Installation Manual

Electrical & Electronic Application And Installation Manual
Production Release Version 1.0
Page 61
5.8.2 Harness Bends Near Connectors
Harness bends within 25mm of the ECM J1 connector should be avoided.
Bending a harness too close to the connector causes the connector seal to be
stretched away from the wire, reducing its sealing capability to dirt and
moisture. To avoid this the wires should exit perpendicular to the connector
before curving as necessary for routing as shown in figure 5.11.
Bends near to other sensor or actuator connectors should be no less than
twice the wire harness diameter. Special consideration should be made to
connectors with large wire counts. Stresses placed upon the retention system
of the connector can cause retention failures and wire pull-out failures. To
avoid these problems pre-form the harness to the required bend radius.
Figure 5.11 Connector Wire Routing and Tension
5.8.3 Cable routing
Cables should be routed such that bend radii are not too tight. A cable should
not be either in compression or tension, nor should it be excessively long or
loose, such that sections may become caught or trapped. Clips should be
used at regular intervals to support cables. These clips should be of the
correct diameter to grip the cable firmly without crushing it.
Ideally, to protect against damage and to ensure reliability throughout the life
of the product the harness routing should provide protection from the
following;
• Chafing / rubbing / vibrating against other parts
• Routed away from sharp edges
• Use as handholds or as support for personal equipment
• Damage by personnel moving within or servicing the vehicle
• Damage by impact
• Damage by battery acid fumes, engine and hydraulic oil, fuel and
coolant
• Abrasion or damage when exposed to rocks, ice, mud etc
• Damage by moving parts
• Harsh environments such as nitrite mines, high temperatures, or areas
susceptible to significant fluid or fume concentration
Conductors carrying high currents or voltages, particularly when these are
alternating or switched, should be physically separated from conductors