Harnesses, Pigtails, Nose Boxes, and Power Cords MASTERY STATEMENT:

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1 GROTE TRAINING SERIES Harnesses, Pigtails, Nose Boxes, and Power Cords MASTERY STATEMENT: 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...2 Pigtails...3 Nose Box...10 Power Cords...11 Additional Resources...12

ULTRA-BLUE-SEAL SYSTEM The Modular Plug & Go Connection System from Grote Modular Design The UBS (Ultra-Blue-Seal ) system provides true Plug & Go modular convenience and reliability for trailer

This system is designed to provide maximum voltage from the power source, through the entire system, to the lamp itself.

The modular design means that all UBS components provide positive connectivity no matter what the design function and position on the trailer requires.

2 ULTRA-BLUE-SEAL SYSTEM The Modular Plug & Go Connection System from Grote Modular Design The 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. Durability Every 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. Modular design eliminates cutting and splicing 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 Reliability The 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 Development Grote 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. Interchangeability The 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. Locking seal collar showing the grease fitting Key Points Our goal was to provide a system to meet all of the requirements as put forward by TMC. 2

PIGTAILS Double Seal Technology At the heart of the UBS system is the patented Grote Double Seal feature. It provides double protection from moisture and contaminants.

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.

Dielectric grease added to female terminals and male terminals to Ultra- Blue-Seal System protects against moisture and contaminants.

This hydraulic effect can prevent the plug from being fully seated in the lamp, creating a potential leak path.

3 PIGTAILS Double Seal Technology At 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 Technology The 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 Terminations Grote 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. UBS lamp connection showing Double Seal features and Grease Groves to male-pin lamp *No Hydraulic Effect* Key Points Double seal technology drastically decreases water intrusion and corrosion

4 Patented double seal design adds double protection against moisture and other contaminants. Center grease reservoir protects against hydraulic pressure forcing connection open. UBS offers a fully integrated, modular wiring and lighting system. The.180 male 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. Key Points The Grote UBS system is the first and only complete modular harness-tolamp system on the market today. 7-Conductor Cable: (SAE J1067 and J560) 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.) 5-Conductor Cable: (chassis ground and without auxiliary circuit) Brown Tail and license lamp, and clearance lamps Black Clearance, sidemarker, and identification lamps Yellow Left turn signal lamp Green Right turn signal lamp Red Stop lamps Heavy Duty 7-Conductor Cable System: (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.) 4-Conductor Cable: (boat trailer harness) White Ground Brown Tail and license lamp, and sidemarker lamps Yellow Left turn signal lamp and stop lamp Green Right turn signal lamp and stop lamp For A 12-Volt System Load in Amps For A 6-Volt System Load in Amps WIRE SIZE CHART Length of (Most Distant Light) 10' 20' 30' 40' 50' 60' 70' 80' 90' 100' Cable Size TEMPERATURE CHART Maximum Current Carrying Capacity (For 12 Volts at Listed Temperatures) 120 F 125 F 150 F Amps 13 Amps 9 Amps Amps 15 Amps 11 Amps Amps 19 Amps 14 Amps Amps 23 Amps 17 Amps Amps 32 Amps 24 Amps Amps 42 Amps 31 Amps 4

5 Example of a trailer harness system Forward Main Harness 2 Intermediate Harness 3 Rear Sill Harness 4 Front Marker 5 ABS Fault Lamp 6 Rear Marker 7 License Lamp 8 Rear I.D

6 Example of a Main Harness Example of a Intermediate Main Harness Examples of a Rear Sill Harness Male Pin Option A ABS Lamp Drop WHT Female Pin Option WHT BLK ULTRA-BLUE-SEAL BRN WHT WHT BRN ULTRA-BLUE-SEAL BLK WHT WHT 6

7 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 7

8 UBS Molded Plugs Commonly Used in Trailer Harness Applications 8

Example of a Boat Trailer Harness using the UBS

This totally sealed, single harness system

9 Example of a Boat Trailer Harness using the UBS System Ultimate LED Trailer Light Kit Plug-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. 9

10 Grote UBS Pigtail Features and Advantages: UBS pigtails are terminated with the slim-line180 male bullet to fit directly into the UBS system UBS uses Double Seal Technology for better mating with the lamp to eliminate the intrusion of moisture and other contaminant UBS incorporates a Grease Groove to eliminate hydraulic effect Grote uses exacting scientific instruments to measure the hardness or 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. Grote provides one of the most extensive pigtail offerings available: - 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. Grote provides the best possible interface at the most critical juncture: the electrical 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 the rule will prevail: if there is a problem, 80% of the time it will be at that juncture 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 Box Bigger 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. Solves the problem of cracked, corroded and crammed truck trailer junction boxes. Push-on plug function. Durable glass-filled nylon housing, insert-molded pins that seal out moisture and corrosive materials and easily replaceable parts. Key Points Grote once offered a harness creation program called Ultra Blue Print Key Points Durometers measure the hardness of a wide variety of rubber, plastics, elastomers, foams and similar material. Key Points SlimLine Vs. Standard SlimLine connectors are typically used for pigtail and under lamp connections and are smaller in diameter Standard connectors with more stable seal connection used mostly for connection in to rear sill. 10

Molded, threaded brass inserts that ensure the nose box is locked down and a special mounting gasket that protects against moisture.

easy access 87140 - Ultra Nose Box 7-Pin Receptacle Insert Repair Kit 97900 - Solid Pin 97800 - Split Pin 97910 - Door Hinge Repair Kit Ultra-Pin

lighting system Retainer plate-high impact Solid Pin Extra Heavy Base Slanted Barrel for Drainage Floating pins for easy alignment High impact

the trailer. They deliver the power to run the electrical system requirements of the trailer.

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

And they re expensive and time consuming to fix. Grote s solid core connectors provide an environmentally sealed power cord system.

11 Molded, threaded brass inserts that ensure the nose box is locked down and a special mounting gasket that protects against moisture. Replaceable 7-pin insert for easy maintenance 39-pin connections eliminates overcrowding of wires Hinged door keeps elements out, while providing easy access Ultra Nose Box 7-Pin Receptacle Insert Repair Kit Solid Pin Split Pin 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 Retainer plate-high impact Solid Pin Extra Heavy Base Slanted Barrel for Drainage Floating pins for easy alignment High impact retainer plate Zinc Die-Cast Ultra-Pin Receptacle Four-Hole Mount Nose Box POWER CORDS Power cords are the life line between the truck and the trailer. They deliver the power to run the electrical system requirements of the trailer. One of the requirements is the trailer lighting system. NON-ABS Power cords come in may lengths, gauges, coiled or straight, and a variety connections. ABS 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 Plug manufactured using molded elastomeric material that resists crushing, acts as potting that seals solid brass terminals from moisture 11

Plug molded with a special adhesive that bonds with cable

are corrosion resistant and provides superior

jacketing material is designed to perform between -55 F to

configurations exceeding minimum legal lamp requirements

resistance Grote coil cord features and benefits versus

points Solid brass nickelplated pins Grote power cords

terminals Back is open to corrosion jacket is molded into

12 Plug molded with a special adhesive that bonds with cable to eliminate the need for a spring Solid brass terminals are corrosion resistant and provides superior current-capacity with minimal voltage drop Advanced polymer jacketing material is designed to perform between -55 F to 190 F Superior power delivery for single or double trailer configurations exceeding minimum legal lamp requirements Coiled Cords have good recoil memory, chemical & abrasion resistance Grote coil cord features and benefits versus repairable power cords Repairable power cords Corrosion points Solid brass nickelplated pins Grote power cords Crush resistant weather-tight epoxy fill Split-pin terminals Back is open to corrosion jacket is molded into plug NOTES ADDITIONAL RESOURCES These resources can be acquired online or through the marketing department. 12

POWER CORDS CORDONS D'ALIMENTATION CABLES DE ENERGÍA. 4 ABS Power Cords. 5 Non-ABS Power Cords. 5 ISO Cords. 6 RV Power Cords. 7 Lift Gate Cables

01 4 ABS Power Cords 5 Non-ABS Power Cords 5 ISO Cords 6 RV Power Cords 7 Lift Gate Cables POWER CORDS CORDONS D'ALIMENTATION CABLES DE ENERGÍA 2 ELECTRICAL CONNECTION AND ACCESSORIES CATALOG 1.800.268.5612