● High voltage systems bring heat and safety problems

● Delays and long lead times are common

● Strict rules add the risk of costly recalls

● Integrating harnesses with advanced vehicle systems is tough

● Sealed and waterproof designs: high Ingress Protection (IP) rating, such as IP67 or IP68.

● Durable jacketing

● EMI/RFI shielding

● Vibration and abrasion tolerance

● Modular design

● Durability: Assemblies are built with robust materials to resist abrasion, oil, chemicals, and mechanical stress common in construction environments.

● Environmental Protection: Outer sheaths and protective tubing guard against moisture, dust, and UV exposure.

● Vibration Resistance: Harnesses are engineered to secure wires and prevent damage from constant vibrations.

● Customization: Assemblies are tailored to specific machine requirements, including length, complexity, and connector types, to ensure precise fit and function.

● Simplified Installation: By bundling wires into a single, manageable unit, harnesses reduce assembly time and complexity for OEMs

● Organized wiring: Saves space, simplifies installation, and organizes the complex electrical wiring in a forklift.

● Protection: The harnesses protect the wires from the harsh conditions including vibrations, moisture, chemicals, and abrasion.

● Optimized performance

● Essential for various functions: Integral to the operation of a range of systems, including lighting, ignition, engine control, battery management (for electric models), and onboard computers.

● Protection from harsh conditions: Assemblies are built to withstand UV exposure, extreme temperatures, vibration, and moisture, particularly for outdoor installations.

● High-voltage and high-current capacity: They are specifically engineered to handle the high-power demands of ESS, with both low- and high-voltage options available.

● afety and reliability: To prevent shorts and ensure long-term reliability, the cables are protected by a durable outer sheath and secured with various fasteners.

● Customizability

● UL certification

● High-voltage (HV) cables: Used for the main electric powertrain to connect the battery pack, motor controller, and motor. These cables feature thick-gauge wire and robust insulation.

● Low-voltage (LV) wiring: Manages all the accessory functions, such as lights, gauges, horn, turn signals, and the onboard charger.

● Connectors and terminals: These electromechanical devices join different electrical conductors. Connectors must be chosen for their ability to withstand vibrations, moisture, and temperature fluctuations common in LSV operating environments.

● Protective sheathing: Materials like PVC, Teflon, or specialized conduits protect the wire assembly from abrasion, heat, moisture, and other environmental hazards.

● Cable management: Items like clips, clamps, and heat shrink tubing keep the assembly neat and secure, preventing strain on the wires.

● Safety features: For street-legal LSVs, the harness must support critical safety components, including brake lights, seat belts, and mirrors, in compliance with federal and state regulations.