 14 of 57 Printed: 09/30/04

Figure 16 INCORRECT. Harness rubs on bumper.

6.1.6 Squeaks & rattles

TDS-SD-5.5 Page 15 of 57 Printed: 09/30/04

6.1.7 Connectors and breakouts

Figure 17 CORRECT. There is a minimum of 102 mm (4”) of clearance.

TDS-SD-5.5 Page 16 of 57 Printed: 09/30/04

Figure 19 CORRECT. Connectors can be easily mated.

6.1.8 Shrink Wrap

6.1.9 Harnesses under the vehicle

TDS-SD-5.5 Page 17 of 57 Printed: 09/30/04

Figure 20 CORRECT. Harness is inside convoluted tubing under the vehicle.

6.1.10 Harness clipping

TDS-SD-5.5 Page 18 of 57 Printed: 09/30/04

TDS-SD-5.5 Page 19 of 57 Printed: 09/30/04

6.1.11 Grommets & Harnesses

TDS-SD-5.5 Page 20 of 57 Printed: 09/30/04

Figure 24 INCORRECT. Harness is in contact with fuel lines.

6.1.13 Wire Identification

TDS-SD-5.5 Page 21 of 57 Printed: 09/30/04

6.1.15 Engine Compartment

TDS-SD-5.5 Page 22 of 57 Printed: 09/30/04

TDS-SD-5.5 Page 23 of 57 Printed: 09/30/04

6.1.16 Congestion In Routing

TDS-SD-5.5 Page 24 of 57 Printed: 09/30/04

Figure 29 CORRECT. A ductwork is provided for routing.

TDS-SD-5.5 Page 25 of 57 Printed: 09/30/04

Figure 30 CORRECT. Harness is held with plastic clips.

6.1.18 Convoluted tubing

6.2 Battery Cables

TDS-SD-5.5 Page 27 of 57 Printed: 09/30/04

6.2.3 Cables And Turns

TDS-SD-5.5 Page 28 of 57 Printed: 09/30/04

Figure 34 CORRECT. Battery cable is captured in a non-conductive saddle. Bend radius

TDS-SD-5.5 Page 29 of 57 Printed: 09/30/04

TDS-SD-5.5 Page 30 of 57 Printed: 09/30/04

6.2.4 Battery Cable Strap Lock

Figure 38 CORRECT. Strap locks are 13mm (0.5”) wide.

6.2.5 Battery Cables And Metal

TDS-SD-5.5 Page 31 of 57 Printed: 09/30/04