Truck-Lite User’s Guides
These guides provide detailed training and education to help readers better understand harness and lighting JVUJLW[Z[OH[HYLYLSL]HU[[VZWLJPÄJPUZ[HSSH[PVUZHZ well as providing preventative maintenance techniques. Truck-Lite’s Lighting and Harness User’s Guides make for excellent training sources in a conveniently sized manual. BASICS IN ELECTRICITY +LÄUP[PVUZ 4HQVY*VUJLW[Z >PYL*HSJ\SH[PVUZ - Useful Formulas
WHY LIGHTS FAIL 4HQVY*H\ZLZ - Tips For Longer Lasting Lighting Systems *OLTPJHS0TWHJ[6U3PNO[PUN - Product Pitfalls
STANDARDS AND SPECIFICATIONS - Federal Requirements 7YVWLY3PNO[:WLJPÄJH[PVU *VTTVU3LNHS8\LZ[PVUZ 0+*VKLZ 9LN\SH[PVU*OHY[Z
EVOLUTION OF LIGHTING - Lighting Evolution 0U[YVK\J[PVU[V3,+3PNO[PUN - Future of LEDs - LED Lifetime Systems - Systems Approach
SUPPORT TOOLS - Laboratory Support - Technical Support 0UK\Z[Y`3PURZ
INDEX/ GLOSSARY BASICS IN ELECTRICITY
SECTION OBJECTIVES 1. +LÄUP[PVUZ 4HQVY*VUJLW[Z >PYL*HSJ\SH[PVUZ 3. Useful Formulas
+LÄUP[PVUZ
A comparison between electrical energy and water ÅV^^PSSIL\ZLM\SPUL_WSHPUPUNHUK\UKLYZ[HUKPUN LSLJ[YPJHSJVUJLW[ZI\[YLTLTILY·^H[LYHUK electricity generally should not be mixed.
1. VOLT (Potential) V The unit of measurementHWWSPLK[V[OLKPɈLYLUJLPU electrical potential between two points; [OH[PZ[OL WV[LU[PHSMVYLSLJ[YPJP[`[VÅV^ • Usually referenced from “ground.” 0U^H[LY]VS[HNLPZYV\NOS`LX\P]HSLU[[V[OLKPɈLYLUJL in elevation from ground to a tank of water elevated above the ground; the electrical potential is similar to water pressure. ;OLOPNOLY[OLWV[LU[PHSVYLSL]H[PVU[OLTVYLMVYJL the water is able to exert and the more likely it is to ÅV^
2. AMP (Current) I ;OL\UP[VMTLHZ\YLTLU[HWWSPLK[V[OLÅV^VMLSLJ[YPJHS current through a conductor. • The amount of current (electrons) passing through a conductor or passing a point in a wire or other electrical devices such as a light bulb. 6/49LZPZ[HUJL9£ (ZLSLJ[YVUZÅV^[OYV\NOJVUK\J[VYZ[OL`TLL[ VWWVZP[PVUK\L[V[OLJVSSPZPVUZIL[^LLU[OLÅV^PUN electrons and the electrons and atoms of the conductor. ;OPZVWWVZP[PVU[VJ\YYLU[ÅV^JHSSLKYLZPZ[HUJLPZ measured in Ohms.
4. WATT (Power) P, W or Pw The unit of power applied to the rate at which energy is used. • Power is the amount of work that can be HJJVTWSPZOLKPUHZWLJPÄLKHTV\U[VM[PTL >VYRPZZPTWS`KLÄULKHZJVU]LY[PUNLULYN`MYVTVUL MVYT[VHUV[OLYLNJOHUNPUNLSLJ[YPJHSLULYN`PU[V light energy.
5. WIRE SIZE (AWG) )LJH\ZLL]LY`[OPUNLSLJ[YPJHSKLWLUKZVUJ\YYLU[ÅV^ the conductors that carry the electricity are a critical part of any electrical system. The size of wires is PTWVY[HU[[VHSSV^[OLWYVWLYÅV^VMLSLJ[YVUZ 9LZPZ[HUJLPZVWWVZP[PVU[VJ\YYLU[ÅV^ • Wires that are too small in diameter will oppose J\YYLU[ÅV^[OPZVWWVZP[PVUPZK\L[VJVSSPZPVUZVM electrons which do not have enough room to pass). • These collisions convert electrical energy into heat PMLUV\NOVM[OLZLJVSSPZPVUZVJJ\Y[OL^PYLJV\SK overheat to the point of causing insulation melt-down HUKVYJH[JOÄYL • Wire sizes are measured according to the American Wire Gauge (AWG).
+LÄUP[PVUZJVU[PU\LKVUUL_[WHNL% 6. VOLTAGE DROP Vd Voltage drop occurs when power is dissipated across a component of the electrical system. 0U[OLJHZLVMHI\SIVYV[OLYSPNO[PUNKL]PJL]VS[HNLPZ dropped in the production of light and heat. ;`WPJHSS`[OLTVYLJ\YYLU[[OH[ÅV^Z[OYV\NOH Z`Z[LT[OLOPNOLY[OL]VS[HNLKYVW^PSSIL =VS[HNLKYVWHJYVZZH^PYLPZ\UKLZPYHISLHZP[PZHU indication that power is being wasted and heat is being generated.
7. HORSEPOWER To determine horsepower required to operate lighting LX\PWTLU[JHSJ\SH[L[OL[V[HSWV^LYYLX\PYLTLU[ZVMHSS lamps (in watts). Then divide that total by a value of 746 (HP = P / 746).
).#!.$%3#%.4 ,%$ 149 ,!-0 490% 4/4!, !-03 4/4!, !-03 #LEARANCE3IDEMARKER)DENTIFICATION ,ICENCE 4AIL MINOR FUNCTION 2EAR #LEARANCE MINOR FUNCTION 3TOP MAJOR FUNCTION 4URN MAJOR FUNCTION
INCANDESCENT LED P = V x I P = V x I P = 12.8v x 14.28a P = 12.8v x 2.04a P = 182.784 watts P = 26.112 watts
HP = P 746 HP = P 746 HP = 182.784 746 HP = 26.112 746 HP = 0.2450 HP = 0.0350 2. Wire Size Calculations
;OLSLUN[OVM^PYLPUHJPYJ\P[PZHTHQVYJVU[YPI\[PUN factor to voltage drop. The table below may be used to determine adequate wire gauge sizes MVYZWLJPÄJSLUN[OZVMJHISL^OLU[OLHTWLYHNL (current) requirements are known.
,]LY`[OPUNLSLJ[YPJHSYLSPLZ\WVUJ\YYLU[ÅV^ • The conductor that carries the electricity is a critical part of the system. >PYLZPaLPZ]P[HS[VHSSV^[OLWYVWLYÅV^VMLSLJ[YVUZ ZTHSSLYKPHTL[LY^PYL^PSSVWWVZLJ\YYLU[ÅV^ *VUZ[YPJ[PUN[OLYVVTMVYLSLJ[YVUZ[VWHZZ^P[OPU[OL ^PYLJH\ZLZJVSSPZPVUVMLSLJ[YVUZ^OPJONLULYH[LZ heat inside the wire.
WIRE GAUGE REQUIREMENTS
TOTAL FOOTAGE OF WIRE FROM POWER SOURCE TO THE MOST DISTANT ELECTRIC LAMP 24v 12v System System 10’ 20’ 30’ 40’ 50’ 60’ 70’ 80’ 90’ 100’ 2.0 1.0 18 18 18 18 18 18 18 18 18 18 3.0 1.5 18 18 18 18 18 18 18 18 18 18 4.0 2.0 18 18 18 18 18 18 18 16 16 16 6.0 3.0 18 18 18 18 18 16 16 16 14 14 8.0 4.0 18 18 18 16 16 16 14 14 14 12 10.0 5.0 18 18 18 16 14 14 14 12 12 12 12.0 6.0 18 18 16 16 14 14 12 12 12 12 14.0 7.0 18 18 16 14 14 12 12 12 10 10 16.0 8.0 18 18 16 14 12 12 12 10 10 10 20.0 10.0 18 16 14 12 12 12 10 10 10 10 22.0 11.0 18 16 14 12 12 10 10 10 10 8
AMPERAGE REQUIRED 24.0 12.0 18 16 14 12 12 10 10 10 8 8 30.0 15.0 18 16 12 12 10 10 10 8 8 8 36.0 18.0 16 14 12 10 10 8 8 8 8 8 40.0 20.0 16 14 12 10 10 8 8 8 8 6 * Values depict wire gauge
>PYL:PaL*HSJ\SH[PVUZJVU[PU\LKVUUL_[WHNL% Example: A lamp is 38’ from the power source HUKYLX\PYLKHTWLYLZ;OPZÄN\YLYV\UKLK upwards to the nearest column heading given in the table is 40’. The wire gauge in the 40’ column corresponding to 10 amperes is No. 12.*
*Recommended minimum wire gauge size for stop light and ground circuits.
Stop Ground (red) (white) Single trailer up to 50’ length 12 ga. 10 ga. Double trailer 2-28’ lengths 12 ga. 10 ga. Doubles trailer 8 ga. 2-40’ lengths 10 ga. Triples trailer 3-28’ lengths 10ga. 8 ga.
*VTWPSLKMYVT:(,;4* 6[OLYZV\YJLZ .180 E
E 0110 .160 AUG G
G .0067 .140 GAU GE 20 8 AU 1 .0045 G .120 6 1
.100 .0028 14 GAUGE .080
.060 12 GAUGE.0018 10 GAUGE1 .040 .001
VOLTAGE DROP PER FOOT VOLTAGE .020
0 5 10 15 20 25 30 35 40 45 50 AMPERES
20 GAUGE WIRE
18 GAUGE WIRE
16 GAUGE WIRE
14 GAUGE WIRE
12 GAUGE WIRE
10 GAUGE WIRE
8 GAUGE WIRE 3. Useful Formulas
V - Potential in Volts (E)* V I - Current in Amps R - Resistance in Ohms IR
* E is the symbol for Electromotive Force in Volts, as defined in Ohms Law.
V = I x R Voltage (volts) = Current (amps) x Resistance (ohms)
V I = R Current (amps) = Voltage (volts) Resistance (ohms)
V R = I Resistance (ohms) = Voltage (volts) Current (amps)
Frequently stated as E = I x R
7V^LYJHUILYLWYLZLU[LKHZ7>VY7^ a) Pw = V x I Power (watts) = Voltage (volts) x Current (amps)
b) Pw = I 2 x R Power (watts) = Current (amps) x Current (amps) x Resistance (ohms) 2 V c) Pw = R Power (watts) = Voltage (volts) x Voltage (volts) Resistance (ohms) a) Pw = V x I 3æ Pw = 12 x 4 Pw = 48w
2 12v b) Pw = I x R Pw = 4 x 4 x 3 Pw = 48w
4a 2 V c) Pw = R Pw = 12 x 12 3 Pw = 48w WHY LIGHTS FAIL
SECTION OBJECTIVES 1. 4HQVY*H\ZLZVM-HPS\YL 2. Tips For Longer Lasting Lighting Systems *OLTPJHS0TWHJ[6U3PNO[PUN 4. Product Pitfalls *V\U[LYMLP[7YVK\J[Z
1. Major Causes Of Failure
Corrosion Causes of Corrosion: >H[LYKPY[ZHS[HUKHU`V[OLYYVHK contaminants can enter a lamp or JVUULJ[VYWYV]PKPUNHULSLJ[YPJHS path which can vastly accelerate corrosion.
4PUPTPaPUN*VYYVZPVU! *VYYVZPVUJHUUV[VJJ\Y^OLU[OL bulb is sealed within the lamp OV\ZPUNHZ[OL`HYLPU;Y\JR3P[L»Z sealed lighting products.
Further Protection: *VUULJ[VYZZOV\SKILZLHSLK^P[O non-conductive grease like electrical JVU[HJ[ZJPYJ\P[Z^P[JOLZHUK Q\UJ[PVUIV_LZ
7\YWVZLVM:LHSHU[! To totally encapsulate the area to protect it from the elements. Shock, Vibration, & Burnout Major Causes of Shock & Vibration: Trailers experience constant road pounding when they travel down a highway. This pounding can cause ÄSHTLU[ZPUHI\SI[VKPZ[VY[HUKWYLTH[\YLS`IYLHR
0UHKKP[PVUZOVJRHUKPTWHJ[KHTHNLJHUILJH\ZLK by things other than road vibration. Some examples are: -Loading a container chassis on to a truck chassis -Dump truck loading or tailgate banging -Loose mounting of cargo hardware -Unloading operations -Impact with stationary objects, e.g., poles or loading docks
Solution To Shock & Vibration: 0UZ[HSSHSHTWKLZPNULK^P[OZOVJRTV\U[LK mechanisms that cradle the bulb and absorb the LɈLJ[ZVMZOVJRHUK]PIYH[PVU[OH[^V\SKV[OLY^PZL IL[YHUZMLYYLKKPYLJ[S`[VMYHNPSLI\SIÄSHTLU[ZVY3,+ lamps.
Baseless Bulbs: Suspended to endure heavy-duty applications better than traditional S-8 non-shock mounted bulb units or standard J-slot bulb sockets.
(K]HUJLK;LJOUVSVN`3,+Z! 3,+ZHYLYH[LKH[OV\YZVMVWLYH[PVU;OL`HYL ZVSPKZ[H[L^OPJOTHRLZ[OLTT\JOSLZZZ\ZJLW[PISL to shock and vibration. The electronics of LEDs are completely sealed in epoxy. 0UHKLX\H[L>PYPUN *HISL :\P[HISL>PYPUN! Wire size or gauge is very important; the use of a wire gauge too small can cause dim or intermittent operation VYL_JLZZP]L]VS[HNLKYVWHUKWYLZLU[ZHWV[LU[PHSÄYL hazard. (]VPKPUN,_JLZZP]L=VS[HNL-S\J[\H[PVU! Suitable wiring can increase product life and safety. A ZLHSLK^H[LYWYVVM^PYPUNOHYULZZZ`Z[LTIHZLKVU electrical load of the vehicle should be selected.
:[YHUKLKJVWWLY^PYLZOV\SKIL\ZLK*VWWLY^PYLOHZ a higher current carrying capability than an aluminum ^PYLVM[OLZHTLZPaL0[PZHSZVTVYLÅL_PISLHUKSLZZ likely to break.
;Y\JR3PNO[6ɈLYZ/HYULZZ:`Z[LTZ;OH[! -Exceed industry standards -Eliminate troublesome splices -Seal out the elements -Provide a common ground -Last the life of the trailer
,_JLZZ=VS[HNL ,_JLZZ]VS[HNLPZHKPɉJ\S[WYVISLTMVYI\SISPML4HU` failures caused by voltage spikes are a result of load dumps (such as starting the engine with the lights on). 6[OLYZV\YJLZVML_JLZZP]L]VS[HNLHYLOLH]`KYH^ electrical devices such as lift gates or welders. When [OL\UP[ZHYL[\YULKVɈ[OL`JHUJYLH[LHIHJRSHZOPU the form of a voltage spike.
Voltage regulators that are set too high can shorten the SPMLVMHI\SIHZJHUKPZJVUULJ[PUN[OLIH[[LY`^OPSL[OL truck is in operation.
A good way to protect the lights from voltage damage is to not use heavy draw accessories or start the vehicle when the lights are on.
Voltage should be checked regularly to ensure the ]LOPJSLPZVWLYH[PUN^P[OPUHZHMLYHUNL6UL]VS[ beyond the designed voltage will reduce the expected SPMLVMHI\SIÄSHTLU[I`TVYL[OHU WLYJLU[3,+ systems eliminate this problem. 7VVY.YV\UKPUN 0UZ[HSSPUNHSPNO[PUNWYVK\J[HUKOHYULZZZ`Z[LT[OH[ uses an internal ground will help maintain an absolute ground because it does not depend on the chassis NYV\UK0U[LYUHSNYV\UKZ^PSSHSZVOLSWLSPTPUH[LY\Z[ and corrosion associated with chassis grounding.
Loss of Bulb Contact 0U[OL[YHKP[PVUHSUVUZOVJRTV\U[PUNI\SI\UP[ZHUK [OLZ[HUKHYK1ZSV[I\SIZVJRL[ZJVYYVZPVUHUKVY loss of spring tension could cause a loss of contact. >P[O[OLPUJLW[PVUVM[OLZLHSLKIHZLSLZZI\SISHTW HUKZVSKLYLKJVUULJ[PVUZI\SIJVU[HJ[PZJLY[HPUHUK WYVK\J[SPMLPZM\Y[OLYLUOHUJLK(NHPU3,+Z`Z[LTZ solve this problem.
7O`ZPJHS+HTHNL ;VOLSWWYL]LU[WO`ZPJHSKHTHNL[OLSLUZZOV\SKILH Z\WLY[V\NOOPNOPTWHJ[WSHZ[PJ[OH[PZPTWLY]PV\Z[V heat generated by the bulb. The lens and the lamp housing should both be THU\MHJ[\YLKMYVTH[V\NOK\YIHISLWSHZ[PJZ\JOHZ polycarbonate. ;OLZ[*LU[\Y`3PNO[PUN:`Z[LT
:[\KPLZOH]LZOV^U[OH[^OLUZLHSLKZOVJRTV\U[LK bulbs and lighting devices are used along with sealed ^PYPUNOHYULZZZ`Z[LTZWYVK\J[SPMLJHUILL_[LUKLK as much as 20 times beyond traditional unsealed bulb units in heavy-duty and tractor/trailer applications.
0[ZOV\SKILL]LY`VUL»ZNVHS[V\ZLHUVYPNPUHS LX\PWTLU[WHY[[OH[SHZ[Z[OLSPMLVM[OL]LOPJSLVY requires little attention and minor cost after the initial purchase. Today’s technology is capable of designing HUKWYVK\JPUNSPNO[PUNWYVK\J[Z[OH[JHUVɈLY [VTPSLZVMTHPU[LUHUJLMYLLZLY]PJLMVYTVZ[ applications.
Product life performance can be extended and overall costs of vehicle operations can be reduced by doing a JHYLM\SL]HS\H[PVUVM[OL[V[HS]LOPJSLSPNO[PUNZ`Z[LT P[ZWYVISLTZHUK[OLTL[OVKZ\ZLK[VJVU[YVSHUK eliminate those problems. ;PWZ-VY(3HZ[PUN:`Z[LT
1 0MH[HSSWVZZPISL[LZ[WYVILZZOV\SKUV[IL\ZLK[V puncture insulation while troubleshooting lighting failure. 0MP[ILJVTLZULJLZZHY`[OLOVSLMYVT[OLWYVILT\Z[ ILYLZLHSLK0M[OLOVSLPZUV[ZLHSLK^PJRPUNHJ[PVUJHU cause moisture to travel considerable distances inside [OL^PYLYLZ\S[PUNPUJVYYVZPVU[OH[OHZ[OLWV[LU[PHS[V destroy the circuit.
>OLUJVYYLJ[PUNPSS\TPUH[PVUWYVISLTZKVU»[ZPTWS` turn up the voltage output. Find the sources that caused the failure to prevent more (and probably more serious) WYVISLTZ6]LY]VS[HNLJHUX\PJRS`RPSSIV[OSHTWZ and batteries. To prevent the loss of current carrying JHWHIPSP[`HS^H`ZYLWSHJL[YHPSLYSPNO[JVYKZ^P[O[OL ZHTLVYIL[[LYX\HSP[`HUKNH\NLVM^PYPUN
2. Under-voltage is often caused by poor electrical JVUULJ[PVUZ;VJVYYLJ[[OPZWYVISLTKVU»[ZPTWS`[\YU \W[OL]VS[HNL·ÄUKV\[[OLYVV[VM[OLWYVISLTMVY LɉJPLU[VWLYH[PVU
3. Do not immediately throw away lamps if they aren’t I\YUPUN0[PZPTWVY[HU[[VWSH`KL[LJ[P]L^OLUZVS]PUN lamp problems; determine that another source isn’t the cause of your lamp failure. Testing the lamp with HTL[LYWV^LYZ\WWS`VYIH[[LY`JHUOLSWKL[LYTPUL the lamp’s cause of failure. The following are common causes of lamp failure:
HI\SI^P[OZ[YL[JOLKVYIYVRLUÄSHTLU[ZTVZ[SPRLS`MHPSLKK\L to vibration -a yellowish, whitish, or bluish glaze on the bulb indicates a rupture in the bulb’s glass envelope HKHYRTL[HSSPJÄUPZOPUKPJH[LZVSKHNL -a black, sooty bulb indicates a poor seal in the bulb 4. Treat the electrical system like you treat the chassis. 3\IYPJH[LZVJRL[ZWPN[HPSZIH[[LY`[LYTPUHSZHUK connections with NYK-77 nonconductive anti-corrosion compound. The purpose of the sealant is to completely encapsulate and protect the electronics from corrosion and other types of water damage. Any type of corrosion WYL]LU[P]LJVTWV\UKZ\JOHZNYLHZLTH`IL\ZLKHZ long as it is not carbon based.
5. 0UZWLJ[[OLLSLJ[YPJHSZ`Z[LTMVYWYVWLYNYV\UK JVUULJ[PVUZ;OPZPZHTHQVYJH\ZLVMSHTWMHPS\YL especially when the trailer is used for a ground. When [OLSHTWZHYLNYV\UKLK[OYV\NO[OLSHTWOV\ZPUN THRLZ\YL[OLYLPZHJSLHUJVUULJ[PVU[OH[PZTL[HS [VTL[HS(ÄM[O^OLLSNYV\UKZ[YHWTH`IL\ZLKMVY added protection on the chassis ground system.
6. 3VVZLIHYLVY\UZ\WWVY[LK^PYLZVYÄ_[\YLZZOV\SK be addressed immediately. Harness and wiring should ILVU[OL\UKLYZPKLVM[OL[VWMYHTLTLTILYZYH[OLY than on the bottom where dirt and road splash connect.
% DESIGN VOLTAGE 50 60 70 80 80 100 110 120 130 140 x10,000 300 x5,000 275 x2,000 x1,000 R 250 E x500 W A O 225 V P x200 E E R L x100 AG D 200 E N x50 L A IF C 175 E
x20 % AMPS OR C.P. x10 150 x5 RES 125 x2 AMPE x1 100 100 PERES x1 AM 75 AV x.5 ER AG x.2 50 ER E L x.1 POW IFE DLE x.05 25 CAN x.02
0 x.01 LIFE FACTOR % AMPS OR C.P. LIFE FACTOR 50 60 70 80 80 100 110 120 130 140 % DESIGN VOLTAGE
7. /LH[PZHTHQVYJVU[YPI\[VY[VSHTWWYVISLTZ3HTWZ must “breathe” or the heat buildup will shorten a lamp’s SPMLZWHU3,+SHTWZOH]LHSV^LYWV^LYKYH^^OPJO JHUHSSL]PH[LTHU`OLH[WYVISLTZ/V^L]LYL]LUH cooler LED lamp can overheat if the lens is covered in dirt. Keep your lamps clean and they will perform better in the resulting cooler environment.
8. There are many household cleaning products that are not compatible with polycarbonate lenses and housing.
9. (S^H`ZYLWSHJL^PYPUN[YHPSLYSPNO[JHISLZHUK harnesses with an equal or heavier gauge of wire than was originally used. Using a lighter gauge wire can lead to problems. See pages 8 and 9 for wire gauge details.
10. You should never crank the truck with lights on; voltage surge is hard on lamps. You should also avoid needlessly using the hazard markers and clearance SPNO[Z>OLUWHYRLKH[H[Y\JRZ[VWVY[LYTPUHS`HYK ZH]L[OLSPNO[ZI`[\YUPUN[OLTVɈ(]VPKWHYRPUN HNHPUZ[[OLKVJR^P[O[OLOHaHYKTHYRLYZ[\YUZPNUHSZ or tail lamps operating. *OLTPJHS0TWHJ[VU3PNO[PUN
What Is It? Almost all cracked parts are caused by incompatible JOLTPJHSZVYJSLHULYZ(S[OV\NOSLUZLZHYL]LY`K\YHISL they can crack due to the combination of stress induced by the molding process and chemical acceleration of the stress.
;`WPJHS,_HTWSLZ0UJS\KL;OL-VSSV^PUN! -Lights on buses or vehicles that are frequently washed with incompatible cleaners -Lights near engines or exhausts 3PNO[ZL_WVZLK[VZVTLZVHWZIVK`JSLHULYZS\IYPJHU[Z WHPU[WHPU[JSLHULYZHU[PMYLLaL^HZOLYÅ\PKZIYHRLÅ\PK and hundreds of other chemicals
What Makes The Plastic Crack? The chemical penetrates the plastic and unhooks the long chains of molecules that make the plastic strong. Anywhere that the plastic is under stress (like a lens weld on a mounting hole) may crack.
*HU*SLHUPUN:VS\[PVUZ)L+HTHNPUN& The use of solvents that are not compatible with WVS`JHYIVUH[L^PSSYLZ\S[PU[OLZVM[LUPUNJYHaPUNHUK or cracking of the plastic part. Polycarbonate lamps and mounting bases may be used under stress in their normal applications 4. Product Pitfalls
Truck-Lite has cataloged numerous problems that occur PU[OLÄLSK/LYLHYLHML^VM[OLYLWLH[VɈLUKLYZ!
6]LY;PNO[LULK4V\U[PUN:JYL^Z! (M[LYH^OPSLWVS`JHYIVUH[L^PSSJYHJR\UKLYZ[YLZZ;OL rule of thumb is to use the minimum torque possible. Never use more than 20 inch-pounds.
Loose Brackets Or Undersized Grommet Holes: Both of these issues can prematurely knock out ÄSHTLU[Z
5V[(KKPUN5@2 ;V7S\NZ6Y3PNO[Z>OLU 0UZ[HSSPUN! Truck-Lite adds only enough NYK-77 for the lamp. Additional NYK-77 should be used on the connection end.
Note: This is not recommended for use with LED lamps that use Fit ‘N Forget® connectors.
*VU[PU\LK:[YL[JOLK6Y7\SSPUN,ZWLJPHSS` :PKL^H`Z6M(*HISL6U(1\UJ[PVU)V_6Y Distribution Module: This may eventually cause a disconnection or an electrical short.
5V[9LWSHJPUN7S\NZ>OPJO:OV^:PNUZ6M Corrosion: ,]LU[OV\NO[OL`TH`^VYR[OL`^PSSWYVTV[LYHWPK pin corrosion on the new replacement light pin (plug) connection. 7HPU[PUN(=LOPJSL(UK (SSV^PUN7HPU[6Y:VS]LU[;V *VU[HJ[3PNO[Z6Y>PYPUN! 4VZ[WHPU[ZL_JS\KPUN^H[LY based) are incompatible with polycarbonate lights. They may also cause wires or cable insulation to crack. (SSV^PUN3PNO[Z[V*VU[HJ[0UZ\SH[PUN4H[LYPHSZ3PRL 3VHKPUN+VJR(PY:LHSZ>OPSL,ULYNPaLK! Another variation of this is the placement of insulation too close to contacts of the light housings. This can result in heat distortion/damage and shorter life. -HPS\YL[V6YPLU[3PNO[Z>P[O[OL>VYK¸;67¹ 7YVWLYS`! ;OPZPZPTWVY[HU[MVYHJV\WSLVMYLHZVUZPUJS\KPUN the fact that the bulb life may be shortened by heat or increased shock. The other reason is that it is an obligation for legal compliance. 6UL=VS[)L`VUK+LZPNULK=VS[HNL>PSS9LK\JL ,_WLJ[LK3PML6M()\SI-PSHTLU[)`4VYL;OHU Percent*: 0[PZUV[HS^H`ZJVU[YVSSHISLI\[[OL¸Y\SLVM[O\TI¹PZ [OH[]LOPJSL]VS[HNLZZOV\SKILHKQ\Z[LK[V[OLTPUPT\T acceptable voltage for proper operation. 5. Counterfeit Products The primary function of vehicle safety lighting systems PZ[VWYV]PKLHZHMLLU]PYVUTLU[MVY]LOPJSLVWLYH[VYZ WLKLZ[YPHUZHUKHU`VULLSZL[OH[PZPU[OL]PJPUP[`VM vehicles. The reliance on lighting products make it extremely important that buyers trust in the products they are using. *V\U[LYMLP[SPNO[PUNWYVK\J[ZHYLVM[LUYL]LYZL engineered look-a-likes of reputable brand name WYVK\J[Z*V\U[LYMLP[LYZZVTL[PTLZ\ZLPKLU[PJHS THYRPUNZWHY[U\TILYZSVNVZHUKL]LUWHJRHNPUN 0TWVY[LKRUVJRVɈWYVK\J[Z^OPJOYLZLTISL[OLSVVR or function of brand name equipment are becoming TVYLWYL]HSLU[PU[OLOLH]`K\[`PUK\Z[Y`0U[OLJHZL VMSHTWZRUVJRVɈZHYLVM[LUKLZPNULK^P[OV\[JHYLMVY patents or trademarks of the original lighting products. 0[»Z\UJVTTVUMVYRUVJRVɈSHTWZ[VTLL[-4=:: ZHML[`YLN\SH[PVUZHUK[OLU\TILYVML_PZ[PUNWYVK\J[ violations in the domestic market is rapidly rising. +V;OL9PZRZ6\[^LPNO;OL9L^HYKZ& These products are designed to mislead customers PU[VILSPL]PUN[OL`HYLI\`PUN[OLVYPNPUHSIYHUK^OPSL infringing upon copyright and trademark rights of the original manufacturer. When counterfeit vehicle safety lighting products are sold to customers who believe [OL`HYLNL[[PUNKLWLUKHISLK\YHISLZVS\[PVUZMVYSLNHS SPNO[PUNHWWSPJH[PVUZ[OL`HYLL_WLJ[PUN[OLZHTLYVHK ZHML[`THPU[LUHUJLZLY]PJLHUKZ\WWVY[SL]LSZVM brand names the products mimic. +PZ[YPI\[VYZVMJV\U[LYMLP[WYVK\J[ZHYLZ\IQLJ[[V[OL ZHTLSLNHSWLUHS[PLZHZ[OLMVYLPNUTHU\MHJ[\YLYZHUK PU[OLJHZLVMKPYLJ[PTWVY[VM[OLWYVK\J[HYLJSHZZPÄLK HZ[OLTHU\MHJ[\YLYVMYLJVYKVUZ\JOWYVK\J[Z0MH distributor or original equipment manufacturer contracts with a manufacturer outside of the United States to have WYVK\J[ZZOPWWLKPU[V[OLPY<:MHJPSP[`[OLKPZ[YPI\[VY VY6,4YL[HPUZHSSVM[OLYLZWVUZPIPSP[`[OH[H[`WPJHS SPNO[PUNJVTWHU`^V\SKOH]L;OPZPUJS\KLZJLY[PÄJH[PVU compliance and product liability. The United States *VUNYLZZHUK[OL5H[PVUHS/PNO^H`;YHUZWVY[H[PVU Safety Administration (NHTSA) employ dedicated positions in support of enforcing actions against noncompliant vehicle lighting products. Supplying falsely marked counterfeit products not only SLHKZ[VKHTHNLKJ\Z[VTLYYLSH[PVUZI\[HSZVOHZ[PLZ to legal prosecution. 5VU*VTWSPHUJL0ZZ\LZ *VTIPUH[PVUSHTWZHUK[OLPYIHZPJWOV[VTL[Y`HYLRL` areas of concern when it comes to counterfeit lamps. 6M[LU[OLZLJVTIPUH[PVUZSHTWZSHJRIHZPJHK]LY[PZLK M\UJ[PVUZZ\JOHZZPKLYLÅL_VYJVTIPUH[PVUWYVWLY[PLZ (KKP[PVUHSS`[OLZ[HUKHYKSPNO[PUNYLX\PYLTLU[Z ULJLZZP[H[L[OH[SPNO[V\[W\[L_[LUKZIL`VUKZWLJPÄJ limits; counterfeit products typically do not meet these requirements. 3HJR6M0UK\Z[Y`2UV^/V^ The growing presence of Light Emitting Diode (LED) safety lighting products in the heavy-duty industry has caused an increase in the number of companies that manufacture and export lighting solutions. 4HU\MHJ[\YPUNSPNO[PUNWYVK\J[ZYLX\PYLZJSVZL TVUP[VYPUNVMWYVK\J[PVUHUKTVZ[\[PSPaLSV^]HYPHUJL standards with supplies and materials. Though they often have some experience in the production of LSLJ[YVUPJZTHU`VM[OLZLUL^ZV\YJLZKVUV[OH]L the necessary experience in and understanding of the OLH]`K\[`SPNO[PUNPUK\Z[Y`HZP[HWWSPLZ[VZHML[`SLNHS YLX\PYLTLU[ZWYVK\J[KV^UMHSSZHUKTVYL·^OPJO ;Y\JR3P[LJHUVɈLY As a longtime member of the traditional heavy-duty ZHML[`Z`Z[LTZPUK\Z[Y`;Y\JR3P[LPZMHTPSPHY^P[O[OL ZWLJPÄJH[PVUZHUKSLNHSYLX\PYLTLU[Z[OH[KYP]LYZHUK THPU[LUHUJLZ[HɈYLS`VU0[PZ^P[O[OH[L_WLYPLUJLHUK education that Truck-Lite designs and manufactures many of the new products and product advancements that are being copied and reproduced elsewhere. 6WWVY[\UP[PLZ>P[O3,+(K]HUJLTLU[Z When incandescent bulb technologies were the only light source capable of delivering the necessary light output that is required for legal vehicles safety HWWSPJH[PVUZT\JOVMHSHTW»ZKL]LSVWTLU[JV\SK rely on the standards of the internal light bulb and its proven expectations. With the use of electrically JOHYNLKJY`Z[HSZ[OLHWWLHYHUJLJVSVYHUKSPNO[ V\[W\[VMH3,+Z]HYPLZMYVTKPVKL[VKPVKL·\USLZZ the manufacturer has standards in place to ensure each KPVKLPZNYV\WLKHUKKYP]LUWYVWLYS`0MKPVKLZHYL UV[JSHZZPÄLKHUK\ZLKIHZLKVU[OLPYZWLJPÄJV\[W\[ YLHKPUNHUKIPUZ[OLYLZ\S[PUNV\[W\[JHU]HY`MYVT lamp to lamp. 0KLU[PM`PUN7YVK\J[4HYRPUNZ 7YVK\J[IYHUKHTHU\MHJ[\YLY»ZPKLU[PÄJH[PVUTHYR HUK[OLWYLZLUJLVMHJLY[PÄJH[PVUZ[HTWHYLHSSRL` indicators that your lighting products can be trusted. 4HU`VɈTHYRL[SPNO[PUNWYVK\J[ZZOV^UVWYPU[LK ZPNUZVM[OLTHU\MHJ[\YLYHUKTHRLP[ULHYS`PTWVZZPISL [VJVU[HJ[HU`VULPUYLNHYKZ[VWYVK\J[WLYMVYTHUJL PUZ[HSSH[PVUJVTWSPHUJLVY^HYYHU[`Z\WWVY[(SZVSVVR MVYJLY[PÄJH[PVUUV[LZVU[OLSHTWHZL]PKLUJL[OH[[OL lighting product was designed to meet the regulations that your application requires. Prevention The NHTSA regulates safety standards to ensure JLY[HPUSL]LSZVMWLYMVYTHUJLHUKZHML[`YLNHYKSLZZVM [OLTHU\MHJ[\YLY)\[HZHUVYNHUPaH[PVU[OL5/;:( OHZUVH\[OVYP[`[VHKKYLZZJV\U[LYMLP[PUN0UZ[LHK[OL H\[OVYP[`ILSVUNZ[V[OL<:*VW`YPNO[6ɉJL[OL<: 7H[LU[HUK;YHKLTHYR6ɉJL[OL-LKLYHS)\YLH\VM 0U]LZ[PNH[PVUZ[OL+LWHY[TLU[VM1\Z[PJLHUK*\Z[VTZ and Border Protection to stop the potentially unsafe WYVK\J[MYVTPTWVY[+LZWP[L[OLPYILZ[LɈVY[ZP[ZPTWS` PZU»[WVZZPISL[VRLLWHSSUVUJVTWSPHU[WYVK\J[ZVɈ store shelves. Buyers can do their part to combat the downfalls of counterfeit products by inspecting lamps for product THYRPUNZHUKJSHZZPÄJH[PVUZHZ^LSSHZPUX\PYPUNHIV\[ the manufacturer at the point of sale. ;OLPUP[PHSW\YJOHZLVMH]LOPJSLSPNO[PUNWYVK\J[· ^OL[OLYP[PZPU[OLVYPNPUHS]LOPJSLW\YJOHZLVY[OL JVZ[ZVMHJX\PYPUNHYLWSHJLTLU[\UP[·PZVUS`[OL beginning of the complete vehicle life cycle cost. (U`PUMLYPVYWYVK\J[ZIYPUNHKKLKJVZ[ZHUKTVYL PTWVY[HU[S`]LOPJSLKV^U[PTL;OLJOVPJL[VPU]LZ[PU a reputable brand such as Truck-Lite brings with it the reliability that ensures you won’t be replacing lamps prematurely. ;OL]HS\L[OH[JVTLZ^P[OWLHJLVMTPUKPZOHYK[VÄUK PUHU\UTHYRLKUVUJVTWSPHU[SHTW NORTH AMERICAN STANDARDS & SPECIFICATIONS SECTION OBJECTIVES 1. Federal Requirements 7YVWLY3PNO[:WLJPÄJH[PVU *VTTVU3LNHS8\LZ[PVUZ 0+*VKLZ 9LN\SH[PVU*OHY[Z 1. Federal Requirements Who’s who when it comes to lighting regulations? DOT is the Department of Transportation. This functions as a large governmental umbrella for anything KLHSPUN^P[O[YHUZWVY[H[PVUPUJS\KPUN[OL5/:;( -/>(L[J;OL+6;SL[[LYPUNPZVM[LUW\[VUSPNO[Z[V show that they conform to all government regulations. NHTSAPZ[OL5H[PVUHS/PNO^H`;YHɉJ:HML[` Administration. They regulate lighting requirements for HSSUL^YVHK]LOPJSLZ^P[O[OLL_JLW[PVUVMWVSL[YHPSLYZ and converter dollies. Their regulations take precedence over state regulations and they have the power to PTWSLTLU[ÄULZYLJHSSZHUKUL^YLN\SH[PVUZ:[H[L Enforcement agencies often use the NHTSA regulations for their light requirements. FMCSAPZ[OL-LKLYHS4V[VY*HYYPLY:HML[` (KTPUPZ[YH[PVU;OL`PZZ\L-LKLYHS4V[VY*HYYPLY:HML[` 9LN\SH[PVUZ-4*:9;OLZLY\SLZYLN\SH[L]LOPJSLZ V]LY ¹^PKLZ\JOHZJVTTLYJPHS]LOPJSLZHUKI\ZLZ :VTLVM[OLZLKLHS^P[OSPNO[PUNHUK^PYPUN4VZ[Z[H[LZ inspect vehicles using these standards. FMVSS 108PZ[OL-LKLYHS4V[VY=LOPJSL:HML[` Standard No. 108. This is the federal code (law) that YLN\SH[LZSPNO[PUNHUKWLYMVYTHUJLYLX\PYLTLU[ZHZ well as the numbers and locations of lights on vehicles. NHTSA publishes the 108 regulations. CMVSS 108PZ*HUHKH»ZHUHSVNV\ZYLN\SH[PVU JVKL^OPJOPZ]LY`ZPTPSHY[V-4=:: ;OLWYPTHY` KPɈLYLUJLZHYL[OH[[OL*4=:: YLX\PYLZKH`[PTL Y\UUPUNSHTWZHUKHSSV^Z,\YVWLHUOLHKSHTWZ^OPSL -4=:: KVLZUV[ ;YHUZWVY[*HUHKH is the department of the *HUHKPHUNV]LYUTLU[^OPJOPZYLZWVUZPISLMVY KL]LSVWPUNYLN\SH[PVUZWVSPJPLZHUKZLY]PJLZVM [YHUZWVY[H[PVUPU*HUHKH 7YVWLY3PNO[:WLJPÄJH[PVU When it comes time to order your next heavy-duty ]LOPJSL[OLYLHYLTHU`KLJPZPVUZ[VJVUZPKLY>P[OZV many costs coming into play with applications other [OHU]LOPJSLSPNO[PUNP[PZLHZ`[VQ\Z[PM`JOLHWLYSLZZLY quality equipment. Despite being marginally cheaper H[[OL[PTLVM[OLPUP[PHSW\YJOHZLW\YJOHZPUNIHZPJ equipment is often more expensive in the long run. ;VM\SS`\[PSPaLPUK\Z[Y`PTWYV]LTLU[Z[VILZ\YL`V\Y ]LOPJSLTLL[ZHSSSLNHSYLX\PYLTLU[ZHUK[VLUZ\YL[OH[ [OL]LOPJSLTLL[Z[OLL_WLJ[H[PVUZVMTHPU[LUHUJLZ[HɈ HUK]LOPJSLVWLYH[VYZP[PZPTWVY[HU[[VWYVWLYS`ZWLJPM` the products being ordered for your vehicle. There are two important points of interest that should be considered prior to “spec’ing” a vehicle order. -SLL[=LOPJSL4HPU[LUHUJL/PZ[VY`HUK Review 0[»ZPTWVY[HU[[OH[-SLL[HUK4HPU[LUHUJL4HUHNLYZ YL]PL^[OLPYÅLL[»Z]LOPJSLTHPU[LUHUJLHUK^HYYHU[` data before specifying a new vehicle build. This data JHUWYV]PKLRL`PUZPNO[PU[VHU`ZWLJPÄJHYLHZVM JVUJLYUHZ[OL`YLSH[L[V`V\YWHY[PJ\SHYÅLL[»Z]LOPJSLZ An appropriate investigation can yield weak areas on [OL]LOPJSLZVYHYLHZ[OH[YLX\PYLZWLJPHSH[[LU[PVU >P[O[OPZKH[HPUOHUK;Y\JR3P[L:HSLZHUK,UNPULLYPUN Representatives can be called upon to provide additional information in terms of product resources [OH[TH`HPKPUHJOPL]PUN`V\YÅLL[»ZILZ[SPNO[PUNPUHU LɉJPLU[M\SSZ`Z[LTZHWWYVHJO 6UJLHZWLJPÄJH[PVUOHZILLUVYKLYLKP[JHUIL ILULÄJPHS[VOH]L`V\YZ\WWSPLYWYLZLU[H[[OLÄYZ[ ]LOPJSLI\PSK[VLUZ\YL[OH[[OLZWLJPÄLKLX\PWTLU[OHZ ILLUPUZ[HSSLKPZPUZ[HSSLKWYVWLYS`HUK^PSSVW[PTPaL[OL ILULÄ[ZP[VɈLYZ 9L]PL^0UK\Z[Y`+L]LSVWTLU[Z With the growing number of new LED technologies ILPUNKL]LSVWLK[OH[LUOHUJLZHML[`PTWYV]LWYVK\J[ LɉJPLUJ`HUKWYVK\J[P]P[`HUKWYV]PKLNYLH[LY M\UJ[PVUHSP[`[OHUL]LYP[»ZPTWVY[HU[[OH[[PTLPZ[HRLU [VYL]PL^[OLSH[LZ[VɈLYPUN /HP[a»Z3H^Z[H[LZ[OH[L]LY`KLJHKL[OLHTV\U[VM light generated per LED package increases by a factor of 20. This has proven true since Truck-Lite’s LED VɈLYPUN[OH[KH[LZIHJR[V[OLLHYS` Z+\L[V[OL LULYN`LɉJPLUJ`VM3,+SHTWZ]ZPUJHUKLZJLU[Z·H ^OVWWPUN YLK\J[PVU·[OL<:+LWHY[TLU[VM Energy has provided additional funding to accelerate the implementation of LED lighting. This has led to the KL]LSVWTLU[VM3,+VW[PVUZMVY^VYRSPNO[PUNPU[LYPVY SPNO[PUNH\_PSPHY`SPNO[PUNHUKTHU`TVYLVɈLYPUNZ that had previously not been possible. As development NYV^ZSHTWVɈLYPUNZILJVTLWVZZPISLZTHSSLYWYVÄSLZ ZPaLZHUKHWWSPJH[PVUZ4HRLZ\YL`V\HYL[HRPUN advantage of all of the technological advancements that HYLH]HPSHISL[V`V\YÅLL[ *VTTVU3LNHS8\LZ[PVUZ >OH[SPNO[ZKV0ULLK& Browse the NHTSA charts (shown later in this section). Truck-Lite Tech Support (888.562.5012.) can be reached for additional questions. Note that states cannot require KPɈLYLU[ZWLJPÄJH[PVUZ[OHU^OH[PZPU I\[[OL`JHU add regulations. ;OL]LOPJSLOHZL]LY`[OPUNULLKLKMVY I\[[OL :[H[L7VSPJLZ[PSSNH]LTLH[PJRL[ :[H[LZJHUYLN\SH[LHU`[OPUNUV[JV]LYLKI` MVY L_HTWSLHU`HJJLZZVY`SPNO[ZVYSPNO[ZPUHKKP[PVU[V [OVZLPU .LULYHSS`[OLWYVISLTSPLZPU[OLZLHYLHZ [OV\NOZVTL[PTLZ[OL`ZPTWS`THRLHTPZ[HRL0MP[PZ [OLSH[[LY;Y\JR3P[L;LJOUPJHS:\WWVY[JHUVM[LU^YP[LH letter to clarify the issue. 0ZP[HSSYPNO[[VTV\U[HSPNO[H[ZVTLHUNSL&;OH[PZ UV[¸ZX\HYL¹VU[OL]LOPJSL& ¸4H`IL¹@V\ULLK[VJVU[HJ[;LJOUPJHS:\WWVY[MVYH [LZ[PU[OH[WVZP[PVU"V[OLY^PZLP[JHUILX\LZ[PVULKI` the NHTSA or enforcement groups. *HU0L]LY\ZL[OL4VKLS^P[O[OLYLÅL_YLÅLJ[VY YPUNSLNHSS`& @LZVUHU`]LOPJSL\UKLY ¹^PKLHZHU¸L_[YH¹SPNO[ VU]LOPJSLZV]LY ¹YLÅL_PZSLNHSVYVU]LOPJSLZTHKL in 1991 or earlier. 0ZP[VRH`[V\ZLHSPNO[MVY¸ZPKL[\YU¹[OH[PZU»[SPZ[LK for that function? 0[PZWLYMLJ[S`ÄULILJH\ZLZPKL[\YUZHYL56;SLNHSS` YLX\PYLK;OH[ZHPKILJHYLM\S[OH[P[KVLZU»[]PVSH[L ZVTLZ[H[LSH^ZYLNHYKPUNJVSVYVYSVJH[PVU0MP[PZHSZV \ZLKHZHZPKLTHYRLY[OH[M\UJ[PVUT\Z[ILSPZ[LKVU the lens code. 0Z:(,VY+6;SL[[LYPUNYLX\PYLKVUSPNO[Z& No lettering is required by the NHTSA (108) except for OLHKSPNO[ZHUKJVUZWPJ\P[`[HWL;OL-LKLYHS4V[VY *HYYPLY:HML[`4HU\HSTLU[PVUZ[OH[ZVTLSPNO[ZZOV\SK be marked SAE but this is not enforced. Truck-Lite THYRZHSSVM[OLPYSPNO[Z^P[O:(,HUKVY+6;THYRPUNZ >OH[PZHJVTIPUH[PVUTHYRLYJSLHYHUJLSPNO[HUK how do I mount it? :PTWS`W\[P[PZVULSPNO[KVPUN[OL^VYRVM[^V0[T\Z[ ILH[H KLNYLLHUNSLVUJVYULYZ[VILSLNHS0[HSZV ULLKZ[VILTHYRLK7*PU[OLSLUZJVKL0M[OLYLPZH X\LZ[PVUJVU[HJ[;LJOUPJHS:\WWVY[ (YL[OLYLZWLJPHSSPNO[PUNYLX\PYLTLU[ZMVY]LOPJSLZ OH\SPUNÅHTTHISLVYL_WSVZP]LTH[LYPHSZ& There are no special Federal requirements as 108 covers all over-the-road vehicles. Some states or T\UPJPWHSP[PLZOH]LYLN\SH[PVUZI\[[OLZLJHUUV[ Z\WLYZLKL ·[OL`JHUVUS`HKK[VP[-4*:9HUK the NFPA (National Fire Protection Association) publish YLX\PYLTLU[ZMVY^PYLWYV[LJ[PVUHZ^LSS Truck-Lite’s sealed lights and wiring systems have been [LZ[LK[VHSSRUV^UZ[HUKHYKZHUKJLY[PÄJH[PVU9LWVY[Z are available from Technical Support. ZH`Z[OH[ZVTLSPNO[ZT\Z[ILTV\U[LKHZ¸OPNO HZWYHJ[PJHISLVYHZMHYHWHY[HZWYHJ[PJHISL¹>OH[ PZ¸WYHJ[PJHISL&¹ The NHTSA has stated that the vehicle manufacturer has the responsibility to choose the best mounting SVJH[PVU¸PUSPNO[VM[OLWHY[PJ\SHYKLZPNUJVUÄN\YH[PVUVM the vehicle involved” and they will not contest it unless P[PZ¸JSLHYS`LYYVULV\Z¹9LJLU[S`*HUHKHOHZZ[HY[LK to enforce the word practical as meaning “capable of ILPUNKVUL¹0U[OLJHZLVMJSLHYHUJLTHYRLYZUV[TVYL than six inches from the edge of the vehicle is practical. 0^HU[[VHKKZVTLH\_PSPHY`SPNO[ZSPRLPSS\TPUH[L ZPNUZKLJLSLYH[PVUSPNO[ZVYKLJVYH[P]LSPNO[Z(YL [OLZLSLNHS& @LZWYV]PKLK[OL`KVUV[YLUKLYPUVWLYH[P]LHU` KL]PJLPUJVTWSPHUJL^P[O ULNH[P]LS`HɈLJ[[OL WLYMVYTHUJLVMYLX\PYLKLX\PWTLU[VYJYLH[LJVUM\ZPVU or misunderstanding of lighting signals. Always contact the Technical Support if you have any questions. >OH[PZ[OL¸:X\HYL0UJO9\SL¹& 6U+LJLTILY [OL5/;:(THKLLɈLJ[P]L[OL ÄUHSY\SPUNYLNHYKPUN[OL:X\HYL0UJO9\SL;OPZ ruling requires that the total luminous lens area for a stop and turn lamp must not be less than 75 square centimeters (11.625 square inches) when used on vehicles over 80” wide. 0[T\Z[ILUV[LK[OH[[OL4VKLSYLÅL_YLÅLJ[VYYPUN cannot be counted as square inch lens area. When the YLÅL_YPUNPZZ\I[YHJ[LKMYVT[OL[V[HSPUJOSLUZP[ leaves less than the 12-square inches that are required. ,_WSHUH[PVUVM0+*VKLZ ;OL:(,1 3PNO[PUN0KLU[PÄJH[PVU*VKLJHUIL KPɉJ\S[[VPU[LYWYL[YLNHYKPUNJSLHYHUJLHUKTHYRLY applications. This additional information may be helpful. 7!*SLHYHUJL:PKLTHYRLYHUK0KLU[PÄJH[PVU3HTWZ This marking is currently used for both “over” 80- PUJOHUK¸\UKLY¹ PUJO]LOPJSLZ0[OHZILJVTL[OL Z[HUKHYKMVY]LOPJSLZ\UKLY PUJOLZI\[NV]LYUTLU[ ZWLJPÄJH[PVUZ-4=:: OH]LUL]LYJHSSLKV\[ increased requirements for the larger width. P2 is the TPUPT\TZ[HUKHYKMVYJSLHYHUJLZPKLTHYRLYHUK PKLU[PÄJH[PVUSPNO[Z(SS;Y\JR3P[LKL]PJLZTLL[[OPZ Z[HUKHYKL]LUPM[OL`HYLTHYRLK7*7L[J 7*!*VTIPUH[PVU:PKL4HYRLYHUK*SLHYHUJL3HTW VY0KLU[PÄJH[PVUMVY]LOPJSLZV]LY PUJOLZ^PKL ;VIL\ZLKHZHJVTIPUH[PVUSPNO[KL]PJLZT\Z[IL mounted on a 45° bevel at the corner of a vehicle. This allows clearance and side marker functions to ILJVTIPULKPUVULSPNO[HUKLSPTPUH[LZ[OLULLK MVYHZLJVUKKL]PJL(7*SPNO[JHUHS^H`ZIL\ZLK HU`^OLYLH7SPNO[^V\SKOH]LILLU\ZLKI\[[OL reverse is not true. 7!*SLHYHUJL:PKLTHYRLYVY0KLU[PÄJH[PVUSPNO[ZMVY use on vehicles over 80-inches wide A P3 designated lamp has higher light outputs than a 7YH[LKSHTW0[PZSLNHS^OLYL]LYH7SPNO[^V\SKIL \ZLK)LJH\ZL[OLMLKLYHSYLN\SH[PVUZ-4=:: OH]L`L[[VHKVW[7THU`THU\MHJ[\YLYZOH]LUV[ made lights to meet the standard. Some of Truck- 3P[L»ZSHTWZKVUV[TLL[[OPZZ[HUKHYKHUKHYLTHYRLK accordingly. PC2: Combination Side Marker and Clearance or 0KLU[PÄJH[PVUSPNO[Z\ZLKVUH]LOPJSLV]LY PUJOLZ wide 7*3HTWZTLL[HUPUJYLHZLKHUNSLV\[W\[HUK are designed as combination lamps. When used HZJVTIPUH[PVUSHTWZ[OL`T\Z[ILTV\U[LKVUH 45° beveled corner. Because the federal regulations -4=:: OH]L`L[[VHKVW[7THU`THU\MHJ[\YLYZ have not made lights to meet the standard. Some of ;Y\JR3P[L»ZSHTWZKVUV[TLL[[OPZZ[HUKHYKHUKHYL marked accordingly. Additional Points of Concern: *\YYLU[S`[OL-4=:: Z[HUKHYKOHZYLJVNUPaLK VUS`[OLZ[HUKHYKZ[OH[JHSSMVY7VY7*THYRPUNZ;OL other markings are for SAE recommended practices. ;OL7*VY7*SPNO[ZVɈLY[OL^PKLZ[WH[[LYUZVM visibility. -4=:: KVLZUV[YLX\PYLHU`VM[OLZLSLUZ THYRPUNZ^P[O[OLL_JLW[PVU[OH[[OL`HJJLW[+6; lettering as certifying legal compliance. • A good rule of thumb is to only buy lighting that has the manufacturer’s name engraved on the lens and has [OL:(,+6;0KLU[PÄJH[PVU*VKLZVUSHTWZ 3PNO[PUN0+*VKLZ! A 9LÅL_YLÅLJ[VYZ A2 >PKLHUNSLYLÅL_YLÅLJ[VYZ C 4V[VYJ`JSLH\_PSPHY`MYVU[SHTWZ D 4V[VYJ`JSLHUKTV[VYKYP]LUJ`JSL[\YUZPNUHSSHTWZ E :PKL[\YUZPNUHSSHTWZ·]LOPJSLZTVYTVYLPUSLUN[O E2 :PKL[\YUZPNUHSSHTWZ·]LOPJSLZSLZZ[OHUTPUSLUN[O F Front fog lamps F2 Fog tail lamps G Truck cargo lamp H Sealed beam headlamp HG Discharge forward lighting (headlamp) HH Sealed beam headlamp housing HR Replaceable bulb headlamp I Turn signal lamps 13 Turn signal lamps spaced from 75 mm to less than 100 mm from headlamp 14 Turn signal lamps spaced from 60 mm to less than 75 mm from headlamp 15 Turn signal lamps spaced less than 60 mm from headlamp 16 Rear mounted turn signal lamps and front mounted turn ZPNUHSSHTWZTV\U[LKTTVYTVYLMYVT[OLOLHKSHTW for use on vehicles 2032 mm or more in overall width 17 Front mounted turn signal lamps mounted less than 100 TTMYVT[OLOLHKSHTWMVY\ZLVU]LOPJSLZTTVY more in overall width J590 ;\YUZPNUHSÅHZOLY J945 /HaHYK^HYUPUNZPNUHSÅHZOLY J1054 >HYUPUNSHTWHS[LYUH[PUNÅHZOLY 2 Front cornering lamps 2 Rear cornering lamps L License plate lamps M 4V[VYJ`JSLHUKTV[VYKYP]LUJ`JSLOLHKSHTWZ· motorcycle type N 4V[VYJ`JSLHUKTV[VYKYP]LUJ`JSLOLHKSHTWZ·TV[VY driven cycle type O Spot lamps P Parking lamps P2 *SLHYHUJLZPKLTHYRLYHUKPKLU[PÄJH[PVUSHTWZ P3 *SLHYHUJLZPKLTHYRLYHUKPKLU[PÄJH[PVUSHTWZMVY\ZLVU vehicles 2032 mm or more in overall width PC *VTIPUH[PVUJSLHYHUJLHUKZPKLTHYRLYSHTWZ PC2 *VTIPUH[PVUJSLHYHUJLHUKZPKLTHYRLYSHTWZMVY\ZLVU vehicles 2032 mm or more in overall width Q ;\YUZPNUHSVWLYH[PUN\UP[Z·*SHZZ( QB ;\YUZPNUHSVWLYH[PUN\UP[Z·*SHZZ) QC Vehicular hazard warning signal operating unit R Backup lamps S Stop lamps S2 Stop lamp for use on vehicles 2032 mm or more in overall width T Tail lamps (rear position lamps) T2 Tail lamps (rear position lamps) for use on vehicles 2032 mm or more in overall width U Supplemental high-mounted stop and turn signal lamps U2 High-mounted stop lamps for trucks 2032 mm or more in overall width U3 *LU[LYOPNOTV\U[LKZ[VWSHTWMVYWHZZLUNLYJHYZSPNO[ [Y\JRZHUK47=Z W >HYUPUNSHTWZMVYLTLYNLUJ`THPU[LUHUJLHUKZLY]PJL vehicles W2 Warning lamps for school buses W3 360 degree emergency warning lamps W4 Emergency warning device *VU[PU\LKVUUL_[WHNL 3PNO[PUN0+*VKLZ! W5-1 KLNYLLNHZLV\ZKPZJOHYNLSHTW·*SHZZ W5-2 KLNYLLNHZLV\ZKPZJOHYNLSHTW·*SHZZ W5-3 KLNYLLNHZLV\ZKPZJOHYNLSHTW·*SHZZ Y Driving lamps Y2 Daytime running lamps Z Auxiliary low beam lamps ;YHPSLY,X\PWTLU[3VJH[PVU Requirements ;Y\JR)\Z47=,X\PWTLU[ Location Requirements EVOLUTION OF LIGHTING SECTION OBJECTIVES 1. Lighting Evolution 0U[YVK\J[PVU[V3,+3PNO[PUN 3. The Future of LEDs 4. LED Lifetime Systems 5. Systems Approach 3PNO[PUN,]VS\[PVU 0U ;OVTHZ,KPZVUMVYTHSS`ÄSLKHWH[LU[YLX\LZ[ MVYOPZSPNO[I\SIPU]LU[PVUHY\KPTLU[HY`I\SI[OH[ \[PSPaLKHJHYIVUPaLKIHTIVVÄS[LY[OH[JV\SKSHZ[ around 1200 hours. This invention paved the way for universal domestic use VMLSLJ[YPJSPNO[(THaPUNS` for nearly 75 years after ,KPZVU»ZWH[LU[[OLYL^HZ very little technological change in incandescent lighting. There were minor improvements to the ÄSHTLU[HUKZ\WWVY[WVZ[Z TH[LYPHSI\[[OLNLULYHS KLZPNUYLTHPULK[OLZHTL ^OPJOTLHU[MVYULHYS` `LHYZI\SIZ^LYLL_[YLTLS` susceptible to corrosion and vibration damage. 0U [^VTLU.LVYNL)HSK^PUHUK/LUY`.YVZZLY provided a solution to the trucking industry with the very ÄYZ[ZLHSLKTHYRLYSHTW;OLPKLHVMTV\U[PUNHIHZL- less bulb in a resilient compound and sealing it in the SHTWHSSV^LK[OLSPNO[[VOH]LHSVUNLYSPMLZWHU·[V 15 times that of a conventional unsealed (bulb replace- HISLSPNO[(UKQ\Z[SPRL[OH[;Y\JR3P[L^HZIVYU 5V[SVUNHM[LY[OLÄYZ[ZLHSLKTHYRLYSHTWSPNO[PUN^HZ [HRLUPUH]HZ[S`KPɈLYLU[KPYLJ[PVU^OLU5PJR/VSVU`HR took lighting in a dynamic new direction. While working H[.LULYHS,SLJ[YPJPU OLKL]LSVWLK[OLÄYZ[WYHJ[P- JHS]PZPISLZWLJ[Y\TYLKSPNO[LTP[[PUNKPVKL3,+0[ would take several years and numerous improvements before LEDs made their way into the commercial vehicle PUK\Z[Y`I\[PU ;Y\JR3P[LYLSLHZLK[OLÄYZ[3,+ Z[VWSHTW[V[OLTHYRL[HZHU alternative light source to the traditional incandescent bulb replaceable and sealed lamps. ;Y\JR3P[LJ\YYLU[S`VɈLYZ[OYLL [`WLZVMSPNO[PUN!PUJHUKLZJLU[ ZLHSLKHUK3,+SPNO[PUN 0UJHUKLZJLU[3PNO[PUN An incandescent bulb is generally inexpensive. Howev- LYHI\SIOHZTHU`KPZHK]HU[HNLZ ;OLTVZ[ZPNUPÄJHU[KPZHK]HU[HNLZPUJS\KL! 3PTP[LKSPMLSLZZ[OHUOYZ Some lighting manufacturers put bulbs in shock mounts [VWYV[LJ[[OLTMYVT]PIYH[PVUI\[L]LU[OLILZ[I\SI ^PSSI\YUV\[VYZ\ɈLYHIYVRLUÄSHTLU[^P[OPU[OYLL `LHYZ0UJHUKLZJLU[SHTWZVWLYH[L[OYV\NO[OLL_JP[L- TLU[VM[\UNZ[LUÄSHTLU[Z[OH[^OLUZLLKLKPUZLHSLK NSHZZOV\ZPUN^PSSWYV]PKLSPNO[V\[W\[;Y\JR3P[LOHZ found that in the original 2-inch round and 4-inch round SPNO[PUNHWWSPJH[PVUZKHTHNL^HZTVZ[VM[LUMV\UK[V have occurred due to bulb damage. :LHSLK3PNO[PUN While Truck-Lite manufactures lamps with shock-mount- ed systems (a method of attaching the bulb to the lamp PUHZ\ZWLUKLK]PIYH[PVUYLZPZ[HU[KL]PJLUV[HSSSHTW MHPS\YLPZHYLZ\S[VM]PIYH[PVU0[^HZ;Y\JR3P[L»ZÄYZ[ development of the sealed lamp that began to tackle the problem of bulb failure. @LHYZHNVI\SIYLWSHJLHISLSHTWZNLULYHSS`OHKWVVY SLUZNHZRL[PUNHUKVM[LUOHKKYHPUOVSLZ;OLKYHPU OVSLZHSSV^LK^H[LYPU[V[OLSHTW^OPJOJH\ZLK corrosion of the bulb socket and electrical contacts. *VSK^H[LYJV\SKJVTLPUJVU[HJ[^P[O[OLOV[NSHZZ VM[OLI\SI^OPJO^V\SKJH\ZL[OLI\SI[VJYHJR;OPZ SLK[VHZSV^SLHRVMHPYPU[V[OLI\SI^OPJOJH\ZLK MHPS\YL;OLÄSHTLU[^V\SKV_PKPaLHUKWYVK\JLHJSV\K` coating on the inside of the bulb. This dramatically reduced the bulb’s light output and reduced the life to a ML^OV\YZH[TVZ[0MHJYHJR^HZZL]LYLMHPS\YLJV\SK happen immediately. Truck-Lite’s work to prevent damage to the bulb result- LKPU[OLHK]LU[VM[OLZLHSLKSHTW*YLH[PUNHSHTW that allowed no way for chemicals or liquids to enter the lamp housing greatly decreased the possibility of damage. 0U[YVK\J[PVU[V3,+3PNO[PUN :PUJL[OL`^LYLÄYZ[Z[\KPLKPU MVYWVZZPISL\ZLPU OLH]`K\[`SPNO[PUNHWWSPJH[PVUZ3,+ZOH]LILJVTL[OL UL^Z[HUKHYKMVYSVUNSPMLHUKSV^J\YYLU[KYH^SPNO[PUN 3,+ZHYLHTVUVJOYVTH[PJSPNO[ZV\YJLTLHUPUNLHJO LED produces exactly one color. The core technology PZHJY`Z[HSNYV^[OVU[VHNP]LUTLKP\T·ZVTL[PTLZ HZPSPJVULTH[LYPHS^OPJOPZHSZV\ZLKHZ[OLIHZLMVY computer chips. When you expose this medium to a JVTIPUH[PVUVMTH[LYPHSZHUKY\ULSLJ[YPJP[`[OYV\NOP[P[ lights up. ,]LUPU[OLLHYS`KH`ZVM3,+\ZL[OLPYILULÄ[Z^LYL JSLHY3,+ZHWWLHYIYPNO[LY^P[OHTVYL]PIYHU[JVSVY They also have a lower current draw. 0U[OLSH[L Z;Y\JR3P[LILNHU[VPU]LZ[PNH[L[OL possibility of white LEDs. Because an LED diode is TVUVJOYVTH[PJWYVK\JPUN^OP[L·^OPJOPZYLHSS`H JVTIPUH[PVUVM[OLJVSVYZYLKNYLLUHUKIS\L·PZ]LY` KPɉJ\S[;OLWYVISLT^HZZVS]LKI`JYLH[PUNHJVTIP- nation of RGB diodes that were packaged together. This ÄUHSWHJRHNLLTP[[LKH^OP[LSPNO[ 5V^^LRUV^[OH[[OLYLHYLTHU`^H`Z[VWYVK\JL ^OP[LSPNO[^P[O3,+Z;OLTVZ[LɉJPLU[^H`PZ[V\ZLH IS\L3,+JOPWHUKL_WVZLP[[VWOVZWOVY^OPJOYLHJ[Z HUKYLSLHZLZWOV[VUZ[OH[ÄSS\W[OLYLZ[VM[OLJVSVY ZWLJ[Y\T,]LUUV^ZPNUPÄJHU[PTWYV]LTLU[ZHYLILPUN THKLPUIS\L3,+[LJOUVSVN`^OPJOPU[\YUPTWYV]LZ white lighting technology. 0U[OLTPKZ;Y\JR3P[L^HZHWWYVHJOLKI`[OL The next phase was to introduce military-grade LED [LJOUVSVN`[V[OLJVTTLYJPHS]LOPJSLTHYRL[^OPJO^HZ done with the 7-inch round and 5x7-inch headlights. Fleets who were already beginning the transition into custom halogen headlamps realized that there was an opportunity for life of the vehicle head lighting that VɈLYLKSVUNLYSPMLSV^LYJ\YYLU[KYH^IL[[LYPSS\TPUH[PVU HUK[OLHJJVTWHU`PUNZHML[`ILULÄ[Z THE BENEFITS OF LED LIGHTING SAFETY • 0UJYLHZLZ]LOPJSLJVUZWPJ\P[`^P[OPU[LUZLKPZWSH`Z of light output • 0UZ[HU[HULV\ZYLZWVUZL[PTLTPSSPZLJVUKZ MHZ[LY[OHU[OH[VMPUJHUKLZJLU[SHTWZJYLH[PUN 18 feet of additional stopping distance for trailing vehicles at highway speeds • Low power consumption increases the length of time disabled vehicles can operate their 4-way ÅHZOLYZ ENERGY EFFICIENCY • 85% reduction of load on electrical systems allows more power for other vehicle applications • 4PUPTPaLZ]VS[HNLKYVWHUKYLK\JLZSVHKVU HS[LYUH[VYZÅHZOLYZHUKZ^P[JOLZ RELIABILITY • 9LSH[LKH[OV\YZVMVWLYH[PVUJV]LYPUN TPSSPVUTPSLZHUK>HYYHU[LKMVYSPML^OLULX\PWWLK with Fit ‘N Forget® connectors and Series 88 harnesses • Extended period of operation translates to less vehicle downtime and zero maintainence DURABILITY • :VSPKZ[H[LJVUZ[Y\J[PVU^P[OL_[YHTLHZ\YLZ[HRLU to assure longevity of circuitry and components • Virtually impervious to shock and vibration Truck-Lite’s LED lamps are extremely reliable and LɉJPLU[ILJH\ZL[OL` Optical Light Beam are internally sealed with Epoxy Lens epoxy to encapsulate the Light electronic elements. The Emitting Semi solid state design makes Conductor for an extremely impact Metal resistant light source that Light Reflector is impervious to shock HUK]PIYH[PVUL]LUPU the most damaging Electrical Connections applications. )LJH\ZLÄSHTLU[MHPS\YLPZUV[HJVUJLYUMVY3,+SPNO[Z [OL`OH]LHUL_[YLTLS`MHZ[[\YUVU[PTLHUKJHUSHZ[ \W[VOV\YZ*VTIPUL[OPZ^P[O[OLPYK\YHIPSP[` and it’s clear that they are ideal for the heavy duty industry. 3,+ZJVTLPUKPɈLYLU[[`WLZ! • “T1-3/4’s” • “HPA’s” • “SnapLED®” *VSVYZ6M3PNO[ ;OLJVSVYZVMSPNO[WYVK\JLKI`ÄSHTLU[SHTWZPU]LOPJSL applications are the result of colored lens placement PUMYVU[VMHUPUJHUKLZJLU[^OP[LÄSHTLU[;OLYLK and amber color produced by LED lamps in vehicle applications are the result of colored light emitted from the diodes. 3. The Future of LEDs ,]LUPU[OLLHYSPLZ[KH`ZVM3,+SPNO[PUN[OLILULÄ[Z ^LYLJSLHYHUKHZ[LJOUVSVN`WYVNYLZZLZ[OLILULÄ[Z HYLJVU[PU\HSS`PTWYV]LK(JJVYKPUN[V/HP[a»Z3H^[OL JVZ[WLYS\TLUVM3,+Z^PSSMHSSI`HMHJ[VYVMHUK the amount of light generated per LED package will increase by a factor of 20 every decade. This contin- \LKYLÄULTLU[VM[OL[LJOUVSVN`OHZJVU[PU\HSS`SLK [VYLK\J[PVUZPUJVZ[HUKPTWYV]LTLU[ZPU[LJOUVSVN` which will continue to open doors to new LED lighting applications. HAITZ’S LAW COST 103 103 100 100 COST PER LUMEN FLUX PER PACKAGE 10-3 10-3 FLUX 1950 1960 1970 1980 1990 2000 2010 2020 0U[OLM\[\YL6,4Z[OH[KVUV[J\YYLU[S`OH]L3,+[LJO- nology will look to implement it right away. There will also be the emergence of new forward lighting method- VSVNPLZ4HU`VM[OLZLKL]LSVWTLU[Z^PSSILMVJ\ZLKVU YLK\JPUNOLHKSPNO[NSHYL^OPJOHJJVYKPUN[V5/;:(PZ one of the most frequent complaints that they receive. 6ULVM[OLTVZ[WYVTPZPUNUL^KL]LSVWTLU[ZILPUN tested is that of adaptive drive beam headlights. The core principal of adaptive drive beam headlights is that vehicles will only have a high beam headlight in their vehicle. The headlight is paired with a forward MHJPUNJHTLYH^OPJOZLUZLZVUJVTPUN[YHɉJHUKI` LP[OLYTLJOHUPJHSVYLSLJ[YVUPJILHTISVJRLYZISVJRZ [OLZWLJPÄJHYLH^OLYL[OLJHTLYHZLUZLZVUJVTPUN [YHɉJVY[HPSSHTWZ 3,+3PML[PTL:`Z[LTZ *\Z[VTLY,_WLYPLUJL The best warranty is one that you never have to use! Lighting has the highest frequency of failure of any device on a truck and trailer and is third in total cost. All vehicles equipped with ;Y\JR3P[L3,+3HTWZ-P[º5-VYNL[*VUULJ[VYZHUK :L- ries “Plug Together” Harness Systems will be under warranty for the life of the vehicle! :LYPLZ¸7S\N;VNL[OLY¹/HYULZZ:`Z[LT :LHSLKWS\N[VNL[OLYZ`Z[LT ,UZ\YLZZVSPK^LH[OLY[PNO[JVU[HJ[Z ,SPTPUH[LZ[OLULLKMVYQ\UJ[PVUIV_LZKPZ[YPI\[PVUV\[SL[Z and troublesome splices 0U[LYUHSNYV\UKN\HYHU[LLZYLSPHIPSP[` *VSVYJVKLKJVUULJ[PVUZHUK^PYLZ 9LHY ^H`HKHW[LYVɈLYZ]LYZH[PSP[` 3PML[PTL:`Z[LTZ>HYYHU[` (3PML[PTL:`Z[LTZ>HYYHU[`PZHTHQVYZ[LWPUTHRPUN]LOP- JSLZZHMLYI`LUZ\YPUNWYVK\J[ZSHZ[SVUNLY;Y\JR3P[L»Z3PML- [PTL:`Z[LTZ>HYYHU[`VɈLYZZPNUPÄJHU[YLK\J[PVUPUTHPU[L- nance costs and provides the peace of mind that your lighting system will keep you on the road. *VTWSL[L:`Z[LTZ(WWYVHJO The common downtime and repair of incandescent lighting extends past the price alone of replacement lamps. Part Cost + Labor + Downtime +V^U[PTLPZJVZ[S`HUK^OLU`V\HKKPU[OLOPKKLUJVZ[Z VMOHSVNLUSHTWZ·YLWHPYZHUKYLWSHJLTLU[Z·[OLPUP[PHS savings from a halogen bulb quickly disappear. While the PUP[PHSJVZ[VM3,+SPNO[PUNWYVK\J[ZTH`ILOPNOLY[OL advantages of not having to replace or repair the lamps will YLZ\S[PUZPNUPÄJHU[ZH]PUNZV]LY[OLSPMLVM`V\Y]LOPJSL 0UKL_.SVZZHY` 0UKL_ Look-a-likes 23 Loose or Tight Brackets 3VZZVM)\SI*VU[HJ[ 15 Lubricant 20 4HQVY*H\ZLZ 12-16 4V\U[PUN:JYL^Z 20 NFPA 32 NHTSA 5VU*VUK\J[P]L.YLHZL 12 5VU*VTWSPHUJL 25 NYK-77® 6/4 5 6OT»Z3H^ 6]LY;PNO[LUPUN:JYL^Z 22 6]LY=VS[HNLL_JLZZ]VS[HNL P2 34-35 P3 34-35 Paint Damage 23 7* 34-35 7* 34-35 Physical Damage 15 7PU*VYYVZPVU 23 Polycarbonate Poor Grounding 15 Potential 4 Power 7YVK\J[4HYRPUNZ 26 Product Pitfalls 22 9LÅL_ Resistance S-8 bulbs 13 SAE Sealant 12 Sealed Lighting Shock 13 :OVJR =PIYH[PVU 13 :OVJR=PIYH[PVU )\YUV\[ 13 Side Turn Lamp usage 32 SnapLED 50 Solid State :VS]LU[Z*SLHULYZ 19-21 Stranded copper wire 14 Suitable Wiring 14 Systems Approach 53 Test Probes 17 Trailer Equipment Location Req.’s 38-45 Troubleshooting Lighting 17 Truck Equipment Location Req.’s 38-45 Under-voltage 17 Useful Formulas 10 Vibration 13 Vibration Resistance 13 Volt Voltage Voltage Drop 14 Voltage Drop Per Foot 8 Voltage Regulators 10 Voltage Spike 14 Voltage Surge 10 Warranty Watt 5 Why Lights Fail 12 Wicking 17 Wire Gauge 8-9 Wire Gauge Size 7-9 Wire Size >PYL:PaL*HSJ\SH[PVUZ 7-9 Wiring harness 14 0UKL_.SVZZHY` .SVZZHY` (JY`SPJ - A glassy thermoplastic polymerized from HJY`SVUP[YPSL^OPJOJHUILJHZ[HUKTVSKLK^OPJOPZ resistant to damage from many cleaning solvents. Aftermarket - A term that refers to the market WSHJLMVYV\YYLWSHJLTLU[VYYL[YVÄ[I\ZPULZZ;OL customer in this market is replacing an existing lamp or accessory on his vehicle. Bracket - A rigid mounting device that allows a lamp to be mounted on the surface of the vehicle body. Some brackets are designed to be used alone or with a grommet. )\SI9LWSHJLHISL6WWVZP[LVMZLHSLK;OLSLUZ is removable on a lamp of this type. When the bulb MHPSZ[OLSHTWTH`ILYLWHPYLKI`YLWSHJPUN[OLI\SI Cab Marker - A lamp similar in function to the THYRLYJSLHYHUJLSHTWI\[[OLZLHYLHS^H`ZTV\U[LK VU[OLYVVMVM[OL[Y\JRVY[YHJ[VYJHI;LJOUPJHSS` [OLZLHYLJHSSLKHMYVU[PKLU[PÄJH[PVUVY0+SHTW Custom Cut - A term that refers to the harnesses that must be cut and terminated to the customer’s ZWLJPÄJH[PVUZ DOT - Grommet - A rubber like device used to mount a lamp into a hole in a vehicle body or a mounting bracket. The grommet may allow a lamp to be mount- LK¸Å\ZO¹PU[V[OLIVK`HUK[OLYLI`WYV[LJ[Z[OLSHTW from physical damage. A grommet also gives the lamp additional protection against shock and vibration. Harness - Also a wiring device. A harness can PUJS\KL4<3;073,WS\NJVUULJ[VYZHUKIL\ZLK[V JVU[YVSKPɈLYLU[[`WLZVMSHTWZ/HYULZZLZ[LUK[VIL OLH]`K\[`QHJRL[LKJHISLHZVWWVZLK[VSPNO[K\[` unprotected wire as in “plugs.” HID - /PNO0U[LUZP[`+PZJOHYNLWYVK\JLZSPNO[I`HU electric arc between two closely spaced electrodes in a quartz glass bulb. HIR - /HSVNLU0UMYH9LKPZHOHSVNLUSHTW^P[OHULS- liptical bulb envelope. The exterior of the bulb is coat- LK^P[OZL]LYHSSH`LYZVMTH[LYPHS^OPJOHYL[YHUZWHYLU[ [V]PZPISLSPNO[I\[YLÅLJ[PUMYHYLKIHJR[V[OLÄSHTLU[ ;OLLɈLJ[PZHIYPNO[LYSPNO[MVYHNP]LUJ\YYLU[ ID Codes - 0+*VKLZHYL[OLJSHZZPÄJH[PVUZNP]LU[V various lighting applications in order to establish min- imum requirements set forth by the SAE J759 regula- tions. 1\UJ[PVU)V_An accessory used with harness systems. All harnesses in a system are connected to this box. Signals from the control devices (switches on IYHRLWLKHSZ[\YUZPNUHSZ^P[JOLZL[JHYLYLJLP]LK in the accessory and are re-routed to the appropriate lamps via the harnesses. 2P[A Truck-Lite term used to describe the combining VMYLSH[LKWYVK\J[Z-VYL_HTWSLHSHTWHNYVTTL[ and a plug can be put together and sold as a unit or ¸2P[¹(¸2P[¹JHUHSZVILHULU[PYL¸]LOPJSLZL[¹PU- JS\KPUNHSSSHTWZOHYULZZLZHUKHJJLZZVYPLZULLKLK to equip a vehicle. LED - Light Emitting Diode. A “solid state” electron- ic device that converts electrical energy directly to light energy. When an electrical current is applied to [OL3,+¸JOPW¹HJVSVYLKSPNO[PZLTP[[LK;OLJVSVY depends on the chemical composition of the chip. Very little heat is produced with this process. Because the ¸KPVKL¹PZJHZ[PU[VHZVSPKISVJRVMLWV_`[OL3,+PZ immune to vibrations and shock and can last up to OV\YZVMVWLYH[PVU Marker Clearance - Also called marker lamp. A small lamp used to mark the edges or corners of the trailer or truck body. These are normally amber in the MYVU[HUKTPKKSLVM[OL]LOPJSLHUKYLKH[[OLYLHY 6[OLYJVSVYZHYLH]HPSHISLMVY¸H\_PSPHY`¹\ZLI\[VUS` red or amber (yellow) are legal for the use as marker clearance lamps in the U.S. Module - A term used to describe a complete rear lighting assembly. The module usually consists of a OV\ZPUNTL[HSVYWSHZ[PJ^P[OVULVYTVYL[HPSSHTWZ and includes a harness or wiring assembly. The TVK\SLTH`HSZVPUJS\KLHTHYRLYSHTWYLÅLJ[VYVY back-up lamps. 4\S[P-\UJ[PVU3HTWA specialized Stop/Turn/ Tail lamp. This type of lamp usually has a larger hous- PUNHUKJHUPUJS\KLZPKLTHYRLYSPJLUZLWSH[LPSS\TPUH- [PVUVYYLÅLJ[VYZPUHKKP[PVU[V[OLIHZPJYLHYSPNO[PUN function. NHTSA - ;OL5H[PVUHS/PNO^H`;YHɉJ:HML[`(KTPU- istration creates values and regulations which underpin [OLHZZ\YHUJLVMZHMLZLJ\YLLɉJPLU[H\[VTV[P]L travel. Ohm’s Law - 6OT»Z3H^KLZJYPILZTH[OLTH[PJHS- S`OV^]VS[HNLJ\YYLU[HUKYLZPZ[HUJLPUHJPYJ\P[HYL YLSH[LK[OYV\NO[OLMVYT\SH!=$0_9^OLYL=PZLX\HS [V7V[LU[PHSPU=VS[Z0PZLX\HS[VJ\YYLU[PUHTWZHUK9 PZLX\HS[V9LZPZ[HUJLPU6OTZ 7S\N;VNL[OLY/HYULZZThe “brand name” for Truck-Lite’s 88 series harness system and accessories. 0[MLH[\YLZHZ`Z[LT[OH[LSPTPUH[LZ[OLULLKMVYHU` type of distribution module. All components simply plug together ensuring a solid electrical contact throughout. 7S\N7PN[HPSThe basic wiring accessory. Usually HVY^PYLKLZPNU^P[O[LYTPUH[PVUKLZPNULK[V mate with a socket or pin connection area on the lamp. 7VS`JHYIVUH[LAny of a family of thermoplastics JOHYHJ[LYPaLKI`OPNOPTWHJ[Z[YLUN[OSPNO[^LPNO[ HUKÅL_PIPSP[`HUK\ZLKHZHZOH[[LYYLZPZ[HU[Z\IZ[P[\[L for glass. 9LÅLJ[VYA non-powered (non-electrical) device KLZPNULK[VYLÅLJ[SPNO[(YLÅLJ[VYKVLZUV[LTP[SPNO[ I`P[ZLSMI\[^PSSYL[\YUSPNO[[OH[PZHPTLKH[P[9LÅLJ- [P]L[HWLVYYLÅLJ[VYZHYLYLX\PYLKI`SH^[VZ\WWSL- ment lighting systems. :LHSLK3HTWAny lighting device that has its bulb permanently sealed inside the lens and housing as- ZLTIS`>OLU[OPZSHTWMHPSZ[OLLU[PYL\UP[T\Z[IL YLWSHJLK\USPRLHI\SIYLWSHJLHISLSHTW Shock Mounted - A system used to suspend and insulate the bulb from vibration and shock (impact). :[VW;\YU3HTWA rear lamp that is brighter than a tail lamp used to indicate that the vehicle is turning or Z[VWWPUN;OL¸THQVY¹ÄSHTLU[VM[OLI\SIPZ\ZLK[V WLYMVYT[OPZM\UJ[PVU:VTL[PTLZYLMLYYLK[VHZH¸:*¹ or single contact lamp. :[VW;\YU;HPS3HTWA rear lamp that contains VULVYTVYLI\SIZ^P[OIV[OTHQVYHUKTPUVYÄSHTLU[ M\UJ[PVUZ;OPZVULSHTWWLYMVYTZ[OLK\[PLZVMIV[O the Stop/Turn lamp and Tail lamp. Sometimes referred [VHZH¸+*¹VYKV\ISLJVU[HJ[SHTW :\WLY:`Z[LTThe “brand name” for Truck-Lite’s 50 Series Harnesses and accessories. This system features both the “custom cut” and customer buildable OHYULZZLZ¸*VTWYLZZPVUÄ[[PUNZ¹HYL\ZLK[VZLHS V\[SL[Z^OLYLOHYULZZLZLU[LY[OLQ\UJ[PVUIV_ ;HPS3HTWThis term is used in general to describe [OLYLHYSPNO[PUNVM[OL]LOPJSL:WLJPÄJHSS`[OL[HPS SHTWM\UJ[PVUPZWLYMVYTLKI`[OL¸TPUVYÄSHTLU[¹VM the bulb. This red light remains “on” as long as the headlamps/parking lamps are in use. This light is not as bright as a turn or stop lamp. Truck-Lite has a proud history of quality in-house harness production and has stood as a leader in the in- novation of new technologies in the heavy-duty industry for decades. 0UHKKP[PVU[VHJVTWSL[LVɈLYPUNVMZ[HUKHYKJH[HSVN HUKZWLJPÄJOHYULZZLZ;Y\JR3P[LOHZLUNPULLYLKH ^PKLHYYH`VMTVSKLKJVUULJ[VYZ^PYL[`WLZHUKLUK seals to complement an entire line of heavy duty lighting HUK]PZPIPSP[`WYVK\J[Z;Y\JR3P[LJHUVɈLYZVS\[PVUZMVY every facet of today’s harness systems with the ability to PUJVYWVYH[LJ\Z[VTLYZWLJPÄLKJVTWVULU[ZPUJS\KPUN NYVTTL[ZZWSP[SVVT[\IPUNIYHPKOLH[ZOYPUR\UPX\L SHILSZHUKPUZ[Y\J[PVUZ ;Y\JR3P[LWYV]PKLZ[OLOPNOLZ[SL]LSZVMX\HSP[`WLY- MVYTHUJLHUKK\YHIPSP[`PUV\YOHYULZZWYVK\J[ZI` JVU[PU\HSS`^VYRPUN[VPTWYV]LLX\PWTLU[WYVJLZZLZ and production methods. We have the added strength of a fully dedicated testing facility to ensure all of our products stand up to the most rigorous of conditions. 6\YZ[HUKHYKSHI[LZ[ZMVYOHYULZZLZPUJS\KL OV\Y JVYYVZPVU[LZ[PUNJOLTPJHS[LZ[PUNJOLTPJHSJVTWH[P- IPSP[`JOLJRZ]PIYH[PVU[LZ[PUNOV[JVSKJ`JSLL_WVZ\YL salt water immersion and drop testing. ;Y\JR3P[L/HYULZZ7YVK\J[ZVɈLY! • plug to lamp interfaces with many Truck-Lite lighting products • harnesses available for both LED or Incandescent connectors, some with internal grounds • sonic welded splices and automated terminations contained in “sealed” molded connections • 100% electrical testing • PVC jacketed cable meets SAE recommendations • many harnesses available in 12” increments to adapt to any application THU`HKHW[LYZH]HPSHISL[V[HPSVY[VZWLJPÄJJ\Z[VTLY requirements