Truck Wiring Harness
Your truck’s electrical system fails when its wiring harness fails. Bad connections cause electrical issues in commercial cars. This means expensive downtime. OurPCB builds custom wiring harnesses for trucks that can take intense road conditions.
We manufacture wire harness components that handle heat, vibration, and moisture. Each harness for truck applications goes through testing. It won’t let you down.
What is Truck Wiring Harness Manufacturing?
Truck wiring harness manufacturing is creating organized bundles. These bundles are wires, connectors, and terminals. They send out power throughout commercial vehicles.
These electrical components are the foundation of your truck. They connect engine controls and lighting systems, plus everything in between. Unlike regular automotive wiring, semi truck wiring harness designs must handle harsher conditions. That also means higher temperatures, more vibration, and chemicals.
Our custom fit truck harnesses protect electrical system components from environmental damage while making installation and troubleshooting much simpler. We use high-quality materials specifically chosen for durability in vehicles where reliability cannot be compromised.
PCB Manufacturing Process
The Benefits of Truck Wiring Harnesses
A wiring harness for truck applications delivers significant advantages for fleet operators and manufacturers. They prevent electrical failures that cause expensive downtime while ensuring consistent power delivery to all vehicle systems.
Enhanced Reliability in Harsh Conditions
- Our harness truck designs feature XLPE insulation rated for temperatures from -40 °F to 257 °F, preventing failures in extreme heat and cold.
- IP67-rated sealed connector options keep out moisture, dust, and road chemicals that quickly damage standard wiring.
Simplified Installation and Maintenance
- Color-coded and labeled wiring reduces technician installation time by up to 40% compared to standard solutions.
- Comprehensive documentation makes repair faster, getting vehicles back on the road quickly.
Regulatory Compliance and Safety
- All harnesses meet IPC/WHMA-A-620 standards and IATF 16949 quality requirements for automotive components.
- Proper circuit design prevents electrical shorts that can cause fires or damage sensitive electronic systems.
Weight Optimization for Fuel Efficiency
- Precisely organized cable assembly eliminates unnecessary wiring, reducing harness weight by 15-20% over standard solutions.
- Optimized wire routing and sizing improves overall vehicle efficiency without compromising performance in your pickup truck or commercial fleet.
Why Choose OurPCB For Truck Wiring Harnesses
OurPCB offers unique advantages as a custom wiring harness manufacturer. Our dual expertise in both PCB assembly and harness manufacturing gives us deeper insight into complete electrical component integration.
Industry-Leading Testing Protocol
- Our 7-point testing includes continuity, insulation resistance, signal integrity, pull force, environmental simulation, functional, and quality inspection.
- Every custom wiring harness for semi truck applications undergoes temperature cycling from -40 °F to 257 °F to verify performance in real-world conditions.
Rapid Prototype Development
- We deliver functional prototypes within 2 weeks of design approval, faster than the industry standard for accessory components.
- Accelerated development lets you test solutions before full production, reducing overall project timelines for your F-150 or heavy-duty truck projects.
Custom Material Selection System
- Our proprietary system analyzes your specification to select the optimal materials for your specific needs.
- We match wire gauge, rubber insulation type, and plug specifications to your exact operating environment to withstand demanding conditions.
Comprehensive Documentation Package
- Each harness kit includes detailed circuit diagrams, component specifications, test results, and maintenance guides.
- Complete documentation simplifies fitment and troubleshooting, reducing long-term support costs for your fleet.
PCB Assembly Services
Our team gives you complete control panels and PCB assembly manufacturing. This is in addition to our truck wire harness manufacturing services. That makes a total electronics solution in one place. This mixed method ensures perfect compatibility between boards and cable assemblies and wire harnesses, while making procurement easy.
We work well in Surface Mount Technology assembly using advanced automation for precise component placement. Our SMT process takes care of components as small as 01005 (0.4 mm × 0.2 mm) with total accuracy.
Supply your own components or use our global sourcing network for turnkey solutions. There’s complete material management with traceability documentation for regulatory compliance.
Specialized assembly services for custom designs that meet high quality standards. Expert handling of complicated layouts, including high-density interconnect (HDI) boards.
Fast production capabilities for time-sensitive projects without giving up quality. We have quicker processes for prototypes through medium-volume production runs.
Manufacturing to meet the special needs for mission-critical military uses. We have strict inspection protocols that go beyond ISO and WHMA certification standards.
Value-added services with the latest equipment handling complex package types. X-ray inspection makes sure there is proper soldering on hidden connections for highest quality products.
Millions of business and innovators use OurPCB
Technical Capabilities
OurPCB’s truck wiring harness manufacturing supports all commercial vehicle classes, from F-250 delivery vans to Class 8 semi trucks. We work with wire types from 22 AWG to 2/0 AWG, with operating temperature ranges from -40 °F to 257 °F. Our assembly equipment ensures precise, consistent connections exceeding IPC/WHMA-A-620 Class 3 standards.
| Feature | Specification | Application | Benefit |
|---|---|---|---|
| Insulation | XLPE, PVC, FEP | Temperature resistance | Prevents melting/cracking |
| Connectors | IP67/IP69K rated | External exposure | Waterproof protection |
| Conductors | Tin-plated copper | Corrosion resistance | Prevents connection failure |
| Shielding | Braided/foil options | EMI/RFI protection | Prevents signal interference |
Our facilities maintain ISO 9001 and IATF 16949 certifications, with full traceability from raw materials to finished products. We offer CAD design services, 3D harness modeling, and electrical load analysis to ensure optimal performance. All harnesses include strain relief features, protective coverings, and secure bracket mounting provisions designed specifically for high-vibration environments in vehicles from Dodge Ram 1500 to F-350 trucks.
The processes include but not limited to the following:
- Wire Gauge: 40AWG-120mm²
- Production Capacity: 10,000 pieces/hour
- Wire Cutting Service: 15-50,000mm, any length as required.
- Wire Stripping Service: Strip the insulation/jacket in required length from the end or retained, then twist or tin the end.
- Wire Marking Service: Labels with Series number, Part number, Date code, etc.
- Label Types: Heat shrink tubing label, Waterproof self-adhesive label, Custom labels.
- Wire Ends Treatment: One or several wires crimped with a terminal, soldered to kinds of connectors/electronic components.
Custom Wire/Cable Service:
- Wire/Cable types
- Wire gauge
- Wire/Cable length
- Insulation/Jacket color
- Core numbers etc.
Custom Cable Assembly Capacities:
All kinds of cable assemblies including
- Electrical cable assembly
- Coaxial cable assembly
- Multi-core cable assembly
- Connector to board cable assembly
- Automobile communication cable assembly
- Power transmission cable assembly
Mon-Fri: 24 hours,
Sat: 9am-6pm, GMT+8
Reach us at
[email protected]
24 hours online
+86-199-30589219
Mon-Fri: 24 hours,
Sat: 9am-6pm, GMT+8
Truck Wiring Harness FAQs
How long do custom truck wiring harnesses typically last?
Custom truck wiring harnesses from OurPCB typically last 7–10 years in commercial applications. This extended durability comes from our premium materials like XLPE insulation and sealed connectors that resist heat, chemicals, and vibration. Environmental exposure and maintenance practices can affect actual service life for your Silverado 2500 or commercial vehicle.
What's the difference between standard automotive and truck-grade wiring harnesses?
Truck-grade wiring harnesses use heavier-duty materials designed specifically for commercial use. Key differences include thicker insulation with higher temperature ratings (257 °F vs. 221 °F), larger conductor sizes for higher current loads, and reinforced strain relief for vibration. These enhancements make truck harnesses approximately 40% more durable in demanding applications than standard GM or Chevy components.
Can you integrate modern electronic systems with custom wiring harnesses?
Yes, our custom wiring solutions support integration with telematics, lighting systems, and digital dash displays. We design with CAN bus compatibility for communication between electronic control units while incorporating appropriate shielding to prevent interference. Our dual expertise ensures complete compatibility between control modules and power distribution for any truck model from 1999-2006 to current vehicles.
Ready to Validate Your PCB Assembly
With Reliable PCB Testing Services?
Request a quote and get a custom testing plan tailored to your design, BOM, and inspection needs. We provide PCB testing services with full traceability, calibrated measurement systems, and certified workflows for Class II and Class III assemblies.
