Hv harness test procedure info needed

[ZSC100]

Yes, we need to know your exact plans to know how to advise you.

This ranges from as little as taking the harness they replaced (assuming you have it) to the dealer service manager and saying, "I tested the harness you replaced and found no problems" I want my $ back.

to

sending the harness to an electrical testing laboratory and having a full electrical and physical test done on it, including a signed and sealed report by a professional engineer licensed in the state it will be used as evidence in a legal case.

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[evowner]

He is testing the take-off that the dealer swapped out for a brand new one.

All that's needed, is resistance & shorts testing for each conductor in the harness.

Even 400v is still "low voltage"

Yes, I understand, but someone else, with less experience, who may not understand that he is testing a harness off of the vehicle may get the idea that there is no difference between 12 and 400 volts. 400vdc is not low voltage, that is all I am saying.

 

[ronscantlin]

Ahhh, ok I do remember seeing in passing in the past, I just went back and read it all.

So, do you have your truck back.

Did you pay the $8k for the harness?

Did they give you the harness?

I have many ideas for how you should proceed, but want to know if you have the harness and have looked it over yourself for visual damage?

Yes, I’ve got the truck back.
Yes, I paid.
Yes, I’ve got the original harness in my possession. A quick look over yielded no external visual damage to either the plugs nor the wires.

 

[chriserx]

Yes, I understand, but someone else, with less experience, who may not understand that he is testing a harness off of the vehicle may get the idea that there is no difference between 12 and 400 volts. That is all I am saying.

Since I've never had to do this sort of testing, I've been reading about it endlessly. I just have an unquenchable thirst for knowledge. Apparently most fault testing can be performed using low voltage. One of the more critical tests, the insulation resistance test, will require high voltage. Arc initiation as well as dynamic load and vibration testing also should use rated voltage and current.

 

[ronscantlin]

That is a risky statement. 400 volts can stop your heart lickety-split. It can also give you some real nasty burns. It IS VERY DANGEROUS and can be FATAL. Proceed with extreme caution.

I was thinking the electrical tape was the risky part. I use flex seal. lol

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