1. WIRING HARNESS
Submitted By:
Ashish Kumar Sharma
2009Btec002

2. WHAT IS WIRING HARNESS?
 A cable harness, also known as a wire
harness, cable assembly, wiring
assembly or wiring loom, is an assembly of
cables or wires which transmit signals or
electrical power. The cables are bound
together by straps, cable ties, cable lacing,
sleeves, electrical tape, conduit, a weave of
extruded string, or a combination thereof.

3. COMPONENTS OF WIRING HARNESS
 Wires
 Terminals
 Connectors
 Caps & Sleeves
 Fuse Boxes

4. WIRES
Wire is a single, usually
cylindrical, flexible strand
or rod of metal. Wires are
used to bear mechanical
loads and to carry electricity
and telecommunication signals.

5. LABELS & SYMBOLS: AUTOMOBILE WIRING
DIAGRAM
 Color Codes
B - Black color wire
BR - Brown color wire
DRK GRN - Dark green color wire
G - Green color wire
L - Blue color wire
LG - Light green color wire
O - Orange color wire
P - Pink color wire
R - Red color wire
SB - Sky blue color wire
V - Violet color wire
W - White color wire
Y - Yellow color wire


6. TERMINALS
Push On Terminal Copper Terminal Correct way
to put
terminal on
wires

7. CONNECTORS
Connectors are used to
make connections
From one device
to another

8. CAPS & SLEEVES
Caps are used to protect the
terminals from being
damaged.
Sleeves are used to
protect the wires from
shrinking due to high
currents.

9. FUSE BOX
To protect the wire lines
from short when high
Intensity of current is
passed.

10. MANUFACTURING PROCESS
STEP 1
 Terminals are fixed on wires
 Then with the help of
applicators wires are
cut on CNC machine
C n c machine

11. MANUFACTURING PROCESS(CONTD…)
STEP 2
 Quality of the wire is being checked by the
Quality Analyst
 Parameters to be checked;
 PVC of the wire
 Terminals of the wire
 Width of the terminal

12. MANUFACTURING PROCESS(CONTD…)
STEP 3
Taping is done on the
wires to protect them
from moisture and heat

13. MANUFACTURING PROCESS(CONTD…)
 After taping, quality is checked
 Then packing is done
 And the final products are dispatched to the
market.

14. SAFETY MEASURES (DO’S)
 Always keep the area around the machine clear of
obstacles.
 Always put material where you can reach it.
 Always check that tools are sharp and set correctly.
 Always check that the correct tool data is entered into
the CNC program
 Always make sure that all guards are in position while
the machine is in operation.
 Always follow company policy on correct procedures
when handling or lifting parts or tooling.

15. SAFETY MEASURES
DON'T:
 Do not use the machine table as a
workbench.
 Do not use compressed air to blow chips
from the parts of the machine, machine
surfaces, cabinets, controls or floor around
the machine.

16. ADVANTAGES
 Advantages over loose wires and cables
 Adverse effects of vibrations, abrasions, and
moisture.
 Usage of space is optimized
 Risk of a short is decreased
 Installation time is decreased and the
process can be easily standardized

17. Thank You