New Energy Power parts Cooling system controller wire harness assembly 3613610-TE850

Built to deliver stable, low-interference signal transmission for cooling system control, this wire harness assembly minimizes signal loss and electromagnetic interference (EMI). Signal lines use twisted-pair conductors (10 twists per meter) with aluminum foil shielding (coverage ≥95%), reducing EMI by 40% compared to unshielded —critical for accurate temperature sensor data (±0.5℃ precision) and controller command transmission. Power lines (for fans/water pumps) feature tinned copper strands (99.99% purity) with low resistance (≤0.01Ω/m at 20℃), ensuring consistent power supply (12V/24V) and avoiding voltage drops that could cause component underperformance. The harness’s signal delay is ≤10ms, enabling the cooling controller to adjust fan speed or pump flow in real time—maintaining the power battery and motor at optimal operating temperatures (25-40℃) and preventing overheating-related efficiency loss

Engineered to withstand the harsh operating environment of new energy truck cooling systems—including wide temperature fluctuations and moisture—the harness assembly features robust protective materials. All wires are insulated with cross-linked polyethylene (XLPE) that tolerates continuous temperatures of -40℃ to 125℃ (short-term peak: 150℃) without insulation hardening or cracking. The outer sheath is made of flame-retardant PVC (UL94 V-0 rating) with abrasion resistance (≥500 cycles of rubbing against steel per ISO 6722), preventing damage from contact with cooling hoses or chassis components. Connectors are IP67-rated, with rubber gaskets and double-locking mechanisms that block water, dust, and road salt—ensuring reliable performance in rainy, snowy, or dusty conditions. This environmental resistance ensures the harness maintains functionality for over 6 years in heavy-duty commercial use

Designed for efficient installation and post-maintenance, the harness assembly comes fully pre-assembled with all required connectors, clips, and labels. It includes 12 nylon mounting clips (pre-sized for OE chassis holes) that secure the harness to the cooling system frame, avoiding loose routing or contact with moving parts. Each wire and connector is labeled with clear identifiers (e.g., “TEMP_SENSOR1,” “FAN_POWER”) and color-coded (per OE standards: red for power, blue for signal, black for ground), eliminating installation errors and reducing troubleshooting time by 50%. The harness’s length is pre-cut to match the vehicle’s cooling system layout—no on-site trimming needed—and the connectors feature keyed designs that prevent reverse insertion. A professional technician can complete installation in 30 minutes or less, minimizing truck downtime for fleet operators

Built to meet strict new energy vehicle safety standards, the harness assembly integrates multiple safety features to prevent electrical hazards. Power lines include inline fuses (5A/10A rated) that protect against short circuits, while all conductors are rated for 150% of the cooling system’s maximum current (≤20A) to avoid overheating. The harness’s shielding is grounded to the vehicle chassis (via dedicated 2mm² ground wire), diverting EMI and preventing signal interference with other high-voltage components (e.g., battery packs). All materials are RoHS-compliant, free of harmful substances (lead, mercury) and meet automotive fire safety standards (ISO 6722-1). Additionally, the harness undergoes 100% electrical testing (continuity, insulation resistance ≥100MΩ) during production, ensuring zero defects. This safety-focused design complies with IEC 60664 (insulation coordination) and ISO 6469-3 (electric vehicle safety), providing long-term reliability and peace of mind for users