CONTRACT WIRING HARNESS MANUFACTURING

 

From the simplest lead wire to the most complex vehicle cab harnesses, we have the flexibility for small, medium and large production runs.

 

We can manufacture from drawings provided or our experienced and dedicated team will work with our clients on developing and designing the most suitable harness assembly for your application.

 

Harness designs can be uploaded from industry standard··software packages directly into our custom designed software, to generate Bill of Materials and Manufacturing Reports, ensuring harnesses are built efficiently and according to specifications.

 

All our harnesses are manufactured in accordance with an ISO9001 QMS system and IPC/WHMA-A-620A Standards.

 

All assemblies are eTESTED for continuity, short circuits and insulation breakdown before final inspection and packaging.

 

BATTERY AND POWER CABLES

 

With high speed automatic cut, strip and crimp technology our heavy duty battery and power cables are manufactured to precise lengths and specifications.

 

With these automated processes repeatability is ensured, with the ability to process large cable sizes from 16mm to 240mm.

 

Our crimping is done on high spec hydraulic crimping presses for demanding applications and are capable of producing 150kN crimp force. With crimp heights, return heights and cycling speed adjusted through an adjustable controller, accuracy is precise, consistent and repeatable.

 

Understanding the critical environment of battery and power cables our crimping goes through strict quality processes with dual range pull force testing equipment, measured up to 10’000 newton to ensure a reliable quality crimp.

 

Our terminal insulator boots range adds a high quality appearance to our cables and complies with international standards.

 

Heavy-duty nylon conduit and high performance PVC coated yarns are some of the various cable protection options we have to offer.

 

AFTERMARKET WIRING HARNESSES AND SOLUTIONS

 

HARNTECH designs and manufactures ready to fit assembly kits to decrease installation time and ensure a quality product is fitted repeatedly. Most aftermarket systems requires wiring harness assemblies to interface to both OEM equipment and individual systems. HARNTECH has successfully partnered with various body builders and manufacturers of Water and Diesel Bowsers, Service Trucks and Fire Trucks to seamlessly integrate their product to OEM equipment.

 

To improve safety and reduce downtime for the off highway vehicle markets we manufacture Isolation and Lockout Stations, Power Distribution Units, Boarding Light Controllers and Optional Lighting Upgrade Kits.

 

CUSTOM DESIGNED OEM REPLACEMENT WIRING HARNESSES

 

Realising the demand for quality, reliable, defect free and reduced pricing on replacement OEM OFF-HIGHWAY harnesses, HARNTECH offers unparalleled services in this specialised field.

 

Customers usually face unavailable stock, long lead times, discontinued products and huge costs, when dealing with the challenges of replacing damaged or faulty harnesses.

 

By paying careful attention to the reverse engineering process of OEM wiring harnesses we pride ourselves in improving the current design where necessary, and providing our clients with the benefits of longer lasting and more robust harnesses.

 

PRICING

 

The extremely high cost of OEM wiring harness assemblies can be reduced substantially by using our LEAN Manufacturing principles and extensive database.

 

We are able to offer more competitive pricing by carrying a large inventory of raw materials for different equipment manufacturers and by using interchangeable components such as industry proven Deutsch Connectors, Automotive Cross Linked·wire and PVC Yarn for braiding.

 

RAPID LEAD TIMES

 

Long lead times from OEMs can often be countered before your machinery goes into production by working with·HARNTECH and earmarking harnesses that are prone to failure, such as engine, transmission and rear frame harnesses.

 

By using reverse engineering skills when supplied with sample harnesses by adding improvements, electronic drawing and design services, creating BOMs, performing cost analysis, all documented on reliable systems to ensure much shorter lead times and providing stock availability when needed.

 

IMPROVEMENTS

 

New OEM equipment harnesses are typically supplied without connector back shells and boots, thus incurring much moisture and dirt from pressure washing and leads to harness failure and in turn equipment downtime.

 

By adding waterproof boots and matching back shells we provide you with a durable harness assembly.

 

Durable wiring harness covering for harsh environmental exposure can be supplied to counteract extreme operating conditions.

 

HARNTECH has successfully improved on many harness designs and selected suitable components to prolong the service life of wiring harnesses that are exposed to harsh conditions such as, extreme heat, corrosion and mechanical damage providing customers with longer lasting solutions.

 

ELECTRICAL REBUILD KITS

 

In today’s fast paced environment many of our clients are looking to minimize their supplier bases and inventory holdings and therefore realize the value of completed electrical assembly kits. These kits typically contain all wiring harness assemblies, battery cables, lighting, dash panels, switches etc. supplied in one kit to ease production lead times and reduce assembly defects on products.

 

HARNTECH·specializes in the sourcing of various products and can design, develop and manufacture complete electrical installation kits for clients opting for this solution.

 

ELECTRICAL CONNECTOR AND REPAIR KITS

 

Our Electrical Connector and Repair Kits are designed to offer Field Service and Maintenance Technicians the correct parts to execute their duties to reduce downtime. Our kits are provided in heavy duty ABS plastic arrangement trays with visual part number references to simplify the reorder process. We offer electrical connector repair kits for the majority off OEMs and also have the flexibility to customise kits to our customer’s requirements.

 

ELECTRICAL AND MECHANICAL·SPARE PARTS

 

HARNTECH offers an extensive range of spare parts to cater for all specific needs. From the most commonly used every day spare parts such as globes, fuses, relays and lighting to the more advanced spare parts such as gear selectors, steering column switches and pressure transducers.

 

With our ever-increasing·HARNTECH range we supply you with isolation and lockout stations, boarding light controllers, power distribution·units and various electrical maintenance kits.

 

Wiring harness kits for engines and transmissions and original spare parts can be supplied for the majority of OEMs at better prices.

 

LASER CUTTING AND ENGRAVING

 

With our laser cutting and engraving capabilities, we can customise and manufacture decals, dash pannels and legends as per our clients requirements – from prototype builds to large volumes.

 

DRAWING AND DESIGN SERVICES

 

By utilising industry standard CAD electrical and wire harness design software we have the capabilities to design electrical systems and provide drawing services to our clients.

 

Our staff will work with you from the earliest stages of concept, circuit design and prototypes, to the very last stage of volume production.

 

Data packs consisting of electrical schematics, harness drawings, complete BOMs, installation instructions and approval documentation can be prepared for new projects.

 

Our in house drafting team will design and develop solutions for electromechanical assemblies such as isolation and lockout stations power distribution units, boarding light kits emergency stop switches and any custom requirements.

 

ON SITE CONSULTING SERVICES

 

By paying careful attention to our customer’s requirements and through evaluations, we offer on-site consulting in various circumstances, as well as performing case studies to identify root causes of electrical failures to provide appropriate solutions.

 

By identifying harnesses and components that are prone to failure, we provide you with well documented root cause investigations and solutions. We provide well documented services in product selection, designing systems and solutions for harsh environmental exposure, reverse engineering of current systems and improvements.