Reasons for Damage to Automotive Wiring Harnesses
1. When replacing wires in an automotive wiring harness, failing to select wires according to specifications (using wires that are too thin) can result in a significant voltage drop and heat generation when large currents pass through them, gradually causing the wire insulation to age and deteriorate. 2. Carelessness during battery installation—such as reversing the positive and negative terminals, causing a short circuit inside the alternator, damaging insulating gaskets and insulating sleeves, or incorrectly connecting the alternator’s field winding and ground wire—can all lead to burning of the wiring harness.
Release time:
2022-11-15
1. When replacing wires in an automotive wiring harness, if the wrong wire gauge is selected (the wire is too thin), a significant voltage drop will occur when high current flows through it, causing the wire’s insulation to gradually age and deteriorate due to heat generation.
2. Carelessness during battery installation—such as reversing the positive and negative terminals, causing a short circuit inside the alternator, damaging insulation gaskets and insulating sleeves, or incorrectly connecting the alternator’s field winding and ground wire—can all lead to burning of the wiring harness.
3. Automotive wiring harnesses are often secured using thin metal clips, whose edges are sharp like blades and whose surfaces are not insulated. During prolonged vehicle operation, under conditions of vibration and bumps, the power cable harnesses are inevitably worn, cut, and shorted to ground, leading to burnout of the harnesses.
4. When temporarily connecting electrical equipment to an automotive wiring harness, failing to clearly identify the input and output terminals of the fuse before randomly tapping into the power supply lines; or, after a fuse has blown, failing to replace it with a fuse of the same specification as required; or substituting a fuse with a thick copper wire—thus losing the protective function and causing the wiring harness to burn out.
5. The two terminals of the ammeter are typically equipped with plastic insulating sleeves. Since plastic has poor thermal conductivity, the ammeter must not only withstand current flow but also endure bumps and vibrations. If the ammeter wiring becomes loose or makes poor contact, it can lead to a rise in temperature, causing the plastic to melt and short-circuit to ground, ultimately resulting in damage to the wiring harness.
6. If the terminal connections are loose, a significant voltage drop will occur, causing overheating. Over time, the insulating gasket may be damaged, leading to a short circuit to ground. Be sure to ensure that the terminals behind the ammeter and other instruments are securely connected. Additionally, the wire connection screws fixed to the vehicle frame’s wiring board should not be excessively long, as this could result in a short circuit to ground and damage the wiring harness.
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