About The E-Max Dura-Seal® - Technical Notes & Specifications

The dura-Seal® by E-max® is the first modular plug and play wiring harness/loom system that is built specifically for Australian trailers.

The product is designed and manufactured here in Australia to exacting specifications for the client (some generic systems available). . All splices and joins are sealed from harms way by either a ‘Flexine’ polymer or a flame retardant V1050 PVC used in the dangerous goods applications. This makes the harness what we call – ‘environmentally sealed’ i.e. all splices, joins and copper are sealed ‘ to become resistant to the nasties of the environment, such as water, oil, diesel and dirt etc. All of these contaminants eventually corrode and destroy the wiring, which in turn reduces the effectiveness or completely destroys the performance of your lights.

The Dura-Seal® is made up of two main sections. The first is the main harness. This usually runs the entire length of the vehicle/trailer. From this, are all of the top front end outline, side markers and mid turn indicators are tapped. Each moulded side/indicator junction has been design to safely allow a maximum of up to 4 X 6 watt incandescent filament bulbs ie four normal side/clearance markers. The second section is the rear module, which is the harness/loom all of rear lighting is wired to, including final clearance lamp, stop/tail indicator combinations, licence plate lamps and top rear end outline markers.

Main Harness Cable Details

The main harness in manufactured from OE quality 7 core sheathed wire, with a temperature rating of 1050C The insulating material being the highest quality self extinguishing, UV stable Polyvinyl Chloride (PVC).

There are two sizes of main harness available. The Blue System most suitable for R Train or B-Double, the black system most suited to single trailer or up to B-double combinations where multi-volt LED lights are exclusively used

The heavy-duty blue system has 7 circuits under the sheath. It has 1 x 8.00mm2 (112/.3 strands) earth circuit and 6 x 5.0mm2 (65/.32) strands) red, yellow, blue, green, black, brown.

The medium duty black system has 7 circuits under the sheath. It has 1 x 5.00mm2 (65/.32 strands) earth circuit and 6 x 3.0mm2 (41/.32) strands) red, yellow, blue, green, black, brown.

You will also note the earth circuit is the largest circuit in both the systems. This is because it is the return circuit; it carries the sum total current of all of the other 6 circuits, common sense and basic electrical theory indicates this is a good design. The Dura-Seal® system comes in both normal and also a dangerous goods compatible system. There are generally 2 types of outlets along the length of the main harness.

Clearance and side marker outlets.
Currently all are wired from the brown circuit. A clearance marker outlet has a maximum of 7 amps per plug - 14 amps per outlet. We can wire into any colour circuit to the customers spec.
Indicator outlet
One side is for the green or right hand circuit the other side is yellow for the left hand circuit. Once again this has a total outlet limitation of 14 amps total.

Along the length of the main harness all electrical plugs are environmentally sealed plugs. These are all OE plugs. We supply as standard the AMP super seal. As options available we have the Deutsch ‘DT series’ and also the Delphi ‘weather pack’. The super seal are the most economical. The DT and weather pack are a little more expensive, but generally do not make it prohibitive to use if this is the product required.

E-max can supply any major brand of lighting to the customer specification. The system is compatible with incandescent and LED lighting. In fact the Dura-Seal™ blue system can alleviate in most situations the very expensive upgrade to LED lights. You will be amazed at the increase performance of your normal lights. Your lights will never have looked so bright!!!

The Elimination of Junction Boxes or Dual Wiring

For road train and other multiple combinations a 7-way splice is available in the harness. This splice will handle the full current load rating of the cable. The mating cable of the splice feeds the rear module, and the main cable continues through to the rear outlet on your trailer. This ensures the most minimal voltage drop and maintains ultimate electrical performance.

The elimination of Junction boxes will ultimately give unparallel savings, as junction boxes become in time areas of high maintenance and electrical failure. They become water and dirt traps, becoming impossible to seal.

This splice is predominately used in the 'A' trailer of the B-double, or the lead trailer in a road train. In the splice there is no break in the main heavy-duty 7-core cable, but can be incorporated in custom designs to suit individual needs.

Understanding The Rear Module

The rear module connection and wring has been designed to accommodate the electrical load of both incandescent and LED lighting in accordance with ADR 13/00.

Plugs directly into the main harness, and is a complete water and dust proof connection. This connection also has a M8 or 5/16” anchor/mounting point. When this part if the module is to be mounted in the trailer, the anchor point in this section 'A' is to be mounted approximately 300mm off the rear of the trailer, unless otherwise designed.
Out of this mould come the outlets for the last side clearance marker, rear combination/signal lamps –& indicators, also reverse if required. An outlet for rear end top outline and indicator if necessary. Please also note there are anchor/mounting holes M8 or 5/16”the same as in the connection point (A) allowing the wiring to be secured to the rear end of the trailer ensuring no possibility of loose wiring ‘flapping’ around in the breeze. A simple modification may be necessary at the rear of the chassis to allow this part of the module to be positioned correctly. If this is required please refer to manufacturers guide or an appropriate qualified tradesperson for guidelines to enlarge a hole in the rear of the chassis.
Is the outlet for the licence plate lamps.

Mounting/ Fastening Main Harness and Rear Harness Connection

Care should be taken when mounting this main/rear module connection. There should be a minimum of 300mm as shown in the drawing below. This no fastening zone is located from the joint line of the connection between the main harness and rear module back towards the main harness or front of the trailer. As a general recommendation, we recommend and believe it is good practice to fasten the main harness every 400mm. Not adhering to fastening at these intervals may void the warranty of the product.

There is much conjecture about what works and what doesn’t. Electrics on Australian trailers are notorious for being unreliable. Multiple trailers, place huge demands on the lighting and in turn the electrical system. The reality is that the more copper you have the better your lights will perform.

The inter connecting cables and plugs between the trailers are also a big issue. To get the best performance out of your trailer you need to have correct and consistent cable size and connection through the whole system. It is no use having a bottle neck between truck and trailer or trailer to trailer.

E-max® only warrants electrical performance if the Max-e-coil® cable is used between both truck and trailer and trailer to trailer using the new Heavy duty style plug. Fear not! The size and weight of this cable will have no adverse effect on the plug nor will it pull or fall out. The new heavy-duty plugs are designed to take this type of weight and cable.

E-max® can quote you a price same day for the dura-seal and deliver is about 3-4 days from placement of order.

Any further technical questions may be answered by one of our technical sales staff on 03 9758 2111 or info@e-max.com.au

E-Max® International Pty Ltd Obligations and Warranty

E-max warranty is limited to 5 years unlimited kilometre against faulty materials and workmanship. This product may not be used for anything it is not designed for. Electrical burn outs and dead shorts, short circuits are not covered by warranty. The system is fully 100% electrically tested before leaving the factory. When ordering a "custom system" it is the responsibility of the purchaser to supply actual dimension information to E-max®.

Our recommendations for the use of this product are based on test believed to be accurate and reliable. The standard quality of our system, materials used and its adherence to our published specifications, if any, are guaranteed. In the event the system or any of its materials is not to the specified quality or specification the seller at its sole obligation will replace the system or faulty material.

Since the Use of this system is beyond the control of the manufacturer, no guarantee, expressed or implied, is made at to such use and effects incidental to such use, handling or possession or the results to be obtained, whether in accordance with directions or claimed to be, E-Max® International Pty Ltd expressly disclaims responsibility therefore.

Further Dura-Seal™ Technical Data Sheets

Other sheet available on request:

Electrical Performance and Calculation Tables: These technical sheets supply valuable information on system design and cable performance.
Electrical Maintenance: Maintenance that is required to be performed to get the best out of you system.
Prime Mover to Trailer & Trailer to Trailer interconnections: Information on hardware to get the most out of you Dura-Seal™ system.