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Electrical Requirements
Body Builder Guide For Tapping into Electrical Systems
Body builder electrical systems that are to be interconnected with the Fuller UltraShift ASW electrical system should adhere to the
latest recommendations of SAE J1292. In addition to SAE J1292, the following recommendations should be followed.
1.
All wiring terminals should be properly insulated to prevent “short circuits”. All terminals should be of insulation grip
design to provide a reliable connection and to prevent terminal fatigue.
2.
Terminals and splices that are connected outside the body should be moisture resistant design. Molded insulator for
ring terminals should be used. Molded connector/insulators are recommended for use with blade or pin type terminals.
3.
Wires must be routed to provide at least 75 mm [3.0”] clearance to moving parts, unless positively fastened or pro-
tected by conduit.
4.
Wire routing should avoid areas where temperatures exceed 80° C [180° F] and a minimum clearance of 100 mm [4.0”]
should be maintained from exhaust system components. Where compliance with this requirement is not possible, heat
insulation and heat shields are required.
5.
Wire routing and component mounting (switches, relays, etc.) should be located to be easily removed for service. Do
not surround the components with body structure that will prevent removal for service.
6.
Wiring to all circuit components (switches, relays, etc.) in exposed locations shall provide a drip loop to prevent mois-
ture from being conducted into the device via the wire connection.
7.
Routing wiring into wheel splash areas should be avoided. When such routing cannot be avoided, adequate clipping or
protective shielding is required to protect wiring from stone and ice damage.
8.
Routing wires under the frame side-members or at points lower than the bottom frame flange should be avoided to pre-
vent damage to the wires in off-road operations.
9.
The wire retainers and grommets installed by the assembly plant are designed to accommodate only the OEM installed
wires. Additional wiring or tubing must be retained by additional clips. When added wires to tubes are routed through
sheet metal panels, new holes must be used (with adequate wire protection and sealing).
10. All wiring connections to components of the factory-installed system must be accomplished by using the correct mat-
ing wire termination. (Connections on studs and ground connections must use ring type terminations).
11. When it is necessary to splice wires, the splice must be adequately crimped to provide a good mechanical and electrical
connection. Double wall heat shrink tubing should be used where the outer wall will provide adequate electrical insula-
tion and the inner wall melts and seals the splice from the environment.
12.
Never add another circuit or splice to the Fuller UltraShift ASW ignition or battery power supplies.
13. Fuse recommended to protect wire. Manual circuit breaker acceptable.
Auto reset breakers are not acceptable.
14.
Never puncture cable insulation with a probe to verify voltage or to check continuity
.
15. Do not use contact lubricant or grease on Duetsch connectors. Lubricate is used only on tin plated contacts.
16. Exposed ring terminals should be protected from the environment. Dielectric grease is recommended to prevent corro-
sion.
