Whether repairing or replacing lights, under the new regulatory environment, longevity and reliability are now crucial elements to consider when choosing a light for your tractor-trailer. Previously regarded an important component, with CSA in effect, lights and lamps have taken on added importance.
Today, 60% of fleets are specifying vehicle lighting systems; half are opting for LED versus incandescent. The improved acceptance is due to the fact that LED technology is maturing and fleets are learning of their success in other fleets, plus the fact that they address total lighting costs. As this shift in lighting technology occurs, the goal is to eliminate shock and filament vibration problems.
To address lighting’s number one enemy: corrosion, light manufacturers report that fleets are employing systems that can fight-off “infection” (corrosion) and connections that are more secure and thus require less maintenance, reducing the chances of having to unplug a connection to diagnose a problem.
“Many fleets and OEMs are moving to modular electrical systems,” said Randy Staggs, Grote business development manager. “The UBS system (from Grote) is designed to branch-off from a main trunk line (or sill). Modular systems expand easily through standardized wiring segments with connectors that snap together and are designed with reservoirs for dielectric grease.”
Brad VanRiper, senior vice president and chief technology officer, TruckLite, offered practical suggestions for fleet managers on extending lighting life, such as “the same solution is not for every fleet, and the exact data and facts drive the changes. Fleet managers should rely more on the vendors’ fleet specialists to teach the fleet technicians better diagnostic and repair procedures.”
From the major lighting suppliers, here are a few of the major causes of safety lighting failures:
Corrosion: Corrosion is the result of water, dirt and other environmental elements of the road and surrounding conditions. Corrosion around the bulb sockets cannot approach the bulb when it is sealed within a lamp housing.
Shock and vibration/filament burnout: The constant road pounding caused by an active tractor/trailer causes filaments to weaken and prematurely break. Install a lamp designed with shock-mounted mechanisms to cradle the bulb and absorb the effects of shock and vibration.
Inadequate wiring and cable: Cutting and splicing or the merging of varying harness and wiring systems can break the system’s modularity. Suitable wiring can have a positive effect on product life and cost reduction.
Excessive voltage: Excessive voltage is always a difficult problem for bulb life. Voltage should be checked regularly to ensure the vehicle is operating within a safe range. Heat is an enemy of lamps – they must “breathe.”
Other practical suggestions for extending life include: inspecting connectors every three months and paying attention to J560 connectors; never use test probes to puncture insulation while troubleshooting; don’t simply dispose of lamps if they’re not burning; inspect for improper ground connections; and look for loose, bare and unsupported wire and fixtures.
Studies have shown that when sealed cradle-shock-mounted bulbs and lighting devices are used along with sealed wiring harness systems, product life can be extended as much as 20 times beyond traditional unsealed bulb units in heavy-duty truck and tractor/trailer applications.
“Upgrading to an LED light package for a minimal upcharge pays huge dividends for the progressive fleet, and a fully-sealed lighting and harness system can guarantee corrosion-free for 10 years – another wise investment,” said Tim Gilbert, corporate director, HD fleet sales, Peterson Manufacturing.
Experts report that technology is readily available today to design and produce lighting products that can offer hundreds of thousands of hours of maintenance-free service. Near-term “challenges and opportunities for lighting life” could include a closer look at type and quality of wiring, and the need for more study on wiring harnesses, suggested TruckLite’s VanRiper.
