Specifications

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SAE J2030 - Heavy-duty electrical connector performance standard
SAE J2223 - Connections for on board vehicle electrical wiring harnesses
NEC - National Electrical Code
SAE J561 - Electrical terminals - Eyelet and spade type
SAE J928 - Electrical terminals - Pin and receptacle type A
For increased reliability and harness integrity, harnesses shall be routed throughout the cab and
chassis in a manner which allows the harnessing to be laid into its mounting location. Routing of
harnessing which requires pulling of wires through tubes shall not be allowed.
Wiring shall be run in loom or conduit where exposed, and have grommets or other edge protection
where wires pass through metal. Wiring shall be color, function and number coded. Wire colors shall
be integral to each wire insulator and run the entire length of each wire. Harnessing containing
multiple wires and uses a single wire color for all wires shall not be allowed. Function and number
codes shall be continuously imprinted on all wiring harness conductors at 2.00" intervals. All wiring
installed between the cab and into doors shall be protected by an expandable rubber boot to protect
the wiring. Exterior exposed wire connectors shall be positive locking, and environmentally sealed to
withstand elements such as temperature extremes, moisture and automotive fluids. Electrical wiring
and equipment shall be installed utilizing the following guidelines:
1. All wire ends not placed into connectors shall be sealed with a heat shrink end cap. Wires
without a terminating connector or sealed end cap shall not be allowed.
2. All holes made in the roof shall be caulked with silicon (no exception). Large fender washers,
liberally caulked, shall be used when fastening equipment to the underside of the cab roof.
3. Any electrical component that is installed in an exposed area shall be mounted in a manner that
shall not allow moisture to accumulate in it. Exposed area shall be defined as any location
outside of the cab or body.
4. For low cost of ownership, electrical components designed to be removed for maintenance shall
be quickly accessible. For ease of use, a coil of wire shall be provided behind the appliance to
allow them to be pulled away from the mounting area for inspection and service work.
5. Corrosion preventative compound shall be applied to non-waterproof electrical connectors
located outside of the cab or body. All non-waterproof connections shall require this compound
in the plug to prevent corrosion and for easy separation of the plug.
6. Any lights containing non-waterproof sockets in a weather-exposed area shall have corrosion
preventative compound added to the socket terminal area.
7. All electrical terminals in exposed areas shall have DOW 1890 protective Coating applied
completely over the metal portion of the terminal.
8. Rubber coated metal clamps shall be used to support wire harnessing and battery cables routed
along the chassis frame rails.
9. Heat shields shall be used to protect harnessing in areas where high temperatures exist.
Harnessing passing near the engine exhaust shall be protected by a heat shield.
10. Cab and crew cab harnessing shall not be routed through enclosed metal tubing. Dedicated
wire routing channels shall be used to protect harnessing therefore improving the overall
integrity of the vehicle electrical system. The design of the cab shall allow for easy routing of
additional wiring and easy access to existing wiring.
11. All braided wire harnesses shall have a permanent label attached for easy identification of the
harness part number and fabrication date.
12. All standard wiring entering or exiting the cab shall be routed through sealed bulkhead
connectors to protect against water intrusion into the cab.