4 Tips on Cable Harnesses Assemblies


A cable harness assembly, also called a wire harness assembly, is an assembly or collection of cables, wires, sleeves, terminators, connectors, and other means through which wires are arranged in an electrical system. While wires are single electrical conductors, a group of insulated wires join to form a cable. Cable harnesses are essential for the success of the electrical system and also for the safety of the individual handling said electrical system.

Many electronic systems like surgical devices or communications equipment are successfully operated through a cable or wire harness assembly. The quality of a wire harness will lead to the success of the system, which is why the manufacturer of the harness should be reliable, like scondar wire harness. Electrical Supply Distributors is one of the leading providers in the Northwest for your Circuit Breaker, and Electrical Equipment needs.

Assembling a cable or wire harness is a task which demands perfection and effort. Although it is not particularly challenging, some tips can definitely make the process easier. For proper wire harness assemblies, there are certain aspects like the positioning of the wire, quality wire straps and the placement of said wire straps that need to be kept in mind. Other tips to be considered include colour coding the wires or cables. Along with quality wires, the terminals should be highly graded, and so should be the terminal crimping tool.

Apart from these, another quick tip: Make sure you begin by drawing how you want the cable harness assembly to be. Your drawing should be as accurate as possible with clearly denoted positioning of the harness. The colour of the wires should be mentioned, and the placement of the terminal should be as precise as possible.

Other tips on cable harness assemblies include:

1. Positioning of the wires

Whenever a cable harness assembly or a wire harness assembly is created, the mechanic or repair man will be either starting from scratch by replacing the corrupt unit or will be adding certain components to the existing harness. To ensure that the safety standards are maintained during the installation is a must. One of the ways in which this is done is to position the wires correctly.

The positioning of the wires should be neat not only for presentation but also for future purposes where a lot of time will be saved to detect the issue in case anything goes wrong. The positioning should be neat enough so that the wires are not tangled or twisted. This neat layout will also prevent any kind of shorting or electric shock which might happen due to twisted wires touching.

2. Securing the wiring

Having an assembly board with nails and wood might also become necessary for a greater amount of wires or cables to wind the wire around it. This will allow the wires to be separated without any damage and would also be the neater option.

The cable harness assembly can benefit from plastic ties instead of electrical tape, along with the assembly board. One simple reason behind this is that electrical wire is more rigid than plastic ties. It cannot be moved up and down the length of the wire, which might cause problems if any adjustment is needed later. Using plastic ties also makes the wires beneath visible, which is not possible when an electric tape is used.

Plastic ties are well-equipped to form a strong and secure connection whenever used. Consider going for plastic ties instead of risking the loosening of electric tape over time with the sticky residue. In the case of plastic ties, installation tools are also available to ensure proper tightening of the ties as well as for cutting the end of the tie to ensure the tie remains in place, tightly bound.

3. Colour Coding the cables and wires


Colour coding is always a favourable tip to adopt. It makes recognising the wires easy and also makes the planning and drawing of the cable harness assembly easier. The wire colours can be standard, but they can also be coded as per the choice of the creator for aesthetic. The standard colours in colour coded wire harness assemblies include:

  • Red wires: Used as a secondary line meant for hot and or positive currents.
  • Green wires: Often used as ground wires in any kind of electrical equipment, especially residential wiring.
  • Blue wires: Used to denote a point of connection.
  • White wires: Used for negative currents.
  • Black wires: Opposite of white colours, black wires stand for positive current.

4. Quality terminal crimping tool

Using good quality terminals will also go a long way as the attachment of the wires to one another would be secure. A quality terminal crimping tool is another must because the wrong crimping tool can damage the wires and, by extension, ruin the durability of the cable harness assembly. Tight crimping can also cause damage, so the applied pressure should be just right.

If one opts for a quality terminal crimping tool, it will work so that the end of the wire is not squashed and flattened, risking exposure. The crimping tool will hold the wire in place but will not have a flat edge. The wire will be held firmly through the curved end of the crimping tool.


Creating or repairing a cable harness assembly is thus made more feasible if certain tips are kept in mind. From the way the wires are arranged on the assembly board to the way they look, everything is important for a wire harness assembly. The wire should be down by quality tools, and the connection should be secure as well.

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