Dongfeng KL Main body wiring harness assy 3724010-C3357

The wiring harness uses tinned copper conductors for all wires, delivering superior electrical conductivity (≤ 0.017Ω/m at 20℃) and corrosion resistance—critical for maintaining stable current transmission in the Dongfeng KL’s high-vibration, high-humidity operating environments. The conductors are stranded (19-65 strands per wire) to enhance flexibility, allowing the harness to bend without breaking during installation or vehicle movement (minimum bending radius: 5× wire diameter). The insulation layer is made of flame-retardant PVC (UL94 V-0 rating) with a thickness of 0.8-1.2mm, which resists high temperatures (operating temperature range: -40℃ to +105℃) and oil/chemical exposure (immune to diesel, engine oil, and coolant). This insulation also prevents short circuits caused by wire abrasion, ensuring the harness meets China’s GB/T 18384.3-2015 safety standard for electric vehicle wiring

Engineered to withstand the harsh conditions of heavy-duty truck use, the harness features a 3-layer protection structure for maximum durability. The outer layer is a braided polyester sleeve (density: 16 strands/mm) that resists mechanical impact (able to withstand 50N tensile force without tearing) and blocks dust/water. Critical sections (e.g., harness segments near the engine or exhaust system) are wrapped in aluminum foil tape for heat insulation, reducing heat transfer from high-temperature components (up to 200℃) to the wires. Additionally, all wire junctions and connectors are sealed with IP67-rated rubber gaskets and heat-shrinkable tubing (adhesive-lined, shrink ratio 2:1), preventing water ingress and ensuring the harness remains functional even in heavy rain or pressure washing (common in truck maintenance)

The harness is pre-routed according to the Dongfeng KL’s chassis and cab layout, with 32 integrated cable ties (nylon 66 material, heat-resistant up to 150℃) that secure it to the truck’s frame rails and cab brackets. This pre-defined routing avoids wire entanglement with moving components (e.g., suspension parts, drive shafts) and ensures consistent positioning across installations. To prevent electromagnetic interference (EMI) between sensitive modules (e.g., ECU and radio), signal wires (e.g., CAN bus wires) are twisted (twist rate: 10 twists/m) and shielded with tinned copper foil (coverage rate: 95%). This design reduces EMI by 40dB, ensuring stable communication between the Dongfeng KL’s electrical modules—critical for avoiding issues like erratic instrument readings or ECU malfunctions

Installing the harness is efficient, even for non-specialized technicians, thanks to its plug-and-play design and detailed labeling. Each connector is marked with a part number and corresponding module (e.g., “ECU-1,” “Headlight-L”), and the harness includes a 2D routing diagram that maps each branch to its mounting point on the Dongfeng KL. No specialized tools are required—standard wire cutters and crimpers suffice for minor adjustments (though the harness is pre-cut to length for direct installation). The assembly fully complies with IATF 16949:2016 (automotive quality management) and Dongfeng’s internal QC standard DF/QR 21-2022, undergoing 100% factory testing: ① continuity tests (100% wire connection verification); ② insulation resistance tests (≥ 100MΩ at 500V DC); ③ environmental tests (salt spray, high/low temperature cycling). It is backed by a 24-month warranty, covering defects in materials or workmanship, and compatible with all Dongfeng KL models (e.g., KL 4×2, 6×4, 8×4) for versatile fleet use