Anyone who's
performed electrical diagnosis has a story about an electrical short
circuit in an out-of-the-way place. Here's my Top 5 List of
believe-it-or-not short circuits in tow trucks:
1. Wires caught in drive
shaft. It sounds
unlikely to go unnoticed but I've repeatedly seen trucks where wires
hanging down in the drive shaft have grounded to the shaft. In these
cases, putting the truck in reverse will often blow fuses. Shorting
to the drive shaft occurs in tow trucks because the cable ties, which hold
wires in the body above the drive shaft, sometimes break, and because the
drive shaft is not as easy to see as it is on other types of commercial
trucks. Prevent this problem by using heavy cable ties and clamps,
and a lot of them.
2. Wires smashed inside
toolbox. This is
one of the most common short circuits in conventional wreckers with tunnel
toolboxes. Frame forks, dolly axles and other heavy, loose hardware
inside the toolbox will abrade and chop up the marker light wires that run
inside the box. While brackets to hold the hardware will help solve
this problem, the ultimate solution is to weld in thick steel guards
around the wires.
3. Conductive or
inflexible sheath.
Truck equipment moves and flexes, and thus requires non-conductive,
flexible sheathing material around the wires. Use plastic wire loom
or some other rubber-like material. Running wires inside metallic
tubing often results in short circuits. Inflexible sheathing
material eventually breaks and creates a sharp edge at the break, which
will cut through the wire's insulation and short out (see photograph
above).
4. Squeezed by toolbox
mounts.
Occasionally a tow truck body installer will accidentally fail to get an
electrical cable out of the way when bolting toolboxes to the truck frame
with an impact wrench. The electrical cable gets sandwiched between
toolbox and frame, often resulting in cross-functioning. For
example, the turn signals will come on when you turn on the beacon
lights.
5. Radio.
The lowly radio is one of the most common culprits in tow truck short
circuits. Radios usually come with many excess unused wires, which
the radio manufacturer has partially stripped for easy installation.
If the radio installer has not closed off those stripped wires, the bare
end of the wire can intermittently short against the steel radio
receptacle in the dash. When the lights dim as you go over a bump
driving down the road, check the radio.
Prevent short circuits by using
ample ties and clamps, fortifying wiring against banging by heavy objects,
using wire loom and closing off unused bare wire ends with dead-end crimp
terminals.