harnesses, pigtails, nose boxes, and power cords€¦ · harnesses, pigtails, nose boxes, and power...

Harnesses, Pigtails, Nose Boxes, and Power CordsMASTERY STATEMENT:

G R O T E T R A I N I N G S E R I E S

In this module you will learn and understand the Ultra-Blue-Seal® harness system, coil cords, and the different types of pigtails offered in the industry.

Ultra-Blue-Seal® System .......................................................................................................2Pigtails ......................................................................................................................................3Nose Box ................................................................................................................................10Power Cords ..........................................................................................................................11Additional Resources ...........................................................................................................12

2GROTE 101 grote.com

Harnesses, Pigtails, Nose Boxes, and Power Cords

ULTRA-BLUE-SEAL® SYSTEM

The Modular Plug & Go Connection System from Grote Modular DesignThe UBS (Ultra-Blue-Seal®) system provides true “Plug & Go” modular convenience and reliability for trailer electrical installations. It is designed around a family of standardized components that plug together to form complete lighting and wiring systems. This system is designed to provide maximum voltage from the power source, through the entire system, to the lamp itself. UBS components can be used to create systems for most styles and sizes of trailers including dry vans, tankers, reefers, flat beds, and special-task trailers such as container chassis trailers. The modular design means that all UBS components provide positive connectivity no matter what the design function and position on the trailer requires. Grote engineers design our lamps to fit our plugs and our plugs to work with our lamps.

DurabilityEvery UBS component is designed to connect securely and provide a strong, moisture tight seal. Each plug is manufactured to precise tolerances that enable the UBS system to meet or exceed trailer industry standards. Internal wire-to-wire connections are sonic welded for a strong, efficient, and reliable connection. UBS plugs designed for Grote male-pin lamps use banded female terminals. Banded terminals ensure that a solid electrical contact is created and maintained each time a connection is made. The bands provide a spring-like effect to the female terminals in addition to ensuring an excellent electrical connection.

Banded terminals are also used in UBS nose box plugs to maintain a secure fit. Grote’s signature blue over-molding encapsulates the connections, providing critical strain relief and a virtually impenetrable moisture barrier. Unique to Grote’s UBS system is the locking collar used between the main & rear sill connection. The rear sill collar locks the main harness to the rear sill harness to avoid vibration and wear. Another feature is the grease fitting which allows dielectric grease to be applied to the connection.

Proven ReliabilityThe UBS system outperformed all competitive products in a tough, salt water immersion and vibration testing environment. Grote products went head-to-head with the competition and had far fewer failures than any challenger. As a complete system, the LED’s and UBS system produced the highest pass rate, lasting 39% longer than the closest competitor. 100% of the Grote LED’s were functioning at the end of the test.

Continuous DevelopmentGrote continues to develop the UBS system to meet the needs of those who demand the best. Our male-pin and double seal technology is carried over into our newest designs resulting in a single harness system that can be used for either incandescent or LED lighting packages. Plugs for incandescent or LEDs offer simpler electrical maintenance management; fewer SKU’s in inventory, and an optimized trailer lighting system.

InterchangeabilityThe modular design also means that the components can be changed without requiring cutting and splicing into the harness system. If, for instance, a jumper is damaged, it can be changed with a new replacement part without the need for trimming to length, crimping, or soldering.

KeyPoints

Our goal was to provide

a system to meet all of the requirements as put forward

by TMC.

Modular design eliminates cutting and splicing

Locking seal collar showing the grease fitting



PIGTAILS

Double Seal TechnologyAt the heart of the UBS system is the patented Grote Double Seal feature. It provides double protection from moisture and contaminants. The Double Seal effect results from a molded-in circular ring in the connector, which corresponds to a mating ring on the lamp. The inner sealing ring covers the terminal area and the outer ring, or dust skirt, seals around the outside area of the lamp plug connection. The Double Seal drastically decreases water intrusion and corrosion.

Another UBS advantage is the Grease Groove design on the male-pin plugs. Dielectric grease added to female terminals and male terminals to Ultra-Blue-Seal® System protects against moisture and contaminants. Sometimes moisture and contaminants cause a hydraulic effect when the lamp and plug are connected. This hydraulic effect can prevent the plug from being fully seated in the lamp, creating a potential leak path. Grease Grooves allow the sealing compound to disperse around the terminals with the excess sealant escaping into the reservoir, eliminating the hydraulic effect.

Male-pin TechnologyThe Grote UBS male-pin system combines male-pin lamps with female connectors on the wiring harness for a corrosion-proof and vibration-resistant connection. It also prevents ground shorts, a common wiring system breakdown associated with road-induced vibration. The key components to the male-pin technology are the solid, spun-brass terminals which are tin-plated for maximum corrosion resistance. This, combined with the patented Grote Double Seal feature, makes the Grote male-pin system the best in the business.

Traditional terminations (female-pin lamps with male-pin plugs) offer limited protection from moisture and corrosion. The two mating components are made from flat, stamped-metal components that are then rolled to form the pin. This technology over time will eventually weaken and cause an inconsistent termination and thus allow corrosion to infiltrate the electrical system.

Advantage of the Grote Male-Pin TerminationsGrote made a decision many years ago to move from the standard female-pin termination to our male-pin system. This termination provides what we believe is the best possible seal at the juncture of the lamp and the pigtail. The double O-ring seal from the plug provides a snug fit around the solid brass pins in the lamp, with the outer O-ring providing a watertight seal with the lamp. This design is used on our latest versions of incandescent lamps, and all of our premium LED SuperNova Lamp connections/terminations.

Consider the Standard Female-Pin Lamp Plug (67000 ). The prongs are the hot lead to the lamp. If this connection should come apart, the hot leads may cause a short, blown fuse, or, in a worst case scenario, a trailer fire.

With the Male-Pin Lamp Pigtail (66815), it is still hot, BUT, if it happened to come loose, there is nothing for the pigtail to short out or cause the potential problems referenced above for the female-pin pigtail. PLUS, you have a much better seal between lamp and pigtail.

This pigtail (66911) is an illustration of what has been discussed earlier in regard to our technology in providing the best connection available between the lamp and the electrical system.

KeyPoints

Double seal technology drastically decreases

water intrusion and

corrosion.

UBS lamp connection showing Double Seal features and Grease Groves to male-pin lamp

*No Hydraulic Effect*

67000

66815

66911



•Patenteddoublesealdesignaddsdoubleprotectionagainstmoistureandother contaminants.

•Centergreasereservoirprotectsagainsthydraulicpressureforcingconnection open.

•UBSoffersafullyintegrated,modularwiringandlightingsystem.The.180male bullet termination plugs directly into the UBS wiring / harness system.

It is this type of engineering of pigtails that complements the UBS harness system which mates with our lamps. This allows Grote to provide a 10-year warranty on our SuperNova® LED product and gives our OE customer base a “Long Life System”.

KeyPoints

The Grote UBS system is the first and

only complete modular

harness-to-lamp system

on the market today.

WIRE SIZE CHARTFor A

12-VoltSystem

For A6-Volt

System

Length of Wire (Most Distant Light)10' 20' 30' 40' 50' 60' 70' 80' 90' 100'

Load inAmps

Load inAmps

WireGauge

WireGauge

WireGauge

WireGauge

WireGauge

WireGauge

WireGauge

WireGauge

WireGauge

WireGauge

1.0 0.5 18 18 18 18 18 18 18 18 18 18

1.5 0.75 18 18 18 18 18 18 18 18 18 18

2.0 1.0 18 18 18 18 18 18 18 16 16 16

3.0 1.5 18 18 18 18 18 16 16 16 14 14

4.0 2.0 18 18 18 16 16 16 14 14 14 12

5.0 2.5 18 18 18 16 14 14 14 12 12 12

6.0 3.0 18 18 16 16 14 14 12 12 12 12

7.0 3.5 18 18 16 14 14 12 12 12 12 10

8.0 4.0 18 16 16 14 12 12 12 10 10 10

10.0 5.0 18 16 14 12 12 12 10 10 10 10

11.0 5.5 18 16 14 12 12 10 10 10 10 8

12.0 6.0 18 16 14 12 12 10 10 10 8 8

15.0 7.5 18 14 12 12 10 10 10 8 8 8

18.0 9.0 16 14 12 10 10 8 8 8 8 8

20.0 10.0 16 16 12 12 10 10 8 8 8 8

TEMPERATURE CHART

Cable SizeMaximum Current Carrying Capacity

(For 12 Volts at Listed Temperatures)

120° F 125° F 150° F

20 Gauge 15 Amps 13 Amps 9 Amps






White Ground (10 ga.)Brown Tail and license lamp, and

clearance lamps (12 ga.)Black Clearance, sidemarker, and

identification lamps (12 ga.)Yellow Left turn signal lamp (12 ga.)Green Right turn signal lamp (12 ga.)Red Stop lamps (12 ga.)Blue Auxiliary circuit (12 ga.)

7-Conductor Cable: (SAE J1067 and J560)

White Ground (8 ga.)Brown Tail and license lamp, and

clearance lamps (12 ga.)Black Clearance, sidemarker, and

identification lamps (12 ga.)Yellow Left turn signal lamp (12 ga.)Green Right turn signal lamp (12 ga.)Red Stop lamps (10 ga.)Blue Auxiliary circuit (10 ga.)

Heavy Duty 7-Conductor Cable System:(SAE J1067 and J560)

Brown Tail and license lamp, andclearance lamps

Black Clearance, sidemarker, andidentification lamps

Yellow Left turn signal lampGreen Right turn signal lamp Red Stop lamps

5-Conductor Cable:(chassis ground and without auxiliary circuit)

White GroundBrown Tail and license lamp, and

sidemarker lampsYellow Left turn signal lamp and stop

lampGreen Right turn signal lamp and

stop lamp

4-Conductor Cable: (boat trailer harness)



1

4

2

3

8

75

6

1 Forward Main Harness2 Intermediate Harness3 Rear Sill Harness4 Front Marker5 ABS Fault Lamp6 Rear Marker7 License Lamp8 Rear I.D.

Example of a trailer harness system



Example of a Main Harness

Example of a Intermediate Main Harness

Examples of a Rear Sill Harness Male Pin Option

A

ABSLampDrop

Female Pin Option

WHT

WHT

WHT

WHT

ULTRA-BLUE-SEAL

ULTRA-BLUE-SEAL

BRN

BRN

BLK

BLK

WHT

WHT



Example of a Front Marker Harness

Example of an ABS Fault Lamp Harness

Example of a Rear Marker Harness

Example of a License Lamp Harness

Example of a Rear I.D. Harness



UBS Molded Plugs Commonly Used in Trailer Harness Applications



Example of a Boat Trailer Harness using the UBS System

Ultimate LED Trailer Light KitPlug-and-Go™ Modular Harness System easily connects to the towing vehicles existing lighting receptacle. This totally sealed, single harness system provides maximum protection from water intrusion and corrosion.



Grote UBS Pigtail Features and Advantages:

•UBSpigtailsareterminatedwiththeslim-line180malebullettofitdirectlyinto the UBS system

•UBSusesDoubleSealTechnologyforbettermatingwiththelamptoeliminate the intrusion of moisture and other contaminant

•UBSincorporatesaGreaseGroovetoeliminatehydrauliceffect •Groteusesexactingscientificinstrumentstomeasurethehardnessor

softness (Durometer) of the PVC material

- Grote uses a 75 durometer-rated material for our male-pin pigtails for a tighter fit on the male-pin terminals

- Grote uses a 55 durometer-rated material for our female plugs to provide a more flexible interface to fit into the female opening and seal down around the outside of that opening

- Grote’s competitors use a hard plastic material for their pigtails which provides little to no flexibility at the point of “interface”, i.e., pigtail to lamp.

•Groteprovidesoneofthemostextensivepigtailofferingsavailable: - Double Seal - Single Seal - Blunt Cut - Ring Terminal - Chassis Ground - Ground Return - Adaptor Plugs to get you from Female to Male; Male to Hard Shell; etc.

Groteprovidesthebestpossible“interface”atthemostcriticaljuncture:theelectrical system to the lamp. There is little that is more important than the mating of the electrical system to the lamp. That is why you will hear much talk about the “interface” between the lamp and the electrical system. This is where the80–20rulewillprevail:ifthereisaproblem,80%ofthetimeitwillbeatthatjuncture in the system.

NOSE BOXES

Grote’s Ultra Nose Box Family Grote offers a range of nose box designs to fit a full range of product performance needs and customer budgets. Together, they offer solutions for solving a range of problems from stress cracks in the box itself, corrosion ingress, and obsolete internal wiring design.

Ultra Pin Nose BoxBigger both in physical size and capacity, Grote’s nose box features 39 pin connections instead of the industry standard 28 and accepts a variety of manufacturers’ plugs. The main receptacle can be swapped out in as little as 10 minutes versus 45 minutes for the old, standard receptacle. The main power cord hatch is replaceable, as is the main receptacle.

•Solvestheproblemofcracked,corrodedandcrammedtrucktrailerjunction boxes.

•Push-onplugfunction. •Durableglass-fillednylonhousing,insert-moldedpinsthatsealout

moisture and corrosive materials and easily replaceable parts.

KeyPoints

Grote once offered a harness creation

program called Ultra Blue

Print

KeyPoints

SlimLine Vs. Standard

SlimLine connectors are typically used for pigtail and

under lamp connections

and are smaller in diameter

Standardconnectors with more stable seal connection used mostly

for connection in to rear sill.

KeyPoints

Durometers measure the hardness of a wide variety of rubber, plastics,

elastomers, foams and

similar material.



NON-ABS

ABS

•Molded,threadedbrassinsertsthatensurethenoseboxislockeddownandaspecial mounting gasket that protects against moisture.

•Replaceable7-pininsertforeasymaintenance •39-pinconnectionseliminatesovercrowdingofwires •Hingeddoorkeepselementsout,whileprovidingeasyaccess

7-Pin Receptacle Insert Repair Kit97900 - Solid Pin97800 - Split Pin

97910 - Door Hinge Repair Kit

Ultra-Pin Receptacle, 4 Hole Mount Nose Box Heavy Bosses and a slanted barrel for drainage gives this zinc die-cast, brass pins box a rugged beginning to a lighting system

•Retainerplate-Highimpact •SolidPin •ExtraHeavyBase •SlantedBarrelforDrainage •Floatingpinsforeasyalignment •Highimpactretainerplate •ZincDie-Cast

POWER CORDS

Power cords are the life line be-tween the truck and the trailer. They deliver the power to run the elec-trical system requirements of the trailer. One of the requirements is the trailer lighting system.

Power cords come in may lengths, gauges, coiled or straight, and a variety connections.

Grote power cords are built to last, not to replace. Repairable power cords invite corrosion. Water wicks into their wiring before you know it. And they’re expensive and time consuming to fix. Grote’s solid core connectors provide an environmentally sealed power cord system. In addition, they’re crush resistant to stand up to the toughest treatment.

Grote pins are drilled from solid brass to resist warping and the need to calibrate the connector to the receptacle.

Features of the Grote UltraLink Power Cord•Plugmanufacturedusingmoldedelastomericmaterialthatresists

crushing, acts as potting that seals solid brass terminals from moisture

87140 - Ultra Nose Box®

87590 - Ultra-Pin Receptacle Four-Hole Mount Nose Box



NOTES

ADDITIONAL RESOURCESThese resources can be acquired online or through the marketing department.

•Plugmoldedwithaspecialadhesivethatbondswithcabletoeliminatetheneedforaspring

•Solidbrassterminalsarecorrosionresistantandprovidessuperiorcurrent-capacitywith minimal voltage drop

•Advancedpolymerjacketingmaterialisdesignedtoperformbetween-55Fto190F•Superiorpowerdeliveryforsingleordoubletrailerconfigurations

exceeding minimum legal lamp requirements •CoiledCordshavegoodrecoilmemory,chemical&abrasionresistance

Grote coil cord features and benefits versus repairable power cords

Corrosion points

Repairable power cords Grote power cords

Solid brass nickel-plated pins

Split-pin terminals

Crush resistant weather-tight epoxy fill

Back is open to corrosion

Wire jacket is molded into plug

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