Cable Assembly
Wire harnesses engineered for medium- and heavy-duty commercial electric trucks — high-voltage traction, low-voltage signal integration, range-extender modules, and chassis harness packages. Built to automotive workmanship standards with IATF 16949 process discipline and ready to scale from pre-series prototype to volume launch.
Application Context
A commercial EV truck harness covers a wider envelope than passenger-EV or legacy truck wiring — bigger currents, longer routing, and a tougher duty cycle. We build the full harness set for class 4-7 platforms: orange-jacketed high-voltage traction harnesses for 400 V and 800 V inverter, motor, and battery-pack interconnect; low-voltage 12 V / 24 V vehicle packages for body, lighting, cab, telematics, and ADAS; range-extender module harnesses; and cell-tap and BMS wiring inside the pack.
Every scope is built to automotive workmanship standards under IATF 16949 process discipline, with serialized lot traceability and the same operators and fixtures carrying a program from pre-series prototype to volume launch.
Capabilities
Engineered for the class 4-7 vehicle envelope — bigger currents, longer routing, tougher duty cycle than a passenger EV, and a different supplier discipline than legacy truck wiring
Orange-jacketed HV harness assemblies for traction inverter, motor, and battery-pack interconnect on 400 V and 800 V architectures. HVIL interlock, shielded conductors, and torque-controlled lug terminations matched to your inverter and pack supplier callouts.
Dedicated harnesses for fuel-cell or genset range-extender modules — high-current DC link, CAN-FD diagnostics, thermal management interconnect, and module-to-pack power coupling for class 5-7 platforms targeting longer-range commercial duty cycles.
Full-vehicle 12 V / 24 V harness packages — body, lighting, cab, telematics, and ADAS sensor integration. Modular sub-harnesses with documented mate connector lists so vehicle engineering can swap variants between platform configurations without re-tooling.
Dedicated harnesses for relay coils, inline liquid sensors, pressure transducers, and telematics fan-out. Tighter EMC discipline than a stock commercial truck harness to keep ADAS and high-voltage paths cleanly decoupled.
Cell-tap, BMS slave, voltage-sense, and balancing harnesses inside the battery pack. Built to pack-OEM strip and lug specs with serialized lot traceability so a field failure can be back-traced to the assembly batch.
Pre-series pilot builds, engineering-revision turnaround under tight launch timelines, and volume ramp into series production once the platform is frozen. The same operators and the same fixtures move from pilot to volume — no supplier hand-off in the middle of the program.
Engineering Challenges
400 V and 800 V traction architectures with HVIL interlock continuity, hex-crimp ring-lug terminations, and 100% continuity + hipot verification before release.
Bigger currents, longer routing, and a tougher duty cycle than passenger EVs — rated -40 °C to +125 °C (150 °C engine-bay on request) and sealed to IP67 / IP6K9K cab and IP69 underbody.
Class 4-7 programs run frequent ECNs during ramp. Fixtures are locked to harness number and revision level, with pilot quantities of new revs built alongside production of the prior rev.
Cell-tap, BMS-slave, and voltage-sense wiring carries serialized lot traceability so a field-return battery pack can be back-traced to the crimp, operator, tool, and wire spool.
Technical Capabilities
IATF 16949 process discipline across the HV traction and LV vehicle harness scopes — from 12 V / 24 V signal wiring to 800 V class HV interconnect.
Manufacturing Process
Quality & Testing
Every commercial EV truck harness gets 100% continuity and hipot on HV assemblies, with pull-force sampling and sealed-splice integrity checks — all logged with operator-ID crimps and lot traceability, and PPAP Level 2-5 support on request, before it ships.
Why WHP
Class 4-7 EV programs don't behave like passenger EV programs — and they don't behave like legacy commercial truck programs either
The same engineering contact, the same operators, and the same fixtures carry your harness from 5-unit prototype to volume launch. No supplier hand-off in the middle of a program, no re-qualification of fixtures, no operator retraining at scale-up.
We build the orange-jacketed HV traction harness and the LV vehicle harness package on the same floor with shared work instructions. Cross-coupling, EMC fan-out, and HVIL chain are reviewed once across the full vehicle harness set.
Class 4-7 programs run engineering changes constantly during ramp. We track ECN cadence by harness number, lock fixtures to revision level, and ship pilot quantities of new revs while running production of the prior rev.
Cell-tap and BMS wiring carries serialized lot traceability through every crimp and splice. A field-return battery pack can be back-traced to the assembly cell, operator, crimp tool, and wire spool that produced the harness inside it.
Automotive QMS by design — control plan, FMEA, PPAP, APQP — applied to the EV harness scope from day one rather than retrofitted at PPAP Level 3 submission.
EPLAN, KBL, and structured BOM intake supported. Drawings stay in source format. No redraw, no tolerance loss, no week-long quote cycle while engineering decodes a screenshot.
FAQ
OEM Program Entry
Send the harness drawing pack, BOM, or wiring schematic. We will review HV path, LV scope, connector callouts, and IATF expectations and quote prototype + series in parallel.
Related Capabilities
Services and platforms that pair with commercial EV truck harness programs
Vehicle Programs
Class 4-7 platforms where battery weight, route range, and uptime define the program
Class 4-5 delivery box trucks for parcel, grocery, and final-mile fleets. Full-vehicle harness packages plus battery pack interconnect for high duty-cycle stop-and-go urban routing.
Regional-haul electric trucks with extended battery capacity or range-extender modules. HV drive harness + cell-tap + BMS wiring tuned for the longer route and heavier payload envelope.
Refuse trucks, utility trucks, and vocational EV platforms with body-mounted power take-off (ePTO) and auxiliary load harnesses on top of the base traction system.
Class 8 yard-tractor and terminal-tractor EV programs running short-cycle high-utilization duty. Battery and HV harnesses tuned for the rapid-charge / rapid-discharge profile.
Tier-1 powertrain integrators supplying inverter, motor, and pack subsystems to multiple commercial EV OEMs. Shared HV harness platforms across OEM customers under common automotive QMS.
Hybrid range-extender and fuel-cell electric truck programs where a secondary energy source pairs with the battery pack. Dedicated module-to-pack harnesses and DC-link interconnect.
Representative Project
Representative project type we handle, shown for illustration. Not a specific named customer.
ev-commercial-truck
USA (West Coast OEM)
2025-2026
Scenario: An American class 4-7 commercial EV truck OEM ramping into pre-series production needed a supplier capable of running multiple harness families (HV drive, LV vehicle package, range-extender, signal coil, inline sensor) on parallel timelines with engineering changes landing weekly.
Challenge: Tight launch deadline, frequent ECNs, simultaneous pilot and quality-rework on different revisions, and a $40,000 credit ceiling reached early in the program. Multiple internal departments (purchasing, quality, engineering, logistics) all engaged on the supplier relationship.
What we did: Locked fixtures to harness-number + revision-level, ran pilot quantities of new revs in parallel with production of the prior rev, and routed all communication through a single program-manager channel so engineering changes never lost the through-line.
Result: Established multiple-harness-family recurring supply, supported the program through pre-series ramp, and moved into a sustained repeat-order relationship across the HV, LV, range-extender, and signal harness scopes.