HARNESS SYSTEMS. Harness Systems & Accessories

Transcription

1 HR HRNESS SYSTEMS Truck-Lite Full Line Product Catalog Harness Systems & ccessories 206

2 Truck-Lite Full Line Product Catalog HRNESS SYSTEMS HR Harness Systems & ccessories Sockets & Plugs Series Plug Together Harnesses Series Super System Harnesses Junction Boxes, Receptacle & ccessories Trailer Cords

3 HR SOCKETS & PLUGS Truck-Lite Full Line Product Catalog HOW TO SELECT SIZE OF ELECTRIC CBLE Voltage drop is the primary consideration in selecting the proper electrical wire size. The length of wire in a circuit is the major contributing factor to voltage drop. The table below may be used in determining adequate wire gauge sizes for specific lengths of cable when the amperage requirements are known. Example: lamp is 38 ft. from the power source and requires 10 amperes. This figure, when rounded upwards to the nearest column heading given in the table, is 40 ft. The wire gauge in the 40-ft. Column corresponding to 10 amperes is No. 12. Total length of cable in circuit from battery to most distant lamp 12 Volt System mperes (pprox.) Up To 30 Feet 40 Feet 50 Feet 60 Fee 80 Feet 100 Feet 120 Feet Gauge Gauge Gauge Gauge Gauge Gauge Gauge *Recommended minimum wire gauge size for stop light and ground circuits. Stop Light (Red) Ground (White) Single trailer (up to 50 length) 12 Gauge 10 Gauge Doubles trailer (2-28 lengths) 12 Gauge 10 Gauge Doubles trailer (2-40 lengths) 10 Gauge 8 Gauge Triples trailer (3-28 lengths) 10 Gauge 8 Gauge Cable size gauge no. (Copper) 20 Ga. 18 Ga. 16 Ga. 14 Ga. 12 Ga. 10 Ga. 8 Ga. length of wire in feet 10 Ft. 10 Ft. 10 Ft. 10 Ft. 10 Ft. 10 Ft. 10 Ft. Maximum current carrying capacity with 0.5 volt drop 4.74 mps 7.53 mps mps mps mps mps mps wire resistance ohms (Ω) per foot Ω /ft Ω /ft Ω /ft Ω /ft Ω /ft Ω /ft Ω /ft. Note: This table gives you the resistance of wire per foot so with ohms law V=I x R you can calculate voltage drops on any of the above wire gauges at any current level and length. For example, voltage drop in 50 ft. 10 WG wire with 20 amp load is V=20 amp x ( Ω /ft.) x 50 ft. = 1.03 volts. Be sure to include both the positive and negative leads when calculating total wire length. SE J560 Standards Conductor Identification Wire Color Lamp and Signal Circuits Wht White Ground return to towing vehicle Blk *Black Clearance, side marker & license plate lamps Yel Yellow Left hand turn signal & hazard signal lamps Red Red Stop lamps and antilock devices Grn Green Right hand turn signal & hazard signal lamps Brn *Brown Tail, clearance, side marker lamps & identification lamps Blu Blue uxiliary/bs power *It is recommended to balance the circuits as practicable. Voltage Drop/Foot/mpere 20 GUGE WIRE 18 GUGE WIRE WIRE SIZE 208 Voltage Drop Per Foot GUGE 18 GUGE GUGE GUGE 12 GUGE GUGE WIRE amperes 16 GUGE WIRE 14 GUGE WIRE 12 GUGE WIRE 10 GUGE WIRE

4 Truck-Lite Full Line Product Catalog SOCKETS & PLUGS HR LED Fit N Forget Marker Clearance Plugs Keeps water, salt & other corrosives from LED lamps Combine with LED lamps for Lifetime Lighting Warranty eligibility Tin plated brass bullets/ receptacles Ground 11.5 P/E connector # White 2 M/C 11.5 P/E connector # Black Ground 4.5 #6 ring terminal White 2 M/C 5 Heat shrink butt splice Black Ground 4.5 #6 ring terminal White 2 M/C molded bullet Black Ground 4.5 #10 ring terminal White 2 M/C molded bullet Black Ground 4.5 #6 ring terminal White 2 M/C molded bullet Black Ground shunt device White 2 M/C shunt device Black Ground molded bullet White 2 M/C molded bullet Black 9/16 hole Ground molded (slim) bullet White 2 M/C molded (slim) bullet Black Ground molded (slim) bullet White 2 M/C molded (slim) bullet Brown Ground molded (slim) bullet White 2 M/C molded (slim) bullet Brown Ground 5 Heat shrink butt splice White 2 M/C 5 Heat shrink butt splice Black LED Fit N Forget Marker Clearance dapter Plug Keeps water, salt & other corrosives from LED lamps Combine with LED lamps for Lifetime Lighting Warranty eligibility Used to dapt LED lamps to conventional plug harness systems ; tin plated brass terminals Ground 4 White 2 M/C 4 Black Marker Clearance Plugs For use in space limited areas Tin plated brass terminals Ground molded receptacle White 2 M/C molded receptacle Black Ground molded bullet White 2 M/C molded bullet Black Ground molded bullet White 2 M/C molded bullet Black Ground 7 #6 ground terminal White 2 M/C 6.5 6/32 wire strip Black Ground 12 #10 ring terminal White 2 M/C 12 6/32 wire strip Black Ground 18 #10 ring terminal White 2 M/C 18 6/32 wire strip Black Ground 6.5 #10 ring terminal White 2 M/C 7 6/32 wire strip Black Ground 6 #6 ground clip White 2 M/C 11 6/32 wire strip Black 209

5 HR SOCKETS & PLUGS Truck-Lite Full Line Product Catalog Ground 6.5 #10 ring terminal White 2 M/C 6.5 6/32 wire strip Black Right ngle Marker Clearance Plugs Ground 6 #10 ring terminal White 2 M/C molded bullet Black Right angle design for use in space limited areas Tin plated brass terminals Ground shunt device White 2 M/C shunt device Black Ground 12 #10 ring terminal White (Cream) 2 M/C 12 12/32 wire strip Black Marker Clearance Socket ssembly For use with 18300R/Y & bulb replaceable lamps Bulb not included 18 gauge wires Ground 7.5 blunt cut Black 2 M/C 7.5 blunt cut Black Ground 7.5 #10 ring terminal White 2 M/C 7.5 6/32 wire strip Black Model 19 Plugs For use with Model 19 incandescent lamps Ground molded receptacle Black 2 M/C molded bullet Black Ground 7.5 P/E Connector # White 2 M/C 7.5 P/E Connector # Black Hot Wire 6 6/32 wire strip Black Hot Wire molded bullet Black M/C 12 6/32 wire strip Black M/C 48 6/32 wire strip Black M/C molded bullet Black M/C molded bullet Black Super 21 Plugs For use with Super 21 incandescent lamps, tin plated brass terminals M/C shunt device Black 210

6 Truck-Lite Full Line Product Catalog SOCKETS & PLUGS HR LED Fit N Forget Identification Harness Keeps water, salt & other corrosives from LED lamps Combine with LED lamps for Lifetime Lighting Warranty eligibility Tin plated brass bullets/receptacles Ground 22 #6 ground terminal White (6 ctr) 2 M/C molded bullet Black Ground 22 #6 ground terminal White (6 ctr) 2 M/C molded bullet Black Ground 27 #6 ground terminal White (9 ctr) 2 M/C molded bullet Black Ground 27 #6 ground terminal White (9 ctr) 2 M/C molded bullet Black Ground 22 #6 ground terminal White (6 ctr) 2 M/C molded receptacle Black Ground 27 #6 ground terminal White (9 ctr) 2 M/C molded receptacle Black Ground molded bullet White (6 ctr) 2 M/C molded bullet Black Ground molded bullet White (9 ctr) 2 M/C molded bullet Black Ground 23 Heat shrink butt splice White (6 ctr) 2 M/C 23 Heat shrink butt splice Black Identification Harness For use with incandescent lamp identification bar 14 gauge GPT wire Tin plated brass terminals Ground 22.5 #10 ring terminal White (8 ctr) 2 M/C 26 11/32 wire strip Black Ground 28 #10 ring terminal White (11 ctr) 2 M/C 32 11/32 wire strip Black Ground 22.5 #10 ring terminal White (8 ctr) 2 M/C molded bullet Black LED Fit N Forget Marker Clearance Multiple Plug Harness Ground 88 Blunt cut White (5 plugs w/10 ctr) (10 ctr) 2 M/C 88 Blunt cut Brown Keeps water, salt & other corrosives from LED lamps Combine with LED lamps for Lifetime Lighting Warranty eligibility Brass terminals For use with bumpers & skirts Ground 108 Blunt cut White (7 plugs w/10 ctr) (10 ctr) 2 M/C 108 Blunt cut Brown Ground 128 Blunt cut White (9 plugs w/10 ctr) (10 ctr) 2 M/C 128 Blunt cut Brown Ground 148 Blunt cut White (11 plugs w/10 ctr) (10 ctr) 2 M/C 148 Blunt cut Brown Ground 61.5 Blunt cut White (4 plugs w/4 ctr) (4 ctr) 2 M/C 61.5 Blunt cut Brown 211

7 HR 212 SOCKETS & PLUGS Truck-Lite Full Line Product Catalog (6 plugs w/4 ctr) Ground 70 2 M/C 70 Blunt cut White Blunt cut Brown (8 plugs w/4-1/2 ctr) Ground 79 2 M/C 79 Blunt cut White Blunt cut Brown (10 plugs w/4 ctr) Ground 88 2 M/C 88 Blunt cut White Blunt cut Brown LED Fit N Forget Marker Clearance Multiple Plug Harness Keeps water, salt & other corrosives from LED lamps Combine with LED lamps for Lifetime Lighting Warranty e ligibility 16 gauge GPT wire Brass t erminals For use with bumpers & skirts (5 plugs w/10 ctr) Ground 88 2 M/C 88 Blunt cut White Blunt cut Brown Marker Clearance Multiple Plug Harness (7 plugs w/10 ctr) Ground M/C 108 Blunt cut White Blunt cut Brown (9 plugs w/10 ctr) Ground M/C 128 Blunt cut White Blunt cut Brown For use with bumpers & skirts 16 gauge GPT wire Tin plated or brass terminals (11 plugs w/10 ctr) Ground M/C 148 Blunt cut White Blunt cut Brown (4 plugs w/4 ctr) Ground 60 2 M/C 60 Blunt cut White Blunt cut Brown (6 plugs w/4 ctr) Ground 68 2 M/C 68 Blunt cut White Blunt cut Brown (8 plugs w/4 ctr) Ground 76 2 M/C 76 Blunt cut White Blunt cut Brown (10 plugs w/4 ctr) Ground 84 2 M/C 84 Blunt cut White Blunt cut Brown (100 plugs w/7.5 ctr) Ground 76 2 M/C 76 Blunt cut White Blunt cut Black (200 plugs w/12 ctr) Ground 84 2 M/C 84 Blunt cut White Blunt cut Black

8 Truck-Lite Full Line Product Catalog SOCKETS & PLUGS HR License Lamp Plugs Use with Molded 17 incandescent license lamps Tin plated brass terminals License 18 Blunt cut Black (90 degree plug) License molded bullet Black (90 degree plug) License 18 6/32 wire strip Black (straight plug) LED Fit N Forget Replacement Connector Replaces damaged plugs or used for retrofitting Replacement connector Note: Recommend using crimping tool Includes 3 terminals, 3 seals and connector LED Fit N Forget Stop/Turn/Tail Plug Keeps water, salt & other corrosives from LED lamps ; tin plated brass terminals Combine with LED lamps for Lifetime Lighting Warranty eligibility Ground 8 #10 ring terminal White 2 Tail 8 6/32 wire strip Black 3 Stop/Turn 8 6/32 wire strip Red Ground 6-1/2.180 molded bullet White 2 Tail 6-1/2.180 molded bullet Black 3 Stop/Turn 6-1/2.180 molded bullet Red LED Fit N Forget Stop/Turn/Tail dapter Plugs Keeps water, salt & other corrosives from LED lamps ; tin plated brass terminals Combine with LED lamps for Lifetime Lighting Warranty eligibility Converts one stop/turn/tail plug into one LED Fit N Forget stop/turn/tail plug Ground 8 White 2 Tail 8 Black 3 Stop/Turn 8 Red Converts one LED Fit N Forget stop/turn/tail plug into one incandescent Ground 8-5/8 White 2 Tail 8-5/8 Black 3 Stop/Turn 8-5/8 Red Converts one stop/turn/tail plug into two Fit N Forget stop/turn/tail plugs Ground 8 White 2 Tail 8 Black 3 Stop/Turn 8 Red Converts one LED Fit N Forget stop/turn/tail plug into two Ground 12 White 2 Tail 12 Brown 3 Stop/Turn 12 Red Converts single male-pin style stop/turn/tail plug into two LED Fit N Forget plugs Ground 13 White 2 Tail 13 Brown 3 Stop/Turn 13 Red 213

9 HR SOCKETS & PLUGS Truck-Lite Full Line Product Catalog Converts single male-pin style stop/turn/tail plug into a LED Fit N Forget stop/turn/tail plug LED Fit N Forget Stop/Turn/Tail dapter Plugs Ground 8 White 2 Tail 8 Black 3 Stop/Turn 8 Red Converts one stop/turn/tail plug into one LED Fit N Forget stop/turn/tail & one LED Fit N Forget M/C plug Keeps water, salt & other corrosives from LED lamps ; tin plated brass terminals Combine with LED lamps for Lifetime Lighting Warranty eligibility Ground 19 White 2 Tail 19 Brown 3 Stop/Turn 19 Red Ground 11 #10 ring terminal White 2 Tail 11 6/32 wire strip Black 3 Stop/Turn 11 6/32 wire strip Red Ground 10 #10 ring terminal White 2 Tail molded bullet Black 3 Stop/Turn molded bullet Red Ground 10 #10 ring terminal White 2 Tail molded bullet Black 3 Stop/Turn molded bullet Red Stop/Turn/Tail Plugs For use with dual function sealed incandescent lamps is popular on UPS vehicles Tin plated brass terminals Ground 49 #10 ring terminal White 2 Tail 49 6/32 wire strip Black 3 Stop/Turn 49 6/32 wire strip Red Ground 11 #10 ring terminal White 2 Tail 11 6/32 wire strip Black 3 Stop/Turn 11 6/32 wire strip Red Ground 14 #10 ring terminal White 2 Tail molded bullet Black 3 Stop/Turn molded bullet Red Ground molded bullet White 2 Tail molded bullet Black 3 Stop/Turn molded bullet Red Right ngle Stop/ Turn/Tail Plugs For use with dual function sealed incandescent lamps Tin plated brass terminals 214

10 Truck-Lite Full Line Product Catalog SOCKETS & PLUGS HR LLV Right ngle Stop/Turn/Tail Plugs Park 19 3/4 Weather-Pack Connector White 2 Ground 19 3/4 P/E # Black 3 Turn 19 3/4 Red For the U.S. Postal Service Long-Life Vehicle incandescent lamps 18 gauge SXL wires Park 4 Weather-Pack Connector White 2 Ground 4 P/E # Black 3 Turn 4 Red Park 4 Metri-Pack Connector White 2 Ground 4 P/E # Brown 3 Turn 4 Red Stop/Turn/Tail Socket ssembles For use with Model 40 bulb replaceable lamps Bulb #1157 included Tin plated brass terminals Ground 7 1/2 #6 ring terminal White 2 Tail 8 6/32 wire strip Black 3 Stop/Turn 8 6/32 wire strip Red For use with Model 60 & Model 91 bulb replaceable lamps Tin plated brass terminals Bulb #3157 included Ground 7 1/2 #10 ring terminal White 2 Tail 8 6/32 wire strip Black 3 Stop/Turn 8 6/32 wire strip Red Right ngle Stop/ Turn/Tail Plugs with dapter Y adapter plug used to accommodate additional side marker requirements Designed to adapt with Truck-Lite jumper harness part numbers 50321, 50322, & Ground 6 White 2 Tail/Marker 6 Brown 3 Stop/Turn 6 Red Y adapter plug used to accommodate additional stop/turn/tail requirements Designed to adapt with 88 series harness Ground 6 White 2 Tail/Marker 6 Brown 3 Stop/Turn 6 Red Converts one incandescent stop/turn/tail plug into two Ground 10 White 2 Tail 10 Brown 3 Stop/Turn 10 Red Ground 18 White 2 Tail 18 Brown 3 Stop/Turn 18 Red 215

11 HR SOCKETS & PLUGS Truck-Lite Full Line Product Catalog Converts single male-pin style stop/turn/tail plug into a conventional two plug mail harness to mate with most incandescent stop/turn/tail lamps Ground 10 White 2 Tail 10 Brown 3 Stop/Turn 0 Red Right ngle Stop/ Turn/Tail Plugs with dapter Ground 8 Metri-Pack Connector White 2 Turn 8 P/E # Red Converts single male-pin style stop/turn/tail plug into a conventional single plug male harness which mates with most incandescent stop/turn/tail lamps Ground 5 White 2 Tail 5 Black 3 Stop/Turn 5 Red Converts one stop/turn/tail plug into one stop/turn/tail plug & one 19 long marker clearance plug Ground 12 White 2 Tail 12 Brown 3 Stop/Turn 12 Red Ground 12 White (L.H.) 2 Tail 6 Brown/Black 3 Turn 6 Yellow 4 Stop 6 Red Ground 12 White (R.H.) 2 Tail 6 Black 3 Stop 6 Red 4 Turn 6 Green Stop/Turn/ Tail Plugs with dapter For use with part numbers 41005R & 41006R Keeps water, salt & corrosives from LED lamps Combine with LED lamps for Lifetime Lighting Warranty eligibility Ground 8 #6 ground terminal White 2 Stop/Turn 8 6/32 wire strip Red LED Fit N Forget Stop/Turn Plug Tin plated brass terminals Ground molded bullet White 2 Stop/Turn molded bullet Red Keeps water, salt & corrosives from LED lamps Combine with LED lamps for Lifetime Lighting Warranty eligibility Converts one incandescent stop/turn/tail plug into one LED stop/turn/tail plug Ground 8 White 2 Stop/Turn 8 Red LED Fit N Forget Stop/Turn dapter Tin plated brass terminals 216

12 Truck-Lite Full Line Product Catalog SOCKETS & PLUGS HR Stop/Turn Plugs Tin plated brass terminals For use with single function sealed incandescent stop/turn lamps is popular on UPS vehicles Ground 11 #10 ring terminal White 2 Stop/Turn 11 6/32 wire strip Red Ground 10 #10 ring terminal White 2 Stop/Turn molded bullet Red Right ngle Stop/ Turn Plugs Tin plated brass terminals For use with single function sealed incandescent stop/turn lamps Ground 10 1/2 #10 ring terminal White 2 Stop/Turn 10 1/4 6/32 wire strip Red LLV Right ngle Stop/Turn Plugs 18 gauge SXL wire For the U.S. Postal Service Long-Life Vehicle incandescent lamps 18 gauge SXL wires Ground 4 Metri-Pack Connector Brown 2 Stop/Turn 4 P/E # Red Ground 4 Metri-Pack Connector Brown 2 Stop 4 P/E # Red Stop/Turn Socket ssemblies For use with Model 40 bulb replaceable lamps Bulb #1156 included Tin plated brass terminals Ground 7 1/2 #6 ring terminal White 2 Stop/Turn 7 6/32 wire strip Red For use with Model 60 & Model 91 bulb replaceable lamps Bulb #3157 included Ground 8 #10 ring terminal White 2 Stop/Turn 10 6/32 wire strip Red Right ngle Tail Plug For using an incandescent stop/turn/tail lamp as marker only Ground 11 #10 ring terminal White 2 Tail 11 6/32 wire strip Black LLV Right ngle Tail Plug 18 gauge SXL wire For the U.S. Postal Service Long-Life Vehicle incandescent lamps Ground 6 Metri-Pack Connector Brown 2 Tail 6 P/E # Red 217

13 HR SOCKETS & PLUGS Truck-Lite Full Line Product Catalog With in-line guide pin for lamps with indexing, bayonet, candelabra type bases (e.g. nos. 1157, 1034 bulbs) Pigtails 9101 Double contact 8 wire For lamps with bayonet, candelabra type bases (e.g. nos. 67, 1073, 1156 bulbs) Pigtails 9102 Single contact 8 wire Packard Metri-Pack connector eliminates corrosion & salt creep easy hook-up 21 length, 18 gauge wire Signal Lamp Plugs series connector Mates with new Male Pin series lamps Male Pin Plugs Plug for marker lamps, 2 pin right angle Plug for stop/tail lamps, 2 pin straight Plug for stop/turn/tail lamps, 3 pin straight Plug for marker lamps,.180 bullets Five pin Packard Metri-Pack # connection to lamps with two (Dual-Pack) connector sockets Used for installation of OEM rear signal lamps where harness is routed down one frame rail of vehicle Signal Lamp Plugs Series dual-pack connector Replacement jumper harness for Daisy Chain lamps supplied as original equipment on Navistar, Volvo & Freightliner vehicles P/E # Signal Lamp Plugs series Daisy Chain jumper harness 218

14 Truck-Lite Full Line Product Catalog HRNESS SYSTEMS HR 6 Conductor Main Cable Dim cond. main cable, 1-10, 5-12 gauge 720 Dimensions indicate standard stocked length harness. Custom length available in 12 increments Conductor Main Cable Dim cond. main cable, 1-10, 6-12 gauge cond. BS main cable, 1-8, 2-10, 4-12 gauge Conductor Main Cable Dim Dim B cond. main cable, 1-10, 6-12 gauge cond. main cable, 1-8, 2-10, 4-12 gauge B YLW WHT BRN 5.00 GRN WHT BRN Main Retro Fit/Repair Harness Dim Main retro fit/repair harness x 12 shrink tube, 1 piece Rear 7-Way dapter Harness Rear 7-way adapter harness Rear 7-Way dapter BS Power Harness Rear 7-way adapter BS power harness

15 HR HRNESS SYSTEMS Truck-Lite Full Line Product Catalog 7 Conductor Main Cable w/nose Box Dim cond. main cable, 1-8, 2-10, 4-12 gauge Note: Uses nosebox Dimensions indicate standard stocked length harness. Custom length available in 12 increments. 7 Conductor Main Cable w/nose Box & Jumpers 8.75 Dim cond. main cable, 1-8, 2-10, 4-12 gauge 27 Note: Uses nosebox 7 Conductor Main Cable Dim cond. main cable, 1-8, 2-10, 4-12 gauge Conductor Main Cable w/center Turn Breakouts GRN BRN WHT Dim Dim B cond. main cable, 1-8, 2-10, 4-12 gauge B BRN WHT YLW

16 Truck-Lite Full Line Product Catalog HRNESS SYSTEMS HR 7 Conductor Nose Box Harness Dim cond. main cable, 1-8, 2-10, 4-12 gauge 72 Note: Uses nosebox 5.00 Dimensions indicate standard stocked length harness. Custom length available in 12 increments. 7 Conductor Nose Box Repair Harness Dim cond. main cable, 1-8, 2-10, 4-12 gauge 24 Note: Uses nosebox Rear 7-Way dapter Harness way adapter harness Rear 7-Way dapter Harness way adapter harness Rear Nose Box Jumper Dim cond. main cable, 1-8, 2-10, 4-12 gauge 14 Note: Uses nosebox 221

17 HR HRNESS SYSTEMS Truck-Lite Full Line Product Catalog Rear Sill Harness LED Rear Sill Harness Rear sill harness Rear sill harness w/o mid-turn dropouts LED rear sill harness LED rear sill harness w/o mid-turn dropouts SHOWN SHOWN Rear Sill Harness with uxiliary Dropouts LED Rear Sill Harness with uxiliary Dropouts Rear sill harness w/auxiliary red/ blue/white dropouts right hand LED rear sill harness w/ auxiliary red/blue/white dropouts right hand Wire Color Coding For ll Rear Sill Dropouts Center (BS Power) 222 left hand Red Blue White Right Hand Green White Brown Black Left Hand Yellow White Brown Black (1) Single - Stop (1) Single - uxiliary/bs (1) Single - Ground (1) Single RH Turn (2) Double Ground (1) Double Marker or Tail (1) Double License or Marker (1) Single LH Turn (2) Double Ground (1) Double Marker or Tail (1) Double License or Marker left hand

18 Truck-Lite Full Line Product Catalog HRNESS SYSTEMS HR BS Power Harness Dim cond. flat cable, 12 gauge Dimensions indicate standard stocked length harness. Custom length available in 12 increments conductor flat cable BS Fault Lamp Jumper Harness 6.00 Dim cond. flat cable, 14 gauge conductor flat cable BS LED Fault Lamp Jumper Harness Dim cond. flat cable, 14 gauge conductor flat cable Single Plug Marker/Clearance Harness 2.00 Dim cond. flat cable, 14 gauge brown/white cond. flat cable, 14 gauge brown/white 36 2 conductor flat cable Marker/clearance harness black/white Marker/clearance harness brown/white Marker/Clearance Jumper Harness 5.00 Dim Marker/clearance jumper harness, brown/white Marker/clearance jumper harness, brown/white Marker/clearance jumper harness, brown/white Marker/clearance jumper harness, brown/white Marker/clearance harness w/jumper plug brown/white

19 HR HRNESS SYSTEMS Truck-Lite Full Line Product Catalog Dimensions indicate standard stocked length harness. Custom length available in 12 increments. LED Single Plug Marker/Clearance Harness Dim cond. flat cable, 16 gauge, black/white 12 2 conductor flat cable cond. flat cable, 14 gauge brown/white LED Marker/Clearance Jumper Harness Dim LED marker/clearance harness w/jumper plug brown/white Marker/clearance jumper harness, brown/white Marker/clearance jumper harness, brown/white Marker/clearance jumper harness, brown/white Marker/clearance jumper harness, brown/white Three Plug Identification Harness Dim Lower ID harness brown/white Upper ID harness brown/white Three Plug Identification Harness Dim Lower ID harness brown/white

20 Truck-Lite Full Line Product Catalog HRNESS SYSTEMS HR LED Three Plug Identification Harness Dim LED lower ID harness black/white LED upper ID harness black/white LED lower ID harness black/white with centers 60 Dimensions indicate standard stocked length harness. Custom length available in 12 increments Four Plug Identification / License Harness Dim Lower ID/license lamp harness brown/white Seven Plug Identification / Marker Harness Dim Lower ID/marker harness brown/white 60 LED Four Plug Identification / License Harness Dim LED lower ID/incandescent license harness black/white 60 3 Plug Plug-In Identification Harness cond. flat cable, 14 gauge, black/white Plug Plug-In Identification Harness cond. flat cable, 14 gauge, black/white

21 HR HRNESS SYSTEMS Truck-Lite Full Line Product Catalog Dimensions indicate standard stocked length harness. Custom length available in 12 increments. 6 Plug Plug-In Identification Harness cond. flat cable, 14 gauge, black/white Plug Plug-In Identification Harness cond. flat cable, 14 gauge, black/white Plug Plug-In Identification Harness cond. flat cable, 14 gauge, black/white From Rear Sill Mid Turn Harness Dim Custom Dim Mid turn/marker harness, L.H Mid turn/marker harness, R.H conductor flat cable 3.00 From Rear Sill LED Mid Turn Harness Dim Custom Dim LED mid turn/marker harness, R.H LED mid turn/marker harness, L.H conductor flat cable 226

22 Truck-Lite Full Line Product Catalog HRNESS SYSTEMS HR LED Marker/Clearance Jumper Feed Harness Dim Marker/clearance jumper feed harness 192 Dimensions indicate standard stocked length harness. Custom length available in 12 increments. Marker/Clearance Jumper Feed Harness Marker/clearance jumper feed harness 12 Dim 2 conductor flat cable Marker/Clearance Jumper Feed Harness Dim Marker/clearance jumper feed harness conductor flat cable Chassis Ground Components Identification / License Harness Dim Front marker/clearance harness Front marker/clearance hot wire Upper ID harness Dim License lamp jumper harness Rear marker/clearance jumper harness Lower ID/license jumper harness Upper ID jumper harness Marker/clearance jumper harness Marker/clearance jumper harness 24 Note: Harnesses in this section feature 14 gauge HDT black wire (.150 diameter). Dim Double receptacle jumper harness Double receptacle jumper harness Double receptacle jumper harness Double receptacle jumper harness Double receptacle jumper harness Double receptacle jumper harness Double receptacle jumper harness Double receptacle jumper harness Double receptacle jumper harness Double receptacle jumper harness filler plug 227

23 HR HRNESS SYSTEMS Truck-Lite Full Line Product Catalog Van Trailer Harness System Internal Ground Part No. LED Part No. Qty Description Conductor Main Cable, Rear Sill Harness Upper ID Harness, Rear Marker Lamp Harness, License Lamp Harness, Front M/C, Harness, BS Power Jumper Harness, BS Fault Lamp Jumper Harness /53 Van Trailer Harness System Internal Ground Part No. LED Part No. Qty Description Conductor Main Cable, Rear Sill Harness Upper ID Harness, Rear Marker Lamp Harness, License Lamp Harness, Front M/C, Harness, Mid Turn Harness, Left Side, Mid Turn Harness, Right Side, BS Power Jumper Harness, BS Fault Lamp Jumper Harness 8 48 Flatbed Trailer Harness System Internal Ground Part No. LED Part No. Qty Description Conductor Main Cable, Rear Sill Harness Lower ID Harness, Rear Marker Lamp Harness, Mid Turn Harness, Left Side, Mid Turn Harness, Right Side, License Lamp Harness Front M/C, Harness BS Power Jumper Harness, BS Fault Lamp Jumper Harness 228

24 Truck-Lite Full Line Product Catalog HRNESS SYSTEMS HR 6 Conductor Main Cable Dimensions indicate standard stocked length harness. range of custom length harnesses are available in 12 increments. Contact Customer Service for lead time and availability. Part No Dim Part No Dim Part No Dim gauge, 5-12 gauge 7 Conductor Main Cable Part No Dim Part No Dim Part No Dim gauge, 2-10 gauge, 4-12 gauge Single Plug Turn/Tail Harness Dim Custom Dim R.H. turn/tail harness, white/green/brown L.H. turn/tail harness, white/yellow/brown conductor flat cable LED Single Plug Stop/Turn/Tail Harness Dim Custom Dim R.H. turn/tail harness, white/green/brown L.H. turn/tail harness, white/yellow/brown Stop/tail harness, white/red/black conductor flat cable Single Plug Stop/Turn/Tail Harness Dim Custom Dim Stop/turn/tail harness, white/red/black Stop/turn/tail harness, white/red/black R.H. turn/marker harness, white/green/brown L.H. turn/marker harness, white/yellow/brown R.H. turn/marker harness, white/green/brown L.H. turn/marker harness, white/yellow/brown conductor flat cable 229

25 HR HRNESS SYSTEMS Truck-Lite Full Line Product Catalog Dimensions indicate standard stocked length harness. range of custom length harnesses are available in 12 increments. Contact Customer Service for lead time and availability. Stop/Turn/Tail Harness Diameter 5 conductor round cable Dim Custom Dim R.H. stop/turn/tail harness L.H. stop/turn/tail harness R.H. stop/turn/tail harness L.H. stop/turn/tail harness LED Stop/Turn/Tail Harness Diameter 5 conductor round cable Dim Custom Dim R.H. stop/turn/tail harness L.H. stop/turn/tail harness BS Power Jumper Harness Dim Custom Dim BS power harness Connect from nosebox or 50-series junction box 3 conductor 12 gauge flat cable for use with compression fitting to connect with 50-series junction box 3 Plug Stop/Turn/Tail and Back-Up Harness 5 conductor round cable Dim Custom Dim R.H. 3 plug stop/turn/tail harness L.H. 3 plug stop/turn/tail harness L.H. 2 plug S/T/T & back-up harness R.H. 2 plug S/T/T & back-up harness LED 3 Plug Stop/Turn/Tail Harness 5 conductor round cable Dim Custom Dim R.H. 3 plug S/T/T harness L.H. 3 plug S/T/T harness Diameter Stop/Turn/Tail and Side Marker Harness conductor round cable Dim Custom Dim R.H. S/T/T & side marker harness L.H. S/T/T & side marker harness R.H. S/T/T & side marker harness L.H. S/T/T & side marker harness

26 Truck-Lite Full Line Product Catalog HRNESS SYSTEMS HR Dimensions indicate standard stocked length harness. range of custom length harnesses are available in 12 increments. Contact Customer Service for lead time and availability. LED Stop/Turn/Tail and Side Marker Harness 1.5 Diameter Dim Custom Dim R.H. S/T/T & rear marker harness L.H. S/T/T & rear marker harness conductor round cable Stop/Turn/Tail and Side Marker Harness Dim Custom Dim R.H. S/T/T & side marker harness L.H. S/T/T & side marker harness conductor round cable Single Plug Marker/Clearance Harness Dim Custom Dim Marker/clearance harness, black/white Marker/clearance harness, black/white Marker/clearance harness, black/white Marker/clearance harness, brown/white Marker/clearance harness, brown/white Marker/clearance harness, brown/white LED Single Plug Marker/Clearance Harness Dim Custom Dim Marker/clearance harness, black/white Marker/clearance harness, black/white Marker/clearance harness, brown/white Marker/clearance harness, brown/white LED Two Plug Marker/Clearance Harness Dim Custom Dim plug, brown/white plug, brown/white Dim Custom Dim plug, brown/white Three Plug Identification Harness Dim Custom Dim Lower, brown/white Upper, brown/white Upper, brown/white

27 HR HRNESS SYSTEMS Truck-Lite Full Line Product Catalog Dimensions indicate standard stocked length harness. range of custom length harnesses are available in 12 increments. Contact Customer Service for lead time and availability. Marker/Clearance Jumper Harness Dim Custom Dim Lower, black/white Upper, black/white Identification & License Lamp Harness Dim Custom Dim Lower, brown/white Upper, brown/white Upper, brown/white Upper Marker and Identification Harness Dim Custom Dim Upper, brown/white LED Upper Marker and Identification Harness Dim Custom Dim Upper, brown/white Marker/Clearance Jumper Harness Dim Custom Dim Marker/clearance harness, brown/white LED Marker/Clearance Jumper Harness Dim Custom Dim Marker/clearance harness, brown/white Marker/Clearance Jumper Harness Dim Custom Dim Marker/clearance jumper harness, brown/white Dim Marker/clearance jumper harness, brown/white 112 LED Marker/Clearance Jumper Harness Dim Custom Dim Marker/clearance jumper harness, brown/white Marker/clearance jumper harness, brown/white Marker/clearance jumper harness, brown/white LED Marker/Clearance Jumper Harness Dim Custom Dim Marker/clearance jumper harness, brown/white

28 Truck-Lite Full Line Product Catalog HRNESS SYSTEMS HR 28 Foot 50 Series Super System Harness 6 6 Part Number Qty Description Conductor Main Cable R.H. Stop/Turn/Tail & Side Marker Harness L.H. Stop/Turn/Tail & Side Marker Harness Identification Lamp Harness License Lamp Harness Front Marker/Clearance Lamp Harness Junction Box Kit /8 I.D. Compression Fitting /2 I.D. Compression Fitting /4 I.D. Compression Fitting Conductor Main Cable * 1 7 Way Receptacle - Front 13 * 1 7 Way Receptacle - Rear BS Power Jumper Harness BS Fault Lamp Jumper Harness The sketch illustrates a typical 28 dry van using Truck-Lite s lighting and harness system. The list demonstrates how each harness system can be used to meet a 28 application. The part numbers listed are recommendations and substitutions may be made to customize each system to your exact needs. 48 Foot 50 Series Super System Harness Part Number Qty Description Conductor Main Cable R.H. Stop/Turn/Tail & Side Marker Harness L.H. Stop/Turn/Tail & Side Marker Harness Identification Lamp Harness License Lamp Harness R.H. Center Turn & Marker/ Clearance Lamp Harness L.H. Center Turn & Marker/ Clearance Lamp Harness Front Marker/Clearance Lamp Harness Junction Box Kit /8 Compression Fitting /2 Compression Fitting /4 Compression Fitting Oval Hole Compression Fitting 14 * 1 7 Way Receptacle BS Power Jumper Harness BS Fault Lamp Jumper Harness The sketch illustrates a typical 48 dry van using Truck-Lite s lighting and harness system. The list demonstrates how each harness system can be used to meet a 48 application. The part numbers listed are recommendations and substitutions may be made to customize each system to your exact needs. 233

29 HR JUNCTION BOXES & RECEPTCLES Truck-Lite Full Line Product Catalog 50% more harness ports; alleviates need for multiple boxes while allowing additional harness systems and increased lighting Larger box makes it easier to work on internal connections Clear lid offers easy viewing of connections, saving time when identifying lighting system problems Dual Dogbone ground strap feature allows 4 terminals to be common, replacing need for multiple junction boxes and saving costs Silicone gasket on lid helps eliminate damage from moisture and corrosives High impact, chemical resistant, approved insulated plastic provides long life, eliminates time & money for repair & replacement Mounted by 4 eyelet reinforced holes in base of box for increased durability Contains 12 pre-tapped holes to accept compression fittings or filler plugs for greater configuration versatility Uses 50 Series compression fittings or filler plugs (6 included in kit) 5.47 Super 50 Junction Box Material: Grey BS plastic box Clear polycarbonate lid 12 ports 16 terminal studs with 4-common grounds Kit: 1 - Grey BS junction box 1 - Clear polycarbonate lid w/ screws 1 - Terminal block w/hardware 1 - Ground strap 1 - Dual ground strap filler plugs Super port junction box kit Super 50 junction box Super 50 junction box cap w/screws Replacement lid & gasket Super 50 ground strap Super 50 dual ground strap Filler plug Replacement lid, gasket & 6 screws Compression Fittings conductors, 3/8 fitting & 5 conductors, 1/2 fitting & 7 conductors, 3/4 fitting Single conductor wire, 5 hole fitting conductor flat cable fitting conductor flat cable fitting DOG BONE CLER LID GSKET EYELETS 3-part fitting consisting of a pre-tapped cap, a threaded base and a black PVC grommet that is available with 6 different hole sizes to accommodate various conductor cables. For 2 conductor cable /8 I.D. fitting For 6 & 7 conductor cable /4 I.D. fitting For 3 conductor flat cable Fitting For 4 & 5 conductor cable /2 I.D. fitting For single conductor wire hole fitting For 4 cond Fitting Steel clips Supplied with all multi-plug S/T/T harness Straight mold, 1-1/2 steel Right angle, 1-1/4 steel

30 Truck-Lite Full Line Product Catalog JUNCTION BOXES & RECEPTCLES HR Made of high impact, chemical resistant plastic Mounted by four holes on 5-1/2 diameter circle Contains 8 pre-tapped holes to accept compression fittings or filler plugs requires a 4-7/8 clearance hole Junction box Junction box Made of high impact, chemical resistant plastic Includes O ring for a weather proof seal Junction box cap & O ring Junction box cap, clear O ring Kit contains terminal block, four filler plugs, assembly and mounting screws Surface Mount Box Buckplate Mount Box Hardware kit Made of approved insulating plastic Contains 8 color coded terminals Terminal block Fill pre-tapped holes in junction box when compression fittings are not used Filler plug Contains junction box, junction box cap, terminal block, four filler plugs and mounting & assembly screws Surface mount assembly Surface mount assembly, clear cap Contains junction box, junction box cap, terminal block, four filler plugs and mounting & assembly screws Buckplate mount assembly Buckplate mount assembly, clear cap Use for installation of 3-part compression fittings in areas other than in the junction boxes 1-1/8 clearance hole required Jam nut Uninsulated terminals for use with 50 series harnesses & junction boxes 25 per bag For gauge wire only diameter bullet terminal #10 ring terminal For external grounding of junction boxes or 7-way receptacles 26 long white wire Ground wire, 8 gauge Crimp tool Crimp tool 235

31 HR JUNCTION BOXES & RECEPTCLES Truck-Lite Full Line Product Catalog Easily installed on new trailers or as a retrofit on existing equipment Chemical resistant and virtually indestructible box Internal electrical contacts sealed to eliminate corrosion 100% electrically pre-tested with a 40 amp capacity vailable with or without circuit breakers Color-coded trailer main cable hook-up terminals for proper connections Nose box, without circuit breakers Nose box, with 15 amp circuit breakers Nose box, right angle Cable grommet Cap latch repair kit, round Cover, rectangular Cable clamp repair kit Nose Boxes Material: Foam polycarbonate box screw hole diameter Tough GE Noryl, non-conductive, corrosion resistant body Floating type, cadmium plated brass pins allow best alignment and long-lasting contact with plug Internal connections feature a direct wired ground Ring terminals are used to connect wires Receptacle pins prevent increased resistance due to standard breakage caused by set screws vailable in standard and circuit breaker version Meets SE J560 standards Circuits are identified by color codes & embossed notations Way Receptacles Surface Mount Material: GE Noryl body Cadmium plated brass pins Standard 7-way body, solid pins Receptacle w/threaded stacking studs, solid pins Standard 7-way body, split pins Receptacle w/15 amp circuit breakers, split pins Receptacle w/20 amp circuit breakers, split pins Receptacle w/threaded stacking studs, split pins Note: We recommend use of rubber boots with flush mounting receptacles. Easy installation on all receptacles Includes Noryl cover, steel hinge pin, stainless steel spring, cotter pin & shaft retainer Not for use with #50805 style 7-ways 5-Piece Cover Service Kit Cover service kit 236

32 Truck-Lite Full Line Product Catalog JUNCTION BOXES & RECEPTCLES HR 7-Way Receptacles Flush Mount Material: GE Noryl body Cadmium plated brass pins Tough GE Noryl, non-conductive, corrosion resistant body with floating type, cadmium plated brass pins that allow best alignment & long-lasting contact with plug Internal connections feature a direct wired ground Circuits are identified by color codes and embossed notations Ring terminals are used to connect wires Receptacle pins prevent increased resistance due to strand breakage caused by set screws Meets SE J560 standards Push-on-terminal design, #50872 & compatible as OEM replacement way body, 2 hole flange, solid pins way body, 2 hole flange, split pins way body, push-on, 2 hole flange, split pins Cover service kit (does not work with 50897) Note: We recommend use of rubber boots with flush mounting receptacles. dapter Boxes Surface Mount Material: GE Noryl box Features molded threaded brass inserts for receptacle mounting Bottom entry for standard wiring with strain relief mechanism vailable with back access hole to accommodate rear entry applications box, bottom access box, rear access Receptacle Boots Material: Natural rubber boots Protects electrical connections from moisture in flush mount applications Large boot fits all full sized receptacles Small boots fit both 2 and 3 bolt flange receptacles with end or bottom access Small boot, rear access Large boot Quick Connect Box Material: Nylon lid & base w/uv stabilizers 4-position Packard Electric connector # on main harness requires P/E connector # on the chassis. Provides secure connection to consumer trailers through stripped wire connection or stripped wire connection w/standard 4-pin flat molded connector Sealed connector to the main power harness in the truck dhesive lined heat shrinks protect main harness connection to the box Easily replaced if necessary Black color blends into mounting location Hinge pin designed to fit tightly into hinge, keeps lid on and reduces chance for water to get into the connection terminals Easily adaptable for trailers, box trucks, retail vehicles, and box vans w/hitch set-up Mounting holes in same location as current Phillips boxes 1/4 bolt used to mount box Box w/ boat mold Box w/o boat mold 237

33 HR JUNCTION BOXES & RECEPTCLES Truck-Lite Full Line Product Catalog Die Cast Receptacles Material: Die cast housing vailable in 7-way, 6-way and 4-way variations Compact socket design with exposed terminals for easy installation in modern trailers Extended interior plug prevents damage to shell Integral finger grips for positive pull way receptacle way receptacle way receptacle Smart Box Material: Plastic housing Replacement Parts: solid pin split pin Eliminates the need to rewire the nose box when replacing a damaged receptacle Fits standard mounting bolt pattern Includes 2 cable entry grommets Wiring remains stationary on studs inside the box No need to disturb wiring when replacing receptacle Receptacle simply plugs in and secures with 2 nuts Brass jumpers bridge from studs to receptacle pins Smart box w/solid pins Smart box w/split pins Cover service kit 238

34 Truck-Lite Full Line Product Catalog JUNCTION BOXES & RECEPTCLES HR Heavy Duty nti-lock Connector Cords Material: 4-12, 2-10, 1-8 gauge Ideal for supplying power to trailer and dolly BS systems Designed for use in wide temperature range (-87 to +195 F) vailable in 12 and 15 foot lengths Meets TMC recommendations (RP137) and SE J % pre-tested Covered by manufacturer s 3 year warranty , green jacket with nylon plugs , green jacket with nylon plugs Heavy Duty Connector Cords Material: 6-12, 1-10 gauge Meets T, SE and TMC requirements Designed for use in wide temperature range (-87 to +195 F) vailable in 12 and 15 foot lengths Meets or exceeds SE J559 or J1067 as applicable 100% pre-tested Covered by manufacturer s 3 year warranty , black jacket with metal plugs , black jacket with metal plugs Replacement Plug Material: Rugged nylon housing or zinc die-cast housing Brass terminals Features brass terminals and rear moisture seal Unique 360 cable clamp that helps prevent the cable from being accidentally pulled out Resistant to degreasers, solvents and contact cleaners Features zinc die-cast housing and brass terminals Nylon insert is resistant to petro- chemicals SHOWN Nylon plug, 7 way Metal plug, 7 way Metal plug, 4 way Metal plug, 6 way SHOWN 239